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 2008011100135 20080111 00135 SO 2008 1 11 0001 2 20070925 G 8530 AEC631397 CYLINDER CESSNA 414 414A 2075907 CE CONT O520 TSIO520NB 17040 SO RT ENGINE CRACKED B FCPR O OTHER O OTHER CR CRUISE 1 NM 09 919FA 1120 414A0628 276632R PILOT WAS INFORMED BY LINE PERSONNEL DURING TAXI TO TIE DOWN, THAT ENGINE WAS MAKING A LOUD (AIR PULSING) SOUND. PILOT C OULD ONLY HEAR THE SOUND AFTER REMOVING NOISE CANCELLING HEAD SET. PILOT THEN SHUTDOWN ENGINE. INSPECTION REVEALED THE N R 4 CYLINDER TO BE CRACKED AT THE PARTING SURFACE. EXHAUST WAS ESCAPING FROM THE CRACK CAUSING THE (AIR PULSING) SOUND. 1 L 7 2 3O 3 O A7CE E8CE 2007050400163 20070504 00163 GL 2007 5 4 050207 1 20070502 G 5210 649 ROD END CIRRUS CIRRUS SR SR22 2130001 GL CONT O550 IO550* SO CABIN DOOR BROKEN G B EMER. DESCENT D INFLIGHT SEPARATION CR CRUISE 1 SO 13 299JW 300 1034 CABIN DOOR DEPARTED AIRCRAFT IN FLIGHT DUE TO THE ROD END HINGE FAILURE. IT APEARS THE ROD END FAILED DUE TO FATIGUE. TH E ROD END SHOULD BE MADE OF A STRONGER MATERIAL. 1 L 7 1 3O 3 O NT A00009CH E3SO 2007062500013 20070625 00013 CE 2007 6 25 061371 1 20070613 G 3397 NTE5916 DIODE RAYTHN DH125 HAWKER800XP 7150012 CE LIGHTS OVERHEATED B O OTHER O OTHER AP APPROACH 1 CE 01 800RC 745 745 258660 PILOT'S NOTED THAT LANDING AND TAXI PULSE LIGHT SYSTEM WAS INOPERATIVE ... LIGHTS WOULD NOT PULSE IN FLIGHT. SYSTEM HAD BEEN UPDATED PER RAYTHEON MANDATORY SERVICE BULLETIN 33-3682. UPON INSPECTION AND TROUBLE SHOOTING SYSTEM, THE CONNECT ORS ATTACHED TO THE DIODES (CR1 THRU CR4) THAT WERE ADDED TO THE SYSTEM AS A RESULT OF THE BULLETIN, WERE LOOSE AND APPE AR TO HAVE OVERHEATED. IN DISCUSSIONS WITH RAYTHEON, IT WAS DETERMINED THAT POSITION OF THE DIODE INSULATORS ON PAGE 25 OR 39 OF THE SERVICE BULLETINS IS INCORRECT AND SHOWN OPPOSITE OF WHAT THEY SHOULD BE. AS A RESULT, THE THINNER INSULAT OR CRACKS AND ALLOWS THE TERMINAL TO SHORT TO GROUND AND OVERHEAT. VISUALLY INSPECT DIODE PANEL AND VERIFY THAT THE 2 L 7 2 4F RT A3EU 2007091700014 20070917 00014 WP 2007 9 17 090107 2 20070904 G 7200 TFE7312B ENGINE LEAR 35 36A 5170603 CE GARRTT TFE731 TFE73122B 01518 WP UNKNOWN E ESPA A UNSCHED LANDING Y J ENGINE STOPPAGE WARNING INDICATION CL CLIMB 1 SO 11 545PA 11017 14 028 74118 DURING CLIMB OUT SHORTLY AFTER TAKEOFF LT ENGINE QUIT. CREW DECLARED AN EMERGENCY WITH DEPARTURE CONTROL, THEY VECTOR A IRPLANE TO PROPER MSA ALTITUDE AND RETURN FOR LANDING. CREW ELECTED, IN FLIGHT ENGINE START CHECK LIST, THE LT ENGINE ST ARTED, AND WAS OPERATING NORMAL. AT THIS POINT CREW NOTIFIED ATC THAT LT ENGINE WAS BACK UNDER NORMAL OPERATING CONDITIO NS. AIRPLANE LANDED UNEVENTFULLY. 2 L 7 2 4F 4 F A10CE E6WE 2008010800358 20080108 00358 CE 2008 1 8 102N07110026 1 20071015 G 3597 CABLE BEECH 56 56TC 1152736 CE LYC O541 TIO541* 41536 EA OXYGEN SYSTEM CHAFED F K NONE B SMOKE/FUMES/ODORS/SPARKS UK UNKNOWN 1 NM 09 420S 463 463 TG74 ISSUE WITH THE FIXED OXYGEN SYSTEM DISPLAY FOR STC SA01078SE WHERE THE DISPLAY (NOT IN CONTACT WITH OXYGEN) RIBBON CABLE CHAFED AND CREATED A SHORT TO GROUND WHERE THE RIBBON CABLE SMOKED BUT DID NOT FAIL, THE INDICATOR LIGHT OF THE SYSTEM, NOR FAILED TO OPERATE. ISSUE WAS NOTED DURING ANNUAL INSPECTION AND NOT REPORTED AT THE TIME OF INCIDENT. MFG HAS BEE N IN CONTACT WITH THE ACO AND IS ISSUING A SERVICE BULLETIN. 1 L 7 2 3O 3 O 3A16 E10EA 2007120500060 20071205 00060 SO 2007 12 5 110107 1 20071120 G 6320 WARNING LIGHT ROTOL GULSTM G159 G159 3952202 SO RROYCE DART DART529 54507 EU GEARBOX ILLUMINATED C E ENGINE SHUTDOWN J WARNING INDICATION CR CRUISE 1 SO 11 810CB 148599 023 DURING CRUISE FLIGHT MISSION, THE RT GEARBOX LIGHT CAME ON STEADY. THE ENGINE WAS SHUTDOWN IAW AFM PROCEDURES. THE AIRCR AFT LANDED UNEVENTFULLY, AND TAXIED TO THE RAMP. NO EMERGENCY WAS DECLARED. 2 L 7 2 4T 4 T 1A17 E297 2007061500196 20070615 00196 GL 2007 6 15 110DJ0507 1 20070515 G 5522 SKIN AMTR 500 ECLIPSE500 05614K5 GL RT ELEVATOR CRACKED C K NONE O OTHER IN INSP/MAINT 1 EA 27 110DJ 117 203452 000007 DURING REMOVAL OF THE ELEVATORS, A SMALL CRACK WAS DISCOVERED ON RT ELEVATOR SKIN BY OB MOST HINGE BRACKET ATTACH POINT. 1 L 7 2 3F RT EXPA1L72 2008010900392 20080109 00392 EU 2008 1 9 120107 2 20071217 G 7200 ENGINE GULSTM G1159 G1159 3953505 SO RROYCE SPEY SPEY511* 54523 EU LEFT VIBRATION E ESPA A UNSCHED LANDING E VIBRATION/BUFFET CL CLIMB 1 SO 11 183PA 108 8571 AFTER LANDING, TEMP.AROUND -12C, FREEZING FOG, CREW ELECTED TO TURN OFF ANTI-ICE AFTER LND. AIRCRAFT SAT FOR 1 HR,ENG'S STARTED. LT ENG HAD VIBRATION HUMMING, RT ENG WAS STABLE.TAXIED OUT W/ANTI-ICE ON THRUOUT. A/C TOOKOFF, IT SEEMED TO B E SMOOTH ON THE ROLL AND INITIAL CLIMB, HOWEVER, OUT OF 10,000 FT LT ENG VIB WAS AROUND 1.5 MILS,ABNORMAL FOR THIS AIRPL ANE. CREW ELECTED TO DIVERT (MAINT.BASE). LANDING WAS UNEVENTFUL. BOTH ENG'S HAD VISUAL CKS, NOTHING NOTED. CONCLUSION I T MUST HAVE BEEN AN ICING/MELTING PROBLEM. 2 L 7 2 4F 4 F RT A12EA E2EU 2007121400345 20071214 00345 EA 2007 12 14 120507 1 20071205 G 6310 A1902 V-BELT BLANCA 1413 14132 1201004 EA ENGINE TO TRANS DISINTEGRATED C A UNSCHED LANDING E VIBRATION/BUFFET CR CRUISE 1 SO 19 413R 503 1531 DURING IFR TRAINING FLIGHT WHILE IN CROSS COUNTRY CRUISE, LOUD NOISES FROM ENGINE AREA PROMPTED CREW TO MAKE UNSCHEDULED LANDING TO SAFE AREA OF FLORIDA STATE ROAD 80 MEDIAN TURN AROUND PAVEMENT. UPON LANDING FOUND AFT BELT OF MAIN DRIVE BE LT HAD SHED ITS OUTER LAYER AND DISINTEGRATED, CAUSING DAMAGE ONLY TO THE FAN SHROUD BEHIND THE ENGINE OIL COOOLER, AND MINOR SKIN DENT BEHIND THE FUEL TANK IN OUTER SKIN. ONE MULTIFUNCTION ANTENNA RG58 TNC CONNECTOR DAMAGED. AIRCRAFT TRAIL ERED TO HANGAR AND AFFECTED AREAS DISSASSEMBLED. REPLACEMANT SERVICABLE FAN SHROUD ASSEMBLY TO BE INSTALLED WITH NEW PAR TS ORDERED FROM ROBINSON. NO ENGINE OR ROTOR OVERSPEED OCCURED. AUTOROTATION WAS NOT REQUIRED. PART 91 FLIGHT TRAINING O 1 L 7 1 3O A773 2007121400347 20071214 00347 GL 2007 12 14 15DR 1 20070411 G 2421 BC4101 ALTERNATOR CIRRUS SR SR22 2130001 GL CONT O550 IO550* SO NR 2 DESTROYED B ODAR O OTHER J WARNING INDICATION NR NOT REPORTED 1 EA 21 15DR 0394 OWNER REPORTED NR2 ALTERNATOR LIGHT ILLUMINATED. REMOVED TOP COWLING TO INSPECT NR2 ALTERNATOR. FOUND NR2 ALTERNATOR B ROKEN OFF AT MOUNTING PLATE BY (3) STUDS. ONE STUD STILL ATTACHED WITH NUT, BUT LOOSE. REMOVED P/N BC410-1, S/N 092140 3. 1 L 7 1 3O 3 O NT A00009CH E3SO 2007040200167 20070402 00167 2007 4 2 200345493 1 20070316 G 7920 4012T16P01 OIL FILTER OIL SYSTEM DEFECTIVE D O OTHER O OTHER NR NOT REPORTED 1 GL 25 INTERNAL BORE TO EACH END OF THE OIL FILTER ASSEMBLIES ARE SHARP AND UNSMOOTH. THIS CONDITION WAS NOTED ON 3 ADDITIONAL FILTERS IN OUR STOCK, LOT 583085. THIS CONDITION CAUSES THE PACKINGS ON THE OIL FILTER BODY TO SHEAR UPON INSTALLATION OF THE FILTER ELEMENT AND COULD CAUSE OIL BYPASS TO OCCUR. THIS FILTER ELEMENT IS USED. (K) 2007020100031 20070201 00031 SO 2007 2 1 200600073 1 20070131 G 5730 SKIN LKHEED 282 C130A 5262502 SO WING CRACKED B KGBR K NONE Z SIGNIFICANT FAILURE REPORT IN INSP/MAINT 1 NM 04 131HP 20233 56534 2EA CRACKS WERE DETECTED WHILE PERFORMING AD 2002-19-14, 1 CRACK EMANATING FROM A FASTENER HOLE LOCATED AT FS 543 RT CW STA 70 LOWER WING AND 1 CRACK EMANATING FROM A FASTENER HOLE AT FS 569, LT CW STA 57, LOWER WING. BOTH CRACKS ARE .125 0 INCH LONG. 2 H 7 4 4T A31NM 2007020100015 20070201 00015 WP 2007 2 1 200600083 1 20070131 G 5711 SPAR CAP CVAC PB4Y2 PB4Y2 2421102 WP WRIGHT R2600 R260035 67050 EA HAMSTD 23E 23E50 NE WING CRACKED B KGBR K NONE O OTHER IN INSP/MAINT 1 NM 04 2872G 7162 66300 WHILE PERFORMING THE REQUIREMENTS IN AD 2003-18-01, CRACKS WERE NOTED THRU-OUT THE WING. THE MAJOR CRACK IS A 4-5 INCH CRACK IN THE FWD LT LOWER SPAR CAP AFT ANGLE AT THE WING ATTACH POINT TO THE BELT FRAME. THE CRACK IS IN THE ANGLE (SPA R CAP AFT LEG), DOUBLER AND SPAR WEB. THERE ARE ALSO CRACKS .1250-.2500 INCH EMANATING FROM 3 OF THE 4 BELT FRAME CUTOU TS ON THE LOWER WING. 2 H 7 4 4R 4 R RT PAGE42 6 C P603 2007110100188 20071101 00188 NM 2007 11 1 200700026 1 20071017 G 2797 WMBMS136OT7C4G20 WIRE BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE TE FLAPS CHAFED C SROM O OTHER S AFFECT SYSTEMS AP APPROACH 1 AL 03 733PA 38672 23466 TRAILING EDGE FLAPS ASYMMETRY LOCKOUT BETWEEN ZERO AND ONE DEGREE. THERE IS A SPLIT IN T/E FLAP INDICATION, LT T/E FLAP S INDICATE ONE DEGREE AND RT T/E FLAPS INDICATE ZERO. FLIGHT CREW EXPERIENCED AN UNEVENTFUL LANDING AND NO UNCOMMANDED ROLL. MAINTENANCE DISCOVERED RT T/E FLAP POSITION TRANSMITTER WIRE HARNESS HAD CHAFED WIRES. REPLACED WIRE HARNESS FRO M RT TRANSMITTER TO DISCONNECT STATION 720R CONNECTOR D4876P. 2 L 7 2 4F 4 F RT A16WE E2EA 2007080700167 20070807 00167 SW 2007 8 7 2007001 1 20070717 G 5714 SPAR CAP CVAC P4Y P4Y2TRANSAIR 2421102 SW WRIGHT R2600 R260035 67050 EA HAMSTD 23E 23E50 NE CENTER WING CRACKED B KGBR K NONE O OTHER IN INSP/MAINT 1 NM 04 2872G 7162 66300 WHILE PERFORMING AD 2003-18-01, CRACKS WERE FOUND UNDER THE LT LOWER, FWD, SPAR CAP DOUBLER IN THE CAP, SPAR WEB AND THE DOUBLER ITSELF. CRACKS WERE ALSO FOUND IN THE WING SKIN CUTOUTS AT ALL 4 LOWER CENTER WING BELT FRAME CUT-OUTS. RT FWD LOWER SPAR CAP CRACKED IN (2) PLACES UNDER THE DOUBLER. 2 H 7 4 4R 4 R AR29 PAGE42 6 C P603 2007020100014 20070201 00014 WP 2007 2 1 200700105 1 20070131 G 5711 SPAR CAP CVAC PB4Y2 PB4Y2 2421102 WP WRIGHT R2600 R260035 67050 EA HAMSTD 23E 23E50 NE WING CRACKED B KGBR K NONE O OTHER IN INSP/MAINT 1 NM 04 2871G 7192 66302 WHILE PERFORMING THE REQUIREMENTS IN AD 2003-18-01, CRACKS WERE NOTED THRU-OUT THE WING. THE MAJOR CRACK IS A 1.5 INCH CRACK IN THE FWD LT LOWER SPAR CAP AFT ANGLE AT THE WING ATTACH POINT TO THE BELT FRAME. THE CRACK IS IN THE ANGLE (SPA R CAP AFT LEG), DOUBLER AND SPAR WEB. THERE ARE ALSO CRACKS .1250-.2500 INCH EMANATING FROM THE 4 BELT FRAME CUTOUTS ON THE LOWER WING. 2 H 7 4 4R 4 R RT PAGE42 6 C P603 2007013100168 20070131 00168 EU 2007 1 31 200700114 1 20070130 G 5720 2121151091 STIFFENER CASA C212 C212 2410200 EU GARRTT TPE331 TPE33110R 0517 WP ROTOL R334 R334482F13 GL LT WING CRACKED B KGBR K NONE O OTHER IN INSP/MAINT 1 NM 04 515RL 5409 405 WHILE PERFORMING CASA COM LETTER 212-224 AND CASA SB 212-57-57-30, A CRACK WAS NOTED FROM THE 4TH RIVET TO THE 5TH RIVET FROM THE BOTTOM, ON THE VERTICAL STIFFINER LOCATED ON THE LT WING AT STA 4700, AFT SPAR WEB. THREE STIFFINERS NEXT TO THE ORIGINAL ARE CRACKED EXACTLY THE SAME, CRACKS ARE LOCATED INT HE SAME POSITIONS, BETWEEN THE 4TH AND 5TH RIVIT FROM THE BOTTOM. THIS TOTALS 4EA CRACKED STIFFINERS. 2 H 7 2 4T 4 T A43EU E4WE 6 C P61GL 2007022600165 20070226 00165 CE 2007 2 26 2007001HAGGAN 1 20070223 G 5740 2322330177 SUPPORT BRACKET GARKENYON 26044 LEAR 60 60LEAR 5170707 CE PWA 305 PW305A 52128 NE ZONE 500 FAILED B H51R O OTHER F FLT CONT AFFECTED AP APPROACH 1 NM 03 252FX 5936 0295 196 DURING FLAP OPERATION, FLAP ACTUATOR SUPPORT BRACKETS FAILED CAUSING FLAP ACTUATOR TO DAMAGE LEFT WING RIB SEGMENT. 2 L 7 2 4F 4 F RT A10CE E35NE 2007080700170 20070807 00170 WP 2007 8 7 2007002 1 20070717 G 5714 SPAR CAP CVAC PB4Y2 PB4Y2 2421102 WP CENTER WING CRACKED B KGBR K NONE O OTHER IN INSP/MAINT 1 NM 04 2871G 7192 66302 WHILE PERFORMING AD 2003-18-01, CRACKS WERE FOUND UNDER THE LT LOWER, FWD, SPAR CAP DOUBLER IN THE CAP, SPAR WEB AND THE DOUBLER ITSELF. CRACKS WERE ALSO FOUND IN THE WING SKIN CUTOUTS AT ALL 4 LOWER CENTER WING BELT FRAME CUT-OUTS. RT FWD LOWER SPAR CAP CRACKED IN ONE PLACE UNDER THE DOUBLER. 2 H 7 4 4R RT 2007040900153 20070409 00153 NE 2007 4 9 200701 2 20070328 G 7210 311300001 GEARBOX ACQCOR F22 F22 8850908 EA PWA JT15 JT15D4 52112 NE ACCESSORY G/B MISDRILLED B LM1R K NONE O OTHER IN INSP/MAINT 1 EA 09 ENGINE WAS ROUTED TO OUR FACILITY FOR OVERHAUL AND DURING A FLUSHING PROCESS WE DISCOVERED A WALL IN AN ACCESSORY GEARBO X WITH A MISDRILLED OIL PASSAGE. THE OIL PASSAGE DID SUPPLY OIL TO THE REQUIRED AREA BUT IT BROKE THROUGH THE WALL DURI NG THE MANUFACTURING PROCESS RESTRICTING THE OIL SUPPLY. THE ENGINE HAS BEEN OPERATING WITH THIS CONDITION WITH NO APPAR ENT EFFECT. THE AGB COMPONENTS WAS INSPECTED AND NO DAMAGE WAS FOUND AS A RESULT OF THIS CONDITION. 1 H 7 1 3O 4 F NC 1A9 E1NE 2007012900391 20070129 00391 NE 2007 1 29 20070125 2 20070124 G 8520 GEAR ROBSIN R44 R44RAVENII 7640122 WP LYC O540 IO540AE1A5 41530 NE ENGINE WORN B EVGR K NONE O OTHER IN INSP/MAINT 1 SO 33 622 10003 L2845148A DURING INSPECTION OF THE ENGINE WHILE REPLACING THE CRANKSHAFT IAW SB 569A, IT WAS OBSERVED THAT (PN 13519647) CRANKSHAF T GEAR WAS EXCESSIVELY WORN. THE GEAR WAS REPLACED WITH A NEW PART. 1 G 7 1 3O 3 O H11NM 1E4 2007110100185 20071101 00185 NM 2007 11 1 20073 1 20071016 G 6720 A3592 ATTACH BRACKET ROBSIN R22 R22BETA 7640110 NM LYC O320 O320* 41508 EA T/R PEDAL CRACKED B LJER A UNSCHED LANDING F FLT CONT AFFECTED HO HOVERING 1 NM 09 721HH 12846 1484 TAIL ROTOR PEDALS JAMMED DURING FLARE TO A HOVER. AIRCRAFT LANDED WITHOUT INCIDENT. UPON INSPECTION IT WAS FOUND THAT TH E TAIL ROTOR PEDAL BLOCK SUPPORT BRACKET ON THE RT SIDE HAD CRACKED AT THE AFT PEDAL BLOCK ATTACH POINT ALLOWING THE PED AL BLOCK TO PIVOT DOWN AND JAM THE PEDALS. REPLACED BRACKET WITH NEW. 1 G 7 1 3O 3 O H10WE E274 2007090600021 20070906 00021 SO 2007 9 6 2007ADP828001 1 20070823 G 3230 159SCH1151 SELECTOR VALVE GULSTM G159 G159 3952202 SO RROYCE DART DART5298X 54507 EU ROTOL R4304 R1844304 EU RT MLG BYPASSING C E ENGINE SHUTDOWN J WARNING INDICATION AP APPROACH 1 SO 11 198PA 1253 027 AIRCRAFT WAS ENROUTE, FLYING THE APPROACH FOR RUNWAY 03. ONCE THE CREW PERFORMED THE APPROACH CHECKLIST, AND GEAR DOWN W AS SELECTED BEFORE LANDING CHECKLIST THEY GOT THE RT MAIN AND NOSE GEAR LIGHT ONLY. CREW TRY THE EMERGENCY PROCEDURES DE SCRIBED ON CHECKLIST. THIS PROCEDURE DID NOT GET THE (3) GREEN GEAR LIGHTS. AIRCRAFT LANDED WITH (2) GEARS DOWN ON RUNW AY 21, AND SLID INTO THE GRASS. NO INJURIES TO CREW OR PASSENGERS. 2 L 7 2 4T 4 T 1A17 E297 6 C P899 2007082100203 20070821 00203 CE 2007 8 21 2007AP080901 1 20070809 G 5521 043200185 SPAR CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA RT ELEVATOR CRACKED B LJER K NONE O OTHER IN INSP/MAINT 1 NM 09 48440 15375 15280910 RT ELEVATOR SPAR FOUND BROKEN/CRACKED AT OB ATTACH POINT. OB HINGE BRACKET PULLED AWAY FROM SPAR. 1 H 7 1 3O 3 O NT 3A19 E223 2007082100209 20070821 00209 CE 2007 8 21 2007AP081001 1 20070810 G 2730 1016100190014 TORQUE TUBE BEECH BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA ELEVATOR WORN B K NONE O OTHER IN INSP/MAINT 1 SW 17 7166P 11959 11959 BB482 BB482 WHILE UNDERGOING A SCHEDULED INSPECTION, FOUND THE RT ELEVATOR HAD DEVELOPED VERTICAL PLAY WHEN GRASPED FROM THE TRAILIN G EDGE. FOUND THE ELEVATOR TORQUE TUBE HAD ROTATIONAL WHERE THE 6 EACH OB BLIND RIVETS ATTACH THE TORQUE TUBE TO THE MOU NT PLATE. 1 L 7 2 4T 4 T A24CE E4EA 2007083000020 20070830 00020 CE 2007 8 30 2007AP0821001 1 20070809 G 2497 36153 TERMINAL BEECH 200 B200 1152922 CE RT GCU BROKEN D B A EMER. DESCENT UNSCHED LANDING B G H SMOKE/FUMES/ODORS/SPARKS MULTIPLE FAILURE ELECT. POWER LOSS-50 PC CR CRUISE 1 CE 07 1925P 9715 BB1094 WIRE NUMBER P73G16N AT RT ENGINE FIREWALL GROUND POINT GS15 SEPARATED FROM THE WIRE TERMINAL DURING CRUISE FLIGHT. THIS WIRE CONNECTS GROUND TO THE GCU PIN G. THE RT GENERATOR OUTPUT SPIKED AND OPENED THE 325 AMP RT BUSS CURRENT LIMITER, TH E 50 AMP RT INVERTER CURRENT LIMITER, AND DAMAGED RADIOS, THE GCU AND SYSTEMS WIRED TO THE RT BUSS. UPON INSPECTION, THE INSULATION OF P73G16N WAS FOUND STRIPPED TOO FAR FROM THE WIRE END THEREBY GIVING NO SUPPORT OF THE WIRE INTO THE TERMI NAL AT THE INSULATION CRIMP AREA. 1 L 7 2 4T A24CE 2007091400201 20070914 00201 EU 2007 9 14 2007F00052 1 20070904 G 7714 AG34 TACH GENERATOR DORNER DO228 DO228202 2992030 EU GARRTT TPE331 TPE33110T WP HARTZL HCB4T HCB4TN5 GL LEFT ENGINE FALSE INDICATION E E ENGINE SHUTDOWN O OTHER CR CRUISE 1 EA 21 403VA 8171 LEFT RPM INDICATION ABNORMAL PERFORMED PRECAUTIONARY SHUTDOWN. INSPECTION FOUND TACH GENERATOR SHAFT BROKEN. REMOVED A ND REPLACED TACH GENERATOR IAW AMM 77-11-03. ENGINE GROUND PERFORMANCE RUN C/W AND PASSED. ALL PARAMETERS NORMAL. AIR CRAFT APPROVED FOR RETURN TO SERVICE. 2 H 7 2 4T 4 T RT A16EU E4WE 6 C P40EA 2007113000144 20071130 00144 CE 2007 11 30 2007F00064 1 20071018 G 3220 13889 BEARING RACE BEECH 100 B100 1152919 CE NLG CORRODED B K NONE O OTHER IN INSP/MAINT 1 GL 25 500KD 200 BE79 FOUND BOTH NOSE WHEEL BEARINGS PN 13889, AND RACES, PN 13836 TO BE CORRODED. CHANGED THESE SAME BEARINGS AND RACES AT L AST INSPECTION DUE TO SAME PROBLEM. BEARINGS HAVE 200 HOURS OR 4 MONTHS ON THEM. NOSE WHEEL IS AN STC WHEEL AND BRAKE ASSEMBLY. WE ALSO REPLACED THESE SAME BEARINGS AND RACES 1 YEAR PRIOR. (K) 1 L 7 2 4T A14CE 2007110500011 20071105 00011 SW 2007 11 5 2007F00065 1 20071016 G 6320 204040016005 TRANSMISSION BELL 204 UH1F 1181411 SW GE T58 T58GE3 NE MAIN ROTOR CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 05 4040P 657911 CRACK FOUND ON MAIN GEARBOX (TRANSMISSION IN VERTICAL CAST WEBBING ABOVE ENGINE TO TRANSMISSION DRIVE QUILL. MILITARY T ECHNICAL MANUAL ALLOWS .2500 INCH RADIUS/POLISH INTO WEBBING THIS CRACK HAS BEEN FOUND ON THREE (3 EACH) TRANSMISSIONS O N OTHER AC WITH ONE PENETRATING THE GEARBOX AND LEAKING FLUID. (K) 1 G 7 1 4U 4 U EXPA1G71 2007010800148 20070108 00148 CE 2007 1 8 2007FA0000001 1 20070102 G 2810 10092004115 LINE BEECH 200 B200 1152922 CE PWA PT6 PT6A42 52043 NE FUEL SYSTEM CHAFED C O OTHER O OTHER NR NOT REPORTED 1 NM 08 155AV BB1216 DURING A SCHEDULED PHASE INSPECTION P/N 100-920041-15 ALUMINUM MAIN FUEL LINE WAS FOUND CHAFED IN THE LT MAIN LANDING GE AR WHEEL WELL WHERE IT ENTERS INTO THE BACK OF THE WING. THE EDGES OF THE HOLE THAT THE LINE PASSES THROUGH WAS PROTECTE D WITH PLASTIC ANTI CHAFE MATERIAL THAT WE CALL TANK TRACKS, OR RAILROAD TRACK, AND HAS A PN MS21266-1N. THIS ANTI CHAF E MATERIAL WAS INSTALLED AT THE FACTORY. THIS ANTI CHAFE MATERIAL CAUSED P/N 100-920041-15 ALUMINUM MAIN FUEL LINE TO BE CHAFED ALMOST THROUGH ITS .030 INCH SIDEWALL THICKNESS. THERE ARE OTHER AC THAT HAVE CHAFED FUEL LINES DUE TO THE CLOS E TOLERANCE OF THE FUEL LINES PASSING THROUGH THE STRUCTURE IN THE MAIN LANDING GEAR WHEEL AREA. 1 L 7 2 4T 4 T A24CE E4EA 2007011600044 20070116 00044 EA 2007 1 16 2007FA0000031 2 20070103 G 8520 13B37024 CRANKSHAFT PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA SNSNCH 74D 74DM EA ENGINE CORRODED D GICR O OTHER O OTHER NR NOT REPORTED 1 NM 01 5347M 2372 2842136 L1949939A A59073 THE ENGINE CURRENTLY UNDERGOING ITS FIRST OVERHAUL SINCE NEW. THE CRANKSHAFT WAS CLEANED, URETHABOND 104 COATING REMOVE D AND CORROSION PITTING WAS DISCOVERED BENEATH COATING. THE PITTING EXCEEDED (SERVICEABLE LIMITS) AS STATED IN SB NR 50 5B. THIS CAUSED THE CRANKSHAFT THE BE REMOVED FROM SERVICE. THE ENGINE AVERAGED 39.5 HOURS/ MONTH SINCE IT WAS NEW . MFG AD COVERS THIS SUBJECT WITH THE COMPLIANCE WITH FAR, BEING TERMINATING ACTION FOR THE REPETITIVE INSPECTION. THE CRANKSHAFT (FROM THE FACTORY) HAD THE COATING AND (PID) STAMPING. NOTE: DUE TO THE URETHABOND 104 COATING, THIS SHOULD HAVE PREVENTED THE CORROSION PITTING WHICH IS A CONCERN OF THIS AD. THE ENGINE OVERHAULER STATED THE COATING WAS NOT W 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 2007012500042 20070125 00042 SO 2007 1 25 2007FA0000036 2 20070102 G 8520 LIFTER CESSNA 206 U206C 2073332 CE CONT O520 IO520F 17032 SO NR 6 CYLINDER DETERIORATED D K NONE O OTHER IN INSP/MAINT 1 AL 03 29114 U2061084 1683457 AFTER DRAINING OIL AND INSPECTING FILTER, LARGE FLAKES OF METAL WERE FOUND. DISASSEMBLED VALVE TRAIN AND FOUND SPALLING ON CYLINDER NR 6 INTAKE LIFTER. DAMAGE OCCURRED TO THE CORRESPONDING CAM LOBE AND CLYINDER NR 5 INTAKE LIFTER DUE TO D ETERIORATION OF CYLINDER NR 6 INTAKE LIFTER. UPON INSPECTION IT WAS DETERMINED THAT THE LIFTER HAS BAD METALLURGY. ALL OTHER LIFTERS NOT NOTED, SHOWED PROPER WEAR, AND HARDNESS TESTING MARKS. THE CAM SHOWED DAMAGE ON CORRESPONDING LOBE, NOT DETERIORATION, AND OTHER LOBES SHOWED PROPER WEAR. THE ENGINE HAS 228.06 HOURS SINCE FACTORY REMANUFACTURE. MFG WA S CONTACTED ABOUT SITUATION, AND NO INTEREST WAS NOTED ON POSSIBLE PROBLEMS. ENGINE WAS SENT TO LOCAL REPAIR STATION FO 1 H 7 1 3O 3 O A4CE E5CE 2007012500250 20070125 00250 EA 2007 1 25 2007FA0000038 1 20070115 G 3233 2953310095200 SEAL ROTOL CNDAIR CL600 CL6002B16 1900305 EA ACTUATOR PISTON POROUS B K NONE K J FLUID LOSS WARNING INDICATION IN INSP/MAINT 1 GL 13 DCL28293 GREEN TWEED SEAL P/N 295-33100-952-0050 INSTALLED ON PISTON ASSEMBLY IN MFG SIDE BRACE ACTUATOR P/N: 6500-3 HAVE BEEN FO UND WITH VOIDS ON THE INNER RAISED SURFACE CAUSING FLUID LEAK. THESE VOIDS ARE UNDETECTED AT INSTALLATION OF NEW SEAL A S THE VOIDS ARE NOT ON THE SURFACE AND DO NOT BECOME VISIBLE UNTIL AFTER MONTHS OF OPERATION. SEAL CONDITION NOTED DURI NG WARRANTY REPAIR. SUBJECT ACTUATOR RETURNED FOR WARRANTY REPAIR AFTER 11 MONTHS OPERATION. 2 L 7 2 4F RT A21EA 2007012400183 20070124 00183 SO 2007 1 24 2007FA0000039 1 20070116 G 2497 WIRE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA UNKNOWN WORN C O OTHER O OTHER NR NOT REPORTED 1 SO 17 456M 318152081 THE WIRING THAT PASSES THROUGH THE NOSE RIB GROMMETS HAVE WORN TO THE EXTENT THAT THE INSULATION IS GONE AT PLACES CAUSI NG THE METAL CONDUCTOR TO SHOW THROUGH. IT APPEARS THAT THIS IS WORSE WITH THE GREATER AMOUNT OF CABLES IN THE BUNDLE. BUNDLES OF ONLY 2 WIRES DO NOT HAVE THIS PROBLEM. APPARENTLY THE BUNDLE IS (SLAPPED) UP AND DOWN WITH VIBRATION. THIS IS CAUSE FOR CONCERN DUE TO SPARKING NEAR THE FUEL TANK. 1 L 7 2 3O 3 O A20SO E14EA 2007012900346 20070129 00346 SO 2007 1 29 2007FA0000040 1 20070116 G 3233 400872 CLEVIS BOLT PIPER PA28 PA28R201 7102816 SO LYC O360 IO360A1A 41514 EA NLG SHEARED B A UNSCHED LANDING F J FLT CONT AFFECTED WARNING INDICATION CR CRUISE 1 GL 21 289ND 4558 2844039 DURING CRUISE FLIGHT, CREW REPORTED LOUD BANG FOLLOWED BY A NOSE GEAR DOWN AND LOCKED INDICATION. AIRCRAFT LANDED WITHOU T INCIDENT. UPON INSPECTION BY MX PERSONNEL NOSE GEAR ACTUATOR ROD END CLEVIS BOLT (AN23-21A) MISSING WITH EVIDENCE OF B OLT FAILURE. 1 L 7 1 3O 3 O 2A13 1E10 2007012600251 20070126 00251 SO 2007 1 26 2007FA0000041 1 20070116 G 3233 400872 CLEVIS BOLT PIPER PA28 PA28R201 7102816 SO LYC O360 IO360A1A 41514 EA NLG SHEARED B OG5R A UNSCHED LANDING F D J FLT CONT AFFECTED INFLIGHT SEPARATION WARNING INDICATION CR CRUISE 1 GL 21 289ND 4558 2844039 DURING CRUISE FLIGHT, CREW REPORTED LOUD BANG FOLLOWED BY A NOSE GEAR DOWN AND LOCKED INDICATION. AIRCRAFT LANDED WITHOU T INCIDENT. UPON INSPECTION BY MX PERSONNEL NOSE GEAR ACTUATOR ROD END CLEVIS BOLT (AN23-21A) MISSING WITH EVIDENCE OF B OLT FAILURE. 1 L 7 1 3O 3 O 2A13 1E10 2007012900347 20070129 00347 SO 2007 1 29 2007FA0000042 1 20070116 G 2497 WIRE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA ELECTRICAL SYS CHAFED C O OTHER O OTHER NR NOT REPORTED 1 SO 17 456M 318152081 THE WIRING THAT PASSES THROUGH THE NOSE RIB GROMMETS HAS WORN TO THE EXTENT THAT THE INSULATION IS GONE AT PLACES CAUSIN G THE METAL CONDUCTOR TO SHOW THROUGH. IT APPEARS THAT THIS IS WORSE WITH THE GREATER AMOUNT OF CABLES IN THE BUNDLE. BUNDLES OF ONLY 2 WIRES DO NOT HAVE THIS PROBLEM. APPARENTLY THE BUNDLE IS (SLAPPED) UP AND DOWN WITH VIBRATION. THIS I S CAUSE FOR CONCERN DUE TO SPARKING NEAR THE FUEL TANK. 1 L 7 2 3O 3 O A20SO E14EA 2007012600006 20070126 00006 CE 2007 1 26 2007FA0000046 1 20070105 G 5713 05112821 STRINGER CESSNA 170 170B 2072306 CE CONT O300 O300* 17022 SO WING CRACKED D K NONE O OTHER IN INSP/MAINT 1 AL 03 3436D 4200 26979 CRACKED AT FORWARD END AND PROGRESSES AFT. PROP STRIKE, OUT OF BALANCE PROP. EXAMPLE FROM C-170B WITH THE ENGINE INSTA LLED. (K) 1 H 7 1 3O 3 O A799 E253 2007012500346 20070125 00346 CE 2007 1 25 2007FA0000047 1 20070105 G 5713 0511282 STRINGER CESSNA 170 170B 2072306 CE CONT O300 O300* 17022 SO WING CRACKED D K NONE O OTHER IN INSP/MAINT 1 AL 03 3436D 4200 26979 CRACKED AT FWD END AND PROGRESSES AFT. PROP STRIKE, OUT OF BALANCE PROP? AIRCRAFT HAS A HISTORY OF WING REPAIRS FROM G ROUND LOOPS BUT HAS SINCE HAD A ENGINE UPGRADE TO MFG. (K) 1 H 7 1 3O 3 O A799 E253 2007012500347 20070125 00347 CE 2007 1 25 2007FA0000048 1 20070105 G 5713 0511282 STRINGER CESSNA 170 170B 2072306 CE WING CRACKED D K NONE O OTHER IN INSP/MAINT 1 AL 03 CRACKED AT FORWARD END AND PROGRESSES AFT. PROP STRIKE, OUT OF BALANCE PROP. (K) 1 H 7 1 3O A799 2007012500281 20070125 00281 EU 2007 1 25 2007FA0000049 1 20070104 G 4980 MY20240035005A3 SEAL MICROTURBO AMD FALC20 FALCON20F5 2730105 EU GARRTT TFE731 TFE731* 01518 WP APU EXHAUST DETERIORATED B JGVR O OTHER S AFFECT SYSTEMS NR NOT REPORTED 1 CE 09 189RB 1673 592 262 DETERIORATED APU EXHAUST DUCT SEAL BETWEEN THE DUCT FLANGE AND AIRCRAFT SKIN ALLOWED HOT EXHAUST GASSES TO ENTER THE TAI LCONE AREA RESULTING IN HEAVY SOOT BUILDUP AND HEAT DAMAGE TO WIRE BUNDLES AND ELECTRICAL CONNECTORS AND STRUCTURAL COMP ONENTS ADJACENT TO THE APU EXHAUST OPENING. ULTRASOUND INSPECTION REVEALED HEAT DAMAGE TO THE AC SKIN ABOVE THE EXHAUST OPENING. THE APU EXHAUST OPENING DOUBLER AND STRINGERS ADJACENT TO THE OPENING. PERIODIC INSPECTION OF THE APU INSTAL LATION, INCLUDING THIS SEAL, IS REQUIRED EVERY A-CHECK IAW MM. (K) 2 L 7 2 4F 4 F RT A7EU E6WE 2007012500197 20070125 00197 SO 2007 1 25 2007FA0000050 1 20070110 G 5521 510229615 ATTACH ANGLE AMRGEN AA5 AA5A 3960106 SO LYC O320 O320* 41508 EA STABILIZER CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 17 9962U 3163 AA5A0362 DURING INSPECTION, ANGLE PN 5102296-15 AND PN 5102296-16, WERE FOUND CRACKED IN THE UPPER END OF THE ANGLE AS INSTALLED. CAUSE OF CRACKING IS BELIEVED TO BE DUE TO HIGHT STRESS LOADS IN THIS AREA. (K) 1 L 7 1 3O 3 O A16EA E274 2007012500198 20070125 00198 CE 2007 1 25 2007FA0000051 1 20070107 G 5230 DOOR CESSNA 500 560CESSNA 2076750 CE PWA JT15 JT15D5 52112 NE CARGO BAY OPEN D K NONE O OTHER LD LANDING 1 WP 01 480DG 5294 5600015 108029 RT BAGGAGE DOOR POPPED OPEN ON ROLLOUT WITHOUT WARNING. COULD NOT DUPLICATE CIRCUMSTANCES, SUGGEST INSPECTING LATCHES A ND DOOR WARNING. ON A MORE REGULAR BASIS. AIRCRAFT RETURNED WITHOUT PROBLEM. (K) 2 L 7 2 4F 4 F RT A22CE E25EA 2007012900355 20070129 00355 EU 2007 1 29 2007FA0000054 1 20070102 G 2435 BEARING LUCAS 23080005 BRAERO DH125 BAE125800A 1500285 EU GARRTT TFE731 TFE731* 01518 WP STARTER GEN FAILED C D RETURN TO BLOCK E VIBRATION/BUFFET CR CRUISE 1 EA 09 180NE 710 95274 NA0401 P91312 FORWARD BEARING FAILED 2 L 7 2 4F 4 F RT A3EU E6WE 2007012500134 20070125 00134 SO 2007 1 25 2007FA0000056 1 20070110 G 5521 510229615 ATTACH ANGLE AMRGEN AG5B AG5B 3990100 SO LYC O360 O360* 41514 EA STABILIZER CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 17 11966 1190 10121 DURING INSPECTION, ANGLE PN 5102296-15 AND PN 5102296-16, WERE FOUND CRACKED IN THE BEND RADIUS OF THE UPPER END OF THE ANGLE AS INSTALLED. CAUSE OF CRACKING IS BELIEVED TO BE DUE TO HIGH STRESS LOADS IN THIS AREA. (K) 1 L 7 1 3O 3 O NT 1L71 E286 2007012500063 20070125 00063 GL 2007 1 25 2007FA0000057 1 20070105 G 5210 ATTACH FITTING DIAMON DA40 DA40 2990002 GL AFT CABIN DOOR BENT D GO3S A UNSCHED LANDING D INFLIGHT SEPARATION NR NOT REPORTED 1 NM 07 422FP 212 40FC022 AFT CABIN DOOR ASSY SEPARATED FROM AC DURING FLIGHT. CONTROL OF THE AC WAS MAINTAINED AND LANDED SAFELY AT DEPARTURE AI RPORT. DOOR WAS EVENTUALLY RECOVERED AND UPON VISUAL INSPECTION OF THE DOOR, THE AFT DOOR LATCH PIN WAS NOT ENGAGED. T HE FRONT DOOR LATCH PIN WAS PROPERLY ENGAGED AND THE DOOR LATCH WAS CLOSED. NO (DOOR OPEN) ANNUNCIATION WAS INDICATED B ECAUSE THE DOOR OPEN SWITCH IS ACTUATED FROM THE FRONT DOOR LATCH PIN. UPON DISASSEMBLY OF THE DOOR, THE AFT DOOR LATCH ROD WAS DETACHED FROM THE LATCH MECHANISM. THE ATTACHMENT CLIP, (PN AND NAME NOT GIVEN; NR 215 IN THE PARTS BOOK) WAS BENT ALLOWING THE ROD TO BECOME SEPARATED FROM THE LATCH. A MUCH STRONGER MATERIAL IS RECOMMENDED FOR THE ATTACHMENT CL 1 L 7 1 3O NT A47CE 2007012500307 20070125 00307 EA 2007 1 25 2007FA0000058 2 20070105 G 8540 61098 GEARSHAFT DIAMON DA40 DA40 2990002 GL LYC O360 O360A4M 41514 EA ENGINE SEIZED D GO3S O OTHER O OTHER NR NOT REPORTED 1 NM 07 423FP 234 40FC023 L4037236A REMOVED VACUUM DRIVE ASSEMBLY AND FOUND DRIVE GEAR SHAFT SEIZED AND (3) TEETH BROKEN OFF OF DRIVE GEAR. FURTHER INSPECT ION REVEALED NO LUBRICATION PORT FOR PRESSURIZED ENGINE OIL TO LUBRICATE THE DRIVE GEAR SHAFT. ALL (3) TEETH WER FOUND IN THE OIL PUMP INLET SCREEN. (K) 1 L 7 1 3O 3 O NT A47CE E286 2007012500138 20070125 00138 SO 2007 1 25 2007FA0000059 1 20070110 G 5521 510229615 ATTACH ANGLE AMRGEN AA5 AA5B 3960105 SO LYC O360 O360* 41514 EA STABILIZER CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 17 4521A 2194 AA5B1070 DURING INSPECTION, ANGLE PN 5102296-15 AND PN 5102296-16, WERE FOUND CRACKED IN THE BEND RADIUS OF THE UPPER END OF THE ANGLE AS INSTALLED. CAUSE OF CRACKING IS BELIEVED TO BE DUE TO HIGH STRESS LOADS IN THIS AREA. (K) 1 L 7 1 3O 3 O A16EA E286 2007012500149 20070125 00149 CE 2007 1 25 2007FA0000063 1 20070110 G 5730 05230294 SKIN CESSNA 172 172N 2072434 CE RT WING MISMANUFACTURED B K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 09 A5OR DURING AN RECEIVING INSPECTION OF NEW RT OB LEADING EDGE SKIN, IT WAS FOUND TO HAVE BEEN DRILLED UP INCORRECTLY SINCE NO NE OF THE NOSE RIBS WOULD LINE UP AND THE SET UP WOULD HAVE LT INSUFFICIENT EDGE DISTANCE ON THE LOWER MAIN WING SPAR RI VET LINE. THIS IS ZND TIME WE HAVE RECEIVED THIS SAME PART. WE ASKED THAT THE PART NOT BE PUT BACK INTO MFG STOCK SINC E PART IS NON-CONFORMING. THE PART CAME WITH 8130-3 AIRWORTHINESS APPROVAL TAG. RECOMMEND MFG PERFORM CLOSE CONFORMITY INSPECTION OF PARTS. (K) 1 H 7 1 3O NT 3A12 2007012500292 20070125 00292 SO 2007 1 25 2007FA0000064 1 20070109 G 3213 6531904 CYLINDER PIPER PA28 PA28140 7102802 SO LYC O320 O320* 41508 EA LT MLG DAMAGED B A5OR K NONE O OTHER IN INSP/MAINT 1 SO 09 15715 3501 287325144 DURING AN ANNUAL INSPECTION FO THE LT MLG CYLINDER ASSY PN 6531904, IT WAS FOUND TO BE LOOSE IN THE MAIN WING SPAR. THE LT MLG WAS REMOVED FOR FURTHER INSPECTION OF THE LT MAIN WING SPAR ASSY GEAR ATTACHING BOLT HOSES AND ATTACH POINTS. C LOSE INSPECTION FO THE WING SPAR SHOWED THAT THE LOWER (4) BOLTS HOLES HAD BEEN ELONGATED. THE HOLES IN THE LT LANDING GEAR CYLINDER WERE FOUND TO BE ELONGATED ALSO. IT APPEARED THAT ALL BOLTS WERE TIGHT AND THIS CONDITION HAD BEEN LOOSE FOR SOME TIME. AIRCRAFT WING SPAR WS REPAIRED AND THE LT MLG CYINDER WAS REPLACE WITH A LATER MODEL CYLINDER ASSY FROM MFG SINCE THE ORIGINAL PART WAS NO LONGER AVAILABLE. RECOMMEND CLOSE INSPECTION OF LANDING GEAR ATTACH POINTS DURING AL 1 L 7 1 3O 3 O 2A13 E274 2007013000176 20070130 00176 EU 2007 1 30 2007FA0000065 1 20070103 G 2742 ACTUATOR PARTEN P68 P68C 6780105 EU LYC O360 IO360A1A 41514 EA PITCH TRIM SEIZED D O OTHER F FLT CONT AFFECTED NR NOT REPORTED 1 GL 03 3832Q 274 (REF NR: PT202781) AIRCRAFT ARRIVED WITH PITCH TRIM ACTUATOR SEIZED IN FULL NOSE UP POSITION. ACTUATOR IS DRIVEN BY TRI M CABLE LOOPED OVER ACTUATOR PULLEY WITH NO MEANS OF PREVENTING CABLE FROM SLIPPING ON THE PULLEY. IT IS POSSIBLE TO RU N TRIM TO FULL TRAVEL ALLOWING ACTUATOR TO BIND. WHEN TRIM CONTROL IS REVERSED THE CABLE CAN SLIP OVER PULLEY WITH OUT MOVING ACTUATOR IF PROPER CABLE TENSION IS NO PRESENT. SUGGEST REVISION TO POH/AFM ADVISING CREW TO VISUALLY CHECK OPER ATION OF PITCH TRIM SYSTEM PRIOR TO FLIGHT. (K) 1 H 7 2 3O 3 O A31EU 1E10 2007013100033 20070131 00033 CE 2007 1 31 2007FA0000070 1 20070108 G 2520 5514551129 ATTACH FITTING CESSNA CESSNA 500 500CESSNA 2076602 CE PWA JT15 JT15D1 52060 NE CABIN CRACKED B ESER O OTHER O OTHER NR NOT REPORTED 1 SO 11 117TW 5000059 UPPER CHAIR BASE ASSEMBLY CRACKED AT CHAIR BACK ATTACH POINTS. CHAIR WAS REPAIRED IAW STC ST01042WI STRUCTURAL SEAT REP AIR. (K) 1 L 7 2 4F 4 F A22CE E1NE 2007020100001 20070201 00001 NE 2007 2 1 2007FA0000071 1 20070110 G 6220 7610208051105 TIE BOLT SKRSKY S76 S76B 8143007 NE PWA PT6 PT6* 52043 EA MAIN ROTOR BROKEN D O OTHER O OTHER NR NOT REPORTED 1 EA 17 411JW 3392 760357 WHILE PERFORMING A ROUTINE INSPECTION OF THE MAIN ROTOR SPINDLES, A SPINDLE TIE BOLT WAS FOUND BROKEN AT THE THREADED EN D OF THE BOLT WHERE THE NUT ATTACHES. THE NUT WAS FOUND INSIDE THE SPINDLE CUFF WHERE THE ROTOR BLADE IS ATTACHED. A B ROKEN SECTION OF THE BOLT WAS STILL THREADED INTO THE NUT. IT IS UNCLEAR WHY THE BOLT BROKE. THE BOLT AND SPINDLE HAVE BEEN REMOVED AND SENT TO MFG AIRCRAFT FOR FURTHER INVESTIGATION TO DETERMINE CAUSE OF FAILURE. (K) 1 G 7 2 4U 3 T H1NE E2NE 2007012900120 20070129 00120 EU 2007 1 29 2007FA0000072 1 20070102 G 2435 BEARING BRAERO DH125 BAE125800A 1500285 EU GARRTT TFE731 TFE731* 01518 WP STATER GEN FAILED C O OTHER E VIBRATION/BUFFET CR CRUISE 1 EA 09 180NE 710 95274 NA0401 P91312 FORWARD BEARING FAILED. 2 L 7 2 4F 4 F RT A3EU E6WE 2007012900357 20070129 00357 2007 1 29 2007FA0000073 1 20070126 G 8011 ES6462751 STARTER ENGINE LEAKING C WS9R O OTHER K FLUID LOSS NR NOT REPORTED 1 NM 07 2 SUBMITTED TO SLC-FSDO BY (WS9R). STARTER LEAKING OUT OF REAR OF STARTER PLATE. 2007013100066 20070131 00066 SO 2007 1 31 2007FA0000074 1 20070123 G 5312 624403 BULKHEAD PIPER PA28 PA28180 7102808 SO LYC O360 O360A3A 41514 EA SNSNCH 76E 76EM8 EA FUSELAGE CORRODED D K NONE O OTHER IN INSP/MAINT 1 GL 09 7095W 4309 28882 L148936C 15028K THE BULKHEAD, BRACKETS, AND DOUBLERS AT STA. 228.3 WERE SEVERELY CORRODED. THIS BULKHEAD IS THE FRONT SUPPORT FOR THE VE RTICAL STABILIZER/RUDDER ASSEMBLY. THE CORROSION COVERED AN AREA APPROXIMATE THE SIZE OF THE FRONT RUDDER ATTACHMENT BRA CKET THAT IS PART OF THIS BULKHEAD ASSEMBLY. THE CORROSION WAS FOUND DURING AN ANNUAL INSPECTION AND WAS ONLY VISIBLE, W ITHOUT DISASSEMBLY, AS SLIGHT BUBBLING OF THE METAL ON THE BRACKETS FACING REARWARD THAT ARE ATTACHED TO THE AFORE MENTI ONED BULKHEAD ASSEMBLY. 1 L 7 1 3O 3 O 2A13 E286 5 N P4EA 2007013100067 20070131 00067 SO 2007 1 31 2007FA0000075 1 20070123 G 5312 624403 BULKHEAD PIPER PA28 PA28180 7102808 SO LYC O360 O360A3A 41514 EA SNSNCH 76E 76EM8 EA FUSELAGE CORRODED D K NONE O OTHER IN INSP/MAINT 1 GL 09 7095W 4309 28882 L148936C 15028K THE BULKHEAD, BRACKETS, AND DOUBLERS AT STA. 228.3 WERE SEVERELY CORRODED. THIS BULKHEAD IS THE FRONT SUPPORT FOR THE VE RTICAL STABILIZER/RUDDER ASSEMBLY. THE CORROSION COVERED AN AREA APPROXIMATE THE SIZE OF THE FRONT RUDDER ATTACHMENT BRA CKET THAT IS PART OF THIS BULKHEAD ASSEMBLY. THE CORROSION WAS FOUND DURING AN ANNUAL INSPECTION AND WAS ONLY VISIBLE, W ITHOUT DISASSEMBLY, AS SLIGHT BUBBLING OF THE METAL ON THE BRACKETS FACING REARWARD THAT ARE ATTACHED TO THE AFORE MENTI ONED BULKHEAD ASSEMBLY. 1 L 7 1 3O 3 O 2A13 E286 5 N P4EA 2007013100073 20070131 00073 SO 2007 1 31 2007FA0000076 1 20070117 G 2434 635796 COUPLING CONT PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360KB 17025 SO MCAULY 3AF32C 3AF32C508 GL ALTERNATOR FAILED C B EMER. DESCENT H G ELECT. POWER LOSS-50 PC MULTIPLE FAILURE CR CRUISE 1 GL 09 321AK 4479 869 B020128 3447021 811403R 960254 ALTERNATOR DRIVE COUPLING FAILED ON LT AND RT ALTERNATORS, IN IMC SIMULTANEOUSLY. 1 PIECE COUPLING WITH A RUBBER LORD B USHING BONDED/INTERFERENCE FIT SLIPPED, CAUSING THE ALTERNATORS FAILURES. PILOTS LOST ELECTRICAL AND DESCENDED THROUGH ICE, UNABLE TO SHED MODERATE TIME ICE ACCUMULATION. TOTAL COMM AND AVIONICS FAILURE, PARTIAL PANEL WITH NO PITOT HEAT AV AILABLE. 1 L 7 2 3O 3 O A7SO E9CE 5 C P22EA 2007013100075 20070131 00075 SO 2007 1 31 2007FA0000077 1 20070117 G 2434 635796 COUPLING CONT PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360KB 17025 SO MCAULY 3AF32C 3AF32C508 GL ALTERNTOR FAILED C B EMER. DESCENT H G ELECT. POWER LOSS-50 PC MULTIPLE FAILURE CR CRUISE 1 GL 09 321AK 4479 869 B020128 3447021 811403R 960254 ALTERNATOR DRIVE COUPLING FAILED ON LT AND RT ALTERNATORS, IN IMC SIMULTANEOUSLY. 1 PIECE COUPLING WITH A RUBBER LORD B USHING BONDED/INTERFERENCE FIT SLIPPED, CAUSING THE ALTERNATORS FAILURES. PILOTS LOST ELECTRICAL AND DESCENDED THROUGH ICE, UNABLE TO SHED MODERATE RIME ICE ACCUMULATION. TOTAL COMM AND AVIONICS FAILURE, PARTIAL PANEL WITH NO PITOT HEAT A VAILABLE. 1 L 7 2 3O 3 O A7SO E9CE 5 C P22EA 2007013000179 20070130 00179 CE 2007 1 30 2007FA0000081 1 20070119 G 3245 850X1000 TUBE CESSNA 208 208B 2073701 CE TIRE DAMAGED C K NONE O OTHER IN INSP/MAINT 1 GL 21 1293E 4 208B0537 RIGHT MAIN GEAR TIRE REPORTED LOW. REMOVED TIRE TO CHECK THE TUBE. THE TUBE APPEARED TO LOOK OLD AND CHECKED. TECHNIC IAN REPLACED WITH NEW TUBE. ONE WEEK LATER TIRE REPORTED LOW AGAIN ON SAME POSITION. REMOVED THE TIRE AND INSPECTED TH E TUBE. THE TUBE LEAKING ON ONE SIDE AND ALMOST WORN THRU ON THE OPPOSITE SIDE. AFTER FURTHER INVESTIGATION DETERMINED THAT THE STICKERS INSIDE THIS 8.50 X 10.00 FC III P/N 850T86-2 S/N 62570185 TIRE HAD CAUSED THE FAILURE. THIS WAS THE SECOND FAILURE ON THE SAME GEAR POSITION WITH THE SECOND NEW TUBE WITHIN 7 WEEKS. AFTER CONTACTING MANUFACTURER TIRE PR ODUCT SUPPORT, SENT A NOTE AND PICTURES ABOUT THE PROBLEM AND THE FAA PMI FROM THE FARGO FSDO. THE MANUFACTURER RESPOND 1 H 7 1 3T A37CE 2007013100100 20070131 00100 2007 1 31 2007FA0000082 2 20070119 G 7414 K3823 DISTRIBUTOR BLK SLICK 6314 MAGNETO MELTED B K NONE M OVER TEMP IN INSP/MAINT 1 GL 21 408ND 493 05100422 DURING TEARDOWN INSPECTION OF 2 SLICK 6314 MAGNETOS THE DISTRIBUTOR BLOCK AND GEAR ASSY PN K3823 WAS FOUND TO BE MELTED TO THE POINT OF EMANATE FAILURE. THE MAGS WERE FROM 2 SEPARATE AIRCRAFT BUT WITH NEAR IDENTICAL TOTAL TIMES ONE AT 493.3 HRS AND THE OTHER AT 498.8.THE MANUFACTURE WAS CONTACTED AND THEY REQUESTED THE MAGS FOR EVALUATION. 2007013100103 20070131 00103 CE 2007 1 31 2007FA0000083 1 20070123 G 7160 07520161011 SEAL CESSNA 180 180J 2072622 CE INTAKE MISSING D K NONE O OTHER IN INSP/MAINT 1 NE 05 9986N 18052641 INTAKE SEALS FOUND MISSING. AD 77-04-05 PERTAINING TO THIS DEFECT HAD BEEN PREVIOUSLY ACCOMPLISHED IN 1977. DUE TO THE A GE OF THE FLEET I BELIEVE THAT THE ONE TIME INSPECTION IAW THIS AD IS INSUFFICIENT. AS THIS IS NOT THE FIRST TIME I HAVE FOUND THE SAME CONDITION ON OTHER AIRCRAFT I WOULD CONSIDER UPDATING THE AD TO INCLUDE REPETITIVE INSPECTIONS AT ANNUAL /100 HOUR INTERVALS. 1 H 7 1 3O 5A6 2007013100104 20070131 00104 CE 2007 1 31 2007FA0000084 1 20070119 G 3245 850X1000 TUBE CESSNA 208 208B 2073701 CE LANDING GEAR WORN C K NONE O OTHER IN INSP/MAINT 1 GL 21 1293E 4 208B0537 RT MAIN GEAR TIRE REPORTED LOW. REMOVED TIRE TO CHECK THE TUBE. THE TUBE APPEARED TO LOOK OLD AND CHECKED. TECHNICIAN RE PLACED WITH NEW TUBE. 1 WEEK LATER TIRE REPORTED LOW AGAIN ON SAME POSITION. WE REMOVED THE TIRE AND INSPECTED THE TUBE. THE TUBE LEAKING ON ONE SIDE AND ALMOST WORN THRU ON THE OPPOSITE SIDE. AFTER FURTHER INVESTIGATION WE DETERMINED THAT THE STICKERS INSIDE THIS 8.50 X 10.00 FC III P/N 850T86-2 S/N 62570185 TIRE HAD CAUSED THE FAILURE. THIS WAS THE SECOND FAILURE ON THE SAME GEAR POSITION WITH THE SECOND NEW TUBE WITHIN 7 WEEKS. AFTER CONTACTING MFG WHO GAVE ME AN E-MAIL FOR THEIR PRODUCT SUPPORT CONTACT WE GOT INFORMATION VERY QUICKLY. I SENT HIM A NOTE AND PICTURES ABOUT THE PROBLEM AND 1 H 7 1 3T A37CE 2007013100106 20070131 00106 SO 2007 1 31 2007FA0000085 1 20070117 G 2434 635796 COUPLING CONT PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360KB 17025 SO MCAULY 3AF32C 3AF32C509 GL ALTERNATOR FAILED C B EMER. DESCENT H G ELECT. POWER LOSS-50 PC MULTIPLE FAILURE CR CRUISE 1 GL 09 321AK 4479 869 3447021 812128R 961321 ALTERNATOR DRIVE COUPLING FAILED ON LT AND RT ALTERNATOR, IN IMC SIMULTANEOUSLY. COUPLING FAILURE RESULTED IN TOTAL ELEC TRICAL FAILURE, RT ENGINE. 1 L 7 2 3O 3 O A7SO E9CE 5 C P22EA 2007013100107 20070131 00107 CE 2007 1 31 2007FA0000086 1 20070126 G 3260 1003810061 DOWNLOCK SWITCH BEECH 200 B200 1152922 CE PWA PT6 PT6A60A 52043 NE LANDING GEAR FAILED E A UNSCHED LANDING N FALSE WARNING LD LANDING 1 GL 07 200EW 7169 70 BB1163 NOSE LANDING GEAR DID NOT HAVE A DOWN AND LOCKED INDICATION GEAR WARNING SYSTEMS ACTIVATED (LIGHT IN SELECTOR HANDLE AND GEAR HORN). AN UNEVENTFUL LANDING HAS MADE VISUAL CHECK OF NOSE GEAR SHOWED TO BE IN THE DOWN AND LOCKED POSITION. SWIT CH REMOVED AND REPLACED WITH A NEW UNIT AND THE SYSTEM CHECKED NORMAL. 1 L 7 2 4T 4 T A24CE E4EA 2007013100256 20070131 00256 CE 2007 1 31 2007FA0000090 1 20070102 G 2730 355246516 CONTROL CABLE BEECH 35 V35 1151538 CE CONT O520 IO520* 17032 SO ELEVATOR SYS BROKEN D K NONE O OTHER IN INSP/MAINT 1 GL 23 767TM 2801 D8556 FOUND BROKEN STRANDS ON ELEVATOR CABLE BEHIND INSTRUMENT PANEL ABOUT 10 INCHES ABOVE THE (PN 535521242-13) BOBWEIGHT. ( K) 1 L 7 1 3O 3 O 3A15 E5CE 2007013100257 20070131 00257 EA 2007 1 31 2007FA0000091 2 20070118 G 7314 AC40295 PUMP AMRGEN AA5 AA5 0631410 SO LYC O320 O320E2G 41508 EA ENGINE LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 SO 01 24AU 302 AA50588 AT ANNUAL FUEL STAINS WERE FOUND ON ENGINE LOWER COWLING. IN AN ATTEMPT TO FIND THE LEAK THE ELECTRIC FUEL PUMP WAS TUR NED ON TO PRESSURIZE THE FUEL SYSTEM BUT NO LEAKAGE WAS FOUND. WHILE TURNING ENGINE OVER BY HAND DURING THE COMPRESSION CHECK A LARGE FLOW OF GAS WAS FOUND LEAKING OUT THE SIDE OF THE FUEL PUMP ABOVE THE OUTLET PORT BETWEEN THE DIAPHRAGM A ND PUMP CASTINGS. REPAIR STATION WAS CONTACTED AND THY INDICATED THAT THE SCREWS THAT HOLD THE PUMP TOGETHER ARE ASSEMB LED AT 25 INCH LBS TORQUE + OR - 5 INCH LBS . PUMP SCREWS WERE CHECKED AND THEY WERE FOUND TO BE TIGHTENED TO ONLY 2-3 INCH LBS OF TORQUE. ALL OF THE SCREWS HAD TORQUE PUTTY ON THEM WHICH INDICATED THE SCREWS HAD NOT BACKED OUT. GUESS IS 1 L 7 1 3O 3 O A16EA E274 2007021500169 20070215 00169 WP 2007 2 15 2007FA0000092 2 20070115 G 7250 31021069 TURBINE WHEEL GULSTM 690TP 690B 7630516 SW GARRTT TPE331 TPE33110T WP HARTZL HCB3T HCB3TN5 GL ENGINE DAMAGED B IZ2R O OTHER O OTHER NR NOT REPORTED 1 SW 15 690LL 2245 11544 P99112C BVA7239 INSPECTION OF ENGINE REVEALED DAMAGE TO 3RD STAGE TURBINE ROTOR VISIBLE THROUGH ENGINE TAILPIPE. ENGINE WAS REMOVED FRO M AIRCRAFT AND THE TURBINE SECTION MODULE REMOVED TO INVESTIGATE FOR CAUSE OF DAMAGE. UPON INSPECTION 4 EA PINS WERE FO UND MISSING FROM 2ND STAGE TURBINE ROTOR ASSEMBLY CAUSING SIGNIFICANT DAMAGE TO VARIOUS TURBINE SECTION COMPONENTS, SEVE RAL OTHER PINS WERE ALSO FOUND LOOSE AND DAMAGED. SB ADDRESSES REMOVAL OF 2ND STAGE TURBINE ROTORS PN 310210610 UTILIZI NG AN IMPROVED PIN DESIGN. FURTHERMORE MFG HAS INDEPENDENT SERVICE CENTER SPECIAL PROGRAM IN PLACE TO COVER PIN REPLACE MENT ON AFFECTED TURBINE ROTORS AT NO CHARGE, COVERING SECONDARY DAMAGE ON A PRORATED BASIS. (K) 1 H 7 2 3T 4 T 2A4 E4WE 6 C P15EA 2007021300165 20070213 00165 EA 2007 2 13 2007FA0000095 2 20070109 G 8520 AEL321031 CRANKSHAFT CESSNA 172 172L 2072432 CE LYC O320 O320E2D 41508 EA ENGINE BROKEN B VA1R O OTHER R J PARTIAL RPM/PWR LOSS WARNING INDICATION DE DESCENT 1 SW 19 15RA 410 17259568 L2207127A ENGINE BEGAN RUNNING ROUGH AND BECAME SMOOTH AGAIN DURING DESCENT. TROUBLESHOOTING FIRST FOUND BRASS METAL PARTICLES IN AIR FILTER AND OIL. CRANKSHAFT WAS APPARENTLY BROKEN OR CRACKED BUT STILL TOGETHER. AFTER NUMEROUS GROUND RUSN AND KN OCKING NOISES HEARD, THE CRANKSHAFT BROKEN AND ROD THROWN THROUGH CASE. THE BREAK WAS BETWEEN NR 3 AND NR 4 ROD JOURNAL S. SENG BACK TO ENGINE COMPONENTS FOR WARRANTY AND ANALYSIS. (K) 1 H 7 1 3O 3 O NT 3A12 E274 2007021400083 20070214 00083 SO 2007 2 14 2007FA0000096 1 20070103 G 3230 455180 CONDUIT PIPER PA24 PA24250 7102404 SO LYC O540 O540* 41532 EA LT MLG PUSH PULL SEPARATED D O OTHER O OTHER NR NOT REPORTED 1 EA 63 6632P 3200 241755 THE LT MAIN LANDING GEAR PUSH PULL CONDUIT SEPARATED AT THE BALL END WHERE IT IS ATTACHED TO THE SUPPORT STRUCTURE IN TH E WHEEL WELL. BELIEVE THIS FAILURE OCCURRED AT THE PREVIOUS LANDING GEAR RETRACTION. (K) 1 L 7 1 3O 3 O 1A15 E295 2007021300176 20070213 00176 2007 2 13 2007FA0000101 2 20070124 G 7414 6320 MAGNETO ENGINE FROZEN B WS9R O OTHER O OTHER NR NOT REPORTED 1 NM 07 SHAFT IN MAGNETO FROZEN, WOULD NOT MOVE. (K) 2007021300189 20070213 00189 EA 2007 2 13 2007FA0000102 1 20070109 G 5755 BRACKET CNDAIR CL600 CL6002B16 1900305 EA GE CF34 CF343B1 NE FLT SPOILER CRACKED B RO3R O OTHER O OTHER NR NOT REPORTED 1 CE 03 684TS 5384 WHILE PERFORMING A 96 MONTH AIRFRAME INSPECTION, DISCOVERED THE LT FLIGHT SPOILER TRANSMITTER BRACKET WAS CRACKED. UPON REMOVING BRACKET, DISCOVERED MATTING SURFACE WITH TRANSMITTER WAS CORRODED. DECIDED TO REMOVE TO INSPECT RT TRANSMITTE R BRACKET AND FOUND THE RT SIDE CORRODED AS WELL. REMOVED AND REPLACED BOTH BRACKETS. RT AND LT HAVE THE SAME PN. (K) 2 L 7 2 4F 4 F RT A21EA E15NE 2007021300164 20070213 00164 EA 2007 2 13 2007FA0000103 1 20070109 G 5755 600913563 BRACKET CNDAIR CL600 CL6002B16 1900305 EA GE CF34 CF34* NE RT FLT SPOILER CRACKED B RO3R O OTHER O OTHER NR NOT REPORTED 1 CE 03 267DW 5391 RT FLIGHT SPOILER POSITION INDICATION WOULD NOT OPERATE PROPERLY. UPON FURTHER INVESTIGATION, FOUND THE FLIGHT SPOILER TRANSMITTER BRACKET WAS CRACKED AND UNABLE TO HOLD POSITION TRANSMITTER. REMOVED AND REPLACED BRACKET. (K) 2 L 7 2 4F 4 F RT A21EA E15NE 2007020500043 20070205 00043 CE 2007 2 5 2007FA0000104 1 20070201 G 2710 S394 CONTROL CABLE CESSNA 172 172S 2072439 CE AILERONS FRAYED B K NONE O OTHER IN INSP/MAINT 1 SO 15 5275S 3179 100 172S9203 DURING A ROUTINE INSPECTION THE AILERON CONTROL DIRECT CABLE WAS FOUND SERIOUSLY WORN IN THE CABIN OVERHEAD AREA. THE AI LERON BALANCE AND DIRECT CABLES ARE SEPARATED AND GUIDED BY 3 PULLIES, P/N-S394, INDEX NR 30, CHAPTER 27-10-00, FIG 3 IN THE CESSNA PARTS MANUAL. THE CENTER CABLE WAS WORN EXTENSIVELY AND HAD BROKEN STRANDS. THE WEAR IS CAUSED BY CONTACT WI TH THE PULLEY. IT IS DIFFICULT TO SEE WITHOUT ROTATING THE CABLE AND EXPOSING THAT PORTION OF THE CABLE THAT CONTACTS TH E PULLEY DURING LEVEL FLIGHT. THE CABLE AT FIRST APPEARS SHINY, BUT WITH THE AID OF A POWERFUL MAGNIFYING GLASS REVEALS MUCH MORE SERIOUS WEAR. OBVIOUSLY, THE FAILURE OF THIS CABLE WOULD LIKELY RESULT IN THE LOSS OF THE AIRCRAFT WITH LITTLE 1 H 7 1 3O NT 3A12 2007020500030 20070205 00030 CE 2007 2 5 2007FA0000105 1 20070202 G 5711 51220311 SPAR CAP CESSNA 310 T310R 2074246 CE CONT O520 TSIO520BB 17040 SO MCAULY 3AF32C 3AF32C87 GL LT WING CORRODED D K NONE O OTHER IN INSP/MAINT 1 EA 17 465DL 1132 310R1622 LT TOP WING SPAR CAPS AND TOP SKINS SEVERELY CORRODED IN AREA OF FACTORY NACELLE FUEL BLADDERS. LT-PN 5122031-1. 1 L 7 2 3O 3 O 3A10 E8CE 5 C P22EA 2007021300174 20070213 00174 GL 2007 2 13 2007FA0000106 1 20070111 G 7603 FRICTION LOCK AMTR LANCAR LANCAIR 05616TS GL WALTER M601 M601E EU POWER LEVER INOPERATIVE G O OTHER O OTHER NR NOT REPORTED 1 SW 11 750TL 154 LIV555 913008 AIRCRAFT EXPERIENCED LOSS OF POWER DURING TAKEOFF AND LANDED WITH LANDING GEAR RETRACTED DEPARTING RUNWAY FROM WHICH TAK EOFF WAS MADE. INVESTIGATION REVEALED FRICTION LOCK WAS NOT EFFECTIVE. (K) 1 L 7 1 3O 3 T RT EXPA1L71 EXPE3T 2007021300063 20070213 00063 EU 2007 2 13 2007FA0000107 1 20070125 G 5210 333045181 SEAL ISRAEL 1124 1124 4500102 EU GARRTT TFE731 TFE731* 01518 WP CABIN DOOR LEAKING D A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 SW 09 300XL 9015 276 THE AIRCRAFT DEPARTED, CLIMBING THROUGH 30000. THE CABIN ALT BEGAN TO CLIMB WITH THE AIRCRAFT. THE PILOTS REQUESTED TO DESCEND. CENTER DECLARED EMERGENCY AND GAVE CREW 12000 FT. AIRCRAFT PRESSURIZED PROPERLY AT THAT ALT. PILOT REQUESTE D DEVIATION AND TO HAVE EMERGENCY CANCELED. THIS WAS GRANTED BY CENTER. AFTER LANDING, CREW LOOKED OVER THE AC AND COU LD NOT FIND ANYTHING WRONG, PROCEEDED, AT 19000 FT. AIRCRAFT PRESSURIZED PROPERLY. IN MAINTENANCE CREW INSPECTED THE A IRCRAFT AND PERFORMED NUMEROUS GROUND PRESSURIZATION RUNS AN COULD NOT DUPLICATE PROBLEM. PILOT MADE STATEMENT THAT THE DOOR MAY NOT OF SEALED PROPERLY. MAINTENANCE LOOKED AT THAT ASPECT AND FOUND THAT THE DOOR CAN BE CLOSED IN A MANOR TH 2 M 7 2 4F 4 F A2SW E6WE 2007021300060 20070213 00060 NE 2007 2 13 2007FA0000108 2 20070101 G 7200 CFM563B1 POWERPLANT BOEING 737 737300 1384610 NM GE CFM56 CFM563B1 13802 NE OIL SYSTEM CONTAMINATED B UOXR A UNSCHED LANDING R Y J PARTIAL RPM/PWR LOSS ENGINE STOPPAGE WARNING INDICATION NR NOT REPORTED 1 SO 19 XAMAA 44927 3514 720721 ENGINE SUFFERED AN IFSD DUE TO POWER LOSS AND A COMMANDED ENGINE SHUTDOWN WAS CARRIED OUT. ENGINE RESTART WAS ATTEMPTED , UNSUCCESSFULLY. FURTHER INVESTIGATION REVEALED THAT NR 10 STRUT ON FAN FRAME (9 O`CLOCK STRUT AFT LOOKING FWD) WHICH RADIAL DRIVE SHAFT IS LOCATED WAS PUNCTURED, BOTH ON UPPER AND LOWER SURFACES OF STRUT. IT WAS AGREED TO CARRY OUT ENGI NE REMOVAL AND RETURN ENGINE TO REPAIR FACILITY. HYDRAULIC FLUID WAS FOUND IN OIL SYSTEM, AIR STARTER AND CSD OIL SUMPS . ALL OIL WETTED ITEMS REQUIRE INSP. ENGINE HAD UNDERGONE TROUBLESHOOTING FOR HIGH OIL CONSUMPTION FOLLOWING REPORTS O N 2 FLIGHTS AND RETURN ON DEC 22, 2006. LEVELS OF 2.08 GALLON QUARTERS/HOUR WERE REPORTED AND AVERAGE OIL CON WAS 0.15 2 L 7 2 4F 4 F RT A16WE E2GL 2007021300055 20070213 00055 CE 2007 2 13 2007FA0000109 1 20070131 G 2730 50524401 BELLCRANK BEECH 90 65A901 1152901 CE PWA PT6 PT6* 52043 EA ELEVATOR FAILED C NBFG O OTHER O OTHER NR NOT REPORTED 1 EA 27 87V LM130 FOUND BROKEN FORK ON ELEVATOR BELLCRANK SUPPORT ARM AT FWD END OF ELEVATOR LT PUSHROD. FOUND THE PUSH ROD FWD ATTACH BO LT HAD BEEN OVER-TORQUED SO MUCH AS TO CREATE A 0.016 INCH -0.021 INCH DEPRESSION IN EACH (MAGNESIUM) FORK WHERE THEY PR ESSED INTO THE ROD END BEARING. MFG SB2231R2 INCLUDES: INSPECTION FOR CRACKS IN THIS AREA OF ELEVATOR BELLCRANK. PROPE R GAP BETWEEN ROD END AND SUPPORT ARM FORKS (0.00 INCH TO 0.01 INCH GAP) PROPER TORQUE OF PUSHROD ATTACH BOLT (70-108 IN CH LBS) RECOMMEND FOLLOWING PROPER INSPECTION, INSTALLATION AND TORQUE WHEN INSTALLING THE BELLCRANK AND PUSHRODS. FOL LOW THE INSTRUCTIONS IN THE MM AND SB2231R2. (K) 1 L 7 2 3T 3 T 3A20 E2NE 2007020900036 20070209 00036 CE 2007 2 9 2007FA0000112 1 20070108 G 7160 1116 AIR FILTER CESSNA 172 R172K 2072431 CE CONT IO360 IO360* 17025 CE TWISTED G K NONE O OTHER IN INSP/MAINT 1 SO 15 758EJ R1723034 DURING REMOVAL OF THE AIR FILTER THE CENTER WIRE MESH SCREEN WAS FOUND TWISTED AND BENT. SOME OF THE WELDS WERE BROKEN. SCREEN DEFORMATION CAN LEAD TO UNFILTERED AIR AND FOD ENTERING THE ENGINE. APPARENT CAUSE IS EITHER OVERTORQUEING WIN G NUT AND/OR INSUFFICIENT STRENGTH OF SCREEN. RECOMMEND UTILIZING A STRONGER MESH/PERFORATED SCREEN OR EVALUATING INSTA LLATION INSTRUCTIONS/TORQUEING PROCEDURES. 1 H 7 1 3O 3 O 3A17 E1CE 2007021200156 20070212 00156 GL 2007 2 12 2007FA0000113 1 20070205 G 6500 E181150P V-BELT AMTR ROTWAY EXEC162F 056037T GL TAIL ROTOR BROKEN G R AUTOROTATION F FLT CONT AFFECTED CR CRUISE 1 CE 07 113JD 80 6107 V BELT PREMATURELY FAILED. THIS IS A 250 HOUR CHANGE OUT PART. 1 G 7 1 3O O EXPA1G71 2007031200062 20070312 00062 SO 2007 3 12 2007FA0000114 1 20070206 G 2820 W70120TE CONNECTOR GULSTM GV GULFSTREAMGV 3980116 SO FUEL LINE LOOSE C K NONE K FLUID LOSS IN INSP/MAINT 1 GL 15 83M 557 FUEL LINE CONNECTOR IN MAIN WHEEL WELL COMING LOOSE, RESULTING IN FUEL LEAKING INTO WHEEL WELL.REFERENCE MFG ILLUSTRATED PARTS CATALOG; 28-26-00, FIGURE 5, PAGE 2, ITEM 205, PN W701-20TE. WE ARE HAVING THIS PROBLEM ON MORE THAN ONE OF OUR AIRCRAFT. THERE IS NO WAY TO SAFETY THIS FITTING. THIS SITUATION COULD RESULT IN FUEL BEING SPRAYED ON A HOT BRAKE RES ULTING IN A FIRE. 2 L 7 2 4F RT A12EA 2007022000010 20070220 00010 CE 2007 2 20 2007FA0000115 1 20070111 G 7120 MOUNT BEECH 36 A36 1151604 CE CONT O550 IO550B SO MCAULY 3A32C D3A32C* GL ENGINE CORRODED D K NONE O OTHER IN INSP/MAINT 1 SW 13 1562F E2857 687034 940159 PERFORMED ANNUAL INSPECTION ON ENGINE, FOUND BLACK (FRETTING) CORROSION BELOW CENTER 2 (LT AFT) ENGINE MOUNT BOLTS. BOL TS WERE LOOSE IN MOUNT, BUT THE NUTS WERE TIGHT ON BOLTS. PROBLEM IS THAT THE BOLTS ARE A LITTLE TOO LONG AND THE NUTS WERE RUNNING OUT OF THREADS ON THE BOLTS. SOLUTION WAS TO ADD ANOTHER WASHER BELOW THE NUTS, THEN RETORQUE BACK TO SPEC S. (K) 1 L 7 1 3O 3 O 3A15 E3SO 5 C P21EA 2007051100144 20070511 00144 2007 5 11 2007FA0000119 1 20070208 G 2435 23085001 STARTER GEN OUT OF TOLERANCE B K NONE O OTHER IN INSP/MAINT 1 EA 65 603W 36 36 S/G SUSPECTED TO HAVE IMPROPER DRIVE SHAFT INSTALLED. DRIVE SHAFT MEASURES LONGER THAN ANOTHER S/G WITH SAME PN. ENGINE HAVE THEIR STARTER MOUNT BEARING FAIL. 2007021300067 20070213 00067 CE 2007 2 13 2007FA0000120 1 20070129 G 3340 CM358910 SWITCH CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA TAXI LIGHT ODOR B ODAR A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS AP APPROACH 1 EA 21 321ME 172S8566 PILOT REPORTED TO APPROACH THAT THERE WAS AN ELECTRICAL SMELL IN CABIN. AN EMERGENCY WAS DECLARED AND AIRCRAFT LANDED W ITHOUT INCIDENT. UPON INSPECTION, FOUND THE TAXI LIGHT CIRCUIT BREAKER/SWITCH WAS SLIGHTLY DISCOLORED, SMELLED BURNED A ND IT WAS INOPERATIVE. THERE WAS NO APPARENT OTHER DAMAGE TO CIRCUIT OR ANY OTHER PART. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 2007022000016 20070220 00016 2007 2 20 2007FA0000121 4 20070130 G 3418 C528072 TRANSDUCER PIPER PA46 PA46500TP 7104622 SO STALL WARNING FAILED G O OTHER O OTHER NR NOT REPORTED 1 CE 07 5337N 320 4697102 THIS UNIT WAS INSTALLED 12 MONTHS AGO. THIS IS A TYPICAL LIFE SPAN. CAUSE OF MALFUNCTION IS UNIT BEING OVERHEATED IN F LIGHT. THEY CAN`T TURN DOWN THE HEAT BECAUSE OF THE WAY IT WAS CERTIFIED. MOST PILOTS DO NOT KNOW THIS UNIT IS INOPERA TIVE. THE STALL WARNING HORN WILL SOUND EVEN THOUGH THE UNIT IS BAD. (K) 1 L 7 1 3O RT A25SO 2007021300057 20070213 00057 EA 2007 2 13 2007FA0000122 2 20070105 G 8530 NUT CESSNA 172 172N 2072434 CE LYC O320 O320* 41508 EA ARM RETAINER LOOSE B ONFR O OTHER O OTHER NR NOT REPORTED 1 EA 05 5123E 1788 17271722 RL8312761 THE NR 3 CYLINDER EXHAUST ROCKER ARM RETAINING NUT BECAME LOOSE, REDUCING LIFT ON THE EXHAUST VALVE, NOT ALLOWING SUFFIC IENT AIR TO EXIT THE CYLINDER. PRESSURE IN THE CYLINDER EXCEDED THE STRENGTH OF THE INTAKE VALVE SYSTEM TO OPEN, CAUSIN G THE INTAKE PUSHROD TO FALL (BEND). RECOMMEND A SIMPLE LOCKPLATE BE ADDED UNDER THE ROCKER ARM RETAINING NUT WITH A LO CK TAB TO ELIMINATE THIS POSSIBLE FAILURE. (K) 1 H 7 1 3O 3 O NT 3A12 E274 2007030900126 20070309 00126 CE 2007 3 9 2007FA0000141 1 20070205 G 2820 0500106326 FUEL LINE CESSNA 180 180 2072602 CE FUEL SYS WORN D O OTHER W INADEQUATE Q C NR NOT REPORTED 1 AL 05 4000 FLAP CABLE WEARING INTO FUEL LINE. FUEL LINE WAS INCORRECTLY ASSEMBLED. VISUAL INSPECTION OF AREA AT ANNUAL OR 100 HR INSPECTIONS. (K) 1 H 7 1 3O NC 5A6 2007022600185 20070226 00185 SO 2007 2 26 2007FA0000144 1 20070205 G 3230 6741102 SWITCH PIPER PA34 PA34200 7103405 SO LYC O360 IO360C1E6 41514 EA MLG FROZEN C O OTHER O OTHER NR NOT REPORTED 1 EA 17 1533E 347350050 UPON LANDING, GEAR EXTENSION, DURING APPROACH TO LANDING, PILOT NOTED AN EXCEPTIONALLY LONG TIME BETWEEN GEAR SWITCH AC TUATION AND INDICATION OF ALL DOWN AND LOCKED. OUTSIDE TEMP +9 F. BELIEVE THAT SWITCH ARM FOR DOWNLOCK HAD FROZEN IN P LACE (UP) AND REQUIRED TIME TO ACTUATE. (K) 1 L 7 2 3O 3 O A7SO 1E10 2007022600076 20070226 00076 CE 2007 2 26 2007FA0000145 1 20070215 G 7810 02R3022406 EXHAUST DUCT BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA LT ENGINE CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 09 6162 731 PCE85441 WHILE PERFORMING SCHEDULED MAINTENANCE, REMOVED LT ENGINE EXHAUST STACKS TO FACILITATE INSPECTING THE EXHAUST DUCT. FOU ND A 14 INCH CRACK FOLLOWING THE CIRCUMFERENCE OF THE SKI SLOPE WITH A 3 INCHES CRACK PROPAGATING LONGITUDELY AT THE 10 O'CLOCK POSITION FROM THE 14 INCHES CRACK. EXHAUST DUCT HAD PWA SB 3380 COMPLIED WITH 731 HOURS EARLIER. BECAUSE OF THE REMAINING ENGINE TIME, IT WILL BE PULLED FOR OVERHAUL. 1 L 7 2 4T 4 T A24CE E4EA 2007022300288 20070223 00288 CE 2007 2 23 2007FA0000147 1 20070201 G 2571 HOSE BEECH 95 B95 1153404 CE BATTERY BOX DISCONNECTED C K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 01 9631R TD314 BATTERY ELECTROLYTE RESIDUE FOUND ON LEFT NOSE GEAR DOOR AND LOWER FORWARD FUSELAGE. INSPECTION REVEALED BATTERY BOX DR AIN HOSE DISCONNECTED AND HANGING IN LOWER NOSE STRUCTURE AREA BELOW THE BAGGAGE FLOOR. ACCESS IS HINDERED BY NUMEROUS FASTENERS THAT ARE HARD TO REMOVE. AT SOME TIME IN THE PAST THE ADF ANTENNA MAST, WHICH DOUBLED AS THE BATTERY DRAIN MA ST, HAD BEEN REMOVED AND THE BATTERY DRAIN HOSE WAS NOT RECONNECTED TO A SUITABLE DRAIN. THIS COULD CAUSE CORROSION DAM AGE TO NOSE AREA LOWER STRUCTURE ON TRAVEL AIR AND BARON AIRPLANES, WHICH HAVE SIMILAR DESIGN. BEECH MODEL 95 PARTS AND SHOP MANUALS CARRY NO REFERENCES ABOUT THE BATTERY DRAIN SYSTEM. SUGGEST REVIEW OF ANY RAYTHEON SERVICE BULLETINS DISC 1 L 7 2 3O 3A16 2007030100236 20070301 00236 SO 2007 3 1 2007FA0000148 1 20070214 G 3234 761213 LEVER PIPER PA23 PA23250 7102308 SO LYC O540 TIO540* 41532 EA COCKPIT BROKEN D F7HS O OTHER O OTHER CL CLIMB 1 WP 13 31PD 7657 277654016 LANDING GEAR LEVER BROKE AT THE RIVET DURING TAKEOFF, AFTER RAISING LANDING GEAR LEVER UP TO RETRACT LANDING GEAR. (K) 1 L 7 2 3O 3 O 1A10 E14EA 2007030100201 20070301 00201 2007 3 1 2007FA0000149 2 20070209 G 7414 6310 MAGNETO ENGINE MALFUNCTIONED B WS9R K NONE R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 NM 07 MAGNETO IS MISSING AT HIGH ALTITUDE. (K) 2007030100202 20070301 00202 2007 3 1 2007FA0000150 2 20070209 G 7414 6310 MAGNETO ENGINE MALFUNCTIONED B WS9R K NONE R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 NM 07 2 MAGNETO`S MISSING AT HIGH ALTITUDE. (K) 2007030900152 20070309 00152 SW 2007 3 9 2007FA0000151 1 20070214 G 5712 FASTENER BBAVIA 7 7ECA 21101NN SW LYC O235 O235* 41505 EA WING OUT OF POSITION D O OTHER O OTHER NR NOT REPORTED 1 NE 05 5505N 126678 RIB NAILS PULLING OUT IN ALMOST EVERY RIB. RT TIP RIB HAS ALL NAILS PULLED OUT AND A SPACE BETWEEN RIBS AND SPARS, BOT H FRONT AND REAR LOCATIONS. LT WING HAS ONE NAIL THAT IS ABOUT TO FALL OUT AS IT IS PULLED/WORKED OUT .4375 INCH. 80 P ERCENT OF RIBS HAVE AT LEAST ONE NAIL OUT OVER .1250 INCH, AND ONLY APPROX 10 PERCENT OF TOTAL NAILS ARE NOT MOVING. HA VE NOT DISASSEMBLE YET FOR SPAR DAMAGE, BUT HAVE SEEN A FEW NAILS THAT ARE (SMOKING) WHERE THEY CONTACT THE ALUMINUM RIB . ALL FOUND DURING ROUTINE INSPECTION AT ANNUAL IAW AD AND APPLICABLE SB`S IAW THE AD. (K) 1 H 7 1 3O 3 O A759 E223 2007030900114 20070309 00114 SO 2007 3 9 2007FA0000155 2 20070212 G 8530 CYLINDER CESSNA 206 U206B 2073322 CE CONT O520 IO520F 17032 SO ENGINE CRACKED D O OTHER O OTHER NR NOT REPORTED 1 AL 03 4988F U2060688 CRACKED CYLINDER HEAD BETWEEN 4TH AND 5TH FIN IB OF TOP SPARK PLUG. CRACKS HEADED TOWARD VALVE SEAT. (K) 1 H 7 1 3O 3 O A4CE E5CE 2007032900296 20070329 00296 SO 2007 3 29 2007FA0000156 2 20070212 G 8530 CYLINDER CESSNA 206 U206F 2073333 CE CONT O520 IO520F 17032 SO ENGINE CRACKED D O OTHER O OTHER NR NOT REPORTED 1 AL 03 7711D U20603170 CRACKED CYLINDER LEAD BETWEEN 4TH AND 5TH FIN IB AT UPPER SPARK PLUG. CRACK NOT VISIBLE INSIDE CYLINDER. (K) 1 H 7 1 3O 3 O A4CE E5CE 2007030900046 20070309 00046 SO 2007 3 9 2007FA0000157 2 20070212 G 8530 AEC63139 CYLINDER CESSNA 206 U206F 2073333 CE CONT O520 IO520F 17032 SO ENGINE CRACKED D O OTHER O OTHER NR NOT REPORTED 1 AL 03 7711D 10226 U20603170 CRACKED CYLINDER BETWEEN 2ND AND 3RD FIN IB OF UPPER SPARK PLUG ORIENTED DOWN SIDE OF CYL HEAD. LARGE NEAR SEPARATION. (K) 1 H 7 1 3O 3 O A4CE E5CE 2007030900127 20070309 00127 SO 2007 3 9 2007FA0000158 2 20070212 G 8530 AEC631397 CYLINDER CESSNA 206 U206F 2073333 CE CONT O520 IO520F 17032 SO ENGINE CRACKED D O OTHER O OTHER NR NOT REPORTED 1 AL 03 7711D U20603170 CYLINDER HEAD CRACKED AT UPPER SPARK PLUG HOLE THRU BEND TO EXHAUST SEAT. (K) 1 H 7 1 3O 3 O A4CE E5CE 2007030900303 20070309 00303 CE 2007 3 9 2007FA0000162 1 20070206 G 5511 233201015 SPAR CAP LEAR LEAR 35 35A 5170602 CE GARRTT TFE731 TFE731* 01518 WP HORIZ STAB CORRODED C BHKR K NONE O OTHER IN INSP/MAINT 1 EA 21 96FN 17284 1187 186 VISUAL CONDITION CHECK PERFORMED ON HORIZONTAL STABILIZER AFT SPAR CAP AND ELEVATOR HINGE BRACKETS FOR CORROSION, BROKEN FASTENERS, ETC. FOUND SEVERE CORROSION ON UPPER SPAR CAP ASSEMBLY ALONG ENTIRE LENGTH. THIS REQUIRED REMOVAL AND REPL ACEMENT OF UPPER SPAR CAP. CORROSION CAUSED BY OPERATING CONDITIONS, LACK OF CONSISTENT WASHING PROGRAM AND POSSIBLE EX POSED, UNPROTECTED METAL. RECOMMENDA CONSISTENT AIRCRAFT WASHING PROGRAM WHEN OPERATIONS ARE IN OR NEAR COSTAL REGIONS AND ENSURING ALL EXPOSED SURFACES ARE PROPERLY TREATED AND PAINTED. (K) 2 L 7 2 4F 4 F A10CE E6WE 2007030900161 20070309 00161 SO 2007 3 9 2007FA0000163 1 20070201 G 8120 FITTING PIPER PA32 PA32301T 7103209 SO LYC O540 TIO540S1AD 41532 EA HARTZL HCE3Y HCE3YR1 GL TURBOCHARGER CRACKED D O OTHER K FLUID LOSS NR NOT REPORTED 1 SW 05 8185Y 522 328024018 L699564A FM1408B THIS PART IS BOLTED TO THE TURBOCHARGER ASSY BETWEEN THE HOT AND COLD SECTIONS. THE HIGH PRESSURE OIL LINE CONNECTS TO THIS PART VIA A FITTING IN THE TOP OF THE PART. AFTER AN ANNUAL INSP, THE ENG WAS RUN-UP AND SYSTEM CHECKED. AN OIL SE EP WAS NOTED IN THE TURBOCHARGER AREA. THE HIGH PRESSURE OIL LINE AND FITTING WAS REMOVED. PN LW 14465 WAS REMOVED AND CLEANED. THE CRACK WAS NOTED. THE PART WAS REPLACED WITH NEW. AFTER RESEARCHING THE AC RECORDS, IT WAS NOTED THAT EXH AUST SYS, INCLUDING TURBOCHARGER WASTE GATE AND CONTROL ROD END WAS NOT OVERHAULED WITH THE ENGINE CORE AS REQUIRED BY M FG. TURBOCHARGER WAS REPLACED WITH NEW UNIT AT TIME OF O/H. UNKNOWN IF PN LW-14465 WAS REPLACED AT THAT TIME. PART IS 1 L 7 1 3O 3 O A3SO E14EA 5 C P33EA 2007032900265 20070329 00265 EA 2007 3 29 2007FA0000164 2 20070206 G 8500 ENGINE CESSNA 206 T206H 2073303 CE LYC O540 TIO540A1A 41532 EA MAKING METAL D K NONE O OTHER IN INSP/MAINT 1 GL 21 3543B T20608330 L1123761A UNDER NORMAL CONDITIONS AND UNDER OIL SAMPLE PROGRAM, ENGINE HAS HAD (6) HIGH BAD SAMPLES, HIGH IRON, COPPER AND ALUMINU M. AC IS A PUBLIC USE AIRCRAFT WITH CUSTOMS AND BORDER PROTECTION, BUT AM REPLACING ENGINE WITH NEW/ OVERHAUL. CONTACT ED MFG ABOUT PROBLEM BUT WAS TOLD TO KEEP CHANGING OIL AND FILTERS. RECOMMEND THA THIS TYPE ENGINE BE INVESTIGATED CLOS ER. THIS ENGINE WAS CHANGED IN 2005 DUE TO SIMILAR PROBLEM. (K) 1 H 7 1 3O 3 O RT A4CE E14EA 2007031200262 20070312 00262 CE 2007 3 12 2007FA0000165 1 20070206 G 5511 233201015 SPAR CAP LEAR 35 36LEAR 5170601 CE GARRTT TFE731 TFE731* 01518 WP HORIZ STAB CORRODED C BHKR K NONE O OTHER IN INSP/MAINT 1 EA 21 12FN 15719 016 VISUAL CONDITION CHECK PERFORMED ON HORIZONTAL STABILIZER AFT SPAR CAP AND ELEVATOR HINGE BRACKETS FOR CORROSION, BROKEN FASTENERS, ETC. FOUND MODERATE CORROSION ON UPPER SPAR CAP ASSY AT LT OB ELEVATOR HINGE AREA. THIS REQUIRED REMOVAL A ND REPLACEMENT OF UPPER SPAR CAP. CORROSION CAUSED BY OPERATING CONDITIONS, LACK OF CONSISTENT WASHING PROGRAM AND POSS IBLE EXPOSED, UNPORTECTED METAL. RECOMMEND A CONSISTENT AC WASHING PROGRAM WHEN OPERATIONS ARE IN OR NEAR COASTAL REGIO NS AND ENSURING ALL EXPOSED SURFACES ARE PROPERLY TREATED AND PAINTED. (K) 2 L 7 2 4F 4 F A10CE E6WE 2007022600030 20070226 00030 EU 2007 2 26 2007FA0000166 1 20070223 G 6230 1090110677 FITTING AGUSTA A109 A109A2 0260120 EU ALLSN 250C 250C20 03013 GL MAIN ROTOR WORN D K NONE O OTHER IN INSP/MAINT 1 EA 35 745HA 32 7413 MAIN ROTOR DRIVELINK UPPER FITTING STEEL BUSHES (109-0110-70-1) AND UPPER SLEEVE (109-0110-69-1) SEVERELY WORN. SLEEVE STEPPED TO LESS THAN HALF MANUFACTURED DIAMETER AT BOTH ENDS. STEEL BUSHES WORN THROUGH COMPLETELY, WEAR EXTENDING INTO FITTING. HOLE IN BOTH ENDS OF FITTING FOR STEEL BUSHES ELONGATED. PHOTOGRAPHS AND DISCREPANT PARTS AVAILABLE IF REQUI RED. DEFECTIVE PARTS REPLACED. 1 G 7 2 3U 3 U H7EU E4CE 2007030900122 20070309 00122 SO 2007 3 9 2007FA0000168 1 20070206 G 5711 SPAR PIPER J3 J3C65 7100510 SO WING CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 05 6609H 2884 19808 DURING REMOVAL OF LT WING FOR INSTALLATION OF WING FUEL TANK, A QUESTIONABLE PREVIOUS REPAIR WAS FOUND AT THE FRONT WOOD SPAR ROOT. FURTHER INVESTIGATION FOUND LONGNATUDINAL CRACKS OF THE LT AND RT, FOR AND AFT WOOD WING SPARS. THESE CRAC KS WERE VISIBLE WITH A BARE EYE WHEN THE FRONT SPAR CARRY ATTACH INSPECTION PANEL WAS REMOVED AND INSPECTED FROM THE FRO NT CABIN AREA. CRACKS ARE NOT UNCOMMON AFTER 60 YEARS OF HARD SERVICE AND NATURAL DEGRADATION OF THE WOOD. (K) 1 H 7 1 3O A691 2007022600170 20070226 00170 SO 2007 2 26 2007FA0000169 1 20070223 G 5751 86562025 AILERON PIPER PA44 PA44180 7104402 SO LYC O360 O360* 41514 EA RIGHT MISREPAIRED B O OTHER W INADEQUATE Q C NR NOT REPORTED 1 WP 07 576ER 3598 4496152 DURING POWER OFF (CLEAN CONFIGURATION) STALLS, THE AIRCRAFT WOULD SUDDENLY BREAK LT AND IF NOT IMMEDIATELY STOPPED COULD LEAD TO A SPIN. AFTER RERIGGING ALL FLIGHT CONTROLS, CHECKING THE AIRCRAFT ALIGNMENT WITH A LASER AND SEVERAL TEST FLI GHTS BOTH BY COMPANY PILOTS AND MFG FACTORY TEST PILOT, IT WAS DETERMINED THAT WE HAD (FAT) AILERONS ON OUR FLEET. MFG HAS A HISTORY OF AILERON SKIN CRACKING. (FOR US, IT HAS JUST BEEN THE RT AILERON THAT HAS HAD THE CRACKING PROBLEM.) O NCE THE CRACK IS PAST A CERTAIN POINT YOU EITHER HAVE TO REPLACE THE AFFECTED SKIN OR REPLACE THE AILERON. DURING SKIN REPLACEMENT, IF THE PREFORMED FACTORY SKIN IS SPREAD APART EVEN A LITTLE THE T/E TAKES ON A (FAT) CONDITION. THIS LEADS 1 L 7 2 3O 3 O A19S0 E286 2007022700048 20070227 00048 CE 2007 2 27 2007FA0000171 1 20070220 G 3230 504501033 TORQUE TUBE CESSNA CESSNA 340 340A 2076405 CE CONT O550 IO550* SO MLG BINDING D K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 15 467DB 340A0467 DURING REPLACEMENT OF ORIGINAL EQUIPMENT TORQUE TUBE (P/N 5045010-18/19) WITH MFG REPLACEMENT P/N 5045010-32/33 INTERFER ENCE BETWEEN THE TORQUE TUBE AND AIRFRAME ATTACHMENT FITTING WAS DISCOVERED. RIGGING THE MLG TO ACHIEVE A .1250 DROP OF F WAS IMPOSSIBLE DUE TO THE INTERFERENCE BETWEEN THE TORQUE TUBE AND THE ATTACHMENT FITTING. DROP OFF IS ACHIEVED ONCE T HE TORQUE TUBE ROTATES FAR ENOUGH OVER CENTER TO ALLOW THE GEAR TO DROP .1250 BACK DOWN FROM ITS MAXIMUM HEIGHT. MFG TE CHNICAL SUPPORT INDICATED THAT THE ORIGINAL TORQUE TUBE (-18/19) HAD A FLAT SPOT BETWEEN THE AFT HINGE ARMS DESIGNED TO CLEAR THE AIRCRAFT STRUCTURE. THIS FLAT SPOT WAS ORIENTED AT A 33 DEGREE OFFSET. THE TORQUE TUBES WERE REDESIGNED IN 197 1 L 7 2 3O 3 O 3A25 E3SO 2007022700051 20070227 00051 2007 2 27 2007FA0000173 2 20070222 G 7414 6310 MAGNETO ENGINE MALFUNCTIONED C O OTHER O OTHER NR NOT REPORTED 1 NM 07 2 MAGNETO CAUSING HIGH ALTITUDE MIS-FIRE. 2007022700087 20070227 00087 CE 2007 2 27 2007FA0000174 1 20070201 G 2432 HOSE BEECH 95 B95 1153404 CE LYC O360 O360* 41514 EA BATTERY DRAIN DISCONNECTED C K NONE K FLUID LOSS IN INSP/MAINT 1 NM 01 9631R TD314 BATTERY ELECTROLYTE RESIDUE FOUND ON LT NOSE GEAR DOOR AND LOWER FORWARD FUSELAGE. INSPECTION REVEALED BATTERY BOX DRAI N HOSE DISCONNECTED AND HANGING IN LOWER NOSE STRUCTURE AREA BELOW THE BAGGAGE FLOOR. ACCESS IS HINDERED BY NUMEROUS FA STENERS THAT ARE HARD TO REMOVE. AT SOME TIME IN THE PAST THE ADF ANTENNA MAST, WHICH DOUBLED AS THE BATTERY DRAIN MAST , HAD BEEN REMOVED AND THE BATTERY DRAIN HOSE WAS NOT RECONNECTED TO A SUITABLE DRAIN. THIS COULD CAUSE CORROSION DAMAG E TO NOSE AREA LOWER STRUCTURE ON TRAVEL AIR AND BARON AIRPLANES, WHICH HAVE SIMILAR DESIGN. PARTS AND SHOP MANUALS CAR RY NO REFERENCES ABOUT THE BATTERY DRAIN SYSTEM. SUGGEST REVIEW OF ANY MFG SB DISCUSSING BATTERY BOX DRAIN COMPONENTS, 1 L 7 2 3O 3 O 3A16 E286 2007030200033 20070302 00033 CE 2007 3 2 2007FA0000175 1 20070216 G 1100 070507109 PLACARD CESSNA 206 206CESSNA 2073302 CE LYC O540 TIO540AJ1A EA MCAULY 3D36C B3D36C432 GL WING FADED D K NONE O OTHER IN INSP/MAINT 1 EA 27 150 T20608291 L1083261A 002324 P/N 0705071-9) FUEL QUANTITY AND TYPE PLACARDS HAVE BEEN REPLACED ABOUT ONCE A YEAR DUE TO FADING. THIS AIRCRAFT IS HAN GARED. THIS FADING HAS BEEN NOTED WITH OTHER MFG AIRCRAFT. RETAIL COST LAST YEAR NR 50.00+. THIS HAS NOW DOUBLED. OW NERS DON'T PLACARD IMPORTANCE FOR AIRWORTHINESS. 1 H 7 1 3O 3 O A4CE E14EA 5 C P58GL 2007031200032 20070312 00032 CE 2007 3 12 2007FA0000176 1 20070222 G 2752 55651904 ROLL PIN CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE SPROCKET BROKEN B K NONE O OTHER IN INSP/MAINT 1 SW 13 797CW 8177 1200 5500232 DURING A PHASE 5 INSPECTION THE FLAPS SEAMED TO BE SLOW AND BINDING. AT CLOSER INSPECTION IT WAS FOUND THAT THE ROLL PIN HAD BROKEN ALLOWING THE SPROCKET TO MOVE FWD. ON THE P/N 5565190-9 BRAZE ASSY-DRIVE THIS CAUSED BINDING AND ALLOWED THE SPROCKET TO EVEN DROP DOWN ON TO THE P/N 6565193-9 CHAIN GUARD-LOWER FWD. THIS IS A HARD AREA TO LOOK AT EVEN WITH A MI RROR. A FEW MORE ACTIONS WITH THE FLAP WOULD HAVE LED TO TOTAL FAILURE OF THIS SYSTEM. 1 L 7 2 4F 4 F A22CE E1NE 2007030200034 20070302 00034 SO 2007 3 2 2007FA0000177 1 20070223 G 5751 86562025 AILERON PIPER PA44 PA44180 7104402 SO LYC O360 O360* 41514 EA WING MISREPAIRED D O OTHER W F INADEQUATE Q C FLT CONT AFFECTED CR CRUISE 1 WP 07 570ER 3583 4496146 DURING POWER OFF (CLEAN CONFIGURATION) STALLS, THE AIRCRAFT WOULD SUDDENLY BREAK LT AND IF NOT IMMEDIATELY STOPPED COULD LEAD TO A SPIN. AFTER RERIGGING ALL FLIGHT CONTROLS, CHECKING THE AIRCRAFT ALIGNMENT WITH A LASER AND SEVERAL TEST FLI GHTS BOTH BY COMPANY PILOTS AND MFG FACTORY TEST PILOT, IT WAS DETERMINED THAT WE HAD (FAT) AILERONS ON OUR FLEET. MFG HAS A HISTORY OF AILERON SKIN CRACKING. (FOR US, IT HAS JUST BEEN THE RT AILERON THAT HAS HAD THE CRACKING PROBLEM). O NCE THE CRACK IS PAST A CERTAIN POINT YOU EITHER HAVE TO REPLACE THE AFFECTED SKIN OR REPLACE THE AILERON. DURING SKIN REPLACEMENT, IF THE PREFORMED FACTORY SKIN IS SPREAD APART EVEN A LITTLE THE TRAILING EDGE TAKES ON A (FAT) CONDITION. 1 L 7 2 3O 3 O A19S0 E286 2007030800056 20070308 00056 SO 2007 3 8 2007FA0000178 1 20070223 G 5751 86562025 AILERON PIPER PA44 PA44180 7104402 SO LYC O360 O360* 41514 EA WING MISREPAIRED B O OTHER W F INADEQUATE Q C FLT CONT AFFECTED CR CRUISE 1 WP 07 571ER 3801 4496147 DURING POWER OFF (CLEAN CONFIGURATION) STALLS, THE AIRCRAFT WOULD SUDDENLY BREAK LT AND IF NOT IMMEDIATELY STOPPED COULD LEAD TO A SPIN. AFTER RERIGGING ALL FLIGHT CONTROLS, CHECKING THE AIRCRAFT ALIGNMENT WITH A LASER AND SEVERAL TEST FLI GHTS BOTH BY COMPANY PILOTS AND PIPER FACTORY TEST PILOT, IT WAS DETERMINED THAT WE HAD (FAT) AILERONS ON OUR FLEET. PI PER HAS A HISTORY OF AILERON SKIN CRACKING. (IT HAS BEEN THE RT AILERON THAT HAS HAD THE CRACKING PROBLEM). ONCE THE C RACK IS PAST A CERTAIN POINT YOU EITHER HAVE TO REPLACE THE AFFECTED SKIN OR REPLACE THE AILERON. DURING SKIN REPLACEME NT, IF THE PREFORMED FACTORY SKIN IS SPREAD APART EVEN A LITTLE THE TRAILING EDGE TAKES ON A (FAT) CONDITION. THIS LEAD 1 L 7 2 3O 3 O A19S0 E286 2007030800057 20070308 00057 SO 2007 3 8 2007FA0000179 1 20070223 G 5751 86562025 AILERON PIPER PA44 PA44180 7104402 SO LYC O360 O360* 41514 EA WING MISREPAIRED A O OTHER W F INADEQUATE Q C FLT CONT AFFECTED CR CRUISE 1 WP 07 572ER 3160 4496148 DURING POWER OFF (CLEAN CONFIGURATION) STALLS, THE AIRCRAFT WOULD SUDDENLY BREAK LT AND IF NOT IMMEDIATELY STOPPED COULD LEAD TO A SPIN. AFTER RERIGGING ALL FLIGHT CONTROLS, CHECKING THE AIRCRAFT ALIGNMENT WITH A LASER AND SEVERAL TEST FLI GHTS BOTH BY COMPANY PILOTS AND MFG FACTORY TEST PILOT, IT WAS DETERMINED THAT WE HAD (FAT) AILERONS ON OUR FLEET. MFG HAS A HISTORY OF AILERON SKIN CRACKING. (FOR US, IT HAS JUST BEEN THE RT AILERON THAT HAS HAD THE CRACKING PROBLEM.) O NCE THE CRACK IS PAST A CERTAIN POINT YOU EITHER HAVE TO REPLACE THE AFFECTED SKIN OR REPLACE THE AILERON. DURING SKIN REPLACEMENT, IF THE PREFORMED FACTORY SKIN IS SPREAD APART EVEN A LITTLE THE TRAILING EDGE TAKES ON A (FAT) CONDITION. 1 L 7 2 3O 3 O A19S0 E286 2007030800058 20070308 00058 SO 2007 3 8 2007FA0000180 1 20070223 G 5751 86562025 AILERON PIPER PA44 PA44180 7104402 SO LYC O360 O360* 41514 EA WING MISREPAIRED B O OTHER W F INADEQUATE Q C FLT CONT AFFECTED CR CRUISE 1 WP 07 573ER 3969 4496149 DURING POWER OFF (CLEAN CONFIGURATION) STALLS, THE AIRCRAFT WOULD SUDDENLY BREAK LT AND IF NOT IMMEDIATELY STOPPED COULD LEAD TO A SPIN. AFTER RERIGGING ALL FLIGHT CONTROLS, CHECKING THE AIRCRAFT ALIGNMENT WITH A LASER AND SEVERAL TEST FLI GHTS BOTH BY COMPANY PILOTS AND PIPER FACTORY TEST PILOT, IT WAS DETERMINED THAT WE HAD (FAT) AILERONS ON OUR FLEET. MF G HAS A HISTORY OF AILERON SKIN CRACKING. (FOR US, IT HAS JUST BEEN THE RT AILERON THAT HAS HAD THE CRACKING PROBLEM). ONCE THE CRACK IS PAST A CERTAIN POINT YOU EITHER HAVE TO REPLACE THE AFFECTED SKIN OR REPLACE THE AILERON. DURING SKI N REPLACEMENT, IF THE PREFORMED FACTORY SKIN IS SPREAD APART EVEN A LITTLE THE TRAILING EDGE TAKES ON A (FAT) CONDITION. 1 L 7 2 3O 3 O A19S0 E286 2007030800059 20070308 00059 SO 2007 3 8 2007FA0000182 1 20070223 G 5751 86562025 AILERON PIPER PA44 PA44180 7104402 SO LYC O320 O320* 41508 EA WING MISREPAIRED B O OTHER W F INADEQUATE Q C FLT CONT AFFECTED CR CRUISE 1 WP 07 577ER 3881 4496153 DURING POWER OFF (CLEAN CONFIGURATION) STALLS, THE AIRCRAFT WOULD SUDDENLY BREAK LT AND IF NOT IMMEDIATELY STOPPED COULD LEAD TO A SPIN. AFTER RERIGGING ALL FLIGHT CONTROLS, CHECKING THE AIRCRAFT ALIGNMENT WITH A LASER AND SEVERAL TEST FLI GHTS BOTH BY COMPANY PILOTS AND MFG FACTORY TEST PILOT, IT WAS DETERMINED THAT WE HAD (FAT) AILERONS ON OUR FLEET. MFG HAS A HISTORY OF AILERON SKIN CRACKING. (FOR US, IT HAS JUST BEEN THE RT AILERON THAT HAS HAD THE CRACKING PROBLEM.) O NCE THE CRACK IS PAST A CERTAIN POINT YOU EITHER HAVE TO REPLACE THE AFFECTED SKIN OR REPLACE THE AILERON. DURING SKIN REPLACEMENT, IF THE PREFORMED FACTORY SKIN IS SPREAD APART EVEN A LITTLE THE TRAILING EDGE TAKES ON A (FAT) CONDITION. 1 L 7 2 3O 3 O A19S0 E274 2007022700060 20070227 00060 EA 2007 2 27 2007FA0000183 2 20070211 G 8540 13S19646 GEAR CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA MCAULY 1A170 1A170E GL CRANKSHAFT LOOSE D A UNSCHED LANDING Y ENGINE STOPPAGE CL CLIMB 1 GL 15 242SP 1855 172S8226 L2830651A SK039 DURING TAKEOFF AT 400 FT AGL ENGINE QUIT FORCING AN OFF AIRPORT EMERGENCY LANDING. INITIAL INSPECTION FOUND NO MOVEMENT OF ACCESSORIES AND VALVE MOVEMENT. REMOVED ACCESSORIES CASE AND FOUND DRIVE GEAR ON CRANKSHAFT MOUNT BOLT LOOSE AND PI N SHEARED. MARKS SHOW THAT BOLT AND GEAR WERE LOOSE FOR SOME TIME ALLOWING WEAR ON PIN UNTIL FAILURE. SUSPECT INCORRECT TORQUE OR INCORRECT SEATING OF GEAR TO FLANGE. ALSO WITH GEAR LOOSE BOLT COULD BE TURNED IN LOCKING TAB. HOLE IN LOCKI NG TAB TOO LOOSE ON BOLT. ENGINE NEW FROM MFG. WITH 1855.3 HOURS. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P857 2007032900295 20070329 00295 EA 2007 3 29 2007FA0000185 2 20070222 G 7414 ESIO357424 BUSHING BENDIX MOONEY M20 M20D 5870210 SW LYC O360 O360A1D 41514 EA MAGNETO LOOSE D O OTHER O OTHER NR NOT REPORTED 1 WP 17 6914U 31 1060379 246 BRONZE BUSHING VERY LOOSE IN DISTRIBUTOR BLOCK AND MAG WOULD NOT OPERATE CORRECTLY. AN EMERGENCY LANDING WAS MADE. (K) 1 L 7 1 3O 3 O 2A3 E286 2007030900172 20070309 00172 SO 2007 3 9 2007FA0000186 2 20070222 G 7414 BUSHING BENDIX CESSNA 172 172D 2072410 CE CONT O300 O300D 17022 SO MAGNETO LOOSE D K NONE O OTHER NR NOT REPORTED 1 WP 17 2948U 194 17250548 BRONZE BUSHING, VERY LOOSE IN DISTRIBUTOR BLOCK AND DISTRIBUTOR ARM WAS CONTACTING PINS IN BLOCK. MAG WOULD NOT OPERATE CORRECTLY. (K) 1 H 7 1 3O 3 O NT 3A12 E253 2007030900140 20070309 00140 EU 2007 3 9 2007FA0000187 1 20070222 G 2910 285683 COUPLING AMD FALC10 FALCON10 2730101 EU GARRTT TFE731 TFE7312 01518 WP HYDRAULIC SYS DEFECTIVE D O OTHER O OTHER NR NOT REPORTED 1 GL 03 43EC 9017 168 THIS COUPLING IS A QUICK-DISCONNECT TYPE FITTING THAT IS IN LINE OF THE ENGINE DRIVEN HYDRAULIC PUMP AND LOCATED IN THE ENGINE PYLON. THERE IS ONLY ONE ON EACH ENGINE AND ONLY ON THE SUCTION LINE. THESE FITTINGS HAVE NO TIME CHANGE REQUIR EMENT. WHEN THIS PART WAS CHANGED (DUE TO EXTERNAL LEAKAGE) IT WAS EXTREMELY DIFFICULT TO SEPARATE. ONCE SEPARATED, TH E LOCKING BALLS HAD DUG SO DEEPLY INTO THE LOCK RING THAT PARTIAL UNSEATING OF THE O-RING HAD OCCURRED. THERE QUICK DIS CONNECT COUPLINGS (LT AND RT) SHOULD BE REQUIRED TO BE INSPECTED AT EACH ENGINE REMOVAL AND REPLACED IF WEAR IS DETECTED . (K) 2 L 7 2 4F 4 F A33EU E6WE 2007032900294 20070329 00294 CE 2007 3 29 2007FA0000188 1 20070215 G 2510 551900922 SEAT CESSNA CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE COCKPIT CRACKED D O OTHER O OTHER NR NOT REPORTED 1 CE 05 404BS 5500403 UPPER CHAIR BASE ASSY CRACKED AT CHAIR BACK ATTACH POINTS. STRESS ON CHAIR BACK AND METAL FATIGUE PROBABLE CAUSE. CHAI R WAS REPAIRED IAW STC 01042WI STRUCTURAL SEAT REPAIR. (K) 1 L 7 2 4F 4 F A22CE E1NE 2007032600101 20070326 00101 CE 2007 3 26 2007FA0000189 1 20070226 G 2750 051010593 CONTROL CABLE CESSNA 172 172N 2072434 CE LYC O320 O320* 41508 EA TE FLAPS FRAYED B O OTHER O OTHER NR NOT REPORTED 1 GL 05 31SZ 13729 13729 17267732 PILOT REPORTED EXCESSIVE MOVEMENT IN LT FLAP DURING PRE-FLIGHT WALK AROUND OF AIRCRAFT. INITIAL INVESTIGATION BY MAINTE NANCE PERSONNEL CONFIRMED FINDINGS. MAINTENANCE PERSONNEL DISCOVERED THAT CABLE P/N 0510105-93 HAD MULTIPLE BROKEN STRA NDS/FRAYING NEAR THE TURNBUCKLE END. SUSPECTED CAUSE OF DAMAGE TO CABLE IS DUE TO EXCESSIVE FLEXING BETWEEN TURNBUCKLE END AND FLAP POSITION INDICATOR CLAMP, P/N 0560037-1. AD 80-06-03 HAD BEEN COMPLIED WITH ON 10/11/1982 BY INSTALLATION OF KIT SK172-60A. 1 H 7 1 3O 3 O NT 3A12 E274 2007030100205 20070301 00205 GL 2007 3 1 2007FA0000190 3 20070221 G 6114 C4201C58 HUB MCAULY MCAULY 2A34C D2A34C58 GL PROPELLER CRACKED B LT4R K NONE O OTHER IN INSP/MAINT 1 SO 19 720009 720009 HUB RECEIVED DISASSEMBLED, CLEANED AND ANODIZED WITH NO CERTIVICATION. BLADE RETENTION THREADS EDDY CURRENT INSPECTED. NR 1 BLADE RETENTION THREAD, 4 THREADS IN AT APPROXIMATELY 6 O`CLOCK POSITION FOUND CRACKED. HUB REMOVED FROM SERVICE. (K) 5 C P3EA 2007030900119 20070309 00119 EU 2007 3 9 2007FA0000191 1 20070227 G 5730 S25WS3001 SKIN BRAERO DH125 HS125700A 4230170 EU GARRTT TFE731 TFE731* 01518 WP RT WING CORRODED D O OTHER O OTHER NR NOT REPORTED 1 WP 23 224EA 9121 257088 RT WING LEADING EDGE(S) HAD SEVERE CORROSION WHERE THE TKS PANELS ATTACH. AFTER COMPLETE DISASSEMBLY IT WAS DETERMINED TO BE BEYOND ECONOMICAL REPAIR. RT WING LEADING EDGE HAD BEEN INSPECTED AT MFG 2.5 YEAR PRIOR TO THIS DISCOVERY. (K) 2 L 7 2 4F 4 F A3EU E6WE 2007032600144 20070326 00144 EU 2007 3 26 2007FA0000192 1 20070227 G 5754 S25WS3002 SKIN BRAERO DH125 HS125700A 4230170 EU GARRTT TFE731 TFE731* 01518 WP RT WING LE CORRODED D O OTHER O OTHER NR NOT REPORTED 1 WP 23 224EA 9121 257088 RT WING LEADING EDGE(S) HAD SEVERE CORROSION WHERE THE TKS PANELS ATTACH. AFTER COMPLETE DISASSEMBLY, IT WAS DETERMNED TO BE BEYOND ECONOMICAL REPAIR. RT WING LEADING EDGE HAD BEEN INSPECTED AT MFG 2.5 YEARS PRIOR TO THIS DISCOVERY. (K) 2 L 7 2 4F 4 F A3EU E6WE 2007040200170 20070402 00170 2007 4 2 2007FA0000193 2 20070213 G 7414 6350 ROTOR MAGNETO BROKEN D O OTHER O OTHER NR NOT REPORTED 1 SW 99 ROTOR AT ROTOR GEAR AND BROKEN. (K) 2007030900133 20070309 00133 EU 2007 3 9 2007FA0000194 1 20070221 G 5512 25TP1001A SKIN BRAERO DH125 HS125700A 4230170 EU GARRTT TFE731 TFE731* 01518 WP HORIZ STAB CORRODED C O OTHER O OTHER NR NOT REPORTED 1 WP 01 224EA 9121 257088 LT AND RT HORIXONTAL STABILIZER LEADING EDGES HAD SEVERE CORROSION WHERE THE TKS PANELS ATTACH. AFTER COMPLETE DISASSEM BLY, IT WAS DETERMINED TO BE BEYOND ECONOMICAL REPAIR. THIS AREA HAD BEEN INSPECTED AT MFG 2.5 YEARS PRIOR TO THIS DISC OVERY. (K) 2 L 7 2 4F 4 F A3EU E6WE 2007032900299 20070329 00299 CE 2007 3 29 2007FA0000195 1 20070129 G 3233 LIMIT SWITCH CESSNA 310 310J 2074226 CE CONT O470 IO470* 17026 SO NLG ACTUATOR FAILED G O OTHER O OTHER NR NOT REPORTED 1 SO 15 3091L 310J0091 UP LIMIT SWITCH FAILED ON LANDING GEAR ACTUATOR, CAUSING OVER EXTENSION OF NOSE GEAR SYSTEM. THIS CAUSED THE INTERMEDIA TE TORQUE TUBE TO BEND. (K) 1 L 7 2 3O 3 O 3A10 E1CE 2007040200168 20070402 00168 WP 2007 4 2 2007FA0000196 2 20070220 G 7261 8961051 COVER BEECH 100 B100 1152919 CE GARRTT TPE331 TPE3316 01514 WP LT ENGINE BROKEN D O OTHER O OTHER NR NOT REPORTED 1 WP 09 241CW BE54 P27188 PILOT REPORTED HIGH OIL CONSUMPTION, INSPECTED LT ENGINE SCAVENGE PUMP AND FOUND THE PUMP COVER BROKEN AND MISSING PIECE S. ALSO FOUND THE SCAVENGE PUMP OIL TUBE COVER BROKEN AND CHAFING A HOLE THROUGH THE OIL TUBE. RECOMMEND REMOVING EXHA UST PIPE AT INSPECTIONS TO INSPECT PUMP COVER AND TUBE ASSY FOR DEFECTS. (K) 1 L 7 2 4T 4 T A14CE E4WE 2007030900116 20070309 00116 CE 2007 3 9 2007FA0000199 1 20070301 G 2571 07120591P SUPPORT CESSNA 182 182T 2072703 CE LYC O540 IO540* 41532 EA BATTERY BOX CRACKED D O OTHER O OTHER NR NOT REPORTED 1 SW 15 3539G 18281039 FOUND BATTERY SUPPORT CRACKED. TOTAL AIRFRAME TIME 1075. THIS IS THE 3RD ONE THAT WE FOUND. SUPPORTS NEED TO BE BEEFE D UP, THEY ARE TOO LIGHT FOR THE APPLICATION. (K) 1 H 7 1 3O 3 O NT 3A13 1E4 2007030900157 20070309 00157 CE 2007 3 9 2007FA0000200 1 20070301 G 2571 07120591P SUPPORT CESSNA 182 182T 2072703 CE LYC O540 IO540* 41532 EA BATTERY BOX CRACKED D O OTHER O OTHER NR NOT REPORTED 1 SW 15 65KC 18281015 FOUND BATTERY SUPPORT CRACKED. TOTAL AIRFRAME TIME 1716. THIS IS THE THIRD ONE THAT WE FOUND SUPPORTS NEED TO BE BEEFE D UP, THEY ARE TOO LIGHT FOR THE APPLICATION. (K) 1 H 7 1 3O 3 O NT 3A13 1E4 2007031200254 20070312 00254 EA 2007 3 12 2007FA0000201 2 20070221 G 8520 V53793493 CRANKSHAFT CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA ENGINE CORRODED B YYBR K NONE O OTHER IN INSP/MAINT 1 GL 03 982BT 4744 2196 17280307 L1466351A THIS CRANKSHAFT WAS LAST INSPECTED AND PID COATED AT THE FACTORY APRIL 23, 2002, YET 6 YEARS AND 2196 HOURS LATER, IT WA S PITTED, AND REQURIED FURTHER MACHINING. THE PID COATING DOES NOT SEEM TO HOLD UP, OR BLOCK THE CORROSION. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 2007031200253 20070312 00253 EA 2007 3 12 2007FA0000202 2 20070223 G 8520 V537925914 CRANKSHAFT CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA ENGINE CORRODED B YYBR K NONE O OTHER IN INSP/MAINT 1 GL 03 988BC 4170 2211 17280472 L2494851A DURING SCHEDULED OVERHAUL, THIS CRANKSHAFT WAS FOUND PITTED IN THE INNER BORE. THIS ENGINE WAS A FACTORY OVERHAUL JULY 2002, AND DID HAVE THE PID COATING. THE COATING DOES NOT SEEM TO BLOCK THE CORROSION. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 2007030900154 20070309 00154 EU 2007 3 9 2007FA0000203 1 20070213 G 8120 LW18607 STRUT PARTEN P68 P68TCOBS 6780108 EU TURBO BROKEN D K NONE O OTHER IN INSP/MAINT 1 SW 01 737 40004OTC RL20464A UPON REMOVING ENGINE FROM SHIPPING CRATE, FOUND (NEW) TURBO SUPPORT STRUT CRACKED. THESE BRACKETS CRACK ALL THE TIME ON THE AIRPLANE. VERY POOR DESIGN! (K) 1 H 7 2 3O RT A31EU 2007030900155 20070309 00155 EU 2007 3 9 2007FA0000204 1 20070213 G 8120 LW18607 STRUT PARTEN P68 P68TCOBS 6780108 EU TURBO BROKEN D K NONE O OTHER IN INSP/MAINT 1 SW 01 737 40004OTC RL20364A UPON REMOVING ENGINE FROM SHIPPING CRATE, FOUND (NEW) TURBO SUPPORT STRUT, CRACKED. THESE BRACKETS CRACK ALL THE TIME I N THE AIRPLANE. VERY POOR DESIGN! (K) 1 H 7 2 3O RT A31EU 2007032900292 20070329 00292 CE 2007 3 29 2007FA0000205 1 20070222 G 3610 1H1069 MIXING VALVE LEAR 60 60LEAR 5170707 CE PWA 305 PW305 NE BLEED AIR SYS INTERMITTENT C A UNSCHED LANDING J B WARNING INDICATION SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 GL 11 500 83 306 SHORTLY AFTER TAKEOFF, AIRCRAFT (L BLEED AIR) WARNING ILLUMINATED, AND (R BLEED AIR) WARNING ILLUMINATED APPROX 5 SEC LA TER, SMELLED ODOR IN CABIN. REDUCED POWER AND WARNING WENT OUT. AIRCRAFT DIVERTED FOR MAINTENANCE. UNABLE TO DUPLICAT E MALFUNCTION ON GROUND RUN, LT MIXING VALVE WAS SUSPECTED, SO REPLACED. PERFORMED GROUND RUN FUNCTIONAL TEST OF BLEED AIR SYSTEM, AND FLIGHT TEST. NO FURTHER BLEED AIR WARNINGS. (K) 2 L 7 2 4F 4 F RT A10CE E35NE 2007030800083 20070308 00083 SO 2007 3 8 2007FA0000206 1 20070223 G 5751 86562025 AILERON PIPER PA44 PA44180 7104402 SO LYC O360 O360* 41514 EA WING MISREPAIRED B BF8X O OTHER W F INADEQUATE Q C FLT CONT AFFECTED CR CRUISE 1 WP 07 575ER 3448 4496151 DURING POWER OFF (CLEAN CONFIGURATION) STALLS, THE AC WOULD SUDDENLY BREAK LEFT AND IF NOT IMMEDIATELY STOPPED COULD LEA D TO A SPIN. AFTER RERIGGING ALL FLIGHT CONTROLS, CHECKING THE AIRCRAFT ALIGNMENT WITH A LASER AND SEVERAL TEST FLIGHTS BOTH BY COMPANY PILOTS AND MFG TEST PILOT, IT WAS DETERMINED THAT WE HAD (FAT) AILERONS ON OUR FLEET. THIS MAKE OF AIR CRAFT HAS A HISTORY OF AILERON SKIN CRACKING. (FOR US, IT HAS JUST BEEN THE RT AILERON THAT HAS HAD THE CRACKING PROBLE M). ONCE THE CRACK IS PAST A CERTAIN POINT , YOU EITHER HAVE TO REPLACE THE AFFECTED SKIN OR REPLACE THE AILERON. DURI NG SKIN REPLACEMENT, IF THE PREFORMED FACTORY SKIN IS SPREAD APART EVEN A LITTLE, THE TRAILING EDGE TAKES ON A (FAT) CON 1 L 7 2 3O 3 O A19S0 E286 2007030900004 20070309 00004 CE 2007 3 9 2007FA0000207 1 20070301 G 2432 G35 BATTERY CESSNA 180 180 2072602 CE CONT O470 O470* 17026 SO LEAKING D O OTHER O OTHER NR NOT REPORTED 1 GL 15 9198C 34 31297 BATTERY ACID LEAKED OR TRANSFERRED TO AFT, LOWEST CELL (AIRCRAFT TAIL WHEEL) AND SPILLED OUT. CORRODED HOLE IN BATTERY BOX AND SPILLED INTO BELLY OF AIRCRAFT. 1 H 7 1 3O 3 O NC 5A6 E273 2007030900005 20070309 00005 CE 2007 3 9 2007FA0000208 1 20070301 G 2432 G35 BATTERY CESSNA 180 180 2072602 CE CONT O470 O470* 17026 SO LEAKING D O OTHER O OTHER NR NOT REPORTED 1 GL 15 9198C 34 31297 BATTERY ACID LEAKED OR TRANSFERRED TO AFT, LOWEST CELL (AIRCRAFT TAIL WHEEL) AND SPILLED OUT. CORRODED HOLE IN BATTERY BOX AND SPILLED INTO BELLY OF AIRCRAFT. 1 H 7 1 3O 3 O NC 5A6 E273 2007032200025 20070322 00025 2007 3 22 2007FA0000209 4 20070306 G 2350 9903334446 AUDIO CONTROL GULSTM G1159 G1159 3953505 SO PWA 530 PW530A NE COCKPIT SHORTED C O OTHER H ELECT. POWER LOSS-50 PC CR CRUISE 1 EA 21 685SF 94 UNIT WAS MANUFACTURED IN AUGUST 06 AND WAS INSTALLED IN DECEMBER 06. THE UNIT POPPED THE CIRCUIT BREAKER ON THE FIRST TR IP. THE UNIT WAS SENT IN FOR REPAIR AND REINSTALLED IN FEBRUARY 07 AND FAILED AGAIN ON THE FIRST FLIGHT. 2 L 7 2 4F 4 F RT A12EA E00053EN 2007030900041 20070309 00041 SO 2007 3 9 2007FA0000210 2 20070220 G 8530 639614639615 ROCKER CONT O300D CESSNA 172 172H 2072424 CE CONT O300 O300D 17022 SO ENGINE INCORRECT D K NONE R PARTIAL RPM/PWR LOSS CR CRUISE 1 EA 17 8848Z 110 64805D6D 17255498 64805D6D PILOT REPORTED LOSS OF POWER (600 RPM DROP) SIGNIFICANT ENGINE ROUGHNESS DURING CLIMB. ENGINE RECOVERED SHORTLY AFTERWAR DS. PILOT ELECTED TO CONTINUE AND HAD SAME PROBLEM AGAIN DURING CRUISE FLIGHT. ENGINE RECOVERED ON ITS OWN ONCE AGAIN. P ILOT SAID CARB HEAT DID NOT MAKE ANY IMPROVEMENT DURING BOTH OCCURRENCES. AIRCRAFT WAS TURNED OVER TO MAINTENANCE. THE ONLY ABNORMALITY DISCOVERED WAS THAT THE EXHAUST VALVES ON 4 OF THE 6 CYLINDERS HAD INCORRECT ROCKER INSTALLED (639614, INTAKE ROCKER). PARTS MANUAL CALLS FOR 639615 (EXHAUST ROCKER) TO BE INSTALLED ON EXHAUST POSITION. 1 H 7 1 3O 3 O NT 3A12 E253 2007030900073 20070309 00073 CE 2007 3 9 2007FA0000214 1 20070307 G 8011 85562020 STARTER CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA ENGINE SPINNING G O OTHER O OTHER NR NOT REPORTED 1 WP 05 767CL 57 172S9987 STARTER SPINS AND WILL NOT ENGAGE. 1 H 7 1 3O 3 O NT 3A12 1E10 2007032200081 20070322 00081 CE 2007 3 22 2007FA0000215 1 20070301 G 3230 MS2764816 BEARING BEECH 90 F90 1152909 CE PWA PT6 PT6A135 52043 NE MLG SEIZED B K NONE O OTHER IN INSP/MAINT 1 SO 07 19RK 9280 LA12 PERFORMING A ROUTINE 6 YEAR LANDING GEAR OVERHAUL, THE LT LANDING GEAR GEARBOX-ACTUATOR TORQUE TUBE HAD A SEIZED MAIN SU PPORT BEARING. THIS MADE THE TORQUE TUBE EXTREMELY HARD TO TURN. THE BEARING WAS FOUND TO BE RUSTED, AND SEIZED. BEARING WAS REPLACED WITH NEW. 1 L 7 2 4T 4 T A31CE E4EA 2007040200169 20070402 00169 EA 2007 4 2 2007FA0000218 2 20070202 G 8550 56G23399 BAFFLE PIPER PA32 PA32301 7103207 SO LYC O540 TIO540AH1A 42003 EA OIL SUMP CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 07 447KC 85 3255047 L1239361A DURING ENGINE OIL CHANGE FOUND RIVET HEAD IN OIL SUMP SCREEN. REMOVED ENGINE AND OIL SUMP ASSY. FOUND OIL SUMP BAFFLE ASY RIVETS SHEARED OFF AND ATTACH HOLES BROKEN OUT AND BAFFLE ASSY CRACKED. RETRIEVED RIVET STEMS AND HEADS. REMOVED A ND REPLACED OIL SUMP BAFFLE ASSY WITH NEW PART. REASSEMBLED ENGINE AND REINSTALLED. (K) 1 L 7 1 3O 3 O A3SO E14EA 2007032900269 20070329 00269 EA 2007 3 29 2007FA0000219 2 20070302 G 7310 B-NUT CESSNA 182 182T 2072703 CE LYC O540 IO540AB1A5 EA FUEL SYSTEM LOOSE D K NONE O OTHER IN INSP/MAINT 1 SO 11 38AL 18281450 L2980148A IN THIS CASE, FOUND THAT THE B-NUT CONNECTING TO THE FUEL CONTROL FROM THE SPIDER WAS LOOSE. IT WAS NOT LEAKING, BUT RE QUIRED A THIRD OF A TURN TO TORQUE DOWN TO PROPER TORQUE. NO OTHER WORK HAS BEEN DONE TO THE SPIDER OR FUEL CONTROL BEC AUSE I HAVE DONE THE WORK SINCE NEW ON THIS AIRCRAFT. TT 228.8. REMEMBER FINDING A LOOSE FIREWALL FITTING ON THE FIRST INSPECTION. THIS IS THE SECOND INSPECTION DONE ON THIS AIRCRAFT. IT WAS CERTIFIED 11/11/2004. (K) 1 H 7 1 3O 3 O NT 3A13 1E4 2007032900280 20070329 00280 CE 2007 3 29 2007FA0000220 1 20070223 G 2510 551900921 SEAT CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE COCKPIT CRACKED D O OTHER O OTHER NR NOT REPORTED 1 CE 05 630CC 5500130 UPPER CHAIR BASE ASSEMBLY CRACKED AT CHAIR BACK ATTACH POINTS. STRESS ON CHAIR BACK AND METAL FATIGUE PROBABLE CAUSE. CHAIR WAS REPAIRED IAW ST01042WI STRUCTURAL SEAT REPAIR. (K) 1 L 7 2 4F 4 F A22CE E1NE 2007040200237 20070402 00237 EA 2007 4 2 2007FA0000221 2 20070222 G 8520 CRANKSHAFT CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA ENGINE CORRODED B YYBR K NONE O OTHER IN INSP/MAINT 1 GL 03 2199 L130951A DURING NORMAL OVERHAUL, CRANKSHAFT FOUND PITTED IN THE INTERNAL BORE. THIS ENGINE WAS LAST OVERHAULED BY THE FACTORY, J ULY 2002.. THE PID COATING DOES NOT SEEM TO PREVENT PITTING OR CORROSION. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 2007050400165 20070504 00165 CE 2007 5 4 2007FA0000222 1 20070215 G 2821 99120154 FUEL FILTER CESSNA 500 500CESSNA 2076602 CE PWA JD15 JT15D1A NE RT WING SEPARATED D J7BR O OTHER O OTHER NR NOT REPORTED 1 SW 01 409S 10045 5000238 THE RT FUEL FILTER ASSY SEPARATED FROM THE STANDPIPE DUE TO THE SNAP-RING BECOMING DISLOGED AND RESULTED IN A SUBSTANTIA L FUEL LEAK. (K) 1 L 7 2 4F 4 F A22CE E25EA 2007032900273 20070329 00273 EA 2007 3 29 2007FA0000223 2 20070124 G 7261 OIL FILTER PIPER PA32 PA32R300 7103213 SO LYC O540 IO540* 41532 EA ENGINE COLLAPSED D K NONE K FLUID LOSS NR NOT REPORTED 1 SW 99 OIL LEAK NOTED AFTER OIL CHANGE. REMOVED OIL FILTER AND DISCOVERED PARTIAL COLLAPSE OF THE OIL FILTER ELEMENT. IT WAS DETERMINED THAT THE ENGINE MOUNTED INTERNAL BY-PASS VALVES OPERATION. PREVIOUS TO THIS OCCURRENCE THE SB MENTION HAD NO T BEEN COMPLIED WITH. AFTER THIS OCCURRENCE, SB WERE COMPLIED WITH AND A NEW OIL FILTER OF THE SAME MAKE AND MODEL WAS INSTALLED AND THE SYSTEM FUNCTIONED PROPERLY. SUBMITTER SUGGESTS THAT DUE TO THE SIGNIFICANT NR OF OCCURRENCES OF THIS TYPE THAT SB SI-1442 AND 1453 BECOME MANDATORY THROUGH AD FOR ADDED SAFETY. (K) 1 L 7 1 3O 3 O A3SO 1E4 2007040200127 20070402 00127 CE 2007 4 2 2007FA0000224 1 20070215 G 2821 99120154 FUEL FILTER PUROLATOR CESSNA 500 500CESSNA 2076602 CE PWA JD15 JT15D1A NE RT WING SEPARATED B J7BR O OTHER O OTHER NR NOT REPORTED 1 SW 01 409S 10045 5000238 76509 THE RT FUEL FILTER ASSY SEPARATED FROM THE STANDPIPE DUE TO THE SNAP-RING BECOMING DISLODGED AND RESULTED IN A SUBSTANTI AL FUEL LEAK. 1 L 7 2 4F 4 F A22CE E25EA 2007032900297 20070329 00297 SO 2007 3 29 2007FA0000225 1 20070215 G 2750 62679000 BRACKET PIPER PA28 PA28* SO COCKPIT CRACKED D O OTHER O OTHER NR NOT REPORTED 1 NE 03 THIS BRACKET IS RIVETED IN THE CENTER TUNNEL AND ACCEPTS (2) BOLTS AT THE FORWARD SIDE OF THE FLAP HANDLE SUPPORT MOUNT. THIS IS A DIFFICULT AREA TO SEE, EVEN WITH A MIRROR. WE HAVE FOUND (6) CRACKED BRACKETS SO FAR TO DATE. SUSPECT FATI GUE AND AIR LOADS CAUSING CRACKS. (K) 1 L 7 1 3O 2A13 2007040200158 20070402 00158 SO 2007 4 2 2007FA0000226 2 20070220 G 8500 ENGINE CESSNA 404 404 2075901 CE CONT O520 GTSIO520M 17032 SO FAILED D O OTHER O OTHER NR NOT REPORTED 1 CE 03 442EH 4040202 604103 THIS ENGINE FAILED TO THE TERMINOLOGY OF CATASTROPHIC AT THE NR 1 AND NR 2 CYLINDER CONNECTING ROD LOCATIONS DURING A MA INTENANCE TEST FLIGHT WITHIN TEN MINUTES INTO THAT FLIGHT WITH A MECHANIC ON BOARD MONITORING THE ENGINE INSTRUMENTS. T HE OIL PRESSURE SUDDENLY DROPPED TO ZERO, THE PROPELLER STARTED TO FEATHER AND DURING SHUTDOWN AND SECURING, THE ENGINE LOCKED UP. PRIOR TO THIS, THE OIL FILTER WAS REMOVED, CUT OPEN AND INSPECTED WITH NO DEFECTS NOTED. AN OIL SOAP SAMPLE WAS TAKEN. THE OIL PUMP AND AIRCRAFT OIL PRESSURE GAUGE WAS CHECKED FOR A POSITIVE OIL PRIME AND INDICATION. AN EXTEN DED ENGINE GROUND RUN WAS DONE AT LOW AND HIGH POWER SETTINGS WITH NO OIL PRESSURE DISCREPANCIES NOTED. THESE CHECKS WE 1 L 7 2 3O 3 O RT A25CE E7CE 2007031300197 20070313 00197 CE 2007 3 13 2007FA0000227 1 20070119 G 8011 85A34117 STARTER CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA ENGINE STUCK G O OTHER O OTHER NR NOT REPORTED 1 WP 05 767CL 527 172S9987 STARTER STUCK IN ENGAGED POSITION. 1 H 7 1 3O 3 O NT 3A12 1E10 2007050400138 20070504 00138 NM 2007 5 4 2007FA0000228 1 20070306 G 3260 SENSOR BOEING 747 747230B 1384889 NM GE CF6 CF650* 30018 NE MLG MALFUNCTIONED B GJPY O OTHER O OTHER NR NOT REPORTED 1 WP 33 760SA 21221 DURING TAKEOFF, THE LANDING GEAR HANDLE WILL NOT GO TO UP OR RETRACT POSITION. AIRCRAFT RETURNED TO BASE. PERFORMED TR OUBLESHOOTING ON THE LANDING GEAR SYSTEM AND FOUND THAT LT WING GEAR TRUCK ROTATION SENSOR AT FAULT. ADJUSTED THE LT WI NG GEAR TRUCK ROTATION SENSOR IAW AMM 32-61-04. PERFORMED LANDING GEAR SYSTEM EXTENSION AND RETRACTION SEVERAL TIMES IA W AMM 32-32-00/501, TEST NORMAL. (K) 2 L 7 4 4F 4 F A20WE E23EA 2007041200027 20070412 00027 EU 2007 4 12 2007FA0000229 1 20070308 G 2820 653014 VALVE ISRAEL 1124 1124A 4500103 EU GARRTT TFE731 TFE731* 01518 WP RT LWR FUEL CELL CRACKED B JGVR O OTHER O OTHER NR NOT REPORTED 1 CE 09 328PC 8597 328 CRACK IN INTERCONNECT VALVE MOTOR HOUSING. FOUND DURING BAG REMOVAL AND REINSTALLATION. CAUSE OF CRACK, UNKNOWN. (K) 2 M 7 2 4F 4 F A2SW E6WE 2007032900293 20070329 00293 SO 2007 3 29 2007FA0000230 1 20070220 G 5521 4602003 RIB PIPER PA31T PA31T 7103124 SO PWA PT6 PT6A28 EA LT ELEVATOR BROKEN B K NONE O OTHER IN INSP/MAINT 1 SO 09 112ED 31T8020060 1 INCH CRACK NOTED ON LOWER SKIN THRU RIVET. DRILLED OPEN SKIN AND FOUND 5 INCH OF RIB FLANGE BROKE OFF 2 INCHS FROM TR AILING EDGE. SKIN AND RIB HAVE TO BE REPLACED. (K) 1 L 7 2 3T 4 T A8EA E4EA 2007032900298 20070329 00298 SO 2007 3 29 2007FA0000231 1 20070215 G 2910 HYDRAULIC LINE PIPER PA23 PA23250 7102308 SO LYC O540 IO540* 41532 EA HYDRAULIC SYS CHAFED G O OTHER K FLUID LOSS NR NOT REPORTED 1 SO 19 144CN 5200 278054036 AIRCRAFT HYDRAULIC SYSTEM RT GEAR DOWN ALUMINUM LINE LOCATED UNDER COCKPIT FLOOR WAS CHAFING AGAINST CONTROL CABLE AND W AS PENETRATED CAUSING LEAK AND DEPLETION OF HYDRO FLUID WHICH RESULTED IN AIRCRAFT LANDING WITH UNSAFE NOSE GEAR AND DAM AGE TO AIRCRAFT NOSE SECTION. THIS AREA SHOULD BE INSPECTED AT LEAST DURING ANNUAL INSPECTIONS. (K) 1 L 7 2 3O 3 O 1A10 1E4 2007050700186 20070507 00186 SO 2007 5 7 2007FA0000232 1 20070305 G 2432 RG380E44 BATTERY LKHEED 1329 1329* SO GARRTT TFE731 TFE7313 01518 WP MASTER FAILED B VXWR O OTHER O OTHER NR NOT REPORTED 1 EA 21 58TS 5079 75238 THESE 2 EA PN RG-380E/44 MAIN SHIP BATTERIES WERE INSTALLED ON 10/30/2006. THESE BATTERIES WERE REPLACEMENTS FOR 2 EA B ATTERIES THAT HAD BEEN IN SATISFACTORY SERVICE IN THIS AC FOR APPROX 48 MONTHS BUT FAILED A CAPACITY CHECK DURING A REGU LAR SCHEDULED INSPECTION. LESS THAN 2 MONTHS AFTER INSTALLATION THE PILOTS WERE UNABLE TO START THE MAIN ENGINES USING THESE BATTERIES. AT THIS TIME THE BATTERIES HAD A TOTAL FLIGHT TIME OF 16 HOURS AND HAD PERFORMED 26 MAIN ENGINE STARTS AND 8 APU STARTS. THE MAIN ENGINES WERE STARTED USING A GROUND POWER UNIT. ALL CHARGING AND ELECTRICAL OPERATIONS APP EARED NORMAL. THE BATTERIES WERE REMOVED AND GIVEN TO REPAIR STATION FOR TESTING. BOTH BATTERIES WERE TESTED IAW (INST 2 L 7 4 4J 4 F 2A15 E6WE 2007032900290 20070329 00290 EA 2007 3 29 2007FA0000233 2 20070312 G 7414 M3081 SPRING SLICK CESSNA 182 T182T 2072738 CE LYC O540 TIO540AK1A EA RT MAGNETO BROKEN D K NONE O OTHER IN INSP/MAINT 1 WP 29 5198G 658 66LC35SDNP T18208150 L1121761A NEW POINTS (PN M3081) WERE INSTALLED IN BOTH MAGNETOS AT THE ANNUAL INSPECTION ON 2/22/07, TT 649.2. ON 3/10/07, TT 658 .2, PART TT - 9.0 HOURS, THE PILOT/OWNER PERFORMED MAG CHECK AND THE ENGINE QUIT. A MECHANIC REMOVED THE RT MAG AND FOU ND THAT THE SPRING THAT HOLDS HALF THE POINTS HAD SNAPPED OFF. THE MECHANIC TOLD THE OWNER THAT HE HAD NEVER SEEN POINT S FAIL LIKE THIS IN HIS 30 YEARS OF AC MAINTENANCE. TOLD HIM THAT I HAD NEVER SEEN THIS TYPE OF MALFUNCTION IN MY 10 YE ARS OF MAINTENANCE. IT APPEARS THAT THE METAL SPRING THAT MAKES UP THE POINT KIT FAILED JUST AFT OF THE AREA WHERE THE METAL IS BENT ON BOTH EDGES FOR STRENGTHING PURPOSE. THE BREAK IS IN A SEMICIRCLE FRO ONE SIDE TO THE OTHER. THE METAL 1 H 7 1 3O 3 O NT 3A13 2007040900162 20070409 00162 GL 2007 4 9 2007FA0000234 3 20070317 G 6111 F8483 BLADE HARTZL HCC3Y HCC3YR GL PROPELLER MISREPAIRED B ME4R O OTHER W INADEQUATE Q C NR NOT REPORTED 1 SO 19 DY5121B (REF NR: 38430A) 2 OF 3 PROPELLER BLADES WERE PREVIOUSLY REPAIRED USING AN UNAPPROVED WELD METHOD IN SEVERAL LOCATIONS O N THE BLADE AIRFOIL. THE BLADES HAVE BEEN SCRAPED PENDING DISPOSITION INSTRUCTIONS FROM MFG. THE CUSTOMER HAS BEEN CON TACTED FOR HISTORICAL RECORDS. (K) 5 C P25EA 2007050700183 20070507 00183 GL 2007 5 7 2007FA0000235 3 20070317 G 6111 F8483 BLADE HARTZL HCC3Y HCC3YR GL PROPELLER MISREPAIRED B ME4R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 19 DY5121B (REF NR 38430A) 2 OF 3 PROPELLER BLADES WERE PREVIOUSLY REPAIRED USING AN UNAPPROVED WELD METHOD IN SEVERAL LOCATIONS O N THE BLADE AIRFOIL. THE BLADES HAVE BEEN SCRAPED PENDING DISPOSITION INSTRUCTIONS FROM MFG. THE CUSTOMER HAS BEEN CON TACTED FOR HISTORICAL RECORDS. (K) 5 C P25EA 2007032900284 20070329 00284 EU 2007 3 29 2007FA0000236 1 20070121 G 2434 TERMINAL SOCATA TB20 TB20TRINIDAD 8680695 EU LYC O540 IO540C4D5 41532 EA ALTERNATOR BROKEN D O OTHER O OTHER NR NOT REPORTED 1 WP 05 711RP 1081 L1813148A FIELD WIRE TERMINAL END BROKEN AT ALTERNATOR TERMINAL LUG CAUSED FAILURE OF ALTERNATOR TO CHARGE BATTERY. (K) 1 L 7 1 3O 3 O RT A51EU 1E4 2007040200214 20070402 00214 CE 2007 4 2 2007FA0000237 1 20070301 G 5610 10138402524 WINDSHIELD BEECH 300 300BEECH 1152930 CE PWA PT6 PT6A60A 52043 NE HARTZL HCB4M HCB4MP3 GL COCKPIT CRACKED B AHTR A UNSCHED LANDING O OTHER CR CRUISE 1 GL 11 200VC 728 FL316 AT AN ALTITUDE OF 17,000 FT OAT -6 DEGREES C, THE RT WINDSHIELD CRACKED FROM THE CENTER OB FROM THE TOP TO THE BOTTOM AB OUT 2 INCHES OB ON THE OUTER PANE. RETURNED TO THE DEPARTING AIRPORT WITHOUT ANY PROBLEMS. WINDSHIELD WAS REPLACED AND NO KNOWN CAUSE FOR THE WINDSHIELD TO CRACK. (K) 2 L 7 2 4T 4 T A24CE E4EA 6 C P56GL 2007032200037 20070322 00037 CE 2007 3 22 2007FA0000238 1 20070316 G 3242 RA66109 BRAKE PADS CESSNA 172 172RG 2072438 CE LYC O360 O360F1A6 41514 EA MCAULY 2D34C B2D34C220 GL MLG FRACTURED D K NONE O OTHER IN INSP/MAINT 1 EA 07 6440V 49 172RG0701 L2783136A 951039 DURING A 50 HR OIL CHANGE AND INSPECTION, FOUND BOTH LT AND RT BRAKE PADS FALLING APART, SEVERELY CRACKED WITH LARGE PIE CES MISSING. BOTH SIDES WERE CHANGED AT THE PREVIOUS 100 HOUR INSPECTION. THIS HAS BEEN A FREQUENT PROBLEM WITH THESE BRAKE PADS ON ALL OF OUR AIRCRAFT (2 C152, 1 C172, 1 C172RG), NEW PADS FAILING WITHIN 200 HOURS OR LESS SINCE WE STARTED USING THEM. PREVIOUSLY, WE USED OTHER MFG PADS WITH VERY FEW PROBLEMS. 1 H 7 1 3O 3 O 3A17 E286 5 C P7EA 2007032200092 20070322 00092 CE 2007 3 22 2007FA0000243 1 20070226 G 5310 VP10 ANTENNA BEECH 33 35B33 1151406 CE CONT O470 IO470* 17026 SO VHF SYSTEM MISINSTALLED B A UNSCHED LANDING W D INADEQUATE Q C INFLIGHT SEPARATION CR CRUISE 1 CE 03 1768G 94 94 CD509 THE DOUBLER FOR THE VHF ANTENNA APPEARS TO HAVE BEEN TOO SMALL(SLIGHLY LARGER THAN THE BASE OF THE ANTENNA)AND WAS NOT R IVITED TO THE FUSELAGE,ALLOWING THE ANTENNA TO FLUTTER WHILE AIRBORNE.ON POST FLIGHT INSPECTION THE PILOT DISCOVERED TEA RING ON THREE SIDES ON TOP OF THE FUSELAGE AROUND THE BASE OF THE ANTENNA.NOTE THE TACH ONLY READS 94.5 1 L 7 1 3O 3 O 3A15 E1CE 2007032200093 20070322 00093 CE 2007 3 22 2007FA0000244 1 20070301 G 5551 071204221 BRACKET CESSNA 185 A185F 2072821 CE CONT O520 IO520* 17032 SO HORIZONTAL STAB CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 07 4640E 18503824 DURING A DETAILED INSPECTION OF THE EMPENAGE, THE RT HORIZONTAL STABILIZER HINGE BRACKET P/N 0712042-2 WAS FOUND CRACKED AND HAD (2) SHEARED RIVETS. UPON DISASSEMBLY THE LT BRACKET P/N 0712042-1 WAS FOUND TO HAVE (2) SHEARED RIVETS. THESE PARTS ARE IN THE MFG 180/185 IPC FIG 32 INDEX NR 36 AND NR 37.THERE IS NOTHING IN THE RECORDS THAT SHOW THESE PARTS CHA NGED, HOWEVER THE RT BRACKET DID HAVE (2) NR 5 RIVETS WHERE ALL OF THE REST ON BOTH BRACKETS WERE NR 4S. LEADING US TO BELIEVE THAT IT MAY HAVE BEEN REPLACED BEFORE. 1 H 7 1 3O 3 O 3A24 E5CE 2007032200098 20070322 00098 CE 2007 3 22 2007FA0000246 1 20070313 G 2820 050011849 LINE CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA FUEL SYSTEM CHAFED D K NONE K FLUID LOSS IN INSP/MAINT 1 SW 05 30LU 847 17281257 DURING PREFLIGHT INSP. PILOT FOUND FUEL ON RAMP UNDER CENTER FUSELAGE MECHANIC INVESTIGATED INSIDE COCKPIT FLOOR AND FO UND ALUMINUM FUEL LINE CHAFING AGAINST RT STEERING TUBE, CAUSING THE FUEL LEAK. MECHANIC INSPECTED 6 OTHER 2005/2006 172 R AIRCRAFT IN OUR FLEET AND FOUND CHAFING IN (3) OTHER AIRCRAFT, WITH ANOTHER LEAK IMMINENT. ALL AC UNDER 900 HRS AFTT. OUR AIRCRAFT CAME FROM THE FACTORY WITH THIS FUEL LINE/STEERING TUBE CONFIGURATION. SUBMITTER SUGGESTS IMMEDIATE INSPECT ION FOR THIS CONDITION. NOTE: FUEL WAS NOT SMELLED IN COCKPIT. 1 H 7 1 3O 3 O NT 3A12 1E10 2007032200140 20070322 00140 CE 2007 3 22 2007FA0000247 1 20070227 G 7160 11702 CLAMP BEECH 58 58P 1152744 CE CONT O520 TSIO520L 17040 SO LT ENGINE FAILED D K NONE O OTHER IN INSP/MAINT 1 GL 25 25RL TJ232 0 LT ENGINE REPORTED TO BE ROUGH RUNNING. INDUCTION HOSE CLAMP(P/N-RAM 1170-2)FAILED; ALLOWING INDUCTION COUPLER(P/N-6323 23) TO SEPARATE FROM INDUCTION TUBE. THIS INDUCTION LEAK OCCURRED BETWEEN THE Y AND INTAKE TUBES TO CYLINDERS NR 2, NR 4 AND NR 6. 1 L 7 2 3O 3 O A23CE E8CE 2007032600107 20070326 00107 CE 2007 3 26 2007FA0000253 1 20070307 G 2720 65651412 ACTUATOR CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE ELEVATOR BINDING C K NONE O OTHER IN INSP/MAINT 1 SW 13 797CW 8177 300 0232 WHILE REPLACING TRIM ACTUATOR P/N 6565141-2 WITH WHAT MFG SAID WAS AN APPROVED SUB PART P/N 5565450-92. IT WAS FOUND T HAT THE LOLLIPOPS (JACK SCREWS) WERE 5.5 INCHES LONG AND THE ORIGINAL LOLLIPOPS ARE 5.75 INCHES LONG. IF YOU LOOK AT THE COMPONENT MANUAL FOR THIS ACTUATOR 6565141-2 IT SHOWS 4 DIFF. DASH NUMBERS. -4 AT 5.5 INCHES, -7 AT 5.5 INCHES, -15 AT 4.85 INCHES, AND -21 AT 5.75 INCHES ALL WHICH IS TO THE SAME LOLLIPOP P/N. THE -92 ACTUATORS FITS UNITS 692 TO 924, WHIL E OUR UNIT IS 232. MFG NEEDS TO FIX THESE P/NS AND CLEAR THE WAY THESE MANUALS ARE WRITTEN FOR CLARITY. TO MANY ACTUATOR S ARE TO ANOTHER P/N WITH INCORRECT JACKSCREW LENGTHS. 1 L 7 2 4F 4 F A22CE E1NE 2007032600116 20070326 00116 CE 2007 3 26 2007FA0000256 1 20070314 G 7810 655503011 DUCT CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE EXHAUST ASSY MISMANUFACTURED B K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 13 797CW 5500232 DURING INSPECTION MULTIPLE PATCHES WERE FOUND ON EXHAUST DUCT ASSY P/N 6555030-11. A REPLACEMENT WAS ORDERED AND FOUND T O HAVE 2 HOLES MISDRILLED BY 2 DEGREES. MFG WAS CONTACTED AS TO WHAT COULD BE DONE AND AFTER CONFIRMING THAT IN TRUTH 2 HOLES WERE NOT PROPERLY PLACED WE WERE TOLD THAT IN FACT 4 DUCTS WERE FOUND NOT BUILT CORRECTLY AND 1 HAD GOTTEN TO THE FIELD. MFG HAS AGREED TO ACCEPT THE DUCT BACK FOR REPAIR BUT WANTS TO BILL US FOR THE FIX ON A NEW PART. AFTER REPAIR, W E ARE TO SUBMIT FOR FINANCIAL REIMBURSEMENT FOR THERE ENGINEERING REPAIR. 1 L 7 2 4F 4 F A22CE E1NE 2007032600125 20070326 00125 EA 2007 3 26 2007FA0000257 2 20070224 G 8530 ROCKER SHAFT UNIVAR 108 1081 9230404 NM FRNKLN 6A4150 6A4150* 27024 EA NR 3 CYLINDER BROKEN G B EMER. DESCENT R PARTIAL RPM/PWR LOSS CR CRUISE 1 WP 11 9088K 1082088 THE NR 3 CYLINDER ROCKER ARM SHAFT FAILED (BROKE) AT THE CENTER SUPPORT POSITION. ADDITIONALLY, (2) OF THE (3) ROCKER A RM BOSS SECURING BOLTS FAILED AND THE THIRD BOLT PULL OUT OF THE HEAD. 1 H 7 1 3O 3 O A767 E238 2007032600127 20070326 00127 CE 2007 3 26 2007FA0000258 1 20070301 G 3210 MS2764816 BEARING BEECH 90 F90 1152909 CE PWA PT6 PT6A135 52043 NE LT MLG SEIZED B O OTHER O OTHER NR NOT REPORTED 1 SO 07 19RK 9280 LA12 PERFORMING A ROUTINE 6 YEAR LANDING GEAR OVERHAUL, THE LT LANDING GEAR GEARBOX-ACTUATOR TORQUE TUBE HAD A SEIZED MAIN SU PPORT BEARING. THIS MADE THE TORQUE TUBE EXTREMELY HARD TO TURN. THE BEARING WAS FOUND TO BE RUSTED, AND SEIZED. BEARING WAS REPLACED WITH NEW. 1 L 7 2 4T 4 T A31CE E4EA 2007032600128 20070326 00128 SO 2007 3 26 2007FA0000259 1 20070301 G 8000 PM1201 STARTER PIPER PA28 PA28236 7102815 SO LYC O540 O540J3A5 41532 EA HARTZL HCF3Y HCF3YK1 GL ENGINE WORN G K NONE O OTHER IN INSP/MAINT 1 SO 05 2177Z 28 28 287911154 L2117640A CM288 THIS AIRCRAFT HAS HAD (5) PM1201 STARTERS INSTALLED SINCE 03-08-2004. THE STARTERS HAD TO BE REPLACED AT THE FOLLOWING I NTERVAL: 58 HOURS TIME IN SERVICE, 18 HOURS TIME IN SERVICE, 11 HOURS TIME IN SERVICE, 5 HOURS TIME IN SERVICE, 28 HOURS TIME IN SERVICE. ALL STARTERS SUFFER THE SAME PROBLEM. AFTER THE ENGINE IS STARTED AND THE AIRCRAFT HAS FLOWN FOR A SH ORT PERIOD OF TIME, (LESS THAN ONE HOUR) THE BENDIX GEAR WILL BEGIN TO CREEP OUT AND TRY TO ENGAGE/RUB THE RING GEAR. I N FEW FLIGHT HOURS THE BENDIX GEAR WILL START SHOWING WEAR ON BOTH THE BENDIX GEAR AS WELL AS THE RING GEAR ON THE FLYWH EEL. ALL THE STARTERS WERE REPORTED TO HAVE HAD THE SAME PROBLEM. THE OWNER DECIDED TO REMOVE THE STARTER FROM HIS AIR 1 L 7 1 3O 3 O 2A13 E295 5 C P31EA 2007040300082 20070403 00082 2007 4 3 2007FA0000260 3 20070219 G 6111 3BLADEWOOD68 PROPELLER AMTR KITFOX KITFOX41200 05626LB GL PROPELLER BROKEN G A UNSCHED LANDING O OTHER CR CRUISE 1 SW 11 880BW 219 6 C96010137 OWNER REPORTED 5 MINUTES AFTER TAKEOFF AT 2500 ASL, ALL 3 PROPELLER BLADES DEPARTED. THERE WAS ONE VIOLENT SHAKE AND TH EN SMOOTH GLIDING TO SAFE LANDING OFF AIRPORT. PRELIMINARY EXAM INDICATES ENGINE MOVED ENOUGH TO CAUSE CARBURETOR TO SE PARATE PREVENTING OVERSPEED. SEPARATED BLADES WERE NEVER LOCATED. PROPELLER TO BE REPLACED BY OWNER, THIS IS AN EXPERI MENTAL HOMEBUILT AIRCRAFT. 1 H 7 1 3I NC EXPA1H71 2007032600060 20070326 00060 CE 2007 3 26 2007FA0000261 1 20070322 G 5210 99120754 SEAL CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE CABIN DOOR SEAL MISMANUFACTURED B K NONE O OTHER IN INSP/MAINT 1 SW 13 797CW 8177 300 5500232 WHILE INSTALLING THIS FACTORY NEW SEAL IT WAS NOTED THAT THE SEAL WAS VERY TIGHT GOING AROUND THE DOOR. UPON CABIN PRESS TEST THE SEAL WILL NOT INFLATE DUE TO BEING TO TIGHT. (2) SEAL FROM STOCK WERE TRIED WITH THE SAME AFFECT. THE LAST SE AL WAS INSTALLED AND INFLATED AS SHOULD BE. THE FACTORY NEEDS TO CHECK THERE SEALS CLOSER UPON RECEIPT FROM THERE VENDOR S. 1 L 7 2 4F 4 F A22CE E1NE 2007032600085 20070326 00085 CE 2007 3 26 2007FA0000262 1 20070322 G 7810 655503011 DUCT CESSNA 500 550 2076604 CE ENGINE UNKNOWN B K NONE O OTHER IN INSP/MAINT 1 GL 19 797CW 8177 300 5500232 UPON RECEIVING THE NEW PART P/N 6555030-11 IT WOULD NOT FIT THE ENGINE. THE ORIGINAL DUCT IS 27 .2500 INCH OUTSIDE AND 2 5.5 INCH INSIDE. THE NEW UNIT IS A FULL .5 INCH SMALLER IN DIAMETER ALL AROUND. THIS IS THE SECOND ISSUE WITH THESE DUCT S THE FIRST WERE MIS-DRILLED BY 2 DEGREES AT THE 1 AND 5 O’CLOCK POSITION. THIS NEW DUCT IS NOT EVEN CLOSE TO FITTING. 1 L 7 2 4F A22CE 2007040300037 20070403 00037 EU 2007 4 3 2007FA0000263 1 20070321 G 7600 L810BQ54 SOLENOID SNIAS 350 AS350B3 8680954 EU TMECA ARRIEL ARRIEL2B NE AUTO THROTTLE UNSERVICEABLE B N37R K NONE O OTHER IN INSP/MAINT 1 SW 15 186AE 189 3872 22484 (REF NR: 186AE-2007-I-0032) WHILE PERFORMING A CHECK OF THE TWIST GRIP SOLENOID, ENGAGED THE SOLENOID BY PLACING THE AUT O/MAN SWITCH TO MAN MODE FOR A TOTAL OF 10 MINUTES. AFTER THE 10 MINUTE PERIOD HAD ELAPSED, RETURNED THE AUTO/MAN SWIT CH TO AUTO. AFTER 15 MINUTES MOVED AUTO/MAN SWITCH BACK TO MAN, THE PISTON FROM THE SOLENOID FAILED TO MOVE. THE PISTO N SHOULD HAVE RETRACED IMMEDIATELY. PROBABLE CAUSE: SOLENOID OVERHEATING AND MALFUNCTIONING. RECOMMENDATION TO PREVENT RECURRENCE: REPLACING CURRENT PN OF SOLENOID WITH ONE THAT CAN EITHER RUN COOLER OR WITHSTAND THE HEAT. (K) 1 G 7 1 3U 3 U H9EU E00054EN 2007040200157 20070402 00157 SO 2007 4 2 2007FA0000264 1 20070306 G 5350 1159B541014 FAIRING GULSTM GV GULFSTREAMGV 3980116 SO RROYCE BR700 BR700715A130 NE FUSELAGE DEPARTED G A UNSCHED LANDING D INFLIGHT SEPARATION NR NOT REPORTED 1 CE 07 401HF 1300 5039 ON MARCH 6, 2007, DURING A FLIGHT, THE SUBJECT AIRCRAFT EXPERIENCED AN IAPPARENT IN-FLIGHT STRUCTURAL FAILURE OF THE RIG HT WING-TO FUSELAGE FORWARD FAIRING. THE INCIDENT OCCURRED AT FLIGHT LEVEL 400 AT 90 DME ON THE (LNK) VOR 220 RADIAL AT .85 MACH. AFTER ONE HOUR AND 45 MINUTES INTO THE FLIGHT (APPROX 2115Z), THE CREW NOTED AN AUDIBLE (THUMP) FOLLOWED BY A (CHANGE IN WIND NOISE). AS THE AIRCRAFT IS EQUIPPED WITH PROXIMITY CAMERAS, THE FIGHT CREW WAS ABLE TO SEE A (HOLE OF SIGNIFICANT SIZE) IN THE AREA OF THE SINGLE POINT REFUELING ACCESS DOOR USING THE LOWER AFT-FACING FUSELAGE CAMERA. TH E FLIGHT CREW NOTIFIED AND REQUESTED EMERGENCY LANDING, WHERE THE AIRCRAFT LANDED WITHOUT FURTHER INCIDENT. THE FSDO WA 2 L 7 2 4F 4 F RT A12EA E00061EN 2007040200134 20070402 00134 CE 2007 4 2 2007FA0000265 1 20070322 G 2910 270213 REGULATOR LEAR 60 60LEAR 5170707 CE HYD SYS PRESSURE LEAKING C O OTHER K J FLUID LOSS WARNING INDICATION CR CRUISE 1 GL 11 500 105 306 IN-FLIGHT FAILURE OF BOTH ENGINE HYDRAULIC PUMPS, AND LOSS OF MAIN HYDRAULIC SYSTEM FLUID. AC DIVERTED TO HOME BASE, DE CLARED EMERGENCY LANDING, UNEVENTFUL. FOUND PRESSURE HOSE ON R ENGINE HAD FAILED, DUE TO OVER-PRESSURE. FOUND RESERVOI R AIR-PRESSURE REGULATOR (PN 2702-12) HAD FAILED, CAUSING LOSS OF HEAD PRESSURE IN RESERVOIR, AND SUBSEQUENT PRESSURE SP IKES IN ENGINE PUMPS, WHICH BURST FLEX LINE ON R ENGINE HYD PUMP, AND DAMAGED FLEX LINE ON L HYD PUMP AS WELL. REPLACED L AND R ENGINE HYDRAULIC PUMPS, ALL FLEX PRESSURE LINES IN ENGINE HYDRAULIC CIRCUIT, HYDRAULIC FILTERS, RESERVOIR PRESS URE REGULATOR, CHECK VALVE, AND FILTER. BLED AIR FROM HYDRAULIC SYSTEM, PERFORMED FUNCTIONAL TESTS AND GROUND RUN, REPL 2 L 7 2 4F RT A10CE 2007050700003 20070507 00003 CE 2007 5 7 2007FA0000266 1 20070315 G 5510 HINGE BRACKET BEECH 23 A23 1151204 CE CONT O346 IO346A 17033 SO SNSNCH 74DC M74DC EA STABILATOR CRACKED B MS2R O OTHER O OTHER NR NOT REPORTED 1 CE 09 3573R 3596 M756 1002075A 8623 UPON REMOVAL OF THE HORIZONTAL STABILATOR FOR BEARING REPLACEMENT, A CRACK WAS NOTED COMING OUT FROM UNDER THE LEFT HING E BRACKET THAT IS RIVETED TO THE SPAR OF THE HORIZONTAL STABILATOR. (K) 1 L 7 1 3O 3 O A1CE E3CE 5 N P88614 2007040200222 20070402 00222 EU 2007 4 2 2007FA0000267 1 20070228 G 8120 4066109031 BEARING SOCATA TB20 TB21 8680697 EU LYC O540 TIO540AB1A 41533 EA TURBOCHARGER FAILED B BNGR O OTHER O OTHER NR NOT REPORTED 1 GL 19 189GT 685 2022 21052261A IN FLIGHT, DROP IN MANIFOLD PRESSURE, TROUBLESHOT, FOUND TURBOCHARGER BEARING FAILURE. FOUND METAL IN OIL FILTER. ENGI NE REMOVED FOR REPAIR. (K) 1 L 7 1 3O 3 O RT A51EU E14EA 2007032900291 20070329 00291 SW 2007 3 29 2007FA0000268 1 20070308 G 2910 20144 B-NUT GULSTM 500 500S 0141107 SW LYC O540 TIO540A1A 41532 EA LT MLG LOOSE D O OTHER O OTHER NR NOT REPORTED 1 GL 19 280MB 3255 PILOT NOTICED A FLUCTUATION AND LOSS OF HYDRAULIC PRESSURE IN FLIGHT, AFTER INSPECTION THE FORWARD HYDRAULIC HOSE B-NUT ON THE LT GEAR ACTUATOR WAS FOUND TO BE LOOSE. THE B-NUT WAS TIGHTENED AND TORQUE SEAL WAS PUT ON THE B-NUT. SERVICED HYDRAULIC RESERVOIR WITH H-5606. AC WAS TEST FLOWN AND LEAK CHECK GOOD. (K) 1 H 7 2 3O 3 O 6A1 E14EA 2007040200129 20070402 00129 CE 2007 4 2 2007FA0000269 1 20070321 G 6100 NONE BEECH 90 C90 1152913 CE PWA PT6 PT6A21 52043 EA HARTZL HCD4N3 HCD4N3A GL PROPELLER UNKNOWN B O OTHER O OTHER NR NOT REPORTED 1 SO 13 427DM LJ804 AIRCRAFT HAS RAISEBECK STC SA3593NM INSTALLED WHICH STATES THE PROPS ARE NOT TO BE OPERATED BELOW THE SET MINIMUM RPM. PRE PHASE INSPECTION RUNS REVEALED THIS CONDITION. IAW MFG SERVICE LETTER 61-254 THIS CAN CAUSE NO REACTION MODE VIBRAT ORY RESONANCE AND MAY RESULT IN HIGH STRESS IN THE BLADES. IT WAS RECOMMENDED THAT THE PROPELLERS BE REMOVED AND BE SENT TO A PROPELLER SHOP FOR INSPECTION. CUSTOMER DECLINED RECOMMENDATION. NO FURTHER ACTION WAS TAKEN AT THIS INSPECTION. BOTH THE LT AND RT PROPELLERS HAVE A TSO OF 957.9 AND A TT OF 2615.2 1 L 7 2 3T 4 T 3A20 E4EA 5 C STC 2007040300049 20070403 00049 CE 2007 4 3 2007FA0000270 1 20070326 G 2710 35524314 CONTROL CABLE BEECH 35 N35 1151528 CE CONT O470 IO470* 17026 SO AILERONS WORN C O OTHER F FLT CONT AFFECTED NR NOT REPORTED 1 WP 23 1363Z 7541 D6787 (REF MODEL 35 SERIES IPC FIG. 27) LT AILERON CABLE FOUND RIDING ON PROP CONTROL CABLE SHEATH, ABOUT 2 INCHES AFT OF FIR EWALL. AILERON CABLE WAS WORN ABOUT HALF THROUGH, AND THE PROP CABLE WAS WORN THROUGH THE SHEATH TO THE INNER STEEL CAB LE. (VERY DIFFICULT TO ACCESS THIS AREA FOR VISUAL INSPECTION.) NO INDICATION OF RUBBING OR DRAGGING DURING GROUND CONT ROL SYSTEM CHECKS, OR IN FLIGHT. IT IS RELATIVELY EASY TO HAVE THE PROP CONTROL CABLE DISPLACED INTO CONTACT WITH THE A ILERON CABLE WHEN WORKING IN THIS AREA DURING, FOR EXAMPLE, PANEL MODIFICATIONS OR AVIONICS UPGRADES. RECOMMEND VISUAL AND TACTILE INSPECTION IN THIS AREA TO CONFIRM CLEARANCE. UPON REMOVAL OF CABLE ASSEMBLY FOR REPLACEMENT, FOUND ADDITIO 1 L 7 1 3O 3 O 3A15 E1CE 2007040300039 20070403 00039 CE 2007 4 3 2007FA0000274 1 20070322 G 2910 270213 REGULATOR LEAR 60 60LEAR 5170707 CE HYD SYSTEM LEAKING C O OTHER K J FLUID LOSS WARNING INDICATION CR CRUISE 1 GL 11 500 105 306 IN-FLIGHT FAILURE OF BOTH ENGINE HYDRAULIC PUMPS, AND LOSS OF MAIN HYDRAULIC SYSTEM FLUID. AIRCRAFT DIVERTED TO HOME BA SE, DECLARED EMERGENCY LANDING, UNEVENTFUL. FOUND PRESSURE HOSE ON R ENGINE HAD FAILED, DUE TO OVER-PRESSURE. FOUND RE SERVOIR AIR-PRESSURE REGULATOR (PN 2702-12) HAD FAILED, CAUSING LOSS OF HEAD PRESSURE IN RESERVOIR, AND SUBSEQUENT PRESS URE SPIKES IN ENGINE PUMPS, WHICH BURST FLEX LINE ON R ENGINE HYD PUMP, AND DAMAGED FLEX LINE ON L HYD PUMP AS WELL. RE PLACED L AND R ENGINE HYDRAULIC PUMPS, ALL FLEX PRESSURE LINES IN ENGINE HYDRAULIC CIRCUIT, HYDRAULIC FILTERS, RESERVOIR PRESSURE REGULATOR, CHECK VALVE, AND FILTER. BLED AIR FROM HYDRAULIC SYSTEM, PERFORMED FUNCTIONAL TESTS AND GROUND RUN, 2 L 7 2 4F RT A10CE 2007040200160 20070402 00160 GL 2007 4 2 2007FA0000276 1 20070306 G 5551 BOLT DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240B 17063 SO SNSNCH W69EK W69EK63 EA HORIZ STAB BROKEN D O OTHER O OTHER NR NOT REPORTED 1 NM 03 921DA C0395 650218 AG5429 AC, RETURN FROM FLIGHT WITH BOTH BOLTS BROKEN; ATTACHING THE FORWARD HORIZONTAL STABILIZER MOUNT BRACKETS. ATT 1) GIVES FLIGHT INFO. ATT 2 AND 3) SHOW THE IPB BRAKE DOWN OF THE BOLTS AND LOCATION FROM MFG PARTS BOOK. ATT 4) PICTURES OF B OLTS AND AIRCRAFT. ATT 5) THE NTSB PAPERWORK. ATT 6) IS SOME EMAIL TRAFFIC. WE REMOVED THE RUDDER AND HORIZONTAL STAB ILIZER TO INSPECT ENTIRE AREA. WE REPLACE THE AFT MOUNT PLATE AND FORWARD MOUNT BRACKET ALONG WITH ALL NEW BOLTS, WASHER S AND NUTS. WE ALSO INSPECTED OUR OTHER 9 AC AND REPLACED BOTH BOTH ON ALL 9 AC. NO OTHER ISSUES WERE FOUND ON OUR OTH ER AC. MFG HAS BEEN BRIEFED AND IS WORKING WITH THE NTSB. (K) 1 L 7 1 3O 3 O NT TA4CH E7SO 5 N TA4CH 2007050700023 20070507 00023 SO 2007 5 7 2007FA0000277 2 20070322 G 8520 A049405N CRANKSHAFT CONT O360 TSIO360EB 17025 SO ENGINE FAILED B LU4R O OTHER O OTHER NR NOT REPORTED 1 SO 19 A049405U CRANKSHAFT FAILED NDI SB MSB96-10. (K) 3 O E9CE 2007040900058 20070409 00058 CE 2007 4 9 2007FA0000279 1 20070228 G 3220 45A3952211 UPLOCK BEECH MU300 400A 1155402 CE NLG OUT OF ADJUST B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 123QS 243 RK486 FLIGHT CREW REPORTED RED LANDING GEAR HANDLE WARNING LIGHT STAYING ILLUMINATED AFTER GEAR RETRACTION. LANDING GEAR CYCL ED SEVERAL TIMES, HANDLE WARNING LIGHT STAYED ILLUMINATED. FOUND NOSE LANDING GEAR UPLOCK NOT FULLY ENGAGING ADJUSTED N OSE LANDING GEAR UPLOCK AS REQUIRED IAW THE MM. LANDING GEAR RETRACT/ EXTENSION CHECKS OK, NO FAULTS NOTED. HAVE NOTED THIS FAULT ON LOW TIME AC SEVERAL TIMES, PARTICULARLY DURING COLD WEATHER OPERATION UPLOCK ADJUSTMENT FAULTS USUALLY SH OW UP DURING MM FUNCTIONAL TESTS DURING THE LOW PRESSURE/LOW FLOW TESTS. (K) 2 H 7 2 4F RT A16SW 2007040200164 20070402 00164 2007 4 2 2007FA0000280 1 20070312 G 3230 452552 BEARING LANDING GEAR INACCURATE D O OTHER O OTHER NR NOT REPORTED 1 NE 03 PN 96522-00, CENTERING SPRING ASSY, HAS A ROD END BEARING ON THE END OF THE SHAFT, WHICH BOLTS TO THE IMOVABLE PORTION O F THE NOSE GEAR. ORIGINAL ROD END BEARING IS .375 INCH THICK WHERE BOLT GOES THRU. NEW ROD END BEARING THAT COMES WITH PN 96522-00 ASSY, IS .433 INCH THICK AND RELOCATES CLEVIS BOLT PN AN24-20A .0625 INCH DOWNWARD (UNFAVORABLE) AND CONTRA DICTS REQUIREMENTS OF MFG MSB 893. (K) 2007050400162 20070504 00162 CE 2007 5 4 2007FA0000284 1 20070317 G 5740 NAS1738B ATTACH FITTING BEECH 300 300BEECH 1152930 CE PWA PT6 PT6A60A 52043 NE WING LOOSE B KX5R K NONE O OTHER IN INSP/MAINT 1 GL 15 1525C 5500 FL88 MANY OF THE BLIND RIVETS, PN NAS1738B6, ATTACHING THE WING SKIN TO THE LOWER FORWARD WING ATTACHMENT FITTING WERE FOUND TO BE LOOSE. CONDITION EXISTED ON BOTH WINGS. CONDITION ALSO FOUND ON AC SN FL59 (8100 HRS). (K) 2 L 7 2 4T 4 T A24CE E4EA 2007050400205 20070504 00205 GL 2007 5 4 2007FA0000285 2 20070319 G 7323 23065121 GOVERNOR HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL ENGINE FROZEN B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 CGPHC 293 180257D DURING AN INSPECTION IT WAS NOTED THAT THE BEAING RETAINING WASHER FOR THE ROD END WAS INCORRECT. AFTER THE BOLT WAS RE MOVED IT WAS THEN DISCOVERED THAT THE THROTTLE ARM WAS SEIZED UP ON THE GOVERNOR, REPLACED GOVERNOR. (K) 1 G 7 1 3U 3 U H3WE E4CE 2007040200159 20070402 00159 GL 2007 4 2 2007FA0000286 1 20070322 G 7120 11925003 MOUNT CIRRUS SR SR20 05628AJ GL ENGINE BROKEN D O OTHER O OTHER NR NOT REPORTED 1 SO 11 155CD 2058 1058 ENGINE MOUNT RT FRONT CROSSOVER TUBE BETWEEN LT AND RT ENGINE SUPPORTS FOUND BROKEN AT THE WELD RT SIDE. ENGINE WAS CHA NGED ABOUT 250 HRS AGO, NO MENTION OF ENGINE MOUNT DAMAGE. COULD HAVE BEEN A HARD LANDING, BUT NO OTHER SIGNS WERE NOTE D. CONTACT WITH MFG SAYS NO OTHER REPORTS HAVE BEEN FILLED. (K) 1 L 7 1 3O NT A00009CH 2007040200166 20070402 00166 SW 2007 4 2 2007FA0000287 1 20070322 G 7110 RIVET MOONEY M20 M20J 5870219 SW LYC O360 IO360A1A 41514 EA COWLING CORRODED D K NONE O OTHER IN INSP/MAINT 1 SO 11 9156X 243253 OWNER BROUGHT COWLINGS IN FOR REPAIR BECAUSE THE THROUGH SKIN RIVETS WERE CORRODING AND SHEARING OFF AT THE MFG HEAD AS EXHIBITED BY BLISTERING PAINT AT THE RIVET LOCATIONS. INSPECTION REVEALED MOST OF THE AD TYPE RIVETS WERE SEVERELY CORR ODED BECAUSE THE COWLINGS WERE CONSTRUCTED WITH A HYBRID COMPOSITE LAMINATE OF E-GLASS AND CARBON GRAPHITE PLIES. IT IS STANDARD INDUSTRY PRACTICE TO USE CORROSION RESISTANT FASTENERS SUCH AS RIVETS THROUGH CARBON GRAPHITE STRUCTURE AND IT IS UNKNOWN WHY ALUMINUM RIVETS ARE USED IN THIS CASE. AFFECTED AREAS: UPPER COWL/ OIL DOOR CUTOUT DOUBLER RIVETS COOLI NG AIR INLET AFT EDGE RIVETS. LOWER COWL/ BOTH UPPER CAMLOCK RECEPTACLE GANG STRIPS (SEVERELY CORRODED AND CONCEALED BY 1 L 7 1 3O 3 O 2A3 1E10 2007040300032 20070403 00032 SO 2007 4 3 2007FA0000288 1 20070402 G 5321 37829007 FLOOR PANEL PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360RB 17025 CE FUSELAGE DEBONDED D IBIR K NONE O OTHER IN INSP/MAINT 1 EA 27 682JK 968 3449154 322291 FLOOR PANEL BETWEEN FORWARD AND REAR WING SPARS ON WHICH AFT FACING CENTER SEATS ARE MOUNTED IS DELAMINATING. THE FLOOR PANEL CONSISTS OF 2 SHEETS OF ALUMINUM (.040 INCH) WITH A SOUND DEADENING STIFF FOAM BETWEEN THEM. THE SEAT MOUNTING BR ACKETS ARE BOLTED THRU BOTH SHEETS, BUT THIS STILL MAY BE A STRUCTURE ISSUE. CALLED MFG FOR GUIDANCE, BUT HAVE NOT HEAR D ANYTHING AS YET. 1 L 7 2 3O 3 O A7SO E9CE 2007040300033 20070403 00033 SO 2007 4 3 2007FA0000289 1 20070402 G 5321 37829007 FLOOR PANEL PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360RB 17025 CE ZONE 100 DEBONDED D IBIR K NONE O OTHER IN INSP/MAINT 1 EA 27 682JK 968 3449154 322291 FLOOR PANEL BETWEEN FORWARD AND REAR WING SPARS ON WHICH AFT FACING CENTER SEATS ARE MOUNTED IS DELAMINATING. THE FLOOR PANEL CONSISTS OF 2 SHEETS OF ALUMINUM (.040 INCH) WITH A SOUND DEADENING STIFF FOAM BETWEEN THEM. THE SEAT MOUNTING B RACKETS ARE BOLTED THRU BOTH SHEETS, BUT THIS STILL MAY BE A STRUCTURE ISSUE. CALLED MFG FOR GUIDANCE, BUT HAVE NOT HEA RD ANYTHING AS YET. 1 L 7 2 3O 3 O A7SO E9CE 2007040300034 20070403 00034 SO 2007 4 3 2007FA0000290 1 20070402 G 5321 37829007 FLOOR PANEL PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360RB 17025 CE ZONE 100 DEBONDED D IBIR K NONE O OTHER IN INSP/MAINT 1 EA 27 682JK 968 3449154 322291 FLOOR PANEL BETWEEN FORWARD AND REAR WING SPARS ON WHICH AFT FACING CENTER SEATS ARE MOUNTED IS DELAMINATING. THE FLOOR PANEL CONSISTS OF 2 SHEETS OF ALUMINUM (.040 INCH) WITH A SOUND DEADENING STIFF FOAM BETWEEN THEM. THE SEAT MOUNTING BR ACKETS ARE BOLTED THRU BOTH SHEETS, BUT THIS STILL MAY BE A STRUCTURE ISSUE. HAVE CALLED MFG FOR GUIDANCE, BUT HAVE NOT HEARD ANYTHING AS YET. 1 L 7 2 3O 3 O A7SO E9CE 2007040300035 20070403 00035 SO 2007 4 3 2007FA0000291 1 20070402 G 5321 37829007 FLOOR PANEL PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360RB 17025 CE ZONE 100 DEBONDED D IBIR K NONE O OTHER IN INSP/MAINT 1 EA 27 682JK 968 3449154 322291 FLOOR PANEL BETWEEN FORWARD AND REAR WING SPARS ON WHICH AFT FACING CENTER SEATS ARE MOUNTED IS DELAMINATING. THE FLOOR PANEL CONSISTS OF 2 SHEETS OF ALUMINUM (.040 INCH) WITH A SOUND DEADENING STIFF FOAM BETWEEN THEM. THE SEAT MOUNTING B RACKETS ARE BOLTED THRU BOTH SHEETS, BUT THIS STILL MAY BE A STRUCTURE ISSUE. HAVE CALLED MFG FOR GUIDANCE, BUT HAVE NO T HEARD ANYTHING AS YET. 1 L 7 2 3O 3 O A7SO E9CE 2007040300036 20070403 00036 SO 2007 4 3 2007FA0000292 1 20070402 G 5321 37829007 FLOOR PANEL PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360RB 17025 CE ZONE 100 DEBONDED D IBIR K NONE O OTHER IN INSP/MAINT 1 EA 21 682JK 968 3449154 322291 FLOORPANEL BETWEEN FORWARD AND REAR WING SPARS ON WHICH AFT FACING CENTER SEATS ARE MOUNTED IS DELAMINATING. THE FLOOR PANEL CONSISTS OF 2 SHEETS OF ALUMINUM (.040 INCH) WITH A SOUND DEADENING STIFF FOAM BETWEEN THEM. THE SEAT MOUNTING BRA CKETS ARE BOLTED THRU BOTH SHEETS, BUT THIS STILL MAY BE A STRUCTURE ISSUE. HAVE CALLED MFG FOR GUIDANCE, BUT HAVE NOT HEARD ANYTHING AS YET. 1 L 7 2 3O 3 O A7SO E9CE 2007050400135 20070504 00135 CE 2007 5 4 2007FA0000293 1 20070322 G 7830 LINK CESSNA 500 560CESSNA 2076750 CE PWA JT15 JT15D5 52112 NE THRUST REVERSER CORRODED D O OTHER O OTHER NR NOT REPORTED 1 GL 15 413LC 6894 5600003 PCE108003 ALL DRIVE LINK PIVOT BOLTS AND OVER CENTER LINKS SEVERELY CORRODED AND WORN. PROBABLE CAUSE IS INADEQUATE LUBE. MANUAL STATES TR`S MUST BE TORN DOWN AND LUBED UPON ASSEMBLY AT SPECIFIC INTERVALS. ENGINEERING STATES THAT TEARDOWN IS NOT N ECESSARY AND ON WING LUBRICATION IS ADEQUATE. THESE FINDINGS INDICATE OTHERWISE. (K) 2 L 7 2 4F 4 F RT A22CE E25EA 2007050400141 20070504 00141 CE 2007 5 4 2007FA0000294 1 20070222 G 3610 1H1069 MIXING VALVE LEAR 60 60LEAR 5170707 CE PWA 305 PW305 NE LT ENGINE INTERMITTENT C O OTHER O OTHER NR NOT REPORTED 1 GL 11 500 83 306 SHORTLY AFTER TAKEOFF, AIRCRAFT (LT BLEED AIR) WARNING ILLUMINATED, AND (RT BLEED AIR) WARNING ILLUMINATED APPROX 5 SEC LATER, SMELLED ODOR IN MAINTENANCE. UNABLE TO DUPLICATE MALFUNCTION ON GROUND RUN; LT MIXING VALVE WAS SUSPECTED, SO RE PLACED. PERFORMED GROUND RUN FUNCTIONAL TEST OF BLEED AIR SYSTEM, AND FLIGHT TEST. NO FURTHER BLEED AIR WARNINGS. (K) 2 L 7 2 4F 4 F RT A10CE E35NE 2007040600160 20070406 00160 CE 2007 4 6 2007FA0000295 1 20070320 G 8120 BEARING CESSNA 414 414A 2075907 CE CONT O520 TSIO520* 17040 SO TURBOCHARGER WORN D O OTHER O OTHER NR NOT REPORTED 1 GL 13 3247M 1031 FKL00044 414A0828 FAILURE OF RT TURBOCHARGER SEAL AND CENTER BEARING CAUSED SMOKE OUT OF EXHAUST AND SQUEALING NOISE RESULTING IN THE FLIG HT CREW TO FEATHER PROPELLER AND SHUTDOWN THE ENGINE. CAUSE OF FAILURE DO TO WEAR. (K) 1 L 7 2 3O 3 O A7CE E8CE 2007040900008 20070409 00008 SW 2007 4 9 2007FA0000297 1 20070305 G 6410 HAC473 BLADE BELL 47 47G5 1181032 SW LYC O435 VO435* 41516 EA TAIL ROTOR DAMAGED B ECGR O OTHER O OTHER NR NOT REPORTED 1 EA 13 1202W 7857 THE STAINLESS STEEL ABRASION STRIP ON THE LEADING EDGE OF THE COMPOSITE TAIL ROTOR BLADE SEPARATED FROM BLADE IN FLIGHT. PILOT NOTED A VIBRATION IN A SPRAY TURN AND ELECTED TO LAND; AND LANDED SAFELY (NO INJURIES). 1 G 7 1 3O 3 O 2H3 E279 2007050400145 20070504 00145 SO 2007 5 4 2007FA0000298 1 20070320 G 2400 100201021346 INVERTER GULSTM GVSP GVSPG550 3980203 SO GE CF34 CF343A 30066 NE SHORTED D O OTHER B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 GL 05 5PG 1383 5046 WHEN TURNING MAIN BATTERY SWITCHES ON, MECHANIC HEARD A LOUD POPPING SOUND, FOLLOWED BY THE AROMA OF SMOKE IN THE ENTRAN CE AREA OF THE AIRCRAFT. THE FLOORBOARD WAS REMOVED AND FOUND THAT WATER FROM THE FORWARD LAVATORY AREA HAD BEEN RUNNIN G ONTO THE TOP OF THE EMERGENCY INVERTER CAUSING H2O AND AC VOLTAGE TO MEET (H2O WON). THE LAV AREA ON BOTH OF OUR AC W ERE INSPECTED FOR LEAKS AND FOUND AREAS WHERE WATER HAD BEEN SITTING, EVEN THROUGH THERE WERE NO LEAKS. IT IS POSSIBLE THAT WHEN STOWING THE SINK (HINGED AND FOLDS UP INTO A CLOSEOUT) RESIDULE WATER IS DUMPING INTO THE CLOSEOUT. THE INVER TER WAS REPLACED AND WE SHUT THE WATER SUPPLY OFF FOR THE FORWARD LAY SINK ON BOTH. THERE IS NO PREFLIGHT OR SCHEDULED 2 L 7 2 4F 4 F RT A12EA E15NE 2007050400148 20070504 00148 CE 2007 5 4 2007FA0000299 1 20070326 G 2820 050011849 LINE CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA FUEL SYSTEM CHAFED D O OTHER O OTHER NR NOT REPORTED 1 EA 23 2470N 400 172S10070 FOUND FUEL LINE PN 05001( 8-49, FUEL RETURN LINE TO RESERVOIR WORN BY RUBBING ON NOSE STEERING ROD JUST BEHIND FIREWALL . INSTALLED NEW LINE SO AS NOT TO RUB ON STEERING. INSTALLED SPIRAL WRAP ON AREA WHERE RUBBING HAD OCCURRED. NOTE: FU EL LINE WAS WORN TO POINT OF LEAKING. RECOMMEND INSPECTING NEW AC FOR PROPER LINE INSTALLATION. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 2007050400144 20070504 00144 CE 2007 5 4 2007FA0000300 1 20070327 G 3240 16011800 HOUSING CLEVELAND CESSNA 208 208B 2073701 CE PWA PT6 PT6A114A 52043 NE MCAULY 3AF34C 3GFR34C703 GL BRAKE CALIPER DEFECTIVE D O OTHER O OTHER NR NOT REPORTED 1 WP 21 PKMPS 017 208B0656 PCEPC0548 001276 THE MAIN CASTING, WHICH HOUSES THE BRAKE CALIPER PISTONS LEAKS FLUID UNDER NORMAL BRAKING PRESSURE. THE LEAKS ARE FROM EXCESSIVE POROSITY IN THE CASTING. CASTING THIS IS THE SECOND OCCURRENCE IN OUR OPERATIONS. THE FIRST WAS NOT REPORTE D. (K) 1 H 7 1 3T 3 T A37CE E4EA 5 C P60GL 2007040600163 20070406 00163 CE 2007 4 6 2007FA0000301 1 20070406 G 1400 NUT CESSNA 172 172S 2072439 CE LYC O360 IO360A1A 41514 EA MISMANUFACTURED B O OTHER O OTHER NR NOT REPORTED 1 EA 07 949SP 172S8145 WHILE INSTALLING KIT MK172-25-10C TO COMPLY WITH SB 04-25-01 R4 AND AD 2007-05-10, ONE OF THE PARTS IN THE KIT WAS MACHI NED IMPROPERLY. THE HEIGHT ADJUSTING NUT HAD THE THRU HOLE FOR THE ULTRALOC WITH MIS FORMED THREADS. THE MINOR DIAMETER OF THE THREAD WAS GREATER THAN THE MAJOR DIAMETER OF THE THREADS ON THE ULTRALOC. THE CROSS HOLE FOR MOUNTING WAS INCORR ECTLY LOCATED WITH INSUFFICIENT EDGE DISTANCE, AND THE PILOT HOLE WAS OFFSET GIVING AN EGG SHAPED HOLE. 1 H 7 1 3O 3 O NT 3A12 1E10 2007040900036 20070409 00036 CE 2007 4 9 2007FA0000302 1 20070403 G 2731 65651412 ACTUATOR CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE ELEVATOR TRIM BINDING B K NONE O OTHER IN INSP/MAINT 1 SW 13 5314J 5592 300 5500663 AFTER A PHASE 1-4 INSPECTION THE ELEVATOR TRIM WAS FOUND TO BE BINDING. INSPECTION OF THIS SYSTEM FOUND THAT THE WILKIE BUTTON IN THE BACK OF THE ACTUATOR TRIM JACK SCREWS HAD COME OUT AND WAS BINDING THE TRIM CHAIN AND SPROCKETS. WHEN THE ACTUATORS ARE LUBED THE WILKIE BUTTONS HAVE A TENDENCY TO POP OUT OF THERE PLACE IF YOU DONT LOOK CLOSELY AFTER LUBING T HESE ACTUATORS THE GREASE PUSHES THESE PLUGS OUT AND THEY STICK TO THE INTERCONNECT CHAIN CAUSING A BINDING CONDITION. T HIS COULD ALSO HAPPEN IN FLIGHT CAUSING A LIKE CONDITION WITH MORE DIRE PROBLEMS. I THINK MFG SHOULD REMOVE THIS PLUG OR MORE SECURELY FIX THIS PLUG IN PLACE. 1 L 7 2 4F 4 F A22CE E1NE 2007040900037 20070409 00037 CE 2007 4 9 2007FA0000303 1 20070403 G 2731 65651412 ACTUATOR CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE ZONE 200 BINDING B K NONE O OTHER IN INSP/MAINT 1 SW 13 5314J 5592 300 5500663 AFTER A PHASE 1-4 INSPECTION THE ELEVATOR TRIM WAS FOUND TO BE BINDING. INSPECTION OF THIS SYSTEM FOUND THAT THE WILKIE BUTTON IN THE BACK OF THE ACTUATOR TRIM JACK SCREWS HAD COME OUT AND WAS BINDING THE TRIM CHAIN AND SPROCKETS. WHEN THE ACTUATORS ARE LUBED THE WILKIE BUTTONS HAVE A TENDENCY TO POP OUT OF THERE PLACE IF YOU DONT LOOK CLOSELY AFTER LUBING T HESE ACTUATORS THE GREASE PUSHES THESE PLUGS OUT AND THEY STICK TO THE INTERCONNECT CHAIN CAUSING A BINDING CONDITION. T HIS COULD ALSO HAPPEN IN FLIGHT CAUSING A LIKE CONDITION WITH MORE DIRE PROBLEMS. I THINK MFG SHOULD REMOVE THIS PLUG OR MORE SECURELY FIX THIS PLUG IN PLACE. 1 L 7 2 4F 4 F A22CE E1NE 2007040900020 20070409 00020 CE 2007 4 9 2007FA0000308 1 20070402 G 3211 508103437 PIN BEECH 200 B200 1152922 CE LT MLG BROKEN E O OTHER J WARNING INDICATION AP APPROACH 1 SW 05 65TW 6551 6551 BB902 UPON EXTENDING THE LANDING GEAR, THE PILOTS GOT A RED GEAR UNSAFE LIGHT IN THE HANDLE, AND THE LT DOWN AND LOCKED LIGHT WAS NOT LIT UP. THE PILOTS TRIED TO EXTEND THE GEAR MANUALLY, BUT THE HANDLE WOULD NOT EXTEND THE GEAR ANY FURTHER, THE PILOTS RETRACTED THE GEAR AND THE RED LIGHT STAYED ILLUMINATED, THE GEAR WAS EXTENDED AGAIN, STILL THE LT DOWN AND LOCKE D LIGHT WAS OFF AND THE RED LIGHT IN THE HANDLE WAS ON. THE PILOTS DECLARED AN EMERGENCY AND LANDED THE AIRCRAFT, WITH N O OTHER EVENTS. THE AIRCRAFT WAS JACKED UP, AND THE LANDING GEAR WAS INSPECTED. THE LT MAIN DOWN LOCKING ASSY PIN WAS FO UND TO BE BROKEN AND HANGING OUT OF THE LOCK HOLES, PREVENTING THE GEAR FROM FULLY EXTENDING AND RETRACTING. THE PIN WAS 1 L 7 2 4T A24CE 2007040900021 20070409 00021 CE 2007 4 9 2007FA0000309 1 20070402 G 3210 508103437 PIN BEECH 200 B200 1152922 CE ZONE 700 BROKEN E O OTHER J WARNING INDICATION AP APPROACH 1 SW 05 65TW 6551 6551 BB902 UPON EXTENDING THE LANDING GEAR, THE PILOTS GOT A RED GEAR UNSAFE LIGHT IN THE HANDLE, AND THE LT DOWN AND LOCKED LIGHT WAS NOT LIT UP. THE PILOTS TRIED TO EXTEND THE GEAR MANUALLY, BUT THE HANDLE WOULD NOT EXTEND THE GEAR ANY FURTHER, THE PILOTS RETRACTED THE GEAR AND THE RED LIGHT STAYED ILLUMINATED, THE GEAR WAS EXTENDED AGAIN, STILL THE LT DOWN AND LOCKE D LIGHT WAS OFF AND THE RED LIGHT IN THE HANDLE WAS ON. THE PILOTS DECLARED AN EMERGENCY AND LANDED THE AIRCRAFT, WITH N O OTHER EVENTS. THE AIRCRAFT WAS JACKED UP, AND THE LANDING GEAR WAS INSPECTED. THE LT MAIN DOWN LOCKING ASSY PIN WAS FO UND TO BE BROKEN AND HANGING OUT OF THE LOCK HOLES, PREVENTING THE GEAR FROM FULLY EXTENDING AND RETRACTING. THE PIN WAS 1 L 7 2 4T A24CE 2007040900032 20070409 00032 CE 2007 4 9 2007FA0000310 1 20070406 G 1400 07900072 NUT CESSNA 172 172S 2072439 CE LYC O360 IO360A1A 41514 EA KIT MISMANUFACTURED B O OTHER W INADEQUATE Q C NR NOT REPORTED 1 EA 07 949SP 172S8145 WHILE INSTALLING KIT MK172-25-10C TO COMPLY WITH SB 04-25-01 R4 AND AD 2007-05-10, ONE OF THE PARTS IN THE KIT WAS MACHI NED IMPROPERLY. THE HEIGHT ADJUSTING NUT HAD THE THRU HOLE FOR THE ULTRALOC WITH MALFORMED THREADS. THE MINOR DIAMETER O F THE THREAD WAS GREATER THAN THE MAJOR DIAMETER OF THE THREADS ON THE ULTRALOC. THE CROSS HOLE FOR MOUNTING WAS INCORRE CTLY LOCATED WITH INSUFFICIENT EDGE DISTANCE, AND THE PILOT HOLE WAS OFFSET GIVING AN EGG SHAPED HOLE. 1 H 7 1 3O 3 O NT 3A12 1E10 2007040900022 20070409 00022 NE 2007 4 9 2007FA0000311 2 20070305 G 7314 REGULATOR NAMER T6 AT6D 6400416 GL PWA R1340 R1340AN1 52016 NE HAMSTD 12D 12D40 NE FUEL PUMP STUCK P O OTHER Y J ENGINE STOPPAGE WARNING INDICATION CR CRUISE 1 NM 03 8541B THE PRESSURE REGULATOR (IN THE WOBBLE PUMP) STUCK IN THE (BYPASS) POSITION CAUSING LOSS OF FUEL PRESSURE AND POWER LOSS DUE TO LACK OF FUEL. 1 L 7 1 3R 3 R A2575 5E2 5 C P257 2007040900081 20070409 00081 WP 2007 4 9 2007FA0000313 2 20070330 G 7210 31030351 BEARING GARRTT TPE331 TPE33110U 01514 WP IDLER GEAR MISINSTALLED B K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 07 723 P44218C SUBASSEMBLY BEARINGS TO 2ND IDLER GEAR ASSEMBLED BACKWARDS, CAGE FAILED. 4 T E4WE 2007040900028 20070409 00028 CE 2007 4 9 2007FA0000315 1 20070402 G 3610 1H1068 MIXING VALVE LEAR 60 60LEAR 5170707 CE PWA 305 PW305 NE LT BLEED AIR SYS OUT OF TOLERANCE B C ABORTED TAKEOFF B SMOKE/FUMES/ODORS/SPARKS TO TAKEOFF 1 GL 09 706CR 168 DURING TAKEOFF ROLL CREW EXPERIENCED A RUSH OF WARM OILY SMELLING AIR IN THE COCKPIT. CREW ABORTED TAKEOFF AND RETURNED TO BASE. MAINTENANCE CREW RAN AIRCRAFT AND DUPLICATED PROBLEM FINDING THE DUCT OVRHT LIGHT AND LT BLEED LIGHT ON AT FULL POWER. FURTHER TROUBLESHOOTING FOUND THAT THE LT BLEED AIR MIXING VALVE WAS ALLOWING MORE THAN 200PSI OUT PUT OF AIR. L T BLEED AIR MIXING VALVE WAS REPLACED WITH A SERVICEABLE INSPECTED VALVE AND OPS CHECKED GOOD. 2 L 7 2 4F 4 F RT A10CE E35NE 2007041000035 20070410 00035 2007 4 10 2007FA0000316 4 20070406 G 2200 0111 TRANSDUCER CESSNA 180 180 2072602 CE AUTO PILOT MALFUNCTIONED D H DEACTIVATE SYST/CIRCUITS J WARNING INDICATION CR CRUISE 1 WP 28 460 ALTITUDE HOLD WAS INOP. WHEN SELECTED THE A/C WOULD PITCH EITHER UP OR DOWN IMMEDIATELY, OR THE A/C WOULD MAINTAIN ALTI TUDE FOR A SHORT TIME AND THEN PITCH IN EITHER DIRECTION. COMPUTER AND PRESSURE TRANSDUCER WERE SENT TO STEC OF TESTING. BOTH UNITS WERE RETURNED AS SERVICEABLE. AFTER INSTALLATION THE PROBLEM WAS STILL THERE. REPLACED THE TRANSDUCER WITH A KNOWN GOOD PART AND PROBLEM WAS SOLVED. STEC ACTED ASTONISHED THAT THEIR BENCH CHECK WOULD NOT FIND THE PROBLEM! 1 H 7 1 3O NC 5A6 2007041000036 20070410 00036 2007 4 10 2007FA0000317 4 20070406 G 2200 0111 TRANSDUCER STEC CESSNA 180 180 2072602 CE AUTO PILOT MALFUNCTIONED D H DEACTIVATE SYST/CIRCUITS O OTHER CR CRUISE 1 WP 28 460 ALTITUDE HOLD WAS INOPERATIVE. WHEN SELECTED THE A/C WOULD PITCH EITHER UP OR DOWN IMMEDIATELY, OR THE A/C WOULD MAINTA IN ALTITUDE FOR A SHORT TIME AND THEN PITCH IN EITHER DIRECTION. COMPUTER AND PRESSURE TRANSDUCER WERE SENT TO STEC FOR TESTING. BOTH UNITS WERE RETURNED AS SERVICEABLE. AFTER INSTALLATION THE PROBLEM WAS STILL THERE. REPLACED THE TRANSDUCE R WITH A KNOWN GOOD PART AND PROBLEM WAS SOLVED.STEC ACTED ASTONISHED THAT THEIR BENCH CHECK WOULDN'T FIND THE PROBLEM! 1 H 7 1 3O NC 5A6 2007041000037 20070410 00037 2007 4 10 2007FA0000318 4 20070406 G 2215 0111 TRANSDUCER STEC CESSNA 180 180 2072602 CE ZONE 200 MALFUNCTIONED D H DEACTIVATE SYST/CIRCUITS O OTHER CR CRUISE 1 WP 28 460 ALTITUDE HOLD WAS INOP. WHEN SELECTED THE A/C WOULD PITCH EITHER UP OR DOWN IMEDIATLEY, OR THE A/C WOULD MAINTAIN ALTIT UDE FOR A SHORT TIME AND THEN PITCH IN EITHER DIRECTION. COMPUTER AND PRESSURE TRANSDUCER WERE SENT TO STEC FO TESTING. BOTH UNITS WERE RETURNED AS SERVICEABLE. AFTER INSTALLATION THE PROBLEM WAS STILL THERE. REPLACED THE TRANSDUCER WITH A KNOWN GOOD PART AND PROBLEM WAS SOLVED.STEC ACTED ASTONISHED THAT THEIR BENCH CHECK WOULDN'T FIND THE PROBLEM! 1 H 7 1 3O NC 5A6 2007041000038 20070410 00038 2007 4 10 2007FA0000319 4 20070406 G 2215 0111 TRANSDUCER STEC CESSNA 180 180 2072602 CE ZONE 200 MALFUNCTIONED D H DEACTIVATE SYST/CIRCUITS O OTHER CR CRUISE 1 WP 28 460 ALTITUDE HOLD WAS INOPERATIVE. WHEN SELECTED THE A/C WOULD PITCH EITHER UP OR DOWN IMMEDIATELY, OR THE A/C WOULD MAINTA IN ALTITUDE FOR A SHORT TIME AND THEN PITCH IN EITHER DIRECTION. COMPUTER AND PRESSURE TRANSDUCER WERE SENT TO STEC FOR TESTING. BOTH UNITS WERE RETURNED AS SERVICEABLE. AFTER INSTALLATION THE PROBLEM WAS STILL THERE. REPLACED THE TRANSDUCE R WITH A KNOWN GOOD PART AND PROBLEM WAS SOLVED.STEC ACTED ASTONISHED THAT THEIR BENCH CHECK WOULDN'T FIND THE PROBLEM! 1 H 7 1 3O NC 5A6 2007050400155 20070504 00155 GL 2007 5 4 2007FA0000321 2 20070401 G 7412 6870885 EXCITER HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL ENGINE INOPERATIVE B EOOR O OTHER O OTHER NR NOT REPORTED 1 AL 03 CGBUY 6109580 CAE833577 PILOT WENT TO START THE AIRCRAFT AND THERE WAS NO IGNITION. FOUND IGNITION EXCITER INOPERATIVE, REPLACED. (K) 1 G 7 1 3U 3 U H3WE E4CE 2007050400152 20070504 00152 SO 2007 5 4 2007FA0000322 1 20070330 G 5730 427 SKIN GULSTM G1159 G1159A 3970109 SO RROYCE SPEY SPEY511* 54523 EU RT WING CORRODED D K NONE O OTHER IN INSP/MAINT 1 SW 05 300WY 427 DURING A WING NDT INSPECTION OF THE UPPER RT WING PLANK AT FS 452 AND BL 33, CORROSION WAS NOTED IN THIS AREA. ENGINEER ING HAS DETERMINED THIS CORROSION IS EXCESSIVE ENOUGH TO REQUIRE ACCOMPLISHMENT OF ASC 229, WHICH REMOVES THE CORROSION ON THE PLANK AND INSTALLS A DOUBLER PLATE AND A NEW STYLE WING ATTACH PIN AS A CORRECTIVE ACTION. (K) 2 L 7 2 4F 4 F A12EA E2EU 2007050700006 20070507 00006 SO 2007 5 7 2007FA0000323 1 20070301 G 3220 95829000 DRAG LINK PIPER PA34 PA34200 7103405 SO LYC O360 IO360A1A 41514 EA NLG JAMMED G R2LS O OTHER O OTHER NR NOT REPORTED 1 SO 15 15338 347350051 THE NOSE GEAR LINK ASSEMBLY JAMS INTERMITTENTLY, KEEPING THE FWD AND AFT NOSE GEAR DRAG LINKS FROM LOCKING COMPLETELY. REFER TO SB NR 1123B. (K) 1 L 7 2 3O 3 O A7SO 1E10 2007050400140 20070504 00140 GL 2007 5 4 2007FA0000324 1 20070317 G 3240 PLATE TCRAFT BC BC12D 8850316 GL CONT O200 O200A 17020 SO MCAULY 1A100 1A100* GL LT BRAKE LOOSE D O OTHER O OTHER NR NOT REPORTED 1 GL 15 43336 1669 6995 666377A G1885 WHEN BRAKES WERE APPLIED AFTER LANDING. IT APPEARS THAT THE PINS HOLD THE BACK PLATE ALLOW IT TO SHIFT ENOUGH TO HAVE P OSSIBLY MADE CONTACT WITH THE BRAKE ACCUATOR ARM AND NOT ALLOW IT TO RELEASE. (K) 1 H 7 1 3O 3 O A696 E252 5 N P918 2007042500263 20070425 00263 CE 2007 4 25 2007FA0000325 1 20070325 G 7810 EXHAUST PIPE CESSNA 182 182A 2072704 CE CONT O470 O470* 17026 SO MCAULY 2A34C 2A34C203 GL RT EXHAUST BROKEN D O OTHER O OTHER NR NOT REPORTED 1 CE 03 5848B 33848 668686L 891146 RT EXHAUST BROKE AT ELBOW, PART HAD BEEN REPAIRED 544 HRS AGO. DID NOT SHOW ANY CRACK 50 HRS EARLIER. DO NOT REPAIR EX HAUST PARTS THAT HAVE 1000 HRS ON THEM. (K) 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 2007042500255 20070425 00255 EU 2007 4 25 2007FA0000328 1 20070406 G 5554 T700A5340023100 FITTING SOCATA TBM TBM700 8682000 EU PWA PT6 PT6A64 EA HARTZL HCE4N HCE4N3 NE RUDDER CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 05 704QD 188 PCEPM0073 HH463 DURING A 6000HR/10 YEAR CORROSION INSPECTION AD2007-06-11 WAS BEING COMPLIED IAW AD AND MANDATORY SB70-=104, AMENDMENT 2 . AFTER COMPLETING THE PENETRANT INSPECTION NO CRACKS WERE DETECTED IN THE SPECIFIED AREAS HOWEVER THE FITTINGS LISTED IN BLOCK 5 WERE REMOVED FROM SERVICE FOR LIGHT PITTING CORROSION. RECENTLY IN OUR FACILITY, THERE WAS A LEVEL 3 NDT REC URRENT COURSE BEING GIVEN AND THE REMOVED FITTINGS WERE CRACK CHECKED USING A ROTARY TOOL FOR BOLT HOLE EDDY CURRENT SET UP ON .030 CORNER EDM NOTCH AS A REFERENCE STANDARD. AT THIS TIME THERE WERE CORROSION PITTING CRACKS DETECTED IN BOTH FITTINGS. THE INSPECTION CRITERIA STATED IN AD AND SB ARE INSUFFICIENT FOR CRACK DETECTION IN THIS AREA. POSSIBLY THE 1 L 7 1 3T 4 T RT A60EU E4EA 5 C P10NE 2007050400168 20070504 00168 EU 2007 5 4 2007FA0000329 1 20070406 G 5510 T700A5530072102 FITTING SOCATA TBM TBM700 8682000 EU PWA PT6 PT6A64 EA HARTZL HCE4N HCE4N3 NE STABILIZER CORRODED D O OTHER O OTHER NR NOT REPORTED 1 EA 05 704QD 5980 188 PCEPM0073 HH463 DURING A 6000HR/10 YEAR CORROSION INSPECTION AD2007-06-11 WAS BEING COMPLIED IAW AD AND MANDATORY SB70-104, AMENDMENT 2. AFTER COMPLETING THE PENETRANT INSPECTION, NO CRACKS WERE DETECTED IN THE SPECIFIED AREAS HOWEVER THE FITTINGS LISTED IN BLOCK 5 WERE REMOVED FROM SERVICE FOR LIGHT PITTING CORROSION. RECENTLY IN OUR FACILITY, THERE WAS A LEVEL 3 NDT REC URRENT COURSE BEING GIVEN AND THE REMOVED FITTINGS WERE CRACK CHECKED USING A ROTARY TOOL FOR BOLT HOLE EDDY CURRENT SET UP ON /030 CORNER EDM NOTCH AS A REFERENCE STANDARD. AT THIS TIME THERE WERE CORROSION PITTING CRACKS DETECTED IN BOTH FITTINGS. THE INSPECTION CRITERIA STATED IN AD AND SB ARE INSUFFICIENT FOR CRACK DETECTION IN THIS AREA. POSSIBLY THE 1 L 7 1 3T 4 T RT A60EU E4EA 5 C P10NE 2007050400171 20070504 00171 GL 2007 5 4 2007FA0000330 2 20070403 G 7240 23031260 COMBUSTION CASE HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL ENGINE CRACKED B EOOR O OTHER O OTHER NR NOT REPORTED 1 AL 03 CGPHC 180257D CAE831562 PILOT NOTICED CRACK IN COMBUSTION CAN ON PREFLIGHT CHECK REPLACED UNIT. (K) 1 G 7 1 3U 3 U H3WE E4CE 2007050400190 20070504 00190 SO 2007 5 4 2007FA0000331 2 20070404 G 7200 629340 ROD BOLT CESSNA 310 310R 2074245 CE CONT O520 IO520MB 17032 SO LT ENGINE BROKEN D O OTHER O OTHER NR NOT REPORTED 1 GL 23 2641D 740 310R1678 829015R PRELIMINARY INSPECTION FINDINGS: IN FLIGHT, LT ENGINE FAILURE ON CLIMB OUT. LT ENGINE HAD 737.1 HOURS AND PUT IN SERVI CE 05/2003. LARGE HOLE IN CASE AROUND NR 5 AND 6 CYLINDER. NR 5 ROD SEPARATED FROM CRANK AND BROKEN IN TWO PIECES A FE W INCHES FROM PISTON PIN. SUBSEQUENT FINDINGS FROM ENGINE TEARDOWN REPORT PERFORMED BY MFG. THE SIGNATURES PRESENT ON THE NR 5 CYLINDER BORE AND THE DAMAGE TO THE NR 5 CONNECTING ROD ARE CONSISTENT WITH A HYDROSTATIC LOCK EVENT. PRELIMIN ARY INFORMATION WAS BASED ON A SB CE-00-07, AND SDR REPORTS ISSUED BETWEEN 1995 AND PRESENT, ON SAME MODEL ENGINE WITH S IMILAR BOLT FAILURES. (K) 1 L 7 2 3O 3 O 3A10 E5CE 2007050400198 20070504 00198 SO 2007 5 4 2007FA0000332 2 20070401 G 8500 SNAP RING CESSNA 180 180A 2072604 CE CONT O470 IO470* 17026 SO ENGINE MISMANUFACTURED D O OTHER O OTHER NR NOT REPORTED 1 AL 03 4145 32840 CS76646PF SNAP RING USED TO RETAIN PLATE PN 643629 AND COUNTERWEIGHT PIN 643626-101 WAS BEING INSTALLED IN COUNTERWEIGHT. UPON IN STALLING, THE LAST SNAP RING, IT WAS NOTICED THAT THE SNAP RING DID NOT HAVE ANY RETAINING PROPERTIES. IT LACKED TEMPER TO SPRING BACK AND COULD BE FORMED INTO ANY POSITION WHICH COULD HAVE ALLOWED THE PLATE AND PIN TO FALL OUT OF THE COUN TERWEIGHT CAUSING ENGINE FAILURE.. THE SNAP RING WAS PURCHASED ON 12 MARCH, 2007. THE BATCH NR LISTED FOR THE SNAP RIN G WAS 0000070137 UNDER API`S PO NR 4500018586. (K) 1 H 7 1 3O 3 O 5A6 E1CE 2007050400137 20070504 00137 EA 2007 5 4 2007FA0000333 2 20070406 G 8530 LW15014 ROCKER CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA ENGINE CYLINDER BROKEN B YYBR O OTHER O OTHER NR NOT REPORTED 1 GL 03 2994E 17271398 L717976T THE STAMPED EXHAUST STEEL ROCKER ARM WAS FOUND BROKEN THROUGH AT PUSH ROD, AND THE INTAKE ROCKER ARM WAS CRACKED, AND TH E PUSH ROD WAS BENT BADLY. THE ENGINE HAD 120 HR TSO AND NEW FACTORY CYLIDERS WERE INSTALLED. (K) 1 H 7 1 3O 3 O NT 3A12 E274 2007042500258 20070425 00258 CE 2007 4 25 2007FA0000334 1 20070402 G 5312 07126161 BULKHEAD CESSNA 182 182L 2072726 CE CONT O470 O470* 17026 SO FUSELAGE CRACKED D K NONE O OTHER IN INSP/MAINT 1 WP 09 42053 4571 18258832 SMALL CRACK AT RUDDER CABLE CUTOUT IB, APPROX .2500 INCH, NO CAUSE. 1 H 7 1 3O 3 O NT 3A13 E273 2007042500257 20070425 00257 EA 2007 4 25 2007FA0000335 2 20070417 G 7414 SPRING SLICK PIPER PA28 PA28181 7102807 SO LYC O360 O360A4M 41514 EA IMPULSE COUPLING BROKEN D O OTHER R PARTIAL RPM/PWR LOSS TX TAXI/GRND HDL 1 NE 05 1603 38 PILOT STARTED AIRCRAFT NORMALLY AND DID RUN UP WITH A BAD MAGNETO CHECK. PILOT DID NOT FLY AIRCRAFT AND RETURNED TO HANG ER. AIRCRAFT WOULD NOT RESTART. IMPULSE COUPLE DID NOT MAKE ANY NOISE, TIMING WAS WAY OFF. FOUND IMPULSE COUPLE SPRING B ROKEN A TURN AND A HALF FROM OUTER END. 1 L 7 1 3O 3 O 2A13 E286 2007042500273 20070425 00273 2007 4 25 2007FA0000336 4 20070416 G 2312 0464105430 RADIO BOLKMS 117 BK117A1 5626010 EU LYC LTS101 LTS101650B1 41560 NE NR 2 COMM SHORTED E BAQR K NONE B SMOKE/FUMES/ODORS/SPARKS AA AIR AMBULANCE 1 EA 03 952CJ S7052 WHILE SHUTTING DOWN AIRCRAFT THE CREW NOTED A WHIFF OF SMOKE AND ELECTRICAL SMELL IN THE COCKPIT. FOUND THE NR (2) COMM RADIO INTERNALLY SHORTED. 1 G 7 2 3U 3 U H13EU E5NE 2007042500247 20070425 00247 GL 2007 4 25 2007FA0000337 1 20070418 G 2710 CONTROL SYSTEM CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO AILERON SYS OUT OF RIG B K NONE O OTHER IN INSP/MAINT 1 EA 07 636ST 2153 DURING INSPECTION, FOUND AILERON RUDDER INTECONNECT OUT OF RIG AND CAUSING INTERFERENCE BETWEEN RUDDER AND AILERON. THIS IS THE FOURTH AIRCRAFT WE'VE FOUND WITH THIS PROBLEM AND ONE ACTUALLY HAD THE RUDDER AND AILERON LOCK IN FULL OPPOSITE DEFLECTIONS JUST PRIOR TO TAKEOFF. 1 L 7 1 3O 3 O NT A00009CH E3SO 2007042400085 20070424 00085 GL 2007 4 24 2007FA0000339 1 20070419 G 2720 ARM CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO RUDDER MISRIGGED B LC1R K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 07 927SE 2238 EACH AC THAT CAME INTO THE SHOP WAS INSPECTED FOR THE SAME CONDITION WITH THE AILERON/RUDDER INTERFERENCE. INSPECTION FO UND RUDDER/AILERON INTERCONNECT MISRIGGED RESULTING IN THE BOLT CONNECTING THE BUNGEE TO THE RUDDER/AILERON INTERCONNECT ARM HITTING THE FORWARD CABLE CLAMP AND DEFLECTING THE RT AILERON CABLE. THE CONTROLS DID NOT LOCK BUT THERE WAS DEFIN ITE INTERFERENCE. IN THE NEUTRAL POSITION, THE DISTANCE FROM THE C/L OF THE ARM IS SUPPOSED TO BE 4.5 INCHES. ON THIS AI RPLANE IT ABOUT 3.75 INCHES. THERE WAS NO EVIDENCE OF ANYONE MOVING THE CLAMP OR THE CLAMP SLIDING. RECORDS SHOW THAT TH ERE WAS NO FLIGHT CONTROL RIGGING DONE SINCE THE AIRCRAFT LT THE FACTORY. 1 L 7 1 3O 3 O NT A00009CH E3SO 2007042400083 20070424 00083 GL 2007 4 24 2007FA0000340 1 20070419 G 2720 ARM CIRRUS SR SR20 05628AJ GL CONT O550 IO550N 17042 SO RUDDER MISRIGGED B LC1R D RETURN TO BLOCK F FLT CONT AFFECTED TX TAXI/GRND HDL 1 EA 07 636ST 1720 PILOT WAS TURNING ONTO RUNWAY IN CROSSWIND WITH FULL OPPOSITE AILERON AND RUDDER CONTROLS. CONTROLS LOCKED IN CROSSED PO SITION AND WOULD NOT RETURN TO NEUTRAL. PILOT RETURNED TO RAMP. INSPECTION FOUND RUDDER/AILERON INTERCONNECT MISRIGGED R ESULTING IN THE BOLT CONNECTING THE BUNGEE TO THE RUDDER/AILERON INTERCONNECT ARM LOCKING OVER THE BOLT GOING THROUGH TH E FORWARD CABLE CLAMP. IN THE NEUTRAL POSITION, THE DISTANCE FROM THE C/L OF THE ARM IS SUPPOSED TO BE 4.5 INCHES. ON TH IS AIRPLANE IT WAS JUST OVER 3 INCHES. THERE WAS NO EVIDENCE OF ANYONE MOVING THE CLAMP OR THE CLAMP SLIDING. RECORDS SH OW THAT THERE WAS NO FLIGHT CONTROL RIGGING DONE SINCE THE AIRCRAFT LEFT THE FACTORY. 1 L 7 1 3O 3 O NT A00009CH E3SO 2007042500246 20070425 00246 GL 2007 4 25 2007FA0000341 1 20070416 G 2750 RELAY CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO T/E FLAP FAILED P A UNSCHED LANDING F FLT CONT AFFECTED CR CRUISE 1 SW 01 105SR 1866 DURING A TRAINING FLIGHT, THE FLAPS BECAME STUCK IN THE DOWN POSITION. THE AIRCRAFT RETURNED TO THE AIRPORT WITHOUT INC IDENT AND THE AIRCRAFT WAS SENT TO MAINTENANCE FOR TROUBLESHOOTING. MAINTENANCE DISCOVERED THE FLAPS DOWN RELAY FAILED. 1 L 7 1 3O 3 O NT A00009CH E3SO 2007042500259 20070425 00259 SO 2007 4 25 2007FA0000342 2 20070421 G 8520 655910 CONNECTING ROD CONT TSIO520E CESSNA 402 402B 207590P CE CONT O520 TSIO520E 17040 SO MCAULY 3AF34C 3AF34C* GL RT ENGINE FAILED E E ENGINE SHUTDOWN E VIBRATION/BUFFET CL CLIMB 1 NM 05 8FB 176257 402B1372 176257 DURING CLIMB AFTER THE POWER HAD BEEN REDUCED FROM THE TAKEOFF SETTING, THE RT ENGINE STARTED TO VIBRATE. THE PILOT COU LD SEE OIL SPLASHING FROM AROUND THE OIL ACCESS DOOR AND RUNNING BACK ON THE TOP COWLING. THE PILOT SHUTDOWN THE ENGINE AND FEATHERED THE RT PROPELLER. THE PILOT RETURNED TO THE DEPARTURE AIRPORT AND LANDED WITHOUT FURTHER INCIDENT. UPON INITIAL INVESTIGATION, A LARGE HOLE WAS FOUND IN THE CRANKCASE ABOVE THE NR 4 ROD JOURNAL. THE NR 4 CONNECTING ROD WAS SEPARATED FROM THE CRANKSHAFT AND PROTRUDING FROM THE HOLE IN THE CASE. THE NR 4 CONNECTING ROD CAP WAS ALSO SEPARATED FROM THE CONNECTING ROD AND WAS STICKING UP OUT OF THE HOLE. 1 L 7 2 3O 3 O A7CE E8CE 5 C P22EA 2007050400146 20070504 00146 WP 2007 5 4 2007FA0000343 2 20070411 G 7261 31080261 SCAVENGE PUMP CESSNA 441 441 2076020 CE GARRTT TPE331 TPE33110 01514 WP LT ENGINE FLUCTUATES B E ENGINE SHUTDOWN J WARNING INDICATION NR NOT REPORTED 1 GL 25 835MA 4410343 P77725 COMMANDED IN-FLIGHT SHUTDOWN OF LT ENGINE DUE TO FLUCTUATING OIL PRESSURE. UNEVENTFUL SINGLE ENGINE LANDING. ENGINE LO ST OIL. OIL EXITED ENGINE FROM TURBINE AIR/OIL SEAL AS A RESULT OF TURBINE SCAVENGE PUMP FAILURE. RECOMMEND COMPLIANCE WITH SB 72-2074R1. (K) 1 L 7 2 3T 4 T RT A28CE E4WE 2007050400173 20070504 00173 EA 2007 5 4 2007FA0000344 2 20070323 G 7320 25765362 SERVO CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA MCAULY 1A170 1A170E GL ENGINE FUEL WORN B HUNR O OTHER O OTHER NR NOT REPORTED 1 NM 01 9522S 1938 17280432 RL30493351A SF010 PILOT REPORTS THAT ENGINE DIED ON FINAL APPROACH. ADJUSTED IDLE STOP SLIGHTLY AND MIXTURE SLIGHTLY. RAN ENGINE AND FOU ND THAT SLIGHT ADJUSTMENTS MADE TO FUEL SERVO CREATED LARGE CHANGES IN THE ENGINE OPERATION. UNABLE TO ADJUST THE FUEL SERVO TO MEET PERFORMANCE REQUIREMENTS STATED IN AD2001-06-17, (D)(2). THIS IS THE SECOND ATTEMPT TO ADJUST THE FUEL SE RVO. THE FUEL SERVO WAS REMOVED FROM THE AIRCRAFT AND FORWARDED FOR REPAIR UNDER THEIR W/O NR 07-00900. ORIGINAL FUEL SERVO, PN 25765362, SN 70148401, REINSTALLED ON AC UPON COMPLETION OF REPAIR, WITH REFERENCE TO MM, CHAP 73. IDLE AND M IXTURE ADJUSTMENT COMPLETED WITH REFERENCE TO MM, CHAP 73. OPERATIONAL/LEAK CHECK GOOD AT THIS TIME. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P857 2007050400204 20070504 00204 2007 5 4 2007FA0000345 4 20070117 G 3417 702490031304 ADC LEAR 35 35A 5170602 CE GARRTT TFE731 TFE731* 01518 WP LT AVIONICS BAY MALFUNCTIONED B O OTHER N FALSE WARNING NR NOT REPORTED 1 GL 07 700SJ 082 WHILE ENROUTE, THE PILOTS ALTIMETER (FROZE UP) AT ABOUT 8000 FT AND THE OVERSPEED HORN WENT OFF. THE PILOT RECYCLED THE ADC AND ITS OPERATION WAS RESTORED. THE ADC WAS TESTED AND NO DEFECTS WERE FOUND. THERE WAS NO EVIDENCE OF WATER OR M OISTURE IN OR AROUND THE ADC. THE ADC WAS REPLACED AND TESTED. THERE HAS BEEN NO PREVIOUS REPORTED FAILURES OF THIS SY STEM IN THIS AIRCRAFT. (K) 2 L 7 2 4F 4 F A10CE E6WE 2007042600267 20070426 00267 2007 4 26 2007FA0000346 4 20070122 G 3417 702490031304 ADC LEAR 35 35A 5170602 CE GARRTT TFE731 TFE731* 01518 WP MALFUNCTIONED B O OTHER O OTHER NR NOT REPORTED 1 GL 07 813AS 167 DURING PRE-FLIGHT, THE CREW NOTED THAT THE PILOTS ALTIMETER AND ALTITUDE ALERTER WERE FLAGGED. ATTEMPTS TO RECYCLE THE SYSTEM WERE NOT SUCCESSFUL. THE CREW GROUNDED THE AIRCRAFT. AN AVIONICS TECH WAS DISPATCHED TO THE AIRCRAFTS LOCATION AND DETERMINED THAT THE ADC HAD FAILED. THE ADC WAS REPLACED. THE SYSTEM WAS TESTED AND INSPECTED AND FOUND TO COMPLY WITH FAR 91.411, PART 43 AND TO REMAIN RVSM COMPLIANT. (K) 2 L 7 2 4F 4 F A10CE E6WE 2007050400186 20070504 00186 CE 2007 5 4 2007FA0000348 1 20070330 G 3240 LINE CESSNA 170 170B 2072306 CE CONT C145 C145* 17012 SO BRAKE CHAFED D O OTHER O OTHER NR NOT REPORTED 1 WP 09 4696C 2611 25640 DURING AN ANNUAL INSPECTION, THE RT BRAKE SUPPLY LINE WAS FOUND CHAFED BY THE ELEVATOR CONTROL CABLE. THE CHAFING OCCUR RED WHEN THE ELEVATOR IS OPERATED NEAR THE (UP) LIMIT OF TRAVEL. THE LOCATION OF CHAFE IS VIEWED DIRECTLY BELOW THE ELE VATOR TRIM WHEEL, LOOKING SLIGHTLY FORWARD. THE BRAKE TUBE WAS NOT SUPPORTED BY ANY CLAMPING MEANS TO SECURE THE TUBE. A REPLACEMENT TUBE WAS FABRICATED AND INSTALLED WITH ADEQUATE CLAMPING TO INSURE NO FURTHER CHAFING ACTION. THE BRAKE WAS SERVICED AND A SATISFACTORY LEAK CHECK WAS ACCOMPLISHED. THE ELEVATOR CONTROL CABLE WAS CHECKED FOR DAMAGE AND IS A CCEPTABLE FOR SERVICE. PHOTOS DETAILING THE CHAFED AREA AND MFG IPC FOR INSTALLATION DETAIL. (K) 1 H 7 1 3O 3 O A799 E253 2007050400172 20070504 00172 SO 2007 5 4 2007FA0000349 1 20070401 G 5753 3087B SPAR MAULE M4 M4210C 5460112 SO CONT IO360 IO360* 17025 CE RT FLAP LOOSE D O OTHER O OTHER NR NOT REPORTED 1 WP 09 9810M 5341 1020C DURING AN ANNUAL INSPECTION, THE RT FLAP IB HINGE/CONTROL BRACKET WAS FOUND TO BE LOOSE. FURTHER INSPECTION REVEALED TH AT THE FLAP SPAR WAS CRACKED AT THE UPPER RIVET ATTACH POINTS. THE CRACK IS 3.5 INCH LONG AND EXTENDS PAST THE RIVET HO LES IN BOTH DIRECTIONS. ADDITIONALLY, BOTH CLOSURE RIBS, AT THEIR ATTACH ANGLES TO THE SPAR. THE SPAR PN IS 3078B, RIB PNS 3046-2 AND 3046-1, RIVET PNS SS/SS 34D AND SS/SS 32D (MFG SUPPLIED). THE FLAP SPAR AND RIBS WERE REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. (K) 1 H 7 1 3O 3 O 3A23 E1CE 2007050400149 20070504 00149 NE 2007 5 4 2007FA0000350 2 20070401 G 7250 1767M75G03 SHAFT GE BOEING 777 777224 1385225 NM GE GE90 GE9090B NE LPT FAN UNSERVICEABLE B QEMY O OTHER O OTHER NR NOT REPORTED 1 EA 35 78017 36785 T900253 31679 900238 AIRCRAFT TAKEOFF WAS ABORTED, A 147 KNOTS AFTER ENGINE LOST POWER. AC WAS STOPPED SAFELY AND ALL PASSENGERS AND CREW DE PLANED SAFELY. UPON INSPECTION OF THE ENGINE, THE FAN ROTATED FREELY, BUT THE LPT DID NOT ROTATE. BS1 OF THE ENGINE SH OWED THAT THE HPT WAS CLEAN, BUT THE LPT WAS HEAVILY DAMAGED. THE ENGINE WAS SHIPPED TO MFG. INITIAL INSPECTIONS SHOWE D THAT THE FAN MID SHAFT WAS SEPARATED IN THE AXIAL PLANE OF THE HPC S3 DISC. THE CENTER VENT TUBE WAS SEPARATED IN 3 P LACES ALL AFT OF FMS SEPARATION. AND INVESTIGATION IS ON GOING. (K) 2 L 7 2 4F 4 F RT T00001SE E00049EN 2007050700051 20070507 00051 NE 2007 5 7 2007FA0000351 2 20070424 G 8560 230319303 THRUST BEARING LYC LF507 LF5071F NE SUPERCHARGER FAILED B O OTHER O OTHER NR NOT REPORTED 1 WP 07 LF07712 NR 8 THRUST BEARING FAILURE RESULTED IN FAN AND SUPERCHARGER ROTORS TO SHIFT FORWARD CAUSING DAMAGE TO SUPERCHARGER 2ND DISK TO CONTACT THE STATORS MACHINING THROUGH THE 2ND SUPERCHARGER DISK WEB, RESULTING IN IN-FLIGHT SHUTDOWN OF NR 1 E NGINE. OPERATIONAL DESCRIPTION OF EVENT DID NOT INDICATE LOW OIL PRESSURE PRIOR TO THE FAILURE. WARNING SEQUENCE WAS D ESCRIBED AS (1) SMELL IN THE CABIN, HIGH VIBRATIONS WARNING AND VISUAL SPARKES COMING FROM ENGINE, THEN SHUT-DOWN. BEAR ING APPEARS TO BE STARVED OF OIL UPON DISASSEMBLY, ALONG WITH VERY LOW OIL CONTENT IN ADJACENT NR 9 BEARING AND PLANETAR Y REDUCTION GEAR CARRIER. CURRENTLY INVESTIGATING CAUSE OF OIL STARVATION. LUBE PUMP IS FROZEN, BUT ENGINE NR 2 AND NR 4 F E6NE 2007050100116 20070501 00116 SO 2007 5 1 2007FA0000352 2 20070424 G 7322 3801552 CARBURETOR CONT A65 A65* 17003 SO ENGINE MALFUNCTIONED B O OTHER O OTHER NR NOT REPORTED 1 EA 07 CARBURETOR WAS SENT IN FOR AN OVERHAUL BECAUSE IT WOULD NOT ACCEPT THROTTLE. THERE WAS VERY LITTLE TIME ON THE CARBURET OR SINCE IT'S LAST OVERHAUL. UPON DISASSEMBLY, IT WAS FOUND THAT THE CARBURETOR HAD THE WRONG VENTURI INSTALLED AND THE RE WAS OLD CORROSION IN THE FLOAT CHAMBER THAT WAS NOT REMOVED DURING THE PREVIOUS OVERHAUL. IT HAD THE WRONG SEAT INST ALLED FOR THE TYPE NEEDLE THAT WAS BEING USED. IT WAS OBVIOUS THAT SOMEONE WHO THOUGHT THEY KNEW CARBURETORS HAD ATTEMP TED TO OVERHAUL THE UNIT UNSUCCESSFULLY. 3 O E205 2007050400199 20070504 00199 CE 2007 5 4 2007FA0000354 1 20070402 G 2697 MS24266R12B12SN CONNECTOR BEECH 200 B200 1152922 CE PWA PT6 PT6* 52043 EA FIRE DETECTION CORRODED D GONR A UNSCHED LANDING N FALSE WARNING NR NOT REPORTED 1 SW 01 200VU 3534 BB1393 THE AIRCRAFT WAS FLYING THROUGH IMC, WITH ALOT OF RAIN ON THEIR WAY TO DESTINATION. AS THE CREW WAS LETTING DOWN TO LAN D THE LT ENGINE FIRE LIGHT LIT UP. THE CREW SCANNED ALL THE GAGES, AND DETERMINED THAT THIS WAS A FALSE LIGHT. THE AC LANDED WITHOUT COMPLICATION. UPON INSPECTION OF THE LT ENGINE FIRE DETECT SYSTEM, THE TECH FOUND SOME VERY LIGHT CORROS ION AND MOISTURE ON THE J102 CONNECTOR PLUG, LOCATED ON THE LT ENGINE FIRE WALL. THE MOISTURE AND CORROSION WAS REMOVED AND THE FIRE DETECT SYSTEM TESTED PROPERLY, THE AC WAS RETURNED TO SERVICE. APPLING A THIN COATING OF DC-4 GREASE IN T HE CONNECTOR PLUG WOULD PREVENT MOISTURE FROM ENTERING THE PLUG AND THEREFORE KEEP THE CORROSION OUT. (K) 1 L 7 2 4T 3 T A24CE E2NE 2007050700005 20070507 00005 CE 2007 5 7 2007FA0000355 1 20070417 G 7810 265401416 EXHAUST DUCT CESSNA 208 208B 2073701 CE PWA PT6 PT6A114A 52043 NE CRACKED D O OTHER O OTHER NR NOT REPORTED 1 AL 01 4365U 208B0253 CRACKING OCCURRED IN A SHORT TIME SPAN, DURING NORMAL OPERATION. CRACKS WERE OVER AN AREA APPROX 7 INCHES X 7 INCHES. ONE PIECE APPROX 3 INCHES X 3 INCHES SEPARATED FROM THE PART. AFTER CRACKING, DEFORMATION OF LOWER TRAILING EDGE OCCURR ED BECAUSE IT WAS NO LONGER RIGID. IF THIS PROBLEM HAD GONE UNNOTICED, HEAT DAMAGE WOULD PROBABLY HAVE OCCURRED TO ADJA CENT PARTS. MATERIAL OR MFG PROCESS COULD BE SUSPECT. RECENT MFG BULLETIN CAB 07-2 AFFECTS SOME PRIMARY EXHAUST DUCTS DUE TO IMPROPER MFG, BUT IT DOES NOT APPLY TO THIS ONE. (MFG HAS BEEN MADE AWARE OF THIS PROBLEM, PART WAS RETURNED TO THEM ON REQUEST FOR EVALUATION). (K) 1 H 7 1 3T 3 T A37CE E4EA 2007050700185 20070507 00185 SO 2007 5 7 2007FA0000356 2 20070418 G 8530 FRCN68OACA01 CYLINDER HEAD CESSNA 182 182A 2072704 CE CONT O470 O470L 17026 SO NR 1 SEPARATED D FO7R K NONE O OTHER IN INSP/MAINT 1 SO 13 5162D 145 51262 PERFORMED CYLINDER COMPRESSION TEST AND FOUND NR 1 CYLINDER READING 0 PSI AND FOUND LEAKING AROUND CYLINDER HEAD AND BAR REL FINS. UPON REMOVAL THE HEAD IS COCKED SIDEWAYS ON THE BARREL. THE HEAD WAS SEPARATING FROM BARREL. THE CYLINDER P N FRCN68. OACA/01 CL68 CERMINIL FREEDOM. CYLINDER ONLY HAD 145.6 HRS TIME IN SERVICE OVERHAUL IN DEC 2003. (K) 1 H 7 1 3O 3 O NT 3A13 E273 2007042700004 20070427 00004 CE 2007 4 27 2007FA0000357 1 20070425 G 3220 LANDING GEAR CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL NOSE BROKEN D O OTHER O OTHER LD LANDING 1 WP 09 757CM 10768 15279633 RL2072615 770307 NOSE LANDING GEAR BROKE AT HARD NOSE LANDING, NO EVIDENCE OF PREVIOUS CRACKS. 1 H 7 1 3O 3 O NT 3A19 E223 5 N P50GL 2007050400154 20070504 00154 CE 2007 5 4 2007FA0000359 1 20070403 G 5510 12320131 FITTING CESSNA 207 T207A 2073614 CE CONT O520 TSIO520M 17040 SO MCAULY D3A34 D3A34C401 GL STABILIZER CRACKED D O OTHER O OTHER NR NOT REPORTED 1 WP 07 803AN 11657 20700570 248811R 765815 FWD RT STABILIZER FITTING CRACKED. FOUND CRACKED FITTING UPON ANNUAL INSPECTION OF EMPENNAGE. (K) 1 H 7 1 3O 3 O A16CE E8CE 5 C P47GL 2007050400212 20070504 00212 EU 2007 5 4 2007FA0000360 1 20070407 G 5340 N325400A BRACKET SNIAS 350 AS350B3 8680954 EU FUSELAGE BROKEN B EOOR O OTHER O OTHER NR NOT REPORTED 1 AL 03 C6YPN 480 3688 DURING 100 HR INSPECTION, THE MECHANIC REACHED TO UNSCREW THE OIL FILTER AND THE BRACKET BROKE OFF IN HIS HAND. REPLACE D UNIT, THE ENTIRE BREAK LOOKED FRESH EVEN WITH 10X MAGNIFICATION. IT IS A POT METAL BRACKET. (K) 1 G 7 1 3U H9EU 2007050400229 20070504 00229 CE 2007 5 4 2007FA0000361 1 20070419 G 2420 COUPLING CESSNA 150 150M 2071830 CE CONT O200 O200A 17020 SO ALTERNATOR WORN B YYBR O OTHER O OTHER NR NOT REPORTED 1 GL 03 63332 15077241 250316 ALTERNATOR DRIVE COUPLING WAS WORN AND SEVERELY LOOSE WITH EXCESSIVE PLAY DUE TO SOFT, UNDERCUT BUSHINGS PN 632050. IN ADDITION, THE DRIVE HUB KEY WAY WAS SEVERELY WORN CAUSING EXCESSIVE PLAY OF THE HUB ON THE SHAFT. CONTINUED OPERATION W OULD RESULT IN DRIVE COUPLING RETAINER PN 352030 FAILING AND POTENTIALLY CAUSING CATASTROPHIC ENGINE FAILURE. THE CURRE NT RUBBER BUSHINGS ARE SOFT AND ALLOW THE DRIVE GEAR TO CRUSH AND DEFORM THEM WHICH REDUCES SHOCK ABSORPTION AND LEADS T O DRIVE COUPLING FAILURE WHEN DRIVE GEAR BEGINS TO CONTACT THE RETAINER CUP DIRECTLY. THIS IS A RECURRING PROBLEM AS FO UND ON OTHER ALTERNATORS USING THIS TYPE OF DRIVE COUPLING AS LISTED IN SB 95-3B. (K) 1 H 7 1 3O 3 O 3A19 E252 2007050400225 20070504 00225 CE 2007 5 4 2007FA0000362 1 20070419 G 2910 98811281 POWERPACK CESSNA 172 172RG 2072438 CE LYC O360 O360* 41514 EA HYD SYSTEM MISREPAIRED D O OTHER O OTHER NR NOT REPORTED 1 SW 03 413EB 172RG0113 INSTALLED A NEWLY OVERHAULED COMPLETE HYDRAULIC POWER PACK UNIT AS RECEIVED. AFTER INSTALLING THE UNIT IN THE AIRCRAFT AND PERFORMING A RETRACT TEST THE NEW OVERHAULED GEAR MOTOR WAS JERKY AND ACTING LIKE IT WAS SHORTING OUT. REMOVED MOTO R AND INSTALLED ANOTHER NEW OVERHAULED MOTOR AND SYSTEM WORKED FINE. (K) 1 H 7 1 3O 3 O 3A17 E286 2007050400233 20070504 00233 CE 2007 5 4 2007FA0000363 1 20070411 G 3210 05412024 BUSHING CESSNA 172 172S 2072439 CE LYC O360 IO360A1A 41514 EA RMLG UNSERVICEABLE B NU7R O OTHER O OTHER NR NOT REPORTED 1 GL 13 106RA 3586 172S8241 BUSHING LINER SEPARATED FROM METAL SHELL, SLID OUT OF SHELL CAUSING AC TO LEAN RT WING TIP LOW. BETTER BONDING ADHESIVE FOR LINER TO SHELL. NEED TO GO TO A TIME SCHEDULE FOR INSPECTION. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 2007050700182 20070507 00182 CE 2007 5 7 2007FA0000364 1 20070420 G 3230 LANDING GEAR CESSNA 500 S550 2076607 CE PWA JT15 JT15D4 52112 NE MALFUNCTIONED B EBVR O OTHER O OTHER NR NOT REPORTED 1 GL 09 32TX S5500026 EMERGENCY LANDING GEAR DEPLOYMENT SYSTEM INSPECTED DURING ROUTINE PHASE INSPECTION. EMERGENCY GEAR CABLES CHECKED FOR C ORRECT RIGGING, AND EMERGENCY GEAR SYSTEM FUNCTION TESTED WITH AIRCRAFT ON JACKS. SYSTEM FUNCTION TESTED PROPERLY. PIL OT ELECTED TO PERFORM IN FLIGHT CHECK OF SAME SYSTEM AND FOUND THAT MAIN GEAR WOULD NOT DEPLOY. PILOT EXTENDED GEAR USI NG NORMAL HYDRAULIC SYSTEM OPERATION AND LANDED WITHOUT INCIDENT. AC WAS FLOWN TO SERVICE CENTER FOR EVALUATION. (K) 1 L 7 2 4F 4 F RT A22CE E1NE 2007050400213 20070504 00213 CE 2007 5 4 2007FA0000366 1 20070412 G 7921 652065 GASKET CESSNA 421 421B 2076014 CE CONT O520 GTSIO520H 17032 SO OIL COOLER BROKEN D O OTHER O OTHER NR NOT REPORTED 1 CE 01 42776 322 421B0394 607077 AIRCRAFT DEPARTED ON A CHARTER , PILOT WAS OVER LAKE WHEN HE NOTICED ENGINE OIL COMING OUT OF TOP ENGINE COWLING COOLING LOUVERS. PILOT NOTIFIED CONTROL HE WAS LOSING OIL. FEATHERED THE RT ENGINE AND DIVERTED . PILOT MADE UNEVENTFUL SING LE ENGINE LANDING AND TAXIED TO MAINTENANCE HANGAR. DISCOVERED THE ENGINE WAS SEIZED AND THE COWLING AND NACESSE BOTTOM COVERED WITH OIL. STARTED DISASSEMBLY AND FOUND THE OIL COOLER GASKET, PN 652065, HAD .1250 INCH SECTION MISSING FROM THE UPPER FORWARD AREA OF THE GASKET. (K) 1 L 7 2 3O 3 O A7CE E7CE 2007050400214 20070504 00214 CE 2007 5 4 2007FA0000367 1 20070420 G 5100 6213011139 DOUBLER CESSNA 650 650 2076802 CE UNKNOWN FATIGUED B CNQR O OTHER O OTHER NR NOT REPORTED 1 CE 07 THE 6213011139 LT DOUBLER AND THE 6213011140 RT DOUBLER FATIGUE CRACKING ON BOTH. THE 6213011139 LT DOUBLER AND THE 621 3011140 RT DOUBLER, ON MODEL 650 IS PART OF THE NOSE WHEEL WELL ASSY, HAS BEEN FOUND WITH FATIGUE CRACKING ON MULTIPLE S N. CURRENTLY THE PART IS BEING REMOVED AND REPLACED AS NEEDED AND A SERVICE CONDITION REPORT (SCR) HAS BEEN SUBMITTED T O ENGINEERING FOR REVIEW. (K) 2 L 7 2 4F A9NM 2007050400227 20070504 00227 CE 2007 5 4 2007FA0000368 1 20070420 G 5310 6213011140 DOUBLER CESSNA 650 650 2076802 CE FS 92-94 FATIGUED D CNQR O OTHER O OTHER NR NOT REPORTED 1 CE 07 THE 6213011-139 LT DOUBLER AND THE 6213011-140 RT DOUBLER FATIGUE CRACKING ON BOTH. THE 6213011-139 LT DOUBLER AND THE 6213011-140 RT DOUBLER, ON MODEL 650 IS PART OF THE NOSE WHEEL WELL ASSY, HAS BEEN FOUND WITH FATIGUE CRACKING ON MULTIP LE SN. CURRENTLY THE PART IS BEING REMOVED AND REPLACED AS NEEDED, AND A SERVICE CONDITION REPORT (SCR) HAS BEEN SUBMIT TED TO ENGINEERING FOR REVIEW. (K) 2 L 7 2 4F A9NM 2007050400223 20070504 00223 CE 2007 5 4 2007FA0000369 1 20070404 G 3210 084100097 LANDING GEAR CESSNA 310 310D 2074212 CE CONT O470 IO470* 17026 SO LT MLG MALFUNCTIONED D O OTHER O OTHER NR NOT REPORTED 1 NM 03 6981T 39281 THE PILOT NOTED THAT SOMETHING WAS HANGING DOWN UNDER THE AC IN CRUISE FLIGHT AND THAT THE AC WAS NOT GOING AS FAST AS I T NORMALLY DID. ANOTHER AC NOTED THAT THE GEAR WAS UP, BUT THAT THE LEFT IB GEAR DOOR WAS HANGING DOWN PART WAY. THE T OWER CONFIRMED THAT THE GEAR APPEARED TO BE DOWN AND LOCKED, BUT THAT THE LT IB GEAR DOOR WAS PART WAY DOWN. ALL INDICA TIONS OF THE GEAR IN THE AC WERE NORMAL AND THE GREEN LIGHT WAS ON WHEN THE AC LANDED. THE AIRCRAFT LANDED NORMALLY AND ROLLED ABOUT 800 FT DOWN THE RUNWAY WHEN THE LEFT MAIN GEAR BROKE OUT OF THE WHEEL WELL. IT WENT STRAIGHT BACK BEHIND THE WING AND THE AC WENT AROUND TO THE LEFT AND OFF THE RUNWAY. THE LT IB DOOR WILL MOVE SOME BY HAND AND SEEMED TO OPE 1 L 7 2 3O 3 O 3A10 E1CE 2007050400133 20070504 00133 2007 5 4 2007FA0000370 4 20070427 G 2562 MN1300 BATTERY ACK PIPER PA28 PA28236 7102815 SO LYC O540 O540J3A5 41532 EA HARTZL HCF2Y HCF2YR1 GL ELT LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 EA 01 12 020150 28791146 L2113440A CM285 BATTERIES LEAKED ACID/ALKALII, CORRODING CONTACTS SERVERLY AND RENDERING ELT INOPERABLE. BATTERIES WERE INSTALLED IN 20 06. SHELF DATE ON BATTERIES WERE MAR 2011. ELT WAS NOT FOUND ACTIVATED. THIS IS THE THIRD CASE OF THIS I HAVE SEEN IN 20 06/2007 AND THERE HAVE BEEN SEVERAL OTHERS IN THE PAST 5 YEARS. IN ALL CASES THE BATTERIES RENDERED THE ELT INOP PRIOR TO THE REPLACEMENT DATE (HALF OF SHELF LIFE IAW FAR 91.207 (C)). ALL PROBLEMS WERE DETECTED DURING ANNUAL INSPECTIONS OF ELT IAW FAR 91.207 D. 1 L 7 1 3O 3 O 2A13 E295 5 C P27EA 2007050400134 20070504 00134 2007 5 4 2007FA0000371 4 20070427 G 2562 MN1300 BATTERY ACK PIPER PA28 PA28236 7102815 SO LYC O540 O540J3A5 41532 EA HARTZL HCF2Y HCF2YR1 GL ELT LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 EA 01 12 020150 28791146 L2113440A CM285 BATTERIES LEAKED ACID/ALKALII, CORRODING CONTACTS SERVERLY AND RENDERING ELT INOPERABLE.BATTERIES WERE INSTALLED IN 2006 . SHELF DATE ON BATTERIES WERE MAR 2011. ELT WAS NOT FOUND ACTIVATED. THIS IS THE THIRD CASE OF THIS I HAVE SEEN IN 2006 /2007 AND THERE HAVE BEEN SEVERAL OTHERS IN THE PAST 5 YEARS. IN ALL CASES THE BATTERIES RENDERED THE ELT INOP PRIOR TO THE REPLACEMENT DATE (HALF OF SHELF LIFE I/A/W FAR 91.207 (C)). ALL PROBLEMS WERE DETECTED DURING ANNUAL INSPECTIONS OF ELT I/A/W FAR 91.207 D. 1 L 7 1 3O 3 O 2A13 E295 5 C P27EA 2007050400153 20070504 00153 2007 5 4 2007FA0000372 4 20070502 G 2562 MN1300 BATTERY AMERIKING CESSNA 182 R182 2072734 CE LYC O540 O540J3C5 41532 EA ELT LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 EA 01 12 12 353328 01165 BATTERIES LEAKED INSIDE ELT UNIT PREVENTING ELT OPERATION AND DESTROYING CONTACTS INSIDE UNIT. THIS IS ONE OF SEVERAL TI MES THIS PROBLEM HAS BEEN SEEN IN THE NEWER OR MORE RECENTLY MANUFACTURED BATTERIES THIS PARTICULAR SET HAD AN EXPIRATIO N OF 2012 AND HAD ONLY BEEN INSTALLED IN THE UNIT FOR ONE YEAR. RECOMMEND BAT REPLACEMENT EVERY 6 MONTHS UNTIL THIS PRO BLEM IS ADDRESSED BY ELT MANUFACTURES OR THE BATTERY COMPANY NOTE OLDER BATTERIES DID NOT EXHIBIT THIS PROBLEM. 1 H 7 1 3O 3 O RT 3A13 E295 2007050400161 20070504 00161 GL 2007 5 4 2007FA0000375 1 20070427 G 2720 CONTROL CABLE CIRRUS SR SR22 2130001 GL CONT O550 IO550* SO AILERONS INTERFERENCE B K NONE O OTHER IN INSP/MAINT 1 EA 07 220SR 0391 DURING INSPECTION FOUND INTERFERENCE BETWEEN RUDDER/AILERON INTERCONNECT SYSTEM AND RT AILERON CABLE. CHECKED RIGGING AN D FOUND CABLE CLAMP ON RT AILERON CABLE OUT OF POSITION. VISUAL INSPECTION INDICATES NO MOVEMENT BETWEEN CABLE AND CLAMP AND RECORDS REVIEW INDICATE THAT NO RIGGING HAS TAKEN PLACE SINCE THE AIRPLANE LEFT THE FACTORY. 1 L 7 1 3O 3 O NT A00009CH E3SO 2007050400170 20070504 00170 CE 2007 5 4 2007FA0000377 1 20070426 G 3232 ROD GARKENYON LEAR 60 60LEAR 5170707 CE WRIGHT R3350 R3350* 67040 EA ACTUATOR FAILED D O OTHER J WARNING INDICATION LD LANDING 1 SO 09 718A 0290 065 WHEN LANDING GEAR WAS CYCLED DOWN, THE RT RED IB GEAR DOOR OPEN LIGHT WOULD NOT EXTINGUISH. GEAR DOWN LOCK LIGHTS WERE G REEN. NORMAL LANDING. INSPECTION REVEALED THAT THE ACTUATOR SHAFT HAD UNSCREWED FROM THE PISTON NOT ALLOWING THE DOOR TO CLOSE. FURTHER EXAMINATION REVEALED THAT THE ROLL PIN SECURING THE SHAFT TO THE PISTON WAS SHEARED. THE LT ACTUATOR WA S INSPECTED AND THE ACTUATOR ROD WAS FOUND TO BE 2.5 TURNS FROM DISENGAGING FROM THE PISTON. 6-7 TURNS BOTTOMS THE ROD I N THE PISTON. REPLACED BOTH DOOR ACTUATORS. 2 L 7 2 4F 4 R RT A10CE E272 2007050400188 20070504 00188 CE 2007 5 4 2007FA0000378 1 20070426 G 3232 66000858 ACTUATOR LEAR 60 60LEAR 5170707 CE WRIGHT R3350 R3350* 67040 EA MLG FAILED D O OTHER J WARNING INDICATION LD LANDING 1 SO 09 718A 4200 065 WHEN LANDING GEAR WAS CYCLED DOWN, THE RT RED IB GEAR DOOR OPEN LIGHT WOULD NOT EXTINGUISH. GEAR DOWN LOCK LIGHTS WERE GREEN. NORMAL LANDING. INSPECTION REVEALED THAT THE ACTUATOR SHAFT HAD UNSCREWED FROM THE PISTON NOT ALLOWING THE DOOR TO CLOSE. FURTHER EXAMINATION REVEALED THAT THE ROLL PIN SECURING THE SHAFT TO THE PISTON WAS SHEARED. THE LT ACTUATOR W AS INSPECTED AND THE ACTUATOR ROD WAS FOUND TO BE 2.5 TURNS FROM DISENGAGING FROM THE PISTON. 6-7 TURNS BOTTOMS THE ROD IN THE PISTON. REPLACED BOTH DOOR ACTUATORS. 2 L 7 2 4F 4 R RT A10CE E272 2007050400206 20070504 00206 CE 2007 5 4 2007FA0000381 1 20070404 G 7810 02R3022406 EXHAUST DUCT BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA RT ENGINE CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 09 13510 514 PCE81382 WHILE PREFORMING SCHEDULED MAINTENANCE, REMOVED LT ENGINE EXHAUST STACK TO FACILITATE INSPECTING THE EXHAUST DUCT. FOUND CRACK FOLLOWING THE CIRCUMFERENCE OF THE SKI SLOPE. THE EXHAUST DUCT HAD SB 3380 COMPLIED WITH 514 HOURS EARLIER.POWER SECTION WAS REMOVED AND SENT FOR REPAIR. 1 L 7 2 4T 4 T A24CE E4EA 2007050400215 20070504 00215 SO 2007 5 4 2007FA0000383 1 20070430 G 5520 2039700 HORN PIPER PA24 PA24250 7102404 SO LYC O540 O540* 41532 EA STABILIZER CRACKED D O OTHER O OTHER NR NOT REPORTED 1 WP 07 5977P 6000 241070 FOUND STABILATOR HORN P/N 20397-00 SEVERELY CRACKED FROM THE INSIDE WHERE THE ATTACH BOLTS CONNECT THE BALANCE WEIGHT TU BE P/N 20398-02 AND STABILATOR TORQUE TUBE ASSEMBLY P/N 20203-03. 1 L 7 1 3O 3 O 1A15 E295 2007061300266 20070613 00266 2007 6 13 2007FA0000385 2 20070501 G 7320 FADEC DIAMON DA40 DA40 2990002 GL MALFUNCTIONED C O OTHER O OTHER NR NOT REPORTED 1 SW 99 103 THE ECU WARNING LIGHTS HAVE COME ON MULTIPLE TIMES NOW. ACCRODING TO THE MANUFACTURER, EACH TIME THESE ANNUNCIATORS COM E ON THE AIRCRAFT MUST BE SERVICED BY AN APPROVED MECHANIC. BY THIELERTS EXPLANATION, IF THE AIRCRAFT GOES INTO A STEEP BANK OR UN-COORDINATED TURN THAN AN AIR BUBBLE CAN GET INTO THE FUEL LINE AND CAUSE UNEVEN PRESSURES BETWEEN THE TWO ENG INES. THE FADEC SENSES THIS AS A PROBLEM AND THE ECU WANRINGS TRIP. ACCORDING TO THIELERT THIS HAS BEEN HAPPENING FREQ UENTLY ON AIRCAFT WITH THEIR FADEC ENGINES. THREE TIMES ALREADY ON OUR WITHIN 100 HOURS. IT IS A NUISANCE BECAUSE AN A IRCRAFT CAN EASILY BE STRANDED IN A LOCATION WITHOUT A THIELERT APPROVED MECHANIC. OR WORSE, IF A GENUINE PROBLEM EXISTE 1 L 7 1 3O NT A47CE 2007050700184 20070507 00184 2007 5 7 2007FA0000386 2 20070501 G 7320 FADEC DIAMON DA40 DA40 2990002 GL MALFUNCTIONED C O OTHER O OTHER NR NOT REPORTED 1 SW 03 103 THE ECU WARNING LIGHTS HAVE COME ON MULTIPLE TIMES NOW. ACCORDING TO THE MANUFACTURER, EACH TIME THESE ANNUNCIATORS COM E ON THE AIRCRAFT MUST BE SERVICED BY AN APPROVED MECHANIC. BY THIELERTS EXPLANATION, IF THE AIRCRAFT GOES INTO A STEEP BANK OR UN-COORDINATED TURN THAN AN AIR BUBBLE CAN GET INTO THE FUEL LINE AND CAUSE UNEVEN PRESSURES BETWEEN THE TWO ENG INES. THE FADEC SENSES THIS AS A PROBLEM AND THE ECU WARNINGS TRIP. ACCORDING TO MANUFACTURE THIS HAS BEEN HAPPENING F REQUENTLY ON AIRCRAFT WITH THEIR FADEC ENGINES. THREE TIMES ALREADY ON OUR WITHIN 100 HOURS. IT IS A NUISANCE BECAUSE AN AIRCRAFT CAN EASILY BE STRANDED IN A LOCATION WITHOUT A THIELERT APPROVED MECHANIC. OR WORSE, IF A GENUINE PROBLEM EX 1 L 7 1 3O NT A47CE 2007052100146 20070521 00146 CE 2007 5 21 2007FA0000388 1 20070413 G 3233 99101368 ACTUATOR CESSNA 414 414A 2075907 CE CONT O520 TSIO520* 17040 SO LT MLG CORRODED D O OTHER O OTHER TX TAXI/GRND HDL 1 EA 61 6672C 7623 414A0053 LT LANDING GEAR ACTUATOR FAILED WHILE TAXING. COLLAPSED LT WING. DAMAGED LT PROP AND WING TIP. ACTUATOR INSPECTED AND FOUND WATER INSIDE. ACTUATOR OVERHAULED AND REINSTALLED NOSE AND RT LG ACTUATOR REMOVED FOR INSPECTION AND CHECKED GOO D. (K) 1 L 7 2 3O 3 O A7CE E8CE 2007052100114 20070521 00114 EA 2007 5 21 2007FA0000389 2 20070420 G 8530 5L32006WA1 CYLINDER CESSNA 172 172N 2072434 CE LYC O320 O320D2J 41508 EA ENGINE CRACKED D O OTHER O OTHER NR NOT REPORTED 1 NM 01 4801D 1400 17272362 CRACK FROM EXH STUD AROUND CYLINDER TO UPPER SPARK PLUG. (K) 1 H 7 1 3O 3 O NT 3A12 E274 2007051400210 20070514 00210 GL 2007 5 14 2007FA0000390 2 20070412 G 7323 369A7701 BRACKET HUGHES 369 369D 4470706 WP ALLSN 250C 250C20 03013 GL GOVERNOR DAMAGED B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 5074R 1151D DURING A PREFLIGHT, THE PILOT NOTICED THE GOVENOR BELCRANK HAD SOME SLOP SUBSEQUENT INSPECTION DISCLOSED THAT THE BELCRA NK PIVOT BOLT WAS MOVING IN THE BRACKET BECAUSE THE HOLE WAS ELONGATED, REPLACED BRACKET. (K) 1 G 7 1 3U 3 U H3WE E4CE 2007052100147 20070521 00147 SO 2007 5 21 2007FA0000391 2 20070411 G 7414 6310 MAGNETO BEECH 33 F33A 1151425 CE CONT O520 IO520BA 17032 SO LEFT FAILED D O OTHER O OTHER NR NOT REPORTED 1 GL 19 11BX 26 CE388 814263R DURING NORMAL FLIGHT, VFR CONDITIONS, LT MAGNETO FAILED TO CONTINUE FIRING. AC LANDED WITHOUT INCIDENT. UPON TROUBLESH OOTING LT MAGNETO FOUND TO ONLY FIRE ON ONE LEAD. MAGNETO REPLACED WITH NEW UNIT. DEFECTIVE MAGNETO FOUND TO HAVE LOOS E PARTS RATTLING INSIDE AFTER REMOVAL FROM ENGINE. MAGNETO NOT DISASSEMBLED DUE TO WARRANTY STATUS OF MAGNETO. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2007051400183 20070514 00183 2007 5 14 2007FA0000392 1 20070301 G 1430 TAB CRACKED B UO2R O OTHER O OTHER NR NOT REPORTED 1 GL 19 WHEN TECH WENT TO BEND THE TAB ATTACHED TO THE WASHER AT THE RADIUS OF THE BEND, THEY WOULD CRACK. (K) 2007052100084 20070521 00084 CE 2007 5 21 2007FA0000393 1 20070409 G 7921 LW10025 OIL COOLER BEECH 60 A60 1153604 CE LYC O541 TIO541E1C4 41536 EA LT ENGINE CRACKED G A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION NR NOT REPORTED 1 SO 09 1873W 142 P231 ON APRIL 9, 2007, MADE A PRECAUTIONARY LANDING, AL (TCL) DUE TO LOW OIL PRESSURE ON THE LEFT ENGINE. MAINTENANCE PERSON NEL REPORTED THAT THE OIL COOLER HAD FAILED DUE TO CRACKS, THE OIL LEVEL WAS DOWN (4) QUARTS, AND THE OIL FILTER WAS INS PECTED WITH NO CONTAMINATION FOUND. ENGINE MAINTENANCE LOG RESEARCH SHOWED THE FAILED OIL COOLER WAS OVERHAULED AND INS TALLED BY FIREWALL FORWARD. THE COOLER WAS REPLACED WITH A NEW PART ON 4/13/2007 AT 1770.6 HOBBS. THE FAILED OIL COOLE R HAD 142.1 HOURS SINCE OVERHAUL. NO DETERMINATION COULD BE MADE OF OIL COOLER TOTAL TIME. (K) 1 L 7 2 3O 3 O A12CE E10EA 2007051400208 20070514 00208 CE 2007 5 14 2007FA0000394 1 20070406 G 3233 98820152 ACTUATOR CESSNA 172 172RG 2072438 CE LYC O360 O360F1A6 41514 EA MCAULY 2D34C B2D34C220 GL LT MLG CRACKED D H2US O OTHER O OTHER AP APPROACH 1 SW 11 9353D 172RG1131 L1868036A 801202 PILOT REPORTED LOUD POP JUST BEFORE INTERING THE PATTERN AT M89. WHEN HE EXTENDED THE GEAR THE GREEN GEAR DOWN LIGHT WO ULD NOT COME ON. FLY BY REVEALED THE LEFT GEAR WAS IN TRANSIENT. GEAR UP LANDING FOLLOWED. INSPECTION OF LT MAIN GEAR ACTUATOR REVEALED THE ACTUATOR HOUSING WAS CRACKED ACROSS THE FORWARD ATTACH BOLT HOLE. THE CRACKED HOUSING ALLOWED TH E PISTON RACK TO JUMP GEARS ON THE PINION GEAR ATTACHED TO MAIN GEAR LEG. THIS AREA IS INSPECTED EACH 100 HR FOR CRACKS AND DEFECTS VERY CAREFULLY WITH LIGHTS AND INSPECTION MIRROWS. TIME SINCE LAST INSPECTION WAS 25 HRS. AD 2001-06-06 W AS CW 8-13-2001 TACH 497, TOTAL TIME 4516 WITH NO DEFECTS FOUND. (K) 1 H 7 1 3O 3 O 3A17 E286 5 C P7EA 2007051400224 20070514 00224 CE 2007 5 14 2007FA0000395 1 20070423 G 3246 13685 BEARING BEECH 1900 1900D 1154162 CE MLG LACK OF LUBE B HY1R K NONE O OTHER IN INSP/MAINT 1 EA 23 733DC 360 UE307 WHILE PERFORMING ROUTINE PREVENTATIVE MAINTENANCEON THE RT IB WHEEL AND TIRE ASSEMBLY (TO CHANGE A WORN TIRE) ONE OF THE WHEEL BEARING ROLLERS CAME OUT OF THE OUTER WHEEL BEARING ONCE THE WHEEL BEARING WAS REMOVED FROM THE WHEEL ASSEMBLY. THE WHEEL BEARING CAGE WAS FOUND TO BE DEFORMED WITH ONE PART OF THE CAGE BROKEN ALLOWING THE ROLLER TO FALL OUT. PIECE S OF METAL WERE FOUND IN THE BEARING SEAL. THE BEARING APPEARS TO HAVE BEEN OVERHEATED. PROPER LUBRICATION WOULD HAVE PREVENTED THIS BEARING FROM OVERHEATING. IT IS IMPERATIVE THAT EACH OPERATOR BE AWARE THAT THE INSPECTION AND LUBRICATI ON REQURIEMENT/INTERVAL FOR THE WHEEL BEARINGS MAY BE LESS THAN THE MFG RECOMMENDATIONS BASED ON THE OPERATORS OWN SPECI 2 L 7 2 4T RT A24CE 2007051400182 20070514 00182 2007 5 14 2007FA0000396 4 20070430 G 3400 593250101 SWITCH CESSNA 414 414 2075908 CE CONT O520 TSIO520* 17040 SO COCKPIT STUCK B YLMR O OTHER O OTHER NR NOT REPORTED 1 WP 23 42SG 2972 4140927 AVIONICS MASTER SWITCH STUCK IN THE ON POSITION AD 2005-20-25 WAS PREVIOUSL COMPLIED WITH AND DID NOT APPLY. DATE CODE OF THE SWITCH WAS 7647. THERE WAS NO BURNING SMELL WHEN THE SWITCH BECAME STUCK. (K) 1 L 7 2 3O 3 O RT A7CE E8CE 2007052100141 20070521 00141 SO 2007 5 21 2007FA0000397 1 20070331 G 3210 BEARING PIPER PA24 PA24250 7102404 SO LYC O540 AEIO540* EA MLG BROKEN D O OTHER O OTHER NR NOT REPORTED 1 EA 61 7178P 242347 L259640 BEARING ROD END BROKEN AT THREAD EXP BEARING (452377) CONDUIT BENT. CONTROL ASSY (455180). 1 L 7 1 3O 3 O 1A15 1E4 2007052100075 20070521 00075 SO 2007 5 21 2007FA0000398 2 20070418 G 7414 6320 MAGNETO CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO MCAULY D3A34 D3A34C402 GL ENGINE CORRODED G A UNSCHED LANDING J WARNING INDICATION NR NOT REPORTED 1 EA 13 5361Y 525 21064183 517975 871106 EMERGENCY RETURN TO FIELD: INSPECTION REQUIREMENTS FOR MAGNETO (PN 6320) ARC NOT ADEQUATE TO INSURE PROPER VENTING (PRE SSURIZED MAG). SB 2-80C SPECIFIES ONLY EXTERNAL INSPECTION IS REQUIRED EVERY 100 HOURS AND AN INTERNAL INSPECTION AFTER 500 HOURS. THE SUBJECT MAGNETOS WITH 525 AND 438 CONTAINED MOISTURE AND EXCESSIVE CORROSION INTERNALLY BECAUSE THE PRE VIOUS REQUIREMENTS TO TEST PRESSURIZED MAGNETOS CONTAINED IN SB 1-88A DO NOT APPLY TO THE 6300 SERIES MAGNETOS. (K) 1 H 7 1 3O 3 O 3A21 E8CE 5 C P47GL 2007052100115 20070521 00115 SO 2007 5 21 2007FA0000399 2 20070418 G 7414 6320 MAGNETO CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO MCAULY D3A34 D3A34C402 GL ENGINE CORRODED G O OTHER O OTHER NR NOT REPORTED 1 EA 13 5361Y 438 21064183 517975 871106 EMERGENCY RETURN TO FIELD: INSPECTION REQUIREMENTS FOR MAGNETO (PN 6320) ARC NOT ADEQUATE TO INSURE PROPER VENTING (PRE SSURIZED MAG). SB2-80C SPECIFIES ONLY EXTERNAL INSPECTION IS REQUIRED EVERY 100 HOURS AND AN INTERNAL INSPECTION AFTER 500 HOURS. THE SUBECT MAGNETOS WITH 525 AND 438 CONTAINED MOISTURE AND EXCESSIVE CORROSION INTERNALLY BECAUSE THE PREVI OUS REQUIREMENTS TO TEST PRESSURIZED MAGNETOS CONTAINED IN SB 1-88A DO NOT APPLY TO THE 6300 SERIES MAGNETOS. (K) 1 H 7 1 3O 3 O 3A21 E8CE 5 C P47GL 2007051400200 20070514 00200 GL 2007 5 14 2007FA0000400 2 20070425 G 7230 BEARING HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL ENGINE FAILED B EOOR O OTHER J WARNING INDICATION NR NOT REPORTED 1 AL 03 511SB 504 1090592D CAE830001 DURING FLIGHT THE UPPER CHIP PULL ILLUMINATED, IT WAS CLEANED IAW MM AND RETURNED TO SERVICE. A COUPLE OF HOURS LATER, A SECOND LIGHT ILLUMINATED. FOUND LOTS OF FINE CHIPS. REPLACED ENGINE. FOUND NR 1 BEARING BAD. (K) 1 G 7 1 3U 3 U H3WE E4CE 2007061500173 20070615 00173 2007 6 15 2007FA0000401 1 20070521 G 5100 31699042 HOUSING UNKNOWN CRACKED B K NONE O OTHER IN INSP/MAINT 1 SW 99 CRACK IN PART ID. 2007061500174 20070615 00174 CE 2007 6 15 2007FA0000402 1 20070522 G 2750 CONTROL CABLE SYMPHO SA160 SA160 05619SU CE TE FLAPS CHAFED P K NONE O OTHER IN INSP/MAINT 1 SO 15 DURING PREFLIGHT INSPECTION, FOUND FLAP CONTROL CABLES CHAFING ON THE FLAP TRACK. DEPTH OF INTERFERENCE BETWEEN CABLE A ND TRACK WAS ABOUT THE DIAMETER OF THE CABLE. 1 H 7 1 3O NT A46CE 2007061500175 20070615 00175 CE 2007 6 15 2007FA0000403 1 20070522 G 5750 CONTROL CABLE SYMPHO SA160 SA160 05619SU CE TE FLAPS CHAFED P K NONE O OTHER IN INSP/MAINT 1 SO 15 DURING PREFLIGHT INSPECTION, FOUND FLAP CONTROL CABLES CHAFING ON THE FLAP TRACK. DEPTH OF INTERFERENCE BETWEEN CABLE A ND TRACK WAS ABOUT THE DIAMETER OF THE CABLE. 1 H 7 1 3O NT A46CE 2007061500176 20070615 00176 EU 2007 6 15 2007FA0000404 1 20070522 G 5330 SKIN ISRAEL 1124 1124 4500102 EU GARRTT TFE731 TFE73131G 29003 NE FUSELAGE CORRODED B K NONE O OTHER IN INSP/MAINT 1 GL 23 600NY 231 FOUND SEVERE PITTING CORROSION ON BOTH THE LT AND RT SIDES BETWEEN FRAME, STATIONS 184 AND 194 BELOW EMERGENCY ESCAPE DO ORS. BELIEVE THIS IS DUE TO WATER LEAKING AROUND THE EMERGENCY ESCAPE DOORS AND SOAKING THE SOUND DAMPENING INSULATION. THE PITTING WAS SO BAD IT CORRODED THROUGH THE SKIN ON THE RT SIDE. THIS CORROSION WAS FOUND DURING AN RVSM INSTALLAT ION WHILE WE WERE MARKING OUT THE CRITICAL REGION AROUND THE STATIC PORTS. WE REPAIRED THE DAMAGE FOLLOWING APPROVED DA TA FROM A STRUCTURAL ENGINEER AND RETURNED TO SERVICE IAW FAA FORM 8110-3. 2 M 7 2 4F 4 F A2SW E6WE 2007061500177 20070615 00177 EU 2007 6 15 2007FA0000405 1 20070522 G 5330 SKIN ISRAEL 1124 1124 4500102 EU GARRTT TFE731 TFE73131G 29003 NE FUSELAGE CORRODED B K NONE O OTHER IN INSP/MAINT 1 GL 23 600NY 231 FOUND SEVERE (PITTING CORROSION) ON BOTH THE LT AND RT SIDES BETWEEN FRAME, STATIONS 184 AND 194 BELOW EMERGENCY ESCAPE DOORS. THIS IS DUE TO WATER LEAKING AROUND THE EMERGENCY ESCAPE DOORS AND SOAKING THE SOUND DAMPENING INSULATION. THE PITTING WAS SO BAD IT CORRODED THROUGH THE SKIN ON THE RT SIDE. THIS CORROSION WAS FOUND DURING AN RVSM INSTALLATION WH ILE WE WERE MARKING OUT THE CRITICAL REGION AROUND THE STATIC PORTS. REPAIRED THE DAMAGE FOLLOWING APPROVED DATA FROM A STRUCTURAL ENGINEER AND RETURNED TO SERVICE IAW FAA FORM 8110-3. 2 M 7 2 4F 4 F A2SW E6WE 2007061400237 20070614 00237 CE 2007 6 14 2007FA0000410 1 20070110 G 3245 0923540 TUBE BEECH 18 D18S 1151004 CE PWA R985 R985* 52008 NE TIRE BROKEN D K NONE O OTHER IN INSP/MAINT 1 SW 99 500MK 50 THIS IS THE THIRD NEW MFG INNER TUBE THAT HAS SPLIT ALONG CIRCUMFERENTIAL WELDED SEAMS. 1 L 7 2 3R 3 R A765 5E1 2007061500171 20070615 00171 EU 2007 6 15 2007FA0000411 1 20070515 G 3210 5321012110 BOLT PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL LANDING GEAR BROKEN B K NONE O OTHER IN INSP/MAINT 1 EA 65 624AF 1576 AM090 624 PR0499 KX227 DURING A 100 HOUR INSPECTION, A VISUAL INSPECTION FOUND A BROKEN BOLT ON THE RT MLG. THE BOLT ATTACHED THE LOWER PART OF THE SHOCK ABSORBER TO LANDING GEAR LEG. THE PN OF THE BOLT IS MOST LIKELY 532.10.12.110. THERE IS A LATER PN 532.10.12. 205 BUT THIS WAS PROBABLY NOT THE PART INSTALLED. THEIR WAS NO MARKING ON THE BOLT ITSELF MAKING IT DIFFICULT TO DETERMI NE THE PN. THIS PROBLEM WAS PREVIOUSLY ADDRESSED BY AD 04-06-05 AND SB 32-015, BUT THIS AIRCRAFT AND SN OF THE LANDING G EAR IN QUESTION ARE WELL BEYOND THE AFFECTIVITY OF BOTH THE AD AND THE SB. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2007061500192 20070615 00192 EU 2007 6 15 2007FA0000412 1 20070515 G 3210 5321012110 BOLT PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL LANDING GEAR BROKEN B K NONE O OTHER IN INSP/MAINT 1 EA 65 624AF 1576 AM090 624 PR0499 KX227 DURING A 100 HOUR INSPECTION, A VISUAL INSPECTION FOUND A BROKEN BOLT ON THE RT MLG. THE BOLT ATTACHED THE LOWER PART OF THE SHOCK ABSORBER TO LANDING GEAR LEG. THE PN OF THE BOLT IS MOST LIKELY 532.10.12.110. THERE IS A LATER PN 532.10.12. 205 BUT THIS WAS PROBABLY NOT THE PART INSTALLED. THEIR WAS NO MARKING ON THE BOLT ITSELF MAKING IT DIFFICULT TO DETERMI NE THE PN. THIS PROBLEM WAS PREVIOUSLY ADDRESSED BY AD 04-06-05 AND SB 32-015, BUT THIS AIRCRAFT AND SN OF THE LANDING G EAR IN QUESTION ARE WELL BEYOND THE AFFECTIVITY OF BOTH THE AD AND THE SB. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2007061500193 20070615 00193 EU 2007 6 15 2007FA0000413 1 20070515 G 3210 5321012110 BOLT PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL ZONE 700 BROKEN B K NONE O OTHER IN INSP/MAINT 1 EA 65 624AF 1576 AM090 624 PR0499 KX227 DURING A 100 HOUR INSPECTION, A VISUAL INSPECTION FOUND A BROKEN BOLT ON THE RT MLG. THE BOLT ATTACHED THE LOWER PART OF THE SHOCK ABSORBER TO LANDING GEAR LEG. THE PN OF THE BOLT IS MOST LIKELY 532.10.12.110. THERE IS A LATER PN 532.10.12. 205 BUT THIS WAS PROBABLY NOT THE PART INSTALLED. THEIR WAS NO MARKING ON THE BOLT ITSELF MAKING IT DIFFICULT TO DETERMI NE THE PN. THIS PROBLEM WAS PREVIOUSLY ADDRESSED BY AD 04-06-05 AND SB 32-015, BUT THIS AIRCRAFT AND SN OF THE LANDING G EAR IN QUESTION ARE WELL BEYOND THE AFFECTIVITY OF BOTH THE AD AND THE SB. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2007061500194 20070615 00194 EU 2007 6 15 2007FA0000414 1 20070515 G 3210 5321012110 BOLT PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL ZONE 700 BROKEN B K NONE O OTHER IN INSP/MAINT 1 EA 65 624AF 1576 AM090 624 PR0499 KX227 DURING A 100 HOUR INSPECTION, A VISUAL INSPECTION FOUND A BROKEN BOLT ON THE RT MLG. THE BOLT ATTACHED THE LOWER PART OF THE SHOCK ABSORBER TO LANDING GEAR LEG. THE PN OF THE BOLT IS MOST LIKELY 532.10.12.110. THERE IS A LATER PN 532.10.12. 205 BUT THIS WAS PROBABLY NOT THE PART INSTALLED. THEIR WAS NO MARKING ON THE BOLT ITSELF MAKING IT DIFFICULT TO DETERM INE THE PN. THIS PROBLEM WAS PREVIOUSLY ADDRESSED BY AD 04-06-05 AND SB 32-015, BUT THIS AIRCRAFT AND SN OF THE LANDING GEAR IN QUESTION ARE WELL BEYOND THE AFFECTIVITY OF BOTH THE AD AND THE SB. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2007053000002 20070530 00002 EA 2007 5 30 2007FA0000416 2 20070415 G 7322 103103 CARBURETOR AMTR VAN HATZVAN 0561383 GL LYC O235 O235C1 41505 EA SNSNCH 76AM M76AM EA ENGINE CONTAMINATED C E ENGINE SHUTDOWN Y J ENGINE STOPPAGE WARNING INDICATION AP APPROACH 1 GL 15 899P 313 335915 12242 DURING INSPECTION OF THE CARBURETOR, DISCOVERED FLAKES OF WHAT APPEARS TO BE METAL IN THE GASCOLATOR SCREEN. ALSO, OBSE RVED SOME SPECS OF RED MATERIAL ABOUT THE SIZE OF PEPPER. WHEN WE PULLED THE CARB APART WE OBSERVED A LINE ON THE BOTTOM OF THE BOWL WHERE SEDIMENT HAD PREVIOUSLY SETTLED IN THE BOWL. HOWEVER, NOTHING SIGNIFICANT WAS NOTED IN THE BOWL DURIN G OUR INSPECTION. FURTHER INSPECTION REVEALED THAT ONCE THE NEEDLE VALVE WAS SEATED BY LIGHTLY PRESSING THE FLOAT UPWAR D, IT WOULD THEN REMAIN SEATED EVEN IF AIR WAS BLOWN IN THE FUEL INLET PORT. HOWEVER, IF THE FLOAT WAS MANIPULATED UP A ND DOWN A FEW TIMES, THE NEEDLE VALVE WOULD THEN NOTICEABLY POP FREE. AND ALTHOUGH NO OBVIOUS DEBRIS WAS NOTED UPON DISA 1 H 7 1 3O 3 O EXPA1H71 E223 5 N 1P210 2007061500195 20070615 00195 CE 2007 6 15 2007FA0000417 1 20070511 G 5711 SPAR BBAVIA 11 11AC 0191102 CE LYC O235 O235* 41505 EA SNSNCH 76AK M76AK EA LT WING DELAMINATED G O OTHER O OTHER NR NOT REPORTED 1 GL 09 3581E 11AC1813 108715 11544 DELAMINATION OCCURRING AT LT FRONT WING SPAR / STRUT LOCATION. CRACK AT BOTTOM EDGE, AT WING ROOT FITTING. POSSIBLE AG E OF SPAR CAUSING DELAMINATION. LONGITUDINAL CRACK AT WING ROOT POSSIBLE EARLIER DAMAGE. REPLACED WITH NEW WOOD SPAR P /N 5146L. 1 H 7 1 3O 3 O A761 E223 5 N 1P210 2007061300214 20070613 00214 CE 2007 6 13 2007FA0000419 1 20070410 G 7810 02R3022406 EXHAUST DUCT BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA ENGINE CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 09 13510 365 WHILE PREFORMING SCHEDULED MAINTENANCE,REMOVED EXHAUST STACKS TO FACILTATE INSPECTING THE EXHAUST DUCT.A CRACK WAS FOUND IN THE SKI SLOPE.THE EXHAUST DUCT SB 3380 HAD BEEN COMPLIED WITH 365 HOURS PRIOR.POWER SECTION WAS REMOVED FOR REPAIR. 1 L 7 2 4T 4 T A24CE E4EA 2007061300205 20070613 00205 SO 2007 6 13 2007FA0000420 1 20070510 G 2571 352020035201 BATTERY BOX PIPER PA28 PA28181 7102807 SO BROKEN B LC1R K NONE O OTHER IN INSP/MAINT 1 EA 07 6151H 287890211 PLASTIC BATTERY BOX BROKE INTO SEVERAL PIECES. LID WOULD NO LONGER HOLD SECURLY ON THE BOX ALLOWING BATTERY TO BE UNSECU RED IN THE AIRCRAFT. PIPER REPIORTED THAT P/N 35201-00 LID AND 35202-00 WAS NO LONGER AVAILABLE. INSTALLED STC'D BATTERY BOX TO REPLACE THE DAMAGED ONE. 1 L 7 1 3O 2A13 2007061500197 20070615 00197 CE 2007 6 15 2007FA0000425 1 20070515 G 5511 0432001466 RIB CESSNA 150 150E 2071812 CE CONT O200 O200A 17020 SO HORIZONTAL STAB CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 01 2586J 8600 15061086 DURING LT LEADING EDGE SKIN REPLACEMENT OF HORIZONTAL STABILIZER DUE TO BIRD STRIKE FOUND BOTH IB LEADING EDGE RIBS PN 0 432001-46/ -6 CRACKED THROUGH UPPER AND LOWER MOUNTING TABS. WORKING RIVETS WERE FOUND AT THE TABS AND 2 RIVETS OB ON FO RWARD SPAR. BIRD STRIKE DID NOT CAUSE CRACKS. THESE TABS ARE DIFFICULT TO INSPECT WITHOUT DISASSEMBLY OF TAIL. ANY EVIDE NCE OF DEFECTS IN THE TAIL STRUCTURE SHOULD BE INVESTIGATED THOROUGHLY AS THEY ARE PRONE TO CRACKING AND WEAR. 1 H 7 1 3O 3 O 3A19 E252 2007061500198 20070615 00198 CE 2007 6 15 2007FA0000426 1 20070515 G 5511 0432001466 RIB CESSNA 150 150E 2071812 CE CONT O200 O200A 17020 SO HORIZONTAL STAB CRACKED D O OTHER O OTHER NR NOT REPORTED 1 CE 01 2586J 8600 15061086 DURING LT LEADING EDGE SKIN REPLACEMENT OF HORIZONTAL STABILIZER DUE TO BIRD STRIKE FOUND BOTH IB LEADING EDGE RIBS PN 0 432001-46/ -6 CRACKED THROUGH UPPER AND LOWER MOUNTING TABS. WORKING RIVETS WERE FOUND AT THE TABS AND 2 RIVETS OB ON FO RWARD SPAR. BIRDSTRIKE DID NOT CAUSE CRACKS. THESE TABS ARE DIFFICULT TO INSPECT WITHOUT DISASSEMBLY OF TAIL. ANY EVIDEN CE OF DEFECTS IN THE TAIL STRUCTURE SHOULD BE INVESTIGATED THOROUGHLY AS THEY ARE PRONE TO CRACKING AND WEAR. 1 H 7 1 3O 3 O 3A19 E252 2007061500199 20070615 00199 CE 2007 6 15 2007FA0000427 1 20070515 G 5511 0432001466 RIB CESSNA 150 150E 2071812 CE CONT O200 O200A 17020 SO HORIZONTAL STAB CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 01 2586J 8600 15061086 DURING LT LEADING EDGE SKIN REPLACEMENT OF HORIZONTAL STABILIZER DUE TO BIRDSTRIKE FOUND BOTH IB LEADING EDGE RIBS PN 04 32001-46/ -6 CRACKED THROUGH UPPER AND LOWER MOUNTING TABS. WORKING RIVETS WERE FOUND AT THE TABS AND 2 RIVETS OB ON FOR WARD SPAR. BIRDSTRIKE DID NOT CAUSE CRACKS. THESE TABS ARE DIFFICULT TO INSPECT WITHOUT DISASSEMBLY OF TAIL. ANY EVIDENC E OF DEFECTS IN THE TAIL STRUCTURE SHOULD BE INVESTIGATED THOROUGHLY AS THEY ARE PRONE TO CRACKING AND WEAR. 1 H 7 1 3O 3 O 3A19 E252 2007061500200 20070615 00200 CE 2007 6 15 2007FA0000428 1 20070515 G 5511 0432001466 RIB CESSNA 150 150E 2071812 CE CONT O200 O200A 17020 SO HORIZONTAL STAB CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 01 2586J 8600 15061086 DURING LT LEADING EDGE SKIN REPLACEMENT OF HORIZONTAL STABILIZER DUE TO BIRDSTRIKE FOUND BOTH IB LEADING EDGE RIBS PN 04 32001-46/ -6 CRACKED THROUGH UPPER AND LOWER MOUNTING TABS. WORKING RIVETS WERE FOUND AT THE TABS AND 2 RIVETS OB ON FOR WARD SPAR. BIRDSTRIKE DID NOT CAUSE CRACKS. THESE TABS ARE DIFFICULT TO INSPECT WITHOUT DISASSEMBLY OF TAIL. ANY EVIDENC E OF DEFECTS IN THE TAIL STRUCTURE SHOULD BE INVESTIGATED THOROUGHLY AS THEY ARE PRONE TO CRACKING AND WEAR. 1 H 7 1 3O 3 O 3A19 E252 2007061500202 20070615 00202 CE 2007 6 15 2007FA0000429 1 20070515 G 7820 E477001 MUFFLER CESSNA 150 150E 2071812 CE CONT O200 O200A 17020 SO ENGINE CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 01 2586J 3128 15061086 PILOT REPORTED FATIGUE WHILE FLYING. NO OBVIOUS EXTERNAL SIGNS OF MUFFLER FAILURE WERE FOUND, SHROUD REMOVAL REVEALED A TIGHT CRACK FROM NR 2 RISER INTO BODY, 3 INCHES LONG THAT LEFT VERY LITTLE STAINING ON INSIDE OF SHROUD. MUFFLER BODY WA S DEFORMED WHERE RISER IS WELDED INTO BODY, NEW MUFFLER HAD NO DEFORMATION IN THIS AREA. 1 H 7 1 3O 3 O 3A19 E252 2007061500201 20070615 00201 CE 2007 6 15 2007FA0000434 1 20070515 G 7820 E477001 MUFFLER CESSNA 150 150E 2071812 CE CONT O200 O200A 17020 SO ENGINE CRACKED E O OTHER O OTHER NR NOT REPORTED 1 CE 01 2586J 3128 15061086 PILOT REPORTED FATIGUE WHILE FLYING. NO OBVIOUS EXTERNAL SIGNS OF MUFFLER FAILURE WERE FOUND, SHROUD REMOVAL REVEALED A TIGHT CRACK FROM NR 2 RISER INTO BODY, 3 INCHES LONG THAT LT VERY LITTLE STAINING ON INSIDE OF SHROUD. MUFFLER BODY WAS DEFORMED WHERE RISER IS WELDED INTO BODY, NEW MUFFLER HAD NO DEFORMATION IN THIS AREA. 1 H 7 1 3O 3 O 3A19 E252 2007061300225 20070613 00225 CE 2007 6 13 2007FA0000435 1 20070209 G 7810 02R3022406 EXHAUST DUCT BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA ENGINE CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 09 13502 422 WHILE PREFORMING SCHEDULED MAINTENANCE,REMOVED EXHAUST STACKS TO FACILTATE INSPECTING THE EXHAUST DUCT.A CRACK WAS FOUND IN THE SKI SLOPE. EXHAUST DUCT SB HAD BEEN COMPLIED WITH 422 HOURS PRIOR. POWER SECTION WAS REMOVED FOR REPAIR. 1 L 7 2 4T 4 T A24CE E4EA 2007053000005 20070530 00005 SO 2007 5 30 2007FA0000436 2 20070410 G 8530 649169 CYLINDER CONT O520 IO520* 17032 SO ENGINE CRACKED C O OTHER O OTHER NR NOT REPORTED 1 SW 17 PARTIAL HEAD AND BARREL SEPARATION. LARGE CRACK STARTING AT THE FUEL INJECTOR PORT RUNNING INTO THE CYLINDER HEAD COMBUS TION CHAMBER, THROUGH THE INTAKE SEAT BOSS AND CONTINUING AROUND TO THE LOWER SPARK PLUG BOSS. 3 O E5CE 2007061500204 20070615 00204 EU 2007 6 15 2007FA0000437 1 20070522 G 5330 SKIN ISRAEL 1124 1124 4500102 EU GARRTT TFE731 TFE73131G 29003 NE FUSELAGE CORRODED B K NONE O OTHER IN INSP/MAINT 1 GL 23 600NY 231 FOUND SEVERE PITTING CORROSION ON BOTH THE LT AND RT SIDES BETWEEN FRAME STATIONS 184 AND 194 BELOW EMERGENCY ESCAPE DOO RS. THIS IS DUE TO WATER LEAKING AROUND THE EMERGENCY ESCAPE DOORS AND SOAKING THE SOUND DAMPENING INSULATION. THE PIT TING WAS SO BAD IT CORRODED THROUGH THE SKIN ON THE RT SIDE. THIS CORROSION WAS FOUND DURING AN RVSM INSTALLATION WHILE WE WERE MARKING OUT THE CRITICAL REGION AROUND THE STATIC PORTS. REPAIRED THE DAMAGE FOLLOWING APPROVED DATA FROM A ST RUCTURAL ENGINEER AND RETURNED TO SERVICE IAW FAA FORM 8110-3. 2 M 7 2 4F 4 F A2SW E6WE 2007061500205 20070615 00205 GL 2007 6 15 2007FA0000443 3 20070525 G 6110 ROD CESSNA 208 208 2073702 CE MCAULY 3AF34C 3GFR34C703 GL PROPELLER FAILED B O OTHER O OTHER NR NOT REPORTED 1 CE 09 001922 RECEIVED PROPELLER FOR OVERHAUL. DURING PREFUNCTION TEST FOUND BLADE NR 1 WAS NOT LINKED TO THE PITCH CHANGE ROD. AFTER DISASSEMBLY OF PROPELLER FOUND NR 1 BLADE ACTUATING PIN PN B5072-1 DISCONNECTED FROM BLADE. ACTUATING PIN ATTACHMENT SCR EWS WERE SAFETIED AND HAD ANTISABOTAGE ON THE SCREW HEADS. THE THREADS HAD BEEN PULLED OUT OF THE BLADE. THERE WAS NO OB VIOUS SIGNS OF SUDDEN STOPPAGE OR A STRIKE. ALL BLADES SHOWED SIMILAR EROSION FROM ROCK DAMAGE. BLADE TRACK WAS .0625 IN CH PLUS OR MINUS AND DIAMETER WAS 106 INCHES.IAW THE RECORD, THIS WAS THE FIRST OVERHAUL EVENT. MANUFACTURE HAS REQUESTE D BLADE, ACTUATING PIN AND LINK BE RETURNED TO THEM FOR EVALUATION. 1 H 7 1 3T NT A37CE 5 C P60GL 2007061800104 20070618 00104 2007 6 18 2007FA0000444 2 20070421 G 8500 12501 ENGINE MALFUNCTIONED C O OTHER O OTHER NR NOT REPORTED 1 SW 03 620TS 20 AIRCRAFT ECU WARNING LIGHT COME ON FREQUENTLY. WE SPOKE WITH THIELERT ABOUT THE PROBLEM AND THEY SAY THAT DURING STEEP BANKS OR YAW THE FUEL PRESSURE CAN BE DIFFERENT BETWEEN THE RAILS ON EACH ENGINE. THE ECU CAN INTERPRET THIS AS A PROBL EM AND TURN ON THE ANNUNCIATOR. THIS IS MOSTLY A NUISANCE BECAUSE EVERYTIME THE AN ANNUNCIATOR TURNS ON WE MUST BRING T HE AIRCRAFT TO A MECHANIC WHO MUST CLEAR THE PROBLEM FORM THE COMMPUTER. WHILE THE ANNUNCIATOR IS ON WE HAVE NO WAY OF KNOWING IF A REAL PROBLEM DEVELOPS BECAUSE THE ANNUCIATOR IS STILL ON. IN ADDITION AS A FLIGHT SCHOOL IT COSTS US SIGNIF ICANT AMOUNTS OF LOST REVENUE EVERY TIME THAT WE MUST TAKE THE AIRPLANE OFF-LINE UNTIL OUR MECHANICE CAN INSPECT IT. O 2007060100116 20070601 00116 EU 2007 6 1 2007FA0000447 1 20070508 G 2150 5700700A HOSE SNIAS 350 AS350B3 8680954 EU TMECA ARRIEL ARRIEL2B NE A/C SYSTEM BURST D K NONE K J FLUID LOSS WARNING INDICATION IN INSP/MAINT 1 EA 01 849BP 3554 22310 HIGH PRESSURE AIR CONDITIONER HOSE BURST. 1 G 7 1 3U 3 U H9EU E00054EN 2007053000016 20070530 00016 EA 2007 5 30 2007FA0000450 2 20070328 G 8530 LW19279 CYLINDER CESSNA 206 206H 2073301 CE LYC O540 TIO540AJ1A EA ENGINE SCRATCHED B O OTHER O OTHER NR NOT REPORTED 1 WP 28 1023 1023 T20608350 172S08719 SET OF 6 CYLINDERS CAME IN WITH 2 BROKEN CONTROL RINGS. CYLINDERS HAD RING STEPS ON TOP AND BOTTOM OF CYLINDER BARRELS. CORROSION WAS PRESENT IN BARRELS FROM THE MIDDLE UP TO THE HEAD OF THE CYLINDERS. EXHAUST GUIDES WERE FAR OUT OF LIMITS AND DIFFICULT TO REMOVE RESULTING IN HAVING TO OVERSIZE 3 BOSSES TO P05 GUIDES AND THE OTHER 3 TO P10. 2 EXHAUST SEATS F ELL OUT DURING THE HEAT SOAK FOR INSTALLING THE EXHAUST GUIDES. BROKEN RINGS DAMAGED 2 PISTONS WHICH HAD TO BE REMOVED F ROM SERVICE. 4 OTHER PISTONS WERE DAMAGED IN THE PISTON PIN BOSSES. THE BROKEN RINGS ALSO CAUSED MODERATE SCRATCHING TO THE BARREL OF THE CYLINDERS WHICH WAS REMOVABLE BY POWER HONING. 2 CYLINDERS HAD TO BE OVERSIZED FROM THE CORROSION AND 1 H 7 1 3O 3 O RT A4CE E14EA 2007061300167 20070613 00167 EA 2007 6 13 2007FA0000451 2 20070328 G 8530 LW19279 CYLINDER CESSNA 206 206H 2073301 CE LYC O540 TIO540AJ1A EA ENGINE SCRATCHED B O OTHER O OTHER NR NOT REPORTED 1 WP 07 1023 1023 T20608350 172S08719 SET OF 6 CYLINDERS CAME IN WITH 2 BROKEN CONTROL RINGS. CYLINDERS HAD RING STEPS ON TOP AND BOTTOM OF CYLINDER BARRELS. CORROSION WAS PRESENT IN BARRELS FROM THE MIDDLE UP TO THE HEAD OF THE CYLINDERS. EXHAUST GUIDES WERE FAR OUT OF LIMITS AND DIFFICULT TO REMOVE RESULTING IN HAVING TO OVERSIZE 3 BOSSES TO P05 GUIDES AND THE OTHER 3 TO P10. 2 EXHAUST SEATS F ELL OUT DURING THE HEAT SOAK FOR INSTALLING THE EXHAUST GUIDES. BROKEN RINGS DAMAGED 2 PISTONS WHICH HAD TO BE REMOVED F ROM SERVICE. 4 OTHER PISTONS WERE DAMAGED IN THE PISTON PIN BOSSES. THE BROKEN RINGS ALSO CAUSED MODERATE SCRATCHING TO THE BARREL OF THE CYLINDERS WHICH WAS REMOVABLE BY POWER HONING. 2 CYLINDERS HAD TO BE OVERSIZED FROM THE CORROSION AND 1 H 7 1 3O 3 O RT A4CE E14EA 2007060700007 20070607 00007 SO 2007 6 7 2007FA0000453 1 20070407 G 5610 1159SCB31023 WINDSHIELD GULSTM G1159 GIV 3980115 SO RROYCE TAY TAY6118 EU COCKPIT FAILED B JUOR O OTHER O OTHER NR NOT REPORTED 1 WP 27 495RS 2735 1161 CREW REPORTS WINDSHIELD FAILURE DURING PART 91 MAINTENANCE POSITIONING FLIGHT. EMERGENCY DECLARED WITH UNEVENTFUL LANDI NG. AIRCRAFT CONTINUED TO DESTINATION AIRPORT UNDER CDL RESTRICTIONS. UNKNOWN CAUSE. (K) 2 L 7 2 4F 4 F RT A12EA E25NE 2007060100107 20070601 00107 SO 2007 6 1 2007FA0000454 2 20070501 G 7414 BRUSHES CIRRUS SR SR20 05628AJ GL CONT O360 IO360ES SO MAGNETO WORN B YYBR O OTHER O OTHER NR NOT REPORTED 1 GL 03 154WF 423 1638 360136 THIS MAGNETO WAS MISFIRING, AND APPEARS TO HAVE CAUSED DETONATION IN THE NR 5 CYLINDER. PISTON MATERIAL WAS FOUND IN TH E OIL FILTER AND OIL COOLER. ENGINE HAD TO BE REMOVED, INSPECTED, AND REPAIRED DUE TO THE DETONATION. THE MAGNETO WAS FOUND TO HAVE A SEVERELY WORN BRUSH (K3215), THE BRUSH BLOCK WAS MELTED (K3823), THE COIL WAS BURNED CLOSE TO THE BRUSH CONTACT POINT (K3975), AND THE POINTS WERE BADLY BURNED (M3081). THIS IS THE (3RD) OCCURRENCE FOUND WITH THIS SAME PROB LEM. (K) 1 L 7 1 3O 3 O NT A00009CH E1CE 2007060100112 20070601 00112 CE 2007 6 1 2007FA0000455 1 20070505 G 3230 08940002 GEARBOX CESSNA 340 340A 2076405 CE CONT O520 TSIO520* 17040 SO MLG DAMAGED B O OTHER O OTHER NR NOT REPORTED 1 SW 17 2745F 340A0949 GEAR MOTOR, REDUCTION GEAR BOX AND GEAR TRANSMISSION WERE REMOVED AND SENT OUT TO FOR INSPECTION. WHEN THEY OPENED GEAR REDUCTION BOX, THEY DISCOVERED THAT ONE OF THE MOUNTING BOLTS HAVE BEEN OF THE IMPROPER LENGTH CAUSING THE THREAD PATTE RN. TBOLT SHOWS SLIGHT WEAR WHERE IT TOUCHED THE GEAR SYSTEM. ACCORDING TO MFG THERE WAS ONLY A SLIGHT TRANSFER TO GEA R, WHICH THEY FEEL WOULD NOT HAVE CAUSED A PROBLEM. CANNOT DETERMINE HOW LONG THIS CONDITION EXISTED. THE BOLTS LOOK T O BE OLD AND THE INTERNAL GEAR BOX SEEMS ALSO TO BE OLD. THE INSTALLATION CALLED FOR A .8750 INCH BOLT FOR THIS MOUNTIN G HOLE, AND REMOVED A 1 INCH BOLT. THE CORRECTIVE ACTION IS TO INSTALL THE REPAIRED GEAR BOX AND THE CORRECT MOUNTING H 1 L 7 2 3O 3 O 3A25 E8CE 2007060700031 20070607 00031 GL 2007 6 7 2007FA0000456 3 20070516 G 6110 B24573 FORK BNORM BN2 BN2 1520202 EU HARTZL HCC2Y HCC2YK2 GL PITCH CHANGE UNSERVICEABLE B ME4R O OTHER O OTHER NR NOT REPORTED 1 SO 19 AU9949B STEEL FATIGUE CRACK NDT (MAGNETIC PARTICLE) DETECTED. PROPELLER ASSY RECEIVED FOR STANDARD OVERHAUL AND DEFECT FOUND IN PROPELLER ASSY (PN C2K00500, DESCRIPTION HC-C2YK-2CUF/FC8477A-4, SN AU9949B), UNDER WO NR 38425A. 1 H 7 2 3O A17EU 5 C P920 2007060700009 20070607 00009 GL 2007 6 7 2007FA0000457 3 20070516 G 6111 F8468A6R BLADE PZLWAR WILGA PZL104W35A 7360104 EU LYC O540 IO540K1B5 41532 EA HARTZL HCC3Y HCC3YR GL PROPELLER CRACKED B ME4R O OTHER O OTHER NR NOT REPORTED 1 SO 19 424HD 00030015 DY2965A ALUMINUM FATIGUE CRACK VISUALLY AND NDT DETECTED. PROPELLER ASSY RECEIVED FOR OVERHAUL AND BLADE NR 2 OF 3 REMOVED FROM PROPELLER ASSY (HC-C3YR-1RF/ F8468A-6R, UNDER WO NR 38598A. NOTE: MANDATORY OVERHAUL REQUIRED DUE TO GROUND STRIKE, HO WEVER, BLADE SUBMITTED WAS NOT BENT AND LEAST DAMAGED. (K) 1 H 7 1 3R 3 O NC EXPA1H71 1E4 5 C P25EA 2007060100113 20070601 00113 WP 2007 6 1 2007FA0000458 2 20070502 G 7321 307080026 FUEL CONTROL AMD FALC90 FALCON900B 2730171 EU GARRTT TFE731 TFE7315BR WP ENGINE FAULTY C O OTHER O OTHER NR NOT REPORTED 1 EA 03 4MB 5476 1861 146 P101199 PILOTS REPORTED THAT ENGINE THAT THIS FUEL CONTROL UNIT WAS INSTALLED ON COULD NOT BE CONTROLLED BY NORMAL COMPUTER MODE , AND THAT WHEN THEY WENT TO MANUAL MODE THAT THEY COULD NOT CONTROL ENGINE SPEED FUNCTIONS EITHER. IT SEEMS THAT THIS FUEL CONTROL HAS SOME INTERNAL FAULT. REPLACEMENT FUEL CONTROL RESOLVED THIS PROBLEM. (K) 2 L 7 3 4F 4 F RT E6WE 2007060600001 20070606 00001 CE 2007 6 6 2007FA0000459 1 20070404 G 2720 04140161532 BRACKET CESSNA 172 172F 2072414 CE CONT O300 O300* 17022 SO RUDDER CONTROL BROKEN D K NONE O OTHER IN INSP/MAINT 1 GL 09 8879U 2961 17252796 DURING ANNUAL INSPECTION BRACKET (PN 04140616-1-532). FOUND BROKEN AND CRACKED IN OTHER LOCATIONS. LOCATED UNDER FLOOR CENTER SECTION AT FLIGHT CONTROL BELL CRACK. REPLACED WITH NEW PART. REQUEST INSPECTORS CHECK THIS AREA OF THE FLIGHT CONTROLS CAREFULLY DURING 100/ANNUAL INSPECTION. (K) 1 H 7 1 3O 3 O NT 3A12 E253 2007060100115 20070601 00115 CE 2007 6 1 2007FA0000460 1 20070430 G 3297 D3899924WD19 CONNECTOR RAYTHN 390 390 7150030 CE WILINT FJ44 FJ44 66000 GL ANTI SKID SYS FAULTY B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 972PF 976 RB38 TROUBLESHOT INTERMITTENT ANTI-SKID SYSTEM FAIL ANNUNCIATION, CABIN DOOR SEAL STAYING INFLATED ON GROUND, AND LIFT DUMP H ANDLE OPERATION. FOUND BAD CRIMP ON PIN (L) FOR WIRE G117B24 IN LT MLG SQUAT SWITCH CONNECTOR. FUNCTIONAL CHECKS OK. (K) 1 L 7 2 3F 4 F RT A00010WI E3GL 2007060100114 20070601 00114 SO 2007 6 1 2007FA0000461 2 20070309 G 7414 1051324 SPRING CONT BEECH 58 58 1152740 CE CONT O550 IO550C SO MAGNETO BROKEN E MKWA O OTHER O OTHER NR NOT REPORTED 1 GL 03 7293R 827 F02CA139R TH590 824323R WHILE TROUBLESHOOTING ENGINE RUNS ROUGH AND WON’T RUN AT ALL OVER 1200 RPM. WE DISCOVERED THE IMPULSE COUPLING SPRINGS ON BOTH MAGS WERE BROKEN. (IMPULSE COUPLING , PN 10-400309) (K) 1 L 7 2 3O 3 O 3A16 E3SO 2007060700033 20070607 00033 SO 2007 6 7 2007FA0000462 2 20070309 G 7414 1051324 SPRING CONT BEECH 58 58 1152740 CE CONT O550 IO550C SO MAGNETO BROKEN D O OTHER O OTHER NR NOT REPORTED 1 GL 03 7293R 827 F02CA164R TH590 824323 WHILE TROUBLESHOOTING ENGINE RUNS ROUGH AND WON`T RUN AT ALL OVER 1200 RPM. WE DISCOVERED THE IMPULSE COUPLING SPRINGS ON BOTH MAGS WERE BROKEN. (IMPULSE COUPLING PN 10400309) (K) 1 L 7 2 3O 3 O 3A16 E3SO 2007060600002 20070606 00002 CE 2007 6 6 2007FA0000463 1 20070514 G 5711 SPAR BBAVIA 11 11BC 0191106 CE LYC O235 O235* 41505 EA SNSNCH 76AK M76AK EA LT WING CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 09 3581E 11AC1813 108715 11544 DELAMINATION OCCURRING AT WING STRUT ATTACH LOCATION. CRACK AT BOTTOM EDGE AT ROOT FITTING. POSSIBLE AGE OF SPAR CAUSI NG DELAMINATION. LONGITUDINAL CRACK AT WING ROOT POSSIBLE EARLIER DAMAGE REPLACE WITH NEW WOOD SPAR (PN 5146L). (K) 1 H 7 1 3O 3 O A761 E223 5 N 1P210 2007061500103 20070615 00103 2007 6 15 2007FA0000464 1 20070430 G 6100 BOLT LYC O360 O360* 41514 EA MCAULY 1A200 1A200* GL PROPELLER SHORT D O OTHER W INADEQUATE Q C NR NOT REPORTED 1 AL 05 866MM 400 YI46003 INSPECTING PROPELLER DURING ANNUAL, FOUND PROPELLER BOLTS 0.25 IN SHORT OF BACK SIDE OF FLANGE INSERTS. ALL BOLT THREAD ENGAGEMENT WAS FORWARD OF INSERT BOSS. AFT .2500 INC OF INSERT, MATERIAL BEHIND CRANK FLANGE, HAD NO THREAD ENGAGEMENT . WRONG BOLTS INSTALLED, CORRECTED BY INSTALLING PROP BOLT KIT (PN 76EM8) WHICH PROVIDED (2) THREADS THROUGH INSERT WHE N TROQUED. (K) 3 O E286 5 N P874 2007060700014 20070607 00014 EU 2007 6 7 2007FA0000465 1 20070509 G 3411 PITOT LINE AMD FALC10 FALCON10 2730101 EU GARRTT TFE731 TFE731* 01518 WP NR 2 LOOSE B EBVR O OTHER O OTHER NR NOT REPORTED 1 CE 09 160FJ 160 WHILE TROUBLESHOOTING A LEAK IN NR 2 STATIC SYSTEM, THE RT SIDE STATIC PLATE HAD TO BE TAKEN LOOSE. UPON REMOVAL OF THE PLATE, SILICONE RTV WAS FOUND ON THE FITTING FOR THE NR 1 STATIC SYSTE. WHEN THE FITTING WAS LOOSENED, FOUND A LAGRE A OUNT OF TEFLON PIPE TAPE WRAPPED AROUND THE NIPPLE OF THE STATIC PLATE, AND THE FLARE OF THE ALUMINUM HARD LINE GOING TO THE STATIC PLATE WAS BROKEN OFF AND LAYING LOOSE IN THE ASSY. A TECH IN THE PAST HAD POSSIBLY EXPERIENCED A LEAK ON TH IS SYSEM, AND LOADED THE NIPPLE WITH TEFLON TAPE AND RTV TTO GET THE SYSTEM TO SEAL, INSTAD OF REPAIRING THE HARD LINE. THESE LINES SHOULD BE REPAIRED IAW STANDARD PRACTICE TO PREVENT PREMATURE FAILURE. (K) 2 L 7 2 4F 4 F A33EU E6WE 2007060500272 20070605 00272 CE 2007 6 5 2007FA0000466 1 20070201 G 3310 LIGHT CESSNA 340 340A 2076405 CE CONT O520 TSIO520* 17040 SO COMPASS FIRE D O OTHER O OTHER NR NOT REPORTED 1 CE 03 340JH 340A0771 COMPASS LIGHT/SOCKET OVERHEATED DURING TAXI AND CAUGHT FIRE BEFORE THE CIRCUIT BREAKER TRIPPED. PILOT EXTINGUISHED FIRE WITH HANDKERCHIEF. CAUSE UNKNOWN, NO DAMAGE TO AIRCRAFT INTERIOR OR STRUCTURE. (K) 1 L 7 2 3O 3 O 3A25 E8CE 2007060700035 20070607 00035 CE 2007 6 7 2007FA0000467 1 20070316 G 5532 SKIN BEECH 1900 1900D 1154162 CE PWA PT6 PT6A6 52043 EA VERTICAL STAB DAMAGED B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 135YV UE135 VERTICAL STABILIZER LEADING EDGE SKIN ATTACH RIVETS WORKING. FOUND THAT THE ORIGINAL UNIVERSAL HEAD RIVETS WERE REPLACE D WITH FLUSH RIVETS. THE SKIN WAS COUNTERSUNK TO ACCOMMODATE THE RIVETS, HOWEVER THE SKIN WAS TOO THIN TO COUNTERSINK A ND EVENTUALLY WORKED LOOSE. SKIN WAS REPAIRED IAW DER ENGINEERING REPORT AND CORRECT RIVETS INSTALLED. STRICT ADHERENC E TO PUBLISHED DATA WOULD HAVE PREVENTED DAMAGE. (K) 2 L 7 2 4T 3 T RT A24CE E4EA 2007060700034 20070607 00034 EU 2007 6 7 2007FA0000468 1 20070501 G 5610 D25W343001009 WINDSHIELD ISRAEL 1125 ASTRASPX 4500205 EU COCKPIT CRACKED B UO2R O OTHER O OTHER NR NOT REPORTED 1 GL 19 411MM 080 THE WINDSHIELD ON THE PILOT`S SIDE CRACKED DURING FLIGHT AT F/L 41,000 FT ON 4/24/2007. THE WINDSHIELD HAD 3104.6 TT. (K) 2 L 7 2 4F RT A16NM 2007060700026 20070607 00026 CE 2007 6 7 2007FA0000469 1 20070227 G 3220 C611300518 LINK BEECH 90 F90 1152909 CE NLG DAMAGED B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 189JR LA61 THIS REPORT IS A RESULT OF REPLACEMENT OF THE FORWARD NOSE GEAR RETRACT CHAIN. TO REPLACE OR TO REINSTALL THIS CHAIN, A NEW PN C-6113005-18, CONNECTING LINK MUST BE USED. A NEW LINK SHOULD HAVE FIVE PIECES. ONE LINK ASSY WITH (2) SHAFTS SWAGED INTO AN END PLATE, TWO CENTER PLATES THAT SHOULD SLIP ONTO THE SHAFTS, ONE END PLATE, AND ONE SPRING CLIP RETAINE R. THE END PLATE SHOULD HAVE SMALLER HOLES IN IT AND REQUIRE PRESSING FOR PROPER ASSY. THIS PRESSED FIT REQUIRES DISTR UCTION OF THE LINK DURING ASSY. WHEN INSTALLING THE NEW CHAIN AND INSTALLING THE NEW LINK, FOUND THAT ALL THREE PLATES HAD THE HOLE SIZE THAT WOULD ALLOW THEM TO BE SLIPPED ONTO THE SHAFTS WITHOUT PRESSING. CHECKED ANOTHER NEW LINK ASSY. 1 L 7 2 4T A31CE 2007060500273 20070605 00273 CE 2007 6 5 2007FA0000470 1 20070226 G 2170 1013840245 EVAPORATOR BEECH 200 B200 1152922 CE AIR CONDITIONER UNSERVICEABLE D E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 AFT CABIN AIR CONDITIONER EVAPORATOR RECEIVED FROM VENDER IN OVERHAULED CONDITION. INITIAL INSPECTION REVEALED HARD LIN E. WHICH SHOULD RUN PARALLEL TO HEAT EXCHANGER, WAS INSTALLED APPROXIMATELY 25 DEGREES TO HEAT EXCHANGER. THE EVAPORAT OR COULD NOT HAVE BEEN INSTALLED WITHOUT STRESSING AIRCRAFT HARD LINES. THIS LINE HAD BEEN REPAIRED (BY WELDING?) HOWEV ER, THE INSIDE SURFACE STILL SHOWED SEVERE PITTING. THE UNIT WAS RETURNED TO VENDER AS WELL AS VENDER SHOULD HAVE CAUGH T THESE DEFECTS. (K) 1 L 7 2 4T A24CE 2007060700032 20070607 00032 SW 2007 6 7 2007FA0000471 1 20070404 G 3213 12984 LOCK NUT BBAVIA 7 7ECA 21101NN SW LYC O290 O290* 41506 EA MLG LEG STRIPPED G O OTHER O OTHER NR NOT REPORTED 1 NM 13 6096F 1642 7ECA352 LOCK NUT THREADS FAILED, MLG STRUT EXTENDED ON TAKEOFF ALLOWING MLG TO SWING FREE. DURING LANDING, MLG WAS UNDER FUSELA GE CAUSING DAMAGE TO LOWER LONGERONS, CONDITION OF THREADS CANNOT BE DETERMINED WITHOUT DISASSEMBLING THE MLG STRUT ASSY . THEREFORE, THE THREADS MAY DETERIORATE SIGNIFICANTLY WITHOUT DETECTION. SUGGEST SPECIAL EMPHASIS INSPECTION ROUTINE AT (5) YEAR INTERVALS TO INCLUDE DISASSEMBLY OF MLG STRUT ASSY. (K) 1 H 7 1 3O 3 O A759 E229 2007060400015 20070604 00015 2007 6 4 2007FA0000472 2 20070510 G 7322 105018 BOWL CARBURETOR DAMAGED B NE2R O OTHER O OTHER NR NOT REPORTED 1 CE 07 A44695 RECEIVED CARBURETOR FROM CUSTOMER WITH THE REQUEST (PLEASE INSPECT UNIT FOR PROPER OPERATION, AIRCRAFT ON GROUND. HAVE BEEN BOMBARDED WITH SERIOUS PROBLEMS TO JUST ABOUT EVERY CARBURETOR WE HAVE) PILOT STATED THAT HE ALMOST CRASHED HELICOP TER DUE TO LACK OF ENGINE RESPONSIVENESS AFTER ROLLING THROTTLE IN AFTER TEST AUTO ROTATION. INSPECTION OF CARBURETOR R EVEALED VENT PORTS IN BOWL AND THROTTLE BODY WERE NOT IN THE NORMAL POSITION NOR THE NORMAL SIDE FOR THIS CARBURETOR MOD EL. COULD NOT POSITIVELY IDENTIFY THE IDLE TUBE AND NOZZLE AS OEM PARTS. THE ACCELERATOR PUMP DISCHARGE CHECK VALVE DI D NOT FUNCTION IN THE MANNER NORMALLY SEEN BY THIS REPAIR STATION. THROTTLE BODY HAS ECONOMIZER JET INSTALLED WHICH IS 2007060600003 20070606 00003 EU 2007 6 6 2007FA0000473 1 20070511 G 6210 1090103019 BLADE AGUSTA A109 A109 0260109 EU ALLSN 250C 250C20B 03013 GL MAIN ROTOR CRACKED D O OTHER E VIBRATION/BUFFET LD LANDING 1 NM 01 109CJ 2031 7280 SKIN CRACKS WERE DISCOVERED IN THIS BLADE UPON INVESTIGATION OF AN UNUSUALLY HIGH VIBRATION LEVEL AS REPORTED BY THE PIL OT. THE ONE-PER-REV VERTICAL VIBRATION WAS ESPECIALLY NOTICEABLE DURING THE LANDING PHASE OF FLIGHT. INSPECTION OF THI S BLADE REVEALED CORD-WISE CRACKS IN THE TOP AND BOTTOM SKINS WHICH EXTEND FROM THE TRAILING EDGE AT STA 3135 TO THE AFT EDGE OF THE SPAR AT STA 3123. THE CRACKS THEN EXTEND SPAN-WISE FROM STA 2940 TO STA 3225. THE CRACK IN THE LOWER SKIN BISECTS A SKIN REPAIR AT STA 3130, APPROXIMATELY 2 INCHES FORWARD OF THE TRAILING EDGE. THIS REPAIR WAS ACCOMPLISHED W ITH AD 2000-15-20 AND BT 109-111 UNDER WO NR 8-080132-84, DATED 4/24/2006. BT 109-50, PART I REQUIRES DAILY VISUAL INSP 1 G 7 2 3U 3 U H7EU E4CE 2007060600004 20070606 00004 NE 2007 6 6 2007FA0000474 2 20070507 G 7420 IGNITION LEAD CESSNA 500 560CESSNA 2076750 CE PWA JT15 JT15D5 52112 NE LT ENGINE OUT OF POSITION B O OTHER R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 EA 25 228PC 5600310 WHILE DEPARTING, ENCOUNTERED A 75 PERCENT THROTTLE SPLIT WITH THE LEFT ENGINE ACHIEVING ONLY 93 PERCENT N1. A MFG PHAS E B INSPECTION WAS PERFORMED ON THE AIRCRAFT ON 5/5/2007. WHILE PERFORMING THE PHASE B INSPECTION ITEM B742001, TASK 74 -31-00-210 (ENGINE IGNITERS OPERATIONAL TEST), IT WAS DETERMINED THAT THE RT IGNITER LEAD ON THE LT ENGINE WAS RE-INSTAL LED IN A POSITION THAT AFFECTED THE THROTTLE LINKAGE AND PREVENTED FULL TRAVEL OF THROTTLE LEVER IN THE FLIGHT DECK. FU RTHER INVESTIGATION REVEALED THAT THERE IS NO REFERENCE OR PRECAUTIONS IN THE MM AS TO THE RE-INSTALLATION POSITION OF T HE LEAD UPON REMOVAL AND RE-INSTALLATION OF THE IGNITER PLUG. INSTALLING THE IGNITER LEAD END TO THE IGNITER WITH A 90 2 L 7 2 4F 4 F RT A22CE E25EA 2007060700003 20070607 00003 EU 2007 6 7 2007FA0000475 1 20070430 G 2520 4311935 HOUSING AMD FALC50 FALCON900 2730160 EU GARRTT TFE731 TFE731* 01518 WP SEAT ROLLER MISMANUFACTURED B UO2R O OTHER W INADEQUATE Q C NR NOT REPORTED 1 GL 19 678CH 47 (8) SEATS, MODEL 5004 (SINGLE) WERE PURCHASED. THE SEATS HAVE (3 FT) ON EACH CORNER (12 TOTAL) THAT ARE TO FIT INTO THE SEAT RAIL. SAID PURCHASED SEATS DID NOT FIT INTO THE EXISTING MFG SEAT RAIL. MFG WAS CONTACTED. IT WAS DETERMINED BY THE MFG THAT THE (3 FEET) BY THE MFG THAT THE (3 FEET) ON EACH CORNER (12 TOTAL) WERE BEING MFG INCORRECTLY. THE SEATS ARE DESIGNED TO FIT INTO (2 TRACKS). THE FRONT 3 AND BACK 3 FEET ON THE LT SIDE OF THE CHAIR ARE PART OF A (ROLLER HOU SING). EACH CHAIR HAS (2) ROLLER HOUSINGS. MFG IS PROVIDING 16 REPLACEMENT ROLLER HOUSINGS (PN 431193-5). (K) 2 L 7 3 4F 4 F RT A46EU E6WE 2007061300166 20070613 00166 GL 2007 6 13 2007FA0000476 1 20070504 G 7160 BA24 AIR FILTER CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO HARTZL HCJ3Y PHCJ3YF1 GL ENGINE INTAKE DEBONDED B K NONE O OTHER IN INSP/MAINT 1 EA 17 711KW 1348 917594 FP3492B APPEARS THAT THE FOAM AIR FILTER ELEMENT, THAT IS CYLINDER SHAPED AND BONDED TOGETHER, DID NOT HAVE SUFFICIENT GLUEUU OR CAME UNBONDED AND WAS ALLOWING UNFILTERED AIR TO ENTER THE ENGINE INTAKE. 1 L 7 1 3O 3 O NT A00009CH E3SO 5 C P36EA 2007061300168 20070613 00168 GL 2007 6 13 2007FA0000477 1 20070507 G 2720 BUNGEE CIRRUS SR SR22 2130001 GL RUDDER MISRIGGED B K NONE O OTHER IN INSP/MAINT 1 EA 07 519SR 2072 DURING INSPECTION FOUND RUDDER AILERON INTERCONNECT BUNGEE MISRIGGED AND INTERTFERING WITH THE AILERON CONTROLS. THERE I S NO EVIDENCE THAT THIS AIRCRAFT HAS HAD ANY MAINTENANCE TO THIS SYSTEM SINCE LEAVING THE FACTORY. ANOTHER AIRCRAFT WITH THIS CONDITION HAD THE CONTROL SYSTEM JAM WITH FULL OPPOSITE RUDDER AND AILERON. IT APPEARS THAT THIS CONDITION IS CAUS ED BY IMPROPER RIGGING OF THE INTERCONNECT SYSTEM AT THE FACTORY. 1 L 7 1 3O NT A00009CH 2007061300204 20070613 00204 EA 2007 6 13 2007FA0000478 2 20070510 G 8530 LW12987 CYLINDER LYC O540 IO540* 41532 EA ENGINE ERODED B O OTHER O OTHER NR NOT REPORTED 1 SW 17 AFTER REMOVAL OF THE CYLINDER BARREL FROM THE CYLINDER HEAD, SEVER ERROSION WAS NOTED JUST ABOVE THE SEAL BAND AREA. IF THE BARREL HAD NOT BEEN REMOVED, THIS ERROSION WOULD HAVE BEEN UNDETECTED AND WOULD HAVE CAUSED A HEAD AND BARREL SEPERA TION. 3 O 1E4 2007061800105 20070618 00105 CE 2007 6 18 2007FA0000479 1 20070516 G 2510 04101342 SEAT CESSNA 150 150F 2071814 CE CONT E185 E185* 17014 SO COCKPIT CRACKED D O OTHER O OTHER NR NOT REPORTED 1 CE 01 8095S 15061695 SEAT PAN WAS FOUND CRACKED AT THE FORWARD END OF PILOTS OB SEAT RAIL STIFFENER, APPROXIMATELY 1 NR LONG ACROSS SCREW HOL ES. STIFFENER PN 0411546-1 WAS ALSO CRACKED AT CUTOUT FOR FUEL LINE. TOTAL AIRFRAME TIME UNKNOWN, BUT GREATER THAN 1300 HOURS. THESE CRACKS ARE SOMEWHAT COMMON ON 3000 TO 5000 HOUR AIRPLANES. 1 H 7 1 3O 3 O 3A19 E246 2007061500224 20070615 00224 SO 2007 6 15 2007FA0000480 1 20070523 G 5711 6707003 SPAR CAP PIPER PA28 PA28140 7102802 SO LYC O320 O320* 41508 EA RT WING CORRODED G K NONE O OTHER IN INSP/MAINT 1 SO 15 4579R 3465 2821321 FUEL TANK REMOVED DUE TO LEAKING VENT LINES. UPON REMOVAL, DISCOVERED RT WING UPPER SPAR CAP SEVERLY CORRODED. MAJOR EXF OLIATION TO THE SPAR CAP AT THE OB SECTION OF THE FUEL TANK OPENING. 1 L 7 1 3O 3 O 2A13 E274 2007061800106 20070618 00106 CE 2007 6 18 2007FA0000481 1 20070523 G 5311 051212497 SPAR CESSNA 172 172RG 2072438 CE LYC O360 O360F1A6 41514 EA MCAULY 2D34C B2D34C220 GL FUSELAGE DAMAGED D K NONE O OTHER IN INSP/MAINT 1 SW 15 5145U 14529 100 172RG0258 L2767336A 961976 FOUND SMOKING RIVETS ON TOP OF FUSELAGE IN AREA OF THE REAR CENTER SECTION SPAR. REMOVED RIVETS (APPROX. EIGHT ON EACH END OF SPAR) AND FOUND RIVET HOLES SEVERELY ELONGATED. FACTORY ORIGINAL RIVETS WERE .1250 INCH DIA. AND SEVERAL HAD BEE N REPLACED IN THE FIELD WITH .1562 INCH RIVETS. ALL OF THE AFFECTED RIVET HOLES HAD BECOME OVERSIZED TO AN EXTENT THAT RENDERED THE SPAR AND OVERLAPPING FUSELAGE SKINS UNSERVICEABLE. 1 H 7 1 3O 3 O 3A17 E286 5 C P7EA 2007061500213 20070615 00213 SO 2007 6 15 2007FA0000482 1 20070523 G 5711 6205401 SPAR PIPER PA28 PA28R180 7102809 SO RT WING CORRODED G K NONE O OTHER IN INSP/MAINT 1 SO 15 3208R 14400 28R3113 RT WING REMOVED DUE TO DAMAGE. WING WAS SCRAPPED AND DEALER WANTED STEEL FITTINGS REMOVED. UPON REMOVAL OF REAR SPAR ATT ACH PLATE, SEVERE CORROSION WAS FOUND ON THE SPAR UNDER THE PLATE. CONDITION WAS VERY SERIOUS AND COULD HAVE LEAD TO AN INFLIGHT FAILURE. 1 L 7 1 3O 2A13 2007061500214 20070615 00214 CE 2007 6 15 2007FA0000483 1 20070525 G 2400 UNKNOWN BEECH 35 K35 1151524 CE CONT O470 IO470N 17026 SO MCAULY 2A36C 2A36C23 GL UNKNOWN C H DEACTIVATE SYST/CIRCUITS H ELECT. POWER LOSS-50 PC CR CRUISE 1 CE 07 6061E D5996 096827R 7710181 LOST ELECTRICAL POWER. 1 L 7 1 3O 3 O 3A15 3E1 5 C P880 2007061500216 20070615 00216 EA 2007 6 15 2007FA0000484 2 20070525 G 7322 MA45 CARBURETOR PIPER PA24 PA24 7102402 SO LYC O360 O360* 41514 EA ENGINE WORN D E A ENGINE SHUTDOWN UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 EA 23 7204P 748 748 242374 THE ACCELERATOR PUMP IN THE CARBURETOR FAILED. INSPECTION SHOWED THAT THE PUMP HEAD GLAND HAD SHRUNK, SO THAT IT DID NO T PROVIDE A SEAL BETWEEN THE CARBURETOR BODY AND THE PUMP ITSELF. THE RESULT WAS THAT ADVANCING THE THROTTLE DID NOT CA USE FUEL TO BE SQUIRTED FROM THE PUMP EXIT ORIFICE. REPLACEMENT OF THE PUMP RESOLVED THE PROBLEM. 1 L 7 1 3O 3 O 1A15 E286 2007061500210 20070615 00210 EU 2007 6 15 2007FA0000486 1 20070530 G 2752 1391T1008 ACTUATOR ISRAEL 1124 1124 4500102 EU GARRTT TFE731 TFE731* 01518 WP FLAP MISALIGNED B K NONE O OTHER IN INSP/MAINT 1 CE 09 27TZ 213 INSTALLED REBUILT FLAP ACTUATOR IN RT OB POSITION; PN 1391T100-8, SN 387AB. FLAP OPERATION WAS NORMAL. WHILE CHECKING AILERON TRAVELS IT WAS DISCOVERED THAT AILERON TRAVELS WERE LIMITED BY THE REBUILT FLAP ACTUATOR. A COVER PLATE ON THE FLAP ACTUATOR HAD BEEN INDEXED INCORRECTLY AND WAS INTERFERING WITH THE AILERON BELLCRANK. PROBABLE CAUSE WAS INCORRECT ASSEMBLY OF FLAP ACTUATOR. 2 M 7 2 4F 4 F A2SW E6WE 2007061500211 20070615 00211 EU 2007 6 15 2007FA0000487 1 20070530 G 2752 1391T1008 ACTUATOR ISRAEL 1124 1124 4500102 EU GARRTT TFE731 TFE731* 01518 WP FLAP MISALIGNED B K NONE O OTHER IN INSP/MAINT 1 CE 09 27TZ 213 INSTALLED REBUILT FLAP ACTUATOR IN RT OB POSITION; PN 1391T100-8, SN 387AB. FLAP OPERATION WAS NORMAL. WHILE CHECKING AILERON TRAVELS IT WAS DISCOVERED THAT AILERON TRAVELS WERE LIMITED BY THE REBUILT FLAP ACTUATOR. A COVER PLATE ON THE FLAP ACTUATOR HAD BEEN INDEXED INCORRECTLY AND WAS INTERFERING WITH THE AILERON BELLCRANK. PROBABLE CAUSE WAS INCORRECT ASSEMBLY OF FLAP ACTUATOR. 2 M 7 2 4F 4 F A2SW E6WE 2007061800108 20070618 00108 2007 6 18 2007FA0000489 2 20070530 G 7414 CAPACITOR MAGNETO FAILED C O OTHER O OTHER NR NOT REPORTED 1 SW 15 IN READING AN ALERT FROM APRIL 2007 REFERRING TO SLICK MAGNETO CAPACITOR FAILURE PN M-3984 STATES THAT OIL/DIELECTRIC FL UID LEAKED FROM THE CAPACITOR. THAT IS A DRY CAPACITOR AND CONTAINS NO FLUID. HAVE CUT OPEN SEVERAL FOR TRAINING AIDS A ND NO LIQUID EXISTS IN THAT PART. 2007061500218 20070615 00218 SO 2007 6 15 2007FA0000490 2 20070525 G 8520 IO240A CRANKSHAFT CONT O240 IO240B 17063 SO ENGINE CRACKED B K NONE O OTHER IN INSP/MAINT 1 SW 17 CRANKSHAFT HAD A VERY LARGE, DEEP FORGING LAP ON THE NR 3 CRANK CHEEK. AN EFFORT WAS MADE TO REMOVE THE LAP BY LOCALIZE D GRINDING BUT THE IT WAS TOO DEEP TO REMOVE. CRANKSHAFT WAS DETERMINED UNAIRWORTHY BY ENGINEERING. 3 O E7SO 2007061500221 20070615 00221 2007 6 15 2007FA0000491 4 20070429 G 2215 065001790100 SERVO CESSNA 182 182S 2072701 CE LYC O540 IO540* 41532 EA AILEONS BINDING D O OTHER F FLT CONT AFFECTED AP APPROACH 1 SW 09 9875F 1056 18280141 PILOT/OWNER REPORTED TO MX THAT ON APPROACH AFTER DISENGAGING AUTOPILOT, AILERONS WERE DIFFICULT TO MOVE. NO WINDS AND S TABLE APPROACH MINIMIZED PROBLEM. MX NOTED AILERONS WERE EXTREMELY DIFFICULT TO MOVE, AND FURTHER MOVEMENT COULD HAVE CA USED EVEN GREATER DIFFICULTY OR COMPLETE IMMOBILIZATION OF THE AILERONS. AILERON SERVO WAS REMOVED AND SENT OUT FOR EXCH ANGE. IT WAS NOTED ON REMOVAL THE OUTPUT SHAFT SUPPORT BEARING WAS LOOSE AND BINDING. 1 H 7 1 3O 3 O NT 3A13 1E4 2007061500222 20070615 00222 CE 2007 6 15 2007FA0000492 1 20070531 G 5753 07620382 BELLCRANK CESSNA 182 182S 2072701 CE LYC O540 IO540* 41532 EA TE FLAPS BROKEN D K NONE O OTHER IN INSP/MAINT 1 SW 09 9875F 1056 18280141 DURING ANNUAL INSPECTION, IT WAS NOTED THAT THE (BELLCRANK ASSY) ON THE FLAP FEEDBACK LEVER, BEHIND THE INSTRUMENT PANEL , WAS BROKEN IN TWO, IT CONSIST OF A PLASTIC BLOCK WITH A SLOT IN IT WHICH MOVES THE MICROSWITCH ASSY TO ACTIVATE, OR DE ACTIVATE THE FLAP DRIVE MOTOR. THE BLOCK IS ATTACHED WITH 2 RIVETS OF SOME TYPE. THE END OF THE BLOCK IS CRACKED COMPLET ELY THROUGH ALLOWING SEPARATION OF THE UPPER AND LOWER HALVES. THIS ALSO STRESSED THE ATTACHING RIVETS CAUSING CRACKS, A ND EXCESSIVE MOVEMENT. (PICS ARE AVAILABLE) IF PART COMPLETELY FAILED IT COULD ALLOW COMPLETE UNCOMMANDED FLAP DEPLOYM ENT OR INABILITY TO RETRACT FLAPS, SUCH AS A BALKED LANDING. 1 H 7 1 3O 3 O NT 3A13 1E4 2007061500223 20070615 00223 2007 6 15 2007FA0000493 2 20070530 G 7414 M3984 CAPACITOR MAGNETO NONE C O OTHER O OTHER NR NOT REPORTED 1 SW 15 IN READING AN ALERT FROM APRIL 2007 REFERING TO SLICK MAGNETO CAPACITOR FAILURE PART NR M-3984 STATES THAT OIL/DIELECTR IC FLUID LEAKED FROM THE CAPACITOR. THAT IS A DRY CAPACITOR AND CONTAINS NO FLUID. I HAVE CUT OPEN SEVERAL FOR TRAININ G AIDS AND NO LIQUID EXSISTS IN THAT PART. 2007061800211 20070618 00211 2007 6 18 2007FA0000494 4 20070604 G 2216 6565001197 CABLE CESSNA 500 550 2076604 CE AUTOPILOT FRAYED B K NONE O OTHER IN INSP/MAINT 1 SW 01 4614N 7737 300 5500659 WE HAVE FOUND THE ELEVATOR CABLE AT THIS SERVO P/N 4006719-904 SHOWING EXCESSIVE WEAR ON AIRCRAFT UNDERGOING PHASE 1-4 A ND ALSO PHASE 5 INSPECTIONS. THE CABLE WAS FOUND WHERE IT PASSES THROUGH AT FS. 428.50 AND IS DIFFICULT TO SEE. THIS CAB LE HAD APROX. 3 STRANDS TO GO TO TOTAL FALURE. THE IPC REFERENCE FOR THE CABLE IS 22-10-00, FIGURE 1, PAGE 3, ITEM 85 1 L 7 2 4F A22CE 2007061800222 20070618 00222 NM 2007 6 18 2007FA0000495 1 20070606 G 3060 SMR2263 HEATER HARTZL LANCAR LC40 LC40550FG 5150000 NM CONT O550 TSIO550C SO PROP BLADES DEBONDED D K NONE O OTHER IN INSP/MAINT 1 SW 07 1439C 226 LX197B 41618 914411 INBOARD PORTION OF ALL THREE PROP DEICE BOOTS DEBONDED AGAIN. ON THIS PROP, NEW BLADES WERE SENT FROM HARTZELL DUE TO D EBOND OF PREVIOUS BOOTS AT 28.4 HRS TT AND AGAIN AT 28.9 HRS TT. RETAINER STRAP AND BOOT DEBONDS DUE TO CENTRIFUGAL FOR CE PULLING DEICE BOOT LEAD ON EACH PROP BLADE. THIS HAS HAPPENED ON FIVE OR MORE LANCAIR COLUMBIA AIRCRAFT. THE SEALIN G PROCESS FOR THE RETAINER STRAP IS LACKING. SMR TECHNOLOGIES AND HARTZELL NEED A BETTER STRAP OR A GOOD TY-RAP. 1 L 7 1 3O 3 O RT A00003SA E5SO 2007061800224 20070618 00224 SO 2007 6 18 2007FA0000496 2 20070530 G 8500 STUD CONT O520 TSIO520* 17040 SO ENGINE CASE CHAFED D O OTHER O OTHER NR NOT REPORTED 1 SW 99 532343 DURING BUILD UP OF A NEW ENGINE FOR INSTALLATION, IT IS ROUTINE FOR US TO R&R THE OIL COOLER TO INSTALL THE GASKET WITH SEALANT AND TO INSPECT THE ADAPTER PLATE MOUNTING STUD HEIGHT. ON THIS PARTICULAR ENGINE, ALL OF THE STUDS WERE INSTALL ED TOO HIGH, SO THAT THEY PROTRUDED ABOVE THE GASKET MOUNTING SURFACE. TWO OF THEM HAD MADE IMPRESSIONS IN THE COOLER S EALING SURFACE. 3 O E8CE 2007061800265 20070618 00265 SO 2007 6 18 2007FA0000497 2 20070607 G 8530 EC646144CN CYLINDER CESSNA 210 210C 2073412 CE CONT O470 IO470S 17026 SO ENGING DAMAGED G A UNSCHED LANDING A FLAME/FIRE CL CLIMB 1 WP 21 3622Y 501 21058122 CS1024292S CYLINDER HEAD DETACHED FROM CYLINDER BARREL CAUSING INJECTOR FUEL LINE TO RUPTURE. A INFLIGHT FIRE OCCURED CAUSING DAMA GE TO WIREING, MAG.,AND OTHE ENGINE COMPONENTS. 1 H 7 1 3O 3 O 3A21 3E1 2007061800266 20070618 00266 CE 2007 6 18 2007FA0000498 1 20070527 G 5610 WINDSHIELD CESSNA 421 421C 2076016 CE COCKPIT BROKEN G B EMER. DESCENT D INFLIGHT SEPARATION CR CRUISE 1 SO 15 237SM 421C0237 MAJOR PORTION OF RT WINDSHIELD SEPARATED FROM AIRCRAFT. 1 L 7 2 3O A7CE 2007061800267 20070618 00267 EA 2007 6 18 2007FA0000501 2 20070607 G 8520 LW13683 MAIN BEARING PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA ENGINE DELAMINATED B K NONE O OTHER IN INSP/MAINT 1 SW 99 1100 318052122 L110868A CUSTOMER FOUND METAL IN FILTER DURING ROUTINE MAINTENANCE. TOOK ENG. APART AND FOUND 2 CENTER MAIN BRGS. WHERE DELAMINAT ED. 1 L 7 2 3O 3 O A20SO E14EA 2007062700015 20070627 00015 NM 2007 6 27 2007FA0000503 1 20070618 G 6510 A04111 BEARING ROBSIN R22 R22BETA 7640110 NM LYC O320 O320* 41508 EA DRIVESHAFT ROUGH B O OTHER O OTHER NR NOT REPORTED 1 NM 09 461H 161 1460 PILOT REPORTS GRINDING NOISE FROM TAIL ROTOR DRIVESHAFT. REMOVED DRIVESHAFT ASSY AND DISCOVERED ROUGH A041-11 DAMPER BEA RING. REPLACED BEARING ASSY. CLOSER EXAMINATION SHOWED PAINT USED DURING DRIVESHAFT ASSEMBLY ON LIP OF SEAL. OVER TIME THIS DAMAGED THE LIP OF THE SEAL AND ALLOWED GREASE TO PURGE FROM BEARING. THIS IS THE SECOND OCCURRENCE OF THIS IN THE PAST 12 MONTHS. MFG NOTIFIED EACH TIME. SUGGEST BETTER QC DURING DRIVESHAFT BUILD UP AT MFG. 1 G 7 1 3O 3 O H10WE E274 2007071100021 20070711 00021 CE 2007 7 11 2007FA0000505 1 20070504 G 5340 24130023 ATTACH FITTING CESSNA 172 172RG 2072438 CE LYC O360 O360* 41514 EA MCAULY 2D34C B2D34C220 GL NLG ACTUATOR CRACKED B BGSR K NONE O OTHER IN INSP/MAINT 1 EA 21 169EC 1345 172RG0515 L2843836A 804955 L/W SEB 93-8 ON NOSE GEAR ACTUATOR ATTACH FITTING AND SOUND CRACK ON LT, LOWER, IB BOLT HOLE OF FITTING. ALSO, BOLT HOL ES IN LOWER SKIN WERE IN EXCESS OF .030. REPLACED ATTACH FITTING, LOWER SKIN AND DOUBLER IAW SK 172-142 AND SK 172-159. 1 H 7 1 3O 3 O 3A17 E286 5 C P7EA 2007071100022 20070711 00022 CE 2007 7 11 2007FA0000506 1 20070517 G 5753 95160000XX SKIN BEECH 60 B60 1153605 CE LYC O541 TIO541* 41536 EA LT TE FLAP CRACKED B HSRR K NONE O OTHER IN INSP/MAINT 1 NM 06 837RJ 5859 P355 BOTH FLAPS CRACKED AT ACTUATOR ATTACH POINT. LT FLAP SKIN AND RIB CRACKED. RT FLAP RIB CRACKED. RIGGING WAS OK, PROBA BLY AN OPERATOR INDUCED PROBLEM. BELIEVE THE FLAPS HAVE BEEN LOWERED AT TOO HIGH AN AIRSPEED. (K) 1 L 7 2 3O 3 O A12CE E10EA 2007071100029 20070711 00029 CE 2007 7 11 2007FA0000507 1 20070515 G 2130 AN8186D NUT BEECH BEECH MU300 400A 1155402 CE PWA JT15 JT15D5 52112 NE TUBE LOOSE B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 132QS RK427 CREW REPORTED PRESSURIZATION CONTROL INEFFECTIVE, CABIN RATE CLIMBING AND DESCENDING, WHILE DESCENDING IN AUTOMATIC MODE . STABILIZED BRIEFLY WHILE IN MANUAL MODE. TROUBLESHOT IAW FIM 21-30-00, EXCESSIVE LEAK RATE NOTED AT TEST PORT 2. FO UND LOOSE (B) NUT ON CONTROL LINE TUBE ASSY. AT TEE FITTING FOR MANUAL CONTROL VALVE. CORRECTED LOOSE FITTING AND SYST EM TESTS OK. RESTORED AC TO NORMAL CONFIGURATION, PRESSURIZATION SYSTEM TESTS SATISFACTORY ON GROUND RUN-UP. UNKNOWN I F PREVIOUS MAINTENANCE PERFORMED IN THIS AREA. (K) 2 H 7 2 4F 4 F RT A16SW E25EA 2007062700007 20070627 00007 WP 2007 6 27 2007FA0000510 1 20070618 G 6520 269A6029 LOCK NUT HUGHES 269 269C 4470504 WP LYC O360 HIO360* 41514 EA T/R GEARBOX BACKED OUT B C ABORTED TAKEOFF O OTHER TX TAXI/GRND HDL 1 NM 09 27YS 1573 DURING GROUND RUNUP, PILOT NOTICED TAIL ROTOR NOT SPINNING. AIRCRAFT SHUTDOWN AND RETURNED TO HANGER. UPON DISASSEMBLY I T WAS NOTED THAT THE NUT PN 269A6029 THAT ATTACHES THE DRIVE COUPLING TO THE GEARBOX HAD BACKED OUT COMPLETELY AND WORN A HOLE THROUGH THE ALUMINUM BUMPER PN 269A5712 THAT IS INSIDE THE TAIL ROTOR DRIVESHAFT. THREADS INSIDE THE TAIL ROTOR G EARBOX INPUT SHAFT PN 269A5626-5 WERE ALSO DAMAGED. PARTS WERE FORWARDED TO MFG FOR EVALUATION. 1 G 7 1 3O 3 O 4H12 1E10 2007071100062 20070711 00062 CE 2007 7 11 2007FA0000511 1 20070530 G 5730 552275563 PANEL CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE WING DELAMINATED B H00R K NONE O OTHER IN INSP/MAINT 1 EA 21 100DS 4430 5500639 DURING COMPLETION OF MFG PROGRAM PHASE 5 INSPECTION, NOTICEABLE DEPRESSION WAS OBSERVED IN UPPER SURFACE OF LT AND RT WI NG SKINS IN AREA OF MLG UPLOCK HOOK ASSY ATTACHMENT. DURING COMPLETION OF LANDING GEAR OPERATIONAL CHECK, IT WAS NOTED THAT DEPRESSION AREA SIZE GREW WHILE MLG WAS IN UP AND LOCKED POSITION. USING THE COIN TAP TEST METHOD CONFORMATION WAS MADE THAT BOTH BONDED PANELS WERE DELAMINATED. IAW TECH SUPPORT, NO DELAMINATION IS ALLOWED ON THESE PANELS. OPTIONS AVAILABLE FOR REMEDY WERE REMOVED AND REPLACED, POSSIBLE REPAIR DEFINITION AND ASSOC 8110FORM, OR POSSIBLE TEMPORARY REP AIR WITH FLIGHT EXTENSION. (K) 1 L 7 2 4F 4 F A22CE E1NE 2007071100063 20070711 00063 CE 2007 7 11 2007FA0000512 1 20070530 G 5730 552277564 PANEL CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE LT WING DELAMINATED B H00R K NONE O OTHER IN INSP/MAINT 1 EA 21 100DS 4430 5500639 DURING COMPLETION OF MFG PROGRAM PHASE 5 INSPECTION, NOTICEABLE DEPRESSION WAS OBSERVED IN UPPER SURFACE OF LT AND RT WI NG SKINS IN AREA OF MLG UPLOCK HOOK ASSY ATTACHMENT. DURING COMPLETION OF LANDING GEAR OPERATIONAL CHECK, IT WAS NOTED THAT DEPRESSION ARE SIZE GREW WHILE MLG WAS IN UP AND LOCKED POSITION. USING THE COIN TAP TEST METHOD. CONFORMATION WA S MADE THAT BOTH BONDED PANELS WERE DELAMINATED. IAW TECH SUPPORT, NO DELAMINATION IS ALLOWED ON THESE PANELS. OPTIONS AVAILABLE FOR REMEDY WERE REMOVED AND REPLACED, POSSIBLE REPAIR DEFINITION AND ASSOC 8110 FORM, OR POSSIBLE TEMPORARY R EPAIR WITH FLIGHT EXTENSION. (K) 1 L 7 2 4F 4 F A22CE E1NE 2007062500003 20070625 00003 2007 6 25 2007FA0000513 4 20070608 G 2562 E0109 CONNECTOR ACK E01ELT PIPER PA16 PA16 7101602 SO ELT MISSING D K NONE O OTHER IN INSP/MAINT 1 SO 25 5834H 1277 87 021767 16453 DURING 100 HOUR INSPECTION IT WAS NOTED THAT THE BNC CONNECTOR ATTACHED TO THE ELT PORTABLE ANTENNA WAS MISSING. AN IN-D EPTH SEARCH OF THE AIRCRAFT BELLY FAILED TO TURN UP THE CONNECTOR. THE CONNECTOR IS ATTACHED TO THE PORTABLE COLLAPSIBLE ANTENNA BY A 6-32 SCREW IN THE BOTTOM OF THE ANTENNA. THERE IS NO PROVISION TO LOCK THIS THREADED ATTACHMENT. 1 H 7 1 3O 1A1 2007062500006 20070625 00006 GL 2007 6 25 2007FA0000516 1 20070612 G 5753 13431004 HINGE CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO HARTZL HCJ3Y PHCJ3YF1 GL FLAP CORRODED G K NONE O OTHER IN INSP/MAINT 1 SW 13 122GH 543 0175 FLAP HINGE ASSEMBLY HAS INTERGRANULAR CORROSION ON THE FORWARD EDGE OF THE HINGE JUST BELOW THE BOTTOM WING SKIN ABOVE T HE HINGE FAIRING. 1 L 7 1 3O 3 O NT A00009CH E3SO 5 C P36EA 2007062500007 20070625 00007 GL 2007 6 25 2007FA0000517 1 20070612 G 5753 13432002 HINGE CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO HARTZL HCJ3Y PHCJ3YF1 GL FLAP CORRODED G K NONE O OTHER IN INSP/MAINT 1 NE 03 122GH 543 0175 FLAP HINGE ASSEMBLY HAS INTERGRANULAR CORROSION ON THE FORWARD EDGE OF THE HINGE JUST BELOW THE BOTTOM WING SKIN ABOVE T HE HINGE FAIRING. 1 L 7 1 3O 3 O NT A00009CH E3SO 5 C P36EA 2007062500025 20070625 00025 SO 2007 6 25 2007FA0000524 2 20070511 G 8500 ENGINE BEECH 36 A36 1151604 CE CONT O550 IO550* SO RIGHT FAILED G B A EMER. DESCENT UNSCHED LANDING J Y T WARNING INDICATION ENGINE STOPPAGE ENGINE CASE PENETRATION CR CRUISE 1 SO 11 814JG 14 E2622 675591 ON MAY 11, 2007 AT APPROXIMATELY 1815 EST, 2205Z, A BEECH BE-36-A36 BONANZA, N814JG, S/N E-2622, AT CRUISE HAD A DECREAS E IN ENGINE CYLINDER TEMPERATURE, FOLLOWED BY A LOSS OF OIL PRESSURE AND ENGINE POWER WITH SUBSEQUENT ENGINE FAILURE. TH E AIRCRAFT MADE AN EMERGENCY LANDING. PILOT WALKED AWAY FROM THE AIRCRAFT WITH NO INJURIES. A VISUAL INSPECTION OF THE A IRCRAFT REVEALED A HOLE IN THE UPPER RIGHT HAND ENGINE COWLING APPROXIMATELY 3 INCHES IN DIAMETER WHICH WAS LIMITED TO S HEET METAL DAMAGE. UPON INSPECTION OF THE ENGINE COMPARTMENT THE FORWARD UPPER CASE OF THE ENGINE WAS HEAVILY DAMAGED RE VEALING SEVERAL DAMAGED PISTONS, PISTON CONNECTING RODS BROKEN AND NR 6 CONNECTING ROD MISSING, ALONG WITH SEVERAL CRANK 1 L 7 1 3O 3 O 3A15 E3SO 2007062500027 20070625 00027 EA 2007 6 25 2007FA0000525 2 20070615 G 7414 M3548 ROTOR SLICK 4370 PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA SNSNCH 74D 74DM EA MAGNETO SHEARED C O OTHER O OTHER NR NOT REPORTED 1 CE 01 335 335 06052245 RIGHT MAGNETO ROTOR SHEARED DIRECTLY UNDER THE MAGNETO CAM. SECOND IDENTICAL FAILURE IN 335 HRS ON THE AIRCRAFT. AIRCR AFT DYNAMIC PROP BALANCE WAS CHECKED AFTER THIS FAILURE AND CHECKED EXCELLENT. 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 2007062500028 20070625 00028 SO 2007 6 25 2007FA0000526 1 20070615 G 2420 TERMINAL CHRYSLER PIPER PA28 PA28180 7102808 SO LYC O360 O360A4A 41514 EA SNSNCH 76E 76EM8S5 EA ALTERNATOR LOOSE C O OTHER O OTHER NR NOT REPORTED 1 CE 01 F082472 217 HOURS AFTER OVERHAUL, THE OUTPUT TERMINAL BECAME LOOSE IN THE BUSS STRAP INSIDE THE ALTERNATOR, CAUSING COMPLETE FA ILURE. LIKELY THIS FIT (NORMALLY A PRESS FIT) WAS NOT AS TIGHT AS IT NEEDED TO BE WHEN THIS UNIT LEFT KELLY. 1 L 7 1 3O 3 O 2A13 E286 5 N P4EA 2007071100061 20070711 00061 GL 2007 7 11 2007FA0000530 1 20070622 G 3222 11907005 STRUT CIRRUS SR SR20 05628AJ GL CONT O550 IO550N 17042 SO NLG CRACKED B K NONE O OTHER IN INSP/MAINT 1 EA 07 961CD 623 1610 NOSE LANDING GEAR STRUT HAS A CRACK AT THE TOP. THE STRUT COMES UP TO A Y FOR MOUNT. AT THE YOKE OF THE Y IS A WELDED RE INFORCEMENT, AND THE CRACK IS AT THE TOP WHERE THIS REINFORCEMENT MEETS THE LEGS OF THE Y ON BOTH SIDES. 1 L 7 1 3O 3 O NT A00009CH E3SO 2007062700020 20070627 00020 EU 2007 6 27 2007FA0000531 1 20070615 G 2750 9450202205 FLEX DRIVE PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL TE FLAPS BROKEN B O OTHER O OTHER DE DESCENT 1 EA 65 591AF 2329 591 PR0454 KX164 DURING APPROACH WHEN THE FLAPS WERE SELECTED TO 15 DEGREES THE FLAPS FAILED TO EXTEND AND A FLAP CAUTION ANNUNCITOR WAS DISPLAYED ON THE CAWS PANEL. THE FLIGHT CREW FOLLOWED THE APPROPRIATE POH PROCEDURES AND LANDED UNEVENTFULLY. INVESTIGAT ION INTO THE FLAP PROBLEM AFTER THE AIRCRAFT LANDED DETERMINED THAT THE LT IB FLAP FLEX DRIVE PN 945.02.02.205, SN S2532 , HAD BROKEN JUST IB OF THE LT IB FLAP ACTUATOR. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2007071100023 20070711 00023 2007 7 11 2007FA0000532 1 20070620 G 3220 608200185 TORQUE KNEE BEECH T34 NLG MISMANUFACTURED B O OTHER O OTHER NR NOT REPORTED 1 CE 09 GL210 PURCHASED BRAND NEW PART. DURING ASSEMBLY IT WAS FOUND THAT THE TORQUE ARM PIN LUGS ARE OF DIFFERENT THICKNESSES. THEY ARE SUPPOSED TO BE THE SAME. THIS DEFECT CAUSED THE HOLES IN THE HOUSING AND THE TORQUE PIN TO NOT ALIGN. 2007071100059 20070711 00059 GL 2007 7 11 2007FA0000533 1 20070622 G 3222 11907004 STRUT CIRRUS SR SR20 05628AJ GL CONT IO360 IO360* 17025 CE NLG CRACKED B K NONE O OTHER IN INSP/MAINT 1 EA 07 217JH 562 1320 NOSE LANDING GEAR STRUT HAS A CRACK AT THE TOP. THE STRUT COMES UP TO A Y FOR MOUNT. AT THE YOKE OF THE Y IS A WELDED RE INFORCEMENT, AND THE CRACK IS AT THE TOP WHERE THIS REINFORCEMENT MEETS THE LEGS OF THE Y. 1 L 7 1 3O 3 O NT A00009CH E1CE 2007062700019 20070627 00019 CE 2007 6 27 2007FA0000534 1 20070619 G 3246 D30257 HUB CESSNA 206 U206F 2073333 CE WHEEL FAILED C O OTHER O OTHER NR NOT REPORTED 1 AL 03 1191V D30 U20602506 WHEEL-BROKE AT CENTER, CASTING FAILED AT BOLT HOLES-8:00X6 TIRES AND TUBES 190-200" NRS AT CAP SCREWS INSTALLED 7-23-03 TACH 1709 CURRENT TACH 2052. 1 H 7 1 3O A4CE 2007071100073 20070711 00073 EU 2007 7 11 2007FA0000535 2 20070501 G 7314 AN9113D NIPPLE NANCNG CJ6A CJ6A 056183N WP VEDENY M14P EU MUHBR MTV MTV9* EU FUEL PUMP UNKNOWN D O OTHER O OTHER NR NOT REPORTED 1 WP 07 552CY 20 4332008 KR822009 FUEL INJECTION FUEL SUPPLY FROM FUEL PUMP FITTING THAT COMES OUT OF PUMP. FIX WOULD BE CHANGE TO STEEL AND SUPPORT LINE WITH BRACKET OR CHANGE TO FIREWALL MOUNT OF FUEL PRESSURE TRANSDUCER. (K) 1 L 7 1 3R RT EXPA1L71 USSR 5 C P24NE 2007071100088 20070711 00088 CE 2007 7 11 2007FA0000536 1 20070530 G 3500 510010746 LINE CESSNA 441 441 2076020 CE CONT O520 GTSIO520* 17032 SO OVERHEAD CABIN CORRODED D K NONE O OTHER IN INSP/MAINT 1 SW 03 377CA 5341 4410289 DURING INSPECTION, HEARD A FAINT GAS LEAK IN OVERHEAD. PULLED O2 OUTLETS IN SUSPECTED AREA, AND CHECKED B-NUTS, ALL SE CURE. PULLED HEADLINER FOR A CLOSER INSPECTION. FOUND O2 LINE JUST FWD OF THE CABIN DOOR CORRODED AND LEAKING. CORR OSION ON THE LINE OCCURRED WHERE THE DUCTING PASSED UNDER IT. EVERYWHERE THIS DUCTING TOUCHED AN O2 LINE THERE WAS CO RROSION. THE LINES & FLEX DUCTING WAS REPLACED WITH NEW. (K) 1 L 7 2 3T 3 O RT A28CE E7CE 2007071100092 20070711 00092 NE 2007 7 11 2007FA0000537 2 20070531 G 7321 312064401 FCU PWA BEECH B300 B300 1159232 CE PWA PT6 PT6A60A 52043 NE LT ENGINE MALFUNCTIONED B VG4R O OTHER O OTHER NR NOT REPORTED 1 SO 15 609BG 403 234 PCEPK0709 FL468 PCEPK0709 ENGINE POWER LOSS AT ALTITUDE. ENGINE ROLLED BACK FROM 50 PERCENT. MFG TECH SUPPORT RECOMMENDS FCU REPLACEMENT. CAUSE UNKNOWN AT THIS TIME. (K) 2 L 7 2 4T 4 T RT A24CE E4EA 2007071100093 20070711 00093 CE 2007 7 11 2007FA0000538 1 20070604 G 5320 FLOOR SUPPORT CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE FS 151 CRACKED B JGVR K NONE O OTHER IN INSP/MAINT 1 CE 09 905CW 9359 5500072 CABIN FLOOR SUPPORT WEB CRACKED AND BROKEN, FUSELAGE STATION 151. FOUND CRACK DURING PHASE INSPECTION. UNABLE TO FIND PN IN MFG PARTS CATALOG. (K) 1 L 7 2 4F 4 F A22CE E1NE 2007071100094 20070711 00094 EU 2007 7 11 2007FA0000539 1 20070530 G 2752 1391T1008 ACTUATOR ISRAEL 1124 1124 4500102 EU GARRTT TFE731 TFE731* 01518 WP TE FLAPS MISALIGNED D JGVR K NONE W INADEQUATE Q C IN INSP/MAINT 1 CE 09 27TZ 213 INSTALLED REBUILT FLAP ACTUATOR IN RT OB POSITION; PN 1391T1008, SN 387AB. FLAP OPERATION WAS NORMAL. WHILE CHECKING A ILERON TRAVELS IT WAS DISCOVERED THAT AILERON TRAVELS WERE LIMITED BY THE REBUILT FLAP ACTUATOR. A COVER PLATE ON THE F LAP ACTUATOR HAD BEEN INDEXED INCORRECTLY AND WAS INTERFERING WITH THE AILERON BELLCRANK. PROBABLE CAUSE; INCORRECT ASS Y OF FLAP ACTUATOR. (K) 2 M 7 2 4F 4 F A2SW E6WE 2007071100098 20070711 00098 SO 2007 7 11 2007FA0000540 1 20070625 G 7500 M1213400 RING ALIDSG GULSTM G1159 G1159A 3970109 SO RROYCE SPEY SPEY* NE PRECOOLER MISSING C O OTHER O OTHER NR NOT REPORTED 1 SW 09 2NA 309 THE COMPONENT OEM (REPORT 4-193), THE MM (CHAPTER 36-02-00), IPC (CHAPTER 36-10-00) AND THE CMP WORK CARDS (364040, 3640 45) ARE MISSING THE REQUIREMENT TO INSPECT AND INSTALL GAMMA RING (PN) M1213-400 DURING THE INSTALLATION OF THE PNEUMATI C SYSTEM PRECOOLER. FAILURE TO INSTALL THE GAMMA RING COULD CAUSE THE HIGH PRESSURE DUCT TO SEPARATE FROM THE PRECOOLER AND CAUSE SIGNIFICANT HEAT DAMAGE TO THE AIRCRAFT SKIN AND STRINGERS. 2 L 7 2 4F 4 T A12EA E2EU 2007071100082 20070711 00082 SO 2007 7 11 2007FA0000543 2 20070625 G 7322 NEEDLE VALVE CESSNA 182 182Q 2072732 CE CONT O470 O470U 17026 SO CARBURETOR MISSING D K NONE O OTHER IN INSP/MAINT 1 SW 99 51 AT THE END OF THE FLIGHT, PILOT REPORTED THAT THE ENGINE WOULD NOT IDLE. DURING INSPECTION OF THE CARBURETOR, MECHANIC FOUND THE MIXTURE ADJUSTMENT NEEDLE VALVE MISSING. CARBURETOR WAS REMOVED AND SENT BACK FOR REPAIR. 1 H 7 1 3O 3 O NT 3A13 E273 2007071100026 20070711 00026 EU 2007 7 11 2007FA0000547 1 20070620 G 2760 69023617 PULLEY BRACKET GLASFL H301 H301LIBELLE 3800337 EU CONT O360 TSIO360E 17025 SO SPOILER CHAFED B K NONE O OTHER IN INSP/MAINT 1 CE 09 301Q 2343 35 ROLL SPOILER CABLE PN:S3779-4P233.7M WAS ROUTED INCORRECTLY OVER LOW FRICTION PULLEY P/N:S3504-4.5 (THROUGH A TOOLING H OLE) IN PULLEY BRACKET P/N:6960236-17. THIS CAUSED AN INTERFERENCE AND WEAR IN THE PULLEY BRACKET, AND FLAT AREAS TO TH E CABLE. CABLE AND BRACKET WERE REPLACED WITH NEW. 1 K 0 0 3 O G12EU E9CE 2007071100027 20070711 00027 CE 2007 7 11 2007FA0000548 1 20070620 G 2760 S37794P2337M CONTROL CABLE CESSNA 680 680CE 2076811 CE SPOILER MISINSTALLED B K NONE W INADEQUATE Q C IN INSP/MAINT 1 CE 09 301QS 2343 6800010 ROLL SPOILER CABLE P/N S3779-4P233.7M WAS ROUTED INCORRECTLY OVER LOW FRICTION PULLEY. CABLE WAS FOUND ROUTED THROUGH TO OLING HOLE IN BRACKET P/N 6960236-17 RATHER THAN ENGAGING PULLEY. THE BRACKET TOOLING HOLE EXHIBITED WEAR FROM THE CABL E RIDING (CUTTING) INTO THE TOOLING HOLE. 2 L 7 2 4F RC T00012WI 2007071100043 20070711 00043 CE 2007 7 11 2007FA0000550 1 20070621 G 3230 50410015 BELLCRANK CESSNA 310 310R 2074245 CE CONT O520 IO520* 17032 SO ZONE 700 BROKEN D O OTHER O OTHER LD LANDING 1 SO 19 1771G 310R0040 LT MAIN GEAR BELLCRANK ASSY BROKE IN MARCH OF 2007. THE PART WAS REPLACED BY A USED SERVICABLE PART WHICH LASTED APPROXI MATLY 58 HRS. THEN FAILED AT THE SAME LOCATION ON THE PART. 1 L 7 2 3O 3 O 3A10 E5CE 2007071100052 20070711 00052 SO 2007 7 11 2007FA0000552 1 20070622 G 2910 177662 HOSE PIPER PA31T PA31T 7103124 SO HYD SYSTEM RUPTURED D O OTHER K J FLUID LOSS WARNING INDICATION NR NOT REPORTED 1 GL 27 970PS 6349 31T8020023 LT MLG IB GEAR DOOR ACTUATOR HYDRAULIC HOSE, HAD A PRESSURE FAILURE, THUS DRAINING HYDRAULIC FLUID IN FLIGHT, RESULTING IN FAILURE OF PROPER GEAR EXTENSION, EMERGENCY GEAR EXTENSION, AND CAUSING AIRCRAFT GEAR UP LANDING. HYDRAULIC HOSE P/N 17766-2 AND PIPER P/N 465-138. HOSE IS ORIGINAL EQUIPMENT INSTALL. 1 L 7 2 3T A8EA 2007071100116 20070711 00116 WP 2007 7 11 2007FA0000553 2 20070626 G 7200 30751604 ENGINE RAYTHN DH125 HAWKER800XP 7150012 CE GARRTT TFE731 TFE7315BR WP NR 2 BINDING C E ENGINE SHUTDOWN E VIBRATION/BUFFET CR CRUISE 1 WP 07 1781 258593 P107918 IFSD OCCURRED ON JUNE 21ST 2007. AN EMERGENCY WAS DECLARED WHEN THE NR 2 ENGINE ITT CLIMBED TO 1066C FOR 5 SECONDS AT F L 260 AND A HIGH VIBRATION WAS FELT. THE PILOT SHUTDOWN THE ENGINE. ALL PARAMETERS WERE FINE UNTIL THIS EVENT. AN OVE RWEIGHT LANDING INSPECTION WAS PERFORMED ON THE AIRCRAFT WITH NO ABNORMALITIES REPORTED. DISASSEMBLY FINDINGS OF THE EN GINE REVEALED LPC2 DISC POST SEPARATIONS AS LISTED IN SB TFE731-72-3711. 2 L 7 2 4F 4 F RT A3EU E6WE 2007071100127 20070711 00127 2007 7 11 2007FA0000554 4 20070628 G 3457 12744001 ANTENNA CIRRUS SR SR20 05628AJ GL CONT IO360 IO360* 17025 CE GPS DISCONNECTED B O OTHER O OTHER CR CRUISE 1 EA 07 5959A 127 1526 WHILE IN CRUISE FLIGHT THE NR 1 GPS STOPPED RECEIVING A SIGNAL. AFTER LANDING, REMOVED THE MFD AND FOUND THE GLUE HOLDIN G THE VELCRO TO THE GPS ANTENNA HAD COME UNDONE. BOTH GPS ANTENNAS ARE HELD IN PLACE WITH VELCRO STRIPS AND IN THE HEAT OF SUMMER, THE GLUE SOFTENS AND COMES UNDONE. 1 L 7 1 3O 3 O NT A00009CH E1CE 2007071200120 20070712 00120 EA 2007 7 12 2007FA0000555 2 20070616 G 8530 EXHAUST VALVE AMERAC S1 S1AAMERAC WP LYC O235 O235C2C 41505 EA MCAULY 1A105 1A105SCM GL ENGINE BENT G A UNSCHED LANDING Y J ENGINE STOPPAGE WARNING INDICATION CL CLIMB 1 GL 03 5651L 1749 1749 AA10051 L961915 52473 EXHAUST VALVE WAS FOUND STUCK IN THE OPEN POSITION ON TEARDOWN OF THE ENGINE. VALVE STEM HAD A SLIGHT BEND. ENGINE TEA RDOWN WAS DUE TO AN AIRCRAFT ACCIDENT. 1 L 7 1 3R 3 O ATC521 E223 5 N P918 2007071100140 20070711 00140 EU 2007 7 11 2007FA0000556 1 20070628 G 6320 305A32031002 GEARBOX SNIAS 350 AS350B3 8680954 EU TMECA ARRIEL ARRIEL2B1 60056 NE UNKNOWN B A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 EA 17 808CP 161 4151 23335 MGB CHIP LIGHT CAME ON IN FLIGHT. INSPECTED CHIP PLUGS IAW AEC MWC AND SPM. NO FURTHER ACTION REQUIRED. 1 G 7 1 3U 3 U H9EU E00054EN 2007071100141 20070711 00141 EU 2007 7 11 2007FA0000557 1 20070628 G 6320 305A32031002 GEARBOX SNIAS 350 AS350B3 8680954 EU TMECA ARRIEL ARRIEL2B1 60056 NE UNKNOWN B PN1R A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 EA 17 808CP 161 4151 23335 MGB CHIP LIGHT CAME ON IN FLIGHT. INSPECTED CHIP PLUGS IAW AEC MWC AND SPM. NO FURTHER ACTION REQUIRED. 1 G 7 1 3U 3 U H9EU E00054EN 2007071100150 20070711 00150 CE 2007 7 11 2007FA0000558 1 20070510 G 3240 LINE CESSNA 185 A185F 2072821 CE CONT O520 IO520* 17032 SO BRAKE LOOSE D O OTHER O OTHER LD LANDING 1 GL 13 4845E 18503887 RT MAIN BRAKE FAILED ON AIRCRAFT ROLLOUT OF NORMAL CROSSWIND LANDING. BRAKE LINE B-NUT FOUND COMPLETELY LOOSE. (K) 1 H 7 1 3O 3 O 3A24 E5CE 2007071100152 20070711 00152 CE 2007 7 11 2007FA0000559 1 20070525 G 5280 45A303794 DOUBLER BEECH MU300 400BEECH CE PWA JT15 JT15D5 52112 NE MLG DOOR CRACKED B E81R O OTHER O OTHER AP APPROACH 1 GL 03 406TS RJ6 FLIGHT CREW REPORTED RED GEAR UNSAFE INDICATION LIGHT AFTER GEAR EXTENSION FOR APPROACH, ALL (3) LANDING GEARS INDICATIN G DOWN AND LOCKED. PERFORMED ALTERNATE GEAR EXTENSION IAW CHECKLIST. AIRCRAFT FERRIED WITH LANDING GEAR DOWN IAW PERMI T TO FACILITY FOR REPAIRS. AFTER NORMAL LANDING, RT MLG FUSELAGE DOOR UNLATCHED AND DRAGGED ON TAXIWAY DURING TAXI-IN. FOUND DOUBLER UNDER RT FUSELAGE DOOR FORWARD HINGE BRACKET CRACKED, ALSO CRACK IN PN 45A30314-6 FRAME ( U-CHANNEL) AT F ORWARD HINGE AREA. SUSPECT CRACKED AREA ALLOWED ENOUGH PLAY IN DOOR ASSY FOR DOOR UPLOCK NOT TO FULLY ENGAGE. DOOR ASS Y APPEARS TO HAVE BEEN REPAIRED PREVIOUSLY. (K) 2 H 7 2 4F 4 F RT A16SW E25EA 2007071100192 20070711 00192 EU 2007 7 11 2007FA0000560 1 20070521 G 5302 STRUCTURE SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1 60030 NE TAIL BOOM CRACKED B QS7R K NONE O OTHER IN INSP/MAINT 1 NM 09 352EV 2542 2555 A CRACK APPROXIMATELY 170 MM LONG WAS FOUND ON THE LEADING EDGE, AFT OF FWD MOUNT POINT. (K) 1 G 7 1 3U 3 U H9EU E19EU 2007071100196 20070711 00196 WP 2007 7 11 2007FA0000561 1 20070525 G 7600 BUSHING HUGHES 269 269C 4470504 WP LYC O360 HIO360D1A 41514 EA THROTTLE LINKAGE WORN B NTBR K NONE O OTHER IN INSP/MAINT 1 NM 05 1666S 192 S1898 L3316351A ENGINE MOUNTED THROTTLE LINKAGE BUSHINGS WORN. FOUND ON INSPECTION WITH EXCESSIVE PLAY. PROBABLY OCCURRED DUE TO EXCES SIVE VIBRATION OR LACK OF SUBRICATION. RECOMMENDATION TO PREVENT WOULD BE TO LUBRICATE MORE FREQUENTLY OR DIFFERENT DES IGN OF LINKAGE. (K) 1 G 7 1 3O 3 O 4H12 1E10 2007071100198 20070711 00198 EA 2007 7 11 2007FA0000562 2 20070629 G 8550 AE3663162J0230 LINE CESSNA 182 T182T 2072738 CE LYC O540 TIO540A1A 41532 EA ENGINE OIL CRACKED B LJER K NONE O OTHER IN INSP/MAINT 1 NM 09 1328N T18208403 L1196661A 30 DEGREE FITTING HAS CRACK ON WRENCH FLAT. (K) 1 H 7 1 3O 3 O NT 3A13 E14EA 2007071100201 20070711 00201 EA 2007 7 11 2007FA0000563 1 20070507 G 3240 SHAFT SCWZER G164 G164A 3952704 EA BRAKE ROUGH D K NONE O OTHER IN INSP/MAINT 1 SW 15 5149 1123 ON DISASSEMBLY, THE SHAFT WAS FOUND TO BE QUIET ROUGH, WHERE THE PARKING BRAKE TAB LEVER 149-1 ENGAGES WITH THE SHAFT. THIS IS NOT APPARENT UNTIL IT IS REMOVED AND TAKEN APART, AS SPRING 02-9 OBSCURES THE NEW OF IT. TO PREVENT REOCCURRED THE SHAFT SHOULD BE CHECKED AND SMOTHERED OR REPLACED. (K) 1 Q 7 1 3R 1A16 2007071100202 20070711 00202 CE 2007 7 11 2007FA0000564 1 20070519 G 7400 4370 ARM CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA POINTS BROKEN D M90R K NONE O OTHER IN INSP/MAINT 1 GL 09 61953 133 17264910 L4116127A POINTS ARM BROKE IB OF POINTS AFTER ONLY 133.1, TIME SINCE INSTALLATION. (K) 1 H 7 1 3O 3 O NT 3A12 E274 2007071100204 20070711 00204 CE 2007 7 11 2007FA0000565 1 20070606 G 2910 41344 VALVE CESSNA 525 525A 2076615 CE WILINT FJ44 FJ44 66000 GL HYD SYSTEM LEAKING D O OTHER K J FLUID LOSS WARNING INDICATION LD LANDING 1 CE 07 301PG 525A0301 PERFORMED AN EMERGENCY LANDING DUE TO LOSS OF HYDRAULIC PRESSURE. THE EMERGENCY BOTTLE WAS USED TO LOWER THE GEAR AND L AND WITHOUT INCIDENT. THE CAUSE HAS BEEN DETERMINED TO BE THE HYDRAULIC LOADING VALVE (PN 4134-4, SN 781) FAILING IN CL OSED POSITION, RESULTING THE HYDRAULIC FLUID IN THE SYSTEM TO BE DUMPED OUT THE VENT TUBE CAUSING THE LOSS OF HYDRAULIC PRESSURE. IT IS ALSO SUSPECTED THAT THE LOADING VALVES FAILURE, CAUSED THE PCB N2108 (CIRCUIT BOARD) TO FAIL AS WELL. THE PCB 2108 WAS REPLACED. THE AIRCRAFT HYDRAULIC SYSTEM HAS BEEN LEAK CHECKED, OPS CHECKED AND HAS BEEN RETURNED TO SE RVICE WITH NO FURTHER INCIDENTS. 1 L 7 1 4F 4 F RT A1WI E3GL 2007071100209 20070711 00209 CE 2007 7 11 2007FA0000566 1 20070608 G 2800 FUEL CESSNA 525 525 2076601 CE WILINT FJ44 FJ44 66000 GL CONTAMINATED C O OTHER O OTHER LD LANDING 1 EA 65 41YP 5250122 PERFORMED AN EMERGENCY LANDING, DUE TO A FUEL BYPASS LIGHT COMING ON IN FLIGHT. THE AIRCRAFT LANDED AND TAXIED TO THE S ERVICE CENTER WITHOUT INCIDENT. THE CAUSE OF THE LIGHT HAS BEEN DETERMINED TO BE THE FUEL ITSELF. THE FUEL IS CONTAMIN ATED WITH VISIBLE DEBRIS AND HAS A CLOUDY TINT TO IT. THE CAUSE OF THE BYPASS LIGHT IS FROM THE PARTICLES IN THE FUEL C LOGGING THE ENGINE FILTERS. THE FUEL FILTERS ON BOTH THE LT AND THE RT ENGINES HAVE BEEN REPLACED IAW MM. THE AIRCRAFT HAS BEEN RETURNED TO SERVICE. NOTE: THE FUEL WAS NOT PURCHASED FROM SERVICE CENTER. (K) 1 L 7 2 4F 4 F RT A1WI E3GL 2007071100210 20070711 00210 CE 2007 7 11 2007FA0000567 1 20070629 G 6100 9696001123 LINE BEECH 58 58 1152740 CE CONT O550 IO550C SO PROPELLER LEAKING D K NONE O OTHER IN INSP/MAINT 1 SO 11 658RA 1501 TH1892 BAD OIL LEAK: DETERMINED METAL ID PLATE ON MP HOSE WORE HOLE INTO PROP UNFEATHERING ACCUMULATOR TUDE. NOTE: THIS IS TH E SUBJECT OF AD 2007-06-07 AND MANDATORY SB 61-3806 BUT DOES NOT COVER THIS AC SN. (K) 1 L 7 2 3O 3 O 3A16 E3SO 2007071100212 20070711 00212 CE 2007 7 11 2007FA0000568 1 20070629 G 3260 602EN6026 UPLOCK SWITCH CESSNA 650 650 2076802 CE NLG DEFECTIVE B EWCR O OTHER N FALSE WARNING CL CLIMB 1 EA 39 750CK 6507015 GEAR SELECTED UP AFTER TAKEOFF. UNSAFE LIGHT WOULD NOT GO OUT AND AIR NOISE FROM NOSE GEAR DOORS OPEN. 2 GEAR CYCLE AT TEMPTS WITH NO CHANGE. RETURNED TO GSO (PTI) AIRPORT, LANDED WITH NORMAL GREEN LIGHTS. AIRCRAFT TURNED OVER TO MFG SER VICE CENTER FOR REPAIR. NOSE GEAR UPLOCK SWITCH FOUND DEFECTIVE. REPLACED SWITCH OPERATION CHECKED NORMAL. (K) 2 L 7 2 4F A9NM 2007071100214 20070711 00214 EU 2007 7 11 2007FA0000569 1 20070517 G 7700 642795431 TRANSMITTER AMD FALC90 FALCON900EX 2730009 EU GARRTT TFE731 TFE73160 NE ENGINE READS LOW B UO2R O OTHER N FALSE WARNING CL CLIMB 1 GL 19 127SF 5144 013 P112149 THE AIRCRAFT WAS CLIMBING AND THE NR 3 ENGINE OIL PRESSURE INDICATION STARTED TO DROP. AT 46 PSI IT WENT RED AND THE PI LOT SHUTDOWN THE ENGINE AND LANDED THE AIRCRAFT. THE OIL LEVEL WAS IN LIMITS AND NO EXTERNAL LEAKS WERE FOUND. A DIRE CT READING PRESSURE GAGE WAS INSTALLED AND SHOWED GOOD OIL PRESSURE AND THAT THE INDICATOR WAS READING LOW. A NEW OIL P RESSURE TRANSMITTER WAS INSTALLED AND CORRECTED THE LOW READING PROBLEM. (K) 2 L 7 3 4F 4 F RT A46EU E1NM 2007071100215 20070711 00215 CE 2007 7 11 2007FA0000570 1 20070529 G 5311 5511118200 FRAME CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE FUSELAGE DAMAGED C JGVR K NONE W INADEQUATE Q C IN INSP/MAINT 1 CE 09 905CW 9359 5500072 FUSELAGE FRAME WEB DAMAGED BY DRILL BIT FROM THE BEND RADIUS OF THE OUTER (SKIN) FLANGE. REPLACEMENT REQUIRED SRM, CHAP TER 53-12-27. PROBABLE CAUSE: INCORRECTLY DRILLED AT AIRCRAFT MFG. (K) 1 L 7 2 4F 4 F A22CE E1NE 2007071100218 20070711 00218 SO 2007 7 11 2007FA0000571 1 20070531 G 3220 67107000 BRACKET PIPER PA28 PA28R200 7102811 SO CONT IO360 IO360* 17025 CE NOSE GEAR FAILED H O OTHER O OTHER LD LANDING 1 SO 33 56066 28R7335346 THE PILOT STATED NOSE GEAR COLLAPSED ON LANDING. AFTER AIRCRAFT REMOVED FROM RUNWAY AND PUT ON JACKS. THE NOSE GEAR WO ULD NOT EXTEND OR RETRACT. THE GEAR WAS EXTENDED BY EMERGENCY EXTENSION. THE NOSE GEAR ALIGNER BRACKET FELL OFF THE GE AR. AGAIN THE NOSE GEAR WAS EXTENDED AND RETRACTED SEVERAL TIMES. THE TT OF THE NOSE GEAR ALIGNER BRACKET COULD NOT BE DETERMINED. (K) 1 L 7 1 3O 3 O 2A13 E1CE 2007071100219 20070711 00219 CE 2007 7 11 2007FA0000572 1 20070525 G 2720 S16751 BEARING CESSNA 210 T210M 2073451 CE RUDDER PEDAL BROKEN D K NONE O OTHER IN INSP/MAINT 1 WP 23 808FS 2721 21061586 WHILE PERFORMING RUN UP OF AIRCRAFT DURING ANNUAL INSPECTION IT WAS NOTICED THAT PILOT RT RUDDER PEDAL HAD AN UNUSUAL FE EL WHILE BRAKING. DURING THE INSPECTION OF THE RUDDER PEDALS IT WAS FOUND THT THE EACH OF THE PILOT SIDE S1675-1 RUDDER IB BEARING HALF HAD BROKEN INTO SEVERAL PARTS. THE S1675-1 BEARING HALFS ARE CONSTRUCTED OF PLASTIC, AND THE LIKELY RE ASON FOR BREAKING WOULD BE DUE TO THE AGING AND EMBRITTLEMENT OF THE PLASTIC. I WOULD RECOMMEND THAT THE BEARINGS BE CO NSTRUCTED OF A MATERIAL OTHER THAN PLASTIC, OF HAVE A PART REPLACEMENT INTERVAL BEFORE BREAKAGE COULD OCCUR. (K) 1 H 7 1 3O 3A21 2007071100220 20070711 00220 CE 2007 7 11 2007FA0000573 1 20070606 G 2720 25137911 PIN CESSNA 208 208B 2073701 CE PWA PT6 PT6* 52043 EA RUDDER PEDAL UNSERVICEABLE B ES4R K NONE O OTHER IN INSP/MAINT 1 AL 01 4365U 18129 208B0253 ON A ROUTINE INSPECTION, A MECHANIC FOUND THAT THE PILOTS RT RUDDER PEDAL PIN WAS ABOUT TO FALL OUT OF THE RUDDER PEDAL. FURTHER INSPECTION FOUND THAT THE ROLL PIN PN: NAS561C318 HAD FALLEN OUR OF ITS HOLE CAUSING THE RUDDER PEDAL PIN TO M IGRATE FROM ITS POSITION. INSPECTION OF RUDDER PEDAL ASSY FOUND THAT THE ROLL PIN HOLE IN THE RUDDER PEDAL HAD BECOME E NLARGED, DUE TO AN UNKNOWN REASON. RECOMMENDATION TO PREVENT RECURRENCE: ATTENTION TO ROLL PIN INSTALLATION FOR ADEQUA TE PRESS FIT AND ADDITIONAL ATTENTION OF ROLL PIN ON ROUTINE INSPECTION. (K) 1 H 7 1 3T 3 T A37CE E2NE 2007071100221 20070711 00221 CE 2007 7 11 2007FA0000574 1 20070629 G 3244 265F868 TIRE BEECH B300 B300 1159232 CE PWA PT6 PT6* 52043 EA NLG UNBALANCED B FTUR K NONE O OTHER IN INSP/MAINT 1 NE 05 5XM 408 FL115 PILOT REPORTED A NOSE SHIMMY, UPON INVESTIGATION IT WAS DETERMINED THAT THE MFG BALANCE WEIGHT HAD COME LOOSE. THIS IS THE SECOND OCCURRENCE OF THIS TYPE FOR THE OPERATOR. (K) 2 L 7 2 4T 3 T RT A24CE E2NE 2007071100222 20070711 00222 NE 2007 7 11 2007FA0000575 2 20070602 G 7321 0292858360 HMU UROCOP EC130 EC130B4 8680989 EU TMECA ARRIEL ARRIEL2B1 60056 NE ENGINE FAILED D O OTHER O OTHER NR NOT REPORTED 1 CE 01 151AC 1609 3732 23065 THE PILOT REPORTED A LOUD THUD AND A SUBSEQUENT YAWING OF THE AC, WITH CONTINUED YAWING OF THE AC, AND NO INDICATION ON THE COCKPIT INSTRUMENTATION THAT HE NOTICED. THE PILOT DECLARED AN EMERGENCY AND PERFORMED AN AUTORATATIVE LANDING AT T HE AIRPORT. THE VEHICLE AND ENGINE MULTIFUNCTION DISPLAY, DISPLAYED FAILURE OF CHANNEL A. THE EC130 IS EQUIPPED WITH A DUAL CHANNEL FADEC SYSTEM WITH A MECHANICAL BACKUP. IN THE FOLLOWING TROUBLESHOOTING PROCESS IT WAS FOUND THAT THE RES OLVER MOTOR ON THE FUEL CONTROL (HMU) HAD A RESISTANCE VALUE THAT WAS OUT OF TOLERANCE. A FIELD TECH WAS BROUGHT IN FR OM MFG TO PERFORM FURTHER TESTING, SINCE THE FAILURE OF ONE CHANNEL OF THE FADEC AND THE SUBSEQUENT SWITCHING TO THE OTH 1 G 7 2 3U 3 U H9EU E00054EN 2007071100232 20070711 00232 CE 2007 7 11 2007FA0000576 1 20070611 G 5300 STRUCTURE BEECH B300 B300 1159232 CE PWA PT6 PT6A60A 52043 NE FUSELAGE MISINSTALLED B BWVR K NONE W INADEQUATE Q C IN INSP/MAINT 1 CE 07 7262U FL532 THE AIRCRAFT ARRIVED NEW FROM THE FACTORY FOR AVIONICS MODIFICATIONS AND DURING OUR INCOMING INSPECTION A TECH NOTED MIS SING RIVETS IN (2) STRINGER CLIPS. THE CLIPS ARE LOCATED AT FS 386 ON THE RT NR3 AND RT NR 5 STRINGERS AS NOTED USING T HE UPPER CENTERLINE STRINGER AS STRINGER NR 1. EACH CLIP WITH (6) RIVETS EACH WERE EITHER MISSING RIVETS AND/OR THE RIV ETS WERE NOT BUCKED SITTING IN THE HOLES. ADVISED MFG OF DISCREPANCY. (K) 2 L 7 2 4T 4 T RT A24CE E4EA 2007071100233 20070711 00233 SO 2007 7 11 2007FA0000577 1 20070512 G 3220 6715003 DOWNLOCK PIPER PA28 PA28R200 7102811 SO CONT IO360 IO360* 17025 CE NLG BROKEN G K NONE O OTHER IN INSP/MAINT 1 GL 03 5094S 3220 28R7135094 THE LOWER LATCH HOOK WAS BROKEN OFF ALLOWING THE NOSE GEAR TO COLLAPSE. (K) 1 L 7 1 3O 3 O 2A13 E1CE 2007071100246 20070711 00246 CE 2007 7 11 2007FA0000578 1 20070605 G 5343 FMI32345010B BUSHING CESSNA 750 750 2076810 CE ALLSN AE3007 AE3007C GL TRUNNION GOUGED B NOZR K NONE O OTHER IN INSP/MAINT 1 WP 23 22NG 7500204 BUSHINGS WHERE OLEO ATTACHES TO TRUNNION. OLEO ATTACH BOLT WAS SEIZED AND HARD TO REMOVE. INNER BORE OF BUSHINGS WERE GOUGED. NO MEANS TO LUBRICATE THESE BUSHINGS EXCEPT AT ASSY. SUGGEST USE OF ANT SEIZE COMPOUND DURING ASSY INSTEAD OF AEROSHELL 17. (K) 2 L 7 2 4J 4 F RT T00007WI TE6CH 2007071100247 20070711 00247 CE 2007 7 11 2007FA0000579 1 20070605 G 5343 67410261 TRUNNION CESSNA 750 750 2076810 CE ALLSN AE3007 AE3007C GL MLG MISALIGNED B NOZR K NONE O OTHER IN INSP/MAINT 1 WP 23 22NG 7500204 AFT TRUNNION ATTACH PIN LOCK PIN HOLE MISALIGNED. LOCK PIN HOLES DRILLED IN TRUNNION DO NOT LINE UP WITH HOLE DRILLED I N MOUNTING PIN. (K) 2 L 7 2 4J 4 F RT T00007WI TE6CH 2007071100249 20070711 00249 CE 2007 7 11 2007FA0000580 1 20070427 G 8011 MHB4016R STARTER CESSNA 182 R182 2072734 CE LYC O540 O540* 41532 EA ENGINE FAILED D K NONE O OTHER IN INSP/MAINT 1 SW 03 182MS 18200791 REMOVED THIS STARTER FROM AIRCRAFT DUE TO BENDIX FAILURE. TIME ON THIS STARTER IS UNKNOWN. (K) 1 H 7 1 3O 3 O RT 3A13 E295 2007071100257 20070711 00257 CE 2007 7 11 2007FA0000581 1 20070518 G 8011 MHB4016R STARTER CESSNA 182 R182 2072734 CE LYC O540 O540* 41532 EA ENGINE MALFUNCTIONED D K NONE O OTHER IN INSP/MAINT 1 SW 03 182MS 62 18200791 REMOVED THIS STARTER FROM SAME AIRCRAFT FOR THE 3RD TIME WITH 62.3 HRS SINCE OVERHAUL. STARTER BENDIX WOULD NOT ENGAGE ANYMORE DURING START UP. NO PROBLEM COULD BE FOUND WITH AIRCRAFT ELECTRICAL SYSTEM. (K) 1 H 7 1 3O 3 O RT 3A13 E295 2007071100258 20070711 00258 CE 2007 7 11 2007FA0000582 1 20070430 G 8011 MHB4016R STARTER CESSNA 182 R182 2072734 CE LYC O540 O540* 41532 EA ENGINE FAILED D K NONE O OTHER IN INSP/MAINT 1 SW 03 182MS 18200791 REMOVED THIS STARTER WITH 3.3 HOURS SINCE OVERHAUL. STARTER BENDIX STAYED ENGAGED DURING START UP. NO PROBLEM COULD BE FOUND WITH AIRCRAFT ELECTRICAL SYSTEM. (K) 1 H 7 1 3O 3 O RT 3A13 E295 2007071100259 20070711 00259 CE 2007 7 11 2007FA0000583 1 20070524 G 8011 MHB4016R STARTER CESSNA 182 R182 2072734 CE LYC O540 O540* 41532 EA ENGINE DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 SW 03 182MS 18200791 REMOVED THIS STARTER FROM SAME AIRCRAFT FOR THE 4TH TIME WITH 11.3 HOURS SINCE OVERHAUL. STARTER BENDIX WOULD NOT ENGAG E ANYMORE DURING STARTUP. NO PROBLEM COULD BE FOUND WITH AIRCRAFT ELECTRICAL SYSTEM. INSTALLED ON ANOTHER AIRCRAFT TO VERIFY PROBLEM AND FOUND THAT THE STARTER WAS DEFECTIVE. (K) 1 H 7 1 3O 3 O RT 3A13 E295 2007071100265 20070711 00265 CE 2007 7 11 2007FA0000584 1 20070521 G 3231 HM4 ROD END CESSNA 310 310P 2074238 CE CONT O470 IO470* 17026 SO NOSE GEAR DOOR FAILED D O OTHER O OTHER CR CRUISE 1 SO 15 5918M 310P0218 ROD END FAILED, ALLOWING NOSE GEAR DOOR TO PARTIALLY CLOSE IN FLIGHT. WHEN GEAR WAS RETRACTED, JAMMED NOSE GEAR ASSY AL ONG WITH GEAR DOOR UP IN GEAR WELL. (K) 1 L 7 2 3O 3 O 3A10 E1CE 2007071100266 20070711 00266 EA 2007 7 11 2007FA0000585 1 20070507 G 5100 AN837A BOLT SCWZER G164 G164A 3952704 EA PWA R1340 R1340AN1 52016 NE UNKNOWN BROKEN C O OTHER O OTHER LD LANDING 1 SW 15 5149 1123 THE BOLTS FAILED DUE TO LANDING WITH WHEEL LOCKED. THINK THE BOLTS WERE FINE BEFORE THIS INCIDENT. (K) 1 Q 7 1 3R 3 R 1A16 5E2 2007071100268 20070711 00268 NM 2007 7 11 2007FA0000588 1 20070413 G 3240 BRAKE DISC BOEING 727 727200 138407E NM LT MLG MALFUNCTIONED H K NONE O OTHER IN INSP/MAINT 1 SW 99 HP161 20780 (REG NR: HP1610) DURING PREFLIGHT INSPECTION, FOUND MAIN TIRE NR 2 WITH FLAT SPOT. ON THIS AIRCRAFT OP SPECS APPROVED BY THIS DGAC, OPERATING BY DHL OF GUATEMALA UNDER THEM. REMOVED AND REPLACED MWA AND BRAKE ASSY. NR 2 DUEL TO DAMAGED , ALSO MAIN WHEEL ASSY NR 1 WAS REPLACED , BECAUSE IT RAN WITH THE TIRE NR 2 DEFLATED. (K) 2 L 7 3 4F RT A3WE 2007071200121 20070712 00121 2007 7 12 2007FA0000589 2 20070622 G 7414 1068256013 GEAR MAGNETO DAMAGED G K NONE E VIBRATION/BUFFET NR NOT REPORTED 1 CE 01 720 REPAIR STATION RECEIVED MAGNETO FOR REPAIR. WHEN THE UNIT WAS DISASSEMBLED IT WAS NOTED BOTH DISTRIBUTOR GEARS TCM PN 10 -682016 WERE MISSING TEETH. IT WAS NOTED THAT A PATTERN OF TEETH THAT WERE MISSING COULD BE SEEN. A TOTAL OF 5 TEETH WER E MISSING FROM BOTH GEARS. WHAT SEEMS TO HAPPEN IS WHEN THE IMPULSE SNAPS THE IMPULSE SNAPS THAT TOOTH OFF THE GEAR? WHE N ASSEMBLED TO VIEW THE GEAR POSITION IT WAS NOTED THAT ONE TOOTH WAS MISSING WITH FIVE EACH OF THE SIX TOTAL ENGAGEMENT S OF THE IMPULSE. ITEMS THAT COULD CONTRIBUTE TO THIS PROBLEM CAN BE FOUND IN SB658. IT IS RECOMMENDED TO FOLLOW SB658 A ND TO INSPECT THE DISTRIBUTOR GEARS ON ALL IMPULSE D-3000 OR D-2000 UNITS FOR WEAR AT EVERY 100 HRS BY REMOVING THE MAGN 2007071200122 20070712 00122 SO 2007 7 12 2007FA0000590 2 20070527 G 7414 10382585 CONTACTOR D4LN2021 CONT O360 IO360A 17025 SO MAGNETO MELTED D E B A ENGINE SHUTDOWN EMER. DESCENT UNSCHED LANDING G Y MULTIPLE FAILURE ENGINE STOPPAGE CR CRUISE 1 NM 03 134DC 114 R2388K L1176351A AIRCRAFT HAD DEPARTED FOR A SIGHT SEEING TRIP. ON THE RETURN, ALL ENGINE POWER WAS LOST, THE AIRCRAFT WAS LANDED IN A ME ADOW WITH MINIMAL DAMAGE TO THE AIRCRAFT. UPON INSPECTION OF THE ENGINE, FOUND THAT THE MFG DUAL MAGNETO D4LN-2021 WAS NOT FUNCTIONAL ON EITHER MAG. UPON FURTHER INVESTIGATION IT WAS DETERMINED THAT THE CAM FOLLOWERS OF THE POINTS HAD GOT TEN TOO HOT AND MELTED TO A POINT THAT RENDERED THE CONTACT ASSEMBLY INOPERATIVE, CAUSING A DUAL FAILURE OF THE MAG. IT WAS NOTED THAT THE SCREW THAT HOLDS THE POINTS CAM IN PLACE HAD A TORQUE CHECK PAINTED ON IT AND HAD TURNED BLACK FROM HEAT. DUE TO THE FACT THAT THE DUAL MAG HAS MORE POSSIBILITIES TO PRODUCE MORE HEAT JUST FROM THE ELECTRICAL PART OF MA 3 O E1CE 2007071200125 20070712 00125 SO 2007 7 12 2007FA0000592 2 20070703 G 8530 SA10203 CYLINDER CESSNA 172 172E 2072412 CE CONT O300 O300D 17022 SO MCAULY 1C172 1C172EM GL NR 5 SEPARATED G E ENGINE SHUTDOWN D INFLIGHT SEPARATION CR CRUISE 1 EA 63 5436T 850 17251336 34640D6D 78634 CYLINDER BARREL SEPARATED APPROXIMATELY 2 NR ABOVE THE CYLINDER BASE FLANGE. 1 H 7 1 3O 3 O NT 3A12 E253 5 N P910 2007071200132 20070712 00132 NM 2007 7 12 2007FA0000593 1 20070703 G 5751 25W171124 SUPPORT FITTING ISRAEL 1125 1125 NM GARRTT TFE731 TFE731* 01518 WP AILERONS DAMAGED B K NONE W INADEQUATE Q C IN INSP/MAINT 1 CE 09 49MN 7037 019 AFTER REMOVAL OF AILERON AND SERVICE SUPPORT FITTING AT BL 9R FUSELAGE STATION 199.579. FOUND SEVERAL MISSED DRILLED/EL ONGATED /FILLED FASTENER HOLES IN T CASTING P/N:25W17124, ANGLE P/N:25W171126 AND AILERON AND SERVICES SUPPORT FITTING CASTING P/N:25W353216 2 L 7 2 4F 4 F RT A16NM E6WE 2007071700012 20070717 00012 NM 2007 7 17 2007FA0000594 1 20070703 G 5751 25W171124 SUPPORT FITTING ISRAEL 1125 1125 NM GARRTT TFE731 TFE731* 01518 WP AILERON MISMANUFACTURED B K NONE W INADEQUATE Q C IN INSP/MAINT 1 CE 09 49MN 7037 019 AFTER REMOVAL OF AILERON AND SERVICE SUPPORT FITTING AT BL 9R FUSELAGE STATION 199.579. FOUND SEVERAL MISSED DRILLED/ELO NGATED /FILLED FASTENER HOLES IN T CASTING P/N:25W17124, ANGLE P/N:25W171126 AND AILERON AND SERVICES SUPPORT FITTING CA STING P/N:25W353216 2 L 7 2 4F 4 F RT A16NM E6WE 2007071800219 20070718 00219 EU 2007 7 18 2007FA0000599 1 20070616 G 2701 103B4411 CONTROL COLUMN GROB 103TWN G103ATWINII 1660206 EU COCKPIT FRACTURED D B A EMER. DESCENT UNSCHED LANDING F FLT CONT AFFECTED CL CLIMB 1 NM 07 4446Y 2650 3825 ON SECOND FLT OF DAY, & WHILE STILL ON AERO-TOW, PILOT WHO WAS FLYING FROM THE REAR SEAT WITH A NON-PILOT PASSENGER IN F RONT, NOTICED THAT IT REQUIRED APPROXIMATELY 20 DEGREES OF RT-STICK CORRECTION TO MAINTAIN LEVEL FLT. PILOT ALSO OBSERV ED AILERONS TO BE IN A NEUTRAL POSITION WITH THIS RT-STICK CORRECTION. PILOT RELEASED FROM TOW, & RETURNED TO AIRPORT & EXECUTED A SUCCESSFUL, UNEVENTFUL LANDING USING MINIMAL, LIGHT CONTROL STICK INPUTS. POST FLT INSPECTION OF AFT CONTROL STICK REVEALED CONTROL COLUMN BASE UNIT TUBING STUB OVER WHICH DETACHABLE REAR CONTROL STICK MOUNTS, TO BE FRACTURED, AP PROXIMATELY 80 PERCENT OF ITS TOTAL CIRCUMFERENCE. IT REQUIRED ONLY MINIMUM FURTHER (BENDING) OF THE CONTROL STICK TO AC 1 K 0 0 3O 0 G39EU 2007071800235 20070718 00235 SO 2007 7 18 2007FA0000601 1 20070710 G 2910 MS21911D6 FITTING GULSTM G1159 GIV 3980115 SO RROYCE TAY TAY6108 NE HYD LINE CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 EA 23 177BB 1073 FOUND CRACKED HYDRAULIC TEE FITTING, PN MS21911D6, IN AUXILIARY HYDRAULIC SYSTEM FILTER RETURN LINE. CRACK WAS FOUND AT THE MALE END WHERE END AND TEE BODY COME TOGETHER. REPLACED FITTING AND PRESSURIZED AND LEAK CHECKED SYSTEM. OP'S CHECK WAS GOOD, NO LEAKS NOTED. 2 L 7 2 4F 4 F RT A12EA E25NE 2007071800237 20070718 00237 SO 2007 7 18 2007FA0000602 1 20070710 G 2910 MS21911D6 FITTING GULSTM G1159 GIV 3980115 SO RROYCE TAY TAY6108 NE HYD LINE CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 EA 23 177BB 1073 FOUND CRACKED HYDRAULIC TEE FITTING, PN MS21911D6, IN AUXILIARY HYDRAULIC SYSTEM FILTER RETURN LINE. CRACK WAS FOUND AT THE MALE END WHERE END AND TEE BODY COME TOGETHER. REPLACED FITTING AND PRESSURIZED AND LEAK CHECKED SYSTEM. OP'S CHECK WAS GOOD, NO LEAKS NOTED. 2 L 7 2 4F 4 F RT A12EA E25NE 2007071800238 20070718 00238 SO 2007 7 18 2007FA0000603 1 20070710 G 2910 MS21911D6 FITTING GULSTM G1159 GIV 3980115 SO RROYCE TAY TAY6108 NE HYD LINE CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 EA 23 177BB 1073 FOUND CRACKED HYDRAULIC TEE FITTING, PN MS21911D6, IN AUXILLIARY HYDRAULIC SYSTEM FILTER RETURN LINE. CRACK WAS FOUND AT THE MALE END WHERE END AND TEE BODY COME TOGETHER. REPLACED FITTING AND PRESSURIZED AND LEAK CHECKED SYSTEM. OP'S CHECK WAS GOOD, NO LEAKS NOTED. 2 L 7 2 4F 4 F RT A12EA E25NE 2007071700013 20070717 00013 SO 2007 7 17 2007FA0000604 1 20070710 G 2910 MS21911D6 TEE FITTING GULSTM G1159 GIV 3980115 SO RROYCE TAY TAY6108 NE HYD SYSTEM CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 EA 23 177BB 1073 FOUND CRACKED HYDRAULIC TEE FITTING, PN MS21911D6, IN AUXILIARY HYDRAULIC SYSTEM FILTER RETURN LINE. CRACK WAS FOUND AT THE MALE END WHERE END AND TEE BODY COME TOGETHER. REPLACED FITTING AND PRESSURIZED AND LEAK CHECKED SYSTEM. OP'S CHECK WAS GOOD, NO LEAKS NOTED. 2 L 7 2 4F 4 F RT A12EA E25NE 2007071700014 20070717 00014 SO 2007 7 17 2007FA0000605 1 20070710 G 2910 MS21911D6 TEE FITTING GULSTM G1159 GIV 3980115 SO RROYCE TAY TAY6108 NE HYD SYSTEM CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 EA 23 177BB 1073 FOUND CRACKED HYDRAULIC TEE FITTING, PN MS21911D6, IN AUXILIARY HYDRAULIC SYSTEM FILTER RETURN LINE. CRACK WAS FOUND AT THE MALE END WHERE END AND TEE BODY COME TOGETHER. REPLACED FITTING AND PRESSURIZED AND LEAK CHECKED SYSTEM. OP'S CHEC K WAS GOOD, NO LEAKS NOTED. 2 L 7 2 4F 4 F RT A12EA E25NE 2007071700018 20070717 00018 EU 2007 7 17 2007FA0000606 1 20070712 G 2913 350A35109221 SHAFT SNIAS 350 AS350B3 8680954 EU TMECA ARRIEL ARRIEL2B 60037 NE HYD PUMP WORN B K NONE O OTHER IN INSP/MAINT 1 SW 15 186AE 545 3872 22484 DURING DAILY INSPECTION DISCOVERED EXCESSIVE PLAY IN HYDRAULIC PUMP DRIVE PULLEY. HYDRAULIC PUMP DRIVE WAS THEN REMOVED FOR FURTHER INSPECTION. IT WAS DISCOVERED THAT THE DRIVE PULLEY SHAFT HAD WORN EXCESSIVELY WHERE THE DRIVE BEARING HAD B EEN SPINNING AROUND IT. THE DRIVE BEARING APPEARED TO BE FINE WITH NO BINDING NOTICED. IT APPEARS THAT THE FIT OF THE BE ARING ONTO THE PULLEY WAS NOT TIGHT ENOUGH TO KEEP THE BEARING RACE FROM SPINNING. 1 G 7 1 3U 3 U H9EU E00054EN 2007071700019 20070717 00019 EU 2007 7 17 2007FA0000607 1 20070712 G 2913 350A35109221 PULLEY SNIAS 350 AS350B3 8680954 EU TMECA ARRIEL ARRIEL2B 60037 NE HYD PUMP WORN B K NONE O OTHER IN INSP/MAINT 1 SW 15 186AE 545 3872 22484 DURING DAILY INSPECTION DISCOVERED EXCESSIVE PLAY IN HYDRAULIC PUMP DRIVE PULLEY. HYDRAULIC PUMP DRIVE WAS THEN REMOVED FOR FURTHER INSPECTION. IT WAS DISCOVERED THAT THE DRIVE PULLEY SHAFT HAD WORN EXCESSIVELY WHERE THE DRIVE BEARING HAD B EEN SPINNING AROUND IT. THE DRIVE BEARING APPEARED TO BE FINE WITH NO BINDING NOTICED. IT APPEARS THAT THE FIT OF THE BE ARING ONTO THE PULLEY WAS NOT TIGHT ENOUGH TO KEEP THE BEARING RACE FROM SPINNING. 1 G 7 1 3U 3 U H9EU E00054EN 2007071700015 20070717 00015 SO 2007 7 17 2007FA0000608 1 20070710 G 2910 MS21911D6 TEE FITTING GULSTM G1159 GIV 3980115 SO RROYCE TAY TAY6108 NE HYD SYSTEM CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 EA 23 177BB 1073 FOUND CRACKED HYDRAULIC TEE FITTING, PN MS21911D6, IN AUXILIARY HYDRAULIC SYSTEM FILTER RETURN LINE. CRACK WAS FOUND AT THE MALE END WHERE END AND TEE BODY COME TOGETHER. REPLACED FITTING AND PRESSURIZED AND LEAK CHECKED SYSTEM. OP'S CHECK WAS GOOD, NO LEAKS NOTED. 2 L 7 2 4F 4 F RT A12EA E25NE 2007071700016 20070717 00016 SO 2007 7 17 2007FA0000609 1 20070710 G 2910 MS21911D6 TEE FITTING GULSTM G1159 GIV 3980115 SO RROYCE TAY TAY6108 NE HYD SYSTEM CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 EA 23 177BB 1073 FOUND CRACKED HYDRAULIC TEE FITTING, PN MS21911D6, IN AUXILIARY HYDRAULIC SYSTEM FILTER RETURN LINE. CRACK WAS FOUND AT THE MALE END WHERE END AND TEE BODY COME TOGETHER. REPLACED FITTING AND PRESSURIZED AND LEAK CHECKED SYSTEM. OP'S CHE CK WAS GOOD, NO LEAKS NOTED. 2 L 7 2 4F 4 F RT A12EA E25NE 2007071700017 20070717 00017 SO 2007 7 17 2007FA0000610 1 20070710 G 2910 MS21911D6 TEE FITTING GULSTM G1159 GIV 3980115 SO HYD SYSTEM CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 EA 23 177BB 1073 FOUND CRACKED HYDRAULIC TEE FITTING, PN MS21911D6, IN AUXILIARY HYDRAULIC SYSTEM FILTER RETURN LINE. CRACK WAS FOUND AT THE MALE END WHERE END AND TEE BODY COME TOGETHER. REPLACED FITTING AND PRESSURIZED AND LEAK CHECKED SYSTEM. OP'S CHECK WAS GOOD, NO LEAKS NOTED. 2 L 7 2 4F RT A12EA 2007071800239 20070718 00239 SO 2007 7 18 2007FA0000611 1 20070710 G 2910 MS21911D6 FITTING GULSTM G1159 GIV 3980115 SO RROYCE TAY TAY6108 NE HYD LINE CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 EA 23 177BB 1073 FOUND CRACKED HYDRAULIC TEE FITTING, PN MS21911D6, IN AUXILIARY HYDRAULIC SYSTEM FILTER RETURN LINE. CRACK WAS FOUND AT THE MALE END WHERE END AND TEE BODY COME TOGETHER. REPLACED FITTING AND PRESSURIZED AND LEAK CHECKED SYSTEM. OP'S CHECK WAS GOOD, NO LEAKS NOTED. 2 L 7 2 4F 4 F RT A12EA E25NE 2007071800246 20070718 00246 EU 2007 7 18 2007FA0000612 1 20070711 G 2741 EM40112 ACTUATOR PIAGIO P180 P180 6960204 EU PWA PT6 PT6A66 52043 NE PITCH TRIM FAILED C O OTHER F FLT CONT AFFECTED AP APPROACH 1 WP 15 5166P 61 1129 ON APPROACH PITCH TRIM ACTUATOR FAILED TO MOVE. AIRCRAFT LANDED WITH PARTIAL FLAPS WITHOUT FURTHER INCIDENT. ONE HOUR LATER TRIM ACTUATOR GROUND TESTED REVEALING NO DEFECTS. ACTUATOR SENT TO MFG FOR INVESTIGATION. 1 H 7 2 3O 4 T RT A59EU E26NE 2007071800270 20070718 00270 CE 2007 7 18 2007FA0000613 1 20070713 G 3350 BATTERY BEECH B300 B300 1159232 CE EMERGENCY LIGHT MELTED B K NONE L NO TEST IN INSP/MAINT 1 NE 05 122RG FL448 AIRCRAFT WAS IN MAINTENANCE FOR AN INSPECTION AND 12 MONTH EMERGENCY LIGHT BATTERY CHANGE. FOUND BATTERIES SEVERELY COR RODED AND HEAT DAMAGED. BATTERIES INSTALLED WERE P/N MN1400. THESE BATTERIES HAVE A TEST STRIP EFFECTIVELY SHORTS THE BATTERY TO CHECK THE CHARGE CONDITION. THE BATTERY HOLDER IN THE EMERGENCY LIGHT ASSEMBLY CLAMPS THE BATTERY. THE BATTE RIES WERE INSTALLED SO THE TEST STRIP WAS CLAMPED SHORTING THE BATTERIES CAUSING THE BATTERIES TO MELT AND CORROD IN THE HOLDERS, DESTROYING THE LIGHT ASSEMBLIES. THE P/N FOR THE BATTERIES FOR THE EMERGENCY LIGHT IS 14A, BATTERIES WHICH HAV E NO TEST STRIP. USE THE CORRECT P/N BATTERIES. 2 L 7 2 4T RT A24CE 2007071900120 20070719 00120 CE 2007 7 19 2007FA0000617 1 20070718 G 2731 556545098 ACTUATOR CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE RT STAB WORN B K NONE O OTHER IN INSP/MAINT 1 SW 13 26494 9131 1200 0605 AT THE PHASE 5 INSPECTION THE ELEVATOR FAILED THE FREE PLAY CHECK. A OVERHAULED UNIT P/N 5565450-98 S/N 0320-63 WAS INST ALLED AND COULD NOT GET THE UP AND DOWN LIMITS TO COME IN TO SPECS. ON CLOSER INSPECTION IT WAS FOUND THAT THE PRIMARY D RIVE GEAR HAS 16 TEETH AND THE ORIGINAL UNIT HAS 14 TEETH. THIS UNIT WAS OVERHAULED 6/8/2007. AS OF THIS WRITING WE ARE IN THE PROCESS OF INSTALLING ANOTHER UNIT WITH THE CORRECT NUMBER OF TEETH. 1 L 7 2 4F 4 F A22CE E1NE 2007071900142 20070719 00142 CE 2007 7 19 2007FA0000618 1 20070717 G 2700 07136242 ANCHOR CESSNA CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA MCAULY 1A170 1A170E GL MASTER CYLINDER WORN D K NONE O OTHER UK UNKNOWN 1 SO 09 3140 172S9480 L1306651A XB23004 ANCHOR PN 0713624-2, FOUND WORN ALMOST THROUGH BY THE STEEL PIN USED TO HOLD MASTER CYLINDER. ANCHOR IS ALUMINUM WHICH W AS QUICKLY WORN OUT BY THE STEEL PIN. IF PIN BREAKS FREE FROM THE ANCHOR THE MASTER CYLINDER CAN STOP MOVEMENT OF THE R UDDER PEDAL. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P857 2007071900144 20070719 00144 NM 2007 7 19 2007FA0000619 1 20070717 G 5714 F13147LR SKIN UNIVAR 415 415C 0420302 NM CONT A75 A75* 17005 SO CENTER WING CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 01 2048H 2500 10 2671 (5) MISSING AN426-3 RIVET HEADS ON LOWER CENTER SECTION SKINS PN F13147-L/-R PROMPTED INSPECTION HOLE INSTALLATION IAW S B-31 FOR REPAIR ACCESS. LIGHT SURFACE CORROSION WAS FOUND ON LOWER SKINS AND STIFFENERS. BOTH SIDES WERE CLEANED AND TRE ATED FOR CORROSION. DURING CLEANING FOUND A 2 INCH SKIN CRACK IN AFT SECTION OF F13147-L AND A .5 INCH CRACK AT THE LOW ER FWD TAB OF RIB PN F13016L, BOTH REPAIRED IAW AC 43.13-1B GUIDELINES. FUEL TANKS WERE REMOVED IAW SB-31 REQUIREMENTS A ND 4 SMALL PATCHES OF LIGHT SURFACE CORROSION WERE FOUND ON THE RT OB END OF FWD FACE OF MAIN SPAR. CORROSION CLEANED AN D TREATED. INSPECTION HOLE INSTALLATION ALLOWS MUCH BETTER VISUAL ACCESS FOR THE INSPECTION OF THE CENTER SECTION THAN W 1 L 7 1 3O 3 O A718 E213 2007071900149 20070719 00149 SO 2007 7 19 2007FA0000620 1 20070525 G 2820 MILH25579 LINE PIPER PA44 PA44180 7104402 SO LYC O360 IO360E1A 41514 EA FUEL SYSTEM LEAKING D O OTHER K FLUID LOSS NR NOT REPORTED 1 SW 13 255ER 5 448195004 L47872T HOSE LEAK, ENGINE CAUGHT FIRE NOT DUE TO HOSE. FUEL FED FIRE OFTEN STARTING AT NR 1 EXHAUST PORT. (K) 1 L 7 2 3O 3 O A19S0 1E10 2007071900150 20070719 00150 WP 2007 7 19 2007FA0000621 2 20070611 G 7261 31011607 SEAL SCWZER G164 G164B 3952802 EA GARRTT TPE331 TPE33143 01514 WP COMPRESSOR LEAKING B G6CR O OTHER O OTHER NR NOT REPORTED 1 SW 09 48429 19B THE COMPRESSOR SEAL WAS LEAKING AND THE REAR SCAVENGE PUMP GEAR SHEARED OFF CAUSING IT TO FAIL. THIS CAUSED MAJOR OIL L OSS AND THE PROP TO FEATHER. HAVE REPLACED THE COMPRESSOR SEAL AND REAR PUMP TO PREVENT RECURRENCE. (K) 1 Q 7 1 3R 4 T 1A16 E2WE 2007071900125 20070719 00125 WP 2007 7 19 2007FA0000622 2 20070611 G 7261 GEAR SCWZER G164 G164B 3952802 EA GARRTT TPE331 TPE33143B 01514 WP SCAV PUMP SHEARED B G6CR O OTHER O OTHER NR NOT REPORTED 1 SW 09 48429 19B P80151 THE COMPRESSOR SEAL WAS LEAKING AND THE REAR SCAVENGE PUMP GEAR SHEARED OFF CAUSING IT TO FAIL. THIS CAUSED MAJOR OIL L OSS AND THE PROP TO FEATHER. HAVE REPLACED THE COMPRESSOR SEAL AND REAR PUMP TO PREVENT RECURRENCE. (K) 1 Q 7 1 3R 4 T 1A16 E2WE 2007071900266 20070719 00266 SO 2007 7 19 2007FA0000623 1 20070616 G 2810 FUEL PIPER PA25 PA25 7102502 SO LYC O320 O320A2B 41508 EA SNSNCH 74D 74DM EA UNKNOWN CONTAMINATED D O OTHER O OTHER NR NOT REPORTED 1 EA 17 6195Z 25229 A61128 WATER IN FUEL. (K) 1 L 7 1 3O 3 O 2A10 E274 5 N P88614 2007071900148 20070719 00148 CE 2007 7 19 2007FA0000625 1 20070622 G 3230 08421022 BELLCRANK CESSNA 310 T310Q 2074244 CE CONT O520 TSIO520* 17040 SO MLG FAILED B MYNR O OTHER O OTHER NR NOT REPORTED 1 GL 11 372CC 4771 310Q1071 FAILED DUE TO MECHANICAL OVERLOAD, NOSE GEAR JAMMED. (K) 1 L 7 2 3O 3 O 3A10 E8CE 2007071900152 20070719 00152 CE 2007 7 19 2007FA0000626 1 20070606 G 2910 EM9159REVC VALVE RAYTHN 390 390 7150030 CE HYDRAULIC SYS STICKING B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 18RF 85 RB127 PILOT REPORTED RT HYDRAULIC SHUTOFF VALVE INITIALLY STUCK DURING PREFLIGHT TEST, THEN OPENED. REPLACED VALVE WITH NEW U NIT, FUNCTIONAL TESTS, OK. REMOVED VALVE ASSY, PN 39045AS65014-003, MANUFACTURED 11/2005. (K) 1 L 7 2 3F RT A00010WI 2007071900154 20070719 00154 SO 2007 7 19 2007FA0000627 1 20070606 G 3230 455180 CONDUIT PIPER PA24 PA24250 7102404 SO LYC O540 O540A1D5 41532 EA RT MLG SEPARATED G O OTHER O OTHER NR NOT REPORTED 1 EA 61 7178P 242347 L359640 RT MLG EXTEND/RETRACT CONDUIT PUSH-PULL TUBING SEPARATED AT THE SWEDGE CONNECTION JUST OB OF THE LANDING GEAR CONTROL SU PPORT BRACKET. THERE WERE NO INDICATIONS OF IMPROPER INSTALLATION. (K) 1 L 7 1 3O 3 O 1A15 E295 2007080700156 20070807 00156 CE 2007 8 7 2007FA0000628 1 20070718 G 5711 NUT PLATE CESSNA 340 340A 2076405 CE CONT O520 TSIO520* 17040 SO SPAR DAMAGED G O OTHER O OTHER NR NOT REPORTED 1 SW 11 345BK 340A0113 WHILE UNDERGOING A ANNUAL INSPECTION INVESTIGATION OF NOISE COMPLAINT FROM THE LANDING GEARBOX IT WAS DISCOVERED THAT TH E FOUR AN3-6A BOLTS THAT ATTACH THE PART 5011013-3 (BRACKET ACUATOR MOUNTING) & GEARBOX TO THE FRONT SPAR WAS LOOSE. AN ATTEMPT AT TIGHTEN THEM REVEALED THAT THE NUT PLATES BUILT INSIDE THE SPAR WERE STRIPPED. ALLOWED THE GEARBOX TO MOVE BACK FROM THE SPAR BY 1/8" AND REAR BULKHEAD FLEXING THE 1/8". (FS152.75) 1 L 7 2 3O 3 O 3A25 E8CE 2007071900117 20070719 00117 CE 2007 7 19 2007FA0000629 1 20070718 G 5340 NUT PLATE CESSNA 340 340A 2076405 CE SPAR LOOSE G K NONE O OTHER IN INSP/MAINT 1 SW 11 60WH 340A0083 WHILE UNDERGOING A ANNUAL INSPECTION INVESTIGATION OF NOISE FROM THE LANDING GEARBOX, IT WAS DISCOVERED THAT THE (4) AN3 -6A BOLTS THAT ATTACH THE PN 5011013-3 (BRACKET ACTUATOR MOUNTING) AND GEARBOX TO THE FRONT SPAR WAS LOOSE. AN ATTEMPT AT TIGHTEN THEM REVEALED THAT THE NUT PLATES BUILT INSIDE THE SPAR WERE STRIPPED. ALLOWED THE GEARBOX TO MOVE BACK FROM THE SPAR BY .1250 INCH AND REAR BULKHEAD FLEXING THE .1250 INCH. 1 L 7 2 3O 3A25 2007080700159 20070807 00159 EU 2007 8 7 2007FA0000630 1 20070524 G 7921 369D25830101 BLOWER HUGHES 369 369FF 4470709 EU ALLSN 250C 250C30 03013 GL OIL COOLER DAMAGED D K NONE O OTHER IN INSP/MAINT 1 WP 13 97FF 475 0097F OIL COOLER BLOWER APPEARS TO BE FOD`D OUT. ONE BLADE WAS FOUND ENABLED IN THE HOUSING. THE OUT OF BALANCE SITUATION BR OKE ALL (4) BEARING CARRIER LEGS. DAMAGED BLOWER WAS REPLACED AND AC WAS RETURNED TO SERVICE. (K) 1 G 7 1 3U 3 U H3WE E1GL 2007080700162 20070807 00162 SW 2007 8 7 2007FA0000631 1 20070628 G 5711 5262 SPAR BBAVIA 7 7GCAA 21101N8 SW LYC O320 O320A2B 41508 EA RT WING CRACKED D K NONE O OTHER IN INSP/MAINT 1 WP 11 11666 23572 L31251278 (2) LONGITUDINAL CRACKS AT SPAR HINGE FITTING. SHAKING AND EXPANDING OF WOOD FIBERS DUE TO MOISTURE OR LACK OF. RECOMM END USING ALUMINUM SPARS OF SUFFICIENT SIZE AND STRENGTH. (K) 1 H 7 1 3O 3 O A759 E274 2007080700164 20070807 00164 CE 2007 8 7 2007FA0000632 1 20070629 G 7830 545300319 LINK ROD RAYTHN DH125 HAWKER800XP 7150012 CE GARRTT TFE731 TFE731* 01518 WP THRUST REVERSER CRACKED B K NONE O OTHER IN INSP/MAINT 1 GL 09 245SM 258567 PERFORMED EDDY CURRENT INSPECTION OF 8 EA THRUST REVERSER LINK ROD. FOUND A CRACK IN (1) LINK ROD. VERIFIED FINDING US ING MAGNETIC PARTICLE INSP METHOD. DURING MP INSP, NOTED ANOTHER CRACK, NOT DETECTED USING EDDY CURRENT. DECIDED TO PE RFORM MP INSP OF ALL RODS AND FOUND 3 MORE CRACKED. CRACKS APPEAR TO BE ON THE INNER SURFACE AND WOULD NOT BE DETECTABL E WITH NDT INSP PRESCRIBED IN THE MM. CURRENT INSPECTION REQUIREMENTS ARE NOT ADEQUATE FOR FINDING THESE TYPES OF DEFEC TS. CRACKS IDENTIFIED ARE ORIENTED LONGITUDINALLY O THE RODS AND VARY IN LENGTH FROM .500 IN TO 3.0 INCH. IT SHOULD BE NOTE THAT MAG PARTICLE INSP IS NOT A REQUIREMENT OF AIR FRAME MFG. (K) 2 L 7 2 4F 4 F RT A3EU E6WE 2007080700169 20070807 00169 CE 2007 8 7 2007FA0000634 1 20070520 G 7160 0750288 SUPPORT CESSNA 182 182E 2072712 CE CONT O470 O470R 17026 SO AIRBOX CRACKED D O OTHER O OTHER NR NOT REPORTED 1 SO 11 2803Y 18253803 MECH DISCOVERED ON A 50 HR INSP, THE SUPPORT COLLAR ON THE AIRBOX MOUNTED TO THE CARBURETOR WAS CRACKED. THIS COULD LEA D TO THE SEPARATION OF THE AIRBOX FROM THE CARBURETOR AND LOSS OF POWER. PN 0750288 WAS REPLACED WITH NEW SUPPORT COLLA R PN 0750288-1 IAW SRM. (K) 1 H 7 1 3O 3 O NT 3A13 E273 2007080700171 20070807 00171 GL 2007 8 7 2007FA0000635 1 20070629 G 2420 646843 ALTERNATOR CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO HARTZL HCJ3Y PHCJ3YF1 GL ENGINE FAILED B T9ZR O OTHER O OTHER NR NOT REPORTED 1 NM 09 769PC 1619 FP3952B UPON RECEIPT OF CURRENT ALTERNATOR, NOTICED THAT SLIP-RING HOUSING WAS CLOCKED 180 DEGREES OUT OF ALIGNMENT OUT OF THE B OX. THIS PLANE HAS HAD SEVERAL REPAIRED ALTERNATORS INSTALLED ON IT. THE MOST RECENT ALTERNATOR HAD ONLY 131.1 HOURS B EFORE IT FAILED AND THE ONE PREVIOUS TO THAT ONE HAD 67.2 HOURS ON IT BEFORE IT FAILED. (K) 1 L 7 1 3O 3 O NT A00009CH E3SO 5 C P36EA 2007080700172 20070807 00172 SW 2007 8 7 2007FA0000636 1 20070701 G 6410 206016201127M BLADE BELL 206 206B 1181511 SW ALLSN 250B 250B* GL TAIL ROTOR DEPARTED D O OTHER D INFLIGHT SEPARATION CR CRUISE 1 SO 15 357DC 1803 THE CENTER TIP WEIGHT SLUNG OUT OF SUBJECT TAIL ROTOR BLADE DURING FLIGHT, CAUSING A VIOLENT VIBRATION. THE VIBRATION C AUSED (3) OF THE TAIL ROTOR GEAR BOX STUDS TO SHEAR BEFORE THE AIRCRAFT COULD AUTO ROTATE TO THE GROUND. IF THE HELICOP TER HAD NOT MADE IT TO THE GROUND WHEN IT DID THE OTHER STUD WOULD HAVE SHEARED AND THE TAIL ROTOR GEAR BOX WOULD HAVE L EFT THE AIRCRAFT AND THE RESULTS WOULD HAVE BEEN DISASTROUS. RECOMMEND THE TIP BLOCKS BE MFG FROM MATERIAL THAT CAN WIT HSTAND THE CENTRIFUGAL FORCES THAT ARE APPLIED TO THE TIP WEIGHTS DURING FLIGHT. RECOMMEND THAT HELICOPTER TAIL ROTOR BL ADE TIPS BE INSPECTED AS SOON AS POSSIBLE AND EVERY 100 HR INSPECTION. (K) 1 G 7 1 3U 3 T H2SW E10CE 2007080700173 20070807 00173 SO 2007 8 7 2007FA0000637 2 20070613 G 8520 SA640518 PISTON CESSNA 182 182H 2072718 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C66 GL NR1 CYLINDER FRACTURED D O OTHER O OTHER NR NOT REPORTED 1 EA 17 1858X 4765K06552 18255958 1308944R 733700 AFTER INSTALLING NEW CYLINDER ASSY SA47006S-A20P WITH NEW PISTON ASSY PN SA640518, WE WERE PERFORMING BREAK IN RUN AT LO W POWER, FIRST AT 800 RPM FOR 2 MIN. SHUTDOWN ENGINE, CLEANED FOULED PLUGS DUE TO OIL IN CYLINDER FROM ASSY. RAN ENGIN E AT 1000 RPM FOR 3 MIN. SHUTDOWN AND CLEANED SPARK PLUGS AGAIN. RESTARTED ENGINE AND ADVANCED TO 1200 RPM, THE CYLIND ER CLEARED OUT AND THEN STOPPED AFTER A FEW SECONDS. AFTER REMOVING THE OIL PAN AND NR 1 CYLINDER THE PISTON APPEARED T O HAVE FRACTURED ALONG A CASTING FAULT IN THE PISTON PIN BOSS. THE RESULTING DEBRIS BENT THE CAM SHAFT, BROKE BOTH CRAN KSHAFT HALVES. (K) 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 2007080700174 20070807 00174 NE 2007 8 7 2007FA0000638 2 20070625 G 7250 BLADES UROCOP EC135 EC135P1 8680990 EU PWA PW206 PW206B 0 NE ENGINE DAMAGED B HDNR A UNSCHED LANDING E R Y VIBRATION/BUFFET PARTIAL RPM/PWR LOSS ENGINE STOPPAGE CR CRUISE 1 SW 03 911SV 0015 BB0113 DURING FLIGHT, A LOUD BANG WAS HEARD AND THEN ALL ENGINE INSTRUMENTS SHOWED AN INDICATION OF A TOTAL ENGINE FAILURE. TH E ENGINE WAS SECURED AND A SINGLE ENGINE LANDING WAS INITIATED WITHOUT INCIDENT. UPON INSPECTION, IT WAS NOTICED THAT T HE EXHAUST AREA OF THE ENGINE, THERE WERE PT ROTOR BLADES MISSING OR DAMAGED. THE ENGINE WILL BE SENT BACK TO THE MFG F OR EVALUATION. (K) 1 G 7 2 3U 3 U O H88EU E42NE 2007080700175 20070807 00175 CE 2007 8 7 2007FA0000639 1 20070507 G 3233 12810013 HOUSING CESSNA 172 172RG 2072438 CE LYC O360 O360* 41514 EA MCAULY 2D34C B2D34C220 GL MLG ACTUATOR CRACKED C O OTHER J WARNING INDICATION CL CLIMB 1 GL 09 4604V 172RG0337 L2232D38A 801046 ON A DUAL TRAINING FLIGHT, STUDENT AND INSTRUCTOR HEARD A NOISE WHEN LANDING GEAR WAS RETRACTED. LT LANDING GEAR REMAIN ED IN A PARTIALLY RETRACTED/ EXTENDED POSITION, UNABLE TO ACTUATE UP OR DOWN. THE LT LANDING GEAR ACTUATOR BODY HAD FAI LED (CRACKED) AT THE FWD MOUNTING BOLT HOLE, ALLOWING THE ACTUATOR BORE TO OPEN ENOUGH SO THAT PISTON WOULD NOT ENGAGE THE LANDING GEAR PIVOT SECTOR GEAR SUFFICIENTLY TO MOVE THE LANDING GEAR. (K) 1 H 7 1 3O 3 O 3A17 E286 5 C P7EA 2007080700176 20070807 00176 SW 2007 8 7 2007FA0000640 1 20070702 G 3250 SOLENOID VALVE SWRNGN SA226 SA226T 8780122 SW GARRTT TPE331 TPE33110U 01514 WP NLG STEERING FAILED B O9IR K NONE O OTHER IN INSP/MAINT 1 NM 09 749L T306 THE NOSE WHEEL STEERING WAS TESTED PRIOR TO FLIGHT, AD TESTED SATISFACTORY. AT AROUND 60 TO 70 KNOTS DURING THE TAKEOFF ROLL, THE AC STEERING FAILED IN A MANOR THAT RESULTED IN THE AC PULLING HARD TO THE LEFT. USING HARD RT BRAKE AND RT R EVERSE THRUST THE AC WAS STOPPED BEFORE RUNNING OFF THE RUNWAY. WHEN THE SPEED LEVER WAS RETARDED THE STEERING , RE-ENG AGED, AS IT SHOULD HAVE, AND THE AC OPERATED NORMALLY. 2 L 7 2 4T 4 T RT A5SW E4WE 2007080800015 20070808 00015 CE 2007 8 8 2007FA0000641 1 20070706 G 2820 16864 LINE CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO FUEL SYSTEM MISMANUFACTURED D O OTHER W INADEQUATE Q C NR NOT REPORTED 1 SW 13 4631C 394 21063582 NEW FUEL INJECTOR LINE NR 5 CYL RAM PMA REPLACEMENT. INSTALLED ON ENGINES, WELD DEFECT ALLOWED DEVIPER END BAIL TO COME LOOSE FROM LINE. NOTED FUEL LEAN ON TOP OF ENGINE AT ANNUAL 100 HR INSP. (K) 1 H 7 1 3O 3 O 3A21 E8CE 2007080800016 20070808 00016 CE 2007 8 8 2007FA0000642 1 20070703 G 2820 L2891948A LINE CESSNA 182 182T 2072703 CE LYC O540 IO540* 41532 EA FUEL SYSTEM LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 EA 21 818CP 923 18281258 L2891948A FOUND HEAVY FUEL STAIN FROM OIL COOLER NR 5 INTAKE PIPE AND ON FIREWALL APPROVED TO BE NR 5 INTAKE PIPE. FURTHER INSPEC TION FOUND NR 5 FUEL INJECTION LINE LOOSE AT INJECTOR. FOUND AND SNUGGED SEVERAL OTHER INJECTOR LINES AT INJECTOR AND F LOW DIVIDER AD-02-01, AD LAST C/W 5-3-07. (K) 1 H 7 1 3O 3 O NT 3A13 1E4 2007080800017 20070808 00017 CE 2007 8 8 2007FA0000643 1 20070613 G 3246 G129 WHEEL CESSNA 172 R172K 2072431 CE NLG STRUT MISREPAIRED G O OTHER O OTHER TO TAKEOFF 1 GL 13 736MV 120 R1722642 DURING TAKEOFF FROM A GRASS STRIP AS THE AIRCRAFT APPROACHED 30 TO 40 KNOTS, BOTH NOSE WHEELS INSTALLED ON THE FLOATS FA ILED, CAUSING THE AIRCRAFT TO FLIP ON TO ITS BACK. UPON EXAMINATION OF THE FLOAT NOSE WHEEL STRUTS THE FAILURE OCCURRED AT THE WELD JOINT OF BOTH LT AND RT WHEEL STRUTS. IT APPEARS THAT THE WELDS DID NOT HAVE ADEQUATE PENETRATION. INVEST IGATION OF MFG IN PROCESS. (K) 1 H 7 1 3O 3A17 2007080700163 20070807 00163 CE 2007 8 7 2007FA0000646 1 20070719 G 2710 05232182 PUSHROD CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA AILERON BENT B K NONE O OTHER IN INSP/MAINT 1 EA 07 2277T 172S9958 AILERON PUSHROD WAS FOUND BENT DURING PREFLIGHT. REMOVED PUSHROD AND WENT TO INSTALL NEW ROD AND FOUND THAT ALL FOUR RO DS IN STOCK HAD BAD THREADS- PD WAS OVERSIZED. 1 H 7 1 3O 3 O NT 3A12 1E10 2007080800010 20070808 00010 EA 2007 8 8 2007FA0000647 2 20070720 G 8520 AE75089 PISTON CESSNA 172 172M 2072418 CE LYC O360 O360A4M 41514 EA NR 2 CYLINDER CRACKED D K NONE O OTHER IN INSP/MAINT 1 WP 27 20858 1522 17263857 L4988127A PISTON SKIRT CRACKED ON 2 CYLINDERS. 1 H 7 1 3O 3 O NT 3A12 E286 2007080800026 20070808 00026 2007 8 8 2007FA0000648 4 20070720 G 3457 GNS530W DISPLAY CESSNA 414 414A 2075907 CE GPS MALFUNCTIONED C O OTHER O OTHER CR CRUISE 1 WP 05 25 SETTING AN EVENT IN THE AUX PAGE FOR A FUTURE TIME CAUSES AUX EVENTS PAGE TO NO LONGER FUNCTION. SELECTING THIS PAGE CA USES THE NAV6, GPS SATELLITE STATUS PAGE TO DISPLAY FOR 1 SECOND, THEN NAV2 PAGE(MAP) TO BE SELECTED. AS A SIDE EFFECT, THE FLIGHT TIMER IS RESET EVERY TIME THE AUX PAGE IS ATTEMPTED TO BE SELECTED. IT APPEARS THAT THE FIRMWARE BECOMES LO ST, BUT RECOVERS. 1 L 7 2 3O A7CE 2007080800027 20070808 00027 CE 2007 8 8 2007FA0000651 1 20070722 G 2810 FUEL CAP CESSNA 185 185F 2072820 CE CONT O520 IO520D 17032 SO WING LEAKING P O OTHER K FLUID LOSS NR NOT REPORTED 1 SW 13 5 18503193 FUEL LEAKING FROM BASE OF NEWLY INSTALLED PREMIUM FUEL CAPS. LOCATION ON WINGS IRRELEVANT. LEAK FROM BOTH IB AND OB CAPS . COMPLIED WITH MFG INSTRUCTIONS IAW VENT LOCATION WITHOUT EFFECT. EVIDENTLY NOT UNCOMMON PROBLEM, AS BLOGS ON MFG CLUB FORUM AND PILOTS ASSOC. FORUM WILL ATTEST. MFG SENT NEW O-RINGS, BUT HAVEN'T TRIED THEM. NEVERTHELESS, CAPS SHOULD BE F OOL-PROOF FROM FACTORY. HARDLY AN IMPROVEMENT OVER MY OLD MFG RAISED INLET CAPS. 1 H 7 1 3O 3 O 3A24 E5CE 2007080800049 20070808 00049 SO 2007 8 8 2007FA0000657 1 20070629 G 2720 480572 ROLL PIN PIPER PA42 PA421000 7104225 SO RUDDER PEDAL SHEARED B GW1R O OTHER O OTHER NR NOT REPORTED 1 EA 03 411BG 5362 425527004 PILOTS RT RUDDER PEDAL ROLL PINS SHEARED. REFERENCE IPC PN 761792, FIG. 103, INDEX 14, PN 480572. FAILURE MAY CAUSE LO SS OF DIRECTIONAL CONTROL OR BRAKING ACTION DURING GROUND OPERATION. (K) 1 L 7 2 4T RT A23SO 2007080800050 20070808 00050 CE 2007 8 8 2007FA0000658 1 20070612 G 2820 052355912 VENT CESSNA CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA LT WING TANK OBSTRUCTED D O OTHER O OTHER NR NOT REPORTED 1 SW 07 52119 9458 0301 17274418 L1058239A ENGINE QUIT IN FLIGHT WITH HALF TANK OF FUEL REMAINING. UPON VISUAL INSPECTION OF LT WING, FOUND THE FUEL VENT LINE PN 052355912 OBSTRUCTED WITH INSET REMAINS (WASP). PHYSICALLY REMOVED OBSTRUCTION AND OPS TESTED ENGINE ON ALL TANK SETTIN GS. UPON SUCCESSFUL OPS CHECK OF FUEL SYSTEM, MADE LOG ENTRY AND RETURNED THE AIRCRAFT TO SERVICE. AIRCRAFT HAS SUCCES SFULLY FLOWN 50 HRS SINCE 6/12/07 WITH NO FURTHER INCIDENT. 1 H 7 1 3O 3 O NT 3A12 E274 2007080800051 20070808 00051 CE 2007 8 8 2007FA0000659 1 20070712 G 3230 HMXL6G ROD END BEECH 58 58 1152740 CE CONT O520 IO520* 17032 SO NLG UNSERVICEABLE G K NONE O OTHER IN INSP/MAINT 1 AL 01 820GW TH13 DURING EXAMINATION OF AIRCRAFT POST INCIDENT, IT WAS DISCOVERED THAT ROD END (PN HMXL6G) ATTACHED TO THE NOSE GEAR RETRA CT ARM (PN 35825172-2) WAS SHEARED OFF BELOW THE BEARING. IT APPEARS THE FAILURE STARTED IN A CRACK IN THE THREADS. TH IS MOST LIKELY RELEASED THE OVER CENTER TENSION ON THE NOSE GEAR DOWNLOCK ALLOWING THE NOSE GEAR TO RETRACT AND SUBSEQUE NTLY THE MAIN LANDING GEAR. RECOMMEND ANNUAL PENETRANT INSPECTION OF ALL LANDING GEAR RETRACTION ROD ENDS. (K) 1 L 7 2 3O 3 O 3A16 E5CE 2007080800052 20070808 00052 EA 2007 8 8 2007FA0000660 2 20070526 G 8530 EXHAUST VALVE PIPER PA28 PA28140 7102802 SO LYC O320 O320E2A 41508 EA NR 4 CYLINDER BROKEN D O OTHER O OTHER NR NOT REPORTED 1 SO 13 7342J 3339 941 2824671 L2283027A NR 4 EXHAUST VALVE BROKE DURING FLIGHT, DAMAGING PISTON CAUSING OIL TO LEAK OUT EXHAUST PORT CREATING OIL SMOKE. (K) 1 L 7 1 3O 3 O 2A13 E274 2007080800057 20070808 00057 SO 2007 8 8 2007FA0000661 1 20070701 G 1210 FUEL MAULE M5 M5210C 5460134 SO CONT O360 IO360A 17025 SO CONTAMINATED D A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION NR NOT REPORTED 1 AL 05 62045 3 6078C WHILE PERFORMING BI-ANNUAL REVIEW. ON LAST TAKEOFF, THE ENGINE BEGAN TO RUN ROUGH. ENGINE DRIVEN FUEL PUMP FAILED AND INSTALLED A FRESHLY OVERHAULED PUMP. ATTEMPTED A RUN UP WITH THE SECOND PUMP AND FOUND THE COVER PLATE AT THE MIXTURE C ONTROL LEVER TO BE LEAKING. REMOVED SECOND PUMP. OVERHAUL SHOP FOUND EVIDENCE OF WATER IN THE FUEL SYSTEM, LIGHT RUST IN THE ORIGINAL PUMP BODY, AND A WHITE FILM UNDER THE PRESSURE VALVE SEAT THAT DISINTEGRATED INTO A WHITE POWDER WHEN I T DRIED. THE PUMP WAS NOT ABLE TO PRODUCE THE PROPER PRESSURE WITH THIS FILM HOLDING THE VALVE OPEN. DECIDED TO FLUSH THE FUEL SYSTEM AND TRY TO DETERMINE THE SOURCE OF CONTAMINATION. FLUSHED ALL OF THE FUEL LINES. THERE WAS LIGHT S 1 H 7 1 3O 3 O 3A23 E1CE 2007080800058 20070808 00058 2007 8 8 2007FA0000662 1 20070628 G 8011 MZ422 STARTER BURNED D O OTHER O OTHER NR NOT REPORTED 1 SW 99 STARTER BURNED UP ON TEST CELL RUN. (K) 2007080800061 20070808 00061 CE 2007 8 8 2007FA0000664 1 20070628 G 3213 07416302 SPRING ASSY CESSNA 182 182R 2072731 CE CONT O470 O470* 17026 SO AXEL FITTING CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 09 5544N 14045 18267782 DURING NDI OF MAIN LANDING GEAR SPRING ASSY, THE RT FITTING WAS FOUND CRACKED. DURING WFPT FOR ASTM E1417. PART WAS RE PLACED WITH A SERVICEABLE UNIT. SUSPECT CRACK WAS DUE TO CORROSION BETWEEN THE SPRING AND ALUMINUM FITTING. (K) 1 L 7 1 3O 3 O NT 3A13 E273 2007080800064 20070808 00064 CE 2007 8 8 2007FA0000665 1 20070726 G 1100 PLACARD CESSNA 172 172S 2072439 CE CABIN INCORRECT C K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 07 AIRCRAFT WITH AVIONICS: LOCATION OF INTERIOR ELT PLACARD IN BAGGAGE COMPARTMENT INDICATES THAT THE ELT IS BEHIND THE LOW ER ACCESS PANEL TO THE AFT FUSELAGE. THAT IS INCORRECT. THE ELT ACCESS IS FROM THE UPPER PANEL. REMOVED PLACARD AND F ABRICATED NEW PLACARD AND PLACED IT ON THE UPPER ACCESS PANEL. 1 H 7 1 3O NT 3A12 2007080800066 20070808 00066 EA 2007 8 8 2007FA0000667 2 20070726 G 8530 AEL85099 CYLINDER HEAD HUGHES 269 269C1 8059504 SW LYC O360 HO360C1A 41514 EA NR 2 CYLINDER SEPARATED B A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 WP 27 2021G 1046 0095 L3725036A NR 2 CYLINDER HEAD SEPARATED FROM CYLINDER BARREL IN FLIGHT. 1 G 7 1 3O 3 O O 4H12 E286 2007080800068 20070808 00068 EU 2007 8 8 2007FA0000669 2 20070710 G 7200 DN3351053050 DAMPER CFMINT CFM56 CFM563C1 13802 EU ENGINE FAILED B UOXR O OTHER O OTHER NR NOT REPORTED 1 SO 19 ESN725219 WAS NOTIFIED BY TEST CELL OPERATOR THAT DAMPER ASSY PN DN335-105-305-0 CAME APART DURING ENGINE TEST CELL OPERATIONS OF ENGINE DURING ENGINE TEST AND AFTER POST ENGINE ADJUSTMENT. THE DAMPER ASSY WAS DISCOVERED IN THE ENGINE INLET AREA. (K ) 4 F E21EU 2007080800069 20070808 00069 CE 2007 8 8 2007FA0000670 1 20070309 G 2460 IN31X100050CM358 MASTER SWITCH CESSNA 402 402C 207590R CE FAILED C O OTHER O OTHER CL CLIMB 1 SW 99 J8VBL 0640 LOST POWER TO THE AVIONICS BUSS. CARRIED OUT THE REQUIRED CHECKS AND TRIED REPEATEDLY TO RESTORE POWER TOT THE AVIONICS BUSS VIA THE EMERGENCY AVIONICS BUSS SWITCH, TO NO AVAIL. LANDED, CONTACTED MAINTENANCE, WHO CONFIRMED THE AVIONICS BU SS FAILURE. (K) INVESTIGATE AVIONICS BUSS SYS FAILURE AND FOUND AVIONICS MASTER SWITCH DEFECTIVE. MASTER SWITCH REMOVE D AND REPLACED WITH NEW ITEM IAW MEB 05-1. FUNCTION CHECK OF MASTER AVIONICS SWITCH AND EMERGENCY AVIONICS BUSS SWITCH CARRIED OUT SATISFACTORY. (K) 1 L 7 2 3O A7CE 2007080700033 20070807 00033 EU 2007 8 7 2007FA0000671 1 20070727 G 5310 A741210N BRIDGE LET L23 L23 1360308 EU CRACKED B O OTHER O OTHER NR NOT REPORTED 1 NM 03 431BA 1693 029013 DURING A ROUTINE DYE-PENETRANT INSPECTION ON TG-10B CRACKS WERE DISCOVERED AT SEVERAL WELDS ON THE A741 210N BRIDGE ASSE MBLY. A REPLACEMENT BRIDGE ASSY CANNIBALIZED FROM ANOTHER TG-10B IN AN EFFORT TO PLACE THE FIRST NOTED AIRCRAFT BACK IN SERVICE. AS A PRECAUTIONARY STEP, DECIDED TO DYE-PENETRANT THE CANNIBALIZED ASSEMBLY AND DISCOVERED IT TOO WAS CRACK ED. DECIDED TO INSPECT THE REST OF THE ACFT. 12 OUT OF 12 ACFT REVEALED CRACKS. 1 K 0 0 RC G24EU 2007080800093 20070808 00093 EU 2007 8 8 2007FA0000672 1 20070727 G 5101 A741210N BRIDGE LET L23 L23 1360308 EU ZONE 100 CRACKED B O OTHER O OTHER NR NOT REPORTED 1 NM 03 431BA 1693 029013 ON JULY 23, 2007 DURING A ROUTINE DYE-PENETRANT INSPECTION ON TG-10B (L-23 SUPER BLANIK, S/N 029013) CRACKS WERE DISCOVE RED AT SEVERAL WELDS ON THE A741 210N BRIDGE ASSEMBLY. IT IS A MAINTENANCE MANUAL REQUIREMENT THAT THIS PART BE DYE-PEN ETRANT INSPECTED EVERY 1000 HOURS. A REPLACEMENT BRIDGE ASSEMBLY WAS CANNIBALIZED FROM ANOTHER TG-10B (L23, S/N 029015) IN AN EFFORT TO PLACE THE FIRST NOTED AIRCRAFT BACK IN SERVICE. AS A PRECAUTIONARY STEP, WE DECIDED TO DYE-PENETRANT T HE CANNIBALIZED ASSEMBLY AND DISCOVERED IT TOO WAS CRACKED. AT THIS POINT IT WAS DECIDED TO INSPECT THE REST OF THE AIR CRAFT HERE AT USAFA. 12 OUT OF 12 AIRCRAFT REVEALED CRACKS. 1 K 0 0 RC G24EU 2007080800096 20070808 00096 CE 2007 8 8 2007FA0000674 1 20070717 G 2910 SA7670024001 LINE RAYTHN DH125 HAWKER800XP 7150012 CE HYD SYSTEM RUPTURED C H DEACTIVATE SYST/CIRCUITS K J FLUID LOSS WARNING INDICATION CL CLIMB 1 EA 27 50AE 1848 258650 FLEXIBLE HYDRAULIC LINE TO THE RT MAIN GEAR IB DOOR ACTUATOR RUPTURED IN FLIGHT. CREW EXTENDED LANDING GEAR AND FLAPS US ING THE AUXILIARY HYDRAULIC SYSTEM AND LANDED WITHOUT INCIDENT. DURING INSPECTION BY MAINTENANCE DEPARTMENT NO APPARENT CAUSE WAS DETERMINED FOR THE LINE FAILURE. MFG HAS BEEN ADVISED OF THE DEFECT. NEW HYDRAULIC LINE WAS INSTALLED, SYSTEM WAS SERVICED WITH FLUID AND BLED, AIRCRAFT WAS RETURNED TO SERVICE. 2 L 7 2 4F RT A3EU 2007080800113 20070808 00113 CE 2007 8 8 2007FA0000675 1 20070712 G 5730 08220009 SKIN CESSNA 340 340A 2076405 CE CONT O520 TSIO520* 17040 SO LT WING CRACKED D O OTHER O OTHER NR NOT REPORTED 1 CE 07 8647K 6580 340A0605 CRACK IN THE TOP SKIN OF THE LT WING AT THE LANDING GEAR SIDE BRACE ATTACHMENT LOCATION, APPROXIMATELY WS 63.45. THE SK IN IS 2024-T63 ALUMINUM, .032 THICK. THE CRACK IS ABOUT 3 INCHES LONG OR LONGER. CANNOT DETERMINE THE TOTAL LENGTH OF THE CRACK. (K) 1 L 7 2 3O 3 O 3A25 E8CE 2007080800111 20070808 00111 EA 2007 8 8 2007FA0000677 2 20070715 G 8530 AEL85099IR CYLINDER HEAD HUGHES 269 269C1 8059504 SW LYC O360 HO360C1A 41514 EA ENGINE SEPARATED G A UNSCHED LANDING E D K VIBRATION/BUFFET INFLIGHT SEPARATION FLUID LOSS CL CLIMB 1 WP 27 2021G 1046 1046 0095 L3725036A 2 NR CYLINDER HEAD ASSEMBLY APPEARS TO HAVE FAILED DURING FLIGHT RESULTING IN A SEVERE ENGINE VIBRATION AND A FORCED LAN DING. EXAMINATION OF UPPER HALF OF FAILED CYLINDER ASSEMBLY REVEALS THAT A CRACK OCCURRED AND PROPAGATED SYMMETRICALLY A ROUND THE CYLINDER APPROXIMATELY .3750 BENEATH WHERE THE CYLINDER BARREL MEETS THE CYLINDER HEAD. NO INTERNAL CYLINDER / PISTON DAMAGE WAS VISUALLY OBSERVED. 1 G 7 1 3O 3 O O 4H12 E286 2007080800110 20070808 00110 GL 2007 8 8 2007FA0000678 1 20070624 G 3230 1956750 SHUTTLE VALVE BLANCA 17 1730A 1220433 GL CONT O520 IO520K 17032 SO HARTZL HCC3Y HCC3YF1 GL MLG MALFUNCTIONED G O OTHER O OTHER LD LANDING 1 SW 01 8847V 1527 4 30359 THE AIRCRAFT LOST ELECTRICAL POWER AND PILOT TRIED TO EXTEND THE LANDING GEAR USING THE EMERGENCY LEVER. THE EMERGENCY LOWERING OF THE LANDING GEAR DID NOT TAKE PLACE AND THE PILOT HAD TO LAND THE AIRCRAFT WITH THE LANDING GEAR IN THE FULL UP POSITION. DAMAGE; PROP STRIKE, LOWER FUSELAGE SKIDDING DAMAGE, LOWER FUSELAGE FUEL DRAIN GROUND OFF, SUDDEN STOPPAG E OF THE ENGINE. 1 L 7 1 3O 3 O A18CE E5CE 5 C P25EA 2007082100024 20070821 00024 SW 2007 8 21 2007FA0000680 1 20070729 G 7933 35C155103 SENSOR ECLIPS EA500 ECLIPSEEA500 3350000 SW PW610FA OIL TEMP FAULTY C O OTHER O OTHER TX TAXI/GRND HDL 1 EA 27 116DJ 32 000021 LA0009 RT ENG HIGH OIL TEMPERATURE CAS MESSAGE UPON LANDING. EXCEEDANCE (OIL TEMP) AFTER LANDING-ENGINE SHUTDOWN DURING TAXI. F OUND FAULTY MOT/MOP SENSOR REPLACED WITH NEW UNIT AND OPERATIONALLY CHECKED SATISFACTORY IAW EMM 79-30-04. 1 L 7 2 4J RT A00002AC 2007080800109 20070808 00109 NE 2007 8 8 2007FA0000681 2 20070731 G 8560 13814 SEAL PWA R1340 R1340AN1 52016 NE SUPERCHARGER LEAKING B O OTHER K FLUID LOSS NR NOT REPORTED 1 SW 15 DISASSEMBLY OF THE ENGINE AND OR REAR SECTION AFTER CUSTOMERS REPORTED SMOKING AND INCREASE IN OIL CONSUMPTION. DURING T HE DISASSEMBLY IT WAS FOUND THAT BLOWER SEALS HAVE FAILED AND BEEN LEAKING. 3 R 5E2 2007082100064 20070821 00064 CE 2007 8 21 2007FA0000683 1 20070712 G 5730 08220009 SKIN CESSNA 340 340CESSNA 2076404 CE CONT O520 TSIO520* 17040 SO RT WING CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 07 5152J 3400542 CRACK IN THE TOP SKIN OF THE RT WING AT THE LANDING GEAR SIDE BRACE ATTACHMENT LOCATION, APPROX WS 63.45. THE SKIN IS 2 024-T3 ALUMINUM, .032 THICK. THE CRACK IS ABOUT 4.5 INCHES LONG. (K) 1 L 7 2 3O 3 O 3A25 E8CE 2007082100065 20070821 00065 EA 2007 8 21 2007FA0000684 2 20070712 G 8520 CRANKSHAFT CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA ENGINE CORRODED B YYBR K NONE O OTHER IN INSP/MAINT 1 GL 03 175AF 4363 17281175 L3097351A FOUND CRANKSHAFT TO BE PITTED, LAST INSPECTION WAS DONE BY MFG (4) YEARS AGO. THIS ENGINE HAD HIGH UTILIZATION AND FREQ UENT OIL CHANGES. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 2007082100067 20070821 00067 SO 2007 8 21 2007FA0000685 2 20070712 G 8550 ES48109 OIL FILTER CONT O520 IO520M 17032 SO ENGINE CONTAMINATED C K NONE O OTHER IN INSP/MAINT 1 GL 11 560171 THE ENGINE OIL SYSTEM WAS CONTAMINATED BY OIL FILTER SEAL DEBRIS. (K) ON DISASSEMBLY OF THE ENGINE RUBBER DEBRIS WAS FOU ND: IN THE OIL PASSAGE THAT FEEDS THE STARTER ADAPTER WITH THE ADAPTER PILOT BEARING PLUGGED. UPON SPLITTING OF THE EN GINE CASE DEBRIS WAS FOUND IN THE OIL PASSAGE TO THE NR 3 MAIN BEARING. BOTH OIL COOLING JETS TO NR 3 MAIN BEARING WERE PLUGGED WITH RUBBER DEBRIS. THE RIGHT WAS PLUGGED WITH A PIECE .6250 INCH LONG AND THE LT WITH A PIECE .1875 INCH LONG . ONE PIECE OF RUBBER DEBRIS WAS LOCATED IN THE OIL PASSAGE TO THE NR 5 BEARING. (K) 3 O E5CE 2007082100068 20070821 00068 CE 2007 8 21 2007FA0000686 1 20070713 G 5510 45A2110422 RIB BEECH MU300 400A 1155402 CE PWA JT15 JT15D5 52112 NE HORIZONTAL STAB CRACKED B KX5R K NONE O OTHER IN INSP/MAINT 1 GL 15 52AW 4500 RK115 HORIZONTAL STABILIZER LEADING EDGE IB RIBS ARE CRACKED AT THE ROLLER BRACKET ATTACHMENT POINTS. SAFETY COMMUNIQUE NR 70 IS ONLY PUBLISHED CRITERIA CONCERNING THIS PROBLEM. (K) 2 H 7 2 4F 4 F RT A16SW E25EA 2007082100070 20070821 00070 GL 2007 8 21 2007FA0000687 1 20070724 G 3230 105932B POWERPACK BLANCA 17 1731A 1220435 GL LYC O540 IO540K1E5 41532 EA MLG BURNED OUT D O OTHER J WARNING INDICATION CL CLIMB 1 SW 15 14746 18 7532156 THIS COMPONENT WAS INSTALLED FRESHLY OVERHAULED ON APRIL 6, 2006 AND HAS A TOTAL IN USE TIME OF 18.0 HOURS. AFTER TAKEO FF THE PILOT NOTICED THE LANDING GEAR WOULD NOT RETRACT. TROUBLESHOOTING OF THE LANDING GEAR SYSTEM FINDS THE HYDRAULIC POWER PACK MOTOR WINDINGS ARE OPEN, MOTOR WILL NOT RUN. UNIT WAS OVERHAULED UNDER WO NR AH-16326. (K) 1 L 7 1 3O 3 O A18CE 1E4 2007080800114 20070808 00114 WP 2007 8 8 2007FA0000688 1 20070710 G 2400 BRACKET HUGHES 269 269C 4470504 WP LYC O360 HIO360D1A 41514 EA ALTERNATOR LOOSE C O OTHER O OTHER NR NOT REPORTED 1 WP 05 9988F S1791 RL2203051A ALTERNATOR BRACKET LOOSE AT ENGINE BOSS. BOLT CAUSES DAMAGE TO ENGINE CRANKCASE WHEN LOOSE. FRETTING OF ARM AND ENGINE CRANKCASE OCCURS. (K) 1 G 7 1 3O 3 O 4H12 1E10 2007082100072 20070821 00072 CE 2007 8 21 2007FA0000689 1 20070701 G 2497 S159660L CIRCUIT BREAKER CESSNA 172 172M 2072418 CE LYC O320 O320* 41508 EA COCKPIT FAILED D K NONE O OTHER IN INSP/MAINT 1 CE 01 80213 17266449 PILOT STATED SMOKE IN COCKPIT. INSPECTION REVEALED ALTERNATOR OUTPUT C/B FAILED, ALTERNATOR HAD BROKEN AND LOOSE PARTS INTERNALLY, AND VOLTAGE REGULATOR FAILED. OPENED C/B AND FOUND INTERNAL PARTS HAD MELTED CAUSING SMOKE. NO SIGNS OF WI RE OVERHEATING, OR SECONDARY DAMAGE WAS FOUND. (K) 1 H 7 1 3O 3 O NT 3A12 E274 2007082100074 20070821 00074 CE 2007 8 21 2007FA0000690 1 20070707 G 5312 07126161 BULKHEAD CESSNA 182 182K 2072724 CE CONT O470 O470* 17026 SO BS 230 CRACKED D K NONE O OTHER IN INSP/MAINT 1 WP 28 2787Q 4575 18257987 DURING INSPECTION OF THE AFT TAILCONE BULKHEAD (STATION 230.187) A CRACK APPROX .375 INCH LONG WAS DISCOVERED. THE CRAC K LOCATION WAS ON THE LT SIDE EMANATING FROM THE RUDDER CUTOUT HOLE AND PROGRESSING TOWARD THE BULKHEAD FLANGE. (K) 1 H 7 1 3O 3 O NT 3A13 E273 2007082100076 20070821 00076 CE 2007 8 21 2007FA0000691 1 20070625 G 2420 991059111RX ALTERNATOR CESSNA 182 182T 2072703 CE LYC O540 IO540AB1A5 EA ENGINE FAILED D K NONE O OTHER IN INSP/MAINT 1 SW 03 232AF 573 18281180 L2860348A AC ARRIVED AT 1R4 WITH A FAILED ALTERNATOR. SYSTEM WAS TESTED TO CONFIRM THAT THE ALTERNATOR WAS THE PROBLEM. ON 6/25/ 07 THE ALTERNATOR IN QUESTION WAS REMOVED FROM THE AC. UPON REMOVING THE ALTERNATOR THE TECHNICAN FOUND THE SAFETY LOCK WIRE FOR THE ALTERNATOR HOUSING HALVES WAS BROKEN AND ONE OF THE FOUR CAP SCREWS WAS MISSING AND THE OTHER (3) WERE LOO SE. THE AC WAS INSPECTED AGAIN TO DETERMINE IF ANY OTHER PART COULD HAVE COME IN CONTACT WITH THE ALTERNATOR TO CAUSE T HE SAFETY LOCK WIRE TO BREAK. NO CONFLICTS WERE NOTED DURING THIS INSPECTION. DIGITAL PICTURES HAVE BEEN TAKEN FOR REC ORD AND ARE AVAILABLE UPON REQUEST. (K) 1 H 7 1 3O 3 O NT 3A13 1E4 2007080800116 20070808 00116 SW 2007 8 8 2007FA0000692 1 20070706 G 5302 206020123048 RIB BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL TAIL BOOM CRACKED D O OTHER O OTHER NR NOT REPORTED 1 SW 05 245AR 4398 DURING THE COURSE OF A SCHEDULED INSPECTION, THE RT HORIZONTAL STABILIZER WAS REMOVED TO TROUBLESHOOT A PROBLEM WITH AN AUXILIARY STROBE LIGHT THAT IS ATTACHED TO THE STABILIZER. DURING REMOVAL, THE FLANGE ON THE IB RIB THAT ATTACHES THE S TABILIZER TO THE TAILBOOM WAS FOUND CRACKED AND SEPARATED INTO 2-PIECES. DUE TO THE LOCATION OF THE CRACK IT WAS NOT VI SIBLE WITH THE STABILIZER INSTALLED. (K) 1 G 7 1 3U 3 U H2SW E4CE 2007082400138 20070824 00138 EA 2007 8 24 2007FA0000693 3 20070621 G 6110 BOLT PIPER PA18 PA18150 7101828 SO LYC O360 O360* 41514 EA SNSNCH W80 W80CM8 EA PROPELLER LOOSE H O OTHER O OTHER NR NOT REPORTED 1 GL 17 530AK 184385 AF5140 PILOT REPORTED SLIGHT VIBRATION DURING FLIGHT OF APPROX (1) HOUR. WHEN POWER WAS REDUCED FOR LANDING, VIBRATION BECAME MORE EVIDENT. INITIAL INSP FOUND (1) PROP BOLT HAD COME OUT FWD AND THROUGH SPINNER AND PROP WAS LOOSE. WITH REMOVAL O F SPINNER, FOUND (2) BOLTS BACKED OUT, (1) THROUGH THE SPINNER AND (1) NEXT TO IT. (2) BOLTS REMAINED SAFETIED, BUT NOT TIGHT. THE REMAINING PAIR OF BOLTS, THE SAFETY WIRE WAS BROKEN BETWEEN THE BOLTS AND THE BOLTS WERE BACKED OUT APPROX (1) INCH. AFTER COMPLETE REMOVAL OF PROP, WHICH REQUIRED CUTTING THE HEAD OFF OF (1) BOLT, THE ATTACHMENT BUSHING FOR T HIS BOLT WAS BROKEN OFF FLUSH WITH THE CRANKSHAFT FLANGE. ANOTHER ATTACHMENT BUSHING WAS ALSO BROKEN OFF, FLUSH WITH TH 1 H 7 1 3O 3 O 1A2 E286 5 N P27NE 2007082100142 20070821 00142 CE 2007 8 21 2007FA0000695 1 20070718 G 5311 SPAR CESSNA 340 340A 2076405 CE CONT O520 TSIO520NB 17040 SO MLG WW DAMAGED G W1NR O OTHER O OTHER NR NOT REPORTED 1 SW 11 60WH 340A0083 WHILE INVESTIGATING A NOISE IN THE LANDING GEAR ACTUATOR GEARBOX, IT WAS DISCOVERED THA THE AN3-6A BOLTS ATTACHING THE A CTUATOR MOUNTING BRACKET, PN 50110133, TO THE FRONT CENTER SPAR WERE LOOSE. AN ATTEMPT TO TIGHTEN THE BOLTS REVEALED TH AT THE NUTPLATES INSIDE THE SPAR WERE STRIPPED. THE NUTPLATES ARE NOT REFERENCED IN THE IPM AND APPEARS HAVE BEEN INSTA LLED INSIDE THE SPAR DURING THE MFG PROCESS (INACCESSIBLE). AS A RESULT OF THE ABOVE CONDITION, WHEN THE GEAR IS RAISED OR LOWERED, THE BRACKET AND GEARBOX PULL AWAY FROM THE FWD CENTER SPAR AND TRANSMIT ALL THE FORCES TO THE AFT ATTACHMEN T BULKHEAD, FLEXING THAT BULKHEAD BY MORE THAN .1250 INCH. NO INSTRUCTIONS FOR REPLACEMENT OF NUTPLATES IN MM. (K) 1 L 7 2 3O 3 O 3A25 E8CE 2007082100267 20070821 00267 EA 2007 8 21 2007FA0000697 2 20070711 G 7414 M3816 CONDENSER SLICK HUGHES 269 269C 4470504 WP LYC O360 HIO360D1A 41514 EA LT MAGNETO DISCONNECTED B K NONE O OTHER IN INSP/MAINT 1 NM 05 7508H 63008049 S1628 2594851A SPRING CLIP ON TERMINAL WIRE CAME OFF ALLOWING WIRE TO DISCONNECT. (K) 1 G 7 1 3O 3 O 4H12 1E10 2007082100268 20070821 00268 SO 2007 8 21 2007FA0000698 2 20070730 G 8530 TISN712ACA CYLINDER BEECH 55 D55 1152730 CE CONT O520 IO520CB 17032 SO NR 6 CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 05 69RP 744 TE766 NR 6 CYLINDER WAS NEW ECI REV 3 E SERIES CRACKED BETWEEN FINS 1-3 BEHIND FUEL INJECTOR. THIS IS 6TH ECI REV 3 E SERIES TO CARCK IN THE SAME LOCATION. (K) 1 L 7 2 3O 3 O 3A16 E5CE 2007082100269 20070821 00269 CE 2007 8 21 2007FA0000699 1 20070703 G 2910 EM0159 SHUTOFF VALVE RAYTHN 390 390 7150030 CE HYD SYSTEM JAMMED B E81R K NONE O OTHER IN INSP/MAINT 1 GL 03 18RF RB127 PILOT REPORTED RT ENGINE HYDRAULIC SHUTOFF VALVE WOULD NOT CLOSE FOLLOWING PREFLIGHT CHECKS. FOUND VALVE ASSY STUCK OPE N. REPLACED VALVE ASSY WITH NEW VALVE ASSY, OPERATIONS NORMAL. VALVE ASSY (PN 45AS65014003) HAVE NOTICED THESE VALVE A SSY TENDING TO FAIL WITH SHORT TIE SINCE NEW IN MFG INSTALLATIONS. VALVE ASSY SEEMS FAIRLY RELAIBLE WHEN USED IN OTHER INSTALLATIONS. (K) 1 L 7 2 3F RT A00010WI 2007082100270 20070821 00270 CE 2007 8 21 2007FA0000700 1 20070711 G 3220 04425037 FORK CESSNA 150 152 2071835 CE LYC O235 O235* 41505 EA NOSE GEAR CRACKED D O OTHER O OTHER NR NOT REPORTED 1 SO 05 68246 15282208 DURING INSPECTION, FOUND NOSE GEAR FORK CRACKED (1.5 INCH LONG) ON LT UPPER RADIUS OF FORK. AIRCRAFT IS USED FOR TRAINI NG. (K) 1 H 7 1 3O 3 O NT 3A19 E223 2007082100272 20070821 00272 EU 2007 8 21 2007FA0000701 1 20070709 G 3233 ROD ISRAEL 1124 1124 4500102 EU GARRTT TFE731 TFE731* 01518 WP MLG ACTUATOR CRACKED B X6UR O OTHER O OTHER TX TAXI/GRND HDL 1 SW 15 40TA 11851 194 75131 (REF CNTRL NR WW1045) RECOVERED AIRCRAFT FROM TAXI WAY AFTER A LANDING WITH NO MLG GREEN LIGHTS. LT GEAR STARTED RETRA CTING DURING TAXI. FOUND LT AFT GEAR RETRACT ACTUATOR PISTON ROD BROKEN INSIDE PISTON WHICH HAD CAUSED A MIS-DIRECT OF GEAR DOWN FLOW TO ROUTE INTO RETURN AND UNLOCKING THE GEAR JURY BRACE. THE PISTON ROD HAD BEEN CRACKED FOR A PERIOD OF TIME APPROX .3333 THROUGH PRIOR FAILURE. (K) 2 M 7 2 4F 4 F A2SW E6WE 2007082100146 20070821 00146 SW 2007 8 21 2007FA0000702 1 20070803 G 3250 S18233 BEARING BBAVIA 7 7GCB 2110130 SW LYC O320 O320* 41508 EA STEERING ROD CRACKED G O OTHER O OTHER LD LANDING 1 AL 01 2423 3342 7GCB55 NOSE LANDING GEAR STEERING ROD END BEARING (P/N S-1823-3) FAILED IN THREADED PART OF ROD, ALLOWING NOSE GEAR TO TURN SID EWAYS, RESULTING IN EXCESSIVE SIDE LOAD ON NOSE LANDING GEAR ASSEMBLY, CAUSING IT TO FAIL AND SEPARATE FROM THE AIRCRAFT RESULTING IN MINOR DAMAGE TO COWLING, PROPELLER, EXHAUST PIPES. THIS ROD END BEARING SHOWS SIGNS OF CORROSION, PITTING AND IS PROBABLY THE ORIGINAL 1963 PART. 1 H 7 1 3O 3 O A759 E274 2007082100171 20070821 00171 CE 2007 8 21 2007FA0000703 1 20070806 G 3411 STATIC LINE LEAR 35 35A 5170602 CE GARRTT TFE731 TFE731* 01518 WP COCKPIT MISINSTALLED B K NONE O OTHER IN INSP/MAINT 1 CE 09 621RB 211 THIS RVSM AIRCRAFT HAD AN ALTIMETRY SYSTEM SPLIT. CONTACTED STC GROUP HOLDER FOR PROPER ROUTING OF STATIC SYSTEM PLUMBIN G. FOUND CO-PILOTS STATIC SYSTEM INSTALLATION WAS NOT CROSS-COUPLED WITH PILOTS SYSTEM. INSTALLED FABRICATED HOSES TO TH E CO-PILOTS SYSTEM TO MEET THE INTENT OF STC NR ST00563DE-D IAW MASTER DOCUMENT LIST. CO-PILOTS STATIC SYSTEM NOT INSTA LLED CORRECTLY AT STC INSTALLATION OR SYSTEMS HAVE BEEN ALTERED/MODIFIED POST-STC AND DID NOT FOLLOW APPROVED DRAWINGS. 2 L 7 2 4F 4 F A10CE E6WE 2007082100194 20070821 00194 NE 2007 8 21 2007FA0000704 2 20070809 G 7310 LINE BOEING 737 7373T0 1384582 NM GE CFM56 CFM563B1 13802 NE FUEL CONTROL LEAKING D O OTHER K J FLUID LOSS WARNING INDICATION NR NOT REPORTED 1 SO 19 1732 320 23372 FLOAT STICKS, CAUSING FUEL TO COME OUT OF CARBURETOR SPLIT LINE. LEAKING FUEL FROM GASKET. 2 L 7 2 4F 4 F RT A16WE E2GL 2007082100195 20070821 00195 SO 2007 8 21 2007FA0000705 1 20070809 G 2434 KELLY4111810 ALTERNATOR PIPER PA28 PA28161 7102803 SO LYC O320 O320* 41508 EA ENGINE FAILED D O OTHER H ELECT. POWER LOSS-50 PC NR NOT REPORTED 1 SO 19 17324 17 287916050 ALTERNATOR FAILED AFTER 17.6 HOURS. 1 L 7 1 3O 3 O 2A13 E274 2007082100197 20070821 00197 SO 2007 8 21 2007FA0000706 1 20070809 G 2434 KELLY4111810 ALTERNATOR PIPER PA28 PA28161 7102803 SO LYC O320 O320* 41508 EA ENGINE FAILED D K NONE O OTHER IN INSP/MAINT 1 SO 19 17324 174 287916050 ALTERNATOR FAIL AFTER 174 HOURS OF NORMAL OPERATION. 1 L 7 1 3O 3 O 2A13 E274 2007090600030 20070906 00030 WP 2007 9 6 2007FA0000708 1 20070813 G 5250 LOCK DOUG DC8 DC8* WP COCKPIT DOOR MALFUNCTIONED C O OTHER O OTHER NR NOT REPORTED 1 SW 99 NOTIFY BY AIR SECURITY REPORT THAT OUR COCKPIT LKD SYSTEM INFORMS US ONLY IF IT'S ARMED OR NOT, BUT NOT IF THE DOOR IS C ORRECTLY CLOSED AND LOCKED. DURING ONE OF THE LAST FLT'S MY COCKPIT DOOR HAS BEEN OPENED BY THE PURSER WITHOUT MY PERMI SSION. THE DOOR SEEMED CLOSED BUT IT WASN’T AND HE COULD OPEN IT EASILY. IT IS UNSAFE FOR US ON BOARD AND FOR ALL PEOP LE THAT WE FLY OVER.EUROPEAN AVIATION SAFETY AGENCYPOSTFACH 10 12 53D-50452 KOELN, GERMANYI'M MD80 CPT OF ALITALIA , I NOTIFY BY AIR SECURITY REPORT THAT OUR COCKPIT LKD SYSTEM INFORMS US ONLY IF IT'S ARMED OR NOT, BUT NOT IF THE DOOR IS CORRECTLY CLOSED AND LOCKED.DU 2 L 7 4 4J F 4A25 2007082100289 20070821 00289 EA 2007 8 21 2007FA0000710 2 20070603 G 7322 30804 FLOAT AMTR COZY COZY 05613R8 GL LYC O290 O290* 41506 EA CARBURETOR SATURATED B K NONE O OTHER IN INSP/MAINT 1 EA 11 369CZ ENGINE FAILED ON SHORT FINAL DUE TO CARB FLOODING FLOAT IN CARB HALF FULL OF GAS. 1 M 7 1 3O 3 O NT EXPA1M71 E229 2007082400247 20070824 00247 GL 2007 8 24 2007FA0000711 1 20070710 G 2497 RESISTOR DIAMON DA40 DA40 2990002 GL CONT IO360 IO360* 17025 CE ALTERNATOR DAMAGED D MZER K NONE O OTHER IN INSP/MAINT 1 GL 15 187DS 169 40574 MFG FABRICATED AN IN-LINE RESISTOR FROM THE ALTERNATOR TO THE VOLTAGE REGULATOR. THE RESISTOR WAS LOCATED APPROXIMATELY 2 INCHES FROM AUX TERMINAL ON ALTERNATOR. IT WAS STRENGTHENED WITH MULTIPLE LAYERS OF HEAT-SHRINK AND TERMINAL WAS CRI MPED ON THE SOLID WIRE LEAD OF THE RESISTOR. THE AIRCRAFT HAD INTERMITTENT ALT FAIL WARNING BUT HAD NORMAL, POSITIVE SY STEM CHARGING. UPON DISCOVERY OF THE FAULT, THE RESISTOR LEAD WAS HELD IN THE TERMINAL CRIMP BY THE HEAT SHRINK BUT THE SOLID WIRE WAS BROKEN, MOMENTARILY MAKING CONTACT CAUSING THE FAULT. THE PROBLEM WAS CORRECTED BY SOLDERING A SMALL SE CTION OF WIRE TO THE RESISTOR AND INSTALLING A NEW TERMINAL TO WIRE. MFG CUSTOMER SUPPORT WAS CONTACTED AND THEY WERE A 1 L 7 1 3O 3 O NT A47CE E1CE 2007082400266 20070824 00266 CE 2007 8 24 2007FA0000712 1 20070727 G 2621 SQUIB BEECH 300 300BEECH 1152930 CE FIRE BOTTLE GROUNDED B ML2R K NONE O OTHER IN INSP/MAINT 1 GL 11 350RK FL516 DURING COMPLETION OF THE INITIAL 200 HOUR PHASE 1 INSPECTION, THE RT ENGINE FIRE BOTTLE SQUIB WAS FOUND TO BE IN A GROUN DED CONDITION. THE TERMINALS WERE WIRED TOGETHER WITH SAFETY WIRE AND A TAG THAT STATED (DISCONNECT AT INSTALLATION, TH E AIRCRAFT SQUIB WIRING WAS ATTACHED OVER THE SAFETY GROUND WIRE. THIS GROUNDED CONDITION IS TYPICALLY FOUND ON SQUIBS THAT ARE PACKAGED FROM THE VENDOR FOR SHIPPING. DURING INSTALLATION OF THE SQUIB ONTO THE FIRE BOTTLE, THE SAFETY GROUN D IS REMOVED. IN THIS CONDITION, THE SQUIB CANNOT DETONATE TO PUT OUT AN ENGINE FIRE. LOG BOOKS WERE NOT AVAILABLE FOR RESEARCH AT THE TIME THE DISCREPANCY WAS DISCOVERED, ALTHOUGH THE AIRCRAFT WAS NEW ENOUGH THAT IT WAS UNLIKELY ANY ENGI 2 L 7 2 4T A24CE 2007082400269 20070824 00269 SO 2007 8 24 2007FA0000713 2 20070731 G 8530 CYLINDER CESSNA 310 T310Q 2074244 CE CONT O520 TSIO520NB 17040 SO NR 6 LEAKING B FTUR K NONE O OTHER IN INSP/MAINT 1 NE 05 7714Q 310Q0214 521496 WHILE PERFORMING OTHER MAINTENANCE A FUEL STAIN WAS NOTICED BETWEEN THE SECOND AND THIRD COOLING FIN AFT OF THE FUEL INJ ECTOR ON THE NR 6 CYLINDER OF THE RT ENGINE. THIS CONDITION PROMPTED A CLOSER INSPECTION OF THE ENGINE RESULTING IN THE DISCOVERY OF SIMILAR STAINING ON THE NR 1 AND NR 5 CYLINDERS. EACH CYLINDER WAS INDIVIDUALLY PRESSURIZED AND LEAK CHEC KED WITH A SOAPY WATER SOLUTION, NR 6 CYLINDER PRODUCED LARGE BUBBLES. THE CYLINDERS ARE ECI CASTING NR AEC65385 AND TH ERE WAS (A) STAMPED ON THE ROCKER BOX FLANGE WHICH REQUIRES NO FURTHER ACTION IAW AD 04-08-10. BY THE PILOTS STATEMENT THEY BELIEVE THERE IS APPROX. 1000 HOURS ON THESE CYLINDERS. RECOMMEND THAT A GOOD VISUAL INSPECTION BE PERFORMED AT 10 1 L 7 2 3O 3 O 3A10 E8CE 2007082400298 20070824 00298 SW 2007 8 24 2007FA0000714 1 20070726 G 5711 5146R SPAR BBAVIA 7 7FC 2110124 SW CONT C90 C90* 17009 SO WING CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 04 9032B 3177 123 AIRCRAFT WAS BEING MODIFIED TO INCLUDE THE INSTALLATION OF WING SPAR INSP HOLE KITS AS SUPPLIED IAW STC NR SA00527SE. A PORTION OF THE WING LEADING EDGE SKIN WAS REMOVED AND THE WING SPAR WAS VISUALLY INSPECTED AS SPECIFIED IN THE INSTALLA TION INSTRUCTIONS SUPPLIED WITH THE STC. DURING THIS VISUAL INSPECTION, A CRACK WAS OBSERVED ON THE TOP SURFACE OF THE RT WING FRONT SPAR. THE CRACK WAS OBSERVED ON THE TOP SURFACE OF THE RT WING FRONT SPAR. THE CRACK ORIGINATES AT THE I B END OF THE AFT PLYWOOD REINFORCEMENT PLATE. REINFORCEMENT PLATE IS LOCATED ON THE AFT SIDE OF THE FRONT SPAR, UNDER T HE LIFT STRUT ATTACHMENT FITTING. THE CRACK PROGRESSES OB ALONG THE TOP SURFACE OF THE SPAR AT A SLIGHT FWD ANGLE (CRAC 1 H 7 1 3O 3 O A759 E252 2007082400307 20070824 00307 CE 2007 8 24 2007FA0000715 1 20070807 G 2910 8907021 ACCUMULATOR BEECH 76 76 1153005 CE LYC O360 LO360A1G6 41514 EA HARTZL HCM2Y HCM2YR GL HYS SYS RUPTURED C XPTS A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CR CRUISE 1 SO 19 61265 1440 ME135 DURING TRAINING FLIGHT IN PREP FOR COMMERCIAL/AMEL, PILOT PERFORMED INTENTIONAL SHUTDOWN OF LT ENGINE (FEATHERED). WAS UNABLE TO RESTART WITH ACCUMULATOR AND BEGAN PROCEDURE TO RESTART WITHOUT ACCUMULATOR WHICH WAS UNSUCCESSFUL. PILOT RET URNED TO DEPARTURE AND LANDED. AN INVESTIGATION OF THE ACCUMULATOR REVEALED A RUPTURED DIAPHRAGM. REPLACED LT ACCUMULA TOR AND RT ACCUMULATOR WAS REPLACED AS A PRECAUTIONARY METHOD. (K) 1 L 7 2 3O 3 O A29CE 1E10 5 C P43GL 2007082400308 20070824 00308 NE 2007 8 24 2007FA0000716 1 20070801 G 3340 SB4580 LAMP SKRSKY S76 S76C 8143008 NE TMECA ARRIEL ARRIEL2S1 60057 NE SEARCH LIGHT BURNED OUT C K NONE O OTHER IN INSP/MAINT 1 EA 25 554L 760567 POSSIBLE MFG PARTS NOT TO SPECIFICATIONS. MFG OF ORIG UNKNOWN. (GENERIC) LESS THAN 7 FLT HOURS IAW LAMP (AVERAGE) FROM INSTALLATION TO REPLACEMENT. HAVE REPLACED AT LEAST 5 LAMPS IAW AIRCRAFT IN LESS THAN 30 FLIGHT HOURS EACH. NO CIRCUIT BREAKERS POPPING. TROUBLESHOOTING SHOWS NO DISCREPANCIES ON EITHER AIRCRAFT. NO MFG INFORMATION ON PARTS BOX OR ON TH E PART. (K) 1 G 7 2 3U 4 U NC H1NE E00054EN 2007082400309 20070824 00309 NE 2007 8 24 2007FA0000717 1 20070801 G 3340 SB4580 LAMP SKRSKY S76 S76C 8143008 NE TMECA ARRIEL ARRIEL2S1 60057 NE LANDING LIGHT BURNED OUT C O OTHER O OTHER NR NOT REPORTED 1 EA 25 552J 760518 POSSIBLE MFG PARTS NOT TO SPECIFICATIONS. MFG OF ORIGIN UNKNOWN. (GENERIC) LESS THAN 7 FLT HOURS PER LAMP (AVERAGE) FRO M INSTALLATION TO REPLACEMENT. HAVE REPLACED AT LEAST 5 LAMPS PER AC IN LESS THAN 30 FLIGHT HOURS EACH. NO CIRCUIT BRE AKERS POPPING. TROUBLESHOOTING SHOWS NO DISCREPANCIES ON EITHER AC. NO MFG INFO ON PARTS BOX OR ON THE PART COPY OF OR IGINAL CERTIFICATION ATTACHED. (K) 1 G 7 2 3U 4 U NC H1NE E00054EN 2007082400249 20070824 00249 2007 8 24 2007FA0000718 2 20070821 G 7322 25765362 FUEL CONTROL CESSNA 172 172S 2072439 CE ENGINE OUT OF LIMITS B D RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TO TAKEOFF 1 SO 15 471ER 134 61 172S10511 DURING PRE TAKEOFF RUN UP, THE MAG DROP (BOTH MAGS) WAS BEYOND LIMITS. THIS AIRCRAFT HAD A RECENT HISTORY OF RICH SERVO OPERATION FOLLOWED BY ADJUSTMENTS, WHICH WOULD NOT STABILIZE. THE SERVO WAS CHANGED. THIS PROBLEM IS COMMON ON MANY OF T HE AIRCRAFT IN THIS FLEET AND HAS CAUSED FLEET-WIDE ADJUSTMENTS WHEN SUBSTANTIAL CHANGES IN ATMOSPHERIC TEMPERATURE OCCU R. IN MANY CASES THE SERVO MUST BE CHANGED WITH ONLY A FEW HOURS SINCE NEW. 1 H 7 1 3O NT 3A12 2007082400265 20070824 00265 EA 2007 8 24 2007FA0000719 2 20070821 G 7300 25765362 FUEL CONTROL CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA ENGINE OUT OF LIMITS B C ABORTED TAKEOFF R PARTIAL RPM/PWR LOSS TO TAKEOFF 1 SO 15 471ER 134 61 172S10511 L3340351E DURING PRE TAKE OFF RUN UP, THE MAG DROP (BOTH MAGS) WAS BEYOND LIMITS. THIS AIRCRAFT HAD A RECENT HISTORY OF RICH SERVO OPERATION FOLLWED BY ADJUSTMENTS, WHICH WOULD NOT STABILIZE. THE SERVO WAS CHANGED. THIS PROBEM IS COMMON ON MANY OF TH E AIRCRAFT IN THIS FLEET AND HAS CAUSED FLEET-WIDE ADJUSTMENTS WHEN SUBSTANTIAL CHANGES IN ATMOSPHERIC TEMPERATURE OCCUR . IN MANY CASES THE SERVO MUST BE CHANGED WITH ONLY A FEW HOURS SINCE NEW. 1 H 7 1 3O 3 O NT 3A12 1E10 2007082400268 20070824 00268 CE 2007 8 24 2007FA0000720 1 20070821 G 2710 0510105364 CONTROL CABLE CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA AILERONS FRAYED B K NONE O OTHER IN INSP/MAINT 1 SO 15 454ER 987 172S10256 L3283951E DURING A ROUTINE INSPECTION, THE AILERON BALANCE CABLE WAS FOUND BADLY WORN IN THE LT WING AT STATION 71.125. THE CABLE IS DIRECTED OVER A FAIRLEAD AT THIS LOCATION AND TYPICALLY WEARS VERY BADLY AT THIS CONTACT POINT. BECAUSE THE WEAR PATT ER IS OVER A STRAIGHT RUN OF CABLE THERE IS NO BENDING OF THE CABLE WHICH WOULD CAUSE THE STRANDS TO FRAY OUTWARD. BECAU SE OF THIS, THE CABLE CAN BE WORN THROUGH MANY STRANDS AND YET APPEAR NORMAL. ONCE THE CABLE IS REMOVED FROM THE AIRCRAF T AND BENT AS SHOWN IN THE AC43.13-1B, PAGE 7-35, FIGURE 7-16, THE BROKEN STRANDS BECOME READILY APPARENT. THIS HAS BEEN AN ISSUE FOR A LONG TIME ON THIS MODEL AIRCRAFT. IF NOT INSPECTED CAREFULLY THE CABLE CAN DETERIORATE TO A DANGEROUS CO 1 H 7 1 3O 3 O NT 3A12 1E10 2007082400320 20070824 00320 GL 2007 8 24 2007FA0000721 1 20070822 G 2497 CABLE DIAMON DA40 DA40 2990002 GL ALTERNATOR BROKEN G A UNSCHED LANDING H ELECT. POWER LOSS-50 PC CR CRUISE 1 WP 05 541AJ 265 40541 ALTERNATOR CABLE INSTALLED AT THE FACTORY WAS TOO SHORT. CABLE CONNECTS TO ALTERNATOR CIRCUIT BREAKER. 1 L 7 1 3O NT A47CE 2007082400321 20070824 00321 SO 2007 8 24 2007FA0000722 1 20070812 G 5520 HORN PIPER PIPER PA18 PA18180 7101880 SO LYC O320 O320* 41508 EA ELEVATOR DAMAGED D A UNSCHED LANDING F FLT CONT AFFECTED CL CLIMB 1 WP 23 4363Z 39 188682 AFTER DEPARTURE PILOT NOTED UNUSUAL STICK RESTRICTION AND ABORTED TOW OF GLIDER. RETURNED FOR LANDING. UPON INSPECTION T HE LOWER ARM/HORN OF THE RT ELEVATOR HORN HAD BROKEN. ALL (3) OTHER ARMS WERE UNDAMAGED AND SHOWED NO SIGN OF CRACKS. BO LTS WERE INTACT AND HOLDING CONTROL CABLE. 1 H 7 1 3O 3 O 1A2 E274 2007082400322 20070824 00322 SO 2007 8 24 2007FA0000723 2 20070823 G 8550 S23611 CHECK VALVE CESSNA 206 TU206C 2073334 CE CONT O520 TSIO520C 17040 SO ENGINE OIL WORN D O OTHER K FLUID LOSS NR NOT REPORTED 1 EA 17 71924 4839 U2061226 178337R AFTER FLIGHT A/C SITTING ON RAMP DEVELOPED LARGE OIL LEAK FROM TURBOCHARGER. FOUND OIL CHECK VALVE FLAPPER VALVE SEVERE LY WORN. 1 H 7 1 3O 3 O A4CE E8CE 2007090600088 20070906 00088 CE 2007 9 6 2007FA0000725 1 20070808 G 2410 CS3100 SENSOR CESSNA 172 172R 2072401 CE LYC O360 IO360A1A 41514 EA MASTER CNTRL BOX INTERMITTENT B MYNR O OTHER N FALSE WARNING TX TAXI/GRND HDL 1 GL 11 9424F 658 17280390 CURRENT SENSOR INDICATES 60A AND WHEN MASTER IS TURNED ON FUNCTIONS NORMALLY FROM TIME TO TIME, TAP ON UNIT AND IT FLUCT UATES THEN ACTS PROPERLY. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 2007090600087 20070906 00087 CE 2007 9 6 2007FA0000726 1 20070703 G 3260 903610373 DOWNLOCK SWITCH RAYTHN C90 C90GT 7150062 CE MLG FALSE INDICATION B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 106ML 203 LJ1757 PILOT REPORTED LT MAIN LANDING GEAR DOWN AND LOCKED INDICATION WITH LANDING GEAR RETRACTED. FOUND SWITCH ASSY INDICATOR SHOWING GREEN DOWN AND LOCKED INDICATION IN GEAR RETRACTED POSITION. REPLACED SWITCH ASSY WITH NEW UNIT. LANDING GEAR RETRACTION/ EXTENSION SYSTEM TESTS NORMAL. (K) 1 L 7 2 3T RT 3A20 2007090600073 20070906 00073 NE 2007 9 6 2007FA0000727 3 20070620 G 6111 6533A12 BLADE HAMSTD AIRTRC AT300 AT301 0390103 SW PWA R1340 R1340AN1 52016 NE HAMSTD 22D 22D40 NE PROPELLER BROKEN G A UNSCHED LANDING E VIBRATION/BUFFET CR CRUISE 1 GL 15 23667 84119 3010410 20788 PP810268 (9 INCHES) OF PROP BLADE BROKE OFF IN FLIGHT. THE SEVERE VIBRATION CAUSED PILOT TO LAND IN MUDDY FIELD. AIRCRAFT WAS T OTALED. (K) 1 L 7 1 3R 3 R A9SW 5E2 5 C P736 2007090600078 20070906 00078 CE 2007 9 6 2007FA0000728 1 20070731 G 2420 DOFF10300B ALTERNATOR CESSNA 182 182R 2072731 CE CONT O470 O470U 17026 SO MCAULY 2A34C C2A34C204 GL SHORTED D O OTHER O OTHER NR NOT REPORTED 1 NM 09 9628X 88 18268567 470887 851589 ALTERNATOR SHORTED, THIS UNIT IS (1) OF (3) REPLACED IN THE LAST MONTHS. (K) 1 L 7 1 3O 3 O NT 3A13 E273 5 C P3EA 2007090600070 20070906 00070 CE 2007 9 6 2007FA0000729 2 20070803 G 8520 538684 BUSHING CONT PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360RB 17025 CE CONNECTING ROD MISINSTALLED D O OTHER O OTHER NR NOT REPORTED 1 NE 03 19WE 3449037 819271R DURING THE PROCESS OF INSPECTING (6 EA) CONNECTING RODS IAW SB 07-1 AND SB 00-3, IT WAS FOUND THAT ALL WRIST PIN BUSHING S WERE INSTALLED NOT IAW THEIR POSITIONS AS REQUIRED IN THE APPLICABLE SB AS REFERENCED. SPLIT LINE OF BUSHING ON WRONG SIDE OF CENTERLINE. PARTS AS RECEIVED FROM MFG. (K) 1 L 7 2 3O 3 O A7SO E9CE 2007090600036 20070906 00036 2007 9 6 2007FA0000730 4 20070813 G 3444 ADS430101AC ANTENNA PIAGIO P180 P180 6960204 EU FUSELAGE SEPARATED B KKQR O OTHER J WARNING INDICATION NR NOT REPORTED 1 GL 11 395KT 3985 1044 RADAR ALTIMETER REPORTED INOPERATIVE. FOUND ANTENNA SENSOR GONE FROM THE BASE, LEAVING .2500 INCH HOLE THROUGH THE COAX CONNECTION. THE FLAT ANTENNA MOUNTS TO A CURVED FUSELAGE WITHOUT CONTOUR ADAPTATION. (K) 1 H 7 2 3O RT A59EU 2007090600090 20070906 00090 SW 2007 9 6 2007FA0000731 1 20070625 G 2120 2784187019 PIPE SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE331* 01514 WP RT WING BLEED AI ARCED G O OTHER O OTHER NR NOT REPORTED 1 SW 11 160WA TC399 IB OF RT NACELLE, BLEED AIR PIPE (PN 2784187019), CHAFED OR BURNED THROUGH THE ASBESTOS SLEEVE SURROUNDING THE STARTER R ELAY WIRING, WHICH THEN ARCED A HOLE IN THE BLEED PIPE, WHICH THEN BURNED THE SHIELDING FROM THE STARTER RELAY WIRES, WH ICH THEN ARCED A HOLE IN A HYDRAULIC LINE (PN 2781032403), RESULTING IN A FIRE. 2 L 7 2 4T 3 T RT A8SW E2WE 2007090600055 20070906 00055 CE 2007 9 6 2007FA0000732 1 20070517 G 2432 6041H274 RELAY CESSNA 310 T310R 2074246 CE CONT O520 TSIO520* 17040 SO BATTERY FAILED D A8XR O OTHER O OTHER NR NOT REPORTED 1 SO 05 16EZ 310R1277 AIRCRAFT EMERGENCY LANDED WITH COMPLETE ELECTRICAL FAILURE, LG EMERGENCY EXTENDED AND LANDED SAFELY. FOUND BATTERY RELA Y FAILURE. UNIT REMOVED 200 AMP FOUND TO BE INCORRECT (PN). SB MEB99-4 ADDRESS THIS PROBLEM, HAD NOT BEEN COMPLIED WIT H, CORRECT RELAY 100 AMP PN 0850469-1 (6041H193) INSTALLED, OPS CHECK OK. (200 AMP RELAY HAD TO HAVE BEEN REPLACED PRIO R TO 1999 WHEN AC IPC REVERSED BATTERY AND STARTER RELAY PN COMPLIANCE WITH SB WOULD HAVE PREVENTED THIS PROBLEM. (K) 1 L 7 2 3O 3 O 3A10 E8CE 2007090600056 20070906 00056 GL 2007 9 6 2007FA0000733 3 20070810 G 6114 PHCC3YF1RF HUB HARTZL CESSNA 207 207 2073602 CE CONT O550 IO550F 17042 SO HARTZL HCC3Y PHCC3YF1 GL PROPELLER CRACKED B LU4R O OTHER O OTHER NR NOT REPORTED 1 SO 19 EE2379A HUB, NDI SHOWS RELEVANT INDICATION OF CRACK.(K) 1 H 7 1 3O 3 O A16CE E3SO 5 C P25EA 2007090600050 20070906 00050 CE 2007 9 6 2007FA0000735 1 20070809 G 2497 36153 GROUND WIRE BEECH 200 B200 1152922 CE PWA PT6 PT6A6 52043 EA GCU BROKEN D B A EMER. DESCENT UNSCHED LANDING B G H SMOKE/FUMES/ODORS/SPARKS MULTIPLE FAILURE ELECT. POWER LOSS-50 PC CR CRUISE 1 CE 07 1925P 9715 BB1094 WIRE NR P73G16N AT RT ENGINE FIREWALL GROUND POINT GS15 SEPARATED FROM THE WIRE TERMINAL DURING CRUISE FLIGHT. THIS WIRE CONNECTS GROUND TO THE GCU PIN G. THE RT GENERATOR OUTPUT SPIKED AND OPENED THE 325 AMP RT BUSS CURRENT LIMITER, THE 50 AMP RT INVERTER CURRENT LIMITER, AND DAMAGED RADIOS, THE GCU AND SYSTEMS WIRED TO THE RT BUSS. UPON INSPECTION, THE INS ULATION OF P73G16N WAS FOUND STRIPPED TOO FAR FROM THE WIRE END THEREBY GIVING NO SUPPORT OF THE WIRE INTO THE TERMINAL AT THE INSULATION CRIMP AREA. 1 L 7 2 4T 3 T A24CE E4EA 2007090600053 20070906 00053 CE 2007 9 6 2007FA0000736 1 20070823 G 3246 178K481 TIRE LEAR 60 60LEAR 5170707 CE LT MLG DEFLATED D D RETURN TO BLOCK O OTHER TX TAXI/GRND HDL 1 WP 27 903AM 269 NOTIFIED BY FLIGHT CREW LT MAIN LANDING GEAR IB AND OB TIRES SEPARATED FROM WHEELS DURING TAXI. TIRES DETACHED FROM WHE EL ASSEMBLIES BUT DID NOT SEPARATED FROM AIRCRAFT. TIRES WERE NOT BLOWN. DAMAGED TIRES AND WHEELS ASSEMBLIES WERE REMO VED. UPON INSPECTION, NO OTHER DAMAGES NOTED ON LANDING GEAR OR SURROUNDING STRUCTURE. NO FOD DAMAGE TO AIRCRAFT. REP LACED WITH SERVICEABLE WHEELS/TIRES ASSEMBLIES. 2 L 7 2 4F RT A10CE 2007091200003 20070912 00003 NM 2007 9 12 2007FA0000741 1 20070828 G 3246 AN535A BOLT PARKERHANFIN COLUMB LC41 LC41550FG400 5150011 NM WHEEL ASSY BROKEN B O OTHER E VIBRATION/BUFFET LD LANDING 1 EA 25 1469W 143 143 MFG406 41733 ON LANDING PILOT FELT AND HEARD A VIBRATION AND BUMPING SOUND. REMOVED RT LANDING GEAR FAIRING AND INSPECTED BRAKE ASSY . ON THE WHEEL FOUND ONE WHEEL HALF ATTACH BOLT MISSING AND ONE BROKEN AND EXTENDING OUT OF THE WHEEL TO THE EXTENT OF CAUSING A GOUGE IN THE BRAKE MASTER CYLINDER AND TORQUE PLATE. ONE BOLT OUT OF THREE WAS HOLDING THE WHEEL HALVES TOGET HER. 1 L 7 1 3O NT A00003SE 2007090600022 20070906 00022 NE 2007 9 6 2007FA0000747 2 20070817 G 7310 3011849 TUBE BEECH 90 F90 1152909 CE PWA PT6 PT6A135 52043 NE LT ENGINE CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 EA 03 50AW 15 LA142 PCE92358 FUEL LEAK NOTED ON SHUTDOWN OF LT ENGINE. FUEL TUBE P/N 3011849 CRACKED AT CONNECTION TO START CONTROL UNIT. 1 L 7 2 4T 4 T A31CE E4EA 2007090600035 20070906 00035 EA 2007 9 6 2007FA0000748 2 20070718 G 7310 3011849 TUBE PIPER PA31T PA31T 7103124 SO PWA PT6 PT6A28 EA LT ENGINE CRACKED B K NONE K FLUID LOSS IN INSP/MAINT 1 EA 03 100CM 5 31T8020073 FUEL LEAK NOTED ON SHUTDOWN. FUEL TUBE P/N 3011849 WAS CRACKED AT CONNECTION TO START CONTROL UNIT. 1 L 7 2 3T 4 T A8EA E4EA 2007090600059 20070906 00059 CE 2007 9 6 2007FA0000749 1 20070829 G 7810 K99102991 EXHAUST PIPE CESSNA 414 414 2075908 CE CONT O520 TSIO520NB 17040 SO MCAULY 3AF32C 3AF32C93 GL ENGINE CRACKED B W99R K NONE O OTHER IN INSP/MAINT 1 WP 09 22MG 1900 4140533 DURING COMPLIANCE WITH AD 2000-01-16 THE TAIL PIPE ON THE RT ENGINE WAS FOUND WITH A 6 INCH CRACK. THE LAST INSPECTION WAS 40 HRS PRIOR. 1 L 7 2 3O 3 O RT A7CE E8CE 5 C P22EA 2007090600012 20070906 00012 NE 2007 9 6 2007FA0000752 2 20070725 G 7200 ENGINE BEECH 90 E90 1152914 CE PWA PT6 PT6A60A 52043 NE LEFT FAILED D A UNSCHED LANDING R X J PARTIAL RPM/PWR LOSS ENGINE FLAMEOUT WARNING INDICATION CR CRUISE 1 SW 13 71WB LW127 AIRCRAFT IN CRUISE AT 22,000 WITH ALL ENGINE INDICATIONS NORMAL. A LOUD NOISE FOLLOWED BY POWER LOSS AND REDLINE ITT ON THE LT ENGINE. THE CT BLADES, ITT PROBES, PT VANE AND PT BLADES ALL MELTED AND WENT THROUGH THE EXHAUST STACKS. COMPR ESSOR STATOR AND SPACER RUB. POSSIBLE COMPRESSOR UNSTACK FAILURE. THIS IS THE FIRST COMPLETE MELT DOWN FAILURE HAVE EV ER SEEN AT ALTITUDE. (K) 1 L 7 2 3T 4 T 3A20 E4EA 2007090600058 20070906 00058 EU 2007 9 6 2007FA0000753 1 20070724 G 2910 704A34412938 LINE SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 60053 NE HYD SYSTEM LEAKING B PG9R O OTHER K J FLUID LOSS WARNING INDICATION LD LANDING 1 WP 19 170PA 2637 AC HAD HYDRAULIC LIGHT, PILOT PERFORMED A PRECAUTIONARY LANDING AT THE AIRPORT. UPON INSP FOUND HYDRAULIC LINE FROM PUM P TO MANIFOLD LEAKING AT THE BOTTOM OF THE SWEDGE FITTING. HYDRAULIC LINE WAS REPLACED WITH NEW LINE. HYDRAULIC SYSTEM WAS SERVICED, GROUND RUN, AND LEAK CHECK NORMAL. FLIGHT CONTROL CHECK NORMAL. AC WAS RETURNED TO SERVICE. (K) 1 G 7 1 3U 3 U H9EU E19EU 2007090600057 20070906 00057 EA 2007 9 6 2007FA0000754 1 20070803 G 2740 604923063 MOTOR CNDAIR CL600 CL6002B16 1900305 EA GE CF34 CF34* NE HORIZ STAB TRIM UNSERVICEABLE C K NONE O OTHER IN INSP/MAINT 1 GL 13 43R 5334 WHILE OPERATING HORIZ STAB TRIM ON CHANNEL NR 2 ONLY THE FOLLOWING OCCURS. PUSHING BUTTON ON CONTROL WHEELS TO NOSE UP, HORIZONTAL ACTUALLY WENT DOWN THEN DISCONNECTED. REPEATED ATTEMPTS, KEPT TRIMMING TO NOSE DOWN POSITION. COULD NOT GE T HORIZONTAL TO TRIM NOSE UP ON JUST CHANNEL NR 2. ONCE CHANNEL NR 1 WAS ENGAGED HORIZONTAL STAB TRIM WORKED CORRECTLY. THIS PART WAS SENT TO THE MFG BY THE PREVIOUS OPERATOR FOR THIS EXACT PROBLEM. MFG REPLACED PARTS AND RETURNED IT TO SERVICE. PROBLEM REOCCURRED, UNIT REMOVED AND SENT BACK TO MFG. (K) 2 L 7 2 4F 4 F RT A21EA E15NE 2007090600002 20070906 00002 CE 2007 9 6 2007FA0000755 1 20070802 G 8011 85070213 STARTER CESSNA 172 172S 2072439 CE LYC O360 IO360A1A 41514 EA ENGINE FAILED D O OTHER O OTHER NR NOT REPORTED 1 EA 05 865SP 172S8124 STARTER WAS INTERMITTENT AND FAILED COMPLETELY. AVERAGE LIFE FOR THE LAST (2) STARTERS HAS BEEN 115 HRS EACH. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 2007090600076 20070906 00076 NE 2007 9 6 2007FA0000758 2 20070828 G 7314 DRIVE SHAFT SUNDSTRANDEM BEECH 200 B200 1152922 CE PWA PT6 PT6A42 52043 NE FUEL PUMP SHEARED D E ENGINE SHUTDOWN X J ENGINE FLAMEOUT WARNING INDICATION CR CRUISE 1 SO 11 544P 1340 9489 BB1265 PCE94081 WHILE AT CRUISE FLIGHT, LT ENGINE SHUTDOWN WITHOUT WARNING. LANDED WITHOUT INCIDENT. FOUND HIGH PRESSURE FUEL PUMP SHAFT SPLINES SHEARED ON INSIDE OF DRIVE COUPLING RENDERING FUEL PUMP AND FUEL CONTROL INOPERABLE. INSPECTION WOULD NOT BE PO SSIBLE WITHOUT PUMP REMOVAL AND DISASSEMBLY OF DRIVE COUPLING. 1 L 7 2 4T 4 T A24CE E4EA 2007090600038 20070906 00038 NE 2007 9 6 2007FA0000759 2 20070831 G 7220 BRR40289 FAIRING RROYCE GULSTM GV GULFSTREAMGV 3980116 SO RROYCE BR700 BR700710A110 NE LP FAN CRACKED B K NONE O OTHER IN INSP/MAINT 1 GL 15 73M 3889 547 11204 DURING INSPECTION OF THE AIR INTAKE ROTATING FAIRING, WE FOUND A CRACK BETWEEN THE MOUNT BOLT HOLE AND THE ADJACENT ALIG NMENT PIN HOLE. 2 L 7 2 4F 4 F RT A12EA E00057EN 2007091700020 20070917 00020 EA 2007 9 17 2007FA0000760 2 20070716 G 8550 LW13383 BAFFLE LYC FOUND FBA FBA2C1 3640103 EA LYC O540 IO540L1A5 41532 EA OIL SUMP CRACKED B K NONE O OTHER IN INSP/MAINT 1 AL 03 796 600 50 L2947748A ENGINE OIL SUMP BAFFLE CONTACTED BOTTOM OF OIL SUMP CRACKING BAFFLE SUPPORT ATTACH POINTS AND SHEARING RIVETS ATTACHING BAFFLE CENTER REINFORCEMENT. SHEARED RIVET LODGED IN OIL PRESSURE RELIEF VALVE CAUSING LOSS OF OIL PRESSURE. ENGINE RE MOVED FOR OVERHAUL. 1 H 7 1 3O 3 O NC A7EA 1E4 2007091700024 20070917 00024 EA 2007 9 17 2007FA0000761 2 20070716 G 8550 LW13383 BAFFLE FOUND FBA FBA2C1 3640103 EA LYC O540 IO540L1A5 41532 EA OIL SUMP CRACKED B K NONE O OTHER IN INSP/MAINT 1 AL 03 794 500 51 L29544548A ENGINE OIL SUMP BAFFLE CONTACTED BOTTOM OF OIL SUMP CRACKING BAFFLE SUPPORT ATTACH POINTS AND SHEARING RIVETS ATTACHING BAFFLE CENTER REINFORCEMENT. 1 H 7 1 3O 3 O NC A7EA 1E4 2007091700025 20070917 00025 GL 2007 9 17 2007FA0000768 1 20070804 G 2810 CAP AMTR SKRAID SKYRAIDER 05610GI GL ROTAX 447 ROTAX447 55555 EU FUEL TANK OUT OF ADJUST G A UNSCHED LANDING W J INADEQUATE Q C WARNING INDICATION DE DESCENT 1 GL 25 31711 35 SK1966 AT CONCLUSION OF 2 HOUR FLIGHT, APPROXIMATELY 2 MILES FROM DESTINATION AIRPORT, PILOT REPORTED AN UNCOMMANDED SIGNIFICAN T POWER REDUCTION. A PRECAUTIONARY LANDING WAS EXECUTED ON A COUNTY ROAD. SUBSEQUENT INVESTIGATION FOUND 1.5 GALLON FU EL IN RT TANK, NONE IN LT TANK. EVIDENCE OF FUEL SIPHONING FROM RT FUEL CAP. PILOT STATED WHEN LT FUEL CAP WAS REMOVED , HISSING NOISE WAS HEARD. PROBABLE THAT COMBINATION OF SIPHONING RT TANK/CAP AND NO VENTING OF LT TANK/CAP CAUSED A FU EL IMBALANCE AND INTERRUPTION OF FUEL FLOW TO HEADER TANK/ENGINE, RESULTING REDUCTION OF ENGINE OPERATION. RECOMMEND AN Y EXPERIMENTAL AIRCRAFT USING FUEL CAPS WITH THREADED CENTER STEM/(O) RING ASSEMBLY FOR VENTING BE MODIFIED TO INCLUDE A 1 H 7 1 3 I EXPA1H71 EXPE3I 2007091700070 20070917 00070 SW 2007 9 17 2007FA0000769 1 20070905 G 5711 SPAR BBAVIA 7 7GCBA 21101PH SW LYC O320 O320* 41508 EA RT WING FRACTURED D K NONE O OTHER IN INSP/MAINT 1 EA 23 9902Y 1480 9 7GCBA8 RT WING MAIN SPAR FOUND FRACTURED IB OF STRUT ATTACH. CURRENT AD INADEQUATE TO PREVENT FURTHER FAILURES. THIS AIRCRAFT H AS LESS THAN 14 HR SINCE LAST ANNUAL INSPECTION.. 1 H 7 1 3O 3 O A759 E274 2007091700008 20070917 00008 SW 2007 9 17 2007FA0000770 1 20070905 G 5711 SPAR BBAVIA 7 7GCBA 21101PH SW RT WING BROKEN D K NONE O OTHER IN INSP/MAINT 1 EA 23 9902Y 1480 9 7GCBA8 RT WING MAIN SPAR FOUND FRACTURED IB OF STRUT ATTACH. CURRENT AD INADEQUATE TO PREVENT FURTHER FAILURES. THIS AIRCRAFT H AS LESS THAN 14 HR SINCE LAST ANNUAL INSPECTION.. 1 H 7 1 3O A759 2007091700059 20070917 00059 CE 2007 9 17 2007FA0000772 1 20070401 G 3210 NAS464P426 BOLT CESSNA 320 320E 2074514 CE CONT O520 TSIO520B 17040 SO MCAULY 3AF32C 3AF32C* GL RT MLG SHEARED D O OTHER O OTHER NR NOT REPORTED 1 WP 17 3424Q 320E0024 AIRCRAFT HAS EXPERIENCED A RT LANDING GEAR FAILURE UPON LANDING. PRIOR TO THIS INCIDENT, THE LANDING GEAR HAD BEEN CHEC KED DURING THE AIRCRAFT ANNUAL INSPECTION AND FOUND TO BE OUT OF RIG IAW SERVICE MANUAL D508-3-13 STANDARDS. THE AIRCRAF T EXPERIENCED A PARTIAL POWER FAILURE UPON THE FIRST FLIGHT AFTER THE AIRCRAFT HAD BEEN RIGGED. SUSPECT THE LANDING GEA R WAS NOT LOCKED PROPERLY UPON LANDING ON THE FIRST FLIGHT DUE TO THE PARTIAL ELECTRICAL POWER FAILURE. UPON THE THIRD FLIGHT LANDING, THE RT GEAR COLLAPSED. PROBABLE CAUSE MAY HAVE BEEN FROM THE FIRST LANDING WHERE GEAR MAY NOT HAVE BEEN ALL THE WAY DOWN. THE BOLT TO THE LANDING GEAR STRUT SHEERED AT THE ATTACH POINT OF THE STRUT, AND ONE ATTACH POINT BR 1 L 7 2 3O 3 O 3A25 E8CE 5 C P22EA 2007091700023 20070917 00023 CE 2007 9 17 2007FA0000778 1 20070906 G 2820 3011849 LINE BEECH 90 F90 1152909 CE PWA PT6 PT6A135 52043 NE FUEL SYS CRACKED B A UNSCHED LANDING K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 EA 03 50AW 6848 LA142 PCE92358 FUEL TUBE CRACKED AT BACKSIDE OF B-NUT SLEEVE LOCATION, CAUSING FUEL TO LEAK UNDER PRESSURE INTO ENGINE NACELLE AREA FOR WARD OF FIREWALL. TUBE FAILED IN FLIGHT CAUSING INITIAL CHANGES IN FUEL FLOW INDICATIONS TO BE NOTICED. 1 L 7 2 4T 4 T A31CE E4EA 2007091700003 20070917 00003 CE 2007 9 17 2007FA0000780 1 20070812 G 2910 AE1011889G0116 LINE CESSNA 750 750 2076810 CE ALLSN AE300 AE3007A GL HYDRAULIC SYS RUPTURED B CNQ3 O OTHER K FLUID LOSS NR NOT REPORTED 1 GL 13 912QS 7516 7500012 THE NOSE WHEEL STEERING CENTERING FLEXIBLE HYDRAULIC HOSE RUPTURED WHERE THE HOSE BODY IS SWEDGED TO A 45 DEGREE FITTING WHICH ATTACHES TO A BULKHEAD FITTING IN THE NOSE WHEEL WELL. THIS CONDITION ALLOWED THE LOSS OF HYDRAULIC FLUID IN THE (A SYSTEM). AIRCRAFT LANDED WITHOUT INCIDENT. THIS HOSE IS CURRENTLY CONSTRUCTED OF KEVLAR AND IS BEING REPLACED WITH STAINLESS STEEL BRAIDED VERSION ALONG WITH OTHER HOSES WHICH ATTACH TO THE NOSE GEAR. (K) 2 L 7 2 4J 4 F RT T00007WI TE6CH 2007091700069 20070917 00069 SO 2007 9 17 2007FA0000781 2 20070810 G 8520 CRANKSHAFT CONT O520 GTSIO520L 17032 SO ENGINE FAILED B LU4R O OTHER O OTHER NR NOT REPORTED 1 SO 19 A511M2 CRANKSHAFT FAILED NDI SB MSB96-10. (K) 3 O E7CE 2007091700019 20070917 00019 GL 2007 9 17 2007FA0000782 3 20070810 G 6114 HUB HARTZL CESSNA 207 207 2073602 CE CONT O550 IO550F 17042 SO HARTZL HCC3Y PHCC3YF1 GL PROPELLER CRACKED B LU4R O OTHER O OTHER NR NOT REPORTED 1 SO 19 EE2379A EE2379A HUB, NDI SHOWS RELEVENT INDICATION OF CRACK. (K) 1 H 7 1 3O 3 O A16CE E3SO 5 C P25EA 2007091700072 20070917 00072 SO 2007 9 17 2007FA0000783 1 20070816 G 2730 62701153 CONTROL CABLE PIPER PA44 PA44180 7104402 SO LYC O360 O360* 41514 EA ELEVATOR BROKEN D O OTHER O OTHER NR NOT REPORTED 1 SO 05 30521 447995076 AFT LOWER ELEVATOR CONTROL CABLE BROKE AT TURN BUCKLE BETWEEN CRIMPED BARREL AND END THREADS. SENT CABLE ASSY TO NTSB F OR LAB REPORT. (K) 1 L 7 2 3O 3 O A19S0 E286 2007091700026 20070917 00026 EA 2007 9 17 2007FA0000784 2 20070708 G 7322 30804 FLOAT PRECISION AMTR VANS RV9A 05614C3 GL LYC O320 O320D2A 41508 EA SNSNCH 70C 70CM6 EA CARBURETOR FAILED D O OTHER O OTHER NR NOT REPORTED 1 SO 03 12HE 33 75992004 91367 L2005739A 38893K THE ENGINE DIED ON FINAL TO AIRPORT, PUMPED THE THROTTLE, AND THE ENGINE STARTED RUNNING AGAIN, RETARDED THROTTLE, AND T HE ENGINE DIED AGAIN. LANDED WITHOUT INCIDENT. COULD NOT GET THE ENGINE TO RESTART ON THE GROUND. ENGINE WAS STARTED THE NEXT DAY, THE FUEL FLOW WAS SHOWING 11 TO 12 GPH AT IDLE. REMOVED THE CARBURETOR AND ONE PONTOON OF THE PLASTIC FLO AT WAS 90 PERCENT FULL OF FUEL. (K) 1 L 7 1 3O 3 O NT EXPA1L71 E274 5 N P28NE 2007091700034 20070917 00034 CE 2007 9 17 2007FA0000785 1 20070807 G 2612 61423473275 SENSOR BEECH 200 A200 1152921 CE PWA PT6 PT6A41 52043 EA MCAULY 4HFR34 4HFR34C752 NE FIRE DETECTION FAULTY E O OTHER O OTHER NR NOT REPORTED 1 EA 05 636B 754 BC61 AT APPROXIMATELY 1635 LOCAL, IN CLOUDY CONDITIONS, ON A MAINTENANCE TEST FLIGHT, THE NR 1 ENGINE FIRE LIGHT BRIEFLY ILLU MINATED, THEN EXTINGUISHED. ALL ENGINE GAUGES INDICATED NORMALLY. ALREADY IN DESCENT, THROUGH 4,500 FT, AND CONTINUED TO A SAFE LANDING. MAINTENANCE DISCOVERED FAULTY LOWER AFT SENSOR AND REPLACED IT. (K) 1 L 7 2 4T 4 T A24CE E4EA 6 C 3PNE 2007091700010 20070917 00010 GL 2007 9 17 2007FA0000786 1 20070516 G 7160 D4F732612001 AIR BOX DIAMON DA40 DA40 2990002 GL LYC O360 O360A4M 41514 EA ENGINE BROKEN D O OTHER O OTHER NR NOT REPORTED 1 NM 07 425FP 357 40FC025 CARBURETOR HEAT CONTROL ARM BROKE OFF OF CARB AIR BOX CAUSING UNCONTROLLED SELECTION OF CARB HEAT VS RAM (COLD) AIR INTA KE. (K) 1 L 7 1 3O 3 O NT A47CE E286 2007091700067 20070917 00067 GL 2007 9 17 2007FA0000787 1 20070521 G 7160 D4F732612001 AIR BOX DIAMON DA40 DA40 2990002 GL LYC O360 O360A4M 41514 EA ENGINE BROKEN D O OTHER O OTHER NR NOT REPORTED 1 NM 07 422FP 383 40FC022 CARBURETOR HEAT CONTROL ARM BROKE OFF OF CARB AIR BOX CAUSING UNCONTROLLED SELECTION OF CARB HEAT VS RAM (COLD) AIR INTA KE WHILE IN FLIGHT. (K) 1 L 7 1 3O 3 O NT A47CE E286 2007091700032 20070917 00032 NE 2007 9 17 2007FA0000788 2 20070810 G 7320 8168776007 EEC UROCOP EC135 EC135P1 8680990 EU PWA PW206 PW206B 0 NE ENGINE FAILED B HDNR O OTHER O OTHER NR NOT REPORTED 1 SW 03 911KB 0013 BB0027 EEC CAUSED ENGINE TO DROP FROM FULL POWER TO IDLE IN CRUISE FLIGHT WITH AN ENGINE FAILURE AND ENGINE MANUAL HORN AND LIG HT. (K) 1 G 7 2 3U 3 U O H88EU E42NE 2007091700006 20070917 00006 SO 2007 9 17 2007FA0000789 2 20070809 G 8520 530196A1 CRANKSHAFT CONT C85 C8512 17008 SO ENGINE DESTROYED G O OTHER O OTHER NR NOT REPORTED 1 GL 13 21407612 DURING LEVEL FLIGHT THIS AIRCRAFT SUSTAINED LOSS OF PROPELLER. AIRCRAFT LANDED ON A COUNTY HIGHWAY SATISFACTORILY WITH NO DAMAGE OR INJURIES. INVESTIGATION REVEALED THE ENGINE CRANKSHAFT FAILED IMMEDIATELY AFT OF THE PROPELLER ATTACH POIN T (THIS CRANKSHAFT HAS A TAPERED SHAFT, NOT A FLANGE). THE PROPELLER WAS LOCATED AT A LATER TIME BY A HIKER IN A STATE PARK. INSPECTION OF THE ENGINE AND PROPELLER INDICATES THE PROBABILITY THAT THE ENGINE HAD SUSTAINED SUDDEN STOPPAGE AT A PRIOR TIME. THIS MAY HAVE RESULTED IN A MINUTE CRACK/FRACTURE THAT EVENTUALLY PROPAGATED INTO THE TOTAL FAILURE OF T HIS CRANKSHAFT. SINCE THERE WAS NO DAMAGE TO THE AIRCRAFT OR OCCUPANTS, THIS SITUATION HAD BEEN DETERMINED TO BE AN INC 3 O E233 2007091700013 20070917 00013 SW 2007 9 17 2007FA0000790 1 20070901 G 3610 2784187015 PIPE SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE331* 01514 WP BLEED AIR DAMAGED D O OTHER O OTHER NR NOT REPORTED 1 SW 11 226AM TC229 NOTE: AIRCRAFT HAS BEEN PARKED FOR 2 YEARS AFTER BEING DAMAGED IN HURRICANE. AIRCRAFT WAS BEING DISASSEMBLED FOR SALVAG E. IB OF RT NACELLE, BLEED AIR PIPE, PN: 27-84187-015, HAS CHAFED/BURNED THROUGH THE ASBESTOS SLEEVE SURROUNDING THE ST ARTER RELAY WIRING AND HAS ARCED A HOLE IN THE BLEED PIPE, WHICH THEN ALLOWED BLEED AIR TO MELT THE SHIELDING FROM ONE O F THE WIRES. (K) 2 L 7 2 4T 3 T RT A8SW E2WE 2007091700033 20070917 00033 WP 2007 9 17 2007FA0000794 1 20070901 G 5730 SKIN DOUG DC9 DC915 3022036 WP PWA JT8 JT8D7 52053 NE WING DAMAGED D C ABORTED TAKEOFF O OTHER TO TAKEOFF 1 SO 17 305PA 45740 BIRD STRIKE ON LT LEADING EDGE, CAUSING DEEP DENT AMD A TEAR 5 INCHES VERTICAL AND 4 INCHES HORIZONTAL, FOUND ON POST FL IGHT INSPECTION. REPAIRED IAW SRM CHAPTER 57-06. 2 L 7 2 4F 4 F A6WE E2EA 2007091700036 20070917 00036 CE 2007 9 17 2007FA0000797 1 20070809 G 2810 FC100 FUEL CAP CESSNA 182 182P 2075816 CE CONT O470 O470* 17026 SO FUEL CELL VENTING G B EMER. DESCENT Y J ENGINE STOPPAGE WARNING INDICATION DE DESCENT 1 GL 15 58776 40 40 18262288 FUEL CAPS WERE INSTALLED ON AIRCRAFT IAW STC SA2376CE AND HAD BEEN IN SERVICE FOR ABOUT 40 HOURS IN A 4 MONTH PERIOD. TH EY BEGAN VENTING FUEL FROM BOTH TANKS RESULTING IN A FORCED EMERGENCY LANDING DUE TO FUEL STARVATION. 1 H 7 1 3O 3 O NT TA13 E273 2007091800102 20070918 00102 EA 2007 9 18 2007FA0000798 2 20070603 G 7322 30804 FLOAT AMTR COZY COZYIII 05605BK GL LYC O290 O290 41506 EA CARBURETOR SATURATED B JULR O OTHER O OTHER NR NOT REPORTED 1 SW 01 369CZ 40 1517 ENGINE FAILED ON SHORT. FINAL DUE TO CARB: FLOODING FLOAT IN CARB, HALF FULL OF GAS. (K) 1 M 7 1 3O 3 O RT EXPA1M71 E229 2007091700007 20070917 00007 SO 2007 9 17 2007FA0000799 1 20070905 G 7820 MUFFLER PIPER PA18 PA18150 7101828 SO LYC O320 O320* 41508 EA EXHAUST BROKEN G K NONE O OTHER IN INSP/MAINT 1 GL 15 7066B 36 185140 ENGINE EXHAUST TAIL PIPE FAILED AT THE MUFFLER WELD. WITH 36 HOURS TOTAL TIME SINCE NEW. LEADING EDGE EXHAUST SYSTEM W AS INSTALLED BY STC SA02200AK. 1 H 7 1 3O 3 O 1A2 E274 2007091700027 20070917 00027 EU 2007 9 17 2007FA0000800 1 20070809 G 3233 485034 ACTUATOR BRAERO DH125 BAE125800A 1500285 EU GARRTT TFE731 TFE7315BR WP RT MLG UNSERVICEABLE D O OTHER O OTHER NR NOT REPORTED 1 WP 01 919SS NA0473 RT MLG ACTUATOR CRACKED ATTACH HOUSING DISCOVERED DURING WHEEL WELL INSPECTION, PART WAS NOT LEAKING BUT COULD SEPARATE AT ANY MOMENT AND CAUSE SEVERE DAMAGE TO AIRCRAFT DATE OF ASSY OF ACTUATOR 1/92. (K) 2 L 7 2 4F 4 F RT A3EU E6WE 2007091700018 20070917 00018 EU 2007 9 17 2007FA0000801 1 20070809 G 5343 25FC5801A SUPPORT BRAERO DH125 BAE125800A 1500285 EU GARRTT TFE731 TFE7315BR WP LT MLG CORRODED D O OTHER O OTHER NR NOT REPORTED 1 WP 01 919SS 5860 NA0473 LT MLG DOOR IB AFT SUPPORT REMOVED FOR OTHER MAINTENANCE AND SEVERE INTERGRANULAR CORRODION DISCOVERED FROM LAVATORY LEA KAGE AS INDICATED BY STAINING ON PART LOCATION WHERE BONDING STRAP ATTACHES. CORROSION SEVERE AND IS ENOUGH TO CAUSE PA RT TO FAIL. (K) 2 L 7 2 4F 4 F RT A3EU E6WE 2007091700074 20070917 00074 2007 9 17 2007FA0000802 1 20070910 G 3245 6006 TUBE TIRE DEFECTIVE D K NONE W INADEQUATE Q C IN INSP/MAINT 1 NE 03 6.00 X 6 TIRE TUBES WILL NOT FIT IN 6.00 X 6 WHEEL. STEM APPEARS TO NOT BE IN CENTER AND SIZE OF TUBE IS SMALLER THAN NO RMAL. (2) TUBES FOUND TO BE IN THIS CONDITION. WHEN WE ATTEMPTED TO RETURN THE TUBES TO OUR VENDOR, WOULD NOT ACCEPT A RETURN AND THAT THE TUBES WERE NOT DEFECTIVE. 2007091700040 20070917 00040 NM 2007 9 17 2007FA0000805 1 20070911 G 2910 82970009325 LINE DHAV DHC8 DHC8106 2809020 NM PWA PW121 PW121 52124 NE HYDRAULIC SYS LEAKING H A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CR CRUISE 1 SW 99 387BC 351 PILOT NOTED LOSE HYDRAULIC LINE. DECLARED EMERGENCY AND LANDED. NO NOSE WHEEL STEERING ON GROUND. INSPECTED ALL HYDRAUL IC LINES AND FITTINGS. NOTED EDP LINE GOING TO PRESSURE MANIFOLD B NUT WAS ABLE TO GET HALF A TURN. SYSTEM SERVICED AND FUNCTIONAL CHECKED SERVICEABLE. 2 H 7 2 4T 4 T RT A13NM E20NE 2007091700063 20070917 00063 2007 9 17 2007FA0000809 1 20070912 G 3220 13022101 TAIL WHEEL WORN G O OTHER O OTHER NR NOT REPORTED 1 SW 17 912S TAILWHEEL SPRING P/N 13022.101 SHOWED EVIDENCE OF LOOSENESS AND ELONGATION OF THE FORWARD ATTACH POINT HOLE. THE ATTACH BOLT P/N AN5-22A EXHIBITED SIGNS OF FRETTING WEAR CONTRIBUTING TO THE TAILWHEEL LOOSENESS. IT WOULD APPEAR THAT THIS C ONDITION COULD INDUCE A SIGNIFICANT SIDE LOAD ON THE TAILWHEEL SPRING AFT ATTACHMENT CLAMP AND HARDWARE. THIS CONDITION WOULD BE DIFFICULT TO DETECT WITH THE WEIGHT OF THE AIRCRAFT ON THE TAILWHEEL. IT IS RECOMMENDED THAT THE CONDITION IN SPECTION INCLUDE SUPPORTING THE FUSELAGE FORWARD OF THE TAILWHEEL SPRING FORWARD ATTACHMENT POINT AND CHECKING THE TAILW HEEL ASSEMBLY FOR SECURITY AND TIGHTNESS. 2007092500184 20070925 00184 CE 2007 9 25 2007FA0000810 1 20070731 G 3222 STRUT CESSNA 182 182T 2072703 CE LYC O540 IO540* 41532 EA NLG LEAKING B AQHR O OTHER K FLUID LOSS NR NOT REPORTED 1 WP 11 5348E 18281212 FOUND NOSE STRUT ASSEMBLY LEAKING. REMOVED STRUT ASSEMBLY FROM AIRCRAFT. ASSEMBLED WITH PN TCNS-1 SEAL KIT IWA SRM AND MM. RELEASED TO AC OWNER. OWNER FOUND FLUID NR 4 ON WHEEL FAIRING AFTER TAXI TO HANGAR. INSPECTION FOUND FLUID COMIN G FROM BEHIND NOSE GEAR STEERING ASSEMBLY. CONTACTED TECH SERVICE, RECOMMENDED THA WE REPLACE THE STRUT TUBE (PN 074309 01). REMOVED LEAKING STRUT TUBE FROM AIRCRAFT. INSTALLED NEW 07430901 TUB USED NEW SEAL KIT TCNC-1 AND SERVICED. INSP ECTED OLD TUBE FOR DAMAGE. FOUND THA THE TUBE WAS LEAKING BETWEEN THE INNER TUBE AND THE OUTER-MACHINED PART. FOUND PI NHOLE IN BRAZING OF THE PARTS. (K) 1 H 7 1 3O 3 O NT 3A13 1E4 2007092500181 20070925 00181 NM 2007 9 25 2007FA0000811 1 20070906 G 2410 B1731 BELT ROBSIN R22 R22BETA 7640110 NM LYC O360 O360C1F 41514 EA ALTERNATOR BROKEN D H A DEACTIVATE SYST/CIRCUITS UNSCHED LANDING D INFLIGHT SEPARATION CR CRUISE 1 WP 23 8372G 852 2782 ALTERNATOR LIGHT CAME ON DURING CRUISE FLIGHT. FOLLOWED HELICOPTER FLIGHT MANUAL PROCEDURES AND RETURNED TO LANDING. U PON INSPECTION IT WAS DISCOVERED THAT THE ALTERNATOR BELT HAD BROKEN AND DEPARTED THE AIRCRAFT IN FLIGHT. NO OTHER DAMA GE RESULTED 1 G 7 1 3O 3 O H10WE E286 2007092500249 20070925 00249 SW 2007 9 25 2007FA0000812 1 20070919 G 6320 20401077503 QUILL ASSY BELL 204 UH1H 1181407 SW LYC T53 T53* 41549 NE WORN B O OTHER O OTHER NR NOT REPORTED 1 WP 17 3053Q 82 661104 QUILL INTERNAL SPLINES WORN AND DAMAGED IN QUILL TUBE CONTACT AREA 1 G 7 1 4U 4 U EXPA1G71 E1EA 2007092500089 20070925 00089 SO 2007 9 25 2007FA0000813 1 20070920 G 5712 7847504 RIB PIPER PA28 PA28R200 7102811 SO LYC O360 IO360A1A 41514 EA WING CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 13 2702R 6441 28R35252 CRACKS FOUND DURING INSPECTION. CRACKS FOUND IN LOWER RELIEF EDGE MADE USE OF REPAIR KIT P/N: 767 - 397 NOT POSSIBLE. T HE CRACK REQUIRED REPLACEMENT OF ENTIRE RIB ASSY WITH NEW PART 78475-004 (AN IMPROVED PART). HAVE DIGITAL PHOTOS OF THE CRACKED RIB, THE CRACKS ARE CAUSED BY FLEXING OF THE SPAR BY THE LANDING GEAR SIDE BRACE DUE TO SIDE LOADS DURING LANDIN G. IF NO REPLACED I DON'T SEE AN INFLIGHT FAILURE, BUT COULD SEE POSSIBILITY OF LANDING GEAR COLLAPSE. 1 L 7 1 3O 3 O 2A13 1E10 2007092500110 20070925 00110 SO 2007 9 25 2007FA0000815 1 20070920 G 5712 7847504 RIB PIPER PA28 PA28R200 7102811 SO LYC O360 IO360A1A 41514 EA WING CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 13 2702R 6441 28R35252 CRACKS FOUND DURING INSPECTION, CRACKS FOUND IN LOWER RELIEF EDGE MADE USE OF REPAIR KIT P/N: 767 - 397 NOT POSSIBLE. TH E CRACK REQUIRED REPLACEMENT OF ENTIRE RIB ASSY. WITH NEW MFG PART 78475-004 (AN IMPROVED PART). HAVE DIGITAL PHOTOS OF THE CRACKED RIB, THE CRACKS ARE CAUSED BY FLEXING OF THE SPAR BY THE LANDING GEAR SIDE BRACE DUE TO SIDE LOADS DURING L ANDING. IF NO REPLACED I DON'T SEE AN INFLIGHT FAILURE, BUT COULD SEE POSSIBILITY OF LANDING GEAR COLLAPSE. 1 L 7 1 3O 3 O 2A13 1E10 2007092500142 20070925 00142 SO 2007 9 25 2007FA0000816 1 20070917 G 3810 91000106 SOCKET GULSTM GV GULFSTREAMGV 3980116 SO RROYCE BR700 BR700710A110 NE BURNED B K NONE B SMOKE/FUMES/ODORS/SPARKS LD LANDING 1 GL 15 23M 3606 579 THE SOCKET ON ONE OF THE (2) LAMPS BURNED CAUSING AN ELECTRICAL ODOR IN THE BAG BIN WHERE THE STERILIZER IS LOCATED. TH E 2 AMP CIRCUIT BREAKER WHICH CONTROLS THE POWER TO THE STERILIZER DID NOT POP. 2 L 7 2 4F 4 F RT A12EA E00057EN 2007092500145 20070925 00145 CE 2007 9 25 2007FA0000817 1 20070917 G 2434 DOFF10300B ALTERNATOR CESSNA 210 T210M 2073451 CE CONT O520 TSIO520* 17040 SO FAILED D D RETURN TO BLOCK H ELECT. POWER LOSS-50 PC TX TAXI/GRND HDL 1 SW 15 732YK 458 21061879 OVERHAULED DOFF10300B ALTERNATOR FAILED AFTER 458 HOURS IN 35 MONTHS OF USE. 1 H 7 1 3O 3 O 3A21 E8CE 2007092500163 20070925 00163 SO 2007 9 25 2007FA0000818 2 20070919 G 8530 639614639615 ROCKER CESSNA 172 172H 2072424 CE CONT O300 O300D 17022 SO VALVE ROCKER MISINSTALLED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 25 4960R 287 17256296 025668R ROCKER COVERS REMOVED DURING 100 HOUR INSPECTION TO INSPECT INTAKE AND EXHAUST ROCKERS FOR CORRECT INSTALLATION. FOUND N R1 AND NR6 CYLINDERS HAD INTAKE ROCKER (P/N 639614) INSTALLED IN THE EXHAUST VALVE POSITION. PARTS MANUAL CALLS FOR P/N 639615 ROCKER TO BE INSTALLED IN EXHAUST VALVE POSITION. THIS IS THE SECOND ENGINE DISCOVERED WITH THE SAME ABNORMALITY AFTER RECENT OVERHAULS FROM SAME OVERHAUL FACILITY. 1 H 7 1 3O 3 O NT 3A12 E253 2007092500170 20070925 00170 EA 2007 9 25 2007FA0000819 2 20070924 G 7414 LW14227 BEARING LYC PIPER PA28 PA28180 7102808 SO LYC O360 O360A4A 41514 EA MAGNETO DESTROYED D K NONE O OTHER IN INSP/MAINT 1 GL 19 5147L 857 857 284432 L3421136A BEARING LW14227 CAGE DESTROYED AND APPROXIMATELY 50 PERCENT MISSING. THIS IS THE ENGINE SIDE BEARING OF THE LW15416 MAG NETO DRIVE ADAPTER (MAGNETO ISOLATION DRIVE FOR RT MAGNETO)ENGINE HAS 857 HOURS SINCE FACTORY OVERHAUL IN 2000. 1 L 7 1 3O 3 O 2A13 E286 2007092500171 20070925 00171 EA 2007 9 25 2007FA0000820 2 20070924 G 8540 LW14227 BEARING PIPER PA28 PA28180 7102808 SO LYC O360 O360A4A 41514 EA ENGINE DESTROYED D K NONE O OTHER IN INSP/MAINT 1 GL 19 5147L 857 857 284432 L3421136A BEARING LW14227 CAGE DESTROYED AND APPROXIMATELY 50 PERCENT MISSING. THIS IS THE ENGINE SIDE BEARING OF THE LW15416 MAG NETO DRIVE ADAPTER (MAGNETO ISOLATION DRIVE FOR RIGHT HAND MAGNETO). ENGINE HAS 857 HOURS SINCE FACTORY OVERHAUL IN 200 0. 1 L 7 1 3O 3 O 2A13 E286 2007092500250 20070925 00250 CE 2007 9 25 2007FA0000822 1 20070904 G 3210 AN39227 PIN BEECH 36 A36 1151604 CE CONT O550 IO550* SO MLG SHEARED G A UNSCHED LANDING O OTHER LD LANDING 1 GL 13 998PL 848 100 E3036 THE LOWER IB BUSHING ON THE LOWER TORQUE LINK KNEE WAS DRY AND THE PIVOT PIN WHICH RIDES IN THE BUSHING WAS VERY TIGHT P OSSIBLY DUE TO A PLUGGED GREASE ZERK FITTING. THIS APPARENTLY CAUSED THE CLEVIS RETAINING PIN TO SHEAR (AS EVIDENCED BY THE SHEAR MARKS ON THE REMAINING PORTION OF THE PIN), THE PIVOT PIN TO FALL OUT AND THE GEAR TO EXTEND TO THE POINT WHER E IT WAS ONLY BEING HELD BY THE BRAKE LINE. ONCE THE AIRCRAFT TOUCHED DOWN THE UNRESTRAINED WHEEL ASSEMBLY TURNED AND WA S TORN FROM THE REST OF THE GEAR. 1 L 7 1 3O 3 O 3A15 E3SO 2007100200050 20071002 00050 EA 2007 10 2 2007FA0000823 2 20070824 G 7414 M3548 ROTOR CESSNA 172 172N 2072434 CE LYC O360 O360A4M 41514 EA SHAFT FAILED C E92R O OTHER O OTHER NR NOT REPORTED 1 GL 09 733XN 367 05120929 17268632 PILOT DEPARTED ON A VFR, DAY FLIGHT. DURING THE CLIMB FROM DEPARTURE, THE PILOT NOTICED A SLIGHT ENGINE ROUGHNESS THAT LASTED ONLY A SECOND. THE ENGINE SMOOTHED OUT UNTIL THE AC WAS LEVELED OUT AT CRUISE ALTITUDE AND CRUISE POWER SETTINGS THE ENGINE BEGAN RUNNING ROUGH. THE PILOT PERFORMED A MAGNETO CHECK IN FLIGHT FINDING THE RT MAGNETO INOPERATIVE. THE PILOT SWITCHED TO LT MAGNETO AND RETURNED TO LAND AT DEPARTURE WITHOUT INCIDENT. UPON OPENING THE MAGNETO, THE ROTO GE AR PN M3827 AND THE GEAR IN THE DISTRIBUTOR BLOCK ASSY PN K3822 WERE NOT DAMAGED AND WERE FREE OF OBSTRUCTION AND MOVED WITHOUT BINDING. THE SHAFT BROKE JUST BELOW THE SLOT IN THE SHAFT THAT HOLDS THE CAM WHICH OPENS THE CONTACTS. THERE D 1 H 7 1 3O 3 O NT 3A12 E286 2007100200052 20071002 00052 CE 2007 10 2 2007FA0000824 1 20070826 G 5343 05430161 FITTING CESSNA 172 172P 2072436 CE LYC O320 O320* 41508 EA NLG CRACKED D O OTHER O OTHER NR NOT REPORTED 1 GL 25 97873 11305 17276236 AC WAS BEING TAXIED FROM THE RAMP TO THE TAXIWAY, AND DURING TAXI, THE PILOTS REPORTED THAT THE NOSE GEAR STEERING SEEME D TO BE MALFUNCTIONING. UPON INSPECTION, THE NOSE GEAR STRUT APPEARED TO BE PRESSED UP AGAINST THE REAR HALF OF THE LOW ER COWLING. THE LOWER NOSE GEAR FITTING (PN 0543016-1) WAS INSPECTED AND FOUND TO BE CRACKED COMPLETELY OFF ON THE RT S IDE. THE LT SIDE OF THE NOSE GEAR FITTING WAS STILL INTACT. THE CAP PN 05430181 WHICH CLAPS THE NOSE GEAR STRUT TO THE LOWER NOSE GEAR FITTING WAS FOUND TO BE MISSING FROM THE AIRCRAFT. THE HARDWARE WHICH ATTACHED THE LT SIDE OF THE CAP TO THE LOWER NOSE GEAR FITTING WAS FOUND TO BE MISSING ALONG WITH THE CAP. (K) 1 H 7 1 3O 3 O NT 3A12 E274 2007100200058 20071002 00058 SO 2007 10 2 2007FA0000825 2 20070821 G 7314 64936849A1 PUMP DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240B 17063 SO SNSNCH W69EK W69EK63 EA FUEL SYSTEM FAILED C B4VS O OTHER O OTHER NR NOT REPORTED 1 WP 07 708DC C0408 650211 AG9712 THE MIXTURE CONTROL SHAFT ON THE ENGINE DRIVEN FUEL PUMP FROZE UP AT HALF TRAVEL BETWEEN FULL RICH AND IDLE CUT OFF. TH IS CREATED A LEAN MIXTURE CONTROL WAS DISCONNECTED FROM THE FUEL PUMP, THEN THE FUEL PUMP CONTROL SHAFT HAD TO BE FREED UP. THE MIXTURE CABLE WAS COMPLETELY FREE WITH NO BINDING ONCE DISCONNECTED FRO THE FUEL PUMP. THE FUEL PUMP WAS REPLA CED AND SENT BACK TO MFG. (K) 1 L 7 1 3O 3 O NT TA4CH E7SO 5 N TA4CH 2007100200086 20071002 00086 CE 2007 10 2 2007FA0000826 1 20070808 G 2731 NAS302261510 CONTROL CABLE BEECH 300 300BEECH 1152930 CE ELEVATOR TRIM FRAYED D K NONE O OTHER IN INSP/MAINT 1 NE 05 122RG 389 FL448 DURING SCHEDULED INSPECTION OF THE AC, THE MECHANIC FOUND THE LT ELEVATOR PITCH TRIM CONTROL CABLE CHAFING ON THE ELEVAT OR CABLE PASS THROUGH HOLE LOCATED IN SKIN PN 101-620000-3. THE ELEVATOR CABLE PASS THROUGH HOLE REQUIRED TRIMMING TO A LLOW PROPER CLEARANCE. ADJUSTMENTS TO PASS THROUGH HOLE ACCOMPLISHED IAW IAW MFG. (K) 2 L 7 2 4T A24CE 2007100200087 20071002 00087 CE 2007 10 2 2007FA0000827 1 20070814 G 7500 4536102150V431 MANIFOLD LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE731* 01518 WP LT ENGINE DAMAGED B KKQR O OTHER O OTHER NR NOT REPORTED 1 GL 11 858MK 2402 141 LT PYLON OVERHEAT INDICATION OCCURRED IN FLIGHT. FOUND HIGH PRESSURE BLEED AIR MANIFOLD MATING FLANGE DEFORMED. REPLAC ED ASSY 4536102150V43-1 WITH NAV ASSY 45361020228-001. CAUSE MAY BE AGE OR REPEATED CLAMPING. ORIGINAL PART HAS BEEN S UPERSEDED BY THE MFG. (K) 2 L 7 2 4F 4 F RT T00008WI E6WE 2007100300004 20071003 00004 SO 2007 10 3 2007FA0000828 2 20070906 G 8530 SA52000A20P CYLINDER CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO NR 2 CRACKED D O OTHER O OTHER NR NOT REPORTED 1 AL 03 4891Z 1790 U20606044 818885R CYLINDER HEAD HAS A CRACK. BEGINNING AT INTAKE PORT AND EXTENDING TO UPPER SPARK PLUG HOLE. (K) 1 H 7 1 3O 3 O A4CE E5CE 2007100200090 20071002 00090 WP 2007 10 2 2007FA0000829 1 20070831 G 6720 369D21800501 CONTROL SYSTEM HUGHES 369 369D 4470706 WP T/R PITCH ROUGH B EOOR O OTHER O OTHER NR NOT REPORTED 1 AL 03 C6DCM 1181 DURING 100 HR INSPECTION, PLAY WAS NOTICED BETWEEN THE ROTATING AND NOT-ROTATING SWASH PLATES OF THE TAIL ROTOR PITCH CO NTROL AFTER REMOVAL, IT WAS NOTED THAT THE BEARING WAS DRY AND ROUGH. RECORDS INDICATE IT WAS REGREASED IN DEC OF 2006. (K) 1 G 7 1 3U H3WE 2007100300006 20071003 00006 CE 2007 10 3 2007FA0000830 1 20070912 G 5755 COVER BEECH MU300 400A 1155402 CE PWA JT15 JT15D5 52112 NE SPOILER MIXER CORRODED B KX5R K NONE O OTHER IN INSP/MAINT 1 GL 15 156DH RK36 WHILE PERFORMING A SCHEDULED A-D INSPECTION FOUND SPOILER MIXER ASSEMBLY BOX COVER NOT SEALED. REMOVED COVER AND FOUND CORROSION ON ACTUATOR AND MIXER ASSEMBLY. RECOMMEND THAT THE SPOILER MIXER AREA BE INSPECTED THOROUGHLY THE BOX COVER R EMOVED. INSTALLED THE BOX COVER WITH THE APPROPRIATE SEALANT. (K) 2 H 7 2 4F 4 F RT A16SW E25EA 2007100300007 20071003 00007 CE 2007 10 3 2007FA0000831 1 20070912 G 2120 45A63517073 AIR DUCT BEECH MU300 400A 1155402 CE PWA JT15 JT15D5 52112 NE BLEED AIR CRACKED B KX5R K NONE O OTHER IN INSP/MAINT 1 GL 15 156DH RK36 WHILE PERFORMING A SCHEDULED A-D INSPECTION FOUND THE LEFT AFT FUSELAGE BLEED AIR LINE BELLOWS BLOWN APART PN 45A63517-0 73 AND THE RT AFT FUSELAGE BLEED AIR LINE BELLOWS BRAIDING FRAYING PN 45A63517-075. WHEN THE LT BLEED AIR LINE BLEW APA RT IT CRACKED A FUSELAGE BULKHEAD AT UPPER FRAME STATION 329.92 AND BP 29.92L. WOULD RECOMMEND THAT DETAILED INSPECTION S OF THESE BLEED AIR LINES BE PERFORMED AT SCHEDULED INTERVALS AND THE UPPER FRAME STATION IN THE AREA AROUND THE BLEED AIR LINES BE CAREFULLY INSPECTED FOR DAMAGE. IT IS SUSPECTED THAT BOTH THE BLEED AIR LINES FAILED DUE TO FATIGUE OR TIM E IN SERVICE. (K) 2 H 7 2 4F 4 F RT A16SW E25EA 2007100300008 20071003 00008 CE 2007 10 3 2007FA0000832 1 20070912 G 5610 45AS3101012 WINDOW BEECH MU300 400A 1155402 CE PWA JT15 JT15D5 52112 NE COPILOT CRACKED B KX5R K NONE O OTHER IN INSP/MAINT 1 GL 15 141DR RK184 WHILE PERFORMING A SCHEDULED A-D INSPECTION FOUND COPILOT COCKPIT SIDE WINDOW CRACKED USING THE PRISM INSPECTION METHOD. THE D-INSPECTION REQUIRES THAT BOTH WINDSHIELDS BE INSPECTED BY REMOVING THE WINDSHIELD RETAINERS OR USING OPTICAL PRI SM INSPECTION METHOD. THERE IS NO STATEMENT IN THE AC MM OR IN THE A-D INSPECTION CHECKLIST THAT REQURIES YOU TO INSPEC T THE COCKPIT SIDE WINDOWS IN THE SAME MANNER AS THE WINDSHIELDS. ALL OF THE WINDOWS IN THE COCKPIT AREA ARE INSTALLED OR FASTENED IN THE SAME MANNER AS THE WINDSHIELDS. IT IS SUSPECTED THAT THE COPILOT SIDE WINDOW CRACKED FROM FATIGUE, O R TOTAL TIME INSTALLED. THE WINDOW WAS MFG MAY OF 1997. WOULD RECOMMEND THAT INSPECTION OF ALL COCKPIT WINDOWS WITH A 2 H 7 2 4F 4 F RT A16SW E25EA 2007100300010 20071003 00010 CE 2007 10 3 2007FA0000833 1 20070912 G 5510 STRUCTURE BEECH MU300 400A 1155402 CE PWA JT15 JT15D5 52112 NE HORIZONTAL STAB DAMAGED B KX5R K NONE O OTHER IN INSP/MAINT 1 GL 15 141DR RK184 WHILE PERFORMING A SCHEDULED A-D INSPECTION FOUND 6 SHEARED RIVETS AND 2 LOOSE RIVETS IN THE FORWARD RIVET LINE OF THE A TTACHMENT PIVOT FITTING PN 45A21183-11 ON THE BOTTOM OF THE HORIZONTAL STABILIZER. IT IS SUSPECTED THAT THE MISSING RIV ETS FAILED FROM FATIGUE. RECOMMEND INSPECTING AREA THOROUGHLY AT EACH INSPECTION, CONTACTING MFG FOR REPAIR OPTIONS. T HIS IS SECOND AC THAT THE SAME DISCREPANCY HAS BEEN FOUND. (K) 2 H 7 2 4F 4 F RT A16SW E25EA 2007100300011 20071003 00011 CE 2007 10 3 2007FA0000834 1 20070912 G 5510 STRUCTURE BEECH MU300 400A 1155402 CE PWA JT15 JT15D5 52112 NE HORIZONTAL STAB DAMAGED B KX5R K NONE O OTHER IN INSP/MAINT 1 GL 15 156DH RK36 WHILE PERFORMING A SCHEDULED A-D INSPECTION FOUND 8 SHEARED RIVETS IN THE FORWARD RIVET LINE OF THE ATTACHMENT PIVOT FIT TING PN 45A21183-11 ON THE BOTTOM OF THE HORIZONTAL STABILIZER. IT IS SUSPECTED THAT THE MISSING RIVETS FAILED FROM FAT IGUE. RECOMMEND INSPECTING AREA THOROUGHLY AT EACH INSPECTION. (K) 2 H 7 2 4F 4 F RT A16SW E25EA 2007100300012 20071003 00012 CE 2007 10 3 2007FA0000835 1 20070802 G 2760 3321209 ADJUSTER LEAR LEAR 25 25D 5170514 CE BRAKE VALVE DAMAGED B O OTHER O OTHER NR NOT REPORTED 1 CE 09 9711105 UPON VISUAL INSPECTION OF THE POWER BRAKE VALVE PN 60810741-804, SN 9711105, IT WAS FOUND THAT THE ADJUSTMENT SCREW HAD BEEN GROUND DOWN AND MODIFIED. AS WE BEGAN TO LOOK THROUGH SB 23/24/25-32-12 AND FOUND THAT THIS UNIT PN WAS NOT IN TH IS SB. WE THEN FOUND THAT THIS UNIT WAS FOR A LEAR 60. WE THEN LOOKED INTO THE MFG PARTS BREAKDOWN AND FOUND THAT THE LEVER AS WELL AS THE MODIFIED ADJUSTMENT SCREW, THE STOP SCREW AND PIN DID NOT BELONG ON THIS PN OF POWER BRAKE VALVE. THISE PARTS ARE FOR A PN 2380002 OR PN 2381443 OR PN 3321200-3 POWER BRAKE VALVE. WE CONTACTED OUR CUSTOMER AND FOUND T HAT THIS UNIT WAS REMOVED FROM LEAR 25D. 2 L 7 2 4J A10CE 2007100300013 20071003 00013 CE 2007 10 3 2007FA0000836 1 20070806 G 3411 STATIC SYSTEM LEAR 35 35A 5170602 CE GARRTT TFE731 TFE731* 01518 WP MISINSTALLED B O OTHER W INADEQUATE Q C NR NOT REPORTED 1 CE 09 621RB 211 THIS RVSM AIRCRAFT HAD AN ALTIMETRY SYSTEM SPLIT. CONTACTED STC GROUP HOLDER FOR PROPER ROUTING OF STATIC SYSTEM PLUMBI NG. FOUND CO-PILOTS SYSTEM WAS NOT CROSS COUPLED WITH PILOTS SYSTEM. INSTALLED FABRICATED HOSES TO THE CO-PILOTS SYSTE M TO MEET STC NR ST 00563DE-D. PROBABLE CAUSE: CO-PILOTS STATIC SYS NOT CROSS-COUPLED AT STC INSTALLATION OR SYSTEM WAS MODIFIED/ ALTERED POST-STC WITHOUT APPROVED DATA. (K) 2 L 7 2 4F 4 F A10CE E6WE 2007100300014 20071003 00014 NE 2007 10 3 2007FA0000837 2 20070822 G 7230 BLADE BOEING 737 737800* NM CFMINT CFM56 CFM567B26US NE HPC DAMAGED B QEMY O OTHER O OTHER NR NOT REPORTED 1 EA 35 EIDCN XAEF2436 892123 ENGINE SURGED ON WING AND WAS INDUCTED INTO SHOP FOR I/V. DURING STRIP IT WAS NOTED THAT 1 OFF HPC STAGE 3 BLADE HAD BE EN LIBERATED TOGETHER WITH A SECTION OF THE DOVETAIL FROM THE STG 3 DISK. SECONDARY DAMAGE WAS ALSO NOTED ON THE HPC RO TOR AND STATORS. INSPECTION OF THE FRONT STATOR CASES REVEALED THAT A VSV STAGE 3 LEVER ARM WAS MISSING AND APPEARED NO T TO HAVE INSTALLED. NB ESN 892123 INPUTTED AS 1ST SV SINCE NEW. (K) 2 L 7 2 4F 4 F RT A16WE E00055EN 2007100300015 20071003 00015 GL 2007 10 3 2007FA0000838 2 20070815 G 7230 6898607 BEARING SCWZER 269 269D 8059501 EA ALLSN 250C 250C20 03013 GL NR 1 FAILED C O OTHER O OTHER NR NOT REPORTED 1 SW 03 411HV 0040A CAE845096 PILOT REPORTED CHIP LIGHT CAME ON DURING TRAINING FLIGHT. LANDED AS SOON AS POSSIBLE AND PROBE REMOVED AND CLEANED. GR OUND RUN MADE IAW MM AND CHIP PULLED AND INSPECTED. MORE METAL FOUND SO ENGINE REMOVED FROM AC AND INSPECTED. FOUND NR 1 BEARING OF COMPRESSOR ASSY FAILING. NO EVIDENCE OF OVERHEATING OR OIL STARVATION. PILOT REPORTED NO LOSS OF OIL PRE SSURE DURING FLIGHT. (K) 1 G 7 1 3U 3 U 0 4H12 E4CE 2007100300018 20071003 00018 SO 2007 10 3 2007FA0000840 2 20070818 G 7322 1048931 CARBURETOR CESSNA 182 182G 2072716 CE CONT O470 O470R 17026 SO ENGINE FAILED D O OTHER O OTHER NR NOT REPORTED 1 WP 19 2347R 18255447 1316145R PILOT REPORTED THAT AFTER A NORMAL START, HE WAS UNABLE TO ADVANCE THE THROTTLE CONTROL TO CRUISE OR TAKEOFF POWER. A P ARTIAL DISASSEMBLY OF THE CARBURETOR REVEALED THAT THE AIR METERING PIN/AIR METERING JET WAS BLOCKING THE THROTTLE SHAFT TRAVEL. THE CARBURETOR WAS SENT FOR REPAIR. (K) 1 H 7 1 3O 3 O NT 3A13 E273 2007100300019 20071003 00019 EA 2007 10 3 2007FA0000841 2 20070818 G 8530 AEL65102 CYLINDER CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA NR 4 FAILED D A UNSCHED LANDING E VIBRATION/BUFFET CR CRUISE 1 GL 13 9815L 17276618 DURING CRUISE FLIGHT, THE PILOT REPORTED A LOUD BANG FOLLOWED BY EXCESSIVE VIBRATION, INCREASED POWER TO FULL TO MAINTAI N ALTITUDE AND MADE A WELL-EXECUTED,, PRECAUTIONARY LANDING. AFTER SHUTDOWN THERE WAS A LARGE OIL PUDDLE DEVELOPING UND ER THE AIRCRAFT. AIRPLANE COWL REMOVED AND NR 4 CYLINDER WAS FOUND TO HAVE THE TOP HALF SEPARATED FROM THE BOTTOM. THI S CYLINDER REPORTED TO BE IN SERVICE LESS THAN A YEAR. THE CYLINDER HAS THE CASTING NR AEL85099 WHICH IS NOT SUBJECT TO AD2006-12-07 OR SB NR 05-8. ENGINE HAS (3) OTHER CYLINDERS WITH THE SAME CASTING NUMBER INSTALLED. IT IS ESTIMATED TH AT ENGINE LOST 2.5 QUARTS OF OIL DURING THE FEW MINUTES BETWEEN THE SEPARATION AND THE SHUTDOWN. MECHANIC SUGGEST FAA L 1 H 7 1 3O 3 O NT 3A12 E274 2007100300020 20071003 00020 SO 2007 10 3 2007FA0000842 2 20070907 G 8530 654375 ROCKER SHAFT CONT O200 O200* 17020 SO CYLINDER LOOSE D K NONE O OTHER IN INSP/MAINT 1 SO 03 977CC 256314 IAW OWNERS REQUEST, REMOVED ALL (4) ROCKER COVERS TO INSPECT THE ROCKER SHAFT AND SET SCREWS. AFTER REMOVING THE ROCKER COVERS. FOUND ALL(4) SET SCREWS LOOSE AND ALL (4) SHAFTS MOVED TOWARD THE INTAKE SIDE OF THE BOSSES. NONE HAVE CUT THE ROCKER COVERS YET, IN ANOTHER 20 HOURS OR SO THEY WOULD. NOTE: THE NEW ENGINE HAVE A FLAT CUT INTO THE ROCKER SHAFT, A ND A SET SCREW IN THE CENTER BOSS, TO RETAIN THE SHAFT. ALSO, THE SHAFT IS SHARP ON THE END, UNLIKE THE OLD STYLE, AND HAVE A CUT MARK ACROSS THE END OF THE SHAFT FOR USE IN ALINING THE FLAT FOR THE SET SCREW. THE SET SCREW IS A MS51963-6 4, AND USES NO LOCKTITE, OR MECHANICAL TYPE LOCK. THE FLAT IN THE ROCKER SHAFT IS NOT DEEP ENOUGH TO PROVIDE ADEQUATE L 3 O E252 2007100300022 20071003 00022 GL 2007 10 3 2007FA0000844 1 20070813 G 2731 700232 CABLE WACO YMF YMFF5C 9600425 GL JACOBS R755 R7557 35003 EA HAMSTD 2B 2B20 NE PITCH SERVO INOPERATIVE C O OTHER O OTHER NR NOT REPORTED 1 GL 09 919TT F5C111 22353 31606 THE PITCH SERVO BRIDLE CABLE WAS FOUND TO BE LOOSE AND NOT CONNECTED TO THE CAPSTAN. IT WAS WOUND BETWEEN THE BOTTOM EN D OF THE CAPSTAN AND THE CAPSTAN END PLATE WITH THE CLAMP TO THE ELEVATOR CABLE HAVING BEEN SLIDING ON THE ELEVATOR CABL E. THE ELEVATOR WAS FOUND TO BE FREE TO MOVE NORMALLY IT IS NOT KNOWN HOW THIS MALFUNCTION OCCURRED. IT IS POSSIBLE TH AT THE BRIDLE CABLE CLAMP WAS NOT SUFFICIENTLY TIGHT ALLOWING THE BRIDLE CABLE TO BECOME SLACK AND COMING LOOSE IN THE C APSTAN. (K) 1 Q 7 1 3R 3 R ATC542 5E11 5 C P255 2007100300023 20071003 00023 SO 2007 10 3 2007FA0000845 2 20070817 G 7414 6314 MAGNETO CIRRUS SR SR20 05628AJ GL CONT O360 IO360ES SO ENGINE ARCED D K NONE O OTHER IN INSP/MAINT 1 SO 05 814RA 444 1663 FP4677 DURING ANNUAL INSPECTIO, 500 HR MAG INSP COMPLIED WITH EARLY DUE TO NR OF HOURS PREVIOUSLY FLOWN. BOTH MAGNETOS SHOWED SAME INTERNAL ARCING, SO SEVERE, THAT BRUSH HOLDER PN K3823 WAS MELTED/ BURNED UP, CONTACTED SLICK TECH SUPPORT 904-739- 4360, OUR MAG S/N`S WERE MATCHED TO PROBLEM MAGS WHICH SLICK WAS AWARE OF CARBON USED IN MFG OF BRUSHES TOO SOFT, CARBON DUST CAUSED ARCING. IT IS A WONDER THIS CUSTOMERS ENGINE CONTINUED TO RUN. (K) 1 L 7 1 3O 3 O NT A00009CH E1CE 2007100300026 20071003 00026 CE 2007 10 3 2007FA0000846 1 20070913 G 5520 05341221 HORN CESSNA 172 172S 2072439 CE LYC O360 IO360A1A 41514 EA ELEVATOR LOOSE D O OTHER O OTHER NR NOT REPORTED 1 NE 05 672EB 1827 172S8672 ELEVATOR HORN BEARING LOOSE IN BORE OF HORN, PN 0534122-1, BEARING ITSELF IS NOT WORN OUT BUT THERE IS PLAY BETWEEN THE TWO PARTS. 1 H 7 1 3O 3 O NT 3A12 1E10 2007100300017 20071003 00017 GL 2007 10 3 2007FA0000849 1 20070926 G 5350 18583002 FAIRING CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO RT WING ROOT SEPARATED D O OTHER D INFLIGHT SEPARATION NR NOT REPORTED 1 EA 21 631SR 200 200 2442 LOWER SECTION OF RT WING ROOT FAIRING SEPARATED FROM AIRCRAFT IN FLIGHT. FAIRING IS RETAINED WITH JUST A FEW SCREWS AND AN AREA OF THE LOWER PORTION OF FAIRING IS RETAINED WITH DOUBLE SIDED TAPE AND AN AREA OF DOUBLE SIDED TAPE CAME DEBOND ED AND AIR GOT UNDER IT AND IT RIPED OFF. 1 L 7 1 3O 3 O NT A00009CH E3SO 2007100300025 20071003 00025 CE 2007 10 3 2007FA0000850 1 20070927 G 7810 02R3022406 EXHAUST DUCT BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA RT ENGINE CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 99 12033 280 PCE85195 WHILE PERFORMING SCHEDULED MAINTENANCE, REMOVED RT EXHAUST STACKS TO FACILITATE INSPECTING THE EXHAUST DUCT. FOUND A 1 INCH CRACK IN THE SKI SLOPE. SB 3380 WAS COMPLIED WITH 711 HOURS EARLIER. POWER SECTION WAS PULLED AND SENT OFF FOR RE PAIR. 1 L 7 2 4T 4 T A24CE E4EA 2007101100208 20071011 00208 CE 2007 10 11 2007FA0000851 1 20071001 G 3250 S11073 ROD END CESSNA 182 182A 2072704 CE CONT O470 O470* 17026 SO MLG BROKEN G O OTHER J WARNING INDICATION LD LANDING 1 SO 15 2145G 51445 ROD END AT STEERING COLLAR SHEARED CAUSING LOSS OF DIRECTIONAL CONTROL. 1 H 7 1 3O 3 O NT 3A13 E273 2007101100211 20071011 00211 NE 2007 10 11 2007FA0000852 3 20070924 G 6114 MS24665134 COTTER PIN RKWELL OV10 OV10A 6402512 GL HAMSTD 33LF 33LF NE PROP SPINNER MISSING G O OTHER O OTHER CR CRUISE 1 SO 15 614V 33813 SPINNER WAS LOST FROM RT ENGINE WHILE IN A RT TURN AT 7000 FT DAMAGING ONE PROPELLER BLADE. SPINNER NOT RECOVERED. 1 H 7 2 4T RT EXPX1H72 5 C P20EA 2007101100220 20071011 00220 CE 2007 10 11 2007FA0000853 1 20070920 G 7810 310103901 FLANGE BEECH 90 E90 1152914 CE PWA PT6 PT6A135 52043 NE EXHAUST CRACKED D O OTHER O OTHER NR NOT REPORTED 1 GL 15 90XS LW342 (2) NEW ENGINES WERE INSTALLED IAW MFG MODIFICATIONS, WITH 938.0 HRS SINCE NEW. AIRCRAFT WAS IN FOR A PHASE INSPECTION AND FOUND 3 OUT OF L1 EXHAUST FLANGES ON THE ENGINE CRACKED. ACCORDING TO THE MFG PARTS MANUAL, EXHAUST STIFFENERS ARE NOT USED ON THIS SN AC AND ARE NOT USED WITH MFG INSTALLATION INSTRUCTIONS. (K) 1 L 7 2 3T 4 T 3A20 E4EA 2007101500227 20071015 00227 CE 2007 10 15 2007FA0000854 1 20070809 G 7810 40B22318 EXHAUST STACK CESSNA 206 T206H 2073303 CE LYC O540 TIO540AJ1A EA MCAULY 3D36C B3D36C432 GL ENGINE LOOSE B Z08R O OTHER O OTHER NR NOT REPORTED 1 CE 07 168JS 98 T20608735 L1266161E DURING AN INSPECTION, FOUND THE EXHAUST STACK AT NR 2 CYLINDER, PULLED DOWN .0625 INCH APPROX. FURTHER INVESTIGATION FO UND THE NR1, NR3, NR5 AND NR 6 ENGINE CYLINDERS EXHAUST STACKS PULLED DOWN, BUT NOT AS MUCH. AFTER RECOMMENDATIONS FROM ENGINE MFG ALSO, THE SUPPLIER EXHAUST SYSTEM (WHICH IS ONE IN THE SAME). DURING THE ENGINE CYLINDER REMOVAL PROCESS FO UND LOWER FWD, .7500 INCH STUD NUT UNDER TORQUED. FURTHER INVESTIGATION REVEALED THE FORWARD 2 STUDS BOTH BELOW, MFG RE COMMENDED DRIVING TORQUE OF CYLINDER HOLDDOWN STUDS IN CASE. INSTALLED NEW OVERSIZE (.003) STUDS IAW ENG MFG RECOMMENDA TIONS. INSTALLED NEW NR 2 ENGINE CYLINDER AND NEW EXHAUST CROSSOVER PIPE AS REQUIRED. TIGHTENING THE EXHAUST FLANGE NU 1 H 7 1 3O 3 O RT A4CE E14EA 5 C P58GL 2007101500229 20071015 00229 GL 2007 10 15 2007FA0000855 2 20070906 G 7320 23072790 FADEC BELL 407 407 1182206 SW ALLSN 250C 250C47B GL FAILED B VK1R O OTHER O OTHER NR NOT REPORTED 1 SW 19 509PD 350 53703 CAE847760 AIRCRAFT WAS STARTED IN A NORMAL MANNER. JUST PRIOR TO LIFT OFF THE (FADEC FAIL), (AUTO RELIGHT) WARNING LIGHTS ILLUMIN ATED AND THE FADEC FAIL HORN SOUNDED. NO LIMITATIONS WERE RECORDED OR OBSERVED. THE FADEC CONTROL ASSY WAS RETURNED TO MFG FOR ANALYSIS. (K) 1 G 7 1 3U 3 U O H2SW E1GL 2007101500233 20071015 00233 2007 10 15 2007FA0000856 4 20070911 G 3457 066011480102 RECEIVER CESSNA 208 208B 2073701 CE PWA PT6 PT6* 52043 EA GPS SMOKE D A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 GL 25 24MG 1664 208B0850 SHORTLY AFTER TAKEOFF FROM ISP THE PILOT NOTICED SMOKE IN THE COCKPIT. THE PILOT IMMEDIATELY RETURNED TO DEPARTURE AND LANDED. THE PILOT REPORTED THAT THE SMOKE APPEARED TO BE CAUSED BY AN ELECTRICAL PROBLEM. THE PILOT REPORTED THAT THE GPS NO LONGER OPERATED. ON 9/12/2007, MECHANIC INSPECTED THE AIRCRAFT, REMOVED THE GPS AND FOUND THAT IT SMELLED OF ELE CTRICAL SMOKE, THE MECHANIC EXAMINED THE RADIO RACK, WIRING HARNESSES AND ENTIRE INSTRUMENT PANEL AREA AND FOUND NO PROB LEM. THE ENGINE COMPARTMENT AND ELECTRICAL EQUIPMENT BOX WERE INSPECTED WITH NO PROBLEMS FOUND. THE AIRCRAFT WAS GROUN D RUN AND ALL ELECTRICAL EQUIPMENT WAS OPERATIONAL TESTED WITH THE GPS UNIT REMOVED AND ALL OPERATED NORMALLY. THE GPS 1 H 7 1 3T 3 T A37CE E2NE 2007102300058 20071023 00058 CE 2007 10 23 2007FA0000858 1 20070427 G 5711 1369 SPAR BBAVIA 11 11CC 9140404 CE CONT C85 C85* 17008 SO RT WNG DETERIORATED D O OTHER O OTHER NR NOT REPORTED 1 NM 05 4546E 11CC249 REPORT IAW AD 200-25-02R1 PARAGRAPH D (4) LOOSE, MISSING AND RUSTED NAILS IN RIBS ALLOWING RUSTY MOISTURE INTO SPAR, FRE TTING ON TOP CAP GREATER THAN .0625 INCH ON LOOSE RIBS, CRACKS AT AILERON BELLCRANK BRACKET, CAUSED FROM OVER TORQUING O F BOLTS, PREVIOUS WING TIP DAMAGE, LOGS MISSING HISTORY, SPARS REPLACED. (K) 1 H 7 1 3O 3 O A796 E233 2007101600001 20071016 00001 SW 2007 10 16 2007FA0000859 1 20070726 G 5711 5146R SPAR BBAVIA 7 7FC 2110124 SW CONT C90 C90* 17009 SO RT WING CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 06 9032B 3177 7FC123 AC WAS BEING MODIFIED TO INCLUDE THE INSTALLATION OF WING SPAR INSPECTION HOLE KIT IAW STC NR SA005278E. A PORTION OF T HE WING LEADING EDGE SKIN WAS REMOVED AND THE WING SPAR WAS VISUALLY INSPECTED AS SPECIFIED IN THE INSTALLATION INSTRUCT IONS SUPPLIED WITH THE STC. DURING THIS VISUAL INSPECTION, A CRACK WAS OBSERVED ON THE TOP SURFACE OF THE RT WING FRONT SPAR. THE CRACK ORIGINATES AT THE IB AND OF THE AFT PLYWOOD REINFORCEMENT PLATE. REINFORCEMENT PLATE IS LOCATED ON TH E AFT SIDE OF THE FRONT SPAR, UNDER THE LT STRUT ATTACHMENT FITTING. THE CRACK PROGRESSES OB ALONG THE TOP SURFACE OF T HE SPAR AT A SLIGHT FORWARD ANGLE (CRACK ANGLE TOWARD THE FORWARD PLYWOOD REINFORCEMENT PLATE). THE SURFACE OF THE CRAC 1 H 7 1 3O 3 O A759 E252 2007101600002 20071016 00002 SO 2007 10 16 2007FA0000860 1 20070815 G 3297 CONNECTOR GULSTM GV GULFSTREAMGV 3980116 SO RROYCE BR700 BR700710A110 NE NLG STEERING CORRODED D O OTHER O OTHER NR NOT REPORTED 1 EA 11 509QS 6740 637 EXCESSIVE CORROSION AT CONNECTOR PINS CAUSING NWS FAIL MSG. SUGGEST PERIODIC INSPECTION AND CLEANING OR IMPROVED CONNEC TOR SEALING FROM MOISTURE. (K) 2 L 7 2 4F 4 F RT A12EA E00057EN 2007101600003 20071016 00003 GL 2007 10 16 2007FA0000861 1 20070820 G 7810 15070001 EXHAUST HEADER CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO NR 5 CRACKED D UV4R O OTHER O OTHER NR NOT REPORTED 1 SO 15 516CR 306 1309 NR 5 EXHAUST HEADER HAS CRACKED OFF AT FLANGE, JUNE 6/06 AT 440.6, NOV 18/06 AT 636.1 HOBBS, MAY 18/07 AT 746.7 HOBBS AN D AGAIN AUG 20/07 HOBBS NOT AVAILABLE. AFTER INSPECTING HEADER IT WOULD SEEM THAT A HEAVER GAUGE PIPE WOULD RESOLVE THE PROBLEM. THE LAST HEADER WAS INSTALLED WITH BACK UP FLANGES WELDED TO PIPE AT FLANGE SECTION WITH NO EFFECT. (K) 1 L 7 1 3O 3 O NT A00009CH E3SO 2007101600004 20071016 00004 GL 2007 10 16 2007FA0000862 2 20070815 G 7230 672332390 RETAINING RING RROYCE ALLSN 250C 250C20B 03013 GL COMPRESSOR FRACTURED C O OTHER O OTHER NR NOT REPORTED 1 SO 05 2 CAC37235 OPERATOR REPORTED ENGINE CHIP LIGHTS AND A PRECAUTIONARY LANDING WAS MADE. INSPECTION OF ENGINE CHIP DETECTORS REVEALED ONE SMALL PIECE OF THE FAILED RETAINING RING HAD CAUSED THE LIGHT. THE COMPRESSOR WAS REMOVED FROM THE ENGINE AND FURT HER INVESTIGATION REVEALED THE RETAINING RING HAD FRACTURED INTO 5 PIECES. 3 PIECES WERE CONTAINED IN THE RETAINING RIN G GROOVE OF THE IMPELLER, 1 PIECE WAS IN THE GEARBOX SUMP AREA AND THE 5TH PIECE WAS RECOVERED FROM THE CHIP DETECTOR. THE FAILED RETAINING RING SCORED THE SPUR ADAPTER GEAR ADJACENT TO THE RETAINING RING GROOVE IN THE IMPELLER. NO FURTHE R DAMAGE WAS NOTED. A NEW SPUR ADAPTER GEAR AND RETAINING RING WERE INSTALLED AND THE COMPRESSOR RETURNED TO SERVICE. 3 U E4CE 2007101600009 20071016 00009 GL 2007 10 16 2007FA0000863 1 20070814 G 2720 30730501 RUDDER PEDAL AVIAT A1 A1B 2210406 GL LYC O360 O360* 41514 EA COCKPIT FAILED D O OTHER O OTHER NR NOT REPORTED 1 AL 03 304C 2113 RUDDER PEDAL OPERATION CAN LEAD TO NO BRAKE OPERATION AT FULL TRAVEL OF RUDDER. SENDING IN THIS FIELD APPROVAL REQUEST FOR A VERNIER MIXTURE CONTROL. BELIEVE THAT THE LT RUDDER PEDAL WHEN PRESSED FULLY ALLOWS YOU TO DEPRESS THE RT BRAKE OV ER CENTER THUS GIVING YOU NO BRAKE AND DILEMMA WHEN APPLYING THE BRAKE. THE SAME THING HAPPENS IN REVERSE WHEN THE RT P EDAL IS DEPRESSED FULLY AND THEN THE LT BRAKE WILL GO OVER CENTER AND BECOME USELESS. THIS AC, AS AN EXAMPLE WAS GROUND LOOPED AT 68 HRS TT. IF THIS CONDITION CAN BE ACHIEVED EASILY ON THE GROUND THEN IT COULD HAPPEN ON LANDING, IN A CRO SSWIND OR TURN. FURTHER MORE THE BRAKE PEDAL IN THE OVER CENTER CONDITION WILL BE POINTED FORWARD AND AT A 90 DEGREE AN 1 H 7 1 3O 3 O NC A22NM E286 2008011400199 20080114 00199 EU 2008 1 14 2007FA0000864 2 20070809 G 8530 02722001002R1 CYLINDER HEAD DIAMON DA42 DA42 2990004 EU THIELT TAE125 TAE12501 59300 EU ENGINE FAILED D O OTHER O OTHER NR NOT REPORTED 1 SW 99 240TS 42072 ENGINE BEGAN LOSING COOLANT BY PRESSURIZING THE COOLING SYSTEM WITH COMBUSTION PRESSURE AND BLOWING COOLANT OVERBOARD. WHEN CYLINDER HEAD WAS REMOVED, EACH CYLINDER HAD A CRACK BETWEEN THE GLOW PLUG AND EXHAUST VALVE RECESS. THE ENGINE HA D PASSED A COMPRESSION CHECK AND IT IS SUSPECTED THAT THE CRACKS WOULD ONLY LEAK WHEN THE ENGINE WAS WARMED TO OPERATING TEMPERATURE. THE RESULTANT COOLANT LOSS ONLY INCREASES THE PROBABILITY OF FURTHER TEMPERATURE EXCURSIONS. A PROBABLE CAUSE WOULD BE INADEQUATE DISTANCE IN THE CASTING OF THE CYLINDER HEAD BETWEEN THE EXHAUST VALVE RECESS AND THE GLOW PLU G. ALTERNATE CAUSES INCLUDE INADEQUATE COOLING PROVIDED BY THE AIRFRAME MFG, INADEQUATE WATER JACKETING IN THE ENGINE R 1 L 7 2 3I 3 B RT A57CE E00069EN 2008011400200 20080114 00200 EU 2008 1 14 2007FA0000865 2 20070809 G 8530 02722001002R1 CYLINDER HEAD DIAMON DA42 DA42 2990004 EU THIELT TAE125 TAE12501 59300 EU ENGINE FAILED D O OTHER O OTHER NR NOT REPORTED 1 NM 11 350TS 42061 ENGINE BEGAN LOSING COOLANT BY PRESSURIZING THE COOLING SYSTEM WITH COMBUSTION PRESSURE AND BLOWING COOLANT OVERBOARD. WHEN CYLINDER HEAD WAS REMOVED, EACH CYLINDER HAD A CRACK BETWEEN THE GLOW PLUG AND EXHAUST VALVE RECESS. THE ENGINE HA D PASSED A COMPRESSION CHECK AND IT IS SUSPECTED THAT THE CRACKS WOULD ONLY LEAK WHEN THE ENGINE WAS WARMED TO OPERATING TEMPERATURE. THE RESULTANT COOLANT LOSS ONLY INCREASE THE PROBABILITY OF FURTHER TEMPERATURE EXCURSIONS. A PROBABLE C AUSE INCLUDE INADEQUATE COOLING PROVIDED BY THE AIRFRAME MFG, INADEQUATE WATER JACKETING IN THE ENGINE RESULTING IN HOT SPOTS WHICH COULD LEAD TO CRACKING, AND ENGINE RUNNING AT A HIGHER RPM THAN THE COOLING SYSTEM COULD HANDLE. 1 L 7 2 3I 3 B RT A57CE E00069EN 2007101600010 20071016 00010 CE 2007 10 16 2007FA0000866 1 20070907 G 2497 691835432 BUSS BAR CESSNA 680 680CE 2076811 CE PWC PW306 PW306C 52169 NE LT JBOX LOOSE D O OTHER O OTHER NR NOT REPORTED 1 EA 03 227DH 655 6800086 THE AIRCRAFT WENT TO START ENGINES, 6 CAS MESSAGES APPEARED ON THE DISPLAY. TROUBLESHOT PROBLEM AND FOUND MOUNTING STUD FOR EMERGENCY BUSS BAR WAS LOOSE CAUSING ARCING AND WELDING OF THE STUD. THIS STUD WAS LOOSE FROM FACTORY. DO AN INSP ECTION OF ALL STUDS TORQUE CHECK) (K) 2 L 7 2 4F 4 F RC T00012WI E35NE 2007101600011 20071016 00011 CE 2007 10 16 2007FA0000867 1 20070911 G 6100 AN520C8R6 SCREW BEECH 58 58 1152740 CE PROPELLER UNSAFETIED B EHHR O OTHER O OTHER NR NOT REPORTED 1 EA 17 755P 63 TH2162 HAVE SEEN THIS ATTACHMENT ARRANGEMENT ON MANY AC. FOUND NON SAFETIED SCREWS ATTACHING PROPELLER DEICE BRUSH ASSY TO MOU NTING. REMOVED NON SAFETIED SCREWS WITHOUT LOCKING DEVICES WITH MS35265-44 SCREW THAT CAN BE LOCKED WITH SAFETY WIRE. (K) 1 L 7 2 3O 3A16 2007101600012 20071016 00012 EU 2007 10 16 2007FA0000868 1 20070911 G 6210 10901030115 BLADE AGUSTA A109 A109 0260109 EU ALLSN 250C 250C20B 03013 GL MAIN ROTOR CRACKED D O OTHER O OTHER NR NOT REPORTED 1 NM 01 2MF 663 7277 CAE834542 EXCESSIVE 1 PER REVOLUTION VIBRATION NOTICED IN MAIN ROTOR SYSTEM. THE AIRCRAFT WAS LANDED WITHOUT INCIDENT. INVESTIGA TION REVEALED CORD WISE CRACKS IN UPPER AND LOWER SKINS AT STATION 1979 EXTENDING FROM THE TRAILING EDGE TO THE AFT SIDE OF THE SPAR. THE HONEYCOMB CORE OF THE BLADE IS ALSO SEPARATED AND DAYLIGHT CAN BE SEEN THROUGH CRACKS IN THE BLADE. THE CRACKS IN BOTH SKINS THEN EXTEND SPAN-WISE ALONG THE SPAR FROM STA 1925 TO STA 2075. THESE CRACKS ARE EXACTLY AS DE SCRIBED IN TECH BULLETIN 109-50, PART 1 REQUIRES DAILY VISUAL INSPECTIONS OF BLADES WITH GREATER THAN 500 HOURS OF OPERA TION BETWEEN STATIONS 1550 AND 3100. BT 109-50, PART II REQUIRES INSPECTION OF THIS AREA WITH A 3X MAGNIFYING GLASS EVE 1 G 7 2 3U 3 U H7EU E4CE 2007101600013 20071016 00013 GL 2007 10 16 2007FA0000869 1 20070801 G 5542 SKIN DIAMON DA40 DA40 2990002 GL RUDDER CRACKED D K NONE O OTHER IN INSP/MAINT 1 WP 07 469JP 654 40469 FOUND 3 INCH CRACK AFT OF RUDDER BALANCE WEIGHT IN COMPOSIT SKIN FWD OF UPPER ATTACH POINT. AIRCRAFT WAS BASED OUT OF A HEAT RELATED AREA. (K) 1 L 7 1 3O NT A47CE 2007101600014 20071016 00014 NE 2007 10 16 2007FA0000870 2 20070912 G 7200 30606266 BLADE AMD FALC50 FALCON50MYST 2730106 EU GARRTT TFE731 TFE73140 29001 NE 3RD STG ROTOR BROKEN D O OTHER O OTHER NR NOT REPORTED 1 GL 11 115SK 1855 330 BROKEN TURBINE BLADE. ENGINE SENT TO MFG FOR INVESTIGATION. (K) 2 L 7 3 4F 4 F A46EU E1NM 2008011400201 20080114 00201 EU 2008 1 14 2007FA0000871 2 20070809 G 8530 02722001002R1 CYLINDER HEAD DIAMON DA42 DA42 2990004 EU THIELT TAE125 TAE12501 59300 EU ENGINE DAMAGED C O OTHER O OTHER NR NOT REPORTED 1 NM 11 240TS 421 42072 ENGINE BEGAN LOSING COOLANT BY PRESSURIZING THE COOLING SYSTEM WITH COMBUSTION PRESSURE AND BLOWING COOLANT OVERBOARD. WHEN THE ENGINE WAS REMOVED AND THE OIL DRAINED, COOLANT WAS FOUND IN THE OIL AND FILLING UP CYLINDER NR 3. IT IS SUSPE CTED THAT IF THE CYLINDER HEAD WOULD HAVE BEEN REMOVED, EACH CYLINDER WOULD HAVE HAD A CRACK BETWEEN THE GLOW PLUG AND E XHAUST VALVE RECESSES. THE ENGINE HAD PASSED A COMPRESSION CHECK AND IT IS SUSPECTED THAT THE CRACKS WOULD ONLY LEAK WH EN THE ENGINE WAS WARMED TO OPERATING TEMPERATURE. THE RESULTANT COOLANT LOSS ONLY INCREASES THE PROBABILIITY OF FURTHE R TEMPERATURE EXCURSIONS. A PROBABLE CAUSE WOULD BE INADEQUATE DISTANCE IN THE CASTING OF THE CYLINDER HEAD BETWEEN THE 1 L 7 2 3I 3 B RT A57CE E00069EN 2007101600015 20071016 00015 CE 2007 10 16 2007FA0000872 1 20070719 G 5730 SKIN CESSNA 421 421C 2076016 CE CONT O520 GTSIO520* 17032 SO WINGS CORRODED D BX4R O OTHER O OTHER NR NOT REPORTED 1 NM 03 648SB 421C0648 LT AND RT WING UPPER SKINS UNDER THE NACELLE FUEL BLADDER TANKS HAD CORROSION PRESENT TO THEM AND RELATED AREA AROUND TH E BLADDER BAYS. WO NR 10688. (K) 1 L 7 2 3O 3 O A7CE E7CE 2007101600016 20071016 00016 EA 2007 10 16 2007FA0000873 2 20070827 G 7414 6361 MAGNETO PIPER PA32 PA32R301T 7103220 SO LYC O540 TIO540AH1A 42003 EA LT DAMAGED D K NONE O OTHER IN INSP/MAINT 1 SO 03 691MA 3257291 THIS AIRCRAFT HAD A SET OF MAGS INSTALLED AT APPROXIMATELY 400 HRS TT, AT 596 HRS TT, INSTALLED ANOTHER O/H MAG ON THE L T, DUE TO AN OVERHEAT SITUATION. IT APPEARS THAT THE COIL HAS BROKEN DOWN DUE TO EXCESS HEAT, DURING NORMAL OPERATION. NEW AC SHOULD HAVE AIR BLAST TUBES INSTALLED FOR EACH MAGNETO, AS WELL AS A COOLING KIT FOR THE VACUUM PUMP. THE MAGS, NOR THE VACUUM PUMP CAN OPERATE UNDER THESE CONDITIONS WITHOUT AN OUTSIDE AIR SUPPLY. SB 1157A AFFECTS AC FOR THE TACH OMETER SENSOR ALLOWING MOISTURE TO DAMAGE THE MAGNETO. (K) 1 L 7 1 3O 3 O A3SO E14EA 2007101600021 20071016 00021 CE 2007 10 16 2007FA0000874 1 20070728 G 3250 MC05430221 ROD END CESSNA 172 172D 2072410 CE CONT O300 O300* 17022 SO NLG STEERING BROKEN D O OTHER O OTHER NR NOT REPORTED 1 AL 01 2423U 17250023 LT SIDE STEERING ROD WITH 215.92 HRS SINCE NEW HAD THE REAR BALL END THAT ATTACHES TO THE RT RUDDER BAR ASSY BREAK. THE BALL ROD END BROKE AND LEFT THE T/R STEERING ROD AS THE ONLY STEERING FOR THE NOSE GEAR. THE RODS ARE NOT SOLID RODS, THEY ARE DESIGNED TO PUSH AND NOT TO PULL THAT SLIP INSIDE WHEN PULLED ON. IT REQUIRES BOTH RODS TO STEER THE RT PEDAL AND LT ROD WILL TURN NOSE TO THE RT AND LT PEDAL AND RT ROD WILL TURN IT TO THE LT. ON LANDING ROLL OUT, THE PLANE STAR TS TO DRIFT TO THE LT AND WITH THE LT RUDDER PEDAL TO NOSE GEAR DISCONNECTED. NOSE GEAR WOULD NOT RESPOND AND THE PLANE WAS SLOWING UP TO THE POINT OF LOSING ENOUGH AIR FLOW OVER THE RUDDER FOR IT TO CONTROL THE PLANE. THE PILOT STARTED TO 1 H 7 1 3O 3 O NT 3A12 E253 2007101600018 20071016 00018 SO 2007 10 16 2007FA0000875 1 20071003 G 5530 BOLT PIPER PA28 PA28181 7102807 SO LYC O360 O360* 41514 EA VERTICAL STAB LOOSE D K NONE O OTHER IN INSP/MAINT 1 WP 09 6365C 1776 1776 287890366 LOSE VERTICAL ATTACH BOLTS ON AFT BULKHEAD. 1 L 7 1 3O 3 O 2A13 E286 2007101600041 20071016 00041 GL 2007 10 16 2007FA0000876 1 20070919 G 7931 PT100GA TRANSMITTER RYAN NAVION NAVION 6150160 GL CONT O520 IO520B 17032 SO ENGINE OIL PRESS UNRELIABLE D K NONE N FALSE WARNING IN INSP/MAINT 1 NM 04 4131K NAV41131 1212867B AIRCRAFT LANDED WITH ZERO OIL PRESSURE INDICATION. AFTER TESTING WITH DIRECT READING GAUGE IT WAS DETERMINED THAT THE AC TUAL ENGINE OIL PRESSURE WAS WITHIN LIMITS SPECIFIED BY THE MFG. FURTHER TESTING REVEALED PRESSURE INDICATING SYSTEM WO ULD OPERATE NORMALLY AFTER ENGINE TEMPERATURES HAD COOLED BUT WOULD PROVIDE FALSE INDICATIONS WITH ENGINE AT OPERATING T EMPERATURE. FEEL THIS IS A SERIOUS PROBLEM BECAUSE THIS SYSTEM IS STC APPROVED AS A PRIMARY INSTRUMENT AND ITS MALFUNCT ION COULD CAUSE UNNECESSARY AND DANGEROUS OFF AIRPORT LANDINGS. 1 L 7 1 3O 3 O RT A782 E5CE 2007101600073 20071016 00073 NM 2007 10 16 2007FA0000877 1 20070807 G 2420 LC41550FG ALTERNATOR COLUMB LC41 LC41550FG400 5150011 NM CONT O550 TSIO550A 41516 SO ENGINE FAILED F O OTHER H ELECT. POWER LOSS-50 PC CR CRUISE 1 NM 09 376PD 350 41018 A FLIGHT TEST WAS BEING CONDUCTED ON 07/30/07 ON A REWORKED THERMAL SYSTEMS (KATS) EVADE SYSTEM, WHEN THE SYSTEM WENT UN STABLE CAUSING THE ALTERNATOR TO GO OFF LINE. THE TECHNICIAN MONITORING THE SYSTEM ON A DIAGNOSTIC LAPTOP COMPUTER ANNO UNCED TO THE PILOT THAT THE SYSTEM WAS FAILED BUT THE PILOT DID NOT HAVE A "FAILED" ANNUNCIATION ON THE INSTRUMENT PANEL . KATS CONFIRMED THAT THERE WAS A PROBLEM WITH THE FAULT DETECTION SOFTWARE THAT WOULD ALLOW THIS UNDER VERY SPECIFIC C ONDITIONS. KATS STATED THAT THEY DO NOT BELIEVE THIS TO BE A SERIOUS SITUATION SINCE THE SYSTEM IS CERTIFIED INADVERTEN T ICING ONLY. 1 L 7 1 3O 3 O NT A00003SE E5SO 2007102300067 20071023 00067 2007 10 23 2007FA0000878 4 20070629 G 3455 TDR906221270001 TRANSPONDER GARRTT TFE731 TFE731* 01518 WP TAILCONE FAILED B BSYR O OTHER O OTHER NR NOT REPORTED 1 GL 07 56EM 144 ON 6/27/2007 WHILE ENROUTE, THE PRIMARY TRANSPONDER FAILED WHILE THE AIRCRAFT WAS OPERATING IN AIRSPACE. THE CREW WAS A BLE TO SWITCH TO THE SECONDARY TRANSPONDER AND CONTINUE THEIR FLIGHT TO LOCK WITHOUT FURTHER INCIDENT. UPON ARRIVAL, TH E PRIMARY TRANSPONDER WAS CONFIRMED FAILED AND WAS REPLACED WITH A SERVICEABLE TRANSPONDER. THE SYSTEM WAS TESTED IAW F AR PART 43, APPENDIX F AND APPENDIX E, SUB PARA C, AND ICA NR 30A05002, REVISION C. THE SYSTEM WAS FOUND TO BE OPERATIN G NORMALLY AND THE AIRCRAFT WAS RETURNED TO SERVICE. (K) 4 F E6WE 2007102300068 20071023 00068 CE 2007 10 23 2007FA0000879 1 20070909 G 2823 12161001 SELECTOR VALVE CESSNA 207 T207A 2073614 CE CONT O520 TSIO520M 17040 SO MCAULY D3A34 D3A34C401 GL FUEL SYSTEM MISMANUFACTURED D O OTHER O OTHER NR NOT REPORTED 1 WP 07 803AN 161 20700570 248811R 765815 WHEN THE FUEL SELECTOR VALVE IS SELECTED TO THE RT TANK, FUEL IS BEING DELIVERED FROM THE LT TANK, VISE VERSA. THIS WAS DISCOVERED DURING A SHORT FLIGHT IN WHICH THE PILOT NOTICED THE RT TANK FUEL GAUGE WAS DROPPING WHEN THE LT TANK WAS SE LECTED. THIS WAS LATER CONFIRMED DURING AN INSPECTION IN WHICH FUEL WAS DRAINED FROM BOTH TANKS. IN FACT THE SELECTOR VALVE IS PUT TOGETHER INTERNALLY BACKWARDS. (K) 1 H 7 1 3O 3 O A16CE E8CE 5 C P47GL 2007102300069 20071023 00069 CE 2007 10 23 2007FA0000880 1 20070917 G 2420 DOFF10300JR ALTERNATOR CESSNA 172 172M 2072418 CE LYC O320 O320* 41508 EA INOPERATIVE D UT2R O OTHER O OTHER NR NOT REPORTED 1 WP 23 9531H 46 17266205 THIS ALTERNATOR WAS OVERHAULED, OPERATED LESS THAN 50 HOURS, FAILED. THE STUD THAT HOLDS THE DIODE PLATE IN THE ALTERNA TOR WAS BROKEN, AND THE SECOND STUD WAS LOOSE. THIS HAS BEEN AN ONGOING PROBLEM WITH OVERHAULS. WE ARE A SMALL SHOP, Y ET WE HAVE HAD MANY FAILURE WITH THIS PRODUCT IN THE PAST 2 YEARS. APPROXIMATELY 70 PERCENT OF THE OVERHAULS WE HAVE IN STALLED HAVE GONE BACK FOR WARRANTY. PROBLEMS INCLUDE LOOSE DRIVE PULLEYS, LOOSE HARDWARE, SHORT CIRCUITS, DEAD FIELD W INDINGS, DEFECTIVE BRUSHES. MY SUPPLIERS STATE THAT THEY HAVE HAD MANY COMPLAINTS ABOUT THIS REPAIR. 1 H 7 1 3O 3 O NT 3A12 E274 2007102300070 20071023 00070 2007 10 23 2007FA0000881 4 20070918 G 8300 23066678 PINION GEAR ALLSN ALLSN 250C 250C47B GL GEARBOX FRACTURED B YKER O OTHER O OTHER NR NOT REPORTED 1 EA 17 CAG47225 CAE847225 RECEIVED THE ENGINE FOR REPAIR DUE TO VIBRATIONS, AND METAL IN OIL. UPON DISASSEMBLY OF THE GEARBOX FOUND THE ROLLER RE TAINER OF THE NR 3 BEARING FRACTURED IN (4) PLACES. ALSO FOUND THAT THE NR 1 TURBINE WHEEL BLADE TIPS HAD BEEN RUBBING THE BLADE TRACK WHICH CAUSED THE VIBRATION. TECH SUSPECTS THE FRACTURED RETAINER MAY HAVE BEEN A RESULT OF THE VIBRATIO N. (K) 3 U E1GL 2007102300071 20071023 00071 GL 2007 10 23 2007FA0000882 1 20070831 G 7820 20559002 MUFFLER CIRRUS SR SR20 05628AJ GL CONT O360 IO360ES SO ENGINE CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 07 824ZB 559 1674 CHECK MUFFLER IAW MFG SB, SB2X-78-07, ISSUED JUNE, 2007. FOUND SPOT WELDS ON EXTERNAL BAFFLE CRACKED. REPLACED MUFFLER . THIS SB APPLIES ONLY TO SR20`S SN 1005 THRU 1797. (K) 1 L 7 1 3O 3 O NT A00009CH E1CE 2007102300072 20071023 00072 SO 2007 10 23 2007FA0000883 1 20070807 G 3213 7873804 AXLE PIPER PA32 PA32300 7103212 SO LYC O540 IO540K1A5 41532 EA HARTZL HCC2Y HCC2YK1 GL LT MLG BROKEN D O OTHER O OTHER NR NOT REPORTED 1 AL 03 8905N 10353 3240690 L2683048E CH35831B ON TAXI TO TAKEOFF, AC TURNED AROUND AFTER BACK TAXI. PIVOTING ON LT M/G. SIDE LOAD BROKE AXLE AT END OF DRILLED OUT C ENTER. EVIDENCE OF PREVIOUS CRACKING FROM INSIDE OB. (K) 1 L 7 1 3O 3 O A3SO 1E4 5 C P920 2007102300074 20071023 00074 CE 2007 10 23 2007FA0000884 1 20070717 G 3240 07516800 PLATE CESSNA 208 208 2073702 CE PWA PT6 PT6A6 52043 EA CRACKED C FE4R O OTHER O OTHER NR NOT REPORTED 1 AL 03 9602F 15966 20800103 FOUND TORQUE PLATE CRACKED DURING ROUTINE INSPECTION. (K) 1 H 7 1 3T 3 T NT A37CE E4EA 2007102300075 20071023 00075 EU 2007 10 23 2007FA0000885 1 20070910 G 5753 257WF101A VANE BRAERO DH125 BAE125800A 1500285 EU GARRTT TFE731 TFE731* 01518 WP TE FLAP CORRODED B JGVR O OTHER O OTHER NR NOT REPORTED 1 CE 09 150SB 5758 258197 LT IB FLAP VANE, UPPER SKIN CORRODED BEYOND LIMITS. POSSIBLE CAUSE: DISSIMILAR METAL CORROSION AS TRAILING EDGE IS MAGN ESIUM AND SKIN IS ALUMINUM OR ENVIRONMENT IN WHICH THE VANE OPERATES. IT IS LOCATED BEHIND THE MLG. ASSURE THE SKIN IS PROPERLY TREATED IAW CORROSION PREVENTION PROCEDURES AND PAINTED WITH EPOXY PRIMER BEFORE INSTALLATION. (K) 2 L 7 2 4F 4 F RT A3EU E6WE 2007102300078 20071023 00078 EA 2007 10 23 2007FA0000886 2 20070817 G 8500 ENGINE BEECH 60 A60 1153604 CE LYC O541 TIO541E1C4 41536 EA MAKING METAL D O OTHER O OTHER NR NOT REPORTED 1 NM 01 98KA P212 RL79259 DURING ROUTINE OIL CHANGE, METAL SHAVINGS WERE FOUND IN OIL FILTER AND SCREEN. SHAVINGS WERE MAGNETIC. THESE ENGINES D O HAVE WEAR ISSUES ON CAM AND LIFTERS. AFTER REMOVING OIL PAN, FOUND CAM BAD AND LIFTER WEAR. OIL ANALYSIS DIDN`T PICK UP LARGER MICRON IN OIL. RECOMMEND INSPECTION OF CAM AND LIFTER BEFORE 1000 HOUR. REMOVED OIL PAN ON RT ENGINES AND F OUND BEAD WEAR AS WELL. NO METAL IN FILTER. (K) 1 L 7 2 3O 3 O A12CE E10EA 2007102300080 20071023 00080 GL 2007 10 23 2007FA0000887 2 20070803 G 7250 TURBINE WHEEL CESSNA STC STC206C 1182107 CE ALLSN 250C 250C30P 03013 GL ENGINE FAILED C K NONE O OTHER IN INSP/MAINT 1 NM 05 5746N 1654 13 45461 890629 AFTER 13 HOURS OF OPERATION SINCE OVERHAUL, DURING A POWER CHECK, THE TURBINE ASSY FAILED CAUSING THE FORCED LANDING OF THE HELICOPTER. FORCED LANDING CAUSED SUBSTANTIAL DAMAGE TO THE AIRCRAFT. (K) 1 H 7 1 3O 3 U NT A4CE E1GL 2007102300083 20071023 00083 CE 2007 10 23 2007FA0000888 1 20070830 G 3246 C163003102 WHEEL CESSNA 172 172M 2072418 CE LYC O360 O360A4M 41514 EA SNSNCH 76E 76EM8 EA LT MLG FAILED D O OTHER O OTHER NR NOT REPORTED 1 NM 01 9898Q 17265842 L3551036A 31674R WHEEL IS A 3 PIECE CONSTRUCTION, OUTER RIM AND THE INNER SPACER. BROKE APART ON TAXIING OF AIRCRAFT. JACKED AIRCRAFT AN D INSTALLED SERVICEABLE UNIT, THREADS STRIPPED OUT OF CENTER SECTION. (K) 1 H 7 1 3O 3 O NT 3A12 E286 5 N P4EA 2007102300086 20071023 00086 SO 2007 10 23 2007FA0000889 2 20070911 G 8530 ROCKER CUBCFT CC11 CC11100 060002H CE CONT O200 O200A 17020 SO NR 4 CYLINDER MISINSTALLED D O OTHER O OTHER NR NOT REPORTED 1 NM 01 787AK 118 CC1100006 256113 FOUND THE ROCKER ARMS REVERSED, INTAKE EXHAUST ROCKERS IN CYLINDER NR 4 LEADING TO POSSIBLE EXHAUST GUIDE AND VALVE DAMA GE DO TO THE EXHAUST ROCKER ARM HAS AN OILING PORT FOR THE EXHAUST VALVE AND THE INTAKE ROCKER ARM DOES NOT HAVE THE OI LING PORT. THE ROCKER ARMS WERE REMOVED AND INSTALLED CORRECTLY. DAMAGE TO VALVE AND GUIDE UNKNOWN AT THIS TIME, WILL HAVE TO CONTACT MFG. (K) 1 H 7 1 3O 3 O NC E252 2007102300088 20071023 00088 SO 2007 10 23 2007FA0000890 2 20070911 G 8530 MS5196364 SETSCREW CUBCFT CC11 CC11100 060002H CE CONT O200 O200A 17020 SO CYL ROCKER BOSS DAMAGED C O OTHER O OTHER NR NOT REPORTED 1 NM 01 787AK 118 CC1100006 256113 IN THE NEW STYLE CYLINDER ASSY PN 655482 FOR THE ENGINE, THE ROCKER ARM PIN PN 654375 IS RETAINED BY A SET SCREW PN MS51 966364 IN THE CENTER ROCKER BOSS SUPPORT. FOUND IN THIS ENGINE (2) SET SCREWS LOOSE AND A THIRD FOUND RATTLING AROUND A ND LODGED UNDER THE INTAKE ROCKER ARM BETWEEN THE CYLINDER HEAD. THE ROCKER SHAFTS ARE MOVING OFF CENTER AND ROTATING A ND WITH A MACHINED SHARP CUT IN THE END OF THE ROCKER SHAFT TO INDICATE WERE SET SCREW IS TO LINE UP WITH THE ROCKER SHA FT, IT IS CUTTING THROUGH THE VALVE COVERS AND WILL LEAD TO LOSS OF ENGINE OIL AND OPERATION OF THE ENGINE AND POSSIBLE LOSS OF PERSONAL LIFE. (K) 1 H 7 1 3O 3 O NC E252 2007102300091 20071023 00091 SO 2007 10 23 2007FA0000891 2 20070914 G 8530 O200D SETSCREW AMCNLG AL3 AL3 060002K CE CONT O200 O200* 17020 SO ROCKER ARM BOSS MISMANUFACTURED D O OTHER O OTHER NR NOT REPORTED 1 SO 05 65LC 42 AL1083 CHECKING ROCKER ARM SHAFT SET SCREWS AND TO ASSURE INTAKE AND EXHAUST ROCKER ARMS NOT SWITCHED IAW INFORMATION TO OWNERS FORM INTERNET OWNERS AIRCRAFT FORUM. CYLINDER NR 1, SN AC06HB070, SET SCREW AND ROCKER ARMS, OK. CYLINDER NR 2, SN AC0 6FA543, SET SCREW LOOSE ENOUGH TO ALLOW SHAFT TO MOVE, ROCKER ARMS, OK. CYLINDER NR 3, SN AC06HA911, SET SCREW OK, INTA KE AND EXHAUST ROCKER ARMS SWITCHED. CYLINDER NR 4, SN AC06HA935, SET SCREW AND ROCKER ARMS, OK. (K) 1 H 7 1 3 O 3O EXPA1H71 E252 2007102300087 20071023 00087 CE 2007 10 23 2007FA0000892 1 20071010 G 2750 1434425 FLEX DRIVE CESSNA 750 750 2076810 CE ALLSN AE3007 AE3007C GL RT TE FLAPS BROKEN B K NONE O OTHER IN INSP/MAINT 1 WP 23 22NG 7500204 THE RT FLAP FLEX DRIVE HOUSING FAILED AT THE SWAGED END OF THE HOUSING AT THE IB END. ON SEPTEMBER 11, 2007 THIS AIRCRA FT HAD A SIMILAR EVENT WITH THE LT OB FLAP DRIVE WHICH ALLOWED THE FLEX DRIVE TO DISENGAGE FROM THE OB FLAP DRIVE CAUSIN G THE FLAPS TOP REMAIN AT 3 DEGREES POSITION AND PREVENTING FURTHER EXTENSION OR RETRACTION. WE OPERATE 2 AIRCRAFT AND THIS IS THE 4TH FAILURE OF THE FLEX DRIVE BETWEEN THE 2 AIRCRAFT. 2 L 7 2 4J 4 F RT T00007WI TE6CH 2007102300127 20071023 00127 WP 2007 10 23 2007FA0000893 2 20070914 G 7230 307516034 TURBINE WHEEL RAYTHN DH125 HAWKER800XP 7150012 CE GARRTT TFE731 TFE7315BR WP LP COMPRESSOR FAILED E E A ENGINE SHUTDOWN UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 NM 04 800WY 3172 258556 107656 CLIMBING THROUGH FL270, A LOUD BANG IN REAR OF ACFT. LT ENGINE COMPUTER LIGHT ILLUMINATED. PF BROUGHT LT ENGINE TO IDL E, PNF PULLED CHECKLIST. AFTER SURVEY OF ENGINE PARAMETERS, PF TURNED LT ENGINE COMPUTER BACK ON TO CONTROL PARAMETERS. ENGINE COMPUTER DID STAY ON & DID APPEAR TO CONTROLL ENGINE. POWER ADVANCED SLOWLY ON LT ENGINE. AT APPROXIMATELY 70 % N1 ANOTHER LOUD BANG IN REAR & LT ENGINE COMPUTER LIGHT ILLUMINATED AGAIN. ENGINE PARAMETERS MOVED TO RED LINE. PF SHUT DOWN LT ENGINE. PNF CONTACTED ATC, DECLARED AN EMERGENCY & REQUESTED & RECEIVED DIRECT CLOSEST AIRPORT. SINGLE ENGINE APPROACH CHECKLIST & PROGRAMMED FMS FOR AN APPROACH. ACFT CLEARED FOR VISUAL APPROACH. AFTER A NON-EVENTFUL LANDING. 2 L 7 2 4F 4 F RT A3EU E6WE 2007102300109 20071023 00109 CE 2007 10 23 2007FA0000895 1 20071001 G 3150 UNKNOWN BEECH MU300 400A 1155402 CE UNKNOWN E O OTHER J WARNING INDICATION CR CRUISE 1 SO 11 418GJ RK418 AC EXPERIENCED A FLAP ASYMMETRIC LIGHT IN FLIGHT. THE CREW DID NOT TRY TO PUT THE FLAPS DOWN AND DIVERTED FOR A NO FLAP LANDING. CRITICAL CARE MAINTENANCE DROVE DOWN TO REPAIR THE AIRCRAFT. MAINTENANCE COULD NOT DUPLICATE THE PROBLEM AFT ER SEVERAL ATTEMPTS. MAINTENANCE INSPECTED AND CLEANED ALL CONNECTORS, INSPECTED HYDRAULIC SYSTEMS, AND FLAP RIGGING AN D CABLES. MAINTENANCE C/W ALL OPERATIONAL CHECK IAW THE MM. THE PROBLEM WAS NEVER DUPLICATED. 2 H 7 2 4F RT A16SW 2007102300003 20071023 00003 CE 2007 10 23 2007FA0000897 1 20071012 G 2730 CONTROL CABLE CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA ELEVATORS WORN D K NONE O OTHER IN INSP/MAINT 1 WP 23 379TA 1560 172S9379 L3083351A CONTROL CABLE, (P/N 0510105-308), FOUND WORN TO REPLACE LIMITS PER AC43.13-1A, CABLE INSPECTION. CABLE WAS WORN DUE TO CONSTANT CONTACT WITH LANDING GEAR BULKHEAD FAIRLEAD P/N S338-7. IT IS BELIEVED THAT THE HOLE MISALIGNMENT CAUSED THIS CONSTANT CONTACT. MM DOES NOT CONTAIN ANY (CABLE WEAR) LIMITS OR COMMENTS, ONLY CABLE WIRE BREAKAGE AND CORROSION LIMIT S. 1 H 7 1 3O 3 O NT 3A12 1E10 2007102300135 20071023 00135 CE 2007 10 23 2007FA0000898 1 20071012 G 5712 051179616 BULKHEAD CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA ZONE 100 MISALIGNED D K NONE O OTHER IN INSP/MAINT 1 WP 23 373ES 3780 17280052 L2701351A CONTROL CABLE, (P/N 0510105-339), FOUND WORN TO REPLACE LIMITS IAW AC43.13-1A, CABLE INSPECTION. CABLE WAS WORN DUE TO CONSTANT CONTACT WITH LANDING GEAR BULKHEAD FAIRLEAD P/N S338-7. IT IS BELIEVED THAT THE HOLE MISALIGNMENT CAUSED THIS CONSTANT CONTACT. CESSNA MAINTENANCE MANUAL DOES NOT CONTAIN ANY (CABLE WEAR) LIMITS OR COMMENTS, ONLY CABLE WIRE BREAK AGE AND CORROSION LIMITS. 1 H 7 1 3O 3 O NT 3A12 1E10 2007102300140 20071023 00140 CE 2007 10 23 2007FA0000900 1 20071012 G 2730 CONTROL CABLE CESSNA 182 182S 2072701 CE LYC O540 IO540AB1A5 EA ZONE 100 WORN D K NONE O OTHER IN INSP/MAINT 1 WP 23 7262Y 1400 18280812 L1241261E CONTROL CABLE, (P/N 0510105-189), FOUND WORN TO REPLACE LIMITS IAW AC43.13-1A, CABLE INSPECTION. CABLE WAS WORN DUE TO CONSTANT CONTACT WITH MICARDA GUARD PLATE OVER FUEL LINES AT FUEL SELECTOR AREA JUST FORWARD OF FRONT SEATS. THE CABLES ARE IN CONSTANT CONTACT WITH PLATES EVEN WITH CABLE TENSION CORRECT. MM DOES NOT CONTAIN ANY (CABLE WEAR) LIMITS OR CO MMENTS, ONLY CABLE WIRE BREAKAGE AND CORROSION LIMITS. 1 H 7 1 3O 3 O NT 3A13 1E4 2007102300134 20071023 00134 CE 2007 10 23 2007FA0000904 1 20071012 G 5712 051179616 BULKHEAD CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA ZONE 100 MISALIGNED D K NONE O OTHER IN INSP/MAINT 1 WP 23 625SP 1560 172S8616 L2922551A CONTROL CABLE, (P/N 0510105-339), FOUND WORN TO REPLACE LIMITS IAW AC43.13-1A, CABLE INSPECTION. CABLE WAS WORN DUE TO CONSTANT CONTACT WITH LANDING GEAR BULKHEAD FAIRLEAD P/N S338-7. IT IS BELIEVED THAT THE HOLE MISALIGNMENT CAUSED THIS CONSTANT CONTACT. MM DOES NOT CONTAIN ANY "CABLE WEAR" LIMITS OR COMMENTS, ONLY CABLE WIRE BREAKAGE AND CORROSION LIMIT S. 1 H 7 1 3O 3 O NT 3A12 1E10 2007102300137 20071023 00137 CE 2007 10 23 2007FA0000906 1 20071012 G 5712 051179616 BULKHEAD CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA ZONE 100 MISALIGNED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 23 658SP 4200 172S8063 L2796451A CONTROL CABLE, (P/N 0510105-308), FOUND WORN TO REPLACE LIMITS IAW AC43.13-1A, CABLE INSPECTION. CABLE WAS WORN DUE TO CONSTANT CONTACT WITH LANDING GEAR BULKHEAD FAIRLEAD P/N S338-7. IT IS BELIEVED THAT THE HOLE MISALIGNMENT CAUSED THIS CONSTANT CONTACT. MM DOES NOT CONTAIN ANY "CABLE WEAR" LIMITS OR COMMENTS, ONLY CABLE WIRE BREAKAGE AND CORROSION LIMIT S. 1 H 7 1 3O 3 O NT 3A12 1E10 2007102300138 20071023 00138 CE 2007 10 23 2007FA0000907 1 20071012 G 5712 051179616 BULKHEAD CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA ZONE 100 MISALIGNED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 23 2630U 1628 17280568 L2761951A CONTROL CABLE, (P/N 0510105-308), FOUND WORN TO REPLACE LIMITS IAW AC43.13-1A, CABLE INSPECTION. CABLE WAS WORN DUE TO CONSTANT CONTACT WITH LANDING GEAR BULKHEAD FAIRLEAD P/N S338-7. IT IS BELIEVED THAT THE HOLE MISALIGNMENT CAUSED THIS CONSTANT CONTACT. MM DOES NOT CONTAIN ANY "CABLE WEAR" LIMITS OR COMMENTS, ONLY CABLE WIRE BREAKAGE AND CORROSION LIMIT S. 1 H 7 1 3O 3 O NT 3A12 1E10 2007102300004 20071023 00004 CE 2007 10 23 2007FA0000908 1 20070919 G 3230 JE1 STOP CESSNA 310 310Q 2074242 CE CONT O470 IO470* 17026 SO MLG GEARBOX BROKEN B OF1R O OTHER O OTHER NR NOT REPORTED 1 EA 17 20SS 3235 310Q0521 PILOT HAD NO LT GEAR DOWN INDICATION. HE CYCLED GEAR WITH NO SUBSEQUENT GEAR DOWN INDICATION. HE ATTEMPTED MANUAL EXTE NSION, CRANKED TO THE MECHANICAL STOP IN THE GEARBOX AND BROKE THE STOP. BELLCRANK CONTINUED PAST DOWN AND THEN WENT PA RTIALLY (UP). GEAR COLLAPSED ON LANDING. (K) 1 L 7 2 3O 3 O 3A10 E1CE 2007102300165 20071023 00165 CE 2007 10 23 2007FA0000909 1 20070911 G 5280 45A3161521 DOOR BEECH MU300 400A 1155402 CE PWA JT15 JT15D5 52112 NE NLG CRACKED B ZKFR K NONE O OTHER IN INSP/MAINT 1 EA 61 262PA RK203 FOUND DURING INSPECTION. NOSE GEAR FOLLOW UP DOOR PN 45A31615-21 ON BRACKETS, PN 45A31613-9 AND 45A31613-7 AT ATTACHING RIVET HAS CRACKS GOING FORWARD TO AFT THROUGH THE FIRST RIVET ALONG THE RIVET ROW. RELATIVE WIND PUSHING AFT ON THE DO OR WHILE GEAR IS EXTENDED FOR TAKEOFF AND LANDING AND VIBRATION. USING THICKER MATERIAL DURING MFG AND OR ADDING A DOUB LER. (K) 2 H 7 2 4F 4 F RT A16SW E25EA 2007102300166 20071023 00166 CE 2007 10 23 2007FA0000910 1 20070920 G 5280 45A3161521 DOOR BEECH MU300 400A 1155402 CE PWA JT15 JT15D5 52112 NE NLG CRACKED B ZKFR K NONE O OTHER IN INSP/MAINT 1 EA 61 268PA RK323 FOUND DURING INSPECTION. NOSE GEAR FOLLOW UP DOOR, P/N 45A31615-21 ON BRACKETS PN 45A31613-9, 45A31613-7 AND 45A31616-3 AT ATTACHING RIVET HAS CRACKS GOING FORWARD TO AFT THOUGH THE FIRST RIVET ALONG THE RIVET ROW. RELATIVE WIND PUSHING AF T ON THE DOOR WHILE GEAR IS EXTENDED FOR TAKEOFF AND LANDING AND VIBRATION. USING THICKER MATERIAL DURING MFG AND OR AD DING A DOUBLER. (K) 2 H 7 2 4F 4 F RT A16SW E25EA 2007110100172 20071101 00172 CE 2007 11 1 2007FA0000911 1 20070917 G 5280 STRUCTURE BEECH MU300 400A 1155402 CE PWA JT15 JT15D5 52112 NE NLG DOOR CRACKED B ZKFR K NONE O OTHER IN INSP/MAINT 1 EA 61 26PA RK256 FOUND DURING INSPECTION. NOSE GEAR FOLLOW UP DOOR PN 45A31615-21 ON BRACKETS PN 45A31613-9 AND 45A31613-7 AT ATTACHING RIVET HAS CRACKS GOING FORWARD TO AFT THROUGH THE FIRST RIVET ALONG THE RIVET ROW. RELATIVE WIND PUSHING AFT ON THE DOO R WHILE GEAR IS EXTENDED FOR TAKEOFF AND LANDING AND VIBRATION. USING THICKER MATERIAL DURING MFG AND OR ADDING A DOUBL ER. (K) 2 H 7 2 4F 4 F RT A16SW E25EA 2007110100173 20071101 00173 CE 2007 11 1 2007FA0000912 1 20071001 G 5610 45AS3101012 WINDOW BEECH MU300 400A 1155402 CE PWA JT15 JT15D5 52112 NE COCKPIT CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 03 480M RK6 WHILE PERFORMING A SCHEDULED A-D INSPECTION FOUND NR 2 (COPILOT) SIDE WINDOW CRACKED USING THE PRISM INSPECTION METHOD. THE D-INSPECTION REQUIRES THAT BOTH WINDSHIELD RETAINERS OR USING OPTICAL PRISM INSPECTION METHOD. THE IS NO STATEMENT IN THE AIRCRAFT MM OR IN THE A-D INSPECTION CHECKLIST THAT REQUIRES YOU TO INSPECT THE COCKPIT SIDE WINDOWS IN THE SAME MANNER AS THE WINDSHIELDS. ALL OF THE WINDOWS IN THE COCKPIT AREA ARE INSTALLED OR FASTENED IN THE SAME MANNER AS THE WINDSHIELDS. IT IS SUSPECTED THAT THE COPILOT WINDOW CRACKED FROM FATIGUE, OR TT INSTALLED. WOULD RECOMMEND THAT INSPEC TIONS OF ALL COCKPIT WINDOWS WITH A PRISM AT SCHEDULED INTERVALS BE COMPLETED. (K) 2 H 7 2 4F 4 F RT A16SW E25EA 2007102300011 20071023 00011 CE 2007 10 23 2007FA0000914 1 20071003 G 5510 FITTING BEECH MU300 400A 1155402 CE PWA JT15 JT15D5 52112 NE HORIZONTAL STAB LOOSE C K NONE O OTHER IN INSP/MAINT 1 GL 03 480M RK6 WHILE PERFORMING AN A-D INSPECTION FOUND 8 LOOSE RIVETS IN THE FORWARD RIVET LINE OF THE ATTACHMENT PIVOT FITTING PN 45A 21183-11 ON THE BOTTOM OF THE HORIZONTAL STABILIZER. IT IS SUSPECTED THAT THE LOOSE RIVETS WERE CAUSED BY FATIGUE AND A GE. RECOMMEND INSPECTING AREA THOROUGHLY AT EACH INSPECTION. RECOMMEND CONTACTING MFG FOR REPAIR OPTIONS. THIS IS THE 3RD AIRCRAFT IN A ROW THAT THESE SAME RIVETS HAVE BEEN LOOSE OR MISSING. (K) 2 H 7 2 4F 4 F RT A16SW E25EA 2007102300007 20071023 00007 CE 2007 10 23 2007FA0000915 1 20071001 G 5544 65900291 HINGE BRACKET CESSNA 500 S550 2076607 CE PWA JT15 JT15D4 52112 NE LT ELEVATOR CORRODED B SI6R K NONE O OTHER IN INSP/MAINT 1 SW 17 52FT S5500056 LT OB HINGE BRACKET BROKE OFF DURING AILERON REMOVAL. APPEARS TO HAVE FAILED DUE TO CORROSION. (K) 1 L 7 2 4F 4 F RT A22CE E1NE 2007102300010 20071023 00010 CE 2007 10 23 2007FA0000916 1 20070928 G 7830 STRUCTURE LEAR 35 35A 5170602 CE GARRTT TFE731 TFE7312 01518 WP THRUST REVERSER DAMAGED C O OTHER O OTHER NR NOT REPORTED 1 EA 17 10UF 0011 166 P74521C DURING THE PILOT PREFLIGHT, THE PILOT HAD NOTICED THAT THERE WAS A TEAR IN THE SHEET METAL OF THE LT ENGINE THRUST REVER SER INNER SKIN. WE COULD NOT IDENTIFY WHAT HAS CAUSED THIS TEAR. THE UNIT WILL BE REPAIRED BY THE MFG AND WILL INFORM YOU WITH ANY INFO THEY GIVE TO US ABOUT THIS INCIDENT. (K) 2 L 7 2 4F 4 F A10CE E6WE 2007102300017 20071023 00017 EA 2007 10 23 2007FA0000917 2 20070820 G 7322 3013460 ROD EMB 110 EMB110P1 3260122 SO PWA PT6 PT6A34 52043 EA FUEL CONTROL BROKEN C O OTHER O OTHER NR NOT REPORTED 1 EA 65 621KC 110335 DURING A 150 HR INSPECTION THE LOWER FUEL CONTROL ROD WAS FOUND BROKEN ON THREADED SHAFT WHERE IT SCREWS INTO COUPLING. IT LOOKS LIKE IT MAY HAVE BEEN BENT AND A MORE DETAILED INSPECTION OF THIS COMPONENT SHOULD OCCUR. (K) 1 L 7 2 4T 4 T A21SO E4EA 2007110100175 20071101 00175 CE 2007 11 1 2007FA0000918 1 20070927 G 2435 23085001 STARTER GEN BEECH 300 300BEECH 1152930 CE PWA PT6 PT6A60A 52043 NE LEFT FAILED B E81R O OTHER H J ELECT. POWER LOSS-50 PC WARNING INDICATION NR NOT REPORTED 1 GL 03 350TT 4822 FL413 PILOT REPORTED LT GENERATOR GOING OFF-LINE ON APPROACH. FOUND STARTER/GENERATOR INOPERATIVE. UPON REMOVAL NOTICED EVID ENCE OF COOLING FAN TIPS RUBBING ON HOUSING, BEARINGS WORN (ARMATURE ASSY LOOSE).(K) 2 L 7 2 4T 4 T A24CE E4EA 2007110100176 20071101 00176 GL 2007 11 1 2007FA0000919 1 20070913 G 7160 CONTROL ARM DIAMON DA40 DA40 2990002 GL LYC O360 O360A4M 41514 EA CARB HEAT BROKEN D O OTHER O OTHER NR NOT REPORTED 1 NM 07 423FP 452 40FC023 CARBURETOR HEAT CONTROL ARM BROKE OFF OF CARB AIR BOX CAUSING UNCONTROLLED SELECTION OF CARB HEAT VS RAM (COLD) AIR INTA KE. (K) 1 L 7 1 3O 3 O NT A47CE E286 2007110100177 20071101 00177 CE 2007 11 1 2007FA0000920 1 20071002 G 2420 DOFF10300JR ALTERNATOR CESSNA 172 172M 2072418 CE LYC O320 O320* 41508 EA ENGINE INOPERATIVE D O OTHER O OTHER NR NOT REPORTED 1 NM 07 9531H 40 17266205 ALTERNATOR, DEFECT UNKNOWN, FAILED INTERNALLY, GROUND POST LOOSE INTERNALY EXCESSIVE ARMATURE END PLAY. RETURNED FOR WA RRANTY. (K) 1 H 7 1 3O 3 O NT 3A12 E274 2007110100178 20071101 00178 CE 2007 11 1 2007FA0000921 1 20071002 G 2420 DOFF10300JR ALTERNATOR CESSNA 172 172M 2072418 CE LYC O320 O320* 41508 EA ENGINE INOPERATIVE D O OTHER O OTHER NR NOT REPORTED 1 NM 07 9531H 40 17266205 ALTERNATOR, DEFECT UNKNOWN, FAILED INTERNALLY. RETURNED FOR WARRANTY. (K) 1 H 7 1 3O 3 O NT 3A12 E274 2007102300015 20071023 00015 CE 2007 10 23 2007FA0000922 1 20071002 G 8011 MHJ4003S MOTOR CESSNA 340 340A 2076405 CE CONT O520 TSIO520* 17040 SO STARTER NOISY D O OTHER O OTHER NR NOT REPORTED 1 NM 07 340RF 46 340A0212 STARTER STARTED MAKING A LOUD SQUEALING NOISE WHEN OPERATING STARTER, AND SLOW ROTATION OF ENGINE. REMOVED AND RETURNED FOR WARRANTY. (K) 1 L 7 2 3O 3 O 3A25 E8CE 2007102600086 20071026 00086 CE 2007 10 26 2007FA0000923 1 20071005 G 2797 CONNECTOR CESSNA 750 750 2076810 CE ALLSN AE3007 AE3007C GL MISINSTALLED B CNQR O OTHER O OTHER NR NOT REPORTED 1 CE 07 964QS 7500164 PRIMARY STAB TRIM FAILED CLIMBING THROUGH FL280 AT 300 KTS. NO CAS MESSAGE WAS PRESENT. CLACKER WAS STUCK ON. STAB WAS NOT MOVING WHEN CLACKER WAS GOING OFF. AUTO PILOT DISENGAGED ON ITS OWN DUE TO HEAVY NOSE CONFIG. AFTER TROUBLESHOOTI NG SHOULD THE ECM TO BE BAD. REMOVED AND REPLACED (ECM NR 421400216J1) WITH NEW PART 4214-0021-11 (LATEST DASH NR) COM PLETED PRIMARY CHANNEL A/B TRAVEL VERIFICATION CHECKS IAW 750 MM, TASK 27-40-00-721, NO FAULTS NOTED. FOUND THE PRIMARY AND SECONDARY CONNECTORS SWAPPED. WHICH HAD NO EFFECT IN THIS FAILURE. (K) 2 L 7 2 4J 4 F RT T00007WI TE6CH 2007102300012 20071023 00012 CE 2007 10 23 2007FA0000924 1 20070616 G 5712 051179616 BULKHEAD CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA FUSELAGE MISLOCATED C K NONE O OTHER IN INSP/MAINT 1 WP 23 2630U 1628 17280568 L2761951A CONTROL CABLE, ( P/N 0510105-308), FOUND WORN TO REPLACEMENT LIMITS IAW CABLE WEAR INSPECTION GUIDELINES IN AC43.13-1A. THE CABLE CONSTANTLY RUBS THE S338-7 FAIRLEAD IN THE LANDING GEAR BULKHEAD HOLE. IT IS BELIEVED THAT A HOLE MISLOCATIO N CAUSES THE MISALIGNMENT WHICH ALLOWS THE CABLE RUB. MM DOES NOT CONTAIN ANY (CABLE WEAR) LIMITS OR COMMENTS, ONLY CA BLE WIRE BREAKAGE AND CORROSION LIMITS. 1 H 7 1 3O 3 O NT 3A12 1E10 2007102300001 20071023 00001 CE 2007 10 23 2007FA0000925 1 20071018 G 7603 632558A1 LINK ROD CESSNA 185 A185F 2072821 CE CONT O520 IO520D 17032 SO THROTTLE WORN D K NONE O OTHER IN INSP/MAINT 1 NM 07 4640E 877 18503824 832429R THROTTLE BUTTERFLY (P/N: 625601G) AND THROTTLE BODY (P/N: 639437)ARE WORN, ALLOWING BUTTERFLY SHAFT TO SLIDE SIDE TO SID E CAUSING THE LINK ROD ASSEMBLY (P/N: 632558A1)TO WEAR CHAFING THE WAVE WASHER AND COTTER PIN. THE COTTER PIN AND WAVE W ASHER AT THE THROTTLE BODY WERE MISSING AT THE TIME OF INSPECTION. IF THE LINK ROD FROM THE THROTTLE BODY ARM AND THE ME TERING BLOCK ARM DETACHES, PROPER FUEL METERING CEASES. 1 H 7 1 3O 3 O 3A24 E5CE 2007102300052 20071023 00052 CE 2007 10 23 2007FA0000926 1 20070812 G 5712 051179616 BULKHEAD CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA ZONE 100 WORN C K NONE O OTHER IN INSP/MAINT 1 WP 23 379TA 1560 172S9379 L3083351A CONTROL CABLE, ( P/N 0510105-308), FOUND WORN TO REPLACEMENT LIMITS IAW CABLE WEAR INSPECTION GUIDELINES IN AC43.13-1A. THE CABLE CONSTANTLY RUBS THE S338-7 FAIRLEAD IN THE LANDING GEAR BULKHEAD HOLE. IT IS BELIEVED THAT A HOLE MISLOCATIO N CAUSES THE MISALIGNMENT WHICH ALLOWS THE CABLE RUB. MM DOES NOT CONTAIN ANY (CABLE WEAR) LIMITS OR COMMENTS, ONLY CAB LE WIRE BREAKAGE AND CORROSION LIMITS. 1 H 7 1 3O 3 O NT 3A12 1E10 2007102300160 20071023 00160 CE 2007 10 23 2007FA0000929 1 20070712 G 5712 051179616 BULKHEAD CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA ZONE 100 MISALIGNED C K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 23 373ES 3780 17280052 L2701351A CONTROL CABLE, ( P/N 0510105-308), FOUND WORN TO REPLACEMENT LIMITS IAW CABLE WEAR INSPECTION GUIDELINES IN AC43.13-1A. THE CABLE CONSTANTLY RUBS THE S338-7 FAIRLEAD IN THE LANDING GEAR BULKHEAD HOLE. IT IS BELIEVED THAT A HOLE MISLOCATIO N CAUSES THE MISALIGNMENT WHICH ALLOWS THE CABLE RUB. MM DOES NOT CONTAIN ANY (CABLE WEAR) LIMITS OR COMMENTS, ONLY CAB LE WIRE BREAKAGE AND CORROSION LIMITS. 1 H 7 1 3O 3 O NT 3A12 1E10 2007110100187 20071101 00187 CE 2007 11 1 2007FA0000930 1 20071018 G 7603 632558A1 LINK ROD CONT CESSNA 185 A185F 2072821 CE CONT O520 IO520D 17032 SO THROTTLE WORN D K NONE O OTHER IN INSP/MAINT 1 NM 07 4640E 877 18503824 832429R THROTTLE BUTTERFLY (P/N: 625601G) AND THROTTLE BODY (P/N: 639437) ARE WORN, ALLOWING BUTTERFLY SHAFT TO SLIDE SIDE TO SI DE CAUSING THE LINK ROD ASSEMBLY (P/N: 632558A1)TO WEAR CHAFING THE WAVE WASHER AND COTTER PIN. THE COTTER PIN AND WAVE WASHER AT THE THROTTLE BODY WERE MISSING AT THE TIME OF INSPECTION. IF THE LINK ROD FROM THE THROTTLE BODY ARM AND THE METERING BLOCK ARM DETACHES, PROPER FUEL METERING CEASES. 1 H 7 1 3O 3 O 3A24 E5CE 2007102300161 20071023 00161 CE 2007 10 23 2007FA0000931 1 20070912 G 5712 051179616 BULKHEAD CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA ZONE 100 MISALIGNED C K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 23 658SP 4200 172S8063 L3083351A CONTROL CABLE, ( P/N 0510105-308), FOUND WORN TO REPLACEMENT LIMITS IAW CABLE WEAR INSPECTION GUIDELINES IN AC43.13-1A. THE CABLE CONSTANTLY RUBS THE S338-7 FAIRLEAD IN THE LANDING GEAR BULKHEAD HOLE. IT IS BELIEVED THAT A HOLE MISLOCATIO N CAUSES THE MISALIGNMENT WHICH ALLOWS THE CABLE RUB. MM DOES NOT CONTAIN ANY (CABLE WEAR) LIMITS OR COMMENTS, ONLY CAB LE WIRE BREAKAGE AND CORROSION LIMITS. 1 H 7 1 3O 3 O NT 3A12 1E10 2007110100186 20071101 00186 EA 2007 11 1 2007FA0000932 2 20071018 G 8520 AS18840 CAMSHAFT BEECH 23 A2324 1151226 CE LYC O360 IO360A1A 41514 EA ENGINE SPALLED B K NONE O OTHER IN INSP/MAINT 1 EA 23 6956Q 556 556 MA304 RL707851A 556 HOURS SINCE MAJOR OVERHAUL, CAMSHAFT AND LIFTERS SPALLED AND CORROSION IS EVIDENT. ENGINE HAS BEEN OPERATED ON PHIL LIPS XC 20W50 OIL. 1 L 7 1 3O 3 O A1CE 1E10 2007110100193 20071101 00193 SO 2007 11 1 2007FA0000933 1 20071019 G 2432 MS915861 SHUNT PIPER PA32 PA32R301T 7103220 SO LYC O540 TIO540* 41532 EA MASTER BATTERY BLOWN D O OTHER O OTHER NR NOT REPORTED 1 NE 03 788JG 440 3257369 COMPLETE ELECTRICAL FAILURE. WHEN BATTERY MASTER SWITCH WAS TURNED ON, NO POWER REACHED MAIN BUSS. FOUND BATTERY AMMETE R SHUNT BURNED THROUGH. BATTERY AMMETER SHUNT INSTALLED WAS 30 AMP VALUE. (P/N MS91586-1) BATTERY AMMETER SHUNT SHOULD BE 100 AMP VALUE. NO RECORD OF BATTERY AMMETER SHUNT BEING REPLACED SINCE AIRCRAFT WAS MANUFACTURED. INSTALLED CORREC T AMP VALUE SHUNT AND ELECTRICAL SYSTEM OPS CHECKED GOOD. PIPER P/N 486-684 (MS91586-6) RECOMMEND THAT ALL SHUNTS BE CH ECKED FOR ALL THIS MODEL AIRCRAFT. (ALTERNATOR AMMETER SHUNT IS SAME P/N) 1 L 7 1 3O 3 O A3SO E14EA 2007110100182 20071101 00182 EA 2007 11 1 2007FA0000935 2 20071018 G 7414 PIN PIPER PA44 PA44180 7104402 SO LYC O360 O360E1A6 41514 EA MAGNETO GROOVED D K NONE O OTHER IN INSP/MAINT 1 GL 09 2916W 633 G03EA044 447995300 L45577T STOP PINS GROOVED BEYOND LIMITS. 1 L 7 2 3O 3 O A19S0 E286 2007102300162 20071023 00162 CE 2007 10 23 2007FA0000937 1 20070912 G 2730 CONTROL CABLE CESSNA 182 182S 2072701 CE LYC IO360 IO360L2A EA ZONE 100 WORN C K NONE O OTHER IN INSP/MAINT 1 WP 23 7262Y 1400 18280812 L3083351A LT AND RT ELEVATOR CONTROL CABLES, ( P/N 0510105-189), FOUND WORN TO REPLACEMENT LIMITS IAW CABLE WEAR INSPECTION GUIDEL INES IN AC43.13-1A. CABLE WAS WORN DUE TO CONSTANT CONTACT WITH THE MICARDA PLATES OVER THE FUEL LINES AT FUEL SELECTOR AREA JUST FORWARD OF THE FRONT SEATS. THE CABLE TENSIONS ARE CORRECT BUT THE CABLES ARE IN CONSTANT CONTACT WITH PLATE S. MM DOES NOT CONTAIN ANY (CABLE WEAR) LIMITS OR COMMENTS, ONLY CABLE WIRE BREAKAGE AND CORROSION LIMITS. 1 H 7 1 3O 3 O NT 3A13 1E10 2007102600095 20071026 00095 SO 2007 10 26 2007FA0000938 1 20071022 G 3297 AN551 BOLT PIPER PIPER PA44 PA44180 7104402 SO LYC O360 O360* 41514 EA DRAG LINK SHEARED B O OTHER O OTHER LD LANDING 1 WP 07 574ER 3743 NA 4496150 FORWARD DRAG LINK BOLT ON NOSE GEAR FAILED DURING TOUCH AND GO PRACTICE. A/C RETURNED TO DEPARTURE AND LANDED WITH THE NOSE GEAR STUCK IN THE NOSEWHEEL WELL. 1 L 7 2 3O 3 O A19S0 E286 2007102600097 20071026 00097 CE 2007 10 26 2007FA0000939 1 20071021 G 3260 LAMP BEECH MU300 400A 1155402 CE PWA JT15 JT15D5 52112 NE MLG INDICATOR INOPERATIVE D O OTHER P NO WARNING INDICATION DE DESCENT 1 SO 11 442GJ RK442 PILOT HAD NO GREEN DOWN AND LOCKED INDICATION FOR THE RT GEAR WHEN LANDING. PILOT CONFIRMED WITH THE TOWER THE GEAR WAS DOWN, ALSO THE PILOT CONFIRMED THAT THE LIGHT WOULD NOT ILLUMINATE WHEN TESTED. AFTER LANDING MAINTENANCE CHECKED OUT AI RCRAFT AND REPLACED LAMP IN GEAR INDICATION. SYSTEM OPERATIONAL CHECK GOOD. 2 H 7 2 4F 4 F RT A16SW E25EA 2007120400004 20071204 00004 SW 2007 12 4 2007FA0000941 1 20071009 G 2700 KS178 ROLL SERVO MOONEY M20 M20K 5870220 SW CONT O360 TSIO360* 17025 SO INSIDE CASE LOOSE D O OTHER O OTHER NR NOT REPORTED 1 EA 13 697SP 160 5644 252002 MOTOR ASSY COMING LOOSE ON SERVO MOUNT. LOOSE HARDWARE, LOOSE MOTOR. RECOMMEND SERVO TO BE INSPECTED FOR PROPER SERVO A SSY (THAT MOTOR AND HARDWARE ARE NOT LOOSE). (K) 1 L 7 1 3O 3 O 2A3 E9CE 2007102600109 20071026 00109 SO 2007 10 26 2007FA0000942 1 20070921 G 3220 LANDING GEAR PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360KB 17025 SO NOSE COLLAPSED C AG3R O OTHER O OTHER NR NOT REPORTED 1 WP 15 84643 348233033 AIRCRAFT TAXIED TO RUNWAY AFTER LOADING CARGO. AFTER NORMAL RUNUP, THE PILOT TAXIED ONTO THE RUNWAY AND STOPPED. THE P ILOT ADVANCED THROTTLES AND RELEASED BRAKES, AFTER RELEASING BRAKE, THE NOSE GEAR COLLAPSED. AIRCRAFT WAS RECOVERED AND TOWED OFF RUNWAY TO A SAFE TIE DOWN SPOT. NO CAUSE IS YET KNOWN AS TO WHY THE NOSE GEAR COLLAPSED. (K) 1 L 7 2 3O 3 O A7SO E9CE 2007102600110 20071026 00110 CE 2007 10 26 2007FA0000944 1 20071012 G 8011 6462751 STARTER CESSNA 421 421C 2076016 CE CONT O520 GTSIO520N 17032 SO RT ENGINE SHORTED C O OTHER O OTHER NR NOT REPORTED 1 EA 25 421KD 29 421C1006 808319R OVERHAULED STARTER FAILED AFTER 30 HOURS. (K) 1 L 7 2 3O 3 O A7CE E7CE 2007102600111 20071026 00111 CE 2007 10 26 2007FA0000945 1 20071012 G 2913 PUMP RAYTHN 390 390 7150030 CE WILINT FJ44 FJ442A GL HYD SYSTEM DAMAGED D JAS2 O OTHER O OTHER NR NOT REPORTED 1 WP 09 408J RB193 HYDRAULIC PUMP ASSY, PN 390-389022-0003, INSPECTED AND FOUND NOT DEFECTIVE. FOUND DEFECTIVE/ DAMAGED PART PN MS28778-6, PACKING. FLIGHT CREW COMPLETED ABNORMAL CHECKLIST. UPON INSPECTION FOUND THAT PACKING AT HYDRAULIC PUMP PRESSURE OUTL ET FITTING HAD FAILED. THIS COMPONENT WAS WORKED ON IAW MFG SAFETY COMMUNIQUE , CONTROL NR JAS-SDR-001. (K) 1 L 7 2 3F 4 F RT A00010WI E3GL 2007102600113 20071026 00113 NM 2007 10 26 2007FA0000946 1 20071016 G 5313 STRINGER BOEING 727 727200 138407E NM PWA JT8 JT8D217C 52053 NE BS940-945 CRACKED B FY4Y K NONE O OTHER IN INSP/MAINT 1 WP 03 705AA 22462 THE AIRCRAFT INPUT FOR 4C CHECK AND CPCP ON SEPT 3, 2007. DURING CPCP, THE INSPECTOR PERFORMED VISUAL INSPECTION AND FO UND 5 INCH CRACK BOTH ON LT AND RT FUSELAGE STRINGER S18A BETWEEN BS940 AND BS945 ON SEPT 21, 2007. A PROPOSAL WAS INIT IALLY SUBMITTED ON SEPT 22. AFTER REPAIR TO THE STRINGERS, FORM 337 WILL BE SUBMITTED TO FAA FOR FINAL RESULT OF CORREC TIVE ACTIONS DETAIL. (K) 2 L 7 3 4F 4 F RT A3WE E9NE 2007110200002 20071102 00002 EU 2007 11 2 2007FA0000947 1 20071003 G 3233 X110061 ACTUATOR DIAMON DA42 DA42 2990004 EU MLG INOPERATIVE D O OTHER O OTHER NR NOT REPORTED 1 NM 07 240TS 681 42072 PILOTS WERE UNABLE TO EXTEND RT MLG WITH THE EMERGENCY EXTENSION HANDLE IN FLIGHT. EMERGENCY SYSTEM OPERATED WITHIN LIM ITS ON THE GROUND. UPON REMOVAL, THE ACTUATOR WAS FOUND TO BE VERY DIFFICULT TO MOVE. ( K) 1 L 7 2 3I RT A57CE 2007102600112 20071026 00112 SO 2007 10 26 2007FA0000948 1 20071024 G 3220 CENTERING MECH PIPER PIPER PA46 PA46310P 7104605 SO CONT O520 TSIO520* 17040 SO NLG FAILED G O OTHER O OTHER LD LANDING 1 SO 11 383SA 4608033 UPON TOUCHDOWN AIRCRAFT VEERED LT ABRUPTLY AND DEPARTED RUNWAY SURFACE. GEAR EXTENSION AND INDICATION WERE NORMAL. INVES TIGATION REVEALED THAT UPON TOUCHDOWN THE NOSE LANDING GEAR HAD FAILED TO CENTER CORRECTLY DURING EXTENSION. 1 L 7 1 3O 3 O RT A25SO E8CE 2007102600106 20071026 00106 NM 2007 10 26 2007FA0000949 1 20071017 G 5610 58935578 WINDSCREEN BOEING 737 7377H4 1384404 NM GE CFM56 CFM567B24 NE COCKPIT CRACKED D H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 WP 01 66ZB 2985 29233 IN CRUISE, 41,000FT (8.5PSID), -60C, ARCING AND SMOLDERING OBSERVED FROM MID BOTTOM OF WINDOW PROPAGATING UP TO TOP FWD EDGE OF RT NR 2 SLIDING WINDOW. WINDOW HEAT, RT, SIDE SWITCH SELECTED OFF. WHILE QRH CONSULTED, AS WINDOW COOLED, CRACK ING OBSERVED ON OUTER PANE ONLY THROUGHOUT THE WINDOW AREA. QRH STATES NO FURTHER ACTION REQUIRED DUE OUTER PANE NOT PR IMARY STRUCTURAL SUPPORT. FLIGHT CONTINUED AT 41,000 FT FOR NEXT 20 MINS TO TOP OF DESCENT. LANDING CARRIED OUT NORMAL LY. WINDOW ASSY REPLACED.. 2 L 7 2 4F 4 F RT A16WE E00055EN 2007102600107 20071026 00107 NM 2007 10 26 2007FA0000950 1 20071017 G 5610 58935578 WINDSCREEN BOEING 737 7377H4 1384404 NM GE CFM56 CFM567B24 NE COCKPIT CRACKED D H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 WP 01 2985 29233 IN CRUISE, 41,000FT (8.5PSID), -60C, ARCING AND SMOULDERING OBSERVED FROM MID BOTTOM OF WINDOW PROPAGATING UP TO TOP FWD EDGE OF RT NR 2 SLIDING WINDOW. WINDOW HEAT, RT, SIDE SWITCH SELECTED OFF. WHILE QRH CONSULTED, AS WINDOW COOLED, CRAC KING OBSERVED ON OUTER PANE ONLY THROUGHOUT THE WINDOW AREA. QRH STATES NO FURTHER ACTION REQUIRED DUE OUTER PANE NOT P IMARY STRUCTURAL SUPPORT. FLIGHT CONTINUED AT 41,000 FT FOR NEXT 20 MINS TO TOP OF DESCENT. LANDING CARRIED OUT NORMAL LY. WINDOW ASSY REPLACED. 2 L 7 2 4F 4 F RT A16WE E00055EN 2007113000142 20071130 00142 EA 2007 11 30 2007FA0000951 2 20070713 G 7261 56G23399 BAFFLE FOUND FBA FBA2C1 3640103 EA LYC O540 TIO540* 41532 EA OIL SUMP BROKEN B O OTHER O OTHER NR NOT REPORTED 1 AL 03 796 599 50 OIL BAFFLE IN SUMP RUBBING ON BOTTOM OF SUMP. 4 OUT OF 6 HOLES CRACKED OUT AROUND MOUNTING AREA. 2 HOLES COMPLETELY WO RN THROUGH AND STILL HAD PARTS OF BAFFLE UNDER WASHER AND MOUNTING SCREW. (K) 1 H 7 1 3O 3 O NC A7EA E14EA 2007110500008 20071105 00008 EA 2007 11 5 2007FA0000952 2 20071010 G 8530 AEL85099 CYLINDER PIPER PA28 PA28161 7102803 SO LYC O320 O320* 41508 EA NR 4 FAILED D O OTHER O OTHER NR NOT REPORTED 1 SO 15 602FT 733 2841196 CYLINDER HAD FAILURE, SEPARATION FROM BARREL AT 733 HRS, NOT INCORPORATED IN AD2006-12-7. (K) 1 L 7 1 3O 3 O 2A13 E274 2007110500009 20071105 00009 2007 11 5 2007FA0000953 4 20071011 G 2562 BATTERY AMERIKING PIPER PA28 PA28151 7102805 SO LYC O320 O320* 41508 EA ELT DAMAGED D O OTHER O OTHER NR NOT REPORTED 1 NM 02 32276 287515109 FOUND ELT BATTERY CASE BULGED ON BOTTOM. FOUND ALL CONTACTS WITHIN BATTERY COMPARTMENT LOOSE DUE TO HIGH TEMPERATURE (C OULD SEE WHERE PLASTIC HAD MELTED) COULD NOT DETERMINE WHAT CAUSED THE SHORT. REPLACED ELT. (K) 1 L 7 1 3O 3 O 2A13 E274 2007110500012 20071105 00012 2007 11 5 2007FA0000954 4 20071011 G 2562 BATTERY AMERIKING CESSNA 210 210C 2073412 CE CONT O470 IO470* 17026 SO ELT DAMAGED D K NONE O OTHER IN INSP/MAINT 1 NM 02 22GP 58202 DURING ANNUAL INSPECTION FOUND DRIED ALKILINE BATTERY SUBSTANCE ON EXTERIOR OF CASE. OPEND CASE AND FOUND THAT THE BATT ERIES, ALKALINE BATTERIES WERE COMING APART AT THE SEAMS AND LEAKING. CLEANED BATTERY COMPARTMENT AND INSTALLED FRESH S ET OF BATTERIES. FUNCTION TESTED OK. THIS IS THE THIRD SUCH OCCURENCE THIS YEAR. OF ACID LEAK INTO THE TRANSMITTER. U NIT HAD TO BE REPLACED. (K) 1 H 7 1 3O 3 O 3A21 E1CE 2007110500014 20071105 00014 SO 2007 11 5 2007FA0000955 2 20070921 G 8530 CYLINDER HEAD BEECH 33 F33A 1151425 CE CONT O520 IO520* 17032 SO NR 2 SEPARATED D O OTHER O OTHER NR NOT REPORTED 1 EA 09 711JA CE478 IN-FLIGHT NR 2 CYLINDER HEAD SEPARATED FROM CYLINDER BASE AT TOP OF SLEEVE. PUSHRODS AND TUBES BENT. EXHAUST MANIFOLD B ENT. NOZZLE ASSEMBLY DAMAGED. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2007113000143 20071130 00143 CE 2007 11 30 2007FA0000956 1 20070919 G 5740 50270025 BRACKET CESSNA 310 310R 2074245 CE CONT O520 IO520* 17032 SO RT MLG WW INOPERATIVE E O OTHER O OTHER NR NOT REPORTED 1 GL 13 5338C 310R1544 THE RT MAIN LANDING GEAR WOULD NOT RETRACT INTO WHEEL WELL. PILOT REPORTED LOUD BANG HEARD AFTER RETRACTING OF GEAR. W HEN EXTENDING THE GEAR FOR LANDING, THE RT GEAR WOULD NOT INDICATE GREEN BUT WAS VISUALLY CONFIRMED DOWN. PILOT LANDED WITHOUT INCIDENT AND GREEN LIGHT ILLUMINATED UPON TOUCHDOWN. INSPECTION OF THE RT GEAR FOUND THE TORQUE TUBE SUPPORT BR ACKET ASSY, PN 50270025, BEARING PULLED LATERALLY FROM BRACKET AND ROD END FOR THE UPLOCK PUSH-PULL TUBE BROKEN OFF AT T HE TORQUE TUBE ATTACH POINT PN HM4, AND FORWARD TORQUE TUBE ATTACH BOLT, PN NAS146-40, BENT SLIGHTLY. FAILURE OF THE SU PPORT BRACKET PN 5027002-5 POSSIBLY DUE TO FATIGUE. (K) 1 L 7 2 3O 3 O 3A10 E5CE 2007113000145 20071130 00145 SO 2007 11 30 2007FA0000957 2 20071004 G 7414 10500556101 MAGNETO CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO ENGINE MISOVERHAULED B YD5R O OTHER W INADEQUATE Q C NR NOT REPORTED 1 GL 15 434SR 20 2557 690898 AIRCRAFT ENGINE RUNNING ROUGH AND BACKFIRING ON FLIGHT TEST. PILOT RETURNED AND GROUNDED AIRCRAFT FOR MAINTENANCE. MAI NTENANCE PERSONNEL PERFORMED INTERNAL INSPECTION OF CONVERTED MAGNETOS TO PRESSURIZATION. MAGNETO CONVERTED TO PRESSURI ZED, INSPECTION REVEALED CARBON BRUSHES MISSING ON BOTH MAGNETOS, INTERNAL TIMING WAS WRONG ON ONE OF THE MAGNETOS, WIRE S WERE CHAFED, EXCESS GREASE WAS FOUND ON ROTOR BRUSH ASSEMBLY. FURTHER INVESTIGATION OF AIRCRAFT WITH MAGNETO PN 10-55 0556-101 MODIFIED, INSTALLED ON AIRCRAFT FOR TURBO NORMALIZING. 6 ADDITIONAL MAGNETOS EXHIBITED THE SAME CONDITIONS LIST ED ABOVE. RECOMMENDATIONS FOR CORRECTION ARE TO CONVERT MAGNETOS IAW PUBLISHED SPECS AND PROCEDURES. (K) 1 L 7 1 3O 3 O NT A00009CH E3SO 2007110500013 20071105 00013 EU 2007 11 5 2007FA0000958 2 20070913 G 7310 CASC216 REGULATOR GULSTM G1159 G1159A 3970109 SO RROYCE SPEY SPEY5118 54523 EU FUEL FLOW FAILED D O OTHER J WARNING INDICATION NR NOT REPORTED 1 EA 07 776MA 891 447 11298 PILOTS REPORT FELT HEAVY VIBRATION FOR 3 TO 4 SECONDS, THEN HEARD A LOUD BANG FOLLOWED BY LT ENGINE SPOOLING DOWN. AIRC RAFT SAFELY LANDED AT AIRPORT. CONTACTED MFG, WHO DISPATCHED A RESPONSE CREW TO AIRPORT. FOUND THAT THE FUEL FLOW REGU LATOR HAD FAILED IN FLIGHT. (K) 2 L 7 2 4F 4 F A12EA E2EU 2007113000146 20071130 00146 WP 2007 11 30 2007FA0000959 2 20071002 G 7314 30708507 PUMP LEAR 35 35LEAR 5170600 CE GARRTT TFE731 TFE73122B 01518 WP RT ENGINE FUEL FAILED B X5ER K NONE O OTHER IN INSP/MAINT 1 SW 05 354PM 4254 015 P74271 RT ENGINE FAILED ON TAKEOFF ROLL JUST BEFORE 80 KNTS IAS. AIRCRAFT WAS STILL ON GROUND. FUEL PUMP, FAILED TO PUMP FUEL . (K) 2 L 7 2 4F 4 F A10CE E6WE 2007113000147 20071130 00147 SO 2007 11 30 2007FA0000960 1 20070906 G 3240 BRAKE MAULE MX7 MX7180A 5460186 SO LYC O360 O360* 41514 EA PARK SYS INOPERATIVE D K NONE O OTHER IN INSP/MAINT 1 SO 03 30822 22003C PARK BRAKE CABLE HANGING ON 90 DEGREE CABIN FITTING COMING THROUGH FIREWALL. AIRCRAFT BRAKES LOCKED ON WHEN LANDING. D ISCONNECTED PARK BRAKE CABLE AND SAFETY WIRED BRAKE LOCK LEVERS ON MASTER CYLINDER IN NEUTRAL/OFF POSITION PLACARD PANEL MADE LOG BOOK ENTRY. (K) 1 H 7 1 3O 3 O NC 3A23 E286 2007110500015 20071105 00015 SO 2007 11 5 2007FA0000961 1 20070718 G 2140 1386725 HEATER PIPER PA31T PA31T 7103124 SO PWA PT6 PT6A60A 52043 NE COCKPIT LEAKING B O OTHER K B J FLUID LOSS SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CR CRUISE 1 GL 25 650RS 1 31T8020071 DURING OPERATION OF COMBUSTION HEATER, THE PILOT NOTED JET FUEL ODOR AND SMOKE IN CABIN. HEATER OPERATION WAS TERMINATE D, CABIN WAS VENTED. EMERGENCY WAS DECLARED AND AIRCRAFT LANDED AT NEAREST AIRPORT WITHOUT INCIDENT. UPON REMOVAL, A F UEL LEAK WAS NOTED AT COMBUSTION HEAD AND FUEL SOLENOID AREA. HEATER WAS REPLACED WITH A SERVICEABLE UNIT. (K) 1 L 7 2 3T 4 T A8EA E4EA 2007113000155 20071130 00155 SO 2007 11 30 2007FA0000962 1 20071018 G 3250 3526202 BUNGEE PIPER PA28 PA28140 7102802 SO LYC O320 O320* 41508 EA NLG STEERING FAILED D O OTHER O OTHER NR NOT REPORTED 1 GL 09 56978 287425077 SHORTLY AFTER TAKEOFF, AIRCRAFT WENT INTO SHARP RT TURN. THE PILOT, BY USING FULL OPPOSITE RUDDER AND AVAILABLE RUDDER TRIM, WAS ABLE TO LAND AIRCRAFT SUCCESSFULLY. INSPECTION DETERMINED THAT THE RT NOSE GEAR STEERING BUNGEE SPRING RETAIN ER HAD DEPARTED AND THE SPRING WAS EXTENDED FROM THE BARREL ASSY. THE TURN WAS ALSO EXAGGERATED BY THE LARGE FIN USED O N THE NOSE WHEEL FAIRING. AS IT IS DIFFICULT TO EXAMINE THE RETAINER DUE TO THE LOCATION OF THE BUNGEE ASSY UNDER THE E XHAUST SYSTEM, IT CAN NOT BE DETERMINED IF THE BACK SIDE OF THE RETAINER IS BEING WORN OR CORRODED. THIS PART IS ONLY H ELD IN PLACE BY A FEW TWISTS OF SAFETY WIRE. IT IS SUGGESTED THAT THE MFG LOOK AT THIS AS A MAJOR SAFETY ISSUE AND EITH 1 L 7 1 3O 3 O 2A13 E274 2007113000157 20071130 00157 CE 2007 11 30 2007FA0000963 1 20071018 G 3222 07436062 FITTING CESSNA 182 182T 2072703 CE LYC O540 IO540AB1A5 EA NLG STRUT CHAFED D K NONE O OTHER IN INSP/MAINT 1 SO 03 6025D 18281830 LOWER STRUT SUPPORT FITTING CLAMPING RING CENTER BORE IS NOT CENTERED. THIS CAUSES THE STEERING COLLAR AND LOWER STRUT SUPPORT TO CHAFE AND FOR METAL TO METAL CONTACT TO OCCUR. HAVE TRIED TWO OTHER NEW LOWER STRUT SUPPORT FITTING RESULTIN G WITH METAL TO METAL CHAFING. INITIALLY CONTACTED MFG AND REPORTED THE PROBLEM REVEALING NUMEROUS IDENTICAL PARTS HAVE THE SAME DEFECT. RECOMMEND THAT CONTACT BE MADE WITH MFG AND TO MEASURE FOR PROPER THICKNESS OF THE RING ON THE LOWER STRUT SUPPORT FITTING. (K) 1 H 7 1 3O 3 O NT 3A13 1E4 2007120400005 20071204 00005 SO 2007 12 4 2007FA0000964 1 20071017 G 2822 35328803 PUMP PIPER PA28 PA28161 7102803 SO LYC O320 O320* 41508 EA FUEL BOOST MALFUNCTIONED D O OTHER Y ENGINE STOPPAGE CR CRUISE 1 NM 02 515MS 2750 2842157 REPORTED ENGINE QUITTING DURING NORMAL CRUISE, PROBLEM ASSOCIATED WITH FUEL SYSTEM, ONCE ELECTRIC FUEL PUMP TURNED ON EN GINE WOULD RUN NORMAL, FUEL PRESS READINGS CONFIRMED FUEL STARVATION PROBLEM, INITIAL INSPECTIONS FAILED TO FIND A PROBL EM & COULD NOT BE DUPLICATED, REPLACED EDP WITH NEW & FLEW ACFT, PROBLEM REOCCURRED & APPEARED TO BE ISOLATED TO THE RT SIDE FUEL TANK SELECTION, REMOVED FUEL LINE AT CARB & PUMPED FUEL USING BOOST PUMP, MONIT