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 2004052600055 20040526 00055 NE 2004 5 26 00141 2 20040524 G 7200 ENGINE LEAR 24 24F 5170317 CE GE CJ610 CJ6106 30006 NE LEFT FLAMED OUT E HAEA O OTHER X J ENGINE FLAMEOUT WARNING INDICATION CR CRUISE 1 SW 05 444TW 15995 10363 24F348 241C050A AIRCRAFT ENCOUNTERED TURBULENCE AT FL390K. LT ENGINE FLAMED OUT. ENGINE RELIGHT NORMAL. 2 L 7 2 4J 4 J A10CE 1E16 2005031000028 20050310 00028 NM 2005 3 10 0041005 1 20041005 G 3097 WIRE BOEING 727 727100 1384036 NM DRAIN HEATER SHORTED C U1IM O OTHER B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 WP 23 727VJ 19318 AFTER TAKEOFF AT 1000 FT, A BURNING ODOR NOTED, NO OBVIOUS PROBLEM WITH GEN LOADS, APPROX 3000 FT VISIBLE SMOKE EMINATIN G BEHIND FE TABLE. NO CB'S POPPED, NO VISIBLE SYS TROUBLE. TROUBLE CEASED & SMOKE CLEARED. ENGINEER DETERMINED ALL SYSTE MS OPERATIONAL. AS IT WAS A DAY TIME FLIGHT AND VMC EXISTED WE ELECTED TO CONTINUE FOR OUR SCHEDULED MX. UPON IVESTIGATI ON DRAIN MAST "AIR" CB DID NOT POP, WIRING FROM CB TO DRAIN MAST BURNED EXPOSING BARE WIRES. TROUBLE TRACED TO FWD DRAIN MAST, FOUND LOOSE INSIDE MAST FAIRING. MAST HEATER WIRE SHORTED TO MAST STRUCTURE. RUN OF WIRE REPLACED, CB'S REPLACED (AIR & GRD) EXERCISED ALL CB'S IN COCKPIT, REPLACED FORWARD DRAIN MAST, MLG ACCESSORY BOX REPLACED DUE TO DAMAGED WIRES. 2 L 7 3 4F RT A3WE 2004022300078 20040223 00078 NM 2004 2 23 01070422H 1 20040107 G 5743 SPAR CAP UNIVAR 415 415D 0420306 NM WING CORRODED D K NONE O OTHER IN INSP/MAINT 1 WP 25 3647 FOUND A POCKET OF EXFOLIATION ON TOP OF BOTTOM SPAR CAP EXTRUSION, AT AREA DIRECTLY BELOW MAIN LANDING GEAR ATTACH BOLT. ALSO FOUND AREA OF EXFOLIATION IN STIFFENER 31107 ON LT SIDE BEHIND WING FILLET. 1 L 7 1 3O A787 2004022500086 20040225 00086 CE 2004 2 25 01222004 1 20040122 G 5210 07110381 HINGE PIN CESSNA 182 182H 2072718 CE LWR RT DOOR BROKEN D K NONE O OTHER IN INSP/MAINT 1 NE 01 2084X 18256184 DURING ANNUAL INSPECTION LOWER RT DOOR HINGE PIN WAS FOUND BROKEN IN 3 PLACES. THIS ITEM IS SIMPLE TO DETECT BY JUST OPE NING AND CLOSING THE DOOR SLOWLY AND WATCH FOR EQUAL ROTATION OF PIN. IF ONLY ONE END TURNS THEN THE PIN MUST BE BROKEN . PART INFO: HINGE PIN P/N 0711038-1, AFFECTING LOWER HINGE (P/N 0711037-20) OF RT DOOR. 1 H 7 1 3O NT 3A13 2004110200127 20041102 00127 SW 2004 11 2 031283 1 20040901 G 5310 TUBE SPARTN 7W 7W 8430302 SW PWA R985 R985* 52008 NE FUSELAGE BENT B W2OR K NONE O OTHER IN INSP/MAINT 1 GL 09 17662 28 DURING SCHEDULED INSPECTION, FOUND AFT FUSELAGE TUBES BENT AND CRACKED. THIS AREA HAD BEEN PREVIOUSLY REPAIRED FOR SIMIL AR CONDITION. DAMAGE WAS APPARENTLY CAUSED BY TAIL WHEEL LINK STRIKING TUBES AS A RESULT OF UNDER INFLATION OR COLLAPSE OF TAIL WHEEL STRUT. THERE IS NO EXTERNAL STOP ON THE TAIL WHEEL ASSEMBLY TO PREVENT THE LINK FROM CONTACTING THE TUBE S DUE TO COLLAPSE OR UNDER INFLATION OF TAIL WHEEL STRUT. RECOMMEND ALL MFG OWNERS CAREFULLY INSPECT THIS AREA DURING I NSPECTIONS AND MAINTAIN THE PROPER SERVICING IN THE TAIL WHEEL STRUT. 1 L 7 1 3R 3 R TC628 5E1 2004042900095 20040429 00095 EA 2004 4 29 033104 2 20040324 G 7230 MS9714XX BOLT BEECH 90 C90 1152913 CE PWA PT6 PT6A20 52043 EA COMPRESSOR BACKED OUT B K NONE O OTHER IN INSP/MAINT 1 SO 17 30HF 370 LJ506 PCE22520 PILOT REPORTS (GRINDING) SOUND WHEN PROPELLER IS SPUN BY HAND. THE ENGINE WAS SPLIT AT THE (C) FLANGE WHERE DEBRIS WAS N OTED AT THE 6 O'CLOCK AREA BETWEEN THE COMPRESSOR TURBINE BLADES AND SHROUD SEGMENTS. AFTER REMOVAL OF THE CT DISK, IT W AS NOTED THAT FOUR BOLTS HOLDING THE INNER EXIT DUCT TO THE ENGINE WERE MISSING. THE DEBRIS WERE THE REMAINS OF THE FOUR BOLTS. SAFETY WIRE WAS NOT PRESENT IN THE REMAINING FOUR BOLTS. 370 HOURS SINCE ENGINE O/H. 1 L 7 2 3T 3 T 3A20 E4EA 2004111900036 20041119 00036 SO 2004 11 19 040103119 1 20040723 G 2913 1159SCH20041 PUMP GULSTM G1159 GIV 3980115 SO RROYCE TAY TAY6118 EU HYD SYSTEM FAILED B Y3PR K NONE O OTHER IN INSP/MAINT 1 SO 35 7800 1098 ENGINE DRIVEN HYDRAULIC PUMP INTERNAL FAILURE. LARGE ACCUMULATION OF METAL SHAVINGS FOUND IN HYDARULIC FILTER AND CANIS TER, CAUSING THE BYPASS INDICATION BUTTON TO POP. 2 L 7 2 4F 4 F RT A12EA E25NE 2004051200092 20040512 00092 EA 2004 5 12 040505 2 20040504 G 8530 68795 ROCKER COVER LYC HELIO H295 H295 4300802 CE LYC O480 GO480G1D6 41527 EA ENGINE WORN B EVGR K NONE O OTHER IN INSP/MAINT 1 SO 33 62JA 370 1443 ROCKER BOX, PN 68795 WAS WORN BY THE VALVE ROCKER SHAFT UNTIL THE SHAFT CUT THROUGH THE SHAFT RETAINER WHICH IS SPOT WEL DED TO THE VALVE COVER. THREE OF SIX COVERS WERE SEVERELY WORN. A FOURTH COVER'S BRACKET WAS WORN THROUGH AND THE RESU LTING SLUG OF METAL (ROCKER SHAFT WAS WORKING LIKE A WAD CUTTER) WAS FOUND LYING IN THE VALVE ROCKER BOX. REPLACED FOUR VALVE COVERS WITH SERVICEABLE PARTS. 1 H 7 1 3O 3 O 1A8 E275 2004050300143 20040503 00143 CE 2004 5 3 040604 1 20040406 G 1430 MS9714XX BOLT BEECH 90 C90 1152913 CE PWA PT6 PT6A20 52043 EA ENGINE DAMAGED B K NONE O OTHER IN INSP/MAINT 1 SO 17 30HF LJ506 PCE22543 THE ENGINE WAS SPLIT AT THE (C) FLANGE. AFTER REMOVAL OF THE C.T. DISC, IT WAS NOTED THAT 2 BOLTS HOLDING THE INNER EXI T DUCT TO THE ENGINE HAD SHEARED OFF AND WERE LODGED IN THE AREA, WITH THE REMAINDER OF THE BOLT SHANKS LEFT IN THE BOLT HOLES. DAMAGE WAS NOTED ON THE C.T. DISC. SAFETY WIRE WAS PRESENT IN ALL THE BOLTS INCLUDING THE SHEARED BOLT HEADS. 1 L 7 2 3T 3 T 3A20 E4EA 2004091500091 20040915 00091 SO 2004 9 15 040624 2 20040624 G 8520 646520646521 CRANKCASE CESSNA 206 206CESSNA 2073302 CE CONT O520 IO520F 17032 SO ENGINE CRACKED B EVGR K NONE K FLUID LOSS IN INSP/MAINT 1 SO 33 5704 4A9388 IT HAD PROP STRIKE WHICH IS WHEN THE DAMAGE PROBABLY OCCURRED. OVERHAULED AND RAN FULL LIFE BUT OIL LEAKS DEVELOPED AT T HE MOST FORWARD THROUGH BOLTS. BECAUSE OF THE OIL LEAK AT BOLT HOLE DURING RUNUP AFTER OVERHAUL THAT WAS JUST COMPLETED . CRACK IS IN FRONT MAIN LOWER THRU BOLT HOLE IN LEFT CASE HALF. CRACK IS ABOUT 2.5 IN. LONG, STARTS INSIDE HOLE ABOUT AN INCH FROM PARTING SURFACE AT ABOUT 9 O'CLOCK AS VIEWED FROM THE OUTSIDE CASE, SPIRALS SLIGHTLY TO ALMOST 11 O'CLOCK POSITION. CRACK CAN BE VIEWED WITH THROUGH BOLT REMOVED AND BY USING A BORESCOPE. SINCE CRACK IS ON FORWARD SIDE OF HO LE, IT COMMUNICATES WITH OIL PASSAGE THAT IS JUST FORWARD OF THROUGH BOLT HOLE, THUS CAUSING THE LEAK. 1 H 7 1 3O 3 O A4CE E5CE 2004030100130 20040301 00130 CE 2004 3 1 041332 1 20040212 G 2823 CCA1550 DRAIN CESSNA CESSNA 172 172 2072402 CE CONT O300 O300* 17022 SO FUEL VALVE CRACKED B W2OR K NONE O OTHER IN INSP/MAINT 1 GL 09 6341E 46441 PILOT REPORT OF FUEL LEAK FROM SELECTOR. FOUND LEAKAGE PAST SHAFT SEAL. REMOVED SELECTOR VALVE FOR REPAIR. CCA-1550 DRAI N VALVE WAS INSTALLED IN BOTTOM OF SELECTOR VALVE. WHEN DRAIN VALVE WAS REMOVED, ORING RETAINING WASHER AT END OF DRAIN VALVE WAS OBSERVED TO BE CRACKED IN NUMEROUS PLACES AND IN IMMINENT DANGER OF FAILURE. HAD THE WASHER BROKEN OFF, AN UNC ONTROLLABLE LOSS OF FUEL THROUGH THE DRAIN VALVE WOULD HAVE OCCURRED. THE ONLY WAY TO PREVENT FUEL LEAKAGE WOULD HAVE BE EN TO SHUT OFF THE FUEL SELECTOR, WHICH RESULTS IN ENGINE STOPPAGE. 1 H 7 1 3O 3 O NT 3A12 E253 2004101300088 20041013 00088 CE 2004 10 13 041403 1 20041005 G 7160 BA5710 AIR FILTER CESSNA 177 177 2073704 CE LYC O320 O320E2D 41508 EA ENGINE WRONG PART B W2OR K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 09 117MM 17700872 L2119627 DURING TROUBLESHOOTING FOR EXCESSIVE MAGNETO DROP, FOUND FACE OF AIR FILTER ELEMENT DETERIORATED. THE INSTALLATION IS FO R A BRACKETT FILTER. REMOVED ELEMENT AND FOUND THAT ELEMENT WAS AN UNAPPROVED PART. THE (FILTER) WAS HAND CUT FROM A PIE CE OF GREEN FOAM .6250 INCH THICK. IT APPEARS THE FACE OF THE FOAM WAS PAINTED BLACK SO AS TO LOOK LIKE A GENUINE BRACKE TT FILTER. HAD THE FILTER DETERIORATED, INGESTION IN THE CARBURETOR COULD HAVE CAUSED A LOSS OF ENGINE POWER WITH POTENT IAL FATAL RESULTS. THIS PRESENTS A SERIOUS SAFETY PROBLEM AND REPRESENTS A LACK OF REGARD FOR SAFETY. NO LOGBOOK ENTRY COULD BE FOUND FOR RECENT INSTALLATION OF FILTER. ANNUAL INSPECTION WAS SIGNED OFF IN AUGUST OF 2004. 1 H 7 1 3O 3 O NT A13CE E274 2004101300089 20041013 00089 EA 2004 10 13 041403A 2 20041005 G 7414 10357586 GEAR BENDIX S4LN21 CESSNA 177 177 2073704 CE LYC O320 O320E2D 41508 EA MAGNETO BROKEN B W2OR A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 GL 09 117MM A13623 17700872 L2119627 LOST POWER ON TAKEOFF. VERIFIED PROBLEM OF LT MAGNETO INOPERATIVE. INSPECTED AND FOUND MAGNETO DISTRIBUTOR GEAR MISSING SEVERAL TEETH. GEAR WAS LOOSE ON SHAFT WHICH PROBABLY CONTRIBUTED TO BREAKAGE. SUSPECT CAUSE WAS LACK OF PROPER MAINTEN ANCE OVER LIFE OF MAGNETO. ANNUAL INSPECTION WAS SIGNED OFF IN AUGUST 2004. 1 H 7 1 3O 3 O NT A13CE E274 2004051000042 20040510 00042 CE 2004 5 10 0423JKW 1 20040424 G 2742 2A9200H ACTUATOR LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE731* 01518 WP HORIZONTAL STAB INOPERATIVE C O OTHER J WARNING INDICATION NR NOT REPORTED 1 CE 09 45HF 258 172 121 CREW REPORTED (PRIMARY TRIM FAULT) WHITE EICAS MESSAGE, WHICH CHANGED TO (PRIMARY AND SECONDARY TRIM FAIL EICAS) AMBER M ESSAGE ON APPROACH TO LANDING. HORIZONTAL STAB SYSTEM LOCKED OUT ALL MOVEMENT FOR REMAINDER OF THE FLIGHT. CREW RESET SYSTEM POST LANDING, ALL FAULTS CLEARED, AND THE SYSTEM RETURNED TO NORMAL OPERATION. NO FAULTS REOCCURED ON NEXT FLIGH T TO HOME STATION. REMOVED ACTURATOR PN662740100-007 SN H0053, INSTALLED ACTUATOR PN 662740100-007 SN H0113. (MFG PN 2A 9200H). COMPLIED WITH AD. (CE09200403217) 2 L 7 2 4F 4 F RT T00008WI E6WE 2004091500117 20040915 00117 CE 2004 9 15 06282004 1 20040628 G 3232 MS166251068 RETAINING RING CESSNA 210 T210M 2073451 CE CONT O520 IO520L 17032 SO MLG DOOR WORN G O OTHER K S FLUID LOSS AFFECT SYSTEMS AP APPROACH 1 WP 27 121JR 4503 11 21061726 511992 A RETAINING RING SEPERATED FROM THE LT MAIN LANDING GEAR DOOR HYDRAULIC ACTUATOR. THIS LEAD TO A LOSS OF HYDRAULIC FLUID AND FAILURE OF THE LANDING GEAR SYSTEM. AIRCRAFT WAS FORCED TO LAND WITH THE NOSE GEAR EXTENDED AND NO MAIN WHEELS. P ILOT REPORTED THAT THE ACTUATOR HAD JUST UNDERGONE REPLACEMENT OF INTERNAL PACKINGS A WEEK AND HALF PRIOR TO THE REPORTE D FAILURE. PILOT COMMENTED THAT THE ACTUATOR FAILED AFTER ABOUT 6 GEAR CYCLES. 1 H 7 1 3O 3 O 3A21 E5CE 2004091500097 20040915 00097 SW 2004 9 15 07092004 1 20040709 G 3210 4196001C LANDING GEAR MOONEY M20 M20F 5870214 SW LYC O360 AEIO360* EA MAINS COLLAPSED G E ENGINE SHUTDOWN G MULTIPLE FAILURE LD LANDING 1 SO 17 6817V 4956 5 LANDING GEAR CIRCUIT BREAKER POPPED, ATTEMPTED TO RESET IT AND SAW SPARKS. PILOT ATTEMPTED MANUAL EXTENSION OF GEAR BU T WAS UNABLE TO GET DOWN AND LOCKED INDICATION. PILOT REPORTED GEAR PROBLEM TO TOWER. GEAR APPEARED TO BE DOWN AND THE PILOT FLEW BY TOWER AND THE CONTROLLER ALSO STATED THAT GEAR APPEARED TO BE DOWN. LANDING WAS MADE AND LANDING GEAR CO LLAPSED CAUSING MINOR DAMAGE TO FUSELAGE AND PROPELLER. MECHANIC IDENTIFIED STRIPPED SPLINES ON EMERGENCY EXTENSION SHA FT WHICH WOULD NOT ALLOW THE GEAR TO FULLY EXTEND MANUALLY. IT IS UNCLEAR WHEN THE SPLINE WAS DAMAGED AND WHY. THE MEC HANIC DID PERFORM A SUCCESSFUL MANUAL EXTENSION DURING THE ANNUAL INSPECTION LAST JULY. 1 L 7 1 3O 3 O 2A3 1E10 2004050300116 20040503 00116 EU 2004 5 3 109041504 1 20040414 G 6720 1090130117 SPIDER AGUSTA A109 A109 0260109 EU T/R PITCH WORN B JBZR O OTHER O OTHER NR NOT REPORTED 1 WP 27 24RX 7185 MECHANIC PERFORMING ROUTINE DAILY INSPECTION NOTICED EXCESSIVE ROTATIONAL PLAY IN THE TAILROTOR PITCH CHANGE SPIDER ASSE MBLY. THIS COMPONENT IS INTERNALLY SPLINED TO THE TAIL ROTOR OUTPUT SHAFT. EXCESSIVE WEAR ON THE SPLINES WILL ULTIMATE LY RESULT IN THE PITCH CHANGE ASSEMBLY TO SKIP OUT OF ITS PROPER POSITION. 1 G 7 2 3U H7EU 2004060100133 20040601 00133 EU 2004 6 1 109052704 1 20040527 G 2910 MS24166D RELAY AGUSTA A109 A109 0260109 EU HYD SYSTEM FAILED B JBZR K NONE O OTHER IN INSP/MAINT 1 WP 27 23RX 7205 DURING ROUTINE SCHEDULED MAINTENANCE, IT WAS NOTED THAT THE HYDRAULIC UTILITY POWER PACK WOULD NOT SHUT OFF AFTER REACHI NG OPERATING PRESSURE. THE PROBLEM WAS TRACED TO AN ELECTRICAL RELAY. THE CONTACT POINTS WERE WORN AND HAD INDICATIONS OF METAL TRANSFER. THE RELAY WAS REPLACED AND SUBSEQUENT FUNCTIONAL TESTS OF THE SYSTEM WERE WITHOUT FAULT. AS A PREC AUTIONARY MEASURE, WE ARE TAKING STEPS TO REPLACE THIS RELAY THROUGHOUT OUR FLEET. 1 G 7 2 3U H7EU 2005030800054 20050308 00054 EU 2005 3 8 11072110704 1 20041107 G 6410 109813201111 BLADE AGUSTA A109 A109E 0260119 EU PWC PW206C PW206C NE TAIL ROTOR CRACKED B DT1R O OTHER E VIBRATION/BUFFET AP APPROACH 1 EA 17 200BK 620 11072 PILOT FELT VIBRATION IN TAIL ROTOR PEDALS DURING APPROACH. POST FLIGHT INSPECTION REVEALED THAT 1 TAIL ROTOR BLADE HAD A CHORD WISE CRACK BEGINNING AFT OF THE SPAR AND EXTENDING THROUGH THE TRAILING EDGE OF THE BLADE. THE CRACK WAS THROUG H BOTH SKINS AND THE HONEYCOMB CORE. SB109EP-30 REV B AND AD 02-25-51 PROVIDE INSPECTION CRITERIA FOR RECURRING INSPECTI ONS IN THIS AREA. 1 G 7 2 3U 3 U RT H7EU E42NE 2004092300062 20040923 00062 SW 2004 9 23 121JW 1 20040622 G 5412 6600011112 FIREWALL GULSTM 690TP 690A 0141722 SW ZONE 400 CRACKED B DSCR K NONE O OTHER IN INSP/MAINT 1 GL 25 121JW 5674 11299 THE LT AND RT ENGINE ALUMINUM FIREWALLS (P/N 660001-11 / -12 CHANNEL) HAVE DEVELOPED VERTICAL CRACK INDICATIONS AT THE L OWER SHEAR CLIP ATTACHMENT TAB. BOTH THE LT AND RT ENGINE IB LOWER TABS ARE COMPLETELY SHEARED AT THE FLANGE RADIUS. 1 H 7 2 3T 2A4 2005031000043 20050310 00043 EU 2005 3 10 122004 1 20041220 G 3233 D52177 HOLDER MESSIER AMD FALC20 FALCON200 2730150 EU PACKING CRACKED B GQRR O OTHER P NO WARNING INDICATION IN INSP/MAINT 1 SW 05 5100 THE PACKING HOLDER P/N D52177 INSIDE OF THE MAIN GEAR ACTUATOR P/N A 23721 HAS BEEN FOUND CRACKED ON TWO OCCASIONS. A S ERVIE BULLETIN F200-110 IS TO MODIFY THE PART TO PREVENT CRACKING. WE HAVE TWO PACKING HOLDERS THAT ARE CRACKED, ONE MOD IFIED AND ONE NOT. WE HAVE NOTIFIED FALCON JET ABOUT THE PROBLEM 2 L 7 2 4F RT A7EU 2005020200143 20050202 00143 CE 2005 2 2 1538T001 1 20041126 G 2520 863422 TABLE CESSNA 421 421B 2076014 CE CABIN MISINSTALLED D O OTHER W INADEQUATE Q C NR NOT REPORTED 1 GL 11 1538T 4704 421B0308 INSPECTED RIGHT HAND CABIN EXECUTIVE TABLE AT THE RECOMMENDATION OF ANOTHER MAINTENANCE FACILITY MAINTAINING SAME TYPE O F AIRCRAFT. FOUND A LEFT HAND TABLE INSTALLED. FORWARD CUP HOLDER WAS SCREWED TO THE TABLE MAKING EMERGENCY EXIT REMOV AL DIFFICULT. EMERGENCY EXIT CHECKED AT LAST TWO ANNUAL INSPECTIONS WITH THE INTERIOR REMOVED. 1 L 7 2 3O A7CE 2005033000145 20050330 00145 SO 2005 3 30 1624112304 1 20041201 G 3244 H34X92518 TIRE GULSTM G1159 GIV 3980115 SO RROYCE TAY TAY6118 EU NR 4 POSITION DAMAGED B VZXR K NONE O OTHER IN INSP/MAINT 1 WP 27 1624 3653 1318 NR 4 TIRE WAS FOUND TO BE DAMAGED FOR SOME UNKNOWN REASON. THE DAMAGE WAS SUCH THAT IT APPEARED TO BE A FAILURE OF THE TREAD AREA. A SECTION LOCATED ON THE TIRE TREAD APPEARED TO HAVE BEEN RIPPED AWAY BY SOME UNKNOWN FORCE. NONE OF THE O THER 3 TIRES DISPLAYED ANY VISIBLE DEFECTS, TRAUMA, OR DAMAGE. WEATHER AT THE LOCATION WAS FREEZING RAIN FOLLOWED BY SN OW AND ICE CONDITION. CAN NOT DETERMINE IF THE WEATHER HAD ANY EFFECT ON THE MALFUNCTION. (K) 2 L 7 2 4F 4 F RT A12EA E25NE 2004091500096 20040915 00096 GL 2004 9 15 16970704 1 20040719 G 7810 15070001 EXHAUST HEADER CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO HARTZL HCJ3Y PHCJ3YF1 GL ENGINE CRACKED B YD5R E ENGINE SHUTDOWN O OTHER UK UNKNOWN 1 GL 15 558CD 26 26 0942 THIS AIRCRAFT HAD THE NR 1,NR 3,NR 5 HEADERS REPLACED WITH NEW PARTS AT 154.0 HRS. THE AIRCRAFT THEN EXPERIENCED A CRAC K IN THE NR 5 HEADER AT 180.0 HRS. THERE DOES NOT SEEM TO BE ANY ABNORMAL STRESS ON THE PART/INSTALLATION. AIRCRAFT EXHA UST SYSTEM WILL BE MONITORED TO INSURE INTEGRITY. 1 L 7 1 3O 3 O NT A00009CH E3SO 5 C P36EA 2004031900013 20040319 00013 NM 2004 3 19 18069 1 20040303 G 5710 STRUCTURE LKHEED P2V P2V7 5260112 NM WRIGHT R3350 R3350* 67040 EA LT WING CRACKED F K NONE O OTHER IN INSP/MAINT 1 NM 04 139HP 9034 145906 THE CRACK/CORROSION IS LOCATED ON THE AFT VERTICAL SIDE OF STRINGER (HAT SECTION) NR 18. IT IS LOCATED IN THE LEFT HAND OUTER WING AT WING STATION 284. THE CRACK/CORROSION IS 1.25 INCH LONG AND RUNS SPAN WISE. THE CORROSION WAS REMOVED C OMPLETELY AT .024 OF GRIND OUT. THE CRACK IS STILL EVIDENT AND APPEARS TO GO ALL THE WAY THRU THE MATERIAL. THE MATERI AL THICKNESS OF THE HAT SECTION IS .120. 2 M 7 2 4R 4 R RT A1RM E272 2004072000002 20040720 00002 NE 2004 7 20 198M2004 2 20040709 G 7310 FILTER GARRTT TFE731 TFE73140 29001 NE ENGINE FUEL CONTAMINATED D O OTHER J WARNING INDICATION AP APPROACH 1 SW 99 198M AIRCRAFT EXPERINCED A SERIES OF FUEL BY-PASS INDICATIONS. DURING THE TROUBLESHOOTING WE DISCOVERED THE FILTERS TO HAVE B EEN CONTAMINATED WITH DIEGME AS A RESULT OF USING AN ANTI-ICE ADDITIVE. I FOLLOWED THE OEM M/M AND REMOVED ALL FUEL PART S ON ALL THREE ENGINES/APU AND FLUSHED THE AIRFRAME FUEL SYSTEM PER THE OEM TO REMOVE THE CONTAMINATION. 4 F E1NM 2004030400046 20040304 00046 CE 2004 3 4 2004001 1 20040211 G 8000 MHB6016 STARTER CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA ENGINE FAILED D K NONE O OTHER TX TAXI/GRND HDL 1 WP 07 97811 163 136 17276232 L1550339A RECEIVED AN OVERHAULED ENGINE FROM MFG ON 5 DEC 2003 AND INSTALLED ON THE AIRCRAFT. STARTER BENDIX DRIVE GEAR SHATTERED AGAINST ENGINE RING GEAR ON A START ATTEMPT. 1 H 7 1 3O 3 O NT 3A12 E274 2004030400048 20040304 00048 CE 2004 3 4 2004002 1 20040220 G 8011 MHB6016 STARTER CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA ENGINE DISENGAGED D K NONE O OTHER TX TAXI/GRND HDL 1 WP 07 97811 17276232 L1550339A STARTER WAS INSTALLED AFTER ORIGINAL STARTER FAILED ON 2/11/2004 (SDR FILED) FOR A SHATTERED BENDIX DRIVE GEAR. ENGINE WAS SUCCESSFULLY STARTED TWICE AND RETURNED TO SERVICE. ON FIRST FLIGHT ATTEMPT AFTER STARTER WAS INSTALLED THE BENDIX DRIVE GEAR WOULD NOT ENGAGE THE ENGINE STARTER RING GEAR, THE STARTER MOTOR WOULD SPIN BUT THE GEAR WOULD NOT COME FORWA RD TO ENGAGE THE ENGINE GEAR. THIS UNIT HAD ZERO HOURS SINCE NEW. 1 H 7 1 3O 3 O NT 3A12 E274 2004071900080 20040719 00080 CE 2004 7 19 200401 1 20040330 G 2720 GTX330TXP TRANSPONDER CESSNA 525 525A 2076615 CE WILINT FJ44 FJ44 66000 GL RUDDER CONTROL MALFUNCTIONED D O OTHER O OTHER NR NOT REPORTED 1 GL 07 692JM 525A0004 INSTALLED VARIOUS RADIOS IN THIS AIRCRAFT INCLUDING THE GTX 330 TRANSPONDER INTO THE LOWER SECTION OF THE CAPTAINS INSTR UMENT PANEL. MONTHS LATER, WHILE THE AIRCRAFT WAS UNDERGOING A PHASE 5 INSPECTION AT THE MFG, IT WAS DISCOVERED THAT TH E NEWLY INSTALLED TRANSPONDER WAS INTERFERING WITH THE RUDDER BELLCRANK ABOVE THE PILOTS RUDDER PEDALS AND PREVENTING TH E RUDDER FROM ACHIEVING FULL TRAVEL TO THE LEFT. THE LOSS OF TRAVEL WAS IDENTIFIED AS BEING 6 DEGREES DURING A FLIGHT C ONTROL (THROW) CHECK. REMANUFACTURED THE PANEL AND RELOCATED THE NR TRANSPONDER TO A MORE APPROPRIATE LOCATION WITH ADE QUATE CLEARANCE. 1 L 7 1 4F 4 F RT A1WI E3GL 2004060100148 20040601 00148 EU 2004 6 1 20040209 1 20040526 G 3251 CA248003 SELECTOR VALVE CASA C212 C212CC 2410204 EU GARRTT TPE331 TPE33110R 0517 WP HARTZL HCB4M HCB4M GL NLG FAILED M K NONE O OTHER LD LANDING 1 WP 28 00177 336 DURING LANDING ROLL-OUT AC VEERED LT. PC WAS STILL ON FLT CNTRLS (CONTROL YOKE, POWER LEVERS, AND RUDDERS) WITH FULL RT RUDDER INPUT AND PWR LEVERS IN FULL REVERSE. PC WAS APPLYING BRAKES. GO-AROUND WAS NOT AN OPTION AS THERE WAS NOT ENOU GH RUNWAY, NOR TIME TO SPOOL UP ENG. GLANCED AT TILLER WHEEL AND IT INDICATED NOSE WHEEL WAS CENTERED. AC DEPARTED RUNWA Y, AND AFTER GOING OVER A SMALL RISE, STOPPED IN SAND BETWEEN RUNWAY AND PARALLEL TAXIWAY. WHEN INSPECTED NOSE-WHEEL ST EERING SYS, FOUND HYD FLUID AROUND STEERING SEL VALVE, INDICATING INTERNAL FAILURE. REPLACED STEERING SEL VALVE. AC WAS TEST-FLOWN AND RELEASED FOR FLIGHT. TEARDOWN REVEALED CENTERING SPRING TENSION WAS LESS THAN SPECIFIED BY CMM 30-50-02. 2 H 7 2 4T 4 T A43EU E4WE 6 C P56GL 2004110300114 20041103 00114 CE 2004 11 3 20040720 1 20040720 G 2810 6225544 HOUSING HELIO H295 H295 4300802 CE LYC O480 GO480B 41527 EA CHECK VALVE CRACKED B EVGR K NONE O OTHER IN INSP/MAINT 1 SO 33 61JA 1286 MFG PN 6-2255-44 CHECK VALVE IN FUEL LINE WAS LEAKING. THE HOUSING OF THE CHECK VALVE WAS CRACKED. 1 H 7 1 3O 3 O 1A8 E275 2004120200211 20041202 00211 EA 2004 12 2 20040816 2 20040813 G 8520 AEL11021M003 BEARING HELIO H295 H295 4300802 CE LYC O480 GO480G1D6 41527 EA ENGINE FLAKING B EVGR K NONE O OTHER IN INSP/MAINT 1 SO 33 RL53137 ASSEMBLED THE ENGINE ACCORDING TO THE LYCOMING OVERHAUL MANUAL AND STANDARD PRACTICES. THE ENGINE WAS PREOILED AND RUN IN A TEST STAND USING AEROSHELL 100W OIL. AFTER A TWO HOUR BREAK-IN RUN WHERE ALL TEMPS AND PRESSURES WERE NORMAL THE O IL FILTER WAS CUT OPEN AND INSPECTED. ABOVE NORMAL AMOUNT OF METAL FLAKES WERE FOUND. IT WAS RUN ANOTHER HOUR TO CHECK OIL CONSUMPTION AND THE FILTER INSPECTED AGAIN. THERE WAS LESS METAL BUT STILL OF CONCERN. NORMALLY THAT IS ALL THE TEST CELL RUNNING WE DO IF ALL LOOKS NORMAL, BUT SINCE WE WERE STILL SEEING METAL, WE PUT IN NEW OIL AND RAN IT ANOTHER TWO HOURS. SINCE STILL SEEING METAL WHICH LOOKED LIKE BEARING MATERIAL WE DISASSEMBLED THE ENGINE TO FIND THE PROB. 1 H 7 1 3O 3 O 1A8 E275 2004083000098 20040830 00098 CE 2004 8 30 20040820 1 20040720 G 2820 6225544 CHECK VALVE HELIO H295 H295 4300802 CE LYC O480 GO480* 41527 EA FUEL SYSTEM CRACKED B EVGR K NONE O OTHER IN INSP/MAINT 1 SO 33 61JA 1286 FUEL SYSTEM CHECK VALVE PN 6-2255-44, HOUSING WAS FOUND CRACKED. 1 H 7 1 3O 3 O 1A8 E275 2004083000131 20040830 00131 EA 2004 8 30 20040823 2 20040820 G 8520 77134 CAMSHAFT HELIO H295 H295 4300802 CE LYC O480 GO480G1D6 41527 EA ENGINE MAKING METAL B EVGR K NONE O OTHER IN INSP/MAINT 1 SO 33 RL53137 AFTER ENGINE O/H, THE ENGINE WAS TEST RUN 5 HOURS ON THE TEST STAND AND THEN DISASSEMBLED BECAUSE OF METAL IN OIL. AS P ART OF INSPECTION NOTED THAT NR 4 EXHAUST CAM LOBE APPEARED TO BE WEARING ABNORMALLY. HAS A ROUGH SURFACE WITH SOME PIT TING AND APPEARANCE OF METAL SMEARING. CAM FOLLOWER SHOWED BEGINNING OF DISTRESS BELIEVED TO BE CAUSED BY CAM. THE CAMS HAFT WAS NEW. 1 H 7 1 3O 3 O 1A8 E275 2004091700095 20040917 00095 CE 2004 9 17 20040915 1 20040915 G 2520 169534024601 SEAT BEECH 23 A2324 1151226 CE LYC O360 IO360A1A 41514 EA CABIN CRACKED B K NONE O OTHER IN INSP/MAINT 1 NE 05 7638R 2908 MA349 LOWER SEAT DEVELOPED CRACKS WHERE UPPER SEAT BACK CONTACTS. 1 L 7 1 3O 3 O A1CE 1E10 2004110300128 20041103 00128 SO 2004 11 3 20041024 1 20040922 G 2410 76028 BRACKET PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA ZONE 400 CRACKED B EVGR K NONE O OTHER IN INSP/MAINT 1 SO 33 69JA 274555 ALTERNATOR BELT ADJUSTMENT BRACKET CRACKED AT THE SLOTTED END. 1 L 7 2 3O 3 O 1A10 1E4 2004050600061 20040506 00061 EA 2004 5 6 2004F00085 2 20040227 G 7310 LW120980100 TUBE BEECH 36 36BEECH 1151602 CE LYC O540 TIO540J2BD 41532 EA FUEL SYSTEM BROKEN D O OTHER O OTHER NR NOT REPORTED 1 CE 07 7886L E10 1719461A THIS IS THE TUBE THAT ATTACHES FROM THE FLOW DIVIDER TO THE INJECTOR. THE TUBE BROKE AT THE WELD ON THE END ATTACHED TO T THE FLOW DIVIDER. THE LACK OF SUPPORT CLAMPS ON THE LINE MAY HAVE CAUSED THE LINE TO VIBRATE AND BREAK. 1 L 7 1 3O 3 O 3A15 E14EA 2004050300226 20040503 00226 EU 2004 5 3 2004F00101 1 20040310 G 3340 017601 HOUSING SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1 60030 NE SPOT LIGHT CRACKED B O OTHER O OTHER NR NOT REPORTED 1 WP 23 232LA 502 3356 CRACKED AT DRIVE FLANGE WELD. POSSIBLE CAUSE- AERODYNAMIC AND MECHANICAL FORCES AT DRIVE FLANGE. RECOMMENDATION-USE OF STRONGER BASE MATERIAL AND STRICTER CONTROL OF WELDING PROCESS. 1 G 7 1 3U 3 U H9EU E19EU 2004051400125 20040514 00125 CE 2004 5 14 2004F00104 1 20040322 G 2701 100524119 CONTROL COLUMN BEECH B300 B300 1159232 CE PWA PT6 PT6A60A 52043 NE COCKPIT INOPERATIVE D O OTHER O OTHER NR NOT REPORTED 1 GL 23 552TP 1753 FL281 PK301 DURING A PHASE INSPECTION A SQUEAK WAS NOTED DURING MOVEMENT OF FLIGHT CONTROL COLUMN. INVESTIGATION REVEALED. LOOSE R IVETS BETWEEN THE CONTROL T COLUMN AND BEARING PLATES AT THE POINT WHERE THE CONTROL COLUMN ATTACHES TO THE AIR FRAME AN D PIVOTS. MFG ISSUED SB. AC WAS INSPECTED AT THAT TIME AND FOUND AIRWORTHY. THIS PROBLEM OCCURRED 12 HOURS AFTER COMP LETION OF SB. WOULD SUGGEST MFG THIS ITEM TO ALL PHASE INSP. 2 L 7 2 4T 4 T RT A24CE E4EA 2004052500028 20040525 00028 SW 2004 5 25 2004F00121 1 20040326 G 3230 71404 LEG ASSY BBAVIA 7 7GCBC 1220601 SW LYC O320 O320A2B 41508 EA SNSNCH 74D 74DM EA MLG BROKEN G O OTHER O OTHER NR NOT REPORTED 1 NM 05 31276 40772 UPON LANDING, GEAR RT MLG, BROKE FLUSH AT FUSELAGE. AIRCRAFT HAD SADDLE BLOCKS INSTALLED BY STC437SWP. THE LANDING GEA R BREAK, SHOW SIGNS OF INTERGRANULAR CORROSION. 1 H 7 1 3O 3 O NC A759 E274 5 N P88614 2004063000141 20040630 00141 EA 2004 6 30 2004F00146 2 20040517 G 7414 M3637 POINTS SLICK PIPER PA32 PA32300 7103212 SO LYC O540 IO540K1G5 41532 EA LT MAGNETO FAILED D O OTHER O OTHER NR NOT REPORTED 1 AL 05 8127K 03060080 327940268 INVESTIGATION OF MAGNETO FAILURE FOUND THAT THE CONTACT ARM OF THE PRIMARY POINT SET HAD SNAPPED OFF. THE BREAK OCCURED AT THE AREA WHERE THE STIFFENER FLANGES FLATEN OUT. JUST AT THE EDGE OF THE NYLON BLOCK. UNABLE TO DETERMINE CAUSE OF FAILURE. (AL05200402443) 1 L 7 1 3O 3 O A3SO 1E4 2004091400183 20040914 00183 EU 2004 9 14 2004F00147 1 20040524 G 2435 BEARING BRAERO DH125 BAE125800A 1500285 EU GARRTT TFE731 TFE7315R 01518 WP STARTER GEN FAILED B O OTHER O OTHER NR NOT REPORTED 1 EA 25 2QG 5834 NA0467 P91528 PILOTS NOTICED VIBRATION ASSOCIATED WITH THE NR 1 ENGINE. TECHNICIAN LOCATED SOURCE OF VIBRATION AS NR 1 STARTER/GENERA TOR. THIS UNIT HAD BEEN REMOVED AND REINSTALLED TWO WEEKS PRIOR TO VIBRATION AFTER REBRUSHING BY AN OUTSIDE FACILITY. UNIT ACCUMULATED 70 HOURS AFTER REBRUSHING PRIOR TO FAILURE. TECHNICIAN SUSPECTS FAILED BEARING DUE TO THE SEVERE SIDE PLAY IN THE STARTER/GENERATOR SHAFT, WHICH SET UP SUFFICIENT VIBRATION TO CAUSE COMPLETE FAILURE AND SEPARATION OF THE G EARBOX TO ENGINE SUPPORT BRACKET FITTINGS ON THE GEARBOX. 2 L 7 2 4F 4 F RT A3EU E6WE 2004071200019 20040712 00019 GL 2004 7 12 2004F00149 1 20040522 G 3230 RGSYS1B CONTROL SYSTEM AMTR VELITY VELOCITYXL 05604JM GL LYC O540 IO540* 41532 EA MLG MALFUNCTIONED G O OTHER O OTHER NR NOT REPORTED 1 EA 17 787SB 3RX097 DURING A NORMAL FLIGHT AND LANDING PROCEDURE, PLACED THE GEAR SWITCH IN THE DOWN POSITION WITH NO RESPONSE. TRIED THIS SEVERAL TIMES STILL NO RESPONSE. DID A MANUAL DROP OF THE GEAR AND RECEIVED GREEN GEAR DOWN AND LOCKED LIGHTS. SET TH E UNIT BACK TO COMPOSITE DESIGN. COMPOSITE DESIGN FOUND A FAILED RELAY REASON NOT KNOWN. (EA17200407757) 1 M 7 1 3O 3 O RT EXPA1M71 1E4 2004071300088 20040713 00088 CE 2004 7 13 2004F00153 1 20040520 G 2460 ELECTRICAL SYS LEAR 60 60LEAR 5170707 CE DC SYSTEM FAILED A B A EMER. DESCENT UNSCHED LANDING H ELECT. POWER LOSS-50 PC CR CRUISE 1 SW 21 54 009 TOTAL AIRCRAFT ELECTRICAL FAILURE IN FLIGHT. PILOT DECLARED IN FLIGHT EMEGENCY AND LANDED AIRCRAFT ON DIMINISHING DC PO WER. (M) 2 L 7 2 4F RT A10CE 2004071300142 20040713 00142 CE 2004 7 13 2004F00154 1 20040223 G 3260 UPLOCK LEAR 60 60LEAR 5170707 CE MLG OUT OF ADJUST A A UNSCHED LANDING E J VIBRATION/BUFFET WARNING INDICATION CL CLIMB 1 SW 21 56 033 RAISED GEAR AND HEARD 6-10 LOUD THUMPS, AIRCRAFT YAWED RUDDER PEDALS BACK AND FORTH. BOTH MAIN RED LIGHTS ON, THEN LIGH TS WENT OUT AND ALL WAS NORMAL. LOWERED GEAR, BURNED FUEL DOWN AND LANDED. REMOVED, ADJUSTED AND REINSTALLED LT MLG UP LOCK STRIKER PLATE. (M) 2 L 7 2 4F RT A10CE 2004091400150 20040914 00150 NM 2004 9 14 2004F00155 1 20040406 G 2435 BRUSHES GULSTM 200 200 4500308 NM PWA 306 PW306B NE STARTER GEN WORN G O OTHER O OTHER NR NOT REPORTED 1 EA 25 707QS Y20083 066 CREW REPORTED APU INOPERATIVE TROUBLESHOT SYSTEM AND FOUND VOLTAGE AVAILABLE AT STARTER GEN. REMOVED STARTER GEN AND BR USH COVER. FOUND 2 OUT OF 4 BUSHES WELDED IN BRUSH HOLDERS AND BUSH WIRES BROKEN OFF. INSULATION STRIP ON INSIDE OF BR USH COVER WORN BURNED THROUGH. INSTALLED REPAIRED STARTER GEN OF SAME PN IAW GAC G200 MM., CH 49-40-05, OPERATIONAL CHE CKS GOOD. 2 L 7 2 4F 4 F RT A53NM E35NE 2004071300152 20040713 00152 CE 2004 7 13 2004F00156 1 20040131 G 3233 7003974731 ACTUATOR CESSNA 650 650 2076802 CE NLG FAILED A O OTHER J WARNING INDICATION CL CLIMB 1 GL 23 5117 6507064 MCO - GEAR UNLOCK FLIGHT STAYED ON FAFTER TAKEOFF FROM NAPLES. TOOK AIRPLANE TO ORLANDO FOR REPAIR. FGC 'B' FAILED EN ROUTE TO ORLANDE. NOSE LANDING GEAR ACTUATOR OUT OF ADJUSTMENT. NR 2 FLIGHT GUIDANCE COMPUTER FAULTY. ADUSTED NLG ACT UATOR, PERFORMED L/G SWING PER CESSNA M/M OPS NORMAL. REPLACED NR 2 FGC, OPS CHECK PER 650 MM 34/21/01 IS GOOD. (M) 2 L 7 2 4F A9NM 2004092000099 20040920 00099 SO 2004 9 20 2004F00235 1 20040803 G 3230 DOWNLOCK PIPER PA31 PA31 7103102 SO LYC O540 TIO540* 41532 EA MLG DIRTY G O OTHER O OTHER NR NOT REPORTED 1 EA 05 87MA 12690 31444 THE RT MAIN LANDING GEAR COLLAPSED AFTER TOUCH DOWN, SUSPECT DIRTY GEARS WITH GRIT ON DOWNLOCK. ALSO AIRCRAFT HAD BEEN OUT OF SERVICE FOR 5 WEEKS AND RUST HAD ACCUMULATED ON DOWN LOCK. (EA05200405925) 1 L 7 2 3O 3 O A20SO E14EA 2004083000019 20040830 00019 2004 8 30 2004F00238 4 20040721 G 2562 45350000999 TRANSMITTER CESSNA 560 560XL 2076702 CE PWA 545 PW545A NE ELT MALFUNCTIONED G O OTHER O OTHER NR NOT REPORTED 1 SW 21 47WP 648 5605317 THE ELT TRANSMITTER WOULD ACTIVATE ITSELF WHILE THE AIRCRAFT WAS STATIC IN THE HANGAR. THE UNIT WOULD ALSO SELF ACTIVAT E WHILE SITTING ON THE BENCH. THE ON/OFF SWITCH ON THE ELT COULD BE TURNED ON THEN BACK TO OFF AND THE ELT WOULD REACTI VATE WITHIN A FEW MINUTES. THERE WERE NO VISUAL DISCREPANCIES NOTED ON THE ELT UNIT. REPLACED ELT UNIT WITH A NEW ONE. CONTACTED REGISTERED OWNER FOR ADDITIONAL INFORMATION. DISCOVERED THAT THE EMERGENCY LOCATOR TRANSMITTER IS ONE OF TH E NEW TYPE: C4062AF (AUTOMATIC FIXED) WHICH WAS PART OF THE ORIGINAL FACTORY INSTALLATION. INDIVIDUAL STATED THAT THEY DID NOT TRY REPLACING THE BATTERIES, BUT OPTED FOR A COMPLETE REPLACEMENT OF THE UNIT. 2 L 7 2 4F 4 F RT A22CE E00059EN 2004092000068 20040920 00068 EU 2004 9 20 2004F00241 1 20040615 G 5220 80161101 SEAL PIAGIO P180 P180 6960204 EU PWA PT6 PT6A6 52043 EA EMERGENCY EXIT SEPARATED D A UNSCHED LANDING O OTHER CL CLIMB 1 WP 11 106SL 1070 AC CLIMBED THRU 25,000 FT, VERY LOUD HOWL, EMANATING FROM EMERG EXIT BEHIND COPILOT SEAT. COMMUNICATION IN AC WAS NEAR LY IMPOSSIBLE AND AC WAS FORCED TO RETURN TO BASE. AT 15,000 FT NOISE SUBSIDED AND AC RETURNED TO DEPARTURE. UPON EXAM OF EMERGENCY EXIT, DOOR SEAL, PN 80-161101, WAS FOUND TO BE SEPARATED AT SPLICE, WHICH IS HELD TOGETHER BY SILICONE ADH ESIVE IN BUTT END SPLICE FASHION. WHEN EMERG EXIT IS REMOVED AND INSTALLED DURING PERIODIC INSP, SEAL SPLICE IS FORCED OVER LOCK PIN PAD ON LWR WINDOW FRAME, IS DEFORMED AS IT PASSES OVER PAD. THIS TENDS TO LOOSEN SPLICE CAUSING A PRESSUR IZATION LEAK THAT CAN BE VERY AUDIBLE. INSTALL SEAL WITH SPLICE AT TOP OF DOOR, ELIMINATING ABUSE OF DOOR SEAL SPLICE. 1 H 7 2 3O 3 T RT A59EU E4EA 2004083000181 20040830 00181 NE 2004 8 30 2004F00269 2 20040524 G 7320 8061633 FMU AIRBUS 320 A320233 3930329 EU IAE V2527 V2527EA5 NE NR 2 ENGINE ERRATIC A C ABORTED TAKEOFF J WARNING INDICATION TO TAKEOFF 1 SO 23 991LR 561 V10860 DURING TAKEOFF, AN ECAM WARNING MESSAGE, ENGINE NR 2 OVERSPEED PROTECTION FAULT CAME ON, AT LOW SPEED. WHEN MOVING TRUS T LEVERS TO FLX MCT POSITION ENGINE NR 1 RESPONDED NORMAL, WHILE ENGINE NR 2 REMAINED AT LOW POWER. THE PLANE YAW TO TH E RT AND THE TAKEOFF WAS ABORTED. AT TGU STATION, TECHNICIANS, PERFORMED TEST ON BOTH ENGINES IAW AMM 71-00-00. FOUND THE FMU NR 2 WORKING ERRATIC AND GIVING TOO MUCH FUEL FLOW. IT WAS REPLACED AND TESTED IAW AMM 7322-52. ALL PARAMETERS WERE FOUND NORMAL, AND AIRCRAFT RETURNED TO NORMAL OPERATION. (M) 2 L 7 2 4F 4 F RT A28NM E40NE 2004090300034 20040903 00034 2004 9 3 2004F00279 4 20040709 G 3416 962830A1 ADC CESSNA 208 208B 2073701 CE NR 1 FAULTY B O OTHER O OTHER NR NOT REPORTED 1 AL 05 331AK 208B0739 UNIT WAS REPORTING 400 PLUS FEET OFF FROM ACTUAL. PROGRESSIVE REPORTING ERROR OVER ONE MONTH TIME FRAME. (M) 1 H 7 1 3T A37CE 2004091000014 20040910 00014 EA 2004 9 10 2004F00282 1 20040804 G 2420 DRIVE ASSY CNDAIR CL600 CL6002B16 1900305 EA NR 2 ENGINE FAILED H C ABORTED TAKEOFF H ELECT. POWER LOSS-50 PC CR CRUISE 1 NE 03 601VH 2086 5043 NR 2 GENERATOR CAME OFF LINE ON TO ROLL OUT OF SBM. TAKEOFF WAS ABORTED BETWEEN 65-75 KTS. GENERATOR RESET WAS SUCCESS FUL ON TAXI BACK. PROCEEDED TO TAKEOFF AND WAS UNEVENTFUL. AFTER REACHING CRUISE GEN NR 2 CAME OFF LINE AGAIN. GENERA TOR REMAINED OFF. CONTINUED FLIGHT TO TEB WITHOUT FURTHER INCIDENT. REMOVED AND REPLACED INTEGRATED DRIVE GEN. O2GA ( M) 2 L 7 2 4F RT A21EA 2004091000015 20040910 00015 CE 2004 9 10 2004F00283 1 20040813 G 5710 622126161 FAIRING CESSNA 650 650 2076802 CE LT WING DEPARTED A O OTHER D INFLIGHT SEPARATION DE DESCENT 1 SW 09 651CV 6500036 LEFT CENTER WING FAIRING PANEL DEPARTED AIRCRAFT WHILE DESCENDING THROUGH FL13 EN ROUTE FROM SAT-HOU. NO PASSENGERS ON BOARD. PILOTS REDUCED SPPED ON DESCENT PRIOR TO LANDING WHEN LOUD NOISE WAS HEARD. (M) 2 L 7 2 4F A9NM 2004091000020 20040910 00020 NE 2004 9 10 2004F00286 2 20040713 G 7230 769251 DUCT SKRSKY S64 S64E 8142604 NE PWA JFTD12 JFTD12A5A 52047 NE DIFFUSER CASE CRACKED B K NONE O OTHER IN INSP/MAINT 1 NM 09 CFCRN 2693 64061 DURING DISASSEMBLY OF N1 SECTION, IT WAS NOTICED THAT THERE WAS A LARGE PIECE OF MATERIAL WEDGED IN BETWEEN TWO 1ST STAG E BLADES. UPON FURTHER DISASSEMBLY/INVESTIGATION THE OUTLET DUCT ASSEMBLY WAS FOUND TO BE MISSING A LARGE SECTION OF TH E OUTER DUCT APPROXIMATELY 1.5 INCHES DIAMETER WHICH WAS DETERMINED TO BE THE PIECE LODGED IN THE BLADES. E8KL (M)TONY CHECK THIS 2 G 7 2 4U 4 U H4EA E15EA 2004091000062 20040910 00062 EU 2004 9 10 2004F00288 1 20040205 G 3260 SQUAT SWITCH BRAERO DH125 HS125700A 4230170 EU MLG FAILED A A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 EA 11 727TA NA0202 UPON TAKEOFF, CREW WAS UNABLE TO ENGAGE GEAR SELECT HANDLE TO RETRACT UP POSITION. INITIAL INSPECTION OF LANDING GEAR S YSTEM INDICATED THAT GEAR SELECT SAFETY LEVER LOCK WAS ENGAGED, INDICATING A LANDING GEAR SYSTEM MALFUNCTION. FURTHER IN SPECTION REVEALED THE LEFT SQUAT SWITCH WAS INTERMITTENT. REPLACED SQUAT SWITCH. GEAR SYSTEM SWING CHECKS ACCOMPLISHED WITH NO PROBLEMS NOTED. AIRCRAFT WAS RETURNED TO SERVICE. (M) 2 L 7 2 4F A3EU 2004092800070 20040928 00070 CE 2004 9 28 2004F00391 1 20040826 G 3246 4040A WHEEL CESSNA 414 414A 2075907 CE CONT O520 TSIO520* 17040 SO MLG SEPARATED G A UNSCHED LANDING D INFLIGHT SEPARATION CL CLIMB 1 CE 07 678JS 414A0090 ON TAKEOFF, LT OB HALF OF WHEEL, TIRE AND TUBE SEPARATED FROM AC. THE IB HALF OF WHEEL STAYED ON THE AXLE AS WELL AS TH E AXLE NUT, BEARING CONE AND INNER RACE FOR OUTER HALF. DUE TO HIGH SPEED AT THE TIME OF INCIDENT THE TIRE AND TUBE HAV E NOT BEEN LOCATED. THE OUTER WHEEEL HALF WAS LOCATED. THE WHEEL HALVES AND REMAINING HARDWARE WERE INSPECTED. NO EVI DENCE WAS FOUND TO INDICATE IMPROPER ASSY. IMPROPER INSTALLATION, OR IMPROPER HARDWARE INSTALLATION. AT THIS TIME CAUS E OF WHEEL SEPARATION IS UNKNOWN. (CE07200416204) 1 L 7 2 3O 3 O A7CE E8CE 2004102600159 20041026 00159 CE 2004 10 26 2004F00415 1 20040507 G 5730 65223053 SKIN CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE LT WING CORRODED B O OTHER O OTHER NR NOT REPORTED 1 CE 05 962J 7106 5500453 PCE71393 AFTER REMOVAL OF THE LT WING DEICE BOOT, CORROSION ON THE IB WING SKIN WAS FOUND. THE DAMAGE WAS MEASURED AND FOUND TO EXCEED THE MANUFACTURERS LIMITS REQUIRING WING SKIN REPLACEMENT. THE DAMAGE WAS LIMITED TO CORROSION PITTING, NONE HAD PENETRATED THOUGH THE SKIN. 1 L 7 2 4F 4 F A22CE E1NE 2004022300017 20040223 00017 EA 2004 2 23 2004FA0000013 2 20040101 G 8520 A8268 ROD PIPER PA24 PA24250 7102404 SO LYC O540 O540* 41532 EA HARTZL HC82V HC82V* GL PISTON ASSY BROKEN B HPFR O OTHER O OTHER NR NOT REPORTED 1 WP 09 8242P 243496 8386 APPEARS THAT ROD (PN A8268) BROKE JUST ABOVE A921-1 ROD FORK. SUBSEQUENT INVESTIGATION BY PROP REPAIR STATION DID NOT F IND ANY MISALIGNMENT OF GUIDE COLLAR RODS DO NOT APPEAR TO BE BENT OR DAMAGED. COULD NOT FIND ANY REASON FOR ROD TO FAI L. 1 L 7 1 3O 3 O 1A15 E295 5 C P23EA 2004020400017 20040204 00017 NE 2004 2 4 2004FA0000020 2 20040106 G 7314 238006015 PUMP LEAR 25 25B 5170511 CE GE CJ610 CJ6106 30006 NE FUEL SYSTEM LEAKING D O OTHER K FLUID LOSS NR NOT REPORTED 1 EA 23 85 180 INSTALLED OVERHAULED FUEL PUMP FROM MFG ON 4NOV03. DURING AIRCRAFT INSPECTION 22DEC04 HAD FUEL SEEP FROM WIRES ON PUMP. 2 L 7 2 4J 4 J A10CE 1E16 2004021700190 20040217 00190 CE 2004 2 17 2004FA0000031 1 20040102 G 2434 STUD CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA MCAULY 1A103 1A103TCM GL ALTERNATOR MELTED D O OTHER H J ELECT. POWER LOSS-50 PC WARNING INDICATION CR CRUISE 1 SO 15 5169F A160568 172S9152 POSITIVE TERMINAL ON ALTERNATOR MELTED. INSPECTED ALTERNATOR WIRING HARNESS FOR CORRECT ROUTING AND DAMAGE. PROBABLE CAU SE FOR THIS MALFUNCTION OCCURRED IN THE ALTERNATOR ITSELF, AS THE POSITIVE STUD AND NUT WERE RECOVERED WITH THE NUT IN T HE TORQUED POSITION. ALSO THERE WAS NO EVIDENCE OF ARCING BETWEEN THE ALTERNATOR AND ADJACENT GROUNDS, (BAFFLES,ENGINE CASE, ECT.) REPAIRED POSITIVE WIRE, INSTALLED OVERHAULED ALTERNATOR PN 9910591-11RX, SN A-174533, AND NEW NOISE FILTER P N S1915-3. RUNUP AND OPERATIONAL CHECK OK. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P50GL 2004021700084 20040217 00084 SO 2004 2 17 2004FA0000032 2 20040107 G 8520 633189 PLUG CONT CESSNA 206 TU206G 2073357 CE CONT O520 TSIO520M 17040 SO MCAULY D3A34 D3A34C402 GL OIL TRANSFR LOOSE D D RETURN TO BLOCK J WARNING INDICATION TX TAXI/GRND HDL 1 WP 23 HCBXB 73 04322 532202 SENT CRANKSHAFT FOR ULTRASONIC AND MAGNAFLUX INSP. REMOVED OIL TRANSFER PLUG FROM CRANKSHAFT AS PART OF INSP. PLUG WA S REINSTALLED INTO CRANKSHAFT BEFORE RETURNING. APPROX. 70 HRS AFTER REPAIR, PROP WOULD NOT CYCLE AT NORMAL RUN-UP. WH EN PILOT APPLIED POWER AFTER STALL, ENG OVERSPED AND GOVERNOR DID NOT CONTROL RPM. AT TEARDOWN OIL TRANSFER PLUG WAS MI SSING FROM CRANKSHAFT. ONLY EXPLANATION IS THAT A LOOSE PLUG FROM CRANKSHAFT. THIS PLUG MOVED AROUND DURING THE APPROX . 70 HRS OF OPERATION LEAKING OIL AND CAUSING THE SLOW, LESS RESPONSIVE PROP CONTROL UNTIL IT FINALLY MOVED FAR ENOUGH O UT OF POSITION TO NOT ROUTE ANY OIL TO THE PROP. PLUG THEN FELL OUT AND WAS LOST IN SHIPPING ENGINE BACK. 1 H 7 1 3O 3 O A4CE E8CE 5 C P47GL 2004022300077 20040223 00077 2004 2 23 2004FA0000033 4 20040105 G 2562 E01 ELT AVIAT A1 A1A 2210405 GL LYC O360 O360A1D 41514 EA CABIN CORRODED P K NONE O OTHER IN INSP/MAINT 1 AL 03 40HU 1315 OPERATIONAL TEST OF ELT ON PRE-FLIGHT AT THE REMOTE SWITCH SHOWED THE ELT WAS NOT WORKING. MANUALLY TURNED THE ELT ON A T THE UNIT, STILL NOT WORKING. REMOVED ELT AND OPENED UP THE UNIT TO DISCOVER CONDENSATION AND ELECTROLYSIS CORROSION H AD COMPLETELY RENDERED THE UNIT USELESS. THE O-RINGS APPEARED TO BE IN GOOD SHAPE. THE ELT HAD BEEN INSPECTED AND NEW BA TTERIES INSTALLED DURING THE 100 HR. INSPECTION ON 9/2003. TEMPERATURES OUTSIDE HAVE BEEN IN THE -30 DEG. F RANGE AND T HE PLANE HAD BEEN PUT INTO THE HANGAR TO WARM UP. 1 H 7 1 3O 3 O NC A22NM E286 2004020400010 20040204 00010 SO 2004 2 4 2004FA0000050 1 20040110 G 3233 SAF2323 ACTUATOR PIPER PA34 PA34200T 7103406 SO MLG LEAKING E O OTHER K FLUID LOSS LD LANDING 1 GL 21 13AG 7433 81 347770115 DURING FLIGHT, THE LANDING GEAR WOUND NOT EXTEND, CYCLED THE GEAR SEVERAL TIMES THEN PERFORMED AN EMERGENCY EXTENSION AN D LANDED. THE RT MAIN GEAR ACTUATOR END CAP O-RING FAILED AND RESULTED IN THE LOSS OF ALL HYDRAULIC FLUID. 1 L 7 2 3O A7SO 2004022300097 20040223 00097 SO 2004 2 23 2004FA0000051 1 20040109 G 7120 824872 FASTENER PIPER PA46 PA46310P 7104605 SO CONT O520 TSIO520* 17040 SO ENGINE MOUNT LOOSE D K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 07 119CP 5527 468508041 DURING A RECENT INSPECTION IT WAS NOTED THAT ALL OF THE LOCK FASTENERS THAT SECURE THE STEEL ATTACH FITTINGS TO THE AIRF RAME FOR THE ENGINE MOUNT LOWER ATTACH POINTS WERE VERY LOOSE (COULD BE TURNED BY HAND). ACCESS TO THE AREA MAKES IT DI FFICULT TO INSPECT. PROBLEM WAS CORRECTED BY INSTALLING THE NEXT SIZE UP LOCK FASTENERS. 1 L 7 1 3O 3 O RT A25SO E8CE 2004022300098 20040223 00098 SO 2004 2 23 2004FA0000052 1 20040109 G 7120 824872 FITTING PIPER PA46 PA46310P 7104605 SO CONT O550 TSIO550C SO ENGINE MOUNT LOOSE D K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 07 135US 2751 4608078 DURING A RECENT INSPECTION IT WAS NOTED THAT THE LOCK FASTENERS SECURING THE STEEL LOWER ENGINE MOUNT ATTACH FITTINGS, I NBOARD AND OUTBOARD, TO THE FUSELAGE WERE EXTREMELY LOOSE. ALL OF THE LOCK FASTENERS WERE CHANGED TO THE NEXT SIZE UP. A CCESS TO AREA MAKES IT DIFFICULT TO INSPECT. 1 L 7 1 3O 3 O RT A25SO E5SO 2004022300084 20040223 00084 SO 2004 2 23 2004FA0000053 1 20040106 G 7603 THROTTLE PIPER PA28 PA28140 7102802 SO ENGINE STUCK G A UNSCHED LANDING O OTHER CR CRUISE 1 EA 21 32285 287525043 THE STUDENT PILOT AND FLIGHT INSTRUCTOR WERE PRACTICING POWER-OFFS STALLS WHEN THE THROTTLE BECAME STUCK AT THE IDLE POS ITION. DUE TO THE MECHANICAL PROBLEM, THE FLIGHT INSTRUCTOR LANDED THE AIRCRAFT IN A VACANT FIELD. THERE WERE NO INJUR IES TO THE PILOT OR FLIGHT INSTRUCTOR, AND THE AIRCRAFT WAS NOT DAMAGED. 1 L 7 1 3O 2A13 2004022300100 20040223 00100 SO 2004 2 23 2004FA0000054 2 20040109 G 8530 CYLINDER MOONEY M20 M20R 5870225 SW CONT O550 IO550G 17042 SO ENGINE CRACKED B K NONE O OTHER IN INSP/MAINT 1 SW 15 39HW 65 50 290215 679455 ENGINE INTAKE TUBE P/N 646207 FOR THE NR 6 CYLINDER CRACKS OUT AT ITS CYLINDER FLANGE. THIS ENGINE HAS CRACKED 3 INTAKE TUBES. THE CRACKS HAVE BEEN FOUND FROM .5000 INCH LONG TO OVER 3 INCHES LONG. THIS CAUSES AN INTAKE FUEL LEAK AND FIR E HAZARD. THE INTAKE MANIFOLD DOES NOT HAVE ANY SUPPORT EXCEPT FOR THE INTAKE TUBES TO THE CYLINDERS. BELIEVE VIBRATIO N CAUSES THE CRACKS. 1 L 7 1 3O 3 O RT 2A3 E3SO 2004022300124 20040223 00124 SO 2004 2 23 2004FA0000055 2 20040109 G 8520 AEC648029 PISTON CONT CESSNA 182 182Q 2072732 CE CONT O470 O470U 17026 SO NR 2 CYLINDER BROKEN C D RETURN TO BLOCK J WARNING INDICATION TX TAXI/GRND HDL 1 WP 23 4810N 260 273185R 18267384 273185R REBARRELED CYL, ECI PISTONS. LOSS OF OIL PRESSURE, 260 STOH, 1043 SMOH. CAUSE, BROKEN NR 2 PISTON, PARTS BLOCKING OIL PICKUP SCREEN. POSSIBLE CAUSES. DEFECTIVE PISTON CASTING, DROPPED PISTON OR IMPROPERLY MACHINED NR 4 RING GROOVE, SQUA RE CUT BOTTOM OF GROOVE. 50 PERCENT OF BOTTOM SKIRT BROKE OFF PISTON. PISTON RING BROKE INTO ABOUT 20 PIECES. 1 H 7 1 3O 3 O NT 3A13 E273 2004022300125 20040223 00125 SO 2004 2 23 2004FA0000057 2 20040109 G 8520 AEC648029 PISTON CONT CESSNA 182 182Q 2072732 CE CONT O470 O470U 17026 SO NR 2 CYLINDER BROKEN C D RETURN TO BLOCK J WARNING INDICATION TX TAXI/GRND HDL 1 WP 23 4810N 783 273185R 18267384 273185R ENGINE OVERHAULED. REBARRELED CYL, ECI PISTONS. LOSS OF OIL PRESSURE, 260 STOH, 1043 SMOH. CAUSE, BROKEN NR 2 PISTON, PARTS BLOCKING OIL PICKUP SCREEN. POSSIBLE CAUSES. DEFECTIVE PISTON CASTING, DROPPED PISTON OR IMPROPERLY MACHINED NR 4 RING GROOVE, SQUARE CUT BOTTOM OF GROOVE. 50 PERCENT OF BOTTOM SKIRT BROKE OFF PISTON. PISTON RING BROKE INTO ABOUT 20 PIECES. 1 H 7 1 3O 3 O NT 3A13 E273 2004022300126 20040223 00126 CE 2004 2 23 2004FA0000058 1 20040110 G 7921 TCM639171 OIL COOLER CESSNA 182 182Q 2072732 CE CONT O470 O470U 17026 SO ENGINE LOOSE C K NONE P NO WARNING INDICATION IN INSP/MAINT 1 WP 23 4810N 206 206 18267384 273185R 8/22/2002, OIL COOLER TCM 639171. TACH TIME NOT LOGGED. APPROX 830 SMOH. 12/1/2003 A MAJOR OIL LEAK DEVELOPED AROUND T HE OIL COOLER AND THE NR 5 CYL PUSH ROD TUBES. ISOLATED LEAK TO OIL COOLER GASKETS. 1036 SMOH. DURING REMOVAL OF OIL C OOLER BASE PLATE, IT WAS DETERMINED THAT THE ATTACHING BOLTS WERE IMPROPERLY TORQUED. NEW GASKETS WERE INSTALLED AND CO OLER ATTACHING BOLTS PROPERLY TORQUED. PROBLEM CAUSED BY IMPROPERLY TORQUED ATTACHING BOLTS. 1 H 7 1 3O 3 O NT 3A13 E273 2004022300130 20040223 00130 EA 2004 2 23 2004FA0000059 2 20040112 G 7324 2524321 FLOW DIVIDER BENDIX PIPER PA28 PA28R180 7102809 SO LYC O360 IO360B1E 41514 EA HARTZL HCC2Y HCC2YK1 GL FUEL SYSTEM BYPASSING G O OTHER G R J MULTIPLE FAILURE PARTIAL RPM/PWR LOSS WARNING INDICATION TO TAKEOFF 1 SO 07 4658J 4947 28R30553 L481751A 7666A2 FUEL FLOW DIVIDER, TEARDOWN AND TEST OF DIVIDER SHOWED UNIT WAS BY-PASSING FUEL , WHICH INTERRUPTED FLOW OF FUEL TO ENG UNDER HIGH POWER SETTINGS, LEADING TO INTERRUPTION OF ENG POWER AND/OR TOTAL LOSS OF ENG POWER. FURTHER TEAR DOWN, REVE ALED DIAPHRAGM WAS STIFF, AN INDICATION OF LONG TIME IN SERVICE. CONNECTING SCREW WHICH ATTACHES DIAPHRAGM TO SHAFT WAS LOSE, NOT TORQUED. ESTIMATED DIAPHRAM WAS MANUFACTURED IN 1967. AFTER TIGHTENING ATTACHMENT SCREW TO ITS PROPER TORQ UE, DIVIDER WAS TESTED AGAIN. AT 2.5 POUNDS OF FUEL PRESSURE APPLIED, NO INDICATION OF FUEL DIVIDER FLOWING UNTIL 3.750 0 POUNDS OF FUEL PRESS WAS APPLIED. 1 POUND OF PRESSURE DIFFERENCE FOR FUEL FLOW WAS DUE TO STIFFNESS OF DIAPHRAGM. 1 L 7 1 3O 3 O 2A13 1E10 5 C P920 2004022300159 20040223 00159 CE 2004 2 23 2004FA0000068 1 20040105 G 7160 AM107635FP AIR FILTER CESSNA 177 177B 2073708 CE LYC O360 O360A1F6 41514 EA ENGINE MISMANUFACTURED D O OTHER W INADEQUATE Q C NR NOT REPORTED 1 CE 01 30695 17701409 L1470036A FACTORY NEW PART- SCREEN ATTACH TABS ARE BENT 90, AND SPOT WELDED ON TO SCREEN FRAME. WELDS DO NOT PENETRATE BASE MATER IAL. ATTACH TABS WORK LOOSE. HAVE FOUND THIS CONDITION 3 TIMES. SOME HAVE BEEN REPAIRED WITH SHEET METAL SCREWS. TAB S SHOULD BE RIVETED ON OR, BETTER WELDS. 1 H 7 1 3O 3 O A13CE E286 2004022300168 20040223 00168 EU 2004 2 23 2004FA0000073 1 20040113 G 1430 5321012077 BOLT PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL MLG BROKEN B K NONE O OTHER IN INSP/MAINT 1 SO 17 454PS 454 PCEPR0323 HJ1674 UPON ARRIVAL OF AIRCRAFT FOR INSPECTION, IT WAS DISCOVERED THAT THE LT MLG TO GEAR ACTUATOR ATTACH BOLT WAS BROKEN OFF. BOLT WAS REMOVED AND REPLACED WITH NEW BOLT SAME P/N 532.10.12.077. DEFECTIVE BOLT WAS SENT TO MFG FOR ANALYSIS. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004022300192 20040223 00192 SO 2004 2 23 2004FA0000076 1 20040114 G 5510 510229616 STIFFENER AMRGEN AA5 AA5B 3960105 SO HORIZONTAL STAB CRACKED B K NONE O OTHER IN INSP/MAINT 1 SO 03 875L 2540 AA5B0672 CRACKS IN TWO STIFFENERS AT HORIZONTAL STABILIZER SPAR, ONE RT SIDE OF FUSELAGE ABOVE THE SPAR. THE OTHER IN HORIZONTAL STIFFENER LOWER LEFT SIDE. FOUND WHILE INSPECTING IAW SPECIAL AIRWORTHINESS INFORMATION BULLETIN NR CE-04-34. 1 L 7 1 3O A16EA 2004022300108 20040223 00108 EU 2004 2 23 2004FA0000077 1 20040104 G 7697 30709341 WIRE HARNESS BRAERO DH125 HS125700A 4230170 EU GARRTT TFE731 TFE7313R 01518 WP RT ENGINE DETERIORATED D A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 CE 03 120JC 6970 6970 NA0247 P80195C WHILE EN ROUTE, NOTED RT ENGINE COMPUTER AMBER WARNING LAMP BECAME ANNUNCIATED. ALSO NOTED, INDICATED LOSS OF POWER RT ENGINE. CONSULTED AND COMPLIED WITH EMERGENCY PROCEDURES WHICH INSTRUCTED TO SWITCH TO MANUAL CONTROL AND MONITOR ALL A PPLICABLE ENGINE PARAMETERS. IMMEDIATE NOTIFICATION TO ATC REQUESTS TO DIVERT TO DAL FOR INSPECTION AND REPAIRS. FOLLO WING TROUBLESHOOTING AND INSPECTION TO DETERMINE SOURCE OF DEFECT, IT WAS NOTED THAT THE RT ENGINE PT2 HARNESS WAS DEFEC TIVE. PARTS WERE REPLACED, ENGINE AND COMPUTER FUNCTIONS WERE TESTED, AND NO RECURRING DEFECTS WERE NOTED. 2 L 7 2 4F 4 F A3EU E6WE 2004022500030 20040225 00030 CE 2004 2 25 2004FA0000079 1 20040119 G 5544 05331341 BALANCE WEIGHT CESSNA 172 172RG 2072438 CE RUDDER MISSING D O OTHER O OTHER TX TAXI/GRND HDL 1 CE 03 4726V 8222 172RG0370 IT WAS NOTED THAT RUDDER BALANCE WEIGHT WAS MISSING FROM LOCATION IN TOP LE OF RUDDER. UPON INSP OF RAMP AREA, IT WAS RE COVERED FROM TAXIWAY. RUDDER TAB AND AC WERE UNDAMAGED FROM IT DEPARTING AC, WEIGHT ASSY WAS INSPECTED TO DETERMINE CAUS E OF DEFECT. SCREW INSERTS WERE FULLY FUNCTIONAL AND IN SERVICEABLE CONDITION. ASSY WAS RE-INSTALLED AND CHECKED FOR SEC URITY OF ATTACHMENT. RUDDER ASSY WAS CHECKED FOR BALANCE AND DETERMINED TO BE IN AN IMBALANCE CONDITION. DETERMINATION IS THAT INCORRECT HARDWARE WAS INSTALLED IN BALANCE WEIGHT ASSY OVER LONG TIME WORKED OUT. NO EXCESSIVE VIBRATION WAS NO TED PRIOR TO OR FOLLOWING REMOVAL AND NO RECENT WORK HAD BEEN PERFORMED ON THE RUDDER, OR WEIGHT ASSY FOR SOME TIME. 1 H 7 1 3O 3A17 2004022500032 20040225 00032 NM 2004 2 25 2004FA0000080 1 20040119 G 5711 SPAR UNIVAR 415 415C 0420302 NM CONT C85 C8512F 17008 SO MCAULY 1A90 1A90CF GL CENTER WING CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 05 93517 840 28872712 598 AD 2002-26-02 CORROSION INSPECTION: REMOVED BOTH WINGS AND BOTH FUEL TANKS. INSPECTED ENTIRE CENTER SECTION AND FOUND FO UR QUARTER SIZED AREAS OF LIGHT CORROSION ON FWD SIDE OF FRONT CENTER SECTION SPAR. CORROSION AREAS WERE SANDED WITH 240 GRIT SANDPAPER AND THE ENTIRE CENTER SECTION WAS CLEANED AND SPRAYED WITH CORROSION PREVENTIVE. CLEANED AND INSPECTED E XTERIOR OF BOTH GAS TANKS AND FOUND NO CORROSION. REPLACED ONE RIVET IN TOP EDGE OF RIGHT FRONT CENTER SECTION SPAR CAP WITH AN OVERSIZE RIVET. REINSTALLED BOTH WING PANELS AND BOTH FUEL TANKS. WORK PERFORMED IAW AC 43.13-1B, SB-31 REVISIO N 1, AC 43-4A AND PATIENCE. 1 L 7 1 3O 3 O A718 E233 5 N P842 2004022500025 20040225 00025 EU 2004 2 25 2004FA0000081 1 20040104 G 7697 30709341 WIRE HARNESS BRAERO DH125 HS125700A 4230170 EU RT ENGINE DETERIORATED E A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 CE 03 120JC 6970 NA0247 WHILE ENROUTE, NOTED RT ENGINE AMBER WARNING LAMP BECAME ANNUNCIATED, ALSO NOTED INDICATED LOSS OF POWER RT ENGINE. CONS ULTED OPERATORS MANUAL AND COMPLIED WITH EMERGENCY PROCEDURES WHICH INCLUDED TO SWITCH TO MANUAL CONTROL AND MONITOR ALL ENGINE PARAMETERS. IMMEDIATE NOTIFICATION TO ATC AND REQUESTED TO DIVERTED FOR INSPECTION. INSPECTION WAS PERFORMED AND FOLLOWING TROUBLESHOOTING AND INSPECTION THAT THE SOURCE OF THE DEFECTS WAS THE RT ENGINE PT2 HARNESS. PARTS WERE REPLA CED AND PN 3070934-1 HARNESS. SYSTEM WAS OPERATIONALLY TESTED WITH NO FURTHER DEFECTS NOTED. 2 L 7 2 4F A3EU 2004022500041 20040225 00041 NM 2004 2 25 2004FA0000088 1 20040112 G 2720 ABC10800318 CONTROL CABLE AMBLP A150 A150 3850110 NM LYC O360 IO360A1A 41514 EA RUDDER FAILED D O OTHER O OTHER NR NOT REPORTED 1 SO 15 154ZP 104 NICOPRESS FITTING FAILED ON THIS PARTICULAR CABLE. 1 B 7 2 3O 3 O 0 SOOOO2SE 1E10 2004022300086 20040223 00086 NM 2004 2 23 2004FA0000095 1 20040108 G 6220 900R2101006107 HUB DOUG DOUG MD900 MD900 3027375 NM PWC PW207 PW207E NE MAIN ROTOR CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 13 3PD 435 435 0099990080 9000085 DURING ACCOMPLISHMENT OF A.D. 2002-10-05(MAIN ROTOR UPPER HUB INSPECTION)FOUND (6) OUT OF (10) UPPER FLANGE BOLT HOLES T O BE CRACKED. CRACKS RUN RADIALLY FROM BOLT HOLE TO INNER EDGE AS DEPICTED IN SB 900-072. PART TOTAL TIME: 435 HRS SIN CE NEW. REPLACED UPPER HUB ASSY WITH NEW IAW MM. 1 G 7 2 3U 3 U NC H19NM E42NE 2004022500071 20040225 00071 EU 2004 2 25 2004FA0000097 1 20040109 G 3230 1090512431 SELECTOR VALVE AGUSTA A109 A109A2 0260120 EU ALLSN 250C 250C20 03013 GL MLG WORN D O OTHER O OTHER NR NOT REPORTED 1 NM 01 1PJ 7262 LANDING GEAR WOULD NOT EXTEND. FINALLY FORCE LANDING GEAR HANDLE DOWN GEAR EXTENDED AND LOCKED BUT STILL HAD TRANSITION LIGHT. PART FAILED PRIMARILY DUE TO AGE AND USE (WEAR). 1 G 7 2 3U 3 U H7EU E4CE 2004012300070 20040123 00070 EU 2004 1 23 2004FA0000101 1 20040101 G 7920 C792A1030802 LINE UROCOP EC120 EC120B 8680987 EU TMECA ARRIUS ARRIU2F NE ENGINE MISMANUFACTURED C O OTHER O OTHER NR NOT REPORTED 1 WP 25 277SD 1470 1134 DURING ROUTINE MAINTENANCE, OIL LINE B-NUT WAS LOOSENED, IT WAS NOTED THAT LINE MOVED AWAY FROM MATING CONNECTOR APPROX .2500 INCH. A SPRING SCALE WAS USED TO PULL THE LINE BACK INTO PLACE, IT REQUIRED 45 LBS OF FORCE TO DO SO. THE MFG WA S CONTACTED, PRINT OF PART WAS OBTAINED AND PART WAS MEASURED. (PRINT DIM: 26.1 CM, PART DIM: 25.7 CM) NEW LINES WERE O RDERED, 2 NEW LINES WERE ALSO TOO SHORT. THESE ARE ENGINE OIL LINES TO THE THERMAL BYPASS VALVE. 1 G 7 2 3U 3 U NC R0001RD E34NE 2004012300072 20040123 00072 EU 2004 1 23 2004FA0000102 1 20040101 G 7920 C792A1030802 LINE UROCOP EC120 EC120B 8680987 EU TMECA ARRIUS ARRIU2F NE ENG OIL MISMANUFACTURED C O OTHER O OTHER NR NOT REPORTED 1 WP 25 266SD 1470 1133 DURING ROUTINE MAINTENANCE, OIL LINE (B NUT) WAS LOOSENED, IT WAS NOTED THAT LINE MOVED AWAY FROM MATING CONNECTOR APPRO X. .2500 INCH. A SPRING SCALE WAS USED TO PULL THE LINE BACK INTO PLACE, IT REQUIRED 45 LBS OF FORCE TO DO SO. THE MAN UFACTURER WAS CONTACTED, A PRINT OF THE PART WAS OBTAINED AND THE PART WAS MEASURED. (PRINT DIM: 26.1 CM, PART DIM: 25. 7 CM) NEW LINES WERE ORDERED, 2 NEW LINES WERE ALSO TOO SHORT. THESE ARE ENGINE OIL LINES TO THE THERMAL BYPASS VALVE. 1 G 7 2 3U 3 U NC R0001RD E34NE 2004022300209 20040223 00209 CE 2004 2 23 2004FA0000116 1 20040115 G 3233 5201KD BEARING BEECH BEECH 55 T42A CE MLG GEARBOX GALLED G O OTHER F B S FLT CONT AFFECTED SMOKE/FUMES/ODORS/SPARKS AFFECT SYSTEMS LD LANDING 1 GL 15 221Q 6342 2137 TC804 DURING TRAINING FLIGHT, LANDING GEAR WOULD NOT EXTEND ELECTRICALLY OR MANUALLY (EMERGENCY EXTENSION). AIRCRAFT LANDED G EAR UP. DURING INVESTIGATION, FOUND BEARING ON ACTUATOR WORM GEAR GALLED AND IN MANY PIECES. WORM GEAR WAS THUS ALLOWE D TO MOVE RADIALLY AND BIND THE SECTOR GEAR. MM SECTION 15 INDICATES THAT THIS PART IS TO BE REPLACED OR OVERHAULED EVE RY 2000 HOURS. 1 L 7 2 3O 3A16 2004022300012 20040223 00012 CE 2004 2 23 2004FA0000117 1 20040106 G 3233 5201KD BEARING BEECH BEECH 55 T42A CE MLG GEARBOX GALLED G O OTHER F B FLT CONT AFFECTED SMOKE/FUMES/ODORS/SPARKS LD LANDING 1 GL 15 221Q 6342 2137 TC804 DURING TRAINING FLIGHT, LANDING GEAR WOULD NOT EXTEND ELECTRICALLY OR MANUALLY(EMERGENCY EXTENSION). AIRCRAFT LANDED GE AR UP. DURING INVESTIGATION, FOUND BEARING ON ACTUATOR WORM GEAR IN MANY PIECES THUS ALLOWING THE WORM GEAR TO BIND THE SECTOR GEAR AGAINST THE LANDING GEAR GEAR BOX HOUSING. MM SECTION 15 INDICATES THAT THIS PART IS TO BE REPLACED OR OVE RHAULED EVERY 2000 HOURS. THIS ACTUATOR ASSEMBLY HAS 2137 HOURS ON IT SINCE LAST OVERHAUL. 6342 HOURS TOTAL TIME OVER A 40 YEAR SPAN. 1 L 7 2 3O 3A16 2004022300118 20040223 00118 CE 2004 2 23 2004FA0000118 1 20040108 G 3243 05411383 MASTER CYLINDER CESSNA 195 195B 2073112 CE BRAKES LEAKING C O OTHER K FLUID LOSS LD LANDING 1 SW 13 6850D 2420 16026 LT MASTER CYLINDER LEAKING WHERE BRAKE PLUNGER INTERFACES WITH MASTER CYLINDER, THERE IS NO O RING SEAL AT THIS LOCATION , FLUID LEAKS OUT DUE TO WEAR, THIS CAUSES GRADUAL LOSS OF FLUID. ALSO LEAKAGE AT HOSE ATTACH FITTING P/N AN922-4D. HOS E P/N AN6262-40-10 ALSO LEAKING WHERE HOSE ATTACHES TO FITTING ON MASTER CYLINDER. GRADUAL LOSS OF FLUID CAUSES BRAKE SY STEM FAILURE. AIRCRAFT HAD SATISFACTORY BRAKE PERFORMANCE DURING PRE TAKEOFF RUN UP, AFTER APPROX ONE HOUR FLIGHT AIRCRA FT RETURNED TO LAND AND HAD NO BRAKE ON LT SIDE, AIRCRAFT GROUND LOOPED ON LANDING. 1 H 7 1 3R A790 2004022500060 20040225 00060 CE 2004 2 25 2004FA0000120 1 20040119 G 5544 05331341 BALANCE WEIGHT CESSNA 172 172RG 2072438 CE RUDDER MISSING D O OTHER O OTHER TX TAXI/GRND HDL 1 CE 03 4726V 8222 172RG0370 RUDDER BALANCE WEIGHT WAS MISSING FROM IT'S LOCATION. UPON INSP OF RAMP AREA, MISSING WEIGHT ASSY WAS FOUND FROM TAXIWAY . RUDDER TAB, AC WERE DETERMINED TO NOT BE DAMAGED FROM PART DEPARTING ITS LOCATION. WEIGHT ASSY WAS INSP, CAUSE OF PART COMING OFF AC WAS RESEARCHED. SCREW INSERTS WERE FULLY FUNCTIONAL AND IN SERVICEABLE CONDITION. ASSY WAS RE-INSTALLED A ND INSP FOR SECURITY OF ATTACHMENT. RUDDER ASSY WAS CHECKED FOR BALANCE, DETERMINED TO BE IN A BALANCED CONDITION. POSSI BLY INCORRECT HARDWARE WAS INSTALLED TO MOUNT WEIGHT ASSY AND WORKED LOOSE OVER TIME. NO EXCESSIVE VIBRATION WAS NOTED P RIOR TO OR FOLLOWING THE WEIGHT ASSY BEING REMOVED FROM RUDDER, NO RECENT WORK TO THAT PART OF AC WAS PERFORMED. 1 H 7 1 3O 3A17 2004022300076 20040223 00076 2004 2 23 2004FA0000122 4 20040105 G 2562 E01 ELT AVIAT A1 A1A 2210405 GL LYC O360 O360A1D 41514 EA CABIN CORRODED P K NONE O OTHER IN INSP/MAINT 1 AL 03 40HU 1315 OPERATIONAL TEST OF ELT ON PRE-FLIGHT AT THE REMOTE SWITCH SHOWED THE ELT WAS NOT WORKING. MANUALLY TURNED THE ELT ON A T THE UNIT, STILL NOT WORKING. REMOVED ELT AND OPENED UP THE UNIT TO DISCOVER CONDENSATION AND ELECTROLYSIS CORROSION H AD COMPLETELY RENDERED THE UNIT USELESS. THE O-RINGS APPEARED TO BE IN GOOD SHAPE. THE ELT HAD BEEN INSPECTED AND NEW BA TTERIES INSTALLED DURING THE 100 HR. INSPECTION ON 9/2003. TEMPERATURES OUTSIDE HAVE BEEN IN THE -30 DEG. F RANGE AND T HE PLANE HAD BEEN PUT INTO THE HANGAR TO WARM UP. 1 H 7 1 3O 3 O NC A22NM E286 2004021700191 20040217 00191 2004 2 17 2004FA0000126 4 20040102 G 2562 EBCG7 HOUSING EBC G SWITCH BROKEN D K NONE O OTHER IN INSP/MAINT 1 GL 19 53442G DURING ANNUAL INSPECTION, WHILE REMOVING UNIT FROM ITS MOUNTING TRAY, THE IMPACT ACTIVATOR EBC G7 HOUSING BROKE FREE FRO M THE BATTERY/TRANSMITTER HOUSING. THESE TWO HOUSINGS APPEARED TO BE EPOXIED TOGETHER. THE UNIT IS 20+ YEARS OLD, ACCO RDING TO THE OWNER. THE EPOXY JOINT FAILED, PERHAPS DUE TO AGE, OR PERHAPS DUE TO BEING DROPPED. ACTUAL REASON UNKNOWN . THIS SUBMITTER'S OPINION IS THAT THE JOINT CONNECTION BETWEEN THE TWO HOUSINGS WITH EPOXY IS OF POOR DESIGN. THIS SU BMITTER BELIEVES A MECHANICAL CONNECTION WOULD BE FAR SUPERIOR. THIS IS THE SECOND DEFECT OF THIS TYPE KNOWN TO THE SUB MITTER. THIS PARTICULAR UNIT REPLACED ANOTHER UNIT OF THE SAME MODEL WHICH HAD THE SAME DEFECT, ACCORDING TO THE OWNER. 2004022500087 20040225 00087 SW 2004 2 25 2004FA0000129 1 20040122 G 5541 SPAR NAMER T28C T28C 6402509 SW RUDDER CRACKED D O OTHER O OTHER NR NOT REPORTED 1 WP 27 1064 2100 610649 CRACKS FOUND ADJACENT TO UPPER HINGE BRACKET ATTACH HOLES ON RUDDER SPAR. FOUR CRACKS FOUND, EACH BETWEEN .7500 INCH AND 1 INCH LONG. ONE WAS VISIBLE, OTHERS FOUND USING DYE PENTRANT. CRACKS CANNOT BE SEEN WITHOUT REMOVAL OF THE HINGE BRACK ET. 1 L 7 1 4R RT EXPA1L71 2004022500088 20040225 00088 SW 2004 2 25 2004FA0000130 1 20040122 G 5541 SPAR GULSTM 112 112 0144701 SW RUDDER CRACKED D O OTHER O OTHER NR NOT REPORTED 1 WP 27 1064 2100 64 CRACKS FOUND ADJACENT TO UPPER HINGE BRACKET ATTACH HOLES ON RUDDER SPAR. FOUR CRACKS FOUND, EACH BETWEEN .7500 INCH AND 1 INCH LONG. ONE WAS VISIBLE, OTHERS FOUND USING DYE PENTRANT. CRACKS CANNOT BE SEEN WITHOUT REMOVAL OF THE HINGE BRACK ET. 1 L 7 1 3O A12SO 2004022500097 20040225 00097 2004 2 25 2004FA0000132 4 20040116 G 3424 303770 INDICATOR PIPER PA28 PA28RT201 7102818 SO LYC O360 IO360C1C6 41514 EA MCAULY 2D34C 2D34C215 GL TURN COORDINATOR FAILED G O OTHER S AFFECT SYSTEMS NR NOT REPORTED 1 WP 17 8227V 236 28R8018085 62208651A 931655PC085 TURN COORDINATOR UNIT FAILED DURING IFR CONDITIONS. PROBLEM SEEMS TO BE INTERMITTENT BECAUSE AFTER LANDING, UNIT WORKED AND CONTINUED FOR DURATION OF FLIGHT (VFR) FROM FCH TO FYI (FAT). (WP17200402720) 1 L 7 1 3O 3 O 2A13 1E10 5 C P7EA 2004022500120 20040225 00120 2004 2 25 2004FA0000133 4 20040119 G 2561 KSD35PO723107 LIFE VEST CELL FAILED B KQ1R K NONE L NO TEST IN INSP/MAINT 1 EA 07 LIFE PRESERVER FAILED MFG RECOMMENDED CELL PSI TEST IAW MANUAL 25-60-7. DOM: MARCH 1985. 2004022500121 20040225 00121 2004 2 25 2004FA0000134 4 20040120 G 2561 KSD35PO723105 LIFE VEST CELL FAILED B KQ1R K NONE L NO TEST IN INSP/MAINT 1 EA 07 LIFE PRESERVER FAILED MFG RECOMMENDED CELL PRESSURE TEST: LIFE PRESERVER DOM: APRIL 1985. 2004021700178 20040217 00178 EA 2004 2 17 2004FA0000137 2 20040128 G 8530 17C21191 KEEPER CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA MCAULY 1A170 1A170* GL NR 2&3 CYLS WORN C O OTHER O OTHER NR NOT REPORTED 1 SO 15 479ER 721 172S8942 L2709951A UC037 DURING A ROUTINE INSPECTION, AND WHILE ACCOMPLISHING SB 388, IT WAS DISCOVERED THAT THE VALVE KEY RETAINERS (P/N-17C2119 1) ON THE EXHAUST VALVE, WERE WORN WHERE THEY CONTACT THE ROTOR CAP. THE WEAR WAS RADIAL, AND THE DEPTH WAS ESTIMATED AP PROXIMATELY .020 INCH TO .030 INCH. THERE WAS NO STRONG INDICATION OF WEAR ON THE ROTATOR CAP OR THE GROOVE IN THE VALV E STEM. THESE PARTS WERE REPLACED WITH NEW PARTS. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P857 2004022500125 20040225 00125 EA 2004 2 25 2004FA0000138 2 20040128 G 8530 17C21191 KEEPER PIPER PA44 PA44180 7104402 SO LYC O360 O360A1H 41514 EA HARTZL HCC2Y HCC2YR2 GL NR 4 CYLINDER WORN B K NONE O OTHER IN INSP/MAINT 1 SO 15 930ER 5358 981 4496154 L54971A AU7685 DURING A ROUTINE INSPECTION, AND WHILE ACCOMPLISHING SB 388, IT WAS DISCOVERED THAT THE VALVE KEY RETAINERS (P/N-17C2119 1) ON THE EXHAUST VALVE, WERE WORN WHERE THEY CONTACT THE ROTATOR CAP. THE WEAR WAS RADICALLY ORIENTED, AND DEPTH WAS ES TIMATED APPROXIMATELY .020 INCH TO .030 INCH. THERE WAS NO STRONG INDICATION OF WEAR ON THE ROTATOR CAP OR THE GROOVE IN THE VALVE STEM. THESE PARTS WERE REPLACED WITH NEW PARTS. 1 L 7 2 3O 3 O A19S0 E286 5 C P920 2004022700002 20040227 00002 SO 2004 2 27 2004FA0000139 1 20040109 G 2810 39824804 CAP PIPER PA34 PA34220T 7103420 SO LT FUEL CELL LOOSE G A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 NE 01 4142R 3449140 PILOT ENCOUNTERED LOSS OF POWER ON LT ENGINE AND MADE PRECAUTIONARY (UNSCHEDULED) LANDING. WATER WAS FOUND IN LT TANK A ND LT FUEL LINES. WATER WAS SUMPED OUT, ENGINE TEST RUN, AND AIRCRAFT RETURNED TO HOMEBASE. AT HOMEBASE LT SIDE FUEL CA P WAS FOUND TO BE A LOUSY FIT, WHICH PROBABLY ALLOWED WATER TO ENTER. AIRCRAFT HAS LOCKING CAPS SWAPPING RT FUEL CAP TO LT WING MADE A SLIGHT IMPROVEMENT, BUT NOT MUCH. CAPS CA NOT BE ADJUSTED LIKE SOME OTHERS CAN. THIS AIRCRAFT IS KEPT I N A HEATED HANGAR. THE CAPS APPEAR TO BE THE PROBLEM NOT THE GASKETS. 1 L 7 2 3O A7SO 2004042700047 20040427 00047 2004 4 27 2004FA0000140 4 20040128 G 6113 SPINNER AMTR RV4 RV4 GL LYC O320 O320E2C 41508 EA SNSNCH 70C 70CM6 EA PROPELLER MISINSTALLED B K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 05 227MJ 33609K PROPELLER DAMAGED BEYOND REPAIR DUE TO IMPROPER SPINNER INSTALLATION. 1 L 7 1 3O 3 O NC EXPA1L71 E274 5 N P28NE 2004022700082 20040227 00082 SW 2004 2 27 2004FA0000142 1 20040123 G 5711 SPAR BBAVIA 7 7AC 2110102 SW CONT A75 A75* 17005 SO WINGS CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 07 83899 7AC2580 AD 200-25-02-R1, INSPECTION OF WING SPARS WAS SIGNED OFF AS COMPLIANCE WITH, ON 19 AUG O1 AS A NON-REOCCURRING INSP. DU RING ANNUAL INSPECTION IN JAN 04, BOTH MAIN SPARS WERE FOUND TO BE CRACKED AT THE ROOT END. 1 H 7 1 3O 3 O A759 E213 2004021700102 20040217 00102 CE 2004 2 17 2004FA0000143 1 20040202 G 5210 07110381 PIN CESSNA 182 182H 2072718 CE CONT O470 O470* 17026 SO DOOR HINGE BROKEN G O OTHER O OTHER NR NOT REPORTED 1 NE 01 2084X 3600 18256184 DURING ANNUAL INSPECTION. THIS LOWER RT DOOR HINGE PIN WAS FOUND BROKEN IN 3 PLACES. IT IS VERY SIMPLE TO DETECT, THIS JUST TO OPEN AND CLOSE DOOR SLOWLY AND WATCH FOR EQUAL ROTATION OF PIN. IF ONLY ONE END TURNS THEN THE PIN MUST BE BRO KEN. 1 H 7 1 3O 3 O NT 3A13 E273 2004022700099 20040227 00099 SO 2004 2 27 2004FA0000144 1 20040112 G 3220 67054003 TRUNNION PIPER PA32 PA32R301 7103218 SO LYC O540 IO540* 41532 EA NLG CRACKED D CDHS O OTHER O OTHER NR NOT REPORTED 1 EA 05 9253M 71 32R8513010 NOSE TRUNNION FOUND CRACKED AT ASSIST SPRING ATTACH BOSS. THIS WAS A NEW MFG TRUNNION WITH 16 MONTH AND 71 HOURS IN SER VICE. THE CRACK OCCURRED AT A POINT THAT IS NOT SUBJECT TO OPERATING STRESS. 1 L 7 1 3O 3 O A3SO 1E4 2004021700128 20040217 00128 CE 2004 2 17 2004FA0000146 1 20040201 G 5200 125083912 HINGE CESSNA 210 T210J 2073440 CE CONT O520 IO520* 17032 SO ALT AIR DOOR WORN D O OTHER O OTHER NR NOT REPORTED 1 SW 09 2271R 2230 T2100421 THE ORIGINAL HINGE MFG OF ALUMINUM WORE OUT AND DROPPED PIECES IN THE INTAKE, CAUSING DAMAGE TO THE TURBOCHARGER. SERIO US DAMAGE WAS AVOIDED BY A TIMELY INSPECTION. THE NEW SUPPLIED PART IS STAINLESS STEEL WITH A HINGE PIN SECURED BY CRIM PING. THIS AREA IS DIFFICULT TO INSPECT ROUTINELY, AND ALL HINGES SHOULD BE CHANGED TO STEEL. 1 H 7 1 3O 3 O 3A21 E5CE 2004021700155 20040217 00155 SW 2004 2 17 2004FA0000148 1 20040109 G 7120 204060031015 FITTING BELL 205 205A1 1181414 SW LYC T53 T5313B 41549 NE ENGINE DAMAGED D O OTHER O OTHER NR NOT REPORTED 1 AL 03 4750R 30009 LEO7587 UPON OPENING PACKED FOR FITTING ASSEMBLY FOUND THREADS ON LONG SIDE OF FITTING PULLED LOOSE. PART REJECTED BEFORE INSTA LLATION. 1 G 7 1 4U 4 U H1SW E17EA 2004021100149 20040211 00149 GL 2004 2 11 2004FA0000149 3 20040120 G 6110 D4170 COUNTERWEIGHT CESSNA 310 310 2074202 CE MCAULY 2AF34C D2AF34C52 GL PROPELLER CRACKED B L2PR O OTHER E VIBRATION/BUFFET NR NOT REPORTED 1 SW 13 1312J 810739 PART HAD APPROX 700.00 HOURS SINCE OVERHAUL, FATIGUE CRACK APPEARS TO HAVE ORIGINATED AT FORWARD BOLT HOLE. PROPELLER/ ENGINE BEGAN VIBRATING IN FLIGHT DUE TO COUNTER WEIGHT SHIFTING ON FERRULE. AIRCRAFT REDUCED POWER, LANDED AND WAS REPA IRED BEFORE FURTHER FLIGHT. (K) 1 L 7 2 3O RT 3A10 5 C P5EA 2004021700077 20040217 00077 NM 2004 2 17 2004FA0000163 1 20040204 G 6320 51003400 LINE DOUG MD900 MD900 3027375 NM PWC PW207 PW207E NE XMSN OIL CRACKED D A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CR CRUISE 1 EA 13 902PD 1261 0062190056 9000084 AIRCRAFT EXPERIENCED LOW TRANSMISSION OIL PRESSURE. DURING RUN-UP AND LEAK CHECK FOUND TRANSMISSION OIL COOLER LINE P/N 900D3409526105 TO BE LEAKING FROM UNDER STEEL BRADE. REPLACED OIL COOLER LINE, OPS AND LEAK CHECK WERE GOOD. CUT BACK STEEL BRADE ON OLD LINE TO FURTHER INVESTIGATE CAUSE AND FOUND LINE TO BE CRACKED BELLOWS. 1 G 7 2 3U 3 U NC H19NM E42NE 2004022700108 20040227 00108 CE 2004 2 27 2004FA0000164 1 20040204 G 2810 125932 FUEL CAP BBAVIA 8 8KCAB 2110612 CE FUEL CELL MISINSTALLED B C D ABORTED TAKEOFF RETURN TO BLOCK D INFLIGHT SEPARATION TO TAKEOFF 1 WP 28 561ER 66 9342003 FUEL TANK CAPS ARE VERY DIFFICULT TO SECURE PROPERLY. IT IS EASY TO PUT THE CAP ON PARTIALLY. THE FACTORY RECOMMENDS T HE CAP GASKETS BE LUBED WITH SILICONE SPRAY. WE ARE ALSO PUTTING ALIGNMENT MARKS ON THE CAP AND WING FOR POSITIVE ENGAG EMENT INDICATION. 1 H 7 1 3O A21CE 2004030100071 20040301 00071 SO 2004 3 1 2004FA0000171 1 20040122 G 5310 45467016017 RIB PIPER PA31 PA31310 7103103 SO LYC O540 TIO540* 41532 EA MLG WW CORRODED B C85R O OTHER O OTHER NR NOT REPORTED 1 NE 01 131PJ 5052 317912030 REPORTED OCCASIONAL GEAR CYCLING PROBLEM. INSPECTED LANDING GEAR AND FOUND RIBS (WHICH ARE IN THE LT AND RT MAIN GEAR W HEEL WELLS) TO BE SEVERELY CORRODED. MOUNTED ON THIS RIBS IS THE BRACKET FOR THE UPLOCK LATCH SWITCH. THERE WAS ENOUG H MOVEMENT IN THE RIBS THAT SWITCH CONTACT BECAME AN ISSUE. BOTH RIBS WERE REPLACED . SOME OF PROBLEMS MIGHT BE CORREC TED BY INSTALLING KIT, WHICH C/W AND CHANGED THE GEAR PUSH-PULL TUBES TO CABLES INSTEAD. THIS WAS ALSO DONE. REMOVED O LD PUSH-PULL TUBES, WHICH WERE CORRODED. (NE01200402913) 1 L 7 1 3O 3 O RT A20SO E14EA 2004021700180 20040217 00180 SO 2004 2 17 2004FA0000172 1 20040112 G 2810 34824804 FUEL CAP PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360* 17025 SO LT WING LOOSE B C85R A UNSCHED LANDING F FLT CONT AFFECTED NR NOT REPORTED 1 NE 01 4142R 620 3449140 PILOT ENCOUNTERED LOSS OF POWER ON LT ENGINE AND MADE AN UNSCHEDULED LANDING. WATER WAS FOUND IN LT TANK AND LT FUEL L INES. WATER WAS SUMPED OUT, ENG TEST RUN, AC RETURNED TO HOMEBASE. LT SIDE CAP WAS FOUND TO BE LOUSY FIT, PROBABLY AL LOWED WATER TO ENTER. SWAPPING RT FUEL CAP TO LT WING MADE A SLIGHT IMPROVEMENT, NOT MUCH. (CAPS CAN NOT BE ADJUSTED) CAPS APPEAR TO BE THE PROBLEM, NOT THE GASKETS. AC IS KEPT IN HEATED HANGAR. 1 L 7 2 3O 3 O A7SO E9CE 2004030100076 20040301 00076 CE 2004 3 1 2004FA0000173 1 20040122 G 3260 DOWNLOCK SWITCH CESSNA 340 340A 2076405 CE CONT O520 TSIO520* 17040 SO MLG FAILED D O OTHER J WARNING INDICATION AP APPROACH 1 GL 17 356D 340A0745 LANDING GEAR WOULD NOT EXTEND, FOUND LANDING GEAR ACTUATOR DOWN LIMIT SWITCH STUCK IN GEAR DOWN POSITION. PERIODIC REPL ACEMENT OF SWITCH WOULD BE THE ONLY WAY TO PREVENT REOCURRENCE. THE SWITCH IS A SEALED UNIT AND CANNOT BE INSPECTED INT ERNALLY. (GL17200402312) 1 L 7 2 3O 3 O 3A25 E8CE 2004030100116 20040301 00116 EA 2004 3 1 2004FA0000178 2 20040109 G 8550 LW13792 SEAL AMRGEN AA1 AA1B 0631206 SO LYC O235 O235C2C 41505 EA ENGINE WORN G O OTHER K FLUID LOSS NR NOT REPORTED 1 EA 25 6291L 1446 AA1B0091 L1121615 FOUND CRANKSHAFT SEAL PUSHED FREE FROM ITS MOUNTING AREA. SEAL APPEARED DRY ROTTED AND INSTALLED WITH INSUFFICIENT SEA LANT. INSTALLED NEW SEAS IAW SRM. INSPECTED OIL SCREEN AND TOOK OIL SAMPLE. NO METAL FOUND SEAL SHOULD BE INSPECTED F OR PROPER MOUNTING EVERY 100 HOURS. 1 L 7 1 3O 3 O A11EA E223 2004021700105 20040217 00105 EU 2004 2 17 2004FA0000181 1 20040110 G 5330 1022704 SKIN PANEL LET L13 L13BLANIK 1360306 EU AFT FUSELAGE CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 01 6288 3076 025520 ON INSPECTION, FOUND CRACKS .50 INCH LONG ON BOTH RT AND LT SIDES, ON BOTTOM OF STABILIZER, HOLE CUTOUTS ONE INCH AFT BU LKHEAD N 14. STOP DRILLED AND REPAIR WITH PLATS OF 2024T3 .050 ALUM. IAW AC. 1 K 0 0 G24EU 2004030100121 20040301 00121 CE 2004 3 1 2004FA0000182 1 20040204 G 2133 40117 CHECK VALVE CESSNA 650 650 2076802 CE GARRTT TFE731 TFE731* 01518 WP CABIN PRESSURE CRACKED G K NONE O OTHER IN INSP/MAINT 1 GL 03 600JD 6500236 WHILE TROUBLESHOOTING A PRESSURIZATION PROBLEM, A CRACKED CHECK VALVE AT THE RT PRESSURE REGULATING AND CHECK VALVE ASSE MBLY WAS FOUND. A PIECE OF THE CHECK VALVE WAS MISSING. THE LT SIDE WAS THEN CHECKED AND AN IDENTICAL CHECK VALVE COND ITION WAS FOUND. A SEARCH FOR THE MISSING PIECE WAS UNSUCCESSFUL. 2 L 7 2 4F 4 F A9NM E6WE 2004021700106 20040217 00106 CE 2004 2 17 2004FA0000183 1 20040204 G 2133 40117 CHECK VALVE CESSNA 650 650 2076802 CE GARRTT TFE731 TFE731* 01518 WP CABIN PRESSURE CRACKED G O OTHER O OTHER NR NOT REPORTED 1 GL 03 600JD 6500236 WHILE TROUBLESHOOTING A PRESSURIZATION PROBLEM, A CRACKED CHECK VALVE AT THE RT PRESSURE REGULATING AND CHECK VALVE ASSE MBLY WAS FOUND. A PIECE OF THE CHECK VALVE WAS MISSING. THE LT SIDE WAS THEN CHECKED AND AN IDENTICAL CHECK VALVE COND ITION WAS FOUND. A SEARCH FOR THE MISSING PIECE WAS UNSUCCESSFUL. 2 L 7 2 4F 4 F A9NM E6WE 2004030100122 20040301 00122 CE 2004 3 1 2004FA0000184 1 20040204 G 2133 40117 CHECK VALVE CESSNA 650 650 2076802 CE GARRTT TFE731 TFE731* 01518 WP CABIN PRESSURE CRACKED G K NONE O OTHER IN INSP/MAINT 1 GL 03 900JD 4923 6500213 WHILE TROUBLESHOOTING A PRESSURIZATION PROBLEM, A CRACKED CHECK VALVE AT THE RT PRESSURE REGULATING AND CHECK VALVE ASSE MBLY WAS FOUND. A PIECE OF THE CHECK VALVE WAS MISSING. THE LT SIDE WAS THEN CHECKED AND AN IDENTICAL CHECK VALVE COND ITION WAS FOUND. A SEARCH FOR THE MISSING PIECE WAS UNSUCCESSFUL. 2 L 7 2 4F 4 F A9NM E6WE 2004030100123 20040301 00123 CE 2004 3 1 2004FA0000185 1 20040204 G 2133 40117 CHECK VALVE CESSNA 650 650 2076802 CE GARRTT TFE731 TFE731* 01518 WP CABIN PRESSURE CRACKED G K NONE O OTHER IN INSP/MAINT 1 GL 03 900JD 4923 6500213 WHILE TROUBLESHOOTING A PRESSURIZATION PROBLEM, A CRACKED CHECK VALVE AT THE RT PRESSURE REGULATING AND CHECK VALVE ASSE MBLY WAS FOUND. A PIECE OF THE CHECK VALVE WAS MISSING. THE LT SIDE WAS THEN CHECK AND AN IDENTICAL CHECK VALVE CONDIT ION WAS FOUND. A SEARCH FOR THE MISSING PIECE WAS UNSUCCESSFUL. 2 L 7 2 4F 4 F A9NM E6WE 2004030100127 20040301 00127 EA 2004 3 1 2004FA0000186 2 20040114 G 7414 4347 MAGNETO MOONEY M20 M20C 5870208 SW LYC O360 IO360A1A 41514 EA ENGINE FAILED D K NONE O OTHER IN INSP/MAINT 1 CE 05 6784V 665 700083 L1506136A ROUGH ENGINE ON RUNUP. MAGNETO REMOVED AND DISASSEMBLED. BEARING CAP ASSEMBLY NOT HELD STATIONARY IN FRAME. RETAINING SCREWS AND TABS WERE FOUND TIGHT BUT NOT TIGHT ON BEARING CAP. BEARINGS FOUND TO BE OK. BELIEVE THAT CAP ON HOUSING W AS MACHINED INCORRECTLY AND WAS NEVER TIGHT FROM DAY ONE. 1 L 7 1 3O 3 O 2A3 1E10 2004021700096 20040217 00096 CE 2004 2 17 2004FA0000187 1 20040206 G 2820 652635537 TUBE CESSNA 500 550 2076604 CE FUEL SYSTEM CHAFED I K NONE O OTHER IN INSP/MAINT 1 EA 23 792MA 11000 5500302 COMPLETING CESSNA SB, WE FOUND BOOST PUMP WIRING CHAFING INTO FUEL TUBE. THE TUBE WAS CHAFED BEYOND LIMITS IAW SB. THE RE IS POTENTIAL OF SPARKING IN THE FUEL BAY AREA IF THE BOOST PUMP WIRES SHORTED TO THE TUBE CAUSING A FIRE. THE BOOST P UMP WIRING HAD SOME CHAFFING ON OUTSIDE SHIELDING BUT WAS IN LIMITS IAW SB. THIS SB SHOULD BECOME AN AD TO PREVENT ANY CHAFFING OF BOOST PUMP WIRES IN THE FUEL BAY AREA. 1 L 7 2 4F A22CE 2004030100047 20040301 00047 SO 2004 3 1 2004FA0000188 1 20040206 G 2823 SELECTOR VALVE PIPER PA18 PA18150 7101828 SO FUEL SYSTEM BROKEN P D RETURN TO BLOCK S AFFECT SYSTEMS TX TAXI/GRND HDL 1 AL 03 188109055 PILOT TURNED FUEL VALVE TO CHECK FOR SMOOTH OPERATION AND DETENTS ON THE FUEL SELECTOR VALVE AS DIRECTED BY FLIGHT INSTR UCTOR. INSTRUCTOR HEARD (FUNNY SOUND) COMING FROM VALVE AND THE VALVE WAS SUBSEQUENTLY DETERMINED TO BE BROKEN. WHEN TH E VALVE BROKE IT WAS STUCK BETWEEN NORMAL POSITIONS. MAINTENANCE REMOVED THE VALVE FROM THE AIRCRAFT. THE VALVE HAS A PLASTIC/SYNTHETIC INSERT THAT FUNCTIONS LIKE A BALL VALVE. THE PLASTIC PART IS BROKEN NEAR THE TOP WHERE THE HANDLE ENG AGES THE CONE. THE INSTRUCTOR PILOT HAD FLOWN THE 2 PREVIOUS FLIGHTS WITHOUT ANY INDICATION OF A VALVE PROBLEM. THIS C OMPONENT FAILURE COULD HAVE CAUSED AN AIRCRAFT ACCIDENT IF IT HAD FAILED UNDER POWER (IN FLIGHT). 1 H 7 1 3O 1A2 2004030100050 20040301 00050 CE 2004 3 1 2004FA0000189 1 20040206 G 5313 STRINGER BEECH 200 200BEECH 1152920 CE PRESS BULKHEAD CRACKED E K NONE O OTHER IN INSP/MAINT 1 GL 21 553R 9597 BB589 STRINGERS NR 8,9 ON THE RIGHT SIDE OF THE AFT PRESSURE BULKHEAD WERE FOUND CRACKED DURING COMPLIANCE OF AD 93-25-07. CR ACKS WERE FOUND AT THE FWD RIVET. REPAIR KITS WERE INSTALLED IAW MANDATORY SB. 1 L 7 2 4T A24CE 2004030100083 20040301 00083 CE 2004 3 1 2004FA0000190 1 20040211 G 5512 04121761 SKIN CESSNA 150 150B 2071806 CE CONT O200 O200A 17020 SO MCAULY 1A100 1A100* GL HORIZONTAL STAB CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 09 1163Y 3548 15059563 30082A 36505 REMOVED HORIZONTAL STABILIZER FOR TAILCONE REPAIR. FOUND TWO 1.5 INCH CRACKS RADIATING FROM LOWER FORWARD CORNER OF TAI L CONE SKIN WHERE BOTTOM OF HORIZONTAL LEADING EDGE RESTS. CRACKS PROGRESSING TOWARDS FORWARD HORIZONTAL STABILIZER MOU NT BOLT HOLES. APPEARS INTERFERENCE FIT BETWEEN HORIZONTAL AND TAIL CONE WAS A CONTRIBUTING FACTOR. AREA HAD TO BE CLE ANED TO FIND CRACK DUE TO THE ACCUMULATION OF DEBRIS AND WEAR MATERIAL. 1 H 7 1 3O 3 O 3A19 E252 5 N P918 2004030100084 20040301 00084 CE 2004 3 1 2004FA0000191 1 20040211 G 5512 04121761 SKIN CESSNA 150 150B 2071806 CE CONT O200 O200A 17020 SO MCAULY 1A100 1A100* GL ZONE 300 CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 09 1163Y 3548 15059563 30082A 36505 REMOVED HORIZONTAL STABILIZER FOR TAILCONE REPAIR. FOUND TWO 1.5 INCH CRACKS RADIATING FROM LOWER FORWARD CORNER OF TAI L CONE SKIN WHERE BOTTOM OF HORIZONTAL LEADING EDGE RESTS. CRACKS PROGRESSING TOWARDS FORWARD HORIZONTAL STABILIZER MOU NT BOLT HOLES. APPEARS INTERFERENCE FIT BETWEEN HORIZONTAL AND TAIL CONE WAS A CONTRIBUTING FACTOR. AREA HAD TO BE CLE ANED TO FIND CRACK DUE TO THE ACCUMULATION OF DEBRIS AND WEAR MATERIAL. 1 H 7 1 3O 3 O 3A19 E252 5 N P918 2004030100093 20040301 00093 CE 2004 3 1 2004FA0000192 1 20040211 G 5521 0732000153 SPAR CESSNA CESSNA 182 182 2072702 CE LEFT ELEVATOR CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 25 6465A 3053 33265 DURING ANNUAL INSPECTION WHAT APPEARED TO BE A DENT WAS FOUND ON THE LOWER LEADING EDGE SKIN OF THE LT ELEVATOR. THIS (D ENT) WAS CROSSED BY A CRACK. EXCESSIVE MOVEMENT OF THE ELEVATOR HORN WAS NOTED WHEN THE ELEVATOR WAS FLEXED. FURTHER INS PECTION REVEALED A CRACK ACROSS THE SPAR 1.5 INCH OUTBOARD OF THE OUTBOARD HINGE BRACKET. THERE IS EVIDENCE ON THE TIP O F THE ELEVATOR OF (HANGAR RASH), THAT CONTACT EVIDENTLY WAS SEVERE ENOUGH TO BUCKLE THE ELEVATOR AT THE HINGE CAUSING TH E SPAR TO FAIL. 1 H 7 1 3O NT 3A13 2004030100094 20040301 00094 CE 2004 3 1 2004FA0000193 1 20040211 G 5521 0732000153 SPAR CESSNA CESSNA 182 182 2072702 CE LEFT ELEVATOR CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 25 6465A 3053 33265 DURING ANNUAL INSPECTION WHAT APPEARED TO BE A DENT WAS FOUND ON THE LOWER LEADING EDGE SKIN OF THE LEFT ELEVATOR. THIS (DENT) WAS CROSSED BY A CRACK. EXCESSIVE MOVEMENT OF THE ELEVATOR HORN WAS NOTED WHEN THE ELEVATOR WAS FLEXED. FURTHER INSPECTION REVEALED A CRACK ACROSS THE SPAR 1.5 INCH OB OF THE OB HINGE BRACKET. THERE IS EVIDENCE ON THE TIP OF THE ELE VATOR OF (HANGAR RASH), THAT CONTACT EVIDENTLY WAS SEVERE ENOUGH TO BUCKLE THE ELEVATOR AT THE HINGE CAUSING THE SPAR TO FAIL. 1 H 7 1 3O NT 3A13 2004030100003 20040301 00003 EA 2004 3 1 2004FA0000195 2 20040204 G 8520 61510 PLUG CESSNA 182 R182 2072734 CE LYC O540 O540J3C5 41532 EA CRANKSHAFT LOOSE B A UNSCHED LANDING K FLUID LOSS CL CLIMB 1 WP 07 35G 1144 1144 R18201785 DURING CLIMB OUT ENGINE RPM WOULD START CLIMBING AND THE PROP CONTROL HAD NO EFFECT ON REDUCING RPM. DURING TROUBLESHOO TING FOUND THE REAR CRANKSHAFT PLUG HAD COME LOOSE IN THE CRANKSHAFT ALLOWING OIL TO BYPASS BACK TO THE ENGINE SUMP. UN ABLE TO DETERMINE THE CAUSE FOR LOOSE PLUG. PLUG REPLACED. 1 H 7 1 3O 3 O RT 3A13 E295 2004030100049 20040301 00049 SO 2004 3 1 2004FA0000197 2 20040206 G 7414 641742 GEAR CONT O550 IO550B SO MAGNETO DRIVE GALLED B K NONE O OTHER IN INSP/MAINT 1 SO 09 500 500 684070 DURING ENGINE DISASSEMBLY FOR CYLINDER REPLACEMENT FOUND RT MAGNETO DRIVE GEAR DISCOLORED AND THRUST SURFACE GALLED. MA GNETO/ACCESSORY DRIVE ADAPTER BUSHING GALLED AND HEAT DAMAGED. 3 O E3SO 2004030300081 20040303 00081 CE 2004 3 3 2004FA0000198 1 20040204 G 7921 654585 OIL COOLER CESSNA 210 T210L 2073449 CE CONT O520 TSIO520* 17040 SO ENGINE CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 15 732HN 465 367 21061527 821036R LOWER OB FLANGE OF ENGINE OIL COOLER IS CRACKED AND LEAKING. 1 H 7 1 3O 3 O 3A21 E8CE 2004030300089 20040303 00089 CE 2004 3 3 2004FA0000199 1 20040202 G 8120 K1250860M105 INLET CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO TURBO EXH SYS MISMANUFACTURED B CVDR K NONE O OTHER IN INSP/MAINT 1 WP 17 111VF 21064005 2935795 UPON INSPECTION OF NEW PARTS DEFECTS WERE FOUND WITH THE TURBO INLET COMPONENT. DAMAGE WAS NOTED ON THE TURBOCHARGER MO UNTING FLANGE AND THE WELDING HAD VERY POOR PENETRATION. PART REJECTED AND SENT BACK TO O/H FACILITY. UPON RECEIVING P ARTS, FACILITY WAS NOT ABLE TO IDENTIFY IF PART WERE NEW OR REPAIRED DUE TO INSUFFICIENT PAPER WORK. W/O AND INVOICE IS ONE AND SAME FOR NEW PARTS AND OVERHAULED PARTS. 1 H 7 1 3O 3 O 3A21 E8CE 2004030300165 20040303 00165 CE 2004 3 3 2004FA0000202 1 20040203 G 2497 WIRE CESSNA 210 210M 2073450 CE ALTERNATOR BROKEN B B EMER. DESCENT H ELECT. POWER LOSS-50 PC LD LANDING 1 GL 15 732PY 21061677 AIRCRAFT LANDED WITH NO ELECTRICAL POWER. REPAIRED DAMAGED ALTERNATOR PRIMARY WIRE AND RESOLDERED CAPACITOR WIRE. TOP C HARGED BATTERY. OPS CHECKED GOOD IAW MFG C210 AMM AND AC43-1B/2A CHAPTER 11-7. 1 H 7 1 3O 3A21 2004050600017 20040506 00017 CE 2004 5 6 2004FA0000203 1 20040219 G 7120 BEAM CESSNA 421 421C 2076016 CE LT ENGINE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CE 03 HBLMR 421C0111 DURING AN INSPECTION, FOUND A LOT OF LOOSE RIVETS ON THE LT ENGINE BEAM ON THE RT WING. THE DISTANCE BETWEEN SHEET METAL AND THE BEAM-WEBCAPS IS APPROXIMATELY 1.5 TO 2 MM. 1 L 7 2 3O A7CE 2004030300187 20040303 00187 2004 3 3 2004FA0000204 4 20040220 G 2210 ST566 AUTOPILOT SYS CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO HARTZL HCJ3Y PHCJ3YF1 GL COCKPIT MALFUNCTIONED C H DEACTIVATE SYST/CIRCUITS S AFFECT SYSTEMS CR CRUISE 1 WP 03 210MT 201 21064165 291649R FP235A ONCE ESTABLISHED IN CRUISE FLIGHT WITH ALTITUDE HOLD ENGAGED, THE S-TEC SYSTEM 55X AUTOPILOT FREQUENTLY BEGINS TO GENTLY PORPOISE IN PITCH. THIS GETS PROGRESSIVELY WORSE UNTIL THE AUTOPILOT CAUSES SERIOUS PITCH EXCURSIONS OF SEVERAL HUNDRE D FEET PER MINUTE UP AND DOWN. THE ONLY SOLUTION FOUND IS TO DISENGAGE THE ALTITUDE HOLD MODE AND SELECT VERTICAL SPEED EQUALS ZERO. THE OTHER MAJOR PROBLEM NOTICED WITH SYSTEM 55X IS THAT DURING THE APPROACH TO LANDING, THE AUTOPILOT WI LL PITCH DOWN ABRUPTLY WHEN THE FLAPS AND/OR GEAR ARE DEPLOYED. THIS CAN BE ALARMING, ESPECIALLY DURING AN INSTRUMENT A PPROACH IN INSTRUMENT METEOROLOGICAL CONDITIONS. 1 H 7 1 3O 3 O 3A21 E8CE 5 C P36EA 2004030300189 20040303 00189 SO 2004 3 3 2004FA0000205 2 20040210 G 8530 AEC631397SN712B CYLINDER CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO ENGINE MISMANUFACTURED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 NE 03 517404 INSPECTED NEW CYLINDER AS RECEIVED. FOUND INSIDE DIAMETER OF EXHAUST VALVE GUIDE DID NOT MEET MINIMUM SIZE DIMENSIONS AN D VALVE SEAT MACHINING NOT CONCENTRIC. 1 H 7 1 3O 3 O 3A21 E8CE 2004050600043 20040506 00043 CE 2004 5 6 2004FA0000206 1 20040219 G 5411 SPAR CAP CESSNA 421 421C 2076016 CE RT NACELLE CORRODED G K NONE O OTHER IN INSP/MAINT 1 CE 09 HBLMR 421C0111 DURING AN INSPECTION FOUND A LOT OF CORROSION IN THE REGION OF RT FIREWALL NACELLE AND THE THE UPPER FWD SPARCAP. BECAU SE OF THIS FACT HE TOOK OUT THE WING LOCKER TANK. IN THIS REGION HE FOUND A LOT OF HEAVY CORROSION. 1 L 7 2 3O A7CE 2004030300190 20040303 00190 SO 2004 3 3 2004FA0000207 2 20040203 G 8530 AEC631397SN712B CYLINDER CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO ENGINE UNSERVICEABLE D K NONE O OTHER IN INSP/MAINT 1 NE 03 517404 INSPECTED NEW CYLINDER ASSY TISN 71.2BCA AS RECEIVED. FOUND VALVE SEAT MACHINING NOT CONCENTRIC AND EXHAUST VALVE SEAT DIAMETER CUT TO APPX. 1.847 INCH WHEN IT SHOULD BE APPX. 1.781 INCH ACCORDING TO PRINT DIMENSIONS IN OVERHAUL MANUAL. 1 H 7 1 3O 3 O 3A21 E8CE 2004030300191 20040303 00191 SO 2004 3 3 2004FA0000208 2 20040211 G 8530 AEC631397SN712B CYLINDER CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO ENGINE UNSERVICEABLE D K NONE O OTHER IN INSP/MAINT 1 NE 03 517404 INSPECTED NEW CYLINDER AS RECEIVED. FOUND EXHAUST VALVE GUIDE INSIDE DIAMETER TO BE BELOW MINIMUM SPECIFICATIONS, AND VA LVE SEAT MACHINING NOT CONCENTRIC. 1 H 7 1 3O 3 O 3A21 E8CE 2004030300196 20040303 00196 SO 2004 3 3 2004FA0000209 2 20040202 G 8530 AEC631397SN712 CYLINDER CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO ENGINE MISMANUFACTURED D K NONE O OTHER IN INSP/MAINT 1 NE 03 517404 INSPECTED NEW CYLINDER ASSY. AS RECEIVED. FOUND INSIDE DIAMETER OF EXHAUST VALVE GUIDE TO BE BELOW MINIMUM MFG. SPECS. AND VALVE SEAT MACHING NOT CONCENTRIC. 1 H 7 1 3O 3 O 3A21 E8CE 2004030300192 20040303 00192 SO 2004 3 3 2004FA0000210 2 20040202 G 8530 AEC631397SN712B CYLINDER CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO ENGINE MISMANUFACTURED D K NONE O OTHER IN INSP/MAINT 1 NE 03 517404 INSPECTED NEW CYLINDER ASSY AS RECEIVED. FOUND INSIDE DIAMETER OF EXHAUST VALVE GUIDE DID NOT MEET MINIMUM MFG. DIMENSI ONS, AND VALVE SEAT MACHINING NOT CONCENTRIC. 1 H 7 1 3O 3 O 3A21 E8CE 2004030300193 20040303 00193 SO 2004 3 3 2004FA0000211 2 20040202 G 8530 AEC631397SN712 CYLINDER CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO ENGINE MISMANUFACTURED D K NONE O OTHER IN INSP/MAINT 1 NE 03 517404 INSPECTED NEW CYLINDER ASSY AS RECEIVED. FOUND INSIDE DIAMETER OF EXHAUST VALVE GUIDE TO BE BELOW MINIMUM MFG SPECS., A ND VALVE SEAT MACHINING NOT CONCENTRIC. 1 H 7 1 3O 3 O 3A21 E8CE 2004030300194 20040303 00194 SO 2004 3 3 2004FA0000212 2 20040202 G 8530 AEC631397SN712 CYLINDER CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO ENGINE UNSERVICEABLE D K NONE O OTHER IN INSP/MAINT 1 NE 03 517404 INSPECTED NEW CYLINDER ASSY. AS RECEIVED. FOUND INSIDE DIAMETER OF EXHAUST VALVE GUIDE TO BE BELOW MINIMUM MFG. SPECS. AND VALVE SEAT MACHINING NOT CONCENTRIC. PRE-SIZED GUIDES ARE USED ON THIS UNIT AND 5 OTHERS IN THIS BATCH INSPECTED. ALL UNAIRWORTHY. ALL BALL SIZED. ALL BELL MOUTHED. 1 H 7 1 3O 3 O 3A21 E8CE 2004030300195 20040303 00195 SO 2004 3 3 2004FA0000213 2 20040202 G 8530 AEC631397SN712 CYLINDER CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO ENGINE UNSERVICEABLE D K NONE O OTHER IN INSP/MAINT 1 NE 03 517404 INSPECTED NEW CYLINDER ASSY. AS RECEIVED. FOUND INSIDE DIAMETER OF EXHAUST VALVE GUIDE TO BE BELOW MFG. MINIMUM SPECS. AND VALVE SEAT MACHINING NOT CONCENTRIC. 1 H 7 1 3O 3 O 3A21 E8CE 2004030300197 20040303 00197 SO 2004 3 3 2004FA0000214 2 20040202 G 8530 AEC631397SN712 CYLINDER CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO ENGINE UNSERVICEABLE D K NONE O OTHER IN INSP/MAINT 1 NE 03 517404 INSPECTED NEW CYLINDER ASSY. AS RECEIVED. FOUND INSIDE DIAMETER OF EXHAUST VALVE GUIDE TO BE BELOW MINIMUM MFG. SPECS. AND VALVE SEAT MACHINING NOT CONCENTRIC. 1 H 7 1 3O 3 O 3A21 E8CE 2004030300093 20040303 00093 SO 2004 3 3 2004FA0000215 2 20040218 G 8530 655166 VALVE GUIDE CONT CONT O520 IO520D 17032 SO CYLINDER LOOSE C K NONE O OTHER IN INSP/MAINT 1 WP 07 109 109 Q226 293450 MFG CYLINDER (109.9HRS) DISASSEMBLED FOR REASONS NOT RELATED TO THIS REPORT. INTAKE VALVE GUIDE FOUND TO BE ONLY FINGER TIGHT, NO INTERFERENCE FIT. P005 FOUND STAMPED NEXT TO GUIDE. 3 O E5CE 2004030300203 20040303 00203 SW 2004 3 3 2004FA0000216 1 20040217 G 3210 P1912506252M ROLL PIN MOONEY MOONEY M20 M20R 5870225 SW CONT O550 IO550G 17042 SO MCAULY 3A32C 3A32C418G GL LT MLG TUBE SHEARED C A UNSCHED LANDING J WARNING INDICATION DE DESCENT 1 GL 09 909WM 1923 182352 290152 679307 010286 SHEAR PINS ON LT MLG TUBE ASSEMBLY FAILED. AFT INSERT SEPARATED FROM TUBE ASSEMBLY. LT MAIN GEAR SUBSEQUENTLY REMAINE D UNSAFE AND RETRACTED UPON CONTACT WITH RUNWAY. RT MLG AND NOSE GEAR WERE IN THE DOWN AND LOCKED AT TIME OF LT MLG FAI LURE. 1 L 7 1 3O 3 O RT 2A3 E3SO 5 C P21EA 2004030400021 20040304 00021 CE 2004 3 4 2004FA0000217 1 20040124 G 1430 NAS679A4 NUT BEECH 58 58 1152740 CE CONT O520 IO520* 17032 SO HORIZONTAL STAB CRACKED D O OTHER O OTHER NR NOT REPORTED 1 SO 03 4423A 7200 TH28 NUTS ON SEVERAL HORIZONTAL STABILIZER REAR SPAR BOLTS WERE CRACKED OR BROKEN. NUT INSTALLED, NO NUTS HAD COME OFF AND B OLTS WERE NOT LOOSE IN SPAR. REPLACED NUTS AND NEW BOLTS WITH CURRENT HARDWARE. 1 L 7 2 3O 3 O 3A16 E5CE 2004030400024 20040304 00024 NE 2004 3 4 2004FA0000218 3 20040201 G 6110 C4784 PISTON PIPER PA 24 PA24180 7102402 CE MCAULY C3D36C C3D36C41582 NE PROPELLER SEIZED G O OTHER O OTHER NR NOT REPORTED 1 SO 03 912230 PISTON SEIZED IN HIGH PITCH POSITION TO PISTON ROD TUBE (HAD TO BE REMOVED AND PRESSED OUT OF PISTON PROP) WOULD NOT CYC LE ON AIRCRAFT. PISTON TUBE AND PISTON SENT TO MFG TECH REP. SUSPECT THAT PROP GOV WORN PARTS ALLOWED METAL INTO PROP AND SEIZED PISTON TUBE. MARKED AND GROOVED PARTS. 1 L 7 1 3O NT 1A15 5 N SA645NE 2004030400025 20040304 00025 WP 2004 3 4 2004FA0000219 1 20040113 G 6120 6873725012 O-RING AEROPRODTSXX CVAC 440 440 2422902 WP ALLSN 501D 501D13 03004 GL TRANSFER TUBE CUT B MV1R A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CR CRUISE 1 EA 17 49 33437 603 R242 479 AT CRUISE FLIGHT NR 1 PROP EXPERIENCED RPM FLUCTUATIONS. AS A PRECAUTIONARY MEASURE, PROP WAS FEATHERED. PILOT LANDED UNEVENTFULLY. FOUND REGULATOR TO PROP, OIL TRANSFER TUBE, O-RING CUT. INSTALLED NEW O-RING. GROUND RUN FUNCTIONAL AND LEAK CHECKS GOOD. 2 L 7 2 4R 4 T 6A6 E282 2004030400034 20040304 00034 GL 2004 3 4 2004FA0000221 2 20040128 G 7323 252469211 GOVERNOR BELL 206 206L3 1182108 SW ALLSN 250C 250C30P 03013 GL ENGINE FAILED D O OTHER O OTHER NR NOT REPORTED 1 SW 11 124AE 645 51591 CAE890804 SUSPECT HIGH END GOVERNOR FAILURE. OVERSPEED OF N2. (SW11200403763) 1 G 7 1 3U 3 U H2SW E1GL 2004030400035 20040304 00035 GL 2004 3 4 2004FA0000222 1 20040107 G 7160 BA111 CAGE CIRRUS SR SR22 2130001 GL AIR FILTER FAILED B NF2R O OTHER O OTHER NR NOT REPORTED 1 GL 03 547 WELDS FAILED ON AIR FILTER CAGE END THAT ATTACHES END RING. 1 L 7 1 3O NT A00009CH 2004030400041 20040304 00041 EA 2004 3 4 2004FA0000223 2 20040130 G 8520 LW16812 LIFTER CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA ENGINE WORN B FTUR K NONE O OTHER IN INSP/MAINT 1 NE 05 73827 1033 17267703 L23476T DURING A ROUTINE OIL CHANGE, WHILE COMPLYING WITH AD. MINUTE METAL PARTICLES WERE FOUND IN THE OIL FILTER WHEN IT WAS C UT OPEN FOR INSPECTION. HYDRAULIC LIFTERS WERE REMOVED FOR A MORE DETAILED INSP. THE ONE CAM LOBE FOR NR 3 AND NR 4 CY LINDERS HAD PLATING SEVERELY WORN OFF THE TOP OF THE LOBE AND THE BASE OF THOSE TWO LIFTERS HAD SEVERE DAMAGE. THIS ENG INE GETS FREQUENT OIL CHANGES. THIS ENGINE HAS THE 76T MOD INSTALLED INFORMATION WAS FORWARDED TO CERTIFICATION OFFICE. THIS ENGINE HAS BEEN REMOVED AND SENT FOR OVERHAUL. (NE05200404276) 1 H 7 1 3O 3 O NT 3A12 E274 2004030400047 20040304 00047 SO 2004 3 4 2004FA0000224 1 20040210 G 5542 63396802 SKIN PIPER PA28 PA28181 7102807 SO LYC O360 O360* 41514 EA RUDDER CRACKED B VJ3R K NONE O OTHER IN INSP/MAINT 1 WP 07 4166H 4759 4759 2843119 DURING PREFLIGHT, FLIGHT INSTRUCTOR FOUND THE RUDDER SKIN CRACKED. PROBABLE CAUSE AIR FLOW OVER THE SKIN. NO RECOMMEND ATIONS AT THIS TIME. 1 L 7 1 3O 3 O 2A13 E286 2004030400049 20040304 00049 SO 2004 3 4 2004FA0000225 1 20040206 G 2420 HOUSING PIPER PA28 PA28181 7102807 SO LYC O360 O360A4M 41514 EA ALTERNATOR BROKEN B VJ3R K NONE O OTHER IN INSP/MAINT 1 WP 07 4130W 99 D071998 2843204 L2847836A DURING ROUTINE INSPECTION, LOWER FRONT ATTACHMENT EAR FOR ALTERNATOR WAS FOUND TO BE CRACKED THROUGH AND BROKEN. PROBAB LE CAUSE IS VIBRATION, POOR MFG OR MATERIAL FAILURE. NO RECOMMENDATIONS AT THIS TIME. 1 L 7 1 3O 3 O 2A13 E286 2004030400050 20040304 00050 SO 2004 3 4 2004FA0000226 2 20040210 G 7310 631526 DIAPHRAGM BEECH 35 M35 1151526 CE CONT O470 IO470C 17026 SO FUEL MANIFOLD CRACKED D ET9T O OTHER O OTHER NR NOT REPORTED 1 NM 07 762AA 3600 D6168 718869C FUEL DIAPHRAGM ON THE FUEL MANIFOLD VALVE SHOWED DETERIORATION DUE TO AGEING. FUEL LEAKED OUT OF THE AIR BLEED HOLE ON THE FUEL MANIFOLD VALVE, CAUSING ENGINE FUEL FLOW PROBLEMS. ADDITIONAL INSPECTIONS AFTER PROLONGED STORAGE. 1 L 7 1 3O 3 O 3A15 E273 2004030400044 20040304 00044 2004 3 4 2004FA0000227 4 20040224 G 2562 AK450 ELT CESSNA 310 310N 2074234 CE CABIN FAILED P K NONE L NO TEST IN INSP/MAINT 1 CE 53 310VD 60 310N0123 FAILED ANNUAL TEST ON FIRST TEST. THIS IS THE SECOND FAILURE OF THIS ELT MODEL. THE FIRST ONE FAILED AFTER FIRST YEAR AL SO. THAT ONE WAS SERIAL NUMBER 50035. IN THIS FAILURE, BATTERIES ARE FINE, BUT THE UNIT IS DEAD ELECTRONICALLY. 1 L 7 2 3O 3A10 2004030400055 20040304 00055 EU 2004 3 4 2004FA0000229 1 20040217 G 5330 DOPE FILM AVIAT S2B PITTSS2B 2210308 EU LYC O540 AEIO540D4A5 41532 EA SKIN FABRIC DELAMINATED C K NONE O OTHER IN INSP/MAINT 1 EA 17 79D 560 5260 ALL OF THE DOPE FILM DELAMINATED FROM THE CECONITE 102 FABRIC. AFTER SEVERAL PHONE CALLS, IT WAS DETERMINED THAT IMPROP ER APPLICATION METHOD WAS USED. THE RANDOLPH DOPE PROCESS REQUIRES THE USE OF RANDO PROOF PRIMER FOR THE FIRST TWO COAT S ON CECONITE FABRIC AND THE FIBERS OF THE FABRIC MUST BE COMPLETELY ENCAPSULATED. AFTER ADDITIONAL CALLS, IT WAS DETER MINED THAT THE FACTORY OMMITED THE RANDO PROOF PRIMER STEP AND FAILED TO ENCAPSULATE THE FABRIC FIBERS RESULTING IN THE DELAMINATION OF THE DOPE FILM. (EA17200405558) 1 Q 7 1 3O 3 O NC A8SO 1E4 2004030400070 20040304 00070 GL 2004 3 4 2004FA0000230 1 20040220 G 5550 2055300099 SLEEVE DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240A SO RUDDER HINGE PIN LOOSE D K NONE O OTHER IN INSP/MAINT 1 NM 03 922AF C0179 THE SLEEVE ON THE RUDDER HINGE PIN CAME LOOSE FROM ITS LOCTITED POSITION ON THE PIN AND WORKED UP INTO THE CAVITY ABOVE THE BEARING ON THE FIN. RUDDER HAD CONSIDERABLE PLAY AT THE TOP. 1 L 7 1 3O 3 O NT TA4CH E7SO 2004030400080 20040304 00080 GL 2004 3 4 2004FA0000234 3 20040206 G 6110 C50462 PLATE CESSNA 182 R182 2072734 CE LYC O540 O540* 41532 EA MCAULY 2D34C B2D34C218 GL PROP BULKHEAD CRACKED D W59R K NONE O OTHER IN INSP/MAINT 1 WP 07 35G 144 R18201785 776893 DURING AN INSPECTION, THE BULKHEAD MOUNTING PLATES WERE FOUND CRACKED AND BROKEN AROUND THE HOLES THROUGH WHICH THE PROP ELLER MOUNTING STUDS PASS. THIS CONDITION IS FOUND VERY OFTEN AND THE PLATES REALLY NEED TO BE REDESIGNED TO NOT CRACK AS EASILY AS THEY DO NOW. SHOULD THE CRACKS GO UNDETECTED, FAILURE OF THE SPINNER ASSEMBLY AND DAMAGE TO THE PROPELLER AND COWLING WILL RESULT. (WP07200403102) 1 H 7 1 3O 3 O RT 3A13 E295 5 C P7EA 2004030400081 20040304 00081 GL 2004 3 4 2004FA0000235 1 20040206 G 2700 STRUCTURE AMTR AMD ALARUSCH2T 0033001 GL LYC O235 O235* 41505 EA STABILATOR CHAFED B KC5R O OTHER O OTHER NR NOT REPORTED 1 GL 13 622AM 28 201023 STABILATOR RUBS AGAINST FUSELAGE SCREW. .5 INCH GAP ON LT SIDE, .2500 INCH GAP ON RT SIDE. (GL13200405339) 1 L 7 1 3 O EXPA1L71 E223 2004030400082 20040304 00082 GL 2004 3 4 2004FA0000236 1 20040206 G 1430 FASTENER AMTR AMD ALARUSCH2T 0033001 GL LYC O235 O235* 41505 EA LT AILERONS CHAFED B KC5R O OTHER O OTHER NR NOT REPORTED 1 GL 13 622AM 28 201023 DEFLECTION OF LT AILERON UP CAUSES IT TO RUB AGAINST AN EXPOSED RIVET. DEFLECTION OF RT AILERON UP CAUSES IT TO RUB AGA INST TWO EXPOSED RIVETS POSSIBLY HINDERING TRAVEL. (GL13200405339) 1 L 7 1 3 O EXPA1L71 E223 2004030400085 20040304 00085 2004 3 4 2004FA0000237 4 20040206 G 6113 SPINNER AMTR AMD ALARUSCH2T 0033001 GL LYC O235 O235* 41505 EA PROPELLER CHAFED B KC5R O OTHER O OTHER NR NOT REPORTED 1 GL 13 622AM 201023 PROP SPINNER RUBS AGAINST COWL, INCH LONG AND GOING THOUGH FIBERGLASS COWL. (GL13200405339) 1 L 7 1 3 O EXPA1L71 E223 2004030400086 20040304 00086 GL 2004 3 4 2004FA0000238 1 20040206 G 5540 RUDDER AMTR AMD ALARUSCH2T 0033001 GL LYC O235 O235* 41505 EA VERTICAL STAB MISINSTALLED B KC5R O OTHER W INADEQUATE Q C NR NOT REPORTED 1 GL 13 622AM 201023 RUDDER CONTACTS FUSELAGE BEFORE REACHING STOPS. (GL13200405339) 1 L 7 1 3 O EXPA1L71 E223 2004030400087 20040304 00087 GL 2004 3 4 2004FA0000239 1 20040206 G 3250 BUNGEE CYLINDER AMTR AMD ALARUSCH2T 0033001 GL LYC O235 O235* 41505 EA NLG STEERING STIFF B KC5R O OTHER O OTHER NR NOT REPORTED 1 GL 13 622AM 201023 NOSE WHEEL STEERING BUNGEES ARE EXTREMELY STIFF, CAUSES THE RUDDER TO REQUIRE EXTREMELY HIGH RUDDER INPUTS IN FLIGHT. P ILOT CAN FEEL A BREAKOVER POINT. (GL13200405339) 1 L 7 1 3 O EXPA1L71 E223 2004030400090 20040304 00090 2004 3 4 2004FA0000240 4 20040206 G 3454 INDICATOR AMTR AMD ALARUSCH2T 0033001 GL LYC O235 O235* 41505 EA VOR SYSTEM INACCURATE B KC5R O OTHER O OTHER NR NOT REPORTED 1 GL 13 622AM 28 201023 NEWLY INSTALLED VORS INDICATORS 6-10 DEGREES DIFFERENCE. NAV 1 G430 W G5, NAV 2 BK W G5 KX 155. (GL13200405339) 1 L 7 1 3 O EXPA1L71 E223 2004030400092 20040304 00092 GL 2004 3 4 2004FA0000241 1 20040206 G 5260 STEP AMTR AMD ALARUSCH2T 0033001 GL LYC O235 O235* 41505 EA PAX DOOR LOOSE B KC5R O OTHER O OTHER NR NOT REPORTED 1 GL 13 622AM 201023 RT ENTRANCE STEP IS EXTREMELY LOOSE. (GL200305339) 1 L 7 1 3 O EXPA1L71 E223 2004030400094 20040304 00094 GL 2004 3 4 2004FA0000242 1 20040206 G 2810 FUEL TANK AMTR AMD ALARUSCH2T 0033001 GL LYC O235 O235* 41505 EA LT WING LEAKING B KC5R O OTHER K FLUID LOSS NR NOT REPORTED 1 GL 13 622AM 201023 WITH FULL FUEL TANKS AND THE AIRCRAFT ON THE GROUND AN AMOUNT OF FUEL (.5 GALLON +) WILL DRAIN FROM THE VENT OF THE LT F UEL TANK AFTER A FORWARD OR AFT MOVEMENT OF THE AIRCRAFT. (GL13200305339) 1 L 7 1 3 O EXPA1L71 E223 2004030400095 20040304 00095 GL 2004 3 4 2004FA0000243 1 20040206 G 5320 BRACKET AMTR AMD ALARUSCH2T 0033001 GL LYC O235 O235* 41505 EA CARB HEAT BROKEN B KC5R O OTHER O OTHER NR NOT REPORTED 1 GL 13 622AM 21 201023 CARB HEAT BRACKET BROKE LOOSE IN FLIGHT. 1 L 7 1 3 O EXPA1L71 E223 2004030400096 20040304 00096 2004 3 4 2004FA0000244 4 20040206 G 2300 AUDIO PANEL AMTR AMD ALARUSCH2T 0033001 GL LYC O235 O235* 41505 EA COCKPIT INOPERATIVE B KC5R O OTHER O OTHER NR NOT REPORTED 1 GL 13 622AM 13 201023 STEREO INPUT INTO AIRCRAFT DOES NOT WORK. (GL13200405339) 1 L 7 1 3 O EXPA1L71 E223 2004030400097 20040304 00097 GL 2004 3 4 2004FA0000245 1 20040206 G 1100 PLACARD AMTR AMD ALARUSCH2T 0033001 GL LYC O235 O235* 41505 EA TRIM CNTRL WHEEL MISSING B KC5R O OTHER O OTHER NR NOT REPORTED 1 GL 13 622AM 13 201023 DOES NOT INDICATE TAKEOFF POSITION, PLACARD MISSING. (GL13200405339) 1 L 7 1 3 O EXPA1L71 E223 2004030400089 20040304 00089 SO 2004 3 4 2004FA0000246 1 20040227 G 3210 400885 BOLT PIPER PA28 PA28R200 7102811 SO LYC O360 IO360A1A 41514 EA NLG DOWNLOCK MISSING D K NONE O OTHER IN INSP/MAINT 1 SO 05 15143 28R7335027 LANDING GEAR (IN-TRANSIT) LIGHT CAME ON INTERMITTENTLY. DURING TROUBLESHOOTING, FOUND NLG DOWNLOCK BOLT MISSING (GOES I N METAL BLOCK ON RT LOWER ENG MOUNT STRUCTURE). THIS IS THE BOLT THE DOWNLOCK HOOK ENGAGES IF THE NLG COLLAPSES. ORDERED REPLACEMENT BOLT AND INSTALLED IAW MM. RETRACTION CHECK OK. ENGINE MOUNT HAD BEEN REMOVED FOR REPAIR. WHEN IT WAS REIN STALLED, THE PART WAS PROBABLY NOT PUT BACK ON (UP LIMIT STOP BOLT WAS ALSO MISSING). THERE IS NO WAY THE GEAR RIG CHECK WAS GOOD AFTER REINSTALLATION OF MOUNT. RECOMMEND MAINTENANCE ACTIONS ON MAJOR ACFT SYSTEMS BE STRICTLY BY THE BOOK. L UCKILY THERE WAS NOT A HARD NOSE LANDING ON THIS ACFT WHILE THE BOLT WAS MISSING. 1 L 7 1 3O 3 O 2A13 1E10 2004030400091 20040304 00091 SO 2004 3 4 2004FA0000247 1 20040227 G 3210 453199 BOLT PIPER PA28 PA28R200 7102811 SO NLG UPLOCK MISSING D K NONE O OTHER IN INSP/MAINT 1 SO 05 15143 28R7335027 LANDING GEAR (IN-TRANSIT) LIGHT CAME ON INTERMITTENTLY. DURING TROUBLESHOOTING, FOUND NLG UP LIMIT BOLT MISSING. ORDER ED REPLACEMENT BOLT AND INSTALLED IAW MM. RETRACTION CHECK OK. ENGINE MOUNT HAD BEEN REMOVED FOR REPAIR. WHEN IT WAS RE INSTALLED, THE PART WAS PROBABLY NOT PUT BACK ON. THERE IS NO WAY THE GEAR RIG CHECK WAS GOOD AFTER REINSTALLATION OF MO UNT. 1 L 7 1 3O 2A13 2004030400093 20040304 00093 SO 2004 3 4 2004FA0000248 1 20040227 G 3230 67502000 RETAINER PIPER PA34 PA34200 7103405 SO LYC O360 IO360A1A 41514 EA RT MLG LOOSE D E H ENGINE SHUTDOWN DEACTIVATE SYST/CIRCUITS W INADEQUATE Q C LD LANDING 1 SO 05 15412 347350060 ON LANDING ROLL-OUT, RIGHT MLG COLLAPSED AFT AND CAME TO REST AGAINST AFT PORTION OF WHEEL WELL.RETAINING PIN HAD SLIPPE D OUT OF TRUNNION, ALLOWING GEAR TO COLLAPSE. THIS GEAR WAS PREVIOUSLY REMOVED FOR SPAR REPAIR. THE RETAINER BOLT WAS EI THER LEFT OUT OR WAS NOT INSTALLED CORRECTLY. OVER A PERIOD OF TIME, THE RETAINER SLID OUT OF THE TRUNNION. RECOMMEND P OST MAINTENANCE INSPECTIONS BE MORE COMPLETE. THIS INCIDENT, IF IT HAD HAPPENED 20 SECONDS EARLIER, WOULD HAVE CAUSED MA JOR STRUCTURAL DAMAGE AND POSSIBLY PERSONAL INJURY. 1 L 7 2 3O 3 O A7SO 1E10 2004030400088 20040304 00088 SO 2004 3 4 2004FA0000249 1 20040227 G 2810 63901038 HOSE PIPER PA28 PA28R200 7102811 SO LYC O360 IO360A1A 41514 EA FUEL SYSTEM MISROUTED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 05 15143 28R7335027 LANDING GEAR (IN-TRANSIT) LIGHT CAME ON INTERMITTENTLY. DURING TROUBLESHOOTING, FOUND FUEL FEED LINE FROM ELECTRIC PUMP TO ENGINE DRIVEN PUMP MISROUTED. HOSE WAS BEING JAMMED BETWEEN NLG TIRE AND ENGINE MOUNT WHEN GEAR IS RETRACTED. THIS CAUSED NLG TO INCOMPLETELY RETRACT, CAUSING UP-LIMIT SWITCH TO BE INTERMITTENT. REROUTED HOSE AND RIGGED GEAR PER MM. O PS CK OK.ENGINE MOUNT HAD BEEN REMOVED FOR REPAIR. WHEN IT WAS REINSTALLED, THE PART WAS PROBABLY NOT PUT BACK ON CORREC TLY AND NOT FOUND DURING POST MAINTENANCE INSPECTION. THERE IS NO WAY THE GEAR RIG CHECK WAS GOOD AFTER REINSTALLATION O F MOUNT. 1 L 7 1 3O 3 O 2A13 1E10 2004050600037 20040506 00037 2004 5 6 2004FA0000250 4 20040227 G 3416 AK350 ENCODER ALTITUDE FALSE INDICATION B QEDR O OTHER O OTHER NR NOT REPORTED 1 GL 17 ENCODER TESTED AND FOUND ALTITUDE OFF. CORRECTED AND RETEST THE NEXT DAY. RETURNED AIRCRAFT TO SERVICE. SAME DAY OF RTS THE MODE (C) WAS OFF. READJUSTED AND COULD NOT KEEP ENCODER FROM WANDERING AROUND. 2004050600038 20040506 00038 2004 5 6 2004FA0000251 4 20040227 G 3416 AK350 ENCODER ALTITUDE FALSE INDICATION B QEDR O OTHER O OTHER NR NOT REPORTED 1 GL 17 ENCODER TESTED AND FOUND ALTITUDE OFF. CORREECTED AND RETEAST THE NEXT DAY. RETURNED AIRCRAFT TO SERVICE. SAME DAY OF R TS THE MODE (C) WAS OFF. READJUSTED AND COULD NOT KEEP ENCODER FROM WANDERING AROUND. 2004040100160 20040401 00160 2004 4 1 2004FA0000255 4 20040105 G 3418 STALL WARNING DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240A SO FROZEN B FE4R O OTHER O OTHER NR NOT REPORTED 1 AL 03 102U 319 C0205 WE HAVE FOUND THAT THE STALL WARNING SYSTEM ON THIS TYPE OF AIRCRAFT IS PRONE TO FREEZE UP. MOISTURE IS INTRODUCED TO T HE SYSTEM THROUGH THE SENSORY HOLE IN THE LEFT WING. MOISTURE TRAVELS TO THE LOW POINT IN THE SYSTEM LOCATED IN THE AIR CRAFT BELLY AD FREEZES UP CAUSING THE STALL WARNING SYSTEM TO NOT FUNCTION. 1 L 7 1 3O 3 O NT TA4CH E7SO 2004040100163 20040401 00163 SO 2004 4 1 2004FA0000256 1 20040116 G 5720 62371008 HINGE PIPER PA28 PA28R200 7102811 SO LYC O360 IO360A1A 41514 EA IB RT AILERON WORN D O OTHER W INADEQUATE Q C NR NOT REPORTED 1 EA 01 56264 28R7535212 RECEIVED 2 NEW HINGES FROM API WITH EXCESSIVE PLAY BETWEEN PIN AND HINGE HALFES. DATE CODES: 12/23/03 AND 01/16/04. H INGES ARE MADE BY AC MFG. 1 L 7 1 3O 3 O 2A13 1E10 2004040100164 20040401 00164 EA 2004 4 1 2004FA0000257 2 20040101 G 8550 LW13388 GASKET PIPER PA32 PA32R300 7103213 SO LYC O540 TIO540* 41532 EA OIL FILTER FAILED G O OTHER K FLUID LOSS NR NOT REPORTED 1 WP 21 589Q 32R7780492 OIL FILTER CONVERTER PLATE GASKET (PN LW13388) PROTRUDED OUT OF THE PLATE CAUSING LOSS OF OIL AND SUBSEQUENT ENGINE SEIZ URE. RECOMMENDATION: CURRENT AD ALONG WIGH LYC SI CAN LEAD INTO MECHANIC TRAP. IF THE OIL FLITER CONVERTER PLATE KIT (PN LW-13904, THIS PROBLEM WOULD BE RESOLVED. (WP21200402668) 1 L 7 1 3O 3 O A3SO E14EA 2004040100165 20040401 00165 2004 4 1 2004FA0000258 4 20040105 G 6113 BULKHEAD CESSNA 172 172S 2072439 CE MCAULY 1A170 1A170E GL PROP SPINNER CRACKED B FE4R O OTHER O OTHER NR NOT REPORTED 1 AL 03 35339 162 172S8891 DURING A PRE-FLIGHT INSPECTION THE PILOT NOTED A .7500 INCH CRACK IN THE SPINNER BULKHEAD. THIS CRACK WAS IN THE CORNER NEXT TO THE SPINNER MOUNT NUTPLATE. SEVERAL PREVIOUS M OR D ON THIS SAME PART. 1 H 7 1 3O NT 3A12 5 N P857 2004040100166 20040401 00166 SO 2004 4 1 2004FA0000259 2 20040207 G 8530 SA10200A1 CYLINDER CESSNA 150 150F 2071814 CE CONT O200 O200A 17020 SO NR 4 BROKEN G O OTHER R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 EA 15 8745S 841 15062045 AIRCRAFT WAS SUBSTANTIALLY DAMAGED DURING A FORCED LANDING AFTER TOTAL LOSS OF ENGINE POWER. INVESTIGATION SHOWED THE C YLINDER HAD COMPLETELY SEPARATED IN THE MIDDLE WHILE IN FLIGHT, CAUSING THE TOTAL LOSS OF POWER. 1 H 7 1 3O 3 O 3A19 E252 2004040100169 20040401 00169 CE 2004 4 1 2004FA0000261 1 20040201 G 3243 988200104 MASTER CYLINDER CESSNA 172 172S 2072439 CE LYC O360 IO360A1A 41514 EA LT BRAKE INOPERATIVE B EHHR O OTHER O OTHER NR NOT REPORTED 1 EA 17 641SP 679 172S8049 PILOT REPORTED NO RESPONSE FROM LT BRAKE PEDAL, FOUND THAT BOTTOM LT BRAKE MASTER CYLINDER ATTACHMENT CLEVIS PIN MISSING . LOCATED CLEVIS PIN ON UPPERSIDE OF BELLY SKIN AND COTTER PIN. FOUND THAT COTTER PIN WAS BARELY BENT AND APPEARENTLY FELL OUT O F CLEVIS PIN HOLE THUS ALLOWING CLEVIS PIN TO FALL OUT OF BRAKE MASTER CYLINDER ATTACHMENT. 1 H 7 1 3O 3 O NT 3A12 1E10 2004040100170 20040401 00170 SW 2004 4 1 2004FA0000262 1 20040213 G 5753 190151 HINGE BBAVIA 8 8GCBC 1220803 SW LYC O360 O360C1E 41514 EA HARTZL HCC2Y HCC2YR1 GL TE FLAP CRACKED D K NONE O OTHER IN INSP/MAINT 1 AL 01 5060M 32679 L2722636A CH24256 CONDUCTED ANNUAL INSPECTION ON AIRCRAFT. FOUND BOTH LEFT AND RIGHT WING FLAP CONTROL ROD ATTACH POINTS TO CONTROL SURFA CES TO BE CRACKED. SPECULATE DAMAGE MAY HAVE BEEN INDUCED BY WIND ACTION AND LACK OF USE OF CONTROL SURFACE LOCK. 1 H 7 1 3O 3 O A21CE E286 5 C P920 2004040100171 20040401 00171 EA 2004 4 1 2004FA0000263 2 20040213 G 7414 IMPULSE COUPLING CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA MAGNETO CRACKED B NF1R O OTHER O OTHER NR NOT REPORTED 1 CE 07 9210H 1936 95120132 17266017 L4305327A ONE OF THE MAGNETO IMPULSE COUPLING PAWLS OR PAWL ATTACH RIVETS FAILED DURING TOUCH AND GO OPERATION. THE PAWL BROKE TH E MAGNETO MOUNTING CASTING AND DEPARTED THE AIRCRAFT. MAGNETO WAS HANGING FROM THE ACCESSORY HOUSING WITH THE HELP OF T HE IGNITION HARNESS. PILOT REPORTED ONLY A SLIGHT BACKFIRE DURING CLIMB OUT WITH A LITTLE LOSS OF POWER. MAGNETO HAD R ECEIVED A 500 HOUR INSPECTION 260 HOURS PRIOR TO FAILURE. IF FAILURE HAD OCCURRED DURING A LONG CROSS COUNTRY FLIGHT, T OTAL LOSS OF OIL MAY HAVE OCCURRED. (PILOT WOULD HAVE PROBABLY ADVANCED THROTTLE SLIGHTLY TO MAKE UP FOR ONE MAGNETO FA ILING AND DROPPING RPM SLIGHTLY). 1 H 7 1 3O 3 O NT 3A12 E274 2004040100172 20040401 00172 CE 2004 4 1 2004FA0000264 1 20040213 G 3244 TIRE CESSNA 172 172M 2072418 CE LYC O320 O320* 41508 EA NLG OUT OF BALANCE D O OTHER E VIBRATION/BUFFET TX TAXI/GRND HDL 1 SW 13 64107 17265023 PILOT REPORTED NOSE WHEEL SHIMMY AFTER TOUCH DOWN AND HIGH SPEED TAXI. INSPECTED NOSE GEAR AND NOTED SHIMMY DAMPENER AN D STEERING COLLAR BEARING A LITTLE MORE THAN NORMAL AXIAL MOVEMENT, TIRE STILL HAD 65 PERCENT TREAD AND SAW NO OBVIOUS TIRE DEFECTS. REMOVED NOSE STRUT TO INSPECT AND RESHIM STEERING COLLAR AND SERVICE/SHIM SHIMMY DAMPENER. WHEN THE NOSE STRUT LOWER FRONT HALF CLAMP WAS REMOVED, THE NOSE STRUT TUBE SPRUNG FORWARD .120 OUT OF ALIGNMENT WITH THE TOP STRUT M OUNT. FOUND NO DAMAGE TO AIRFRAME OR NO NOSE GEAR HISTORY. POSSIBLE LEAVING FACTORY LIKE THIS. INSPECTED AND RESHIMED NOSE GEAR ASSEMBLY AND LOWER STRUT CLAMP UP TO RELIEVE STRESS. MOUNTED NEW TIRE, DIFFERENT BRAND. NO SHIMMY DETECTED. 1 H 7 1 3O 3 O NT 3A12 E274 2004040100174 20040401 00174 EA 2004 4 1 2004FA0000265 2 20040129 G 7322 30768 FLOAT PIPER PA44 PA44180 7104402 SO LYC O360 O360E1A6 41514 EA CARBURETOR SATURATED B WIWR O OTHER K FLUID LOSS NR NOT REPORTED 1 WP 07 923RS 75132505 447995196 RL70177T PILOTS REPORTED THAT UPON LANDING THE LEFT ENGINE DIED AND THAT FUEL WAS DRIPPING FROM THE COWLING. MAINTENANCE INSPECT ED LEFT ENGINE AND COULD NOT FIND FUEL LEAKAGE. AIRCRAFT WAS GROUND RUN AND OPERATIVE NORMALLY EXCEPT AT IDLE. AT IDLE AIRCRAFT RAN SMOOTHLY FOR ABOUT 15 TO 20 SECONDS AND THEN WOULD BEGIN TO DIE AS IF THE ENGINE WAS EXCESSIVELY RICH. MI XTURE WAS LEANED TO ICO AND ENGINE CONTINUED TO RUN AND THERE WAS FUEL DRIPPING FROM THE AIRBOX. CARBURETOR WAS REMOVED FROM THE AIRCRAFT AND THE TOP OPENED. THE FLOAT INSIDE THE CARBURETOR WAS FOUND TO BE HALF FILLED WITH FUEL. MFG TO M ONITOR PRODUCTION OF FLOATS. (WP07200410619) 1 L 7 2 3O 3 O A19S0 E286 2004040100175 20040401 00175 CE 2004 4 1 2004FA0000266 1 20040218 G 3260 12700344 SAFETY SWITCH CESSNA 337 337H 2075732 CE CONT O360 IO360GB 17025 SO MCAULY 2AF34C D2AF34C* GL NLG DAMAGED B LX5R A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 GL 19 1244S 5920 33701892 236691R 780550 AFTER TAKE OFF PILOT WAS UNABLE TO RETRACT THE LANDING GEAR, THE GEAR DID SHOW DOWN AND LOCKED. THE PLANE LANDED WITHOU T INCIDENT. FOUND NOSE GEAR SAFETY SWITCH BAD INTERNALLY NOT ALLOWING NOSE GEAR TO RETRACT, (SENSING STILL ON GROUND). IT IS SUSPECTED THAT THIS WAS NORMAL WEAR OF SWITCH. THERE WAS NO EVIDENCE OF EXTERNAL DAMAGE. 1 H 7 2 3O 3 O A6CE E1CE 5 C P5EA 2004040100176 20040401 00176 CE 2004 4 1 2004FA0000267 1 20040212 G 3297 SM50D7 RELAY BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO MLG INTERMITTENT B VJ3R O OTHER O OTHER NR NOT REPORTED 1 WP 07 1565A CE1331 825800R PILOT REPORTED THAT LANDING GEAR WOULD NOT EXTEND. AFTER GEAR HANDLE CYCLED SIX TIMES GEAR CAME DOWN. UPON TROUBLESHOO TING OF THE LANDING GEAR SYSTEM FOUND LANDING GEAR DYNAMIC RELAY INTERMITTENT. NO RECOMMENDATIONS AT THIS TIME. 1 L 7 1 3O 3 O 3A15 E5CE 2004042700003 20040427 00003 WP 2004 4 27 2004FA0000269 1 20040214 G 7712 6510043 GAUGE HUGHES 369 369E 4470707 WP ALLSN 250C 250C20R2 GL TORQUE INACCURATE D A UNSCHED LANDING N FALSE WARNING NR NOT REPORTED 1 WP 05 1726B 2231 829 0551E PILOT REPORTED OPERATIONAL EXCEEDANCE DURING FLIGHT RETURNED AC TO HELIPORT. UPON FURTHER INSPECTION AND EVALUATION IT WAS DETERMINED THAT THE DIAMOND J. TORQUE GAUGE WAS READING APPROX 15 LBS. LOW. AT 60 KNOTS AIRSPEED TORQUE READING 26- 27 LBS. NORMAL READING 42 LBS. HOVERING BEFORE TAKEOFF, FIFTY POUND RANGE NORMAL IS 65 LBS. GROUNDED AIRCRAFT, REMOVAL INSTRUMENT AND TRANSDUCER SENT TO MANUFACTURE FOR TESTING AND EVALUATION. 1 G 7 1 3U 3 U H3WE E4CE 2004042300011 20040423 00011 SO 2004 4 23 2004FA0000270 1 20040205 G 2822 BEARING PIPER PA32 PA32R300 7103213 SO LYC O540 IO540K1A5 41532 EA HARTZL HCC2Y HCC2YK1 GL BOOST PUMP WORN D O OTHER O OTHER NR NOT REPORTED 1 AL 03 200HM 2AV3 32R7680025 RL2471148A CH34707 CIRCUIT BREAKER POPPED DUE TO FUEL PUMP ELECTRICAL DRAW ON SYSTEM HIGH RESISTANCE. 1 L 7 1 3O 3 O A3SO 1E4 5 C P920 2004042300012 20040423 00012 SW 2004 4 23 2004FA0000271 1 20040219 G 6720 407340334101 BEARING BELL 407 407 1182206 SW ALLSN 250C 250C47B GL T/R CONTROL SEIZED D O OTHER O OTHER NR NOT REPORTED 1 WP 17 601MT 843 53428 BEARING SEIZED DURING TRAINING FLIGHT, RESULTING IN D/S FAILURE AND LOSS OF T/R CONTROL ALLOWING THE TAIL ROTOR BLADES T O STRIKE TAILBOOM. (WP17200403114) 1 G 7 1 3U 3 U O H2SW E1GL 2004042700007 20040427 00007 NE 2004 4 27 2004FA0000272 2 20040213 G 7310 0301007710 PIPE SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE LT FUEL INJECTOR CRACKED D O OTHER K R J FLUID LOSS PARTIAL RPM/PWR LOSS WARNING INDICATION TX TAXI/GRND HDL 1 SW 15 448AE 704 3210 9639 DURING ENGINE START AFTER CHANGING THE START DRAIN VALVE, LT FUEL INJECTOR PIPE WAS SPRAYING FUEL AT INJECTOR FITTING. INSPECTION OF PIPE REVEALED A CACK AT THE TOP OF THE FLARE ON THE PIPE. CAUSE OF CRACK APPEARS TO BE FROM THE FLARE NOT BEING CENTERED ON THE LINE DURING MANUFACTURE. 1 G 7 1 3U 3 U H9EU E19EU 2004042700008 20040427 00008 CE 2004 4 27 2004FA0000274 1 20040217 G 3220 5082020517 DRAG BRACE BEECH 1900 1900D 1154162 CE PWA PT6 PT6* 52043 EA HARTZL HCE4A HCE4A3A NE NLG CORRODED D O OTHER O OTHER NR NOT REPORTED 1 GL 03 842E UE336 THE LOWER BOLT WAS SEVERELY CORRODED IN PLACE REQUIRING IT TO BE DRIVEN OUT FOR REPLACEMENT. THIS BOLT, CENTER DRAG BRA CE ASSY PIVOT, IS LUBRICATED ON BOTH ENDS VIA THRU BOLT GREASE PROVISIONS. THE CENTER PORTION HAS NO PROVISION FOR GREA SE SINCE THIS AREA IS NON ROTATING. THERE IS NO REQUIREMENT TO REMOVE THIS BOLT UNTIL THE 5 YEAR OVERHAUL BY WHICH TIME THE BOLT AND DRAG BRACE HAVE CORRODED TO THE POINT OF REQUIRING REPLACEMENT. 2 L 7 2 4T 3 T RT A24CE E2NE 5 C P10NE 2004042700011 20040427 00011 SO 2004 4 27 2004FA0000275 1 20040227 G 3240 D2113 BRAKE ASSY PIPER J3 J3C65 7100510 SO CONT A65 A65* 17003 SO RT MLG BROKEN D K NONE O OTHER IN INSP/MAINT 1 GL 15 25WF 5671 AFTER DISASSEMBLY OF THE RT WHEEL AND BRAKE COMPONENTS FOR INSPECTION, ONE OF SIX BRAKE BLOCK (NR B27-59-D) WAS FOUND TO BE BROKEN, AND ONE OF SIX SPRING RETAINERS (NR R21-35) WAS FOUND TO BE BROKEN, AND LOOSE. THIS CLIP (RETAINER) MAY HAV E JAMMED UNDER A BRAKE BLOCK AND CAUSED THE RT WHEEL TO DRAG EXCESSIVELY ENOUGH TO CAUSE LOSS OF CONTROL DURING THE LAND ING ROLLOUT. ACTUAL TIME OF SERVICE FOR COMPONENTS ARE UNKNOWN. 1 H 7 1 3O 3 O A691 E205 2004042700012 20040427 00012 SO 2004 4 27 2004FA0000276 1 20040224 G 2424 68804007 VOLT REGULATOR PIPER PA28 PA28181 7102807 SO LYC O360 O360C1F 41514 EA LT KICK PANEL FAILED B VJ3R O OTHER J WARNING INDICATION TX TAXI/GRND HDL 1 WP 07 4188T 1 2843124 ALTERNATOR INOPERATIVE LIGHT CAME ON DURING GROUND RUN UP. TROUBLESHOOT SYSTEM AND FOUND NO OUTPUT VOLTAGE TO THE FIELD WIRE. PROBABLE CAUSE REGULATOR FAILED INTERNALLY, NO RECOMMENDATIONS AT THIS TIME. 1 L 7 1 3O 3 O 2A13 E286 2004042300016 20040423 00016 SO 2004 4 23 2004FA0000277 2 20040224 G 8530 CYLINDER PIPER PA34 PA34200T 7103406 SO CONT O360 LTSIO360EB 17025 SO ENGINE LEAKING B FFKR O OTHER O OTHER NR NOT REPORTED 1 SO 05 1063X 1058 394 347570198 807611R VALVE COVER GASKETS ON RT ENGINE WERE SEEPING. PROCEEDED TO CHANGE GASKETS ON NR 1 CYLINDER AND DISCOVERED THE LOCKING SAFETY FOR THE NUTS ON THE VALVE ROCKER ARM WERE NOT BENT TO SECURE THE NUT FROM BACKING OFF. INSPECTED ALL 6 CYLINDERS AND FOUND ALL SIX TO BE IN THE SAME CONDITION. CHECKED TORQUE ON THE NUTS AND BENT LOCK TANGS. NO FURTHER ACTION WAS REQUIRED. AFTER REVIEW OF ENGINE LOG BOOK, THIS ENGINE WAS DISASSEMBLED IN APRIL OF 2003 FOR A PROP STRIKE. SUSPECT TH IS TO BE AN ISOLATED INCIDENT. 1 L 7 2 3O 3 O A7SO E9CE 2004042700043 20040427 00043 EA 2004 4 27 2004FA0000278 2 20040223 G 8520 LW11750 CONNECTING ROD PIPER PA32 PA32260 7103206 SO LYC O540 O540E4B5 41532 EA ENGINE BROKEN G A UNSCHED LANDING R Y PARTIAL RPM/PWR LOSS ENGINE STOPPAGE CR CRUISE 1 GL 03 3370W 6526 1381 32216 L1034040 WHILE IN CRUISE FLIGHT, ENGINE STARTED TO RUN ROUGH, CATASTROPHIC ENGINE FAILURE OCCURED. PILOT MADE AN EMERGENCY LANDI NG, MINOR DAMAGE TO AIRCRAFT. INSPECTION OF FAILED ENGINE REVIELD A BROKEN NR 1, (ONE) CONNECTING ROD. 1 L 7 1 3O 3 O A3SO E295 2004042200133 20040422 00133 EU 2004 4 22 2004FA0000280 1 20040226 G 6320 7052A3652038 PLUG UROCOP EC120 EC120B 8680987 EU TMECA ARRIUS ARRIU2F NE GEARBOX LOOSE D E ENGINE SHUTDOWN K J FLUID LOSS WARNING INDICATION TX TAXI/GRND HDL 1 SW 17 1240W 1240 PILOT STARTED ENGINE, COMPLETED CHECKLIST AND (BEEPS) IN HEADSET AND VISUAL WARNING ON CAUTION PANEL OF MAIN GEAR BOX (L OW OIL PRESSURE). SHUT DOWN ENGINE AND OPENED COWL, TRANSMISSION FILLED WAS COVERING BOTH ENGINE DECK AND TRANSMISSION DECK. DISCOVERED THAT THE BLANKING PLUG HAD COME LOOSE FROM TRANS INPUT FLANGE CAUSING LOSS OF TRANS FLUID. THIS (LOOS E BLANKING PLUG) ADDRESSED IN ALERT SB 63-003, WHEN THIS EVENT HAPPENS IT IS NOT JUST A SMALL LEAK WITH MINOR CONSEQUENC ES, BUT A MAJOR LEAK, EMPTYING THE TRANSMISSION WITHIN A SHORT PERIOD CAUSING A POWER REDUCTION IAW FLIGHT MANUAL, A RUN ON LANDING, OR POSSIBLE CRASH. 1 G 7 2 3U 3 U NC R0001RD E34NE 2004032200111 20040322 00111 CE 2004 3 22 2004FA0000282 1 20040315 G 3244 178K235 TIRE LEAR 35 35A 5170602 CE MLG FAILED C O OTHER D INFLIGHT SEPARATION TO TAKEOFF 1 SO 07 35SM 419 TREAD ON RIGHT MAIN LANDING GEAR OUTBOARD TIRE SEPARATED ON TAKEOFF. THE TIRE WAS INSTALLED ON FEBRUARY 8, 2002. AT TH AT TIME THE AIRCRAFT TOTAL TIME WAS 3683.3 ON MARCH 7, 2004 THE TREAD SEPARATED, AT THE TIME OF SEPARATION THE AIRCRAFT TOTAL TIME WAS 3889. 2 L 7 2 4F A10CE 2004050300203 20040503 00203 CE 2004 5 3 2004FA0000284 1 20040303 G 3230 0541153 U BOLT CESSNA 172 172F 2072414 CE CONT O300 O300* 17022 SO LT GEAR LEG SHEARED D O OTHER O OTHER NR NOT REPORTED 1 NE 05 5705R 3600 17253359 FOUND U BOLT ON LT MAIN GEAR SHEARED IN THREAD AREA UNDER NUT. PROBABLY NUT WAS OVERTORQUED. 1 H 7 1 3O 3 O NT 3A12 E253 2004050400051 20040504 00051 2004 5 4 2004FA0000285 4 20040316 G 2561 GA12P0201 LIFE VEST CABIN FAILED B KQ1R O OTHER O OTHER NR NOT REPORTED 1 EA 07 INDIVIDUAL FLOAT DEVICE FAILED. MFG RECOMMENDED CELL PRESSURE TEST IAW 25-60-13. DOM: JULY 1980. 2004050300204 20040503 00204 EU 2004 5 3 2004FA0000286 1 20040128 G 6321 3637GR85 ROD END AGUSTA A109 A109E 0260119 EU ROTOR BRAKE BROKEN D O OTHER O OTHER NR NOT REPORTED 1 EA 17 109DU 11503 ON SHUTDOWN A BUMP WAS FELT WHEN ENGINES WERE SET TO IDLE, SHUTDOWN AND WHEN ROTOR BRAKE WAS APPLIED. ON POST FLIGHT BR OKEN DAMPER ROD END WAS FOUND. PROBABLE CAUSE WAS POSSIBLE MATERIAL DEFECT. AD2003-26-04 DAMPER ROD END INSPECTION ADD RESSES THIS PROBLEM. 1 G 7 2 3U RT H7EU 2004051000043 20040510 00043 SO 2004 5 10 2004FA0000287 1 20040219 G 2701 20965 CONTROL WHEEL PIPER PA30 PA30 7103002 SO LYC O320 IO320* 41508 EA PILOT CRACKED C K NONE O OTHER IN INSP/MAINT 1 SO 35 752CF 5839 30592 A CRACK WAS FOUND IN THE CO-PILOT CONTROL WHEEL WHEN IT WAS REMOVED. THE BOTTOM OF THE WHEEL FROM FRONT TO REAR THROUGH THE PIN HOLE. THIS CRACK IS NOT VISABLE FROM THE OUTSIDE. 1 L 7 2 3O 3 O A1EA 1E12 2004050600057 20040506 00057 EA 2004 5 6 2004FA0000289 2 20040301 G 7324 2526388 DIAPHRAGM LYC O540 IO540* 41532 EA FUEL DIVIDER IMPROPER B CY4R K NONE O OTHER IN INSP/MAINT 1 AL 03 MATERIAL TOO THIN OR TOO SOFT. WHEN TORQUING RETAINING SCREW MATERIAL SQUEEZES OUT WITH NR 5 TORQUE. FUEL FLOW DIVIDER , BENDIX. 3 O 1E4 2004042200186 20040422 00186 EA 2004 4 22 2004FA0000290 2 20040315 G 7414 COIL PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA HARTZL HCE3Y HCE3YR2A GL MAGNETO INOPERATIVE C O OTHER O OTHER NR NOT REPORTED 1 AL 01 712MA G03JA028R 317405217 L55868A DJ8171A WEAK COIL, SUSPECT BREAK DOWN IN COIL. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004050600078 20040506 00078 CE 2004 5 6 2004FA0000291 1 20040318 G 5312 05530315 FIREWALL CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA MCAULY 1C235 1C235LFA GL FUSELAGE CRACKED C O OTHER O OTHER NR NOT REPORTED 1 SO 13 98528 500 17280605 L769436A R1152 LOWER FIREWALL NUMEROUS CRACKS IN LOWER LEFT SIDE ZONE, 124, RADIATING FROM LOWER BATTERY MOUNT AND COWL MOUNT BRACKETS. THIS IS THE THIRD FIREWALL THAT DEVELOPED CRACKS IN THE SAME AREA. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P12EA 2004050300169 20040503 00169 SO 2004 5 3 2004FA0000292 2 20040305 G 8530 24077 RETAINER CESSNA 172 172D 2072410 CE CONT O300 O300D 17022 SO CYLINDER FAILED D O OTHER O OTHER NR NOT REPORTED 1 NM 11 2650U 17250250 2513770R FOUND UPPER VALVE RETAINER ABOUT 09 PERCENT WORN THROUGH BY OUTER SPRING (PN 625958) BUT HAD NOT FAILED YET. PN 24077 U PPER VALVE SPRING RETAINER. 1 H 7 1 3O 3 O NT 3A12 E253 2004050600080 20040506 00080 SO 2004 5 6 2004FA0000293 2 20040305 G 8530 RETAINER CESSNA 172 172D 2072410 CE CONT O300 O300D 17022 SO ENGINE WORN D O OTHER R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 NM 08 2650U 17250250 2513770R FOUND PN 24077, UPPER VALVE SPRING RETAINER WORN OUT ALLOWING VALVE SPRING TO BYPASS IT. CAUSED LOSS OF STATIC RPM AND SOME ROUGHNESS OCCASIONALLY. 1 H 7 1 3O 3 O NT 3A12 E253 2004050600062 20040506 00062 CE 2004 5 6 2004FA0000295 1 20040127 G 2842 58380019 SENSOR BEECH 55 E55 1152732 CE CONT O520 IO520* 17032 SO FUEL TANK FAULTY D O OTHER O OTHER NR NOT REPORTED 1 NM 08 4000W TE1004 FLOAT DOES NOT BRING ARM TO FULL UP STOP WHEN SUBMERGED. IT WILL COME UP TO APPROX .7500 TO .8750 OF ITS TRAVEL. TAPPI NG ON THE HOUSING WILL EVENTUALLY BRING IT TO THE UP STOP. THIS, IAW MFG, DOES NOT MEET THEIR SPECIFICATIONS. THE FLOA T APPEARS TO NOT HAVE ENOUGH BUOYANCY. FOUR (4) OF THESE TRANSMITTERS WERE TRIED, WITH NO FAVORABLE RESULTS. 1 L 7 2 3O 3 O 3A16 E5CE 2004042200125 20040422 00125 CE 2004 4 22 2004FA0000296 1 20040325 G 5523 1695240761 ROD BEECH 23 C23 1151242 CE LYC O360 O360* 41514 EA TRIM TAB CORRODED D O OTHER O OTHER NR NOT REPORTED 1 GL 09 24652 M1430 DURING ANNUAL INSPECTION THE TRIM TAB ROD WAS FOUND TO HAVE RUST ON IT. WHILE CLEANING THE PART, A HOLE WAS FOUND AT TH E MID POINT OF THE ROD AND MOISTURE(WATER) WAS FOUND INSIDE. IT APPEARS THIS ROD IS RUSTING FORM THE INSIDE OUT. THIS UNIT SHOULD BE TAKEN APART, INSPECTED, CLEANED, PAINTED INSIDE AND OUT AND REASSEMBLED TO ASURE THE AIRCRAFT HAS A SERVI CEABLE PART. (GL092004040017) 1 L 7 1 3O 3 O A1CE E286 2004050600068 20040506 00068 2004 5 6 2004FA0000297 4 20040206 G 3418 DETECTOR CESSNA 421 421C 2076016 CE CONT O520 GTSIO520* 17032 SO STALL WARNING INOPERATIVE D O OTHER N FALSE WARNING NR NOT REPORTED 1 GL 27 421ZM 421C1058 THIS NEWLY OVERHAULED DETECTOR WAS INSTALLED AND OPS CHECKED AFTER A COUPLE OF CHECKS THE STALL HORN WILL STAY ON. RETU RNED UNIT FOR ANOTHER O/HED DETECTOR. THIS ABOUT SECOND AIRCRAFT I WENT THROUGH THIS WITH (ORDERING DETECTORS UNTIL I G ET ONE THAT WORKED. NEED BETTER QC). 1 L 7 2 3O 3 O A7CE E7CE 2004042200148 20040422 00148 CE 2004 4 22 2004FA0000298 1 20040315 G 5312 07126167 BULKHEAD CESSNA 182 182P 2075816 CE CONT O470 O470* 17026 SO AFT FUSELAGE CRACKED D O OTHER O OTHER NR NOT REPORTED 1 WP 05 20844 2890 18261251 DURING COMPLIANCE WITH AD72-07-09 REFERENCED BUKHEAD WAS FOUND CRACKED PART REPLACED WITH NEW. SUSPECT FAILURE OCCURRED DUE TO AGE. 1 H 7 1 3O 3 O NT TA13 E273 2004042200181 20040422 00181 2004 4 22 2004FA0000300 4 20040308 G 2210 BRIDAL CABLE CESSNA 172 172S 2072439 CE LYC O360 IO360B1E 41514 EA ROLL SERVO WORN B EHHR O OTHER O OTHER NR NOT REPORTED 1 EA 17 642SP 462 172S8050 ROLL SERVO BRIDLE CABLE WAS IMPROPERLY INSTALLED. TOP PORTION OF CABLE WAS WRAPPED AROUND PRIMARY AILERON CABLE, CAUSIN G BRIDLE CABLE TO CHAFE AGAINST A PULLEY FLANGE. INSTALLATION OF CABLE ASSEMBLY OCCURRED AT THE FACTORY AND HAS NOT BEE N REPLACED SINCE AIRCRAFT WAS MANUFACTURED. REPAIRED BY REMOVING BRIDLE CABLE AND INSTALLING CABLE CORRECTLY. (EA17200 405907) 1 H 7 1 3O 3 O NT 3A12 1E10 2004050300141 20040503 00141 NM 2004 5 3 2004FA0000301 1 20040326 G 2530 BS0063 COUPLER BOEING 717 717200 1383700 NM COFFEEMAKER INOPERATIVE B K NONE L NO TEST IN INSP/MAINT 1 SO 15 02120207 OPTO COUPLER (MOD-16) INSTALLED BY MFG IS MISWIRED, CAUSING OVER TEMP PROTECTION CIRCUIT TO BECOME INOPERATIVE. 2 L 7 2 4F TR A6WE 2004050600042 20040506 00042 CE 2004 5 6 2004FA0000302 1 20040325 G 3210 101810505 STOP BEECH B300 B300B350C CE DRAG LEG STOP MISINSTALLED C K NONE O OTHER NR NOT REPORTED 1 SW 07 FOUND DRAG LEG STOPS INSTALLED UPSIDE DOWN. STOPS CAUSED DAMAGE TO THE UPPER DRAG LEG. UPPER DRAG LEG CANNOT HAVE ANY DA MAGE IAW THE COMPONENT MM. NO PREVIOUS MAINTENANCE PERFORMED ON THE LANDING GEAR. SUSPECT AIRCRAFT WERE DELIVERED WITH THIS PROBLEM. 2 L 7 2 4T RT A24CE 2004051000040 20040510 00040 EA 2004 5 10 2004FA0000303 2 20040402 G 7314 200F5003 PUMP PIPER PA31 PA31350 7103110 SO LYC O540 TIO540* 41532 EA FUEL SYSTEM LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 SO 05 350PC 318152006 DURING ENGINE 100 HOUR INSPECTION AND SERVICE FOUND THAT THE ENGINE DRIVEN FUEL PUMP LEAKING FUEL FROM THE REGULATOR HOU SING. (SO05200407947) 1 L 7 2 3O 3 O A20SO E14EA 2004042200160 20040422 00160 GL 2004 4 22 2004FA0000304 3 20040322 G 6114 D4883 HUB MCAULY MCAULY 2AF34C 2AF34C55 GL PROPELLER CRACKED B L2PR O OTHER K FLUID LOSS NR NOT REPORTED 1 SW 13 740453 PROPELLER WAS LEAKING RED DYE FROM HUB, PROP WAS DISASSEMBLED FOR RESEAL AND INSPECTION, CRACK WAS NOTED DURING VISUAL I NSPECTION AND CONFIRMED BY EDDY CURRENT. PROBABLE CAUSE FOR CRACK IS FATIGUE FAILURE, RED DYE/ OIL IS PLACED INSIDE HUB TO DETECT POSSIBLE CRACKS BEFORE CATASTROPHIC FAILURE (AD 91-15-04), MANY OWNER/OPERATORS ARE NOT AWARE OF THE SIGNIFIC ANCES OF THESE LEAKS AND IGNORE THEM. 5 C P5EA 2004050300209 20040503 00209 EA 2004 5 3 2004FA0000305 2 20040407 G 8520 SL13521 ROD BEARING PIPER PA32 PA32260 7103206 SO LYC O540 O540E4B5 41532 EA NR 6 POSITION DELAMINATED B YYBR O OTHER O OTHER NR NOT REPORTED 1 GL 03 L1034040 ENGINE EXPERIENCED FAILURE OF CONNECTING ROD BOLT, PN 74644 OR DELAMINATION OF CONNECTING ROD BEARING, PN SL 13521 IN N R 6 CONNECTING ROD POSITION. NOT SURE WHICH CAUSED THE FAILURE OF THE ENGINE. A ROD BEARING HALF WAS FOUND IN THE SUMP , MANGLED BUT INTACT; ITS MATE HAD DISINTEGRATED AND WAS SCATTERED THROUGHOUT THE ENGINE. THE ROD BOLT IN QUESTION WAS MISSING THREADS, AND WAS BLUE IN COLOR FROM EXCESSIVE HEAT. THE ROD NUT AND BOLT HEAD WERE NOT FOUND IN THE ENGINE AND SUSPECTED THAT THEY EXITED THE CRANKCASE THROUGH THE HOLE CREATED BY THE CONNECTING ROD BEING THROWN OFF THE CRANKSHAFT . THE ENGINE DID NOT SHOW SIGNS OF OIL STARVATION OR PROBLEMS WITH ANY OF THE OTHER CONNECTING ROD BEARINGS OR BOLTS. 1 L 7 1 3O 3 O A3SO E295 2004050600076 20040506 00076 CE 2004 5 6 2004FA0000306 1 20040409 G 2720 S100343A BEARING CESSNA 182 182S 2072701 CE LYC O540 IO540* 41532 EA RUDDER BAR MISSING D K NONE O OTHER IN INSP/MAINT 1 WP 15 182TA 18280062 DURING THE ANNUAL INSPECTION, IT WAS DETERMINED THAT THE BEARING FOR THE CO-PILOT RT RUDDER BAR TO BRAKE BELLCRANK WAS M ISSING. THE FACTORY TORQUE SEAL ON THE ATTACHING HARDWARE WAS UNDISTURBED. 1 H 7 1 3O 3 O NT 3A13 1E4 2004050600025 20040506 00025 CE 2004 5 6 2004FA0000307 1 20040409 G 2497 103003 WIRE CESSNA 172 172P 2072436 CE LYC O320 O320* 41508 EA ALTERNATOR SHORTED D O OTHER O OTHER NR NOT REPORTED 1 GL 15 54589 383 17275007 THE 3 WIRES COMING FROM THE STATOR WERE SHORTED OUT ON THE CASE, THIS IS THE 4TH ALTERNATOR OVERHAULED WITH THE SAME FAI LURE. WITH LESS THAN 390.0 HOURS SINCE OVERHAUL. WIRES NOT INSULATED PROPERLY. 1 H 7 1 3O 3 O NT 3A12 E274 2004050700031 20040507 00031 SW 2004 5 7 2004FA0000308 1 20040413 G 6220 206010450113 SWASHPLATE BELL 206 206L3 1182108 SW ALLSN 250C 250C30 03013 GL MAIN ROTOR INCORRECT D O OTHER W INADEQUATE Q C NR NOT REPORTED 1 WP 01 383SH 12050 51073 RECEIVED SWASHPLATE ASSY FROM VENDOR OVERHAUL SHOP. DURING INSTALLATION FOUND LEVER (PN 206-010-467-001) WAS INSTALLE D UP-SIDE-DOWN. ALSO FOUND SHIMS (PN 206-010-463-005) WERE NET STACKED EVENLY. PROBABLE CAUSE: WORKMANSHIP AND QA PROB LEM. 1 G 7 1 3U 3 U H2SW E1GL 2004042200124 20040422 00124 NE 2004 4 22 2004FA0000309 2 20040401 G 7250 557501 TURBINE WHEEL PWA JT8 JT8D7B 52053 NE ENGINE WORN B ZAVR O OTHER O OTHER NR NOT REPORTED 1 WP 07 7381 4723 649049 T-1 DISC RUB ON INNER TURBINE NOZZLE CASE SEAL. SEAL COMPLETELY RUBBED OFF. 4 F E2EA 2004042300001 20040423 00001 GL 2004 4 23 2004FA0000310 3 20040322 G 6114 HUB MCAULY 2AF34C 2AF34C55 GL PROPELLER FATIGUED B L2PR O OTHER O OTHER NR NOT REPORTED 1 SW 13 714499 PROPELLER WAS LEAKING RED DYE FROM HUB, PROPELLER WAS DISASSEMBLED FOR RESEAL AND INSPECTION, CRACK WAS NOTED DURING VIS UAL INSPECTION AND CONFIRMED BY EDDY CURRENT. PROBABLE CAUSE FOR CRACK IS FATIGUE FAILURE, RED DYE/ OIL IS PLACED INSID E HUB TO DETECT POSSIBLE CRACKS BEFORE CATASTROPHIC FAILURE (AD 91-15-04), MANY OWNER/ OPERATORS ARE NOT AWARE OF THE SI GNIFICANCES OF THESE LEAKS AND IGNORE THEM. 5 C P5EA 2004050600047 20040506 00047 CE 2004 5 6 2004FA0000311 1 20040108 G 5280 245000615 BUMPER BLOCK CESSNA 172 172RG 2072438 CE LYC O360 O360* 41514 EA LT NLG DOOR WORN B CMXR O OTHER O OTHER NR NOT REPORTED 1 CE 05 9084F 172RG0352 NG DOOR OB EDGE CAUGHT ON GEAR WELL BUMPERS AND PREVENTED NG DOORS FROM OPENING WHEN GEAR SELECTED DOWN. IT IS CAUSED B Y DOORS BEING RIGGED WITH TOO LITTLE CLEARANCE, BUMPERS WEAR THIN AND ALLOW GEAR DOORS TO RAISE ON TOP OF BUMPER AND WED GE DOORS. NOSE GEAR WOULD NOT EXTEND BECAUSE DOORS WERE WEDGED AND COULD NOT OPEN CAUSING A LANDING WITHOUT NOSE GEAR D EPLOYED, CAUSING DAMAGE TO THE PROPELLER AND NOSE GEAR DOORS. CLEARANCE IS .160 MAX AND .100 MIN. BUMPER IS .375 IN WI DTH AND IF BUMPER WEARS THIN OR EVEN AWAY THEN THERE IS AN EDGE THAT DOOR CAN WEDGE ON. CHECK GEAR DOOR OB EDGES TO INS URE SPOT WELDS ARE INTACT AND DOOR SKINS HAVE NOT SEPARATED ALLOWING ONE SKIN TO CATCH ON BUMPERS. 1 H 7 1 3O 3 O 3A17 E286 2004050300105 20040503 00105 CE 2004 5 3 2004FA0000312 1 20040108 G 5320 245000616 BUMPER BLOCK CESSNA 172 172RG 2072438 CE LYC O360 O360* 41514 EA RT NLG WW WORN B CMXR O OTHER O OTHER NR NOT REPORTED 1 CE 05 9084F 172RG0352 NG DOOR OB EDGE CAUGHT ON GEAR WELL BUMPERS AND PREVENTED NG DOORS FROM OPENING WHEN GEAR SELECTED DOWN. IT IS CAUSED B Y DOORS BEING RIGGED WITH TOO LITTLE CLEARANCE, BUMPERS WEAR THIN AND ALLOW GEAR DOORS TO RAISE ON TOP OF BUMPER AND WED GE DOORS. NOSE GEAR WOULD NOT EXTEND BECAUSE DOORS WERE WEDGED AND COULD NOT OPEN CAUSING A LANDING WITHOUT NOSE GEAR D EPLOYED, CAUSING DAMAGE TO THE PROPELLER AND NOSE GEAR DOORS. CLEARANCE IS .160 MAX AND .100 MIN BUMPER IS .375 IN WIDT H AND IF BUMPER WEARS THIN OR EVEN AWAY THEN THERE IS AN EDGE THAT DOOR CAN WEDGE ON. CHECK GEAR DOOR OB EDGES TO INSUR E SPOT WELDS ARE INTACT AND DOOR SKINS HAVE NOT SEPARATED ALLOWING ONE SKIN TO CATCH ON BUMPERS. 1 H 7 1 3O 3 O 3A17 E286 2004050300157 20040503 00157 CE 2004 5 3 2004FA0000313 1 20040108 G 5280 24130832 DOOR CESSNA 172 172RG 2072438 CE LYC O360 O360* 41514 EA NOSE GEAR OUT OF RIG B CMXR O OTHER O OTHER NR NOT REPORTED 1 CE 05 9084F 172RG0352 NOSE GEAR OB EDGE CAUGHT ON GEAR WELL BUMPERS AND PREVENTED NG DOORS FROM OPENING WHEN GEAR SELECTED DOWN. IT IS CAUSED BY DOORS BEING RIGGED WITH TOO LITTLE CLEARANCE, BUMPER WEAR THIN AND ALLOW GEAR DOORS TO RAISE ON TOP OF BUMPER AND WE DGE DOORS. NOSE GEAR WOULD NOT EXTEND BECAUSE DOORS WERE WEDGED AND COULD NOT OPEN CAUSING A LANDING WITHOUT NOSE GEAR DEPLOYED, CAUSING DAMAGE TO THE PROPELLER AND NOSE GEAR DOORS. CLEARANCE IS .160 MAX AND .100 MIN. BUMPER IS .375 IN W IDTH AND IF BUMPER WEARS THIN OR EVEN AWAY THEN THERE IS AN EDGE THAT DOOR CAN WEDGE ON. CHECK GEAR DOOR OB EDGES TO IN SURE SPOT WELDS ARE INTACT AND DOOR SKINS HAVE NOT SEPARATED ALLOWING ONE SKIN TO CATCH ON BUMPERS. 1 H 7 1 3O 3 O 3A17 E286 2004050600074 20040506 00074 CE 2004 5 6 2004FA0000314 1 20040108 G 5280 24130831 DOOR CESSNA 172 172RG 2072438 CE LYC O360 O360* 41514 EA NLG OUT OF RIG B CMXR O OTHER O OTHER LD LANDING 1 CE 05 9084F 172RG0352 NG DOOR OB EDGE CAUGHT ON GEAR WELL BUMPERS AND PREVENTED NG DOORS FROM OPENING WHEN GEAR SELECTED DOWN. IT IS CAUSED BY DOORS BEING RIGGED WITH TOO LITTLE CLEARANCE, BUMPERS WEAR THIN AND ALLOW GEAR DOORS TO RAISE ON TOP OF BUMPER AND WE DGE DOORS. NOSE GEAR WOULD NOT EXTEND BECAUSE DOORS WERE WEDGED AND COULD NOT OPEN CAUSING A LANDING WITHOUT NOSE GEAR DEPLOYED, CAUSING DAMAGE TO THE PROPELLER AND NOSE GEAR DOORS. CLEARANCE IS .160 MAX AND .100 MIN. BUMPER IS .375 IN W IDTH AND IF BUMPER WEARS THIN OR EVEN AWAY THEN THERE IS AN EDGE THAT DOOR CAN WEDGE ON. CHECK GEAR DOOR OB EDGES TO IN SURE SPOT WELDS ARE INTACT AND DOOR SKINS HAVE NOT SEPARATED ALLOWING ONE SKIN TO CATCH ON BUMPERS. 1 H 7 1 3O 3 O 3A17 E286 2004050700002 20040507 00002 EA 2004 5 7 2004FA0000315 2 20040313 G 8520 PISTON PIPER PA28 PA28RT201 7102818 SO LYC O360 IO360C1C6 41514 EA MCAULY 2D34C 2D34C215 GL NR 3 CYLINDER MELTED D O OTHER O OTHER NR NOT REPORTED 1 EA 03 8364N 7226 1760 28R8118060 L1544651A 805737 NR 3 PISTON/ CYLINDER MELTED. 1 L 7 1 3O 3 O 2A13 1E10 5 C P7EA 2004050600075 20040506 00075 CE 2004 5 6 2004FA0000316 1 20040408 G 2434 DOFF10300BR WIRE CESSNA 210 210M 2073450 CE CONT O520 IO520* 17032 SO ALTERNATOR SHORTED D O OTHER O OTHER NR NOT REPORTED 1 GL 15 761SP 21062483 THE 3 WIRES COMING FROM THE STATOR ARE SHORTED OUT ON THE CASE. THIS IS 4TH ALTERNATOR OVERHAUL BY FACILITY WITH THE SA ME FAILURE, ALL 4 ALTERNATORS HAD LESS THAN 390 HOURS SINCE OVERHAUL. THERE NEED TO BE MORE INSULATION ON THE 3 WIRES. 1 H 7 1 3O 3 O 3A21 E5CE 2004050300165 20040503 00165 CE 2004 5 3 2004FA0000317 1 20040408 G 2497 WIRE CESSNA 172 172P 2072436 CE LYC O320 O320* 41508 EA ALTERNATOR SHORTED D O OTHER O OTHER NR NOT REPORTED 1 GL 15 65045 237 A155851 17275674 THE 3 WIRES COMING FROM THE STATOR ARE SHORTED OUT ON THE CASE. THIS IS THE 4TH ALTERNATOR OVERHAULED BY FACILITY WITH THE SAME FAILURE. ALL 4 ALTERNATORS HAD LESS THAN 390 HOURS SINCE OVERHAUL. THERE NEEDS TO BE MORE INSULLATION ON THE 3 WIRES. 1 H 7 1 3O 3 O NT 3A12 E274 2004050300158 20040503 00158 EA 2004 5 3 2004FA0000318 1 20040316 G 3520 STCSA8082NMD OXYGEN SYSTEM CNDAIR CL600 CL6002B16 1900305 EA GE CF34 CF34* NE PAX FAILED B TJ4R K NONE L NO TEST IN INSP/MAINT 1 GL 11 316FX 5387 DURING A 12 MONTH OXYGEN SYS OPERATIONAL TEST, FOUND NO OXYGEN FLOW TO LT SIDE CABIN MASKS (6 EA) LOCATED IN LT CABIN OV ERHEAD PASSENGER SERVICE UNIT. (PSU) 6 MASKS SUPPLY EMERGENCY OXYGEN FOR 4 LT CABIN SEATS. THERE WAS SUFFICIENT PRESSUR E IN THE SYSTEM FOR THE MASKS TO DEPLOY FROM THE DEPLOYMENT CONTAINERS LOCATED IN THE PSU, BUT WHEN THE MASK LANYARDS WE RE PULLED TO ENABLE OXYGEN FLOW TO THE MASKS THERE WAS NO FLOW OF OXYGEN TO THE MASKS. DISCOVERED THE OXYGEN SUPPLY HOS E (PN17341024) FOR THE LT SIDE OF THE CABIN WAS PINCHED BETWEEN THE OVERHEAD PSU AND THE INTERIOR SHELL PANEL DUE TO MIS ALIGNMENT OF THE HOSE PASS-THROUGH HOLES AT FS364. HOSE WAS REPLACED WITH NEW, AND PASS-THROUGH CLEARANCE PROVIDED. 2 L 7 2 4F 4 F RT A21EA E15NE 2004051000039 20040510 00039 2004 5 10 2004FA0000320 4 20040415 G 8300 GEAR MOONEY M20 M20C 5870208 SW LYC O360 O360A1D 41514 EA ACCESSORY G/B WORN D O OTHER O OTHER NR NOT REPORTED 1 NM 02 78940 1974 1635236A REMOVED OIL PUMP TO CHECK ON TYPE OF GEARS, FOUND SINTERED IRON IMPELLERS. REPLACED WITH HARDEN GEAR KIT. 1 L 7 1 3O 3 O 2A3 E286 2004050500044 20040505 00044 SO 2004 5 5 2004FA0000321 2 20040323 G 8530 654959A1 CYLINDER CESSNA 182 182D 2072710 CE CONT O470 O470* 17026 SO ENGINE DAMAGED B UGZR K NONE R PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 AL 03 8924X 18253324 COULD NOT GET ENGINE TO RUN PROPERLY. COMPRESSION GOOD ON NR 6, FINALLY DETERMINED NR 6 WAS NOT OPERATING PROPERLY. RE MOVED CYLINDER, SENT FOR OVERHAUL. FOUND HOLE IN EXHAUST VALVE PORT. (VOID IN THE CYLINDER CASTING) CYLINDER REJECTED AND RETURNED WITH LETTER. 1 H 7 1 3O 3 O NT 3A13 E273 2004050300102 20040503 00102 NM 2004 5 3 2004FA0000322 1 20040413 G 6220 900R2101006107 HUB DOUG DOUG MD900 MD900 3027375 NM PWC PW207 PW207E NE UPPER HUB ASSY CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 11 3PD 102 0099990080 9000085 DURING ACCOMPLISHMENT OF AD2002-10-05 (MAIN ROTOR UPPER HUB INSP.) FOUND (3) OUT OF (10) BOLT HOLES CRACKED AS DEPICTED IN MFG SERVICE BULLETIN 900-072. CRACKS START IN BOLT HOLE CHAMFER. PART TOTAL TIME: 102.0 HRS. 1 G 7 2 3U 3 U NC H19NM E42NE 2004050300103 20040503 00103 NM 2004 5 3 2004FA0000323 1 20040413 G 6220 900R2101006107 HUB DOUG DOUG MD900 MD900 3027375 NM PWC PW207 PW207E NE UPPER HUB ASSY CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 11 3PD 102 0099990080 9000085 DURING ACCOMPLISHMENT OF AD2002-10-05 (MAINROTOR UPPER HUB INSP.) FOUND (3) OUT OF (10) BOLT HOLES CRACKED AS DEPICTED I N MFG SERVICE BULLETIN 900-072. CRACKS START IN BOLT HOLE CHAMFER. PART TOTAL TIME: 102.0 HRS. 1 G 7 2 3U 3 U NC H19NM E42NE 2004050300106 20040503 00106 NM 2004 5 3 2004FA0000324 1 20040421 G 6220 900R2101006107 HUB DOUG DOUG MD900 MD900 3027375 NM PWC PW207 PW207E NE UPPER HUB ASSY CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 11 3PD 102 0099990080 DURING ACCOMPLISHMENT OF AD 2002-10-05 (MAIN ROTOR UPPER HUB INSPECTION), FOUND (3) OUT OF (10) BOLT HOLES TO BE CRACKED AS DEPICTED IN MFG SERVICE BULLETIN 900-072. CRACKS START IN BOLT HOLE CHAMFER. PART TOTAL TIME: 102.0HOURS. REMOVED AN D REPLACED UPPER HUB WITH NEW. 1 G 7 2 3U 3 U NC H19NM E42NE 2004050300123 20040503 00123 EA 2004 5 3 2004FA0000325 2 20040329 G 8530 PUSHROD ROBSIN R22 R22MARINER 7640115 NM LYC O360 O360J2A 41514 EA NR 2 CYLINDER BENT C A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 SW 03 203CP 2659M L3525336A NUMBER 2 CYLINDER EXHAUST VALVE STUCK AND BENT PUSHROD CAUSING ENGINE POWER LOSS. PILOT THEN EXECUTED A PRECAUTIONARY L ANDING. 1 G 7 1 3O 3 O H10WE E286 2004050300145 20040503 00145 EA 2004 5 3 2004FA0000329 2 20040329 G 8530 PUSHROD ROBSIN R22 R22MARINER 7640115 NM LYC O360 O360J2A 41514 EA ENGINE BENT C A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CR CRUISE 1 SW 03 203CP 2659M L3525336A NR 2 CYLINDER EXHAUST VALVE STUCK AND BENT PUSHROD CAUSING ENGINE POWER LOSS. PILOT THEN EXECUTED A PRECAUTIONARY LANDI NG. 1 G 7 1 3O 3 O H10WE E286 2004042900028 20040429 00028 NM 2004 4 29 2004FA0000330 1 20040303 G 6220 900R2101006107 HUB DOUG DOUG MD900 MD900 3027375 NM PWC PW207 PW207E NE MAIN ROTOR CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 15 902PD 399 106 0099990078 DURING ACCOMPLISHMENT OF AD 2002-10-05 INSP. (MAIN ROTOR UPPER HUB INSP.) FOUND (2) OUT OF (10) FLANGE BOLT HOLES WITH C RACKS AS DEPICTED IN MFG SERVICE BULLETIN 900-072. CRACKS RUN RADIALLY FROM BOLT HOLE INWARD TO FLANGE EDGE. PART TOTAL TIME WAS 399.65 HRS. UPPER HUB WAS FLOWN 106 HRS WITH MFG SERVICE BULLETIN 900-093 (INCREASED BOLT TORQUE) INCORPORATED. REMOVED AND REPLACED HUB WITH SERVICEABLE PART IAW MFG MM. 1 G 7 2 3U 3 U NC H19NM E42NE 2004050300161 20040503 00161 NM 2004 5 3 2004FA0000331 1 20040413 G 6220 900R2101006107 HUB DOUG DOUG MD900 MD900 3027375 NM PWC PW207 PW207E NE UPPER HUB ASSY CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 11 3PD 102 102 0099990080 DURING ACCOMPLISHMENT OF AD 2002-10-05 (MAIN ROTOR UPPER HUB INSP.) FOUND (3) OUT OF (10) BOLT HOLES CRACKED AS DEPICTE D IN SERVICE BULLETIN 900-072. CRACKS START IN BOLT HOLE CHAMFER. PART TOTAL TIME: 102 HRS. 1 G 7 2 3U 3 U NC H19NM E42NE 2004050300183 20040503 00183 NM 2004 5 3 2004FA0000332 1 20040413 G 6220 900R2101006107 HUB DOUG DOUG MD900 MD900 3027375 NM PWC PW207 PW207E NE UPPER HUB ASSY CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 11 3PD 102 0099990080 9000085 DURING ACCOMPLISHMENT OF AD2002-10-05 (MAINROTOR UPPER HUB INSP.) FOUND (3) OUT OF (10) BOLT HOLES CRACKED AS DEPICTED IN MFG SERVICE BULLETIN 900-072. CRACKS START IN BOLT HOLE CHAMFER. PART TOTAL TIME: 102.0 HRS. 1 G 7 2 3U 3 U NC H19NM E42NE 2004042900037 20040429 00037 SW 2004 4 29 2004FA0000333 1 20040325 G 6220 2040121127 STRAP BELL BELL 204 UH1H 1181407 SW LYC T53 T53L13B 41549 NE M/R HEAD CRACKED B K NONE O OTHER IN INSP/MAINT 1 NM 04 667HP 4815 131 ARA0638 659952 22986B AIRCRAFT WAS EXPERIENCING VIBRATIONS DURING FLIGHT, MAINTENANCE WAS UNABLE TO REMOVE THE VIBRATION THROUGH TRACK AND BAL ANCE PROCEDURES. THE MAIN ROTOR ASSEMBLY WAS REMOVED FOR INSPECTION. DURING THE INSPECTION A TENSION-TORSION STRAP WAS F OUND CRACKED AT BOTH ENDS WHERE THE PINS HOLD THE STRAPS IN PLACE. UPON FURTHER INVESTIGATION IT WAS DISCOVERED THAT THE STRAPS INSTALLED WERE NOT THE PROPER STRAPS FOR THIS M/R HEAD CONFIGURATION. 1 G 7 1 4U 4 U EXPA1G71 E17EA 2004050600046 20040506 00046 GL 2004 5 6 2004FA0000334 1 20040303 G 1410 HOSE AMTR VORTEX VORTEX 05603FA GL ROTAX 582 ROTAX582 55555 EU VACUUM SYSTEM IMPROPER PART G C ABORTED TAKEOFF Y ENGINE STOPPAGE TO TAKEOFF 1 WP 25 96XV 12 5437430 THE VACUUM LINE GOING TO THE FUEL PNEUMATIC PUMP HAD AN IRREGULAR PART INSTALLED. THE MM REQUIRES A HARD, NON-COLLAPSIBL E, FUEL RESISTANT LINE. THE LINE INSTALLED WAS FLEXIBLE/COLLAPSABLE AND HAD A 45 DEGREE KINK ON THE VACUUM SIDE. THIS MA Y LEAD TO LESS VACUUM TO THE FUEL PUMP LOWERING THE CAPABILITY OF THE PUMP. RECOMMEND FOLLOW THE MFG PROCEDURES WHEN INS TALLING THE ENGINE. 1 G 7 1 3I 3 I NT EXPA1G71 EXPE3I 2004050300104 20040503 00104 CE 2004 5 3 2004FA0000336 1 20040305 G 5712 08522350 RIB CESSNA 402 402B 207590P CE LT WING CRACKED E O OTHER O OTHER NR NOT REPORTED 1 NM 11 707H 11745 402B0117 FOUND OIL CANNING IN LT WING OF HIGH TIME WHEN LIFTING AFT END OF TIP TANK. WING WAS INSPECTED AND ONLY DEFECT WAS LWR FLANGE ON 4 OF INTERSPAR RIBS WERE CRACKED, STRINGER PASS-THROUGH. CRACK WAS .5-.75 INCHES LONG, EXTENDED PAST FIRST RI VET. AFTER REPAIRING, OIL CANNING WAS STILL EVIDENT. OIL CANNING SKIN IS NOT RESULT OF RIB CRACKS BUT CRACKS ARE DIRECT RESULT OF OIL CANNING SKIN. IF LEFT UNDETECTED COULD LEAD TO STRUCTURAL FAILURE OF RIB. OIL CANNING WHEN GENTLE LIFTING FORCE IS PLACED ON AFT END OF TIP TANK (CAUSE OF DAMAGE) AND POSSIBLY SOME LOOSE OR SMOKING RIVETS ON RIB LINE (RESULT OF THE DAMAGE) IF RIVETS ARE LOOSE OR SMOKING BE SURE TO INSPECT INNER STRUCTURE BEFORE PUTTING BLIND FASTENER IN. 1 L 7 2 3O A7CE 2004042900039 20040429 00039 EU 2004 4 29 2004FA0000337 1 20040329 G 8097 52621 CABLE AIMM AMT200 AMT200S 0160001 EU STARTER BROKEN B O OTHER O OTHER NR NOT REPORTED 1 NM 03 139XS 178 200139 STARTER CABLE PN 52621 BROKE AT THE LUG CONNECTED TO THE STARTER. 1 L 7 1 3I NC TG0004A 2004050300115 20040503 00115 CE 2004 5 3 2004FA0000338 1 20040422 G 2710 63610027 CONTROL CABLE CESSNA 525 525A 2076615 CE WING AILERON BROKEN B O OTHER O OTHER NR NOT REPORTED 1 GL 09 630TF 1061 525A0022 DURING ACCOMPLISHMENT OF THE AIRCRAFT'S FIRST PHASE 5 INSPECTION, FOUND ALL FOUR AILERON WING CABLES TO BE HEAVILY FLAT SPOTTED AT THE FAIRLEADS LOCATED AT WS 58.00, 103.43 AND 149.18. THE RT UPPER CABLE (P/N 6361002-7) HAD ONE BROKEN STRA ND. THESE CABLES NORMALLY LAST MUCH LONGER THAN 1061 HRS. SUSPECT A HEAVIER THAN NORMAL CONTACT BETWEEN THESE WING AIL ERON CABLES AND THE NOTED FAIRLEADS WHILE IN FLIGHT. RECOMMEND CLOSE INSPECTION OF THE AILERON WING CABLES IN THE FAIRL EAD AREAS AT THE NEXT AVAILABLE INSPECTION. 1 L 7 1 4F RT A1WI 2004042900036 20040429 00036 SO 2004 4 29 2004FA0000339 1 20040323 G 8120 60051004 HOUSING PIPER PA28 PA28RT201T 7102817 SO CONT O360 TSIO360FB 17025 SO TURBOCHARGER CRACKED C O OTHER O OTHER NR NOT REPORTED 1 WP 07 8177C 1119 CGR0706 28R8231065 REMOVED TURBO FOR OTHER WORK, INSPECTED HOUSING PN 600510-04 AND FOUND IT TO BE CRACKED AS SHOWN IN AD 82-27-03 FIGURE 2 , AD 82-27-03 DOES NOT APPLY TO THIS HOUSING NUMBER, RECOMMEND INSPECTING ALL TURBOS REGARDLESS OF AD. 1 L 7 1 3O 3 O 2A13 E9CE 2004050500155 20040505 00155 SO 2004 5 5 2004FA0000340 2 20040331 G 8530 631996 ROCKER CESSNA 172 R172K 2072431 CE CONT O360 IO360KB 17025 SO ENGINE BROKEN B H00R O OTHER O OTHER NR NOT REPORTED 1 EA 21 736DU R1722452 288641 FOUND HOLE IN ROCKER COVER CAUSED BY ROCKER ARM ON EXHAUST SIDE. FOUND FWD STUD ASSY BROKEN OFF FLUSH WITH CYLINDER HEA D. STUD (PN 401852). ROCKER RETAINER (PN 631996) WAS BROKEN AND HALF MISSING (GONE OUT OF HOLE IN COVER) IB STUD HOLD DOWN NUT WAS 4 TO 5 THREADS FROM COMING OFF. SUSPECT NUTS WERE NOT PROPERLY TORQUED. 1 H 7 1 3O 3 O 3A17 E1CE 2004050400054 20040504 00054 2004 5 4 2004FA0000341 4 20040315 G 2561 KS9P0101125NC LIFE VEST CABIN FAILED B KQ1R O OTHER O OTHER NR NOT REPORTED 1 EA 07 LIFE PRESERVER FAILED. MFG RECOMMENDED CELL PRESSURE CHECK IAW 25-60-1. DOM: MAY 1984. 2004050400053 20040504 00053 2004 5 4 2004FA0000342 4 20040315 G 2561 GA12P0201 LIFE VEST CABIN FAILED B KQ1R O OTHER O OTHER NR NOT REPORTED 1 EA 07 INDIVIDUAL FLOAT DEVICE FAILED MFG RECOMMENDED CELL PRESSURE TEST IAW 25-60-13. DOM: AUG 1981. 2004050300208 20040503 00208 SO 2004 5 3 2004FA0000343 2 20040331 G 7414 10160844 BRUSHES S6RH1225 CESSNA 206 TU206G 2073357 CE CONT O520 TSIO520M 17040 SO MAG DIST GEAR MISINSTALLED D O OTHER W INADEQUATE Q C NR NOT REPORTED 1 SW 99 PKMAR F02HA216 U20606231 523210 UPON COMPLETING THE FIRST 500 HOUR INSPECTION ON THE MAGNETO, IT WAS DISCOVERED THAT THE CARBON BRUSH AND SPRING ASSY (P N 10160844) WERE NOT INSTALLED. THE BUSHING IN THE DISTRIBUTOR GEAR HAD BEEN MAKING CONTACT WITH THE TAB ON THE COIL SO THE MAGNETO APPEARED TO BE FUNCTIONING NORMALLY. ADDITIONALLY, THE WEDGES (PN 10349219) THAT SECURE THE COIL ASSEMBLY INTO THE CASE WERE OVER-DRIVEN, BENT AND MALFORMED SEVERELY BY THE INSTALLATION PROCESS WHEN MANUFACTURED. 1 H 7 1 3O 3 O A4CE E8CE 2004050300132 20040503 00132 CE 2004 5 3 2004FA0000344 1 20040312 G 5541 SPAR CESSNA 150 152 2071835 CE LYC O235 O235* 41505 EA RUDDER CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 17 68329 15282261 FOUND RUDDER SPAR CRACKED AT LIGHTENING HOLE JUST UNDER TOP RUDDER MOUNTING HINGE. 4 CRACKS WERE PRESENT, THE LONGEST W AS .5 INCH. RECOMMEND INSPECTION EVERY 100 HOURS, REPLACE WITH NEW SPAR MISSING LIGHTENING HOLE IF DEFECTIVE. 1 H 7 1 3O 3 O NT 3A19 E223 2004050300135 20040503 00135 CE 2004 5 3 2004FA0000345 1 20040426 G 3010 632242014 PICCOLO TUBE CESSNA 525 525A 2076615 CE ANTI-ICE BROKEN B O OTHER O OTHER NR NOT REPORTED 1 GL 09 630TF 1061 525A0022 DURING THE PHASE 5 INSPECTION THE RT WING ANTI-ICE PICCOLO TUBE WAS FOUND BROKEN AT THE ANIT-ROTATION TAB. THE TUBE WOR KED ITS WAY INBOARD APPROXIMATELY 4 INCHES. THE FLEX COUPLING KEPT IT FROM TRAVELING INBOARD ANY FURTHER. NEW PART WAS ORDERED AND INSTALLED. THIS SAME CONDITION WAS FOUND ON ANOTHER 525 AND 525A. 1 L 7 1 4F RT A1WI 2004050300137 20040503 00137 CE 2004 5 3 2004FA0000346 1 20040403 G 5320 20430129 RUB STRIP CESSNA CESSNA 177 177RG 2073709 CE LYC O360 IO360A1B6 41514 EA NLG DOOR ACT MISSING D K NONE O OTHER IN INSP/MAINT 1 CE 07 8828Y 100 177RG1289 DURING ANNUAL INSPECTION LANDING GEAR RETRACTION TEST WAS PERFORMED AND THE NOSE GEAR DOORS WOULD NOT FULLY CLOSE. INVES TIGATION FOUND THE TEFLON RUB STRIP ON THE NOSE LANDING GEAR DOOR ACTUATOR MISSING. 1 H 7 1 3O 3 O A20CE 1E10 2004050300139 20040503 00139 CE 2004 5 3 2004FA0000347 1 20040331 G 2434 646843 ALTERNATOR BEECH 33 F33A 1151425 CE CONT O520 IO520* 17032 SO ENGINE FAILED C A UNSCHED LANDING H ELECT. POWER LOSS-50 PC CL CLIMB 1 SO 11 42RK 24 24 CE934 813981 OVERHAULED GEAR DRIVEN ALTERNATOR REPEATED FAILURE. ALTERNATOR P/N 646843 S/N D022878 WENT TO TWO TIMES FOR REPAIR OR OV ERHAUL AND FAILED VERY SOON AFTERWARDS EACH TIME. 25 HOURS FIRST TIME AND .5 HOURS SECOND TIME. FIRST TIME WO NR MW25590 SECOND TIME WO NR MW29610. 1 L 7 1 3O 3 O 3A15 E5CE 2004050300144 20040503 00144 CE 2004 5 3 2004FA0000348 1 20040318 G 3230 3A0500002 CYLINDER CESSNA 185 A185F 2072821 CE CONT O520 IO520* 17032 SO MLG LEAKING G O OTHER O OTHER NR NOT REPORTED 1 NM 01 185TH 18503456 LEAKING CYLINDER CAUSED GEAR NOT TO LOCK, GEAR COLLAPSED DURING TAXI. 1 H 7 1 3O 3 O 3A24 E5CE 2004050300147 20040503 00147 SO 2004 5 3 2004FA0000349 1 20040401 G 8097 A02855688499 SWITCH PIPER PA46 PA46500TP 7104622 SO PWA PT6 PT6A42 52043 NE AUTO START SYS SHORTED D K NONE O OTHER IN INSP/MAINT 1 EA 07 77Y 531 4697035 AUTO START SYSTEM WOULD NOT DISENGAGE AUTOMATICALLY AT 56 PERCENT NG. FOUND ELECTRONIC CONTROL MODULE 1012 (P/N 688-499) INTERNALLY SHORTED CAUSING POWER TO CONSTANTLY FLOW REGARDLESS OF COMMANDS. 1 L 7 1 3O 4 T RT A25SO E4EA 2004050300149 20040503 00149 EU 2004 5 3 2004FA0000350 1 20040405 G 3411 LINE PILATS PC12 PC1245 7090551 EU PWA PT6 PT6* 52043 EA PITOT SYSTEM SEPARATED B O OTHER G J MULTIPLE FAILURE WARNING INDICATION CR CRUISE 1 SO 11 529PB 188 529 PILOT EXPERIENCED AN ALTITUDE PORPOISE WITH AUTOPILOT ENGAGED. AIRSPEED IND INDICATED THAT AIRSPEED WAS DECREASING, ALT HOUGH AIRSPEED REMAINED SAME. BOTH PITOT SYS WERE CHECKED, OK. RT STATIC SYS WAS CHECKED, FOUND TO BE OK. THE LT STATI C SYS WOULD NOT PRESSURIZE AT ALL. ISOLATED THE STATIC SYS LEAK TO FITTING AT AFT PRESSURE BULKHEAD (FRAME 36, STATION 380.7). STATIC LINE TUBING ON INSIDE OF PRESSURE BULKHEAD HAD PULLED OUT OF THE FITTING, IT HAD BEEN CUT TOO SHORT AT T HE FACTORY. WHEN THIS LINE PULLED OUT, IT EXPOSED THE PILOT SIDE STATIC SYS TO CABIN PRESSURE. MAKE THE STATIC LINES SL IGHTLY LONGER DURING THE MFG PROCESS, THUS PREVENTING THEM PULLING OUT OF THE FITTINGS AS THE AC STRETCHES. 1 L 7 1 3T 3 T RT A78EU E2NE 2004050300152 20040503 00152 EU 2004 5 3 2004FA0000351 1 20040315 G 2823 SF2601314611 ROD MRCHTI SF260 SF260 8121206 EU LYC O540 O540* 41532 EA FUEL VALVE BROKEN G A UNSCHED LANDING Y J ENGINE STOPPAGE WARNING INDICATION AP APPROACH 1 GL 07 260MN 5342 121 PILOT WAS MOVING FUEL SELECTOR KNOB FROM WING TIP TANKS TO WING TANKS AND THE FUEL SELECTOR ROD BROKE AT THE FUEL SELECT OR VALVE WITH THE FUEL SELECTOR VALVE IN BETWEEN TANK POSITIONS. THE ENGINE STOPPED AND AN EMERGENCY LANDING WAS ACCOMP LISHED. INVESTIGATION REVEALED THE FUEL SELECTOR ROD BROKE WERE IT WAS DRILLED FOR THE TAPERED PIN, P/N AN385H40-7. INF O ON MFG'S PART BOOK AT PAGE 8-22-01, FIGURE 1. 1 L 7 1 3O 3 O A10EU E295 2004050300154 20040503 00154 2004 5 3 2004FA0000352 4 20040312 G 2210 55X AUTOPILOT SYS CESSNA 182 TR182 2072735 CE LYC O540 O540L3C5 41532 EA COCKPIT INOPERATIVE C O OTHER O OTHER AP APPROACH 1 GL 19 738QV 300 10 R18200955 IN APR AND NAV MODE, AUTOPILOT WILL NOT PROPERLY INTERCEPT AND TRACK LOCALIZER AND/OR VOR SIGNAL. AUTOPILOT WILL SCALLOP ACROSS COURSE. AUTOPILOT HAS BEEN SENT IN FOR EVALUATION. WE HAVE EVALUATED OUR PN-101 HSI TO DETERMINE IF THEY ARE TH E SOURCE. AFTER EVALUATIONS THE AUTOPILOT IS SOURCE OF THE PROBLEM. ALSO, WHEN FLAPS AND GEAR ARE EXTENDED ON APPROACH, AUTOPILOT WILL PITCH UP AND DOWN WILDLY. THIS PROBLEM HAS PERSISTED SINCE INSTALLATION AND ON-SITE EVALUATION. AWARE O F SEVERAL OTHER AIRCRAFT THAT HAVE THIS PROBLEM. AUTOPILOT NEEDS TO BE FULLY RE-EVALUATED BY THE FAA AND MANUFACTURER. 1 H 7 1 3O 3 O 3A13 E295 2004050300166 20040503 00166 CE 2004 5 3 2004FA0000353 1 20040311 G 2720 22601145 TORQUE TUBE CESSNA 182 R182 2072734 CE LYC O540 O540* 41532 EA ZONE 100 DETACHED D A UNSCHED LANDING D INFLIGHT SEPARATION CR CRUISE 1 SO 09 736ZX 5075 R18200813 LT RUDDER BAR TORQUE TUBE ASSEMBLY, PN 2260114-5 FAILURE. FAILURE OCCURRED IN FLIGHT RESULTING IN LT SIDE PILOT'S TOTAL LOSS OF LT RUDDER AND STEERING CONTROL. NATURE OF FAILURE; LT OB RUDDER PEDAL SOCKET ON TORQUE TUBE BROKE AWAY FROM THE TORQUE TUBE. THERE IS NO OBVIOUS REASON WHY THIS MIGHT HAVE HAPPENED. THERE ARE NO BENT OR DAMAGED COMPONENTS WITHIN TH E SAME SYSTEM, AND THE STEEL TORQUE TUBE HAS ONLY VERY LIGHT INTERNAL CORROSION. 1 H 7 1 3O 3 O RT 3A13 E295 2004050300178 20040503 00178 CE 2004 5 3 2004FA0000354 1 20040427 G 2750 99141873 CONTROLLER CESSNA 650 650 2076802 CE GARRTT TFE731 TFE731* 01518 WP TE FLAP DEFECTIVE B O OTHER O OTHER NR NOT REPORTED 1 GL 11 934H 6500172 FLAP CONTROLLER FAILED TO INDICATE PROPERLY ON SYSTEM TEST. 2 L 7 2 4F 4 F A9NM E6WE 2004050300179 20040503 00179 SO 2004 5 3 2004FA0000355 2 20040427 G 8530 CYLINDER HEAD CESSNA 421 421B 2076014 CE CONT O520 GTSIO520C 17032 SO ENGINE CRACKED C O OTHER O OTHER NR NOT REPORTED 1 GL 09 5988M 421B0231 AIRCRAFT NDT SERVICE WAS CONTRACTED TO VERIFY CRACKS IN THE ENGINE CYLINDER HEADS BETWEEN THE SPARK PLUG AND FUEL INJECT OR MOUNTING BOSS. AN EDDY CURRENT EXAMINATION DETERMINED THAT ALL TWELVE CYLINDER HEADS WERE CRACKED. THE OPERATOR REPL ACED ALL TWELVE CYLINDER HEADS WITH FRESH OVERHAULED HEADS. AN EDDY CURRENT EXAMINATION DETERMINED THAT FIVE OF THE TWEL VE OVERHAULED HEADS WERE CRACKED IN THE SAME LOCATION. 1 L 7 2 3O 3 O A7CE E7CE 2004050300186 20040503 00186 GL 2004 5 3 2004FA0000357 1 20040307 G 3350 D4125609000 BATTERY PACK DIAMON DA40 DA40 2990002 GL LYC O360 IO360A1A 41514 EA INSTRUMENT PNL SHORTED D K NONE O OTHER IN INSP/MAINT 1 EA 09 338MA 207 40298 EMERGENCY BATTERY PACK SHORTED DUE TO SET SCREW FALLING THROUGH HOLE IN BOTTOM OF INSTRUMENT PANEL DIRECTLY ABOVE BATTER Y PACK TERMINALS. HOLE IS FOR WIRES FROM BATTERY PACK, HAS A RECESS IN AREA OF ELECTRICAL TERMINALS. WHEN SET SCREW FE LL THROUGH HOLE, LODGED BETWEEN TERMINAL CONNECTIONS IN RECESS, COMPLETELY DRAINING EMERGENCY BATTERY PACK. BATTERIES R EACHED HIGH ENOUGH TEMP DURING SHORT/DISCHARGE CYCLE THAT INDIVIDUAL BATTERY JACKETS WERE DEFORMED OR ACTUALLY MELTED, SOME OF BATTERY CASES SPLIT, SPILLING CONTENTS. ANYTHING THAT FALLS THROUGH THIS HOLE IN THE INSTRUMENT PANEL (INCLUDIN G WATER) WILL NATURALLY BE TRAPPED IN RECESS IN TOP OF EMERGENCY BATTERY PACK. 1 L 7 1 3O 3 O NT A47CE 1E10 2004050600020 20040506 00020 GL 2004 5 6 2004FA0000358 1 20040307 G 3350 D4125609000 BATTERY PACK DIAMON DA40 DA40 2990002 GL INSTRUMENT PANEL SHORTED D K NONE O OTHER IN INSP/MAINT 1 EA 09 338MA 207 40298 EMERGENCY BATTERY PACK SHORTED DUE TO A SET SCREW FALLING THROUGH HOLE IN BOTTOM OF INSTRUMENT PANEL DIRECTLY ABOVE BATT ERY PACK TERMINALS. HOLE IS FOR WIRES FROM BATTERY PACK. BATTERY PACK ITSELF HAS A RECESS IN AREA OF THE ELECTRICAL T ERMINALS. WHEN SET SCREW FELL THROUGH HOLE, IT LODGED BETWEEN TERMINAL CONNECTIONS IN RECESS, COMPLETELY DRAINING EMERG ENCY BATTERY PACK. BATTERIES THEMSELVES REACHED HIGH ENOUGH TEMPERATURE DURING SHORT/DISCHARGE CYCLE THAT INDIVIDUAL BA TTERY JACKETS WERE DEFORMED OR ACTUALLY MELTED. SOME OF BATTERY CASES SPLIT, SPILLING CONTENTS. ANYTHING THAT FALLS TH ROUGH THIS HOLE IN THE INSTRUMENT PANEL (INCLUDING WATER) WILL NATURALLY BE TRAPPED IN THE RECESS. 1 L 7 1 3O NT A47CE 2004050300187 20040503 00187 CE 2004 5 3 2004FA0000359 1 20040312 G 3040 1295428 REGULATOR VALVE CESSNA 441 441 2076020 CE BLEED AIR DEFECTIVE B K NONE O OTHER IN INSP/MAINT 1 NM 03 ALL WINDSHIELD BLEED AIR TEMP SENSOR/REGULATOR WHICH ARE REQUIRED TO BE FUNCTIONALLY TESTED AND REPLACED IF NECESSARY EVERY PHASE 13 (3 YRS) ARE NO LONGER AVAILABLE FROM MANUFACTURE. 1 L 7 2 3T RT A28CE 2004050500094 20040505 00094 EA 2004 5 5 2004FA0000360 2 20040420 G 8550 73772 COOLING JET PIPER PA28 PA28R201 7102816 SO LYC O360 IO360C1C6 41514 EA CRANKCASE MISSING B NX42 K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 15 703ER 2079 2844057 L3013951A UPON DISASSEMBLY FOR ITS FIRST OVERHAUL, THE TECH FOUND TAPERED PIPE PLUGS WERE INSTALLED IN CRANKCASE INSTEAD OF THE RE QUIRED PISTON COOLING JETS. PISTONS AND CYLINDERS SHOWED SIGNS OF OVERHEATING ALTHOUGH NO MALFUNCTION OCCURRED. ENGINE RECORDS INDICATE THE ENGINE WAS BUILT FACTORY NEW, INSTALLED ON AC AND HAS HAD NO HISTORY OF CYLINDER REMOVAL OR REPLAC EMENT. 1 L 7 1 3O 3 O 2A13 1E10 2004050600019 20040506 00019 SO 2004 5 6 2004FA0000361 2 20040429 G 8530 CYLINDER GULSTM 680 685 0141612 SW CONT O520 GTSIO520K 17032 SO NR 3 DAMAGED B O OTHER O OTHER NR NOT REPORTED 1 SO 09 414C 12021 NR 3 CYLINDER ON LT ENGINE HOLD DOWN STUDS BROKE OFF ON UPPER FWD AND LOWER FWD. ONLY ONE NUT WAS TIGHT ENOUGH TO USE A WRENCH. THE OTHER NUTS WERE LOOSE. AFTER CYLINDER REMOVAL A PIECE OF THE CASE HALF CAME OFF WITH THE CYLINDER APPROX. 6 INCHES ACROSS ALONG THE TOP OF THE CYLINDER. EXHAUST PIPE FOR THE NR3 CYLINDER BROKE OFF AT THE FLANGE. 1 H 7 2 3O 3 O 2A4 E7CE 2004050600026 20040506 00026 CE 2004 5 6 2004FA0000362 1 20040325 G 1430 AN824A BOLT CESSNA 150 150M 2071830 CE WING ATTACHING CORRODED D O OTHER O OTHER NR NOT REPORTED 1 GL 05 66062 4681 15075807 WHEN PERFORMING MAINT. ON A/C, NOTED RUST ON HEADS OF MAIN SPAR WING ATTACHING BOLTS. REMOVED BOLTS FINDING THEM BADLY C ORRODED AND RUSTED. INSPECTED FUSELAGE BEARING BORE AND SPAR BOAR AND INSTALLED NEW AN8-24A BOLTS. AGE AND ENVIRONMENT M AY BE PROBLEM, RECOMMEND COATING BOLTS AND BORE WITH EPOXY PRIMER AND INSTALLING WET. 1 H 7 1 3O 3A19 2004050600029 20040506 00029 CE 2004 5 6 2004FA0000363 1 20040413 G 5210 551123514 HINGE CESSNA CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE CABIN DOOR BROKEN D O OTHER O OTHER NR NOT REPORTED 1 GL 25 92B 6678 5500471 WHEN PILOT OPENED CABIN DOOR, A GUST OF WIND CAUGHT DOOR AND SLAMMED IT INTO STOP. PILOT REPORTED A LOUD (POP) AND PAINT FELL FROM DOOR HINGE. INSPECTION REVEALED LOWER LEG OF DOOR HINGE HAD BROKEN. DISASSEMBLY REVEALED EVIDENCE OF A PRE EXISTING SUBSURFACE CRACK IN CASTING, 3 INCH AFT OF HINGE BEARING. A SURFACE CRACK 1INCH LONG 1.5 INCH AFT OF HINGE BEAR ING WAS HIDDEN BY HEAVY PAINT COATING. THESE CRACKS WOULD NOT BE VISIBLE WITHOUT PAINT REMOVAL. RECOMMEND PAINT BE REMO VED AND CAST PORTION OF HINGE INSPECTED UNDER MAGNIFICATION AT 500 HR INTERVALS. 1 L 7 2 4F 4 F A22CE E1NE 2004050600039 20040506 00039 EA 2004 5 6 2004FA0000364 2 20040315 G 7320 FUEL CONTROL PIPER PA18 PA18 7101802 SO LYC O320 O320* 41508 EA ENGINE MISMARKED D K NONE O OTHER IN INSP/MAINT 1 EA 23 AS MANUFACTURED, THE FUEL VALVE SELECTOR HANDLE CONSISTS OF A SMALL POINTER AND A SILVER HANDLE OPPOSITE OF EACH OTHER O N THE LT INTERIOR WALL BY THE FRONT SEAT. OPPOSITE BOTH FUEL VALVE SELECTIONS OF (LT) AND (RT) IS AN (OFF) POSITION. T HE POINTER IS OFTEN PAINTED THE SAME COLOR AS THE BACKGROUND COLOR OF THE INTERIOR, USUALLY DARK RED. THIS LEADS TO THE POSSIBILITY OF SOMEONE INADVERTENTLY USING THE SILVER HANDLE TO MAKE THE VALVE SELECTION INSTEAD OF THE POINTER, PERHAP S TURNING THE VALVE (OFF) INSTEAD OF SELECTING A FUEL TANK. THE POINTER SHOULD BE PAINTED A DISTINCTIVE COLOR AND PERHA PS THE VALVE SELECTOR SHOULD BE PLACARDED: (USE POINTER NOT SILVER HANDLE TO MAKE VALVE SELECTION). 1 H 7 1 3O 3 O 1A2 E274 2004050600044 20040506 00044 CE 2004 5 6 2004FA0000365 1 20040329 G 1420 52621 CABLE BEECH 35 M35 1151526 CE STARTER BROKEN B K NONE O OTHER LD LANDING 1 NM 03 136X 318 D6215 STARTER CABLE PN 52621 BROKEN AT THE LUG CONNECTED TO THE STARTER. 1 L 7 1 3O 3A15 2004050600045 20040506 00045 CE 2004 5 6 2004FA0000366 1 20040324 G 1430 AN823A BOLT CESSNA 172 172K 2072430 CE SPAR CORRODED D K NONE O OTHER IN INSP/MAINT 1 GL 07 78203 3400 17257525 WHILE REMOVING WING BOLTS, FOUND BOLTS RUSTED AND CORRODED. RECOMMENDED BOLTS BE INSPECTED AND COATED WITH EPOXY PRIMER , INSTALLING NEW BOLTS. 1 H 7 1 3O NT 3A12 2004051400114 20040514 00114 EU 2004 5 14 2004FA0000368 1 20040329 G 8097 52621 CABLE AIMM AMT200 AMT200S 0160001 EU STARTER BROKEN B O OTHER O OTHER LD LANDING 1 NM 03 136XS 318 200136 STARTER CABLE PN 52621 BROKE AT THE LUG CONNECTED TO THE STARTER. 1 L 7 1 3I NC TG0004A 2004050600079 20040506 00079 SO 2004 5 6 2004FA0000369 2 20040429 G 8520 SA627246 MAIN BEARING CESSNA 150 150E 2071812 CE CONT O200 O200* 17020 SO ENGINE SEPARATED D K NONE O OTHER IN INSP/MAINT 1 CE 01 2586J 2385 15061086 605994A AFT THRUST FACES OF BOTH FRONT MAIN BEARING HALVES WERE SEPARATED FROM BEARING. THIS IS A ONE PIECE STYLE THRUST/MAIN B EARING. PROBLEM FOUND DURING OVERHAUL, NO INDICATIONS OF FAILURE NOTED BEFORE DISASSEMBLY. NO DAMAGE TO CASE OR CRANKS HAFT. 1 H 7 1 3O 3 O 3A19 E252 2004050600070 20040506 00070 SO 2004 5 6 2004FA0000370 2 20040426 G 8530 AEC626820ST2J CYLINDER CESSNA 182 182Q 2072732 CE CONT O470 O470U 17026 SO NR 1 SEPARATED D O OTHER O OTHER NR NOT REPORTED 1 SO 09 97660 18267161 466461 NR 1 CYLINDER HEAD SEPARATED FROM CYLINDER BASE IN FLIGHT. (SO09200406841) 1 H 7 1 3O 3 O NT 3A13 E273 2004051000034 20040510 00034 SO 2004 5 10 2004FA0000371 1 20040423 G 3245 TUBE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540* 41532 EA TIRE BLEW OUT G O OTHER O OTHER LD LANDING 1 EA 17 102WM 250 318152112 NOSE TIRE BLEW ON LANDING. NO CAUSE COULD BE DETERMINED BY MAINT. THEY SUSPECTED LOW TIRE PRESSURE. TUBE VALVE SHEARE D OFF. 1 L 7 2 3O 3 O A20SO E14EA 2004051300035 20040513 00035 2004 5 13 2004FA0000372 4 20040420 G 2561 AV2AS2000 LIFE VEST CABIN FAILED B KQ1R O OTHER O OTHER NR NOT REPORTED 1 EA 07 LIFE PRESERVER FAILED MFG RECOMMENDED CELL PRESSURE TEST. DOM: JULY 1979 2004051200016 20040512 00016 SO 2004 5 12 2004FA0000373 2 20040506 G 7310 6561511A5M MANIFOLD DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240B 17063 SO SNSNCH W69EK W69EK63 EA ENGINE FUEL MALFUNCTIONED C A UNSCHED LANDING Y J ENGINE STOPPAGE WARNING INDICATION AP APPROACH 1 NM 03 491 C0208 806463 AF0823 ENGINE DIED ON DOWNWIND. PILOT LANDED SAFELY. ENGINE STARTED ON GROUND, BUT WAS IDLING AT 750 HAS BEEN SET AT 900. ALSO, HAD NO MIXTURE RISE. DURING SETUP FOR FUEL PRESSURE TESTS THE LINE FROM THE THROTTLE BODY TO THE FUEL MANIFOLD HAD RESI DUAL PRESSURE. THE FUEL MANIFOLD WAS CHANGED AND ENGINE BEHAVED NORMALLY. 1 L 7 1 3O 3 O NT TA4CH E7SO 5 N TA4CH 2004051200023 20040512 00023 SO 2004 5 12 2004FA0000374 1 20040511 G 5341 6676200 ATTACH FITTING PIPER PA28 PA28R201 7102816 SO LYC O360 IO360C1C6 41514 EA MCAULY 2D34C B2D34C213 GL FUSELAGE LOOSE B K NONE O OTHER IN INSP/MAINT 1 SO 15 703ER 2155 2844057 L2983151A 010001 DURING A ROUTINE INSPECTION, THE LT AFT WING ATTACHMENT FITTING WAS FOUND TO HAVE A LOOSE ATTACHING BOLT. THIS PROBLEM H AS BEEN TYPICAL ON A FLEET OF 6 AIRCRAFT OF THIS MODEL. THE PARTS IN QUESTION ARE: P/N-401-187 BOLT (AN5-7A), P/N-66762- 00 (PLATE-AFT SPAR) AND P/N-62448-02 (FITTING-LWR LT FUSELAGE). ONLY THE LT SIDE FITTING HAS BEEN FOUND LOOSE ON ANY OF THESE AIRCRAFT. THE MANUFACTURER HAS BEEN ADVISED OF THIS PROBLEM AND HAS INSPECTED THE SUBJECT AIRCRAFT. THE ONLY PREVE NTIVE MAINTENANCE AT THIS TIME IS REPETITIVE TORQUING OF THE BOLT, VERY OFTEN. 1 L 7 1 3O 3 O 2A13 1E10 5 C P7EA 2004051200026 20040512 00026 SO 2004 5 12 2004FA0000375 1 20040504 G 1430 400873 BOLT PIPER PIPER PA28 PA28R201 7102816 SO LYC O360 IO360C1C6 41514 EA MCAULY 2D34C B2D34C213 GL NLG SHEARED B A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 SO 15 708ER 1692 35 2844067 L3023651A 011204 DURING FLIGHT, THE PILOT REPORTED THAT THE GEAR UNSAFE LIGHT WAS ILLUMINATED DURING GEAR RETRACTION. THE GEAR WAS EXTEND ED AND 3 GREEN LIGHTS WERE OBSERVED. DURING THE SUBSEQUENT INSPECTION, THE BOLT IDENTIFIED BELOW WAS FOUND SHEARED AND T HE PORTION OF THE BOLT WITH THE HEX ON IT WAS NOT FOUND. THE THREADED PORTION, WITH THE NUT AND WASHER STILL ATTACHED, W AS FOUND TO BE THE ONLY ATTACHING ITEM CONNECTING THE ACTUATOR ROD END TO THE OVER CENTER DEVICE. NO OTHER DAMAGE WAS FO UND AND THE HARDWARE WAS REPLACED WITH NEW. 1 L 7 1 3O 3 O 2A13 1E10 5 C P7EA 2004051200029 20040512 00029 SO 2004 5 12 2004FA0000376 1 20040504 G 3220 400873 BOLT PIPER PIPER PA28 PA28R201 7102816 SO LYC O360 IO360C1C6 41514 EA MCAULY 2D34C B2D34C213 GL ZONE 700 SHEARED B A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 SO 15 708ER 1692 35 2844067 L3023651A 011204 DURING FLIGHT, THE PILOT REPORTED THAT THE GEAR UNSAFE LIGHT WAS ILLUMINATED DURING GEAR RETRACTION. THE GEAR WAS EXTEND ED AND 3 GREEN LIGHTS WERE OBSERVED. DURING THE SUBSEQUENT INSPECTION, THE BOLT IDENTIFIED BELOW WAS FOUND SHEARED AND T HE PORTION OF THE BOLT WITH THE HEX ON IT WAS NOT FOUND. THE THREADED PORTION, WITH THE NUT AND WASHER STILL ATTACHED, W AS FOUND TO BE THE ONLY ATTACHING ITEM CONNECTING THE ACTUATOR ROD END TO THE OVER CENTER DEVICE. NO OTHER DAMAGE WAS FO UND AND THE HARDWARE WAS REPLACED WITH NEW. 1 L 7 1 3O 3 O 2A13 1E10 5 C P7EA 2004051400024 20040514 00024 GL 2004 5 14 2004FA0000377 2 20040510 G 8500 BEARING AMTR VANS RV8A 05608J0 GL AMTR CHEVY6 CHEVYV6 GL ENGINE SEIZED G A UNSCHED LANDING G MULTIPLE FAILURE CL CLIMB 1 SW 13 82LS 5 81013 THIS WAS SECOND FLIGHT ON THE AIRCRAFT, AIRCRAFT DEPARTED, AND UPON CLIMB OUT ENGINE EXPERIENCED HIGH OIL TEMPERATURE AN D REDUCED RPM, PILOT RETURNED TO RUNWAY AND LANDED SHORT OF RUNWAY THRESHOLD. EXAMINATION OF ENGINE BY THE PILOT REVEALE D THAT MAIN BEARINGS AND ROD BEARING CLEARANCES WERE TOO TIGHT AND ENGINE PARTIALLY SEIZED. ENGINE INSTALLED IN THIS EXP ERIMENTAL AIRCRAFT IS CONVERTED FOR AIRCRAFT USE. TOTAL RUN TIME ON ENGINE IS APPROXIMATELY FIVE HOURS. 1 L 7 1 3O 3 V NC EXPA1L71 EXPE3V 2004051200051 20040512 00051 2004 5 12 2004FA0000378 4 20040510 G 3416 5934P1 ALTIMETER COCKPIT FAILED C O OTHER O OTHER NR NOT REPORTED 1 SW 17 MOUNTING POST ON DIAPHRAGM ASSEMBLY P/N 2644-452101 SEPARATED FROM DIAPHRAGM, CAUSING COMPLETE FAILURE OF OPERATION. 2004051300019 20040513 00019 CE 2004 5 13 2004FA0000379 1 20040415 G 2720 CONTROL CABLE CESSNA 182 182R 2072731 CE CONT O470 O470* 17026 SO RUDDER FRAYED B OACR O OTHER O OTHER NR NOT REPORTED 1 NE 05 9873E 2357 18268459 WHILE INSTALLING THE BATTERY AFTER SERVING, IT WAS NOTICED THAT THE FORWARD RT RUDDER CABLE WAS FRAYED IN TWO SPOTS. IT WAS DETERMINED THAT, AT SOMETIME, DURING BATTERY REMOVAL OR REINSTALLATION THE RUDDER CABLE ARCED ON BOTH POSITIVE AND NEGATIVE POSTS. THE FORWARD SPOT WAS ARCED THROUGH MORE THAN HALF THE DIAMETER OF THE CABLE. AFTER REMOVING THE CABLE IT WAS NOTICED THAT ONLY TWO STRANDS OF THE CABLE HELD IT TOGETHER. THE CABLE WAS REPLACED WITH FACTORY NEW. THE BATTE RY REMOVAL AND REINSTALLATION ON THIS MODEL AC REQUIRES GOING THROUGH A PANEL IN THE AFT SIDE FUSELAGE. 1 L 7 1 3O 3 O NT 3A13 E273 2004051400122 20040514 00122 CE 2004 5 14 2004FA0000380 1 20040511 G 5730 WING ROOT CESSNA 310 310H 2074220 CE LT & RT BUCKLED C O OTHER O OTHER AB AEROBATIC 1 NM 07 5000 N1091Q AIRCRAFT WAS LOOPED, SPUN, AND BARREL ROLLED. INFORMED, BUT NOTHING WAS DONE. PILOT WAS/IS STILL FLYING CLUB PLANES AN D ANOTHER VISUAL. A RECENT LOOK AT THE AIRCRAFT INDICATES POSSIBLE STRUCTURAL DAMAGE AT THE WING ROOTS. GETTING INDICATI ONS FROM OTHER PILOTS THAT THIS WAS NOT AN ISOLATED INCIDENT. OTHER PILOTS ARE USING THE AIRCRAFT NOT KNOWING OF IT'S P AST HISTORY. THERE ARE OTHER AIRCRAFT AT THIS CLUB THAT WERE ALSO SPUN/LOOPED BUT HAVE NO FIRST HAND KNOWLEDGE OF THIS ( OTHER THAN WHAT OTHER MEMBERS HAVE SAID) 1 L 7 2 3O 3A10 2004051400124 20040514 00124 CE 2004 5 14 2004FA0000381 1 20040511 G 5730 WING CESSNA 310 310H 2074220 CE ZONE 600 BUCKLED C O OTHER O OTHER AB AEROBATIC 1 NM 07 5000 N1091Q AIRCRAFT WAS LOOPED, SPUN, AND BARREL ROLLED. PILOT WAS/IS STILL FLYING CLUB PLANES AND ANOTHER VISUAL. A RECENT LOOK A T THE AIRCRAFT INDICATES POSSIBLE STRUCTURAL DAMAGE AT THE WING ROOTS. GETTING INDICATIONS FROM OTHER PILOTS THAT THIS WAS NOT AN ISOLATED INCIDENT. OTHER PILOTS ARE USING THE AIRCRAFT NOT KNOWING OF IT'S PAST HISTORY. THERE ARE OTHER AIR CRAFT AT THIS CLUB THAT WERE ALSO SPUN/LOOPED BUT HAVE NO FIRST HAND KNOWLEDGE OF THIS (OTHER THAN WHAT OTHER MEMBERS HA VE SAID). 1 L 7 2 3O 3A10 2004051400115 20040514 00115 EU 2004 5 14 2004FA0000382 1 20040329 G 8097 52621 CABLE AIMM AMT200 AMT200S 0160001 EU STARTER BROKEN B O OTHER O OTHER LD LANDING 1 NM 03 140XS 200140 STARTER CABLE PN 52621 BROKE AT THE LUG CONNECTED TO THE STARTER. 1 L 7 1 3I NC TG0004A 2004051300022 20040513 00022 EA 2004 5 13 2004FA0000383 2 20040329 G 8500 IO360L2A ENGINE CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA MAKING METAL D K NONE O OTHER IN INSP/MAINT 1 WP 07 52531 776 172S9172 L3045551A DURING A PHASE INSPECTION, SOME METAL WAS FOUND IN THE FILTER, TOOK OIL SAMPLE FROM OIL COOLER, REMOVED SUCTION SCREEN, MORE METAL WAS FOUND, SENT FILTER AND OIL TO LAB FOR ANALYSIS, SENT METAL FROM SCREEN, WAS ADVISED THAT THE SCREEN MATE RIAL WAS FROM BEARINGS, REMOVED ENGINE FROM SERVICE. THIS IS THE 2ND ENGINE FROM THIS AREA WITH THIS PROBLEM. THIS AIRC RAFT HAS BEEN ON A PHASE INSPECTION PROGRAM SINCE NEW, WITH OIL CHANGES EVERY 50 HRS. 1 H 7 1 3O 3 O NT 3A12 1E10 2004051300023 20040513 00023 EU 2004 5 13 2004FA0000384 1 20040421 G 1430 5PA108 NUT AIMM AMT200 AMT200S 0160001 EU LANDING GEAR MISSING B O OTHER O OTHER LD LANDING 1 NM 03 136XS 318 200136 UPON LANDING AIRCRAFT VEERED OFF THE RUNWAY. UPON INSPECTION IT WAS FOUND THAT THE NUT, (PN 5PA-108) HAD FALLEN OFF ALLO WING THE LINK (PN 32358) TO SEPARATE. 1 L 7 1 3I NC TG0004A 2004051300024 20040513 00024 SO 2004 5 13 2004FA0000385 2 20040426 G 8530 AEC626820ST2J CYLINDER HEAD CESSNA 182 182Q 2072732 CE CONT O470 O470U 17026 SO MCAULY 2A34C C2A34C204 GL ENGINE SEPARATED D A UNSCHED LANDING B E K SMOKE/FUMES/ODORS/SPARKS VIBRATION/BUFFET FLUID LOSS CL CLIMB 1 SO 09 97660 404 18267161 466461 804513 NR 1 CYLINDER HEAD SEPARATED FROM CYLINDER BASE IN FLT. MAY NEED TO BE ADDED TO AD 2004-08-10. 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 2004051900111 20040519 00111 CE 2004 5 19 2004FA0000386 1 20040405 G 7810 22540122 EXHAUST STACK CESSNA 182 TR182 2072735 CE LYC O540 O540L3C5 41532 EA ENGINE FRACTURED C B A EMER. DESCENT UNSCHED LANDING R PARTIAL RPM/PWR LOSS CR CRUISE 1 GL 09 738QV 1200 1200 R18200955 DURING CRUISE FLT AT 7,500 FT. VFR, AIRCRAFT WOULD NOT MAINTAIN 25 INCHES MP. MP DROPPED TO 23 INCHES AFTER APPROX. 15 M IN. MP DROPPED ABRUPTLY TO 18.5 INCHES MP MADE EMERGENCY DESCENT & UNSCHEDULING LANDING AT VNX WITHIN 3 MINUTES OF POWER LOSS. UPON EXAMINATION, FOUND EXHAUST STACK ASSY COMPLETELY FRACTURED, FULL CIRCUMFERANCE OF PIPE AROUND BASE OF FLANGE . ADDITIONALLY, FOUND COMPLETE CIRCUMFERAL FRACTURE OF CROSSOVER AT THE WYE INTERSECTION DOWNSTREAM OF WASTEGATE. ADDITI ONAL HEAT DAMAGE TO EGT PROBE AND WIRING, & LANDING LIGHT & WIRING. DUE TO THE DESIGN OF THIS SYSTEM, & AFTER READING N TSB REPORT CHI02LA218. RECOMMEND AN AD BE ISSUED. 1 H 7 1 3O 3 O 3A13 E295 2004051300026 20040513 00026 SO 2004 5 13 2004FA0000387 2 20040507 G 7313 TITAN ADAPTER CESSNA 310 310Q 2074242 CE CONT O470 IO470VO 17026 SO FUEL NOZZLE BACKED OUT D K NONE O OTHER IN INSP/MAINT 1 SO 15 3310D 45 310Q0630 2 FUEL INJECTION NOZZLE ADAPTERS BACKED OUT WITH FUEL NOZZLES. 1 L 7 2 3O 3 O 3A10 3E1 2004051300033 20040513 00033 SO 2004 5 13 2004FA0000388 1 20040316 G 1430 NAS464P427 BOLT PIPER PA44 PA44180 7104402 SO DRAG BRACE SHEARED B O OTHER O OTHER LD LANDING 1 WP 07 575ER 1350 4496151 ON LANDING ROLLOUT THE NOSEGEAR COLLAPSED. INSPECTION REVEALED THE DRAG BRACE CENTER PIVOT BOLT (PN NAS464P4-27) HAD SH EARED. THESE SAME BOLTS WERE REMOVED AND REPLACED WITH NEW BOLTS ON THE REST OF THE FLEET. ALL BOLTS WERE FOUND TO BE WORN IN A SHEAR TO SOME DEGREE. ALL BOLTS SHOWED SOME EVIDENCE OF CORROSION SUGGESTING INADEQUATE LUBRICATION. THIS OP ERATOR WILL BE FOLLOWING MORE AGGRESSIVE LUBRICATION AND REMOVAL OF THE BOLTS AT 1000 HOURS FOR DETAILED INSPECTION. 1 L 7 2 3O A19S0 2004051300034 20040513 00034 SW 2004 5 13 2004FA0000389 1 20040417 G 7810 6414185 EXHAUST DUCT GULSTM 680 685 0141612 SW CONT O520 GTSIO520K 17032 SO NR 3 CYLINDER BROKEN B A UNSCHED LANDING A FLAME/FIRE CR CRUISE 1 SO 35 414C 12021 226116 IB EXHAUST ON LT ENGINE BROKE AT THE WELD BELOW NR 3 CYLINDER. BURNED HOLE IN LOWER ENGINE COWLING. BURNED WIRE BUNDLE O N THE FIREWALL AFT OF NR 1 CYLINDER. SCORCHED FIRE SLEEVE ON THREE FUEL HOSES. 1 H 7 2 3O 3 O 2A4 E7CE 2004051300037 20040513 00037 CE 2004 5 13 2004FA0000391 1 20040405 G 5712 08522350 RIB CESSNA 402 402B 207590P CE LT WING CRACKED E O OTHER O OTHER NR NOT REPORTED 1 NM 11 4167G 11745 402B1214 RAMP INSP FOUND OIL CANNING IN LT WING OF HIGH TIME. WING WAS INSPECTED AND ONLY DEFECT FOUND WAS LWR FLANGE ON 4 OF IN TERSPAR RIBS WERE CRACKED AT STRINGER PASS-THROUGH. CRACK WAS .5-.75 INCHES LONG AND USUALLY EXTENDED PAST FIRST RIVET. AFTER REPAIRING IAW SRM THE OIL CANNING WAS STILL EVIDENT. CONCLUSION THAT OIL CANNING SKIN IS NOT RESULT OF RIB CRACKS BUT CRACKS ARE DIRECT RESULT OF OIL CANNING SKIN. OIL CANNING WHEN A GENTLE LIFTING FORCE IS PLACED ON AFT END OF TIP TANK (CAUSE OF DAMAGE) AND POSSIBLY SOME LOOSE OR SMOKING RIVETS ON RIB LINE (RESULT OF THE DAMAGE) IF RIVETS ARE LOOSE OR SMOKING BE SURE TO INSPECT INNER STRUCTURE BEFORE PUTTING A BLIND FASTENER IN. 1 L 7 2 3O A7CE 2004051300039 20040513 00039 NM 2004 5 13 2004FA0000392 1 20040429 G 2597 BS0063 CONNECTOR BOEING 717 717200 1383700 NM COFFEEMAKER MISMANUFACTURED B K NONE L NO TEST IN INSP/MAINT 1 SO 15 MOD 16 INSTALLED BY OEM MISWIRED. THIS IS CAUSING THE OVER TEMP PROTECTION CIRCUIT TO BECOME INOPERATIVE. 2 L 7 2 4F TR A6WE 2004051400071 20040514 00071 EA 2004 5 14 2004FA0000394 2 20040414 G 7320 70210301 SERVO CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA MCAULY 1A170 1A170E GL FUEL SYSTEM INOPERATIVE D O OTHER O OTHER NR NOT REPORTED 1 WP 27 665SP 1 172S8069 L1699851A S4101 ENGINE HAD VERY ROUGH AND RICH IDLE, COULD NOT ADJUST IDLE MIXTURE IAW AD. FUEL SERVO WAS INSTALLED ON A FRESH O/H ENGI NE AND FUEL SERVO WAS ALSO FRESH FROM O/H. ENGINE WAS OPERATED AND LEAK CHECKED. AFTER .2 HOURS OF ENGINE OPERATION. FUEL SERVO BECOME ROUGH AND RICH. IDLER MIXTURE COULD NOT BE ADJUSTED. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P857 2004051400100 20040514 00100 CE 2004 5 14 2004FA0000395 1 20040318 G 2820 RSA5AD1 SERVO CESSNA 172 172S 2072439 CE LYC O320 IO320* 41508 EA MCAULY 1A170 1A170E GL FUEL SYSTEM INOPERATIVE D O OTHER O OTHER NR NOT REPORTED 1 WP 27 974SP 2195 172S8178 L2893651A TB007 FUEL MIXTURE CONTROL ARM WILL NOT ROTATE TO (IDLE CUT-OFF) POSITION. 1 H 7 1 3O 3 O NT 3A12 1E12 5 N P857 2004051400094 20040514 00094 SO 2004 5 14 2004FA0000396 1 20040413 G 3340 6041H202 RELAY PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360* 17025 SO STROBE LIGHT INOPERATIVE D O OTHER O OTHER NR NOT REPORTED 1 SO 13 312AJ 3449188 DURING A RAIN STORM FLIGHT PERSONNEL REPORTED TO RAMP 66 MAINTENANCE DEPT THAT AC. WINGS AND TAIL STROBE LIGHTS CAME ON . MAINT MECH CHECKED BATTERY SWITCH. SWITCH WAS TURNED OFF. DURING TROUBLESHOOT AFT COMPARTMENT FLOORING WAS REMOVED BEHIND PASSENGER SEATS. WATER WAS STANDING 2 INCHES IN BELLY OF AC. BATTERY RELAY WAS STANDING IN WATER. AFTER REMOVI NG, WATER WAS FOUND INSIDE OF THE RELAY. RELAY HAD LARGE PITTING HOLE AND SHOWED SIGNS OF ARCING. 1 L 7 2 3O 3 O A7SO E9CE 2004051400092 20040514 00092 SO 2004 5 14 2004FA0000397 2 20040501 G 7414 10400316 IMPULSE COUPLING CESSNA 337 T337G 2075726 CE CONT O360 TSIO360CB 17025 SO MAGNETO BROKEN D O OTHER O OTHER NR NOT REPORTED 1 SO 13 8AH 36 P3370030 824766 PILOT REPORTED REAR ENGINE WAS HARD TO START. AFTER TROUBLESHOOTING, THE LT MAGNETO WAS REMOVED. UPON INSPECTION THE I MPULSE COUPLING WOULD NOT ROTATE IN THE CORRECT DIRECTION. THE MECH WAS NOT SURE IF WRONG IMPULSE COUPLING OR SPRING TU RN BACKWARD. DUE TO ONLY 36 HRS AND 1 YR 10 MO. SINCE ENGINE WAS REBUILT BY MFG. MFG INSPECTED IMPULSE COUPLING AND DI SCOVERED IMPULSE SPRING BROKEN. 1 H 7 2 3O 3 O A6CE E9CE 2004051400095 20040514 00095 SO 2004 5 14 2004FA0000398 1 20040317 G 5720 STRAP MICCO 145A MAC145A 5660000 SO LYC O540 IO540T4B5 41532 EA WING CRACKED D LM8S O OTHER O OTHER NR NOT REPORTED 1 NM 07 969WC 188 260010 DURING AN ANNUAL INSPECTION THE BUTT WELDS IN THE LOWER MAIN SPAR REINFORCEMENT STRAP, APPROX 3.25 INCHES IB FROM EACH E ND OF THE REINFORCEMENT STRAP, DO NOT HAVE PROPER PENETRATION AND ARE CRACKED THRU THE WELD. MFG WAS CONTACTED AND REPA IR INSTRUCTIONS WERE PROVIDED. THE WELDS WERE PROPERLY PREPARED AND REWELDED IAW THE MFG INSTRUCTIONS BY A CERTIFIED WE LDING REPAIRMAN. 1 L 7 1 3O 3 O RC 1E4 2004051400096 20040514 00096 SO 2004 5 14 2004FA0000399 1 20040317 G 5720 STRAP MICCO 145A MAC145A 5660000 SO LYC O540 IO540* 41532 EA WING CRACKED D LM8S O OTHER O OTHER NR NOT REPORTED 1 NM 07 969WC 260010 L2797148A DURING AN ANNUAL INSPECTION THE BUTT WELDS IN THE LOWER MAIN SPAR REINFORCEMENT STRAP. APPROX 6.50 INCHES IB FROM EACH E ND OF THE REINFORCEMENT STRAP. DO NOT HAVE PROPER PENETRATION AND ARE CRACKED THRU THE WELD. MFG WAS CONTACTED AND REP AIR INSTRUCTIONS WERE PROVIDED. THE WELDS WERE PROPERLY PREPARED AND REWELDED IAW MFG. 1 L 7 1 3O 3 O RC 1E4 2004051400067 20040514 00067 SO 2004 5 14 2004FA0000400 1 20040317 G 5740 ATTACH BRACKET MICCO 145A MAC145A 5660000 SO LYC O540 IO540T4B5 41532 EA HARTZL HCC3Y HCC3YR GL LT WING CRACKED D LM8S O OTHER O OTHER NR NOT REPORTED 1 NM 07 969WC 260010 L2797148A DY4978B DURING AN ANNUAL INSPECTION THE WELD JOINT THAT ATTACHES THE UPPER WING SKIN ATTACH BRACKET TO THE UPPER MAIN WING SPAR CENTER SECTION JUST ABOVE THE UPPER LT WING ATTACHMENT FITTING WAS CRACKED. MANUFACTURER WAS CONTACTED AND REPAIR INSTR UCTIONS WERE PROVIDED. THE LT WING WAS REMOVED FOR ACCESS. THE LT WING WELD AREA WAS PROPERLY PREPARED AND REWELDED IA W MM. 1 L 7 1 3O 3 O RC 1E4 5 C P25EA 2005022200002 20050222 00002 GL 2005 2 22 2004FA0000401 1 20040513 G 3242 DP600 PAD AMTR VM1 VM1 05601TD GL BRAKES BINDING G C ABORTED TAKEOFF W INADEQUATE Q C TO TAKEOFF 1 GL 07 626EA 133 E180032 PILOT WAS IN PROCESS OF TAKEOFF ROLL, PILOT REPORTED A/C VEERED TO LT HITTING A RUNWAY LIGHT, WENT OVER SOME TERRAIN AND ENDED PARTIALLY SUBMERGED IN A BODY OF WATER. AN EXAMINATION OF THE A/C WAS CONDUCTED. THE A/C CONFIG INCLUDES A FREE C ASTORING NOSE WHEEL AND BRAKES ARE OF A MOTO-GUZZI MOTORCYCLE. LT BRAKE FOUND TO BE DRAGGING SUBSTANTIALLY, AFFECTING TH E SMOOTH ROTATION OF THE LT MAIN GEAR WHEEL. THE RT WHEEL AND BRAKE WERE SATISFACTORY. THE BRAKE WAS REMOVED. IT WAS FOU ND THE DESIGN OF WIRE LOOP USED AS A MEANS TO HOLD BRAKE PADS ALIGNED, APPLIES CONSTANT RESISTANCE ON THE BRAKE PADS. TH IS CONSTANT RESISTANCE PREVENTS THE BRAKE PADS FROM FLOATING AT ALL, THERE IS MINIMAL CLEARANCE, FROM THE BRAKE DISC. 1 L 7 1 3O NT EXPA1L71 2004051400116 20040514 00116 CE 2004 5 14 2004FA0000402 1 20040310 G 2752 1015210161R ACTUATOR BEECH 200 A200 1152921 CE PWA PT6 PT6A41 52043 EA TE FLAPS SEPARATED D D RETURN TO BLOCK F J FLT CONT AFFECTED WARNING INDICATION TX TAXI/GRND HDL 1 WP 23 200ET 3753 BC73 CREW RETRACTED FLAPS, FLAPS STOPPED .5000 WAY UP. SPLIT FLAP SAFETY CIRCUIT STOPPED FLAP RETRACTION. REVEALED THAT LT IB FLAP ACTUATOR HAD FAILED. 90 DEGREE DRIVE (P/N 50-380153-3) HAD COMPLETELY SEPARATED FROM MAIN BODY (SCREW DRIVE) OF ACTUATOR. FAILURE WAS CAUSED BY LOCKING PIN IN 90 DEG. DRIVE WHICH HAD NOT BEEN PROPERLY ENGAGED INTO GROOVE IN MAIN B ODY AT LAST O/H. WEAR EVIDENCE SHOWS, PIN WAS IMPROPERLY ENGAGED IN MAIN BODY, DID NOT ENGAGE GROOVE APPROPRIATELY. GR OOVE AND PIN WORE UNTIL IT ALLOWED THE 90 DEGREE DRIVE TO DISENGAGE FROM MAIN BODY, 3352 LANDINGS AND 3753 HOURS SINCE A CTUATOR ASSY WAS LAST OVERHAULED. THERE IS NO PRESCRIBED OVERHAUL TIME OR CYCLE LIMIT REQUIREMENT FOR THIS ACTUATOR. 1 L 7 2 4T 4 T A24CE E4EA 2004051400117 20040514 00117 NM 2004 5 14 2004FA0000403 1 20040513 G 5310 41513128 SPAR CAP UNIVAR UNIVAR 415 A2AALON 0540104 NM FUSELAGE CORRODED D K NONE O OTHER IN INSP/MAINT 1 NM 01 224PW 3798 B253 DURING INSPECTION REQUIRED BY AD-2003-21-01, INTERGRANULAR AND EXFOLIATION CORROSION WAS DISCOVERED ON THE MAIN SPAR LOW ER CAP. THE CENTER SECTION FRONT SPAR WILL REQUIRE REPLACEMENT. 1 L 7 1 3O A787 2004052000078 20040520 00078 CE 2004 5 20 2004FA0000404 1 20040517 G 3040 66004047 WINDSHIELD LEAR 55 55LEAR 5170702 CE COCKPIT CRACKED B K NONE G MULTIPLE FAILURE IN INSP/MAINT 1 CE 03 345RJ 6711 078 SEVERE DELAMINATION OF OUTER PLY ON LT WINDSHIELD UNDER BLEED AIR DUCT AND ANTI-ICE SPRAY NOZZLE. SUSPECT SEALER FAILED AND ALLOWED METHYL ALCOHOL TO MIGRATE THROUGH SEALER AND SETTLE BETWEEN LAYERS AND DETERIORATED THE WINDSHIELD. 2 L 7 2 4F A10CE 2004052400059 20040524 00059 CE 2004 5 24 2004FA0000406 1 20040518 G 2520 SEAT LEAR 35 31A 5170531 CE CABIN MISMANUFACTURED B K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 09 766AJ 103 FOUND WIDTH BETWEEN CABIN SEATS WAS 8.5 INCHES IN AREA FROM FLOOR UP TO TWENTY FIVE INCHES ABOVE FLOOR. ARMRESTS WERE SO URCE OF THIS DISCREPANCY. IAW TYPE CERTIFICATE THIS AIRCRAFT MODEL IS SPECIFICALLY EXCLUDED FROM THE SERIES 24/25 AND 3 5/36 EQUIVALENT LEVEL OF SAFETY FINDING FOR 14CFR, PART 2, SECTION 25.815 ALLOWING LESS THAN NINE INCH AISLE WIDTH. TECH SUPPORT CONFIRMED THAT AISLE WIDTH ON THIS MODEL AIRCRAFT MUST BE AT LEAST NINE INCHES MEASURED FROM FLOOR UP TO TWENTY FIVE INCHES ABOVE FLOOR. DETERMINED THAT CHAIRS HAD EXCESS FOAM PADDING ON LOWER SHROUD BASE. REMOVED FOAM PADDING FRO M LOWER SHROUD BASE, THUS ALLOWING ARMREST TO MOVE FARTHER OB. THIS ENABLED A NINE INCH AISLE WIDTH TO BE OBTAINED. 2 L 7 2 4F RT A10CE 2004052400055 20040524 00055 SO 2004 5 24 2004FA0000407 2 20040520 G 7322 45A10396512 CARBURETOR CESSNA 180 180 2072602 CE CONT O470 O470* 17026 SO ENGINE WORN D O OTHER O OTHER NR NOT REPORTED 1 NM 03 180C 4000 32312 CARBURETOR STICKING AT FULL THROTTLE DUE TO WEAR OF THE FULL THROTTLE STOP. IT WAS ACTUALLY GOING PAST FULL THROTTLE. THE PUMP LEVER ASSEMBLY WOULD TURN PAST THE AIR METERING PIN AND HANG UP THE THROTTLE SHAFT IN WIDE OPEN POSITION. 1 H 7 1 3O 3 O NC 5A6 E273 2004052500031 20040525 00031 CE 2004 5 25 2004FA0000408 1 20040430 G 2110 45AS63019009 SHUTOFF VALVE BEECH MU300 400A 1155402 CE PWA JT15 JT15D5 52112 NE AIR CONDITIONER INOPERATIVE B E81R C ABORTED TAKEOFF J WARNING INDICATION TO TAKEOFF 1 GL 03 453CW RK53 PILOT REPORTED EMERGENCY PRESSURIZATION SYSTEM CAME ON DURING TAKEOFF WITH AIR CONDITIONING FAIL ANNUNCIATOR LIGHT ILLUM INATED. TROUBLESHOT SYS IAW MM21-00-00. FOUND RT PRESSURE REGULATING/SHUT-OFF VALVE (PRSOV) HAD FAILED, ALLOWING FULL BLEED AIR VOLUME THROUGH AT ALL THROTTLE SETTINGS. REPLACED PRSOV WITH OVERHAULED VALVE IAW MM21-10-00. ENVIRONMENTAL SYS OPERATIONAL CHECKS NORMAL ON GROUND RUN-UP. MAINTENANCE RECORDS UNAVAILABLE. 2 H 7 2 4F 4 F RT A16SW E25EA 2004052600056 20040526 00056 WP 2004 5 26 2004FA0000409 2 20040524 G 7250 8687466 GASKET GARRTT TPE331 TPE33110 01514 WP PLENUM FAILED B O OTHER O OTHER NR NOT REPORTED 1 GL 25 P36043C PLENUM FUEL NOZZLE BOSS BLANK-OFF COVER GASKET PN 868746-6 (BLEW OUT) ON 5 OF 5 BOSSES. GASKET FAILURE ALLOWS HOT COMPR ESSOR GAS LEAKING. GASKETS WERE ALL REPLACED AND ENGINE WAS TEST RUN. 3 OF 5 NEW GASKETS (BLEW OUT) DURING TEST RUN. 4 T E4WE 2004052600068 20040526 00068 WP 2004 5 26 2004FA0000410 2 20040524 G 7250 8687466 GASKET GARRTT TPE331 TPE33110 01514 WP PLENUM FAILED B O OTHER O OTHER NR NOT REPORTED 1 GL 25 P36043C PLENUM FUEL NOZZLE BOSS BLANK-OFF COVER GASKET PN 868746-6 (BLEW OUT) ON 5 OF 5 BOSSES. GASKET FAILURE ALLOWS HOT COMPR ESSOR GAS LEAKING. GASKETS WERE ALL REPLACED AND ENGINE WAS TEST RUN. 3 OF 5 NEW GASKETS (BLEW OUT) DURING TEST RUN. 4 T E4WE 2004052600070 20040526 00070 NM 2004 5 26 2004FA0000411 1 20040525 G 2910 280411 FUSE BOEING 737 737300 1384610 NM HYD SYSTEM BROKEN C O OTHER O OTHER NR NOT REPORTED 1 SW 05 INSIDE THE HYDRAULIC FUSE P/N 2-8041-1 IS A MATCHED SET OF PARTS P/N 7-2500-6 SEPARATED BY A FORMED WASHER. UPON DISASS EMBLY OF THESE PART THE FORMED WASHER HAS BEEN FOUND TO BE BROKEN. THESE UNITS ARE SUPPLIED TO US FROM AN AIRLINE TO I NSPECT, MANY OF THESE APPEAR TO SHOWING UP IN OUR SYSTEM. HOURS ARE UNKNOWN. SERIAL NUMBERS RANDOM. 2 L 7 2 4F RT A16WE 2004052600126 20040526 00126 CE 2004 5 26 2004FA0000413 1 20040506 G 7921 53E22144 VALVE CESSNA 150 150J 2071820 CE LYC O720 IO720A1B 41546 EA OIL COOLER INOPERATIVE D O OTHER J WARNING INDICATION NR NOT REPORTED 1 GL 15 50786 12 15069552 RL146754A PILOT REPORTED HIGH OIL TEMPERATURE 220-225 DEGREES, REMOVED VALVE AND TESTED SIDE BY SIDE WITH NEW VALVE, OLD VALVE DID NOT CLOSE AT THE SAME RATE AS NEW VALVE, INSTALLED NEW VALVE AND OIL TEMP DECREASED TOO. 1 H 7 1 3O 3 O 3A19 1E15 2004052600130 20040526 00130 SO 2004 5 26 2004FA0000414 1 20040514 G 2197 WIRE PIPER PA23 PA23250 7102308 SO LYC O540 IO540* 41532 EA FAN BURNED C D RETURN TO BLOCK B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 SO 15 661SC 5694 010316 278054052 COCKPIT BEGAN TO FILL WITH SMOKE WHILE TAXIING FOR TAKE-OFF. AIRCRAFT WAS SHUTDOWN AND UPON INSPECTION FOUND AVIONIOCS FAN TO BE BURNT ON CORNER WHERE WIRES ENTER FAN ASSEMBLY. THE DATE STAMPED ON FAN IS NOV. 1979. SUSPECT THE AGE AND TI ME IN SERVICE WOULD BE THE CAUSE OF DEFECT. THESE ELECTRICAL PARTS SHOULD BE INSPECTED CLOSELY FOR ANY SIGNS OF MELTING OR DISCOLORED PLASTIC. 1 L 7 2 3O 3 O 1A10 1E4 2004052600127 20040526 00127 2004 5 26 2004FA0000415 4 20040422 G 2561 KSE35L8PO723E105 LIFE VEST CABIN FAILED B KQ1R O OTHER O OTHER NR NOT REPORTED 1 EA 07 LIFE PRESERVER FAILED MFG RECOMMENDED CELL PRESSURE TEST IAW 25-60-12. DOM: DEC 1990. 2004052600128 20040526 00128 2004 5 26 2004FA0000416 4 20040422 G 2561 AV35S211506300 LIFE VEST CABIN FAILED B KQ1R O OTHER O OTHER NR NOT REPORTED 1 EA 07 LIFE VEST FAILED MFG RECOMMENDED CELL PRESSURE TEST IAW MM 25-60-200. LIFE PRESERVER MFG, DATE: AUSUST 1989. 2004052600129 20040526 00129 CE 2004 5 26 2004FA0000417 1 20040504 G 5511 053200196 SPAR CESSNA 172 172S 2072439 CE LYC O360 IO360A1A 41514 EA HORIZONTAL STAB DAMAGED B LC1R K NONE O OTHER IN INSP/MAINT 1 EA 07 24787 172S8804 WHILE PERFORMING THE INSPECTIONS REQUIRED BY MFG SB04-55-01, FOUND THE RT SIDE HOLE IN THE HORIZONTAL STABILIZER AFT SPA R ELONGATED. THIS ELONGATION OPENED THE HOLE APPROX. .040 TO .050 INCHES IN THE 5 O`CLOCK DIRECTION (VIEWING THE HOLE F ROM THE ACCESS IN THE TIO STABILIZER SKIN, LOOKING AFT). ELONGATION DID NOT APPEAR TO EXTEND INTO THE PN 0531006-113 HO RSESHOE FITTING ON THE VERTICAL STABILIZER OR INTO THE PN 05121595 AFT BULKHEAD. ADDITIONALLY, THE BOLT DID NOT APPEAR TO BE WORN. IAW MFG TECH SUPPORT, HOLE WILL BE ENLARGED TO NEXT BOLT SIZE AND APPROPRIATE SIZE BOLT WILL BE INSTALLED. CONDITION SB IS INSPECTING FOR WAS NOT FOUND. 1 H 7 1 3O 3 O NT 3A12 1E10 2004052800057 20040528 00057 GL 2004 5 28 2004FA0000418 1 20040503 G 2720 CONTROL CABLE YAKLEV YAK983 YAK50 9830220 GL RUDDER MISINSTALLED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 07 150YK 822308 UPON CONDITIONAL INSPECTION, WHILE AIRCRAFT PARKED ON RAMP. FOUND AFT RT RUDDER CABLE PULLEY OUT OF TERMINAL END. SENT TO REPAIR SHOP AND WAS TOLD TERMINAL END WAS NOT SWAGED PROPERLY DURING ASSY. INSPECTED AND REPLACED ALL CABLE CONTROL S AS PRECAUTIONARY MEASURES. 1 L 7 1 3R RT EXPA1L71 2004060100006 20040601 00006 SO 2004 6 1 2004FA0000419 2 20040406 G 8530 655474 CYLINDER CONT O520 GTSIO520* 17032 SO ENGINE CRACKED B VA1R K NONE O OTHER NR NOT REPORTED 1 SW 19 RAM AIRCRAFT HAS FOUND NUMEROUS CYLINDERS WITH LOW HOURS CRACKED IN AN AREA EXTENDING FROM FUEL INJECTOR BOSS AREA TO TH E SPARK PLUG HOLE. IN THIS AREA IS A MACHINED AREA WITHOUT SUFFICIENT RADIUS. SUGGEST RADIUS OF THIS AREA TO PREVENT C RACKING. 3 O E7CE 2004060100008 20040601 00008 CE 2004 6 1 2004FA0000421 1 20040421 G 3610 99144022 PRECOOLER CESSNA 525 525 2076601 CE WILINT FJ44 FJ441A GL RT PYLON SPLIT D K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 CE 01 195ME 4395 5250110 PILOTS NOTICED SLIGHT TEMP RISE IN RT ENGINE, AND AN UNUSUAL VIBRATION ALL ENGINE INDICATIONS IN NORMAL RANGES POSTFLIGH T WALK AROUND NOTICED A SPLIT IN THE PRESSURIZATION (BLEED AIR) PRE-COOLER IN THE RT PYLON. PAINT DISCOLORATION WAS NOT ED NO DAMAGE TO ADJACENT STRUCTURES. NO EVIDENCE OF IMPACT DAMAGE. IT SHOULD BE NOTED THAT THIS PRE-COOLER IS UP-STREA M OF THE BLEED AIR SHUT OFF VALVES. INCLUDE INSPECTION AT PRE-POST FLIGHT. 1 L 7 2 4F 4 F RT A1WI E3GL 2004060100009 20040601 00009 SO 2004 6 1 2004FA0000422 1 20040301 G 7120 5501111501 MOUNT AMRGEN AA5 AA5B 3960105 SO LYC O360 O360* 41514 EA ENGINE CRACKED C K NONE O OTHER IN INSP/MAINT 1 WP 23 74608 4700 AA5B0282 DURING ANNUAL INSP, A CRACK WAS NOTED IN THE LOWER HORIZONTAL CROSSPIECE OF THE ENGINE MOUNT. THE CRACK IS APPROX .5000 INCH AWAY FROM THE PILOT SIDE END OF THIS TUBE, NEAR THE WELD THAT ATTACHES THIS TUBE TO THE DIAGONAL TUBE THAT ATTACHE S TO THE FIREWALL LOWER PILOT SIDE SUPPORT BRACKET. THIS SAME CRACK LOCATION HAS BEEN SEEN IN SEVERAL AIRCRAFT. APPEAR S TO BE A POINT OF HIGH VIBRATION INDUCED STRESS, AS THERE IS LITTLE LOAD ON THE PART DURING OPERATION. 1 L 7 1 3O 3 O A16EA E286 2004052700078 20040527 00078 SW 2004 5 27 2004FA0000423 1 20040325 G 6220 K910005007 PIN KAMAN K1200 K1200 05625F6 SW LYC T53 T5317A 41549 NE LT ROTOR HUB UNSERVICEABLE D O OTHER O OTHER NR NOT REPORTED 1 SO 15 358KA 269 A940029 THE LEADING EDGE OF THE LT SIDE TEETER PIN WAS DAMAGED (MUSHROOMED). FURTHER INSPECTION SHOWED THAT THE HEAD SIDE OF TH E INSIDE DIAMETER OF THE LINER THAT THE TEETER PIN SITS IN IS ALSO DAMAGED. THE LINER IS DEFORMED AND PROTRUDES IN AN I RREGULAR MANNER ON THE LEADING EDGE. THE TEETER PIN SHOWS CROSS-CORNER WEAR. THE TEETER THRUST WASHER ON THE HEAD SIDE WAS ALSO MISSING. THERE WAS RESIDUE OF THE COATING ON THE ID OF THE LINER. THE DAMAGES EXCEED THE INSPECT LIMITS ON T HE TEETER PIN NON-CRITICAL AREA IAW THE CRITERIA ON THE ROTOR HUB ASSY INSP. RESIDUE WAS FOUND ON THE HEAD SIDE OF THE RIGHT TEETER PIN. PLAY GREATER THAN .015 ON THE TEETER PIN ALLOWABLE PLAY LIMITS WAS ALSO NOTED. 1 G 7 1 4F 4 U NT TR7BO E17EA 2004060100102 20040601 00102 CE 2004 6 1 2004FA0000424 1 20040529 G 5412 05131092956 DOUBLER CESSNA 172 172N 2072434 CE FIREWALL CORRODED D K NONE O OTHER IN INSP/MAINT 1 SO 06 734BZ 3695 17268738 DURING ANNUAL INSPECTION FOUND POPPED RIVET HEADS IN FIREWALL DOUBLERS, REMOVED DOUBLERS FOUND EXFOLIATION EXCEEDING 40 PERCENT THICKNESS ON BACK SIDE OF DOUBLERS, REPLACED DOUBLER, RECOMMEND CLOSE INSPECTION OF RIVET HEADS IN THIS AREA. 1 H 7 1 3O NT 3A12 2004071200182 20040712 00182 CE 2004 7 12 2004FA0000425 1 20040601 G 5751 6524010810 SKIN CESSNA 500 560CESSNA 2076750 CE AILERON DELAMINATED C O OTHER O OTHER NR NOT REPORTED 1 SW 99 5511 AILERON TRAILING EDGE DELAMINATED WITH LOSS OF MATERIAL. 2 L 7 2 4F RT A22CE 2004061400212 20040614 00212 CE 2004 6 14 2004FA0000427 1 20040506 G 2421 643840 BEARING CESSNA 210 210L 2073448 CE CONT O520 IO520L 17032 SO ALTERNATOR FAILED C O OTHER O OTHER NR NOT REPORTED 1 GL 23 59292 21060196 294956 BEARING AT PULLEY END, PN 643840, FAILED, ALLOWING BELT TO BECOME OUT OF ALIGNMENT. BELT CAME OFF OF PULLEY CAUSING ALT ERNATOR TO BECOME INOPERATIVE. 1 H 7 1 3O 3 O 3A21 E5CE 2004061400220 20040614 00220 SO 2004 6 14 2004FA0000428 1 20040428 G 2820 231311 LINE BALWKS FIREFY FIREFLY11 1050125 SO FUEL DIST INADEQUATE B B24R O OTHER O OTHER NR NOT REPORTED 1 WP 07 2192Y 159 F112004 UPON INSPECTION OF VALVE LINE SEVERAL LOCATIONS WERE FOUND WHERE THE INNER KEVLAR LINE HAS BUNCHED UP AND BECAME EXPOSED THROUGH THE OUTER PROTECTIVE NYLON COVER. THIS WAS FOUND IN VARIOUS PLACES ALONG LENGTH OF LINE. EACH OF THE PEA SIZE D EXPOSED AREAS HAVE ABRASION ON THE EXPOSED KEVLAR. THIS LINE WAS REMOVED FROM SERVICE. 1 B 0 0 A14SO 2004061400265 20040614 00265 CE 2004 6 14 2004FA0000429 1 20040527 G 2730 0510105291 CONTROL CABLE CESSNA 172 172M 2072418 CE LYC O320 O320* 41508 EA ELEVATOR BROKEN B KH5R K NONE O OTHER IN INSP/MAINT 1 GL 15 4366R 17263117 ANNUAL INSPECTION FOUND UPPER ELEVATOR CABLE WITH SOME BROKEN STRANDS. REPLACED BOTH CABLES BOTH AIRCRAFT HAVE A LITTLE OVER 5000.0 HOURS ON THEM. 1 H 7 1 3O 3 O NT 3A12 E274 2004061400202 20040614 00202 CE 2004 6 14 2004FA0000430 1 20040527 G 2730 0510105291 CONTROL CABLE CESSNA 172 172P 2072436 CE ELEVATOR BROKEN B KH5R K NONE O OTHER IN INSP/MAINT 1 GL 15 53373 17274734 ANNUAL INSPECTION FOUND UPPER ELEVATOR CABLE WITH SOME BROKEN STRANDS. REPLACED BOTH CABLES. AIRCRAFT HAS A LITTLE OVE R 5000.0 HOURS. 1 H 7 1 3O NT 3A12 2004061400203 20040614 00203 2004 6 14 2004FA0000431 4 20040511 G 2561 D21343153 LIFE VEST EMERGENCY EQUIP FAILED B KQ1R K NONE L NO TEST IN INSP/MAINT 1 EA 07 LIFE PRESERVER FAILED, MFG RECOMMENDED CELL PRESSURE TEST IAW 25-60-05. 2004061400269 20040614 00269 SO 2004 6 14 2004FA0000432 2 20040521 G 7314 6467682 PUMP CESSNA 210 T210L 2073449 CE CONT O520 TSIO520H 17040 SO ENGINE INOPERATIVE D O OTHER O OTHER NR NOT REPORTED 1 NM 07 93379 3 21060383 506168 ENGINE DRIVEN FUEL PUMP NO METERED OR UN METERED FUEL PRESSURE WHILE ENGINE RUNNING. FUEL PUMP RECENTLY INSTALLED HAD 2 .7 HOURS ON IT, AFTER OVERHAUL. INSTALLED NEWLY OVERHAULD PUMP. OPS CHECK GOOD. PROBABLE CAUSE OF PUMP FAILURE, UNKNO WN. 1 H 7 1 3O 3 O 3A21 E8CE 2004061400264 20040614 00264 CE 2004 6 14 2004FA0000433 1 20040514 G 2130 26011 VALVE CESSNA 650 650 2076802 CE GARRTT TFE731 TFE731* 01518 WP EMER PRESS FAILED C A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 GL 03 900JD 556 6500213 DURING CLIMBOUT FROM MLI, THE RT EMERGENCY PRESSURIZATION VALVE OPENED ALLOWING HIGH PRESSURE BLEED AIR TO ENTER THE CAB IN. THIS CAUSED THE CABIN TEMP TO RISE AND A LOUD AUDIBLE RUSH OF AIR TO BE HEARD IN THE CABIN. THE FLIGHT CREW ELECTE D TO RETURN TO POINT OF DEPARTURE (MLI). MAINTENANCE CONFIRMED THE FAILURE AND REPLACED THE VALVE. GROUND TESTS CONCLU DED THAT THE NEW VALVE WAS WORKING PROPERLY. A FLIGHT WAS INITIATED WITHOUT PASSENGERS TO CONFIRM THAT THERE WERE NO MO RE ANOMALIES WITH THE EMERGENCY PRESSURIZATION SYSTEM. 2 L 7 2 4F 4 F A9NM E6WE 2004062100144 20040621 00144 CE 2004 6 21 2004FA0000434 1 20040609 G 5753 FLAP TRACK CESSNA 206 T206H 2073303 CE WING MISINSTALLED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 07 2378X T20608023 MECHANIC HEARD (POPPING) NOISE WHEN FLAPS WERE EXTENDED OR RETRACTED. FOUND THE UPPER FLAP TRACK HARDWARE WAS HITTING T HE FLAP WELL CUT OUTS. THE BOLTS WERE INSTALLED FACING OB AT THE FACTORY. REVERSED HARDWARE AND PROBLEM WENT AWAY. 1 H 7 1 3O RT A4CE 2004062100168 20040621 00168 CE 2004 6 21 2004FA0000435 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195 2073102 CE JACOBS R755 L4* 35003 EA AILERON CRACKED D O OTHER O OTHER NR NOT REPORTED 1 CE 03 4352V 7261 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ) WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED. 1 H 7 1 3R 3 R NC A790 TC121 2004062100124 20040621 00124 CE 2004 6 21 2004FA0000436 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195 2073102 CE JACOBS R755 R7557 35003 EA AILERON CRACKED D O OTHER O OTHER NR NOT REPORTED 1 CE 03 1030D 7643 INSPECTED ORIGINAL MAGENSIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED. 1 H 7 1 3R 3 R NC A790 5E11 2004062200210 20040622 00210 CE 2004 6 22 2004FA0000437 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195 2073102 CE AILERON CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 03 9836A 7529 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESES BRACKET S). WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED. 1 H 7 1 3R NC A790 2004062200156 20040622 00156 CE 2004 6 22 2004FA0000438 1 20040525 G 5751 03227091 HINGE BRACKET CESSNA 195 195 2073102 CE AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 4426C 16011 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORHTY DUE TO CORROSION, 35 PERCENT ARE CRACKED. 1 H 7 1 3R NC A790 2004062200149 20040622 00149 CE 2004 6 22 2004FA0000439 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195A 2073110 CE JACOBS R755 R7557 35003 EA AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 9331A 7410 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR AL OF THE FOLLOWING CONDITIONS: SEVERELY CORRO DED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEET . PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESES BRACKETS ). WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED. 1 H 7 1 3R 3 R A790 5E11 2004062300039 20040623 00039 CE 2004 6 23 2004FA0000440 1 20040525 G 5751 0322790 HINGE BRACKET CESSNA 195 195 2073102 CE AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 1508D 7730 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED. 1 H 7 1 3R NC A790 2004062300040 20040623 00040 CE 2004 6 23 2004FA0000441 1 20040525 G 5751 03227091 HINGE BRACKET CESSNA 195 195 2073102 CE AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 4345V 7272 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED. 1 H 7 1 3R NC A790 2004062200155 20040622 00155 CE 2004 6 22 2004FA0000442 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195B 2073112 CE JACOBP R755 R755B1 35007 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 195AC 7907 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED. 1 H 7 1 3R 3 R A790 TC237 2004062300041 20040623 00041 CE 2004 6 23 2004FA0000443 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195A 2073110 CE AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 41X 7775 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERLY CORRO DED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEET . PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS. (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKET S). WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED. 1 H 7 1 3R A790 2004062200150 20040622 00150 CE 2004 6 22 2004FA0000444 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195B 2073112 CE AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 2194C 16179 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED. 1 H 7 1 3R A790 2004062300042 20040623 00042 CE 2004 6 23 2004FA0000445 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195 2073102 CE PWA R985 R985* 52008 NE AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 4383V 7305 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED. 1 H 7 1 3R 3 R NC A790 5E1 2004062200209 20040622 00209 CE 2004 6 22 2004FA0000446 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195B 2073112 CE AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 2152C 16137 INSPECTED ORIGINAL MAGNESIUM INBOARD AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTIN G FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS ( THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE B RACKETS). WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED. 1 H 7 1 3R A790 2004062200152 20040622 00152 CE 2004 6 22 2004FA0000447 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195 2073102 CE AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 195EL 7794 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED. 1 H 7 1 3R NC A790 2004062200207 20040622 00207 CE 2004 6 22 2004FA0000448 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195B 2073112 CE AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 3050B 7933 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ) WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED. 1 H 7 1 3R A790 2004062200151 20040622 00151 CE 2004 6 22 2004FA0000449 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195 2073102 CE JACOBP R755 R755A1 35006 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 4381V 7303 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING AND/OR MOUNTING FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS). WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNA IRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED. 1 H 7 1 3R 3 R NC A790 TC237 2004062200153 20040622 00153 CE 2004 6 22 2004FA0000450 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195 2073102 CE JACOBP R755 R755A1 35006 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 4331N 7078 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ) WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED. 1 H 7 1 3R 3 R NC A790 TC237 2004062200208 20040622 00208 CE 2004 6 22 2004FA0000451 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195 2073102 CE JACOBP R755 R755A1 35006 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 195SC 7402 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED. 1 H 7 1 3R 3 R NC A790 TC237 2004062200154 20040622 00154 CE 2004 6 22 2004FA0000452 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195 2073102 CE JACOBP R755 R755A1 35006 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 9810A 7489 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS . 1 H 7 1 3R 3 R NC A790 TC237 2004062300104 20040623 00104 CE 2004 6 23 2004FA0000453 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195 2073102 CE JACOBP R755 R755A1 35006 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 3006B 7889 INSPECTED ORIGINAL MAGNESIUM INBOARD AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTIN G FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRA CKETS). WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED. 1 H 7 1 3R 3 R NC A790 TC237 2004062200193 20040622 00193 CE 2004 6 22 2004FA0000454 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195 2073102 CE CONT R670 W670* 17016 SO AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 3089B 7974 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ) WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED. 1 H 7 1 3R 3 R NC A790 E162 2004062200176 20040622 00176 CE 2004 6 22 2004FA0000455 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195A 2073110 CE JACOBS R755 R7557 35003 EA AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 1LE 7729 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED. 1 H 7 1 3R 3 R A790 5E11 2004062200195 20040622 00195 CE 2004 6 22 2004FA0000456 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195B 2073112 CE JACOBP R755 R755B1 35007 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 2158C 16143 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING AND/OR MOUNTING FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS). 1 H 7 1 3R 3 R A790 TC237 2004062200203 20040622 00203 CE 2004 6 22 2004FA0000457 1 20040525 G 5751 HINGE BRACKET CESSNA 195 195A 2073110 CE JACOBP R755 R755A1 35006 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 90K 7439 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 3 R A790 TC237 2004062200211 20040622 00211 CE 2004 6 22 2004FA0000458 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195A 2073110 CE JACOBP R755 R755A1 35006 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 10N 7657 INSPECTED ORIGINAL MAGNESIUM INBOARD AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTIN G FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRA CKETS). 1 H 7 1 3R 3 R A790 TC237 2004062300028 20040623 00028 CE 2004 6 23 2004FA0000459 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 190 190 2072902 CE CONT R670 W670* 17016 SO AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 1551D 7773 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS CRACKING AND/OR MOU NTING FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS). 1 H 7 1 3R 3 R NC A790 E162 2004062300061 20040623 00061 CE 2004 6 23 2004FA0000460 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195A 2073110 CE JACOBS R755 L4* 35003 EA AILERON CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 03 4372N 7034 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKEST AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ONTWO DIFFERENT SETS OF THESE BRACKETS) . 1 H 7 1 3R 3 R A790 TC121 2004062300055 20040623 00055 CE 2004 6 23 2004FA0000461 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195B 2073112 CE JACOBP R755 R755A1 35006 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 2112C 16097 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ) 1 H 7 1 3R 3 R A790 TC237 2004062200157 20040622 00157 CE 2004 6 22 2004FA0000462 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 190 190 2072902 CE CONT R670 W670* 17016 SO AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 9359A 7522 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 3 R NC A790 E162 2004062300044 20040623 00044 CE 2004 6 23 2004FA0000463 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195 2073102 CE JACOBS R755 L4* 35003 EA AILERON CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 03 4332V 7238 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 3 R NC A790 TC121 2004062300037 20040623 00037 CE 2004 6 23 2004FA0000464 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195 2073102 CE JACOBP R755 R755A1 35006 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 6857D 7848 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRO DED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEET . PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS) . 1 H 7 1 3R 3 R NC A790 TC237 2004062300035 20040623 00035 CE 2004 6 23 2004FA0000465 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195B 2073112 CE JACOBP R755 R755B1 35007 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 2139C 16124 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 3 R A790 TC237 2004062300038 20040623 00038 CE 2004 6 23 2004FA0000466 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195B 2073112 CE JACOBP R755 R755B1 35007 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 4462C 16047 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS . 1 H 7 1 3R 3 R A790 TC237 2004062300062 20040623 00062 CE 2004 6 23 2004FA0000467 1 20040525 G 5751 HINGE BRACKET CESSNA 195 195B 2073112 CE JACOBP R755 R755B1 35007 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 3042B 7925 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 3 R A790 TC237 2004062300049 20040623 00049 CE 2004 6 23 2004FA0000468 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195A 2073110 CE JACOBS R755 L4* 35003 EA AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 195WG 7926 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 3 R A790 TC121 2004062200158 20040622 00158 CE 2004 6 22 2004FA0000469 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195 2073102 CE JACOBP R755 R755A1 35006 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 9334A 7413 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FE ET. PRIMER AND/OR BODY FILLER TO HIDE SETS OF THESE BRACKETS). 1 H 7 1 3R 3 R NC A790 TC237 2004062200192 20040622 00192 CE 2004 6 22 2004FA0000470 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195 2073102 CE JACOBP R755 R755A1 35006 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 195H 7200 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/ OR MOUNTING FE ET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKET S). 1 H 7 1 3R 3 R NC A790 TC237 2004062300022 20040623 00022 CE 2004 6 23 2004FA0000471 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195A 2073110 CE JACOBP R755 R755B1 35007 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 4448C 16033 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 3 R A790 TC237 2004062200159 20040622 00159 CE 2004 6 22 2004FA0000472 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195 2073102 CE AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 9339A 7419 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS) . 1 H 7 1 3R NC A790 2004062300023 20040623 00023 CE 2004 6 23 2004FA0000473 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195B 2073112 CE JACOBP R755 R755A1 35006 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 2193C 16178 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 3 R A790 TC237 2004062200162 20040622 00162 CE 2004 6 22 2004FA0000474 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195A 2073110 CE JACOBP R755 R755A1 35006 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 8266R 7550 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESES BRACKET S). 1 H 7 1 3R 3 R A790 TC237 2004062300090 20040623 00090 CE 2004 6 23 2004FA0000475 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195 2073102 CE JACOBP R755 R755A1 35006 SW AILERON CORRODED D O OTHER O OTHER NR NOT REPORTED 1 CE 03 4468C 16053 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 3 R NC A790 TC237 2004062300045 20040623 00045 CE 2004 6 23 2004FA0000476 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 190 190 2072902 CE JACOBS R915 L6 35005 EA AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 1525D 7747 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 3 R NC A790 TC195 2004062300048 20040623 00048 CE 2004 6 23 2004FA0000477 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195 2073102 CE JACOBP R755 R755A1 35006 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 195TG 7341 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/ OR MOUNTING FE ET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKET S). 1 H 7 1 3R 3 R NC A790 TC237 2004062200160 20040622 00160 CE 2004 6 22 2004FA0000478 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195 2073102 CE JACOBP R755 R755B1 35007 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 4494C 16078 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 3 R NC A790 TC237 2004062300024 20040623 00024 CE 2004 6 23 2004FA0000479 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195 2073102 CE JACOBP R755 R755A1 35006 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 3869V 7330 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 3 R NC A790 TC237 2004062300050 20040623 00050 CE 2004 6 23 2004FA0000480 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195A 2073110 CE JACOBS R755 L4* 35003 EA AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 1524D 7746 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 3 R A790 TC121 2004062200161 20040622 00161 CE 2004 6 22 2004FA0000481 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195B 2073112 CE JACOBP R755 R755B1 35007 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 3035B 7918 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 3 R A790 TC237 2004062200163 20040622 00163 CE 2004 6 22 2004FA0000482 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195B 2073112 CE JACOBP R755 R755B1 35007 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 195BT 16176 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 3 R A790 TC237 2004062300025 20040623 00025 CE 2004 6 23 2004FA0000483 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195A 2073110 CE JACOBS R755 L4* 35003 EA AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 195ST 7527 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKES SPANNING COMPLETELY ACROSS THE BEARING BOSS AND OR MOUNTING FE ET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKET S). 1 H 7 1 3R 3 R A790 TC121 2004062300091 20040623 00091 CE 2004 6 23 2004FA0000484 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195 2073102 CE JACOBP R755 R755A1 35006 SW AILERON CORRODED D O OTHER O OTHER NR NOT REPORTED 1 CE 03 4301V 7205 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 3 R NC A790 TC237 2004062300026 20040623 00026 CE 2004 6 23 2004FA0000485 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195A 2073110 CE JACOBP R755 R755A1 35006 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 1022D 7630 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 3 R A790 TC237 2004062200206 20040622 00206 CE 2004 6 22 2004FA0000486 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195B 2073112 CE JACOBP R755 R755A1 35006 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 2141C 16126 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 3 R A790 TC237 2004062200169 20040622 00169 CE 2004 6 22 2004FA0000487 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195 2073102 CE RROYCE VIPER VIPER522 54552 EU AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 4408C 7993 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 4 J NC A790 E3EU 2004062300013 20040623 00013 CE 2004 6 23 2004FA0000488 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195 2073102 CE JACOBP R755 R755A1 35006 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 60W 7385 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FE ET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKET S). 1 H 7 1 3R 3 R NC A790 TC237 2004062300064 20040623 00064 CE 2004 6 23 2004FA0000489 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195A 2073110 CE JACOBS R915 L6 35005 EA AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 9855A 7548 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 3 R A790 TC195 2004062300014 20040623 00014 CE 2004 6 23 2004FA0000490 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195A 2073110 CE JACOBS R915 L6 35005 EA AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 9855A 7548 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 3 R A790 TC195 2004062300001 20040623 00001 CE 2004 6 23 2004FA0000491 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195A 2073110 CE JACOBS R755 L4* 35003 EA AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 1075D 7687 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 3 R A790 TC121 2004062300015 20040623 00015 CE 2004 6 23 2004FA0000492 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195A 2073110 CE JACOBP R755 R755A1 35006 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 47KL 7053 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS ( THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKET S). 1 H 7 1 3R 3 R A790 TC237 2004062300008 20040623 00008 CE 2004 6 23 2004FA0000493 1 20040525 G 5751 HINGE BRACKET CESSNA 195 195A 2073110 CE JACOBP R755 R755A1 35006 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 5N 7356 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKET S). 1 H 7 1 3R 3 R A790 TC237 2004062300009 20040623 00009 CE 2004 6 23 2004FA0000494 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195 2073102 CE JACOBS R755 L4* 35003 EA AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 4666T 7802 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 3 R NC A790 TC121 2004062300010 20040623 00010 CE 2004 6 23 2004FA0000495 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195 2073102 CE JACOBP R755 R755A1 35006 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 3890V 7361 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITION: SEVERELY CORRO DED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEET . PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS) . 1 H 7 1 3R 3 R NC A790 TC237 2004062300004 20040623 00004 CE 2004 6 23 2004FA0000496 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195 2073102 CE JACOBP R755 R755A1 35006 SW AILERON CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 03 195VF 7268 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 3 R NC A790 TC237 2004062300075 20040623 00075 CE 2004 6 23 2004FA0000497 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195 2073102 CE JACOBP R755 R755A1 35006 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 4347V 7256 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEET . PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS) . 1 H 7 1 3R 3 R NC A790 TC237 2004062300016 20040623 00016 CE 2004 6 23 2004FA0000498 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195A 2073110 CE JACOBP R755 R755A1 35006 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 9303A 7382 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 3 R A790 TC237 2004062300011 20040623 00011 CE 2004 6 23 2004FA0000499 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195 2073102 CE JACOBP R755 R755A1 35006 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 9818A 7497 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 3 R NC A790 TC237 2004062300002 20040623 00002 CE 2004 6 23 2004FA0000500 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 190 190 2072902 CE JACOBS R755 L4* 35003 EA AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 195P 7218 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 3 R NC A790 TC121 2004062300076 20040623 00076 CE 2004 6 23 2004FA0000501 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195A 2073110 CE JACOBS R755 L4* 35003 EA AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 3083B 7968 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 3 R A790 TC121 2004062300005 20040623 00005 CE 2004 6 23 2004FA0000502 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195 2073102 CE JACOBS R755 L4* 35003 EA AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 3443V 7133 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 3 R NC A790 TC121 2004062300077 20040623 00077 CE 2004 6 23 2004FA0000503 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195B 2073112 CE JACOBP R755 R755B1 35007 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 4418C 16003 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 3 R A790 TC237 2004062300006 20040623 00006 CE 2004 6 23 2004FA0000504 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195 2073102 CE JACOBP R755 R755A1 35006 SW AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 1566D 7788 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 3 R NC A790 TC237 2004062300017 20040623 00017 CE 2004 6 23 2004FA0000505 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195 2073102 CE AILERON CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 03 4051A 7318 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R NC A790 2004062300003 20040623 00003 CE 2004 6 23 2004FA0000506 1 20040525 G 5751 0322709 HINGE BRACKET CESSNA 195 195A 2073110 CE JACOBS R755 L4* 35003 EA AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 03 195KR 7160 INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORR ODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEE T. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS ). 1 H 7 1 3R 3 R A790 TC121 2004062300074 20040623 00074 EA 2004 6 23 2004FA0000507 2 20040413 G 8530 5015 STUD BEECH 23 A2324 1151226 CE LYC O360 IO360A2B 41514 EA CYLINDER BROKEN B MW2R K NONE O OTHER IN INSP/MAINT 1 GL 17 7987L 2702 849 MA148 L299351A NR 4 DECK STUD BROKEN AT 8 O’CLOCK POSITION. 1 L 7 1 3O 3 O A1CE 1E10 2004062300012 20040623 00012 EA 2004 6 23 2004FA0000508 2 20040504 G 8530 STUD PIPER PA28 PA28140 7102802 SO LYC O320 O320* 41508 EA NR 4 CYLINDER SHEARED D O OTHER O OTHER NR NOT REPORTED 1 NM 09 174PC 287425187 PILOT REPORTS EXHAUST PIPE LOOSE ON NR 4 CYLINDER. FOUND 4 STUDS SHEARED ON CYLINDER HOLD DOWN FLANGE. THIS CAUSED EXH AUST TO VIBRATE LOOSE. CHECK NUTS ON ANNUAL OR ANYTIME EXHAUST STUDS DROP OUT. 1 L 7 1 3O 3 O 2A13 E274 2004063000113 20040630 00113 SO 2004 6 30 2004FA0000509 1 20040504 G 3240 BRAKE PIPER PA28 PA28181 7102807 SO LYC O360 O360* 41514 EA LANDING GEAR MALFUNCTIONED D K NONE O OTHER IN INSP/MAINT 1 NM 09 2382M 287890250 DURING ANNUAL, SPONGY BRAKE FOUND. UNABLE TO BLEED. FOUND (AGED) HYD OIL LEAD TO DETERIORATION OF SEALS IN 4 TOE BRAKE S AND PARKING BRAKE. NO RECORD OF ANY PREVIOUS REPAIR. SUGGEST AC OVER 10 YEAR OLD HAVE SYSTEM FLUSH AND SEAL REPLACEM ENT. 1 L 7 1 3O 3 O 2A13 E286 2004063000125 20040630 00125 CE 2004 6 30 2004FA0000510 1 20040602 G 2420 DOFF10300BR ALTERNATOR CESSNA 172 172RG 2072438 CE LYC O540 O540* 41532 EA ENGINE DETACHED D BLVR O OTHER F FLT CONT AFFECTED NR NOT REPORTED 1 GL 17 5301R 172RG0050 PILOT REPORTED HE THOUGHT ALTERNATOR THREW THE BELT. REMOVED THE COWLING, FOUND ALTERNATOR LYING IN ENGINE COMPARTMENT, WIRING INTACT, COOLING FINS TORN OFF BELT PULLEY, BELT SHREDDD. AN7-40A MOUNTING BOLT NOT FOUND. BELT ADJUSTMENT BRAC KET AN5 ATTACH BOLT FOUND IN COWLING WITH SAFETY WIRE, BOLT HOLE THREADS IN ENGINE CASE STRIPPED/WORN. INSTALLED HELI-C OIL IN BOLT HOLE. INSTALLED EXCHANGE ALTERNATOR WITH NEW ATTACH HARDWARE AND BELT. RUN-UP CHECK NORMAL. PROBABLE CAUSE IS FAILURE OF AN7 BOLT OR NUT, ALLOWING ALTERNATOR TO BECOME UN-ATTACHED. 1 H 7 1 3O 3 O 3A17 E295 2004063000005 20040630 00005 SO 2004 6 30 2004FA0000511 1 20040528 G 3260 7642603 DRAG BRACE PIPER PA28 PA28R201T 7102813 SO NLG CRACKED B TUDR O OTHER O OTHER NR NOT REPORTED 1 SW 13 2919Q 4273 28R7703079 PILOT REPORTED A LOUD SOUND SIMILAR TO A RIFLE SHOT WHILE IN CRUISE FLIGHT AT 7500 FEET MSL. IMMEDIATELY, THE LANDING G EAR UNSAFE LIGHT ILLUMINATED. PRIOR TO LANDING, HE LOWERED THE GEAR NORMALLY AND GOT DOWN AND LOCKED INDICATIONS FOR AL L THREE LANDING GEAR. LANDING WAS NORMAL. THE UPPER DRAG BRACE WAS CRACKED JUST FORWARD OF THE AREA WHERE THE LANDING ACTUATOR ATTACHES TO THE BRACE. THERE DID NOT APPEAR TO BE ANY OTHER DAMAGE IN THE AREA. A POSSIBLE CAUSE OF FAILURE I S FATIGUE DUE TO THE NR OF HOURS OR CYCLES ON THE PART. (SW13200404055) 1 L 7 1 3O 2A13 2004063000134 20040630 00134 GL 2004 6 30 2004FA0000512 3 20040303 G 6110 B24521 CYLINDER PIPER PA23 PA23250 7102308 SO LYC O540 IO540* 41532 EA HARTZL HC83X HC83X* GL PROPELLER DAMAGED B LU4R O OTHER O OTHER NR NOT REPORTED 1 SO 17 BP9634 CYLINDER (PN B2452-1) SEPARATED FROM PROPELLER ON GROUND RUN. INSPECTION SHOWED THREAD DAMAGE OF CYLINDER. AFTER DISCU SSION WITH MANUFACTURER THE LIKELY CAUSE IS DUE TO HIGH PRESSURE FROM GOVERNOR, USUALLY CAUSED BY STICKING PRESSURE RELI EF VALVE. 1 L 7 2 3O 3 O 1A10 1E4 5 C P884 2004063000010 20040630 00010 SO 2004 6 30 2004FA0000513 1 20040519 G 7160 67775000 DOOR PIPER PA28 PA28R201 7102816 SO LYC O360 IO360C1C6 41514 EA HEAT BOX FAILED D A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION NR NOT REPORTED 1 NM 07 2495M 28R7837090 PARTIAL LOSS OF ENGINE POWER OCCURRED JUST AFTER TAKEOFF. THE MANIFOLD PRESSURE DROPPED TO 15 INCHES HG, RPM DROPPED TO 1900. PRE TAKEOFF ENGINE RUN UP, ALTERNATE AIR CHECK WAS REPORTED AS NORMAL. A POST FLIGHT INSPECTION REVEALED THAT ALTERNATE AIR (HEAT BOX) DOOR HAD SEPARATED FROM ALTERNATE AIR BOX ASSY, WAS INGESTED INTO FUEL SERVO INTAKE, PARTIALLY BLOCKED ENGINE INDUCTION AIR FLOW AND RESULTED IN A PARTIAL LOSS OF POWER. MS20470AD3 RIVETS (3EA) THAT SECURE DOOR TO AIR BOX ASSY HAD FAILED. IMPROPERLY BUCKED RIVETS DUE TO EXCESSIVE SPRING TENSION DURING ASSY AND/OR TOO MUCH SPRING TE NSION FOR THE RIVETS TO BEAR. 1 L 7 1 3O 3 O 2A13 1E10 2004063000023 20040630 00023 SO 2004 6 30 2004FA0000514 1 20040524 G 2622 FIRE BOTTLE GULSTM G1159 GIV 3980115 SO RROYCE TAY TAY6118 EU LEFT MISMARKED B K NONE L NO TEST IN INSP/MAINT 1 GL 05 3PG 4366 1260 DURING THE LT FIRE BOTTLE WEIGHT CHECK, THE INSPECTOR NOTICED THE COLOR OF THE CABLE MARKER TIES AND THE HEAT SHRINK SLE EVES FOR THE LT BOTTLE, DID NOT MATCH THE COLOR OF THE DECALS ON THE PLUMBING, EVEN THOUGH THE NOMENCLATURE ON THE TIES IS CORRECT. ASC WAS INSTALLED IN PRODUCTION IN 1995. AD WAS ISSUED TO ENSURE ASC146A IS INCORPORATED. ORDERED REPLACE MENT TIES, SHRINK SLEEVES, AND TERMINALS TO CORRECT THE PROBLEM. NOTIFIED THE MFG AND RECOMMENDED THEY CHECK OTHER GIV` S IN THIS SN RANGE. 2 L 7 2 4F 4 F RT A12EA E25NE 2004063000054 20040630 00054 EA 2004 6 30 2004FA0000515 2 20040603 G 7414 LC100101 REGULATOR AMTR MURPHY MURPHYREBEL 05623QL GL LYC O320 O320E2D 41508 EA SPARK ADVANCE INOPERATIVE C O OTHER O OTHER NR NOT REPORTED 1 WP 15 7229N 422REB AC IN FOR NO SPARK DURING START-UP. REMOVED LT AND RT MAGNETOS AND SPARK ADVANCED REGULATOR. OWNER INSTALLED BUSH KIT MODIFICATION, LT MAG WITH IMPULSE COUPLING. MAG, NR 4755, SN 04030730. MAGS TIMING SET WITH T-300 IGNITION TIMING TOO L. PERFORMED GROUND OP CHK. MAG CHECKS AT 1700 RPM 50 FOR BOTH MAGS SMOOTH. BOTH MAGS CHECKED AT FULL POWER. ENG CK G OOD. BEFORE FLIGHT MAG CK WAS GOOD. FIRST TAKE-OFF NO PROBLEMS NOTED. SECOND TAKE-OFF, ENG LOST POWER, RAN VERY ROUGH . POST FLIGHT, BOTH MAGS CHK NORMAL. ON FULL PWR, OPS NORMAL FOR 1 MINUTE, WITHOUT WARNING, SUDDEN POWER LOSS. ENG BA CKFIRING, RUNNING ROUGH. RPM DROPPED FROM 2450 TO 2100 RPM. REDUCED TO 1900 RPM, ENG SMOOTHED OUT WITH NORMAL MAG CK. 1 H 7 1 3O 3 O NC EXPA1H71 E274 2004063000041 20040630 00041 CE 2004 6 30 2004FA0000516 1 20040519 G 3231 ARM CESSNA 210 210E 2073416 CE CONT O520 IO520A 17032 SO NLG DOOR INOPERATIVE D O OTHER J WARNING INDICATION NR NOT REPORTED 1 CE 07 4916U 21058616 112609R NOSE GEAR ON THIS AC WOULD NOT EXTEND DURING NORMAL, SUBSEQUENT EMERG L/G EXTEND PROCEDURE. UPON JACKING AC, FREEING NO SE GEAR, IT WAS DISCOVERED NOSE L/G DOOR ACTUATION ARM AND ROLLER ASSY WAS POSITIONED ON AFT SIDE OF NOSE GEAR FORK. WH EN WEIGHT OF AC WAS ONCE AGAIN ON NOSE GEAR, NOSE L/G STRUT WAS COMPLETELY COLLAPSED. IT IS POSSIBLE THAT AT THE TAKE-O FF PRIOR TO THIS INCIDENT, THAT NOSE GEAR DID NOT EXTEND FULLY, DOOR ACTUATION ARM WAS ABLE TO ROLL TO AFT SIDE OF NOS E L/G FORK. AC WAS PREVIOUSLY MODIFIED. STC NR SA 3612SW, WHICH ELIMINATES MAIN GEAR DOORS AND MODIFIES NOSE GEAR DOOR ACTUATION METHOD BY INSTALLING MECHANICAL ARM, ROLLER ASSY AGAINST NOSE GEAR FORK ARE MISSING ON THIS INSTALLATION. 1 H 7 1 3O 3 O 3A21 E5CE 2004063000099 20040630 00099 GL 2004 6 30 2004FA0000517 1 20040526 G 3220 BRACE AMTR GAIR GLASAIRIII 05691HK GL LYC O540 IO540* 41532 EA NLG INOPERATIVE C O OTHER O OTHER NR NOT REPORTED 1 SW 17 27001 3045 IN FLIGHT, AC LOST HYDR PRESSURE FOR UNRELATED CAUSE. HYDR PRESSURE NORMALLY ASSISTS L/G TO REMAIN IN DOWN AND LOCKED P OSITION. ON LANDING, AC TOUCHED DOWN NORMALLY. ON ROLLOUT, NOSE LANDING COLLAPSED. LANDING GEAR SYS IS DESIGNED TO RE MAIN DOWN AND LOCKED WITHOUT AID OF HYDR PRESSURE BY USE OF SPRINGS THAT SHOULD APPLY TENSION TO OVERCENTER DESIGN OF LA NDING GEAR BRACES. NOSE LANDING GEAR BRACE ONLY GOES OVER CENTER A SMALL AMOUNT, JUST A COUPLE OF DEGREES. LOW OVERCEN TER ASSIST SPRING TENSION COUPLED WITH A SMALL AMOUNT OF OVERCENTER TRAVEL ALLOWED NOSE GEAR TO COLLAPSE IN ABSENCE OF H YDR PRESSURE. ON JACKS N/G COULD BE MADE TO UNLOCK WITH A MODEST KICK TO THE NOSEWHEEL. (SW17200407156) 1 L 7 1 3O 3 O RT EXPA1L71 1E4 2004063000100 20040630 00100 GL 2004 6 30 2004FA0000518 1 20040608 G 5330 FABRIC AMTR SKYBLT SKYBOLT GL LYC O540 IO540* 41532 EA RT WING FAILED G O OTHER O OTHER NR NOT REPORTED 1 SW 15 25BM 116 SBM001 5 FEET OF THE TOP RT WING FABRIC FAILED. POLYFIBER AC COATINGS TB 89-1D. STATES FABRIC WEIGHING LESS THAN 2.4 OZ SHOUL D BE USED ON AC WITH ENGINES UP TO 145 HORSEPOWER THIS AC HAD A 300 HP ENGINE INSTALLED LT WING HAD BROKEN RIB STITCHING BUT FABRIC HAD NOT FAILED YET. (SW15200410524) 1 Q 7 1 3O 3 O EXPA1Q71 1E4 2004063000098 20040630 00098 NE 2004 6 30 2004FA0000520 2 20040423 G 7250 3020159 RETAINING RING PWA PT6 PT6A34AG 52053 NE TURBINE SECTION DAMAGED B CP2R O OTHER O OTHER NR NOT REPORTED 1 SW 15 PH0094 DISASSEMBLY OF THE HOT SECTION, SMALL EXIT DUCT REVEALED THE SEGMENT RETAINING RING ENDS STACKED AND APPROXIMATELY 4-4.5 INCHES OF THE RING OUT OF PLACE. SEGMENTS IN THE AFFECTED AREA WERE BEGINNING TO MOVE OUT OF OPERATING POSITION. THE HOT SECTION WAS BEING INSPECTED AS PART OF A LIGHT OVERHAUL OF THE UNSERVICEABLE CONDITIONS RELATING TO THE ENGINE. THE HOT SECTION WAS IN OTHERWISE SERVICEABLE CONDITION. UNCONTAINED SEGMENTS CAN MOVE INTO THE PATH OF THE COMPRESSOR TURB INE BLADES DESTROYING HOT SECTION SEALING, RESULTING IN LOSS OF POWER. 4 T E4EA 2004063000081 20040630 00081 SO 2004 6 30 2004FA0000521 1 20040415 G 8012 9937711 SWITCH PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360* 17025 SO STARTER FAILED D O OTHER O OTHER NR NOT REPORTED 1 NM 07 103JH 347570087 WATER FROM WASHING THE AIRCRAFT WENT DOWN LEFT SIDE WINDOW INTO SWITCH PANEL CAUSING MASTER SWITCH TO ACTIVATE MASTER SO LENOID (WHEN IN OFF POSITION). THE WATER FROM WASHING ALSO CAUSED LT ENGINE STARTER SWITCH TO ACTIVATE STARTER SPINNING PROPELLER (WHEN IN OFF POSITION) NOTE: PROP STARTED TO SPIN ABOUT 1 HOUR AFTER WASHING. 1 L 7 2 3O 3 O A7SO E9CE 2004063000124 20040630 00124 SO 2004 6 30 2004FA0000522 1 20040415 G 2400 9937713 MASTER SWITCH PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360* 17025 SO COCKPIT FAILED D O OTHER O OTHER NR NOT REPORTED 1 NM 07 103JH 347570087 WATER FROM WASHING THE AIRCRAFT WENT DOWN LEFT SIDE WINDOW INTO SWITCH PANEL CAUSING MASTER SWITCH TO ACTIVATE MASTER SO LENOID (WHEN IN OFF POSITION). THE WATER FROM WASHING ALSO CAUSED LT ENGINE STARTER SWITCH TO ACTIVATE STARTER SPINNING PROPELLER (WHEN IN OFF POSITION). NOTE: PROP STARTED TO SPIN ABOUT 1 HOUR AFTER WASHING. 1 L 7 2 3O 3 O A7SO E9CE 2004063000118 20040630 00118 CE 2004 6 30 2004FA0000523 1 20040601 G 5520 1016100198 TORQUE TUBE BEECH 200 B200C 1152924 CE PWA PT6 PT6A60A 52043 NE ELEVATOR LOOSE D K NONE O OTHER IN INSP/MAINT 1 WP 19 7232R 8067 BL69 DURING PHASE INSPECTION, THE RT ELEVATOR CONTROL TORQUE TUBE THAT ATTACHES TO THE IB END RIB OF THE RT ELEVATOR WAS FOUN D TO HAVE PLAY BETWEEN THE COLLAR WITH THE FLANGE THAT BOLTS TO THE END RIB AND THE TORQUE TUBE ITSELF. THE 4 MOUNTING BOLTS WERE TIGHT TO THE END RIB, BUT THE RIVETS ATTACHING THE COLLAR TO THE TUBE HAD BECOME LOOSE ALLOWING FOR POTENTIAL UNCOMANDED MOVEMENT (FLUTTER) OF THE ELEVATOR. (WP19200405628) 1 L 7 2 4T 4 T A24CE E4EA 2004071200043 20040712 00043 CE 2004 7 12 2004FA0000524 1 20040701 G 2730 1016100197 TORQUE TUBE BEECH 200 B200C 1152924 CE PWA PT6 PT6A60A 52043 NE ELEVATOR LOOSE D O OTHER O OTHER NR NOT REPORTED 1 WP 19 7232R 8067 BL69 DURING AN INSPECTION, THE LT ELEVATOR CORNTOL TORQUE TUBE THAT ATTACHES TO IB END RIB OF THE LT ELEVATOR WAS FOUND TO HA VE PLAY BETWEEN THE ACTUATING HORN AND THE TORQUE TUBE ITSELF. THE COLLAR WITH THE FLANGE AND THE 4 MOUNTING BOLTS ATTA CHING THE TORQUE TUBE TO THE END RIB WERE TIGHT, BUT THE 8 RIVETS ATTACHING THE ACTUATING HORN TO THE TUBE HAD BECOME LO OSE ALLOWING FOR POTENTIAL UNCOMMANDED MOVEMENT (FLUTTER) OF THE ELEVATOR. 1 L 7 2 4T 4 T A24CE E4EA 2004071200051 20040712 00051 EU 2004 7 12 2004FA0000525 1 20040517 G 3260 JKL6839 BULB BRAERO DH125 HS125700A 4230170 EU GARRTT TFE731 TFE7313R1H 29001 WP MLG INDICATOR FAILED D O OTHER P NO WARNING INDICATION AP APPROACH 1 GL 05 41HF NA0208 ON APPROACH CREW SELECTED THE GEAR HANDLE DOWN, THE NOSE DOWNLOCK ANNUNCIATOR DID NOT ILLUMINATE WITH GEAR HANDLE IN DOW N POSITION. CREW ATTEMPTED TO CHANGE THE NOSE DOWNLOCK ANNUNCIATOR BULBS, BUT COULD NOT REMOVE THE ANNUNCIATOR. WHEN T HE AIRCRAFT ARRIVED AT THE HANGAR, REMOVED THE NOSE GEAR DOWN LOCK ANUNCIATOR, THE ANNUNCIATOR HOUSES FOUR BULBS, TWO FO R GEAR UP ANNUNCIATION, TWO FOR THE DOWN AND LOCKED ANNUNCIATION. THE TWO BULBS FOR THE DOWN AND LOCKED ANNUNCIATION WE RE BURNED OUT. REPLACED THE DOWNLOCK BULBS AND ANNUNCIATORS TEST GOOD. INSTALLED A SCREW DRIVER ON THE AC TO ASSIST IN REMOVING THE ANNUNCIATOR. (GL05200405284) 2 L 7 2 4F 4 F A3EU E6WE 2004091500118 20040915 00118 CE 2004 9 15 2004FA0000527 1 20040325 G 5340 101620000638 FITTING BEECH 200 200BEECH 1152920 CE PWA PT6 PT6* 52043 EA HORIZONTAL STAB CORRODED B O OTHER O OTHER NR NOT REPORTED 1 WP 09 70AJ BB206 DURING A PHASE 2 AIRFRAME INSPECTION, EXFOLIATION CORROSION WAS FOUND ON THE HORIZONTAL STABILIZER UPPER ATTACH FITTING IN TWO PLACES. ALSO EXFOLIATION CORROSION WAS FOUND ON THE RT UPPER SPAR CAP OF THE HORIZONTAL STABALIZER. BOTH ARTICL ES ARE BEING REPLACED WITH MANUFACTURERS NEW PARTS. 1 L 7 2 4T 3 T A24CE E2NE 2004071200020 20040712 00020 SO 2004 7 12 2004FA0000529 2 20040426 G 8530 SA10200A20 CYLINDER CESSNA 150 150L 2071826 CE CONT O200 O200A 17020 SO ENGINE CRACKED D A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION NR NOT REPORTED 1 GL 09 1050C 1211 509 15074893 647526A PILOT REPORTED ENG RUNNING ROUGH AND SMELLED OIL IN COCKPIT SHORTLY AFTER TAKE OFF, MANAGED TO MAKE EMERGENCY LANDING ON DEPARTURE AIRPORT, DETERMINED CYLINDER NR 2 BARREL CRACKED ALMOST ALL THE WAY AROUND 2.8750 INCHES UP FROM BASE CAUSE U NKNOWN EXCEPT POSSIBLE DEFECTIVE PART. SOLUTION SHOULD BE TO CHECK OUT CYLINDER BARRELS AT ANNUAL INSPECTION OR 100 HOU R AND EACH TIME COWL REMOVED FOR LEAKS AND CRACKS AND IF LEAKS OIL OR SEE CRACK IN BARREL SHOULD BE EASIER TO FOLLOW. S N ON HEAD IS F20056. 1 H 7 1 3O 3 O 3A19 E252 2004070800210 20040708 00210 CE 2004 7 8 2004FA0000530 1 20040510 G 5541 12310345 SPAR CESSNA 206 TU206G 2073357 CE CONT O520 TSIO520* 17040 SO RUDDER CRACKED D O OTHER O OTHER NR NOT REPORTED 1 WP 25 6207Z 3619 U20606188 LT SKIN CRACKED 6 INCHES AFT OF LOWER RUDDER HINGE POINT. RT SKIN WRINKLED 6 INCHES AFT OF LOWER HINGE POINT. LOWER RI B CRACKED 5 INCHES AFT OF SECURING POINT TO FORWARD RUDDER SPAR, CRACKED ON LT SIDE. PROBABLE CAUSE UNNECESSARY ROUGHNE SS. (WP25200406045) 1 H 7 1 3O 3 O A4CE E8CE 2004070900001 20040709 00001 CE 2004 7 9 2004FA0000531 1 20040510 G 5541 12310372 SPAR CESSNA 206 TU206G 2073357 CE CONT O520 TSIO520* 17040 SO RUDDER CRACKED D O OTHER O OTHER NR NOT REPORTED 1 WP 25 6207Z 3619 U20606188 LT SKIN CRACKED 6 INCHES AFT OF LOWER RUDDER HINGE POINT. RT SKIN WRINKLED 6 INCHES AFT OF LOWER HINGE POINT. LOWER RI B CRACKED 5 INCHES AFT OF SECURING POINT TO FORWARD RUDDER SPAR, CRACKED ON LT SIDE. PROBABLE CAUSE UNNECESSARY ROUGHNE SS. (WP25200406045) 1 H 7 1 3O 3 O A4CE E8CE 2004070900002 20040709 00002 CE 2004 7 9 2004FA0000532 1 20040510 G 5541 12310346 SPAR CESSNA 206 TU206G 2073357 CE CONT O520 TSIO520* 17040 SO RUDDER CRACKED D O OTHER O OTHER NR NOT REPORTED 1 WP 25 6207Z 3619 U20606188 LT SKIN CRACKED 6 INCHES AFT OF LOWER RUDDER HINGE POINT. RT SKIN WRINKLED 6 INCHES AFT OF LOWER HINGE POINT. LOWER RI B CRACKED 5 INCHES AFT OF SECURING POINT TO FORWARD RUDDER SPAR, CRACKED ON LT SIDE. PROBABLE CAUSE UNNECESSARY ROUGHNE SS. (WP25200404045) 1 H 7 1 3O 3 O A4CE E8CE 2004071200053 20040712 00053 CE 2004 7 12 2004FA0000534 1 20040427 G 7603 22500531 NUT CESSNA 182 TR182 2072735 CE LYC O540 O540* 41532 EA THROTTLE MISSING B PAIR O OTHER F D FLT CONT AFFECTED INFLIGHT SEPARATION AP APPROACH 1 SO 05 738PK 1642 R18200950 JUST TURNED FINAL AND WENT TO PULL POWER BACK AND FOUND NO THROTTLE RESPONSE. PILOT WAS ABLE TO LAND USING MAG SWITCH T O ADD AND REDUCE POWER. UPON INSPECTION FOUND LOCK NUT MISSING FROM THROTTLE CONNECTION AND BOLT LAYING HALF OUT OF THR OTTLE /TURBO ACTUATOR. (MS203651032C AND 22500531). INSPECTED BOLT FOUND NO DEFECTS. INSTALLED NEW BOLT, NUT, BEARING , AND WASHERS. OPS NORMAL. 1 H 7 1 3O 3 O 3A13 E295 2004071200158 20040712 00158 EA 2004 7 12 2004FA0000535 1 20040623 G 1430 MS20008H20 BOLT SCWZER G164 G164A 3952704 EA PWA R1340 R1340AN1 52016 NE HAMSTD 12D 12D40 NE MLG SHEARED G A UNSCHED LANDING O OTHER NR NOT REPORTED 1 SW 09 6567 11006 706 19315 76343 AIRCRAFT WAS LOADED WITH 1600LBS OF FERTILIZER AND WAS TAKING OFF TO THE SOUTH ON A DIRT RUNWAY. PILOT WAS APPROACHING 65 MPH, WHEN THE RT MAIN WHEEL AND TIRE SEPARATED FROM THE AIRCRAFT. PROPELLER STRUCK THE GROUND SEVERAL TIMES, CAUSING THE AIRCRAFT TO FLIP OVER AND CAME TO REST FACING NORTH. INSPECTORS FOUND BRAKE ATTACHMENT CLIP APPROX 270 FEET FROM A IRCRAFT WRECKAGE ON THE RUNWAY. RT WHEEL AND TIRE ASSY. STILL HAD THE AIRCRAFT AXLE ATTACHED. THREE ATTACHMENT BOLTS T HAT SECURE THE AXLE SHAFT TO THE RT SPRING GEAR HAD SHEARED OFF. TWO OF THE THREE BOLTS SHOWED SIGNS OF CORROSION, BEFO RE SHEARING. 1 Q 7 1 3R 3 R 1A16 5E2 5 C P257 2004071200162 20040712 00162 CE 2004 7 12 2004FA0000536 1 20040701 G 2497 WIRE CESSNA 210 T210N 2073456 CE VERTICAL STAB CHAFED D K NONE O OTHER IN INSP/MAINT 1 SO 06 2077 FOUND BEACON CIRCUIT WIRING RUNNING UP THROUGH THE VERTICAL STABILIZER CHAFED IN 3 PLACES WHERE THE WIRES WERE ROUTED TH ROUGH 3 RIBS. REPLACED THE WIRES AND INSTALLED THE NEW WIRES IN A FIBERGLASS LOOM TO PREVENT FURTHER CHAFING. OPERATOR STATED THE BEACON CIRCUIT BREAKER WOULD POP IN TURBULENCE. 1 H 7 1 3O 3A21 2004071200063 20040712 00063 CE 2004 7 12 2004FA0000537 1 20040505 G 5711 SPAR BBAVIA 8 8KCAB 2110612 CE LYC O360 AEIO360* EA RT WING CRACKED D O OTHER O OTHER NR NOT REPORTED 1 GL 03 1182E 945 31677 SPAR INSPECTED IAW 00-25-02R1. FOUND 2 CRACKS IN BUTT END, DOUBLER PLATES APPEAR TO BE LOOSENING. CRACKS ARE HORIZONT AL ACROSS THE END GRAIN. 1 H 7 1 3O 3 O A21CE 1E10 2004092000096 20040920 00096 SO 2004 9 20 2004FA0000538 2 20040220 G 8530 10351002 RISER CIRRUS SR SR20 05628AJ GL CONT O360 IO360ES SO NR 5 EXHAUST BROKEN D O OTHER O OTHER NR NOT REPORTED 1 GL 03 7329Y 1394 357644 NR 5 EXHAUST RISER BROKEN COMPLETELY OFF AT MOUNTING FLANGE. POSSIBLE DEFECTIVE WELDING. 1 L 7 1 3O 3 O NT A00009CH E1CE 2004091400177 20040914 00177 CE 2004 9 14 2004FA0000539 1 20040525 G 5343 24130023 MOUNT CESSNA 172 172RG 2072438 CE LYC O360 O360* 41514 EA ACTUATOR BROKEN D O OTHER O OTHER NR NOT REPORTED 1 NM 07 6098V 172RG0579 NOSE GEAR COLLAPSED DUE TO PART FAILURE ON LANDING ROLL OUT. (NM07200406705) 1 H 7 1 3O 3 O 3A17 E286 2004092300109 20040923 00109 NM 2004 9 23 2004FA0000540 1 20040103 G 5751 ATTACH FITTING UNIVAR 415 415C 0420302 NM CONT A75 A75* 17005 SO AILERON CORRODED D O OTHER O OTHER NR NOT REPORTED 1 GL 19 94107 1289 1430 FOUND SEVERE GALVANIC CORROSION BETWEEN THE AILERON ATTACH BRACKETS AND REAR SPAR IN SEVERAL LOCATIONS. STEEL HAD ORIGI NALLY BEEN CADIMUM PLATED. THIS WAS CRITICAL AS IT COULD ALLOW THE AILERON TO DEPART THE AIRPLANE. COULD NOT FIND A PN IN THE CATALOG AS THIS IS CALLED THE REAR BEAM ASSEMBLY. THE REAR AILERON ATTACH POINTS ARE REINFORCED WITH STEEL PLAT ES. THE CORROSION WAS LOCATED BETWEEN THE PLATES AND THE ALUMINUM BEAM. (GL19200404422) 1 L 7 1 3O 3 O A718 E213 2004070900003 20040709 00003 NM 2004 7 9 2004FA0000541 1 20040117 G 5320 SUPPORT UNIVAR 415 415C 0420302 NM CONT A75 A75* 17005 SO BATTERY BOX CORRODED D O OTHER O OTHER NR NOT REPORTED 1 GL 19 94107 1430 THE SUPPORT ASSY THAT SUPPORTS THE BATTERY BOX AND BATTERY IS SEVERLY CORRODED. NO PART NUMBER FOUND IN MFG PARTS CATAL OG. 1 L 7 1 3O 3 O A718 E213 2004092300058 20040923 00058 CE 2004 9 23 2004FA0000542 1 20040603 G 2400 S199411 MASTER SWITCH CESSNA 150 152 2071835 CE LYC O235 O235* 41505 EA INSTRUMENT PANEL FAILED D O OTHER O OTHER NR NOT REPORTED 1 NE 01 4918H 15284020 LOWER CONNECTION ON MASTER SWITCH CONTAINS TWO TERMINALS, ONE THAT IS NOT USED. THIS CONTACT THAT IS NOT USED IS THE LO WEST ONE ON THE SWITCH AND CAN COM INTO CONTACT WITH THE INSTRUMENT PANEL CAUSING SEVERE ARCING AND POTENTIAL FIRE HAZAR D IF HIT WITH NEE OR OTHER MEANS OF CONTACT UNDER THE PANEL. RECOMMENDED CORRECTION: CHECK FOR SATISFACTORY CLEARANCE AT INSTRUMENT PANEL AND INSULATE TERMINAL END FROM CONTACT. POSSIBLE INSPECTION RECURRING AD DUE TO CLOSE PROXIMITY TO FULL PRIMER AND LINE. 1 H 7 1 3O 3 O NT 3A19 E223 2004092300074 20040923 00074 EA 2004 9 23 2004FA0000543 2 20040606 G 7322 FLOAT CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA CARBURETOR STICKING C A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION AP APPROACH 1 GL 03 63012 CK36716 17275372 RL707939A ON SHORT FINAL THE ENGINE LOST POWER. A DECISION WAS MAKE TO MAKE AN OFF FIELD LANDING IN A CORNFIELD. FOLLOW-UP STATI C RUN SHOW NO PROBLEMS AND TEST FLIGHT WAS SCHEDULED. DURING THE TEST FLIGHT ENGINE POWER LOSS TOOK PLACE ON SHORT FINA L. CARBURETOR WAS REMOVED AND INSPECTED FINDING MARKS ON THE FLOAT AND CARBURETOR BODY INDICATING THE FLOAT WAS STICKIN G CAUSING FUEL STARVATION. RECOMMEND SPECIAL EMPHASIS BE PLACE ON CENTERING THESE FLOATS IN THE CARBURETOR BODY TO PREV ENT STICKING AND POSSIBLE FUEL STARVATION. (GL03200409863) 1 H 7 1 3O 3 O NT 3A12 E274 2004071200031 20040712 00031 SW 2004 7 12 2004FA0000544 1 20040520 G 5711 SPAR BBAVIA 7 7BCM 2110106 SW CONT O200 O200A 17020 SO MCAULY 1A105 1A105* GL RT WING DAMAGED D O OTHER O OTHER NR NOT REPORTED 1 SW 15 59Z 3887 7BCM93 6416R 3167 A LONGITUDINAL CRACK WAS FOUND AT OB AILERON ATTACH FITTING OF THE REAR WOOD SPAR. THE CRACK IS LOCATED ON RT WING REAR SPAR, OB AILERON ATTACH POINT EMANATING FROM LOWER BOLT HOLE ON FORWARD SIDE OF SPAR. THE CRACK WAS FOUND DURING ANNUA L INSP WHILE COMPLING WITH AD. THE CRACK EXTENDS IB FROM THE BOLT APPROXIMATELY FOUR INCHES AND OB APPROX 5.5 INCHES. THE REAR SPAR IS A TWO PIECE SPRUCE LAMINATE, AND THE CRACK IS ONLY VISIBLE ON FWD FACE, IT DOES NOT APPEAR ON OPPOSITE SIDE. CRACK WAS POSSIBLY CAUSED OVER TIME BY AILERON ATTACH BOLTS BEING OVER TORQUED. THIS AC HAS NO KNOWN DAMAGE HIST ORY. 1 H 7 1 3O 3 O A759 E252 5 N P918 2004092000115 20040920 00115 CE 2004 9 20 2004FA0000545 1 20040616 G 3230 24411003 PIVOT CESSNA 172 172RG 2072438 CE LYC O360 O360* 41514 EA LANDING GEAR CRACKED B WIWR O OTHER O OTHER NR NOT REPORTED 1 WP 07 6623Z 737 172RG0240 WHILE REPLACING A BROKEN GEAR ACTUATOR THE PIVOT WAS REMOVED AND INSPECTED. A CRACK WAS FOUND IN THE LOWER RADIUS AT TH E BOTTOM OF THE GEAR SPLINES. TO PREVENT THIS PROBLEM IT IS SUGGESTED THAT THE MLG PIVOTS BE REMOVED FROM THE AIRCRAFT AND INSPECTED EVERY 1000 HOURS. IT IS ALSO SUGGESTED THAT THE MFG OF THIS PART REDESIGN THE PART OUT OF STEEL. 1 H 7 1 3O 3 O 3A17 E286 2004092000088 20040920 00088 CE 2004 9 20 2004FA0000546 1 20040616 G 3233 12810013 ACTUATOR CESSNA 172 172RG 2072438 CE LYC O360 O360* 41514 EA RT MLG MALFUNCTIONED B WIWR O OTHER O OTHER NR NOT REPORTED 1 WP 07 6623Z 172RG0240 DURING A FLIGHT, THE PILOT REPORTED HEARING A LOUD POP WHEN THE GEAR WAS CYCLED DOWN. UPON INSPECTION OF THE LANDING GE AR, THE LT MLG ACTUATOR WAS FOUND TO BE CRACKED ALL THE WAY ACROSS THE LARGE BORE AT THE FORWARD BOLT HOLE AND THERE WER E TWO OTHER SMALL CRACKS IN THE LARGE BORE. THE LOWER BOLT FOR THE ACTUATOR WAS FOUND BROKEN OFF IN THE IB GEAR CASTING , THE SECTOR GEAR WAS DAMAGED AND THE MLG PIVOT WAS CRACKED. THE MANUFACTURER SHOULD REDESIGN THE ACTUATOR AND GEAR PIV OT ASSEMBLIES, MAKING THEM OUT OF STEEL OR SOME OTHER MATERIAL THAT WILL WITH STAND THE REPEATED STRESS THAT ARE PUT ON THESE PARTS. THIS IS A RECURRING PROBLEM WITH THIS TYPE OF LANDING GEAR. 1 H 7 1 3O 3 O 3A17 E286 2004071200045 20040712 00045 CE 2004 7 12 2004FA0000547 1 20040526 G 2720 RUDDER PEDAL CESSNA 172 172RG 2072438 CE LYC O360 O360F1A6 41514 EA MCAULY 2D34C B2D34C220 GL COCKPIT DAMAGED B WIWR O OTHER O OTHER NR NOT REPORTED 1 WP 07 6623Z 3300 172RG0240 RL3382736A 820229 PILOTS REPORTED AFTER PERFORMING A SIMULATED WING FIRE MANUVER (A STEEP TURN TO THE LEFT) THEY HEARD A LOUD BANG AND THE N LOST CONTROL OF THE RUDDER. THE AIRCRAFT LANDED SAFELY. MAINTENANCE INSPECTED THE RUDDER SYSTEM AND FOUND THE WELD A SSEMBLY GEARS HAD (JUMPED) A TOOTH AND REDUCED RUDDER TRAVEL TO APPROX .3333 OF NORMAL TRAVEL. AFTER REMOVAL OF THE WEL D ASSEMBLIES MAINTENANCE FOUND THE BULKHEADS THAT THE OUTBOARD RUDDER BEARINGS MOUNTED TO HAD ELONGATED HOLES THAT WOULD ALLOW THE BEARING TO SHIFT FORWARD WHEN EXCESSIVE PRESSURE WAS APPLIED TO THE OB RUDDER PEDALS ON EITHER SIDE OF THE CO CKPIT. THE RUDDER BEARINGS SHOWED NO ABNORMAL WEAR FOR THIS TYPE OF AIRCRAFT. ONE TIME OCCURANCE BEFORE SB 98-3. 1 H 7 1 3O 3 O 3A17 E286 5 C P7EA 2004071200161 20040712 00161 EU 2004 7 12 2004FA0000548 1 20040709 G 2550 23509600 CARGO HOOK AEROSP AS355 AS355* EU INSTALLED G K NONE O OTHER IN INSP/MAINT 1 SW 99 HBZET 228 DURING A MAINTENANCE CHECK, IAW ONBOARD SYSTEMS SB NO. 159-013-00, FOUND CRACKS IN THE WELD PART OF SWING ASSY. 1 G 7 2 3U H11EU 2004071200155 20040712 00155 SW 2004 7 12 2004FA0000549 1 20040710 G 7120 600429503 HEAT SHIELD MOONEY M20R MOONEY M20 M20R 5870225 SW CONT O550 IO550* SO MCAULY 2A34C 2A34C* GL ISOLATOR GOUGED B K NONE O OTHER IN INSP/MAINT 1 SW 17 242M 250 290292 HEAT SHIELD WAS FOUND TO BE MAKING CONTACT WITH TUBULAR ENGINE MOUNT. THIS CONTACT CREATED A GOUGE APPROXIMATELY .200 IN CH IN LENGTH AND APPROXIMATELY .045 INCH DEEP. 1 L 7 1 3O 3 O RT 2A3 E3SO 5 C P3EA 2004071200200 20040712 00200 EA 2004 7 12 2004FA0000550 2 20040707 G 8530 73111 EXHAUST VALVE PIPER PA32 PA32R300 7103213 SO LYC O540 IO540K1G5 41532 EA ENGINE BROKEN G A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 GL 07 9SA 1884 1884 32R7780530 L1493248 THE PILOT REPORTED A LOSS OF POWER AND LOSING ALTITUDE TO AIR TRAFFIC. AN EMERGENCY LANDING WAS ACCOMPLISHED AT A PUBIC AIRPORT. MAINTENANCE PERSONNEL FOUND THE NR 2 CYLINDER HAD A BROKEN EXHAUST VALVE, WITH THE PISTON AND CYLINDER DAMAGED DUE TO THE HEAD OF THE VALVE IN THE CYLINDER. THE STEM OF THE VALVE WAS STILL ON THE ENGINE. THE ENGINES WAS LAST OVERHA ULED ON 08/24/1983. 1 L 7 1 3O 3 O A3SO 1E4 2004071200205 20040712 00205 WP 2004 7 12 2004FA0000551 2 20040606 G 7250 STATOR GULSTM 690TP 695A 7630519 SW GARRTT TPE331 TPE33110 01514 WP ENGINE DAMAGED B DSCR E ENGINE SHUTDOWN B K J SMOKE/FUMES/ODORS/SPARKS FLUID LOSS WARNING INDICATION NR NOT REPORTED 1 GL 25 600CM 15020 P38327 DURING ENGINE START THE OPERATOR OBSERVED SMOKE EXITING THE ENGINE EXHAUST DUCT. THE OPERATOR SHUT THE ENGINE DOWN. VI SUAL INSPECTION REVEALED OIL AND IMPACT DAMAGE IN THE EXHAUST PATH. THIRD STAGE TURBINE WHEEL BLADES WERE FRACTURED. F RAGMENTS FROM THE FRACTURED BLADES ENTERED THE GAS FLOW PATH RESULTING IN SECONDARY IMPACT DAMAGE TO THE THIRD STAGE STA TOR, AFT SCAVENGE PUMP OIL TRANSFER TUBE AND SHIELD, AFT SCAVENGE PUMP COVER, EGT HARNESS, ENGINE EXHAUST DUCT AND AIRFR AME EXHAUST PIPE. THE THIRD STAGE STATOR SEAL ASSEMBLY LOWER RETAINER SEGMENT WAS SEPARATED FROM THE RETAINER RIVETS AN D EXITED THE ENGINE THROUGH THE EXHAUST. THE RETAINER RIVETS AND SPACERS REMAINED IN THE STATOR SEAL. 1 H 7 2 4T 4 T 2A4 E4WE 2004072100062 20040721 00062 EA 2004 7 21 2004FA0000553 2 20040701 G 8550 LW14784 DIPSTICK CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA ENGINE DESTROYED D A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CL CLIMB 1 NM 03 733RL 6118 45 17268489 RL529976T PILOT CHKD OIL DURING PREFLIGHT, REINSERTED DIPSTICK, TURNED C/W UNTIL SNUG. INSTRUCTOR PILOT CHECKED DIPSTICK AND FOUND SNUG. AFTER T/O OIL BEGAN STREAMING FROM COWL. PILOT RETURNED TO BASE AND MADE UNEVENTFUL LANDING. AMT OPENED COWL AND FOUND THAT DIPSTICK WAS MISSING. REMOVED AND CUT OIL FILTER, FOUND MASSIVE AMTS OF ALUMINUM SUBSTANCE IN FILTER ELEMENT . REMOVAL OF SUMP SCREEN REVEALED PIECES OF ALUMINUM ROD IN BOTTOM OF SUMP. WITH CYLINDER NR 4 NEAR TDC, DIPSTICK COULD BE FULLY INSERTED INTO CRANKCASE ALONG CRANKSHAFT, AND CROSS-THREADED UNTIL SNUG WHEN TILTED SLIGHTLY AFT. LOCATION OF SMALL ACCESS DOOR ON THE TOP OF COWL OF AC IT IS DIFFICULT TO VISUALLY INSPECT DIPSTICK FOR PROPER THREAD ENGAGEMENT. 1 H 7 1 3O 3 O NT 3A12 E274 2004091300120 20040913 00120 CE 2004 9 13 2004FA0000554 1 20040625 G 2510 MM201057 LOCK CESSNA 172 172S 2072439 CE LYC O360 IO360A1A 41514 EA SEAT BACK BROKEN B A UNSCHED LANDING O OTHER CR CRUISE 1 WP 07 516ER 2886 172S8620 PILOT SEAT BACK CYL LOCK ASSY ROD BROKE AT SWAGED ROD END. AC RETURNED TO AIRPORT. MFG RESCINDED SB DUE TO PROBLEMS WIT H CYL LOCK ASSY. ANOTHER SB04-25-02 WHICH IS SUPPOSED TO TAKE CARE OF ANY PROBLEMS. ELECTED TO REMOVE ALL CYL LOCK ASS Y, INSTALL SOLID RODS IAW SB04-25-02 UNTIL SUCH TIME AS ALL NEW CYL LOCK ASSY ARE RECEIVED FROM MFG, SEATS ARE RETURNED TO ORIGINAL CONFIGURATION. OFFSET ATTACHMENT AT BACK OF SEAT CONTRIBUTES TO BENDING MOMENT BEING APPLIED TO ROD END AND SIDE LOADS CYL LOCK ASSY. IT IS IMPOSSIBLE TO OBSERVE ROD CRACKING AT SWAGED END PRIOR TO FAILURE DUE TO PLASTIC COVER OVER END THAT IS NOT REMOVABLE. THIS IS SECOND CYL LOCK ASSY ROD END TO BREAK SINCE SB04-25-01 WAS INCORPORATED. 1 H 7 1 3O 3 O NT 3A12 1E10 2004071900055 20040719 00055 SO 2004 7 19 2004FA0000555 2 20040629 G 7322 1048941 CARBURETOR CONT O200 O200A 17020 SO MCAULY 1A102 1A102OCM GL ENGINE BROKEN D A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 SO 15 1214 1214 254630A48 K20557 AC ENTERED A POWER ON STALL, DURING RECOVERY THE ENGINE BEGAN LOOSING POWER. INSTRUCTOR TRIED TO MAINTAIN POWER BY MANE UVERING THROTTLE IN AND OUT BUT WAS ONLY ABLE TO MAINTAIN ABOUT 1100 RPM MAXIMUM CONTINUES. MECHANICS QUICKLY IDENTIFIE D THE PROBLEM AS THE CARBURETOR. UPON REMOVAL AND EXTERNAL INSPECTION OF THE CARBURETOR, FOUND THE NOZZLE ASSEMBLY PIN 47-799 TO BE CRACKED, ABOUT HALF INCH FROM THE END OF THE NOZZLE AND JUST ABOUT ALL THE WAY AROUND. CARBURETOR WAS OVER HAULED ON 7/31/2002 WO NR M992180. 3 O E252 5 N P918 2004071900056 20040719 00056 GL 2004 7 19 2004FA0000556 1 20040616 G 2823 EFS20X2 SELECTOR DIAMON DA40 DA40 2990002 GL FUEL MISPINNED B K NONE O OTHER IN INSP/MAINT 1 SO 15 801ER 378 75 40305 THIS FLEET OPERATOR OPERATES 10 DA40 AIRCRAFT. THERE WAS A PILOT REPORT OF THE FUEL SELECTOR NOT FUNCTIONING PROPERLY, AND NOT ALLOWING THE PILOT TO SELECT THE OTHER TANK. A FLEET INSPECTION WAS INITIATED, AND THIS AIRCRAFT WAS FOUND TO H AVE THE SELECTOR SHAFT UNIVERSAL JOINTS WITH LOOSE OR MISSING ATTACH PINS. 1 L 7 1 3O NT A47CE 2004071900075 20040719 00075 WP 2004 7 19 2004FA0000557 2 20040606 G 7250 31022471 RETAINER GARRTT TPE331 TPE33110 01514 WP TURBINE SECTION DAMAGED B K NONE O OTHER IN INSP/MAINT 1 GL 25 600CM P38327 SECOND STAGE STATOR AIR SEAL RETAINING RIVETS FOUND LOOSE DURING INSPECTION/REPAIR FOR TURBINE SECTION DAMAGE. RETAINER PLATE RIVET HOLE DIAMETER(S) WERE ENLARGED BEYOND MAX RIVET MANUFACTURER SPECIFICATIONS. ENGINE MANUFACTURER MANUALS L ACK ANY INSPECTION CRITERIA FOR RETAINER PLATE RIVET HOLE DIAMETER. ENLARGED RETAINER PLATE RIVET HOLE DIAMETER MAY RES ULT IN LOOSE RETAINER AND/OR AIR SEAL CONTACTING TURBINE ROTOR HUB DURING ENGINE OPERATION. 4 T E4WE 2004071900060 20040719 00060 CE 2004 7 19 2004FA0000558 1 20040503 G 5510 12320412 ATTACH BRACKET CESSNA 210 T210N 2073456 CE CONT O520 TSIO520* 17040 SO HORIZONTAL STAB MISINSTALLED D O OTHER O OTHER NR NOT REPORTED 1 SW 13 4631C 21063582 WHEN PN 1232041 ARE INSTALLED, INCORRECT FIT UNLESS SK210-125 ALSO INSTALLED ON STA 209.0 BULKHEAD. NO CORRELATING REFE RENCE IN MFG PARTS OR SERVICE. TOOK 2 WEEKS WITH MFG TECH TO WORK OUT. IMPROPER FIT CAUSES STRESS AND BINDING ON PARTS THAT COULD LEAD TO FAILURE AND LOSS OF AIRCRAFT. OLD STYLE FITTING CLEAR RIVETS IN BULKHEAD BUT NEW PART KITS, SHOP RI VET LEAVING APPROX .075 GAP UNLESS 210-125 DONE TO CHANGE TO COUNTERSINK RIVETS. 1 H 7 1 3O 3 O 3A21 E8CE 2004071900061 20040719 00061 CE 2004 7 19 2004FA0000560 1 20040415 G 5230 LATCH CESSNA 208 208B 2073701 CE CARGO DOOR INOPERATIVE D Q03E O OTHER O OTHER NR NOT REPORTED 1 SW 99 303PW 208B0985 CARGO DOOR OPENED IN FLIGHT. INSPECTED DOOR AND ADT LATCH. 1 H 7 1 3T A37CE 2004071900058 20040719 00058 EU 2004 7 19 2004FA0000561 1 20040429 G 5520 A730201N ROCKER LET L23 L23 1360308 EU ELEVATOR CRACKED D O OTHER O OTHER NR NOT REPORTED 1 NM 09 251BA 917817 NDT ELEVATOR ROCKER IAW ASTM E-1444. CLEANED AND MAGNETIC PARTICLE INSPECTED IAW ASTM E-1444 AND NDT MT-001. CRACKS FO UND IN SEVERAL PLACES. LACK OF PENETRATION AROUND MANY WELDS. RED TAGGED PART. 1 K 0 0 RC G24EU 2004092000116 20040920 00116 CE 2004 9 20 2004FA0000562 1 20040713 G 5711 SPAR BBAVIA 11 11AC 0191102 CE CONT A65 A65* 17003 SO LT WING CRACKED D O OTHER O OTHER NR NOT REPORTED 1 WP 23 9628E 11AC1266 LT AFT WING SPAR HAD A VERTICAL COMPRESSION CRACK AT THE OB EDGE OF THE LIFT STRUT PLATE. ALSO, IT WAS CRACKED HORIZONT ALLY FROM THE COMPRESSION CRACK TO THE OB LIFT STRUT ATTACHMENT POINT. ALSO, ALL FOUR SPARS WERE CRACKED AT THE IB WING ATTACHMENT BOLT HOLES TO THE END OF THE SPAR. SPAR WAS PROBABLY CRACKED AS THE RESULT OF A HARD LANDING WHICH VISIBLY DAMAGED THE RT WING. AFTER HARD LANDINGS RESULTING IN WING DAMAGE, THE INTERIOR WING ATTACHMENT POINTS, INCLUDING LIFT STRUT ATTACHMENT POINTS, SHOULD BE INSPECTED FOR CRACKS. 1 H 7 1 3O 3 O A761 E205 2004092300090 20040923 00090 CE 2004 9 23 2004FA0000563 1 20040504 G 7603 RA1039C CLIP BEECH 55 95A55 1152704 CE CONT O470 IO470* 17026 SO THROTTLE CONTROL FAILED D O OTHER O OTHER NR NOT REPORTED 1 GL 23 102FA TC483 LT THROTTLE CONTROL LEVER FAILED TO CHANGE POWER DURING CHANGE FROM TAKE-OFF TO CRUISE POWER SETTING. IT WAS DISCOVERED THT THE CRIMPING HAS FAILED ON THE CLIP THROTTLE CONTROL PN RA1039C WHICH IS PART OF THE THROTTLE CABLE ASSY PN 50-3890 12-15. THIS CLIP IS LOCATED ON THE ENGINE SIDE OF THE CONTROL CABLE AND IS ATTACHED TO BRAKE THROTTLE CONTROL PN 96-940 021. 1 L 7 2 3O 3 O 3A16 E1CE 2004071900009 20040719 00009 CE 2004 7 19 2004FA0000564 1 20040712 G 5210 CJ1028 HANDLE CESSNA 172 172R 2072401 CE LYC O360 IO360A1A 41514 EA PAX DOOR OUT OF ADJUST B O OTHER O OTHER NR NOT REPORTED 1 SW 19 9528W 2600 17280467 CABIN DOOR LATCH ASSEMBLY, TWO IN FLEET. THE DOOR LATCH ASSEMBLIES CONTINUALLY GET OUT OF ADJUSTMENT CAUSING THE INSIDE DOOR HANDLE TO FALL TO THE CLOSED POSITION WHEN THE DOOR IS CLOSED FROM THE OUTSIDE. THIS CAUSES THE DOOR TO LOCK AND BE UNABLE TO OPEN FROM THE OUTSIDE. PROPER TEACHING OF DOOR CLOSING PROCEDURES HELPS, BUT ON A FLIGHT SCHOOL / RENTAL A IRCRAFT IT IS NOT ALWAYS POSSIBLE. 1 H 7 1 3O 3 O NT 3A12 1E10 2004071900010 20040719 00010 CE 2004 7 19 2004FA0000565 1 20040712 G 5210 CJ1028 HANDLE CESSNA 172 172R 2072401 CE LYC O360 IO360A1A 41514 EA PAX DOOR OUT OF ADJUST B O OTHER O OTHER NR NOT REPORTED 1 SW 19 9528W 2600 17280467 CABIN DOOR LATCH ASSEMBLY, TWO IN FLEET. THE DOOR LATCH ASSEMBLIES CONTINUALLY GET OUT OF ADJUSTMENT CAUSING THE INSIDE DOOR HANDLE TO FALL TO THE CLOSED POSITION WHEN THE DOOR IS CLOSED FROM THE OUTSIDE. THIS CAUSES THE DOOR TO LOCK AND BE UNABLE TO OPEN FROM THE OUTSIDE. PROPER TEACHING OF DOOR CLOSING PROCEDURES HELPS, BUT ON A FLIGHT SCHOOL / RENTAL A IRCRAFT IT IS NOT ALWAYS POSSIBLE. 1 H 7 1 3O 3 O NT 3A12 1E10 2004092300064 20040923 00064 GL 2004 9 23 2004FA0000566 1 20040524 G 7603 CONTROL CABLE CIRRUS SR SR20 05628AJ GL CONT IO360 IO360* 17025 CE MIXTURE CONTROL CHAFED D O OTHER O OTHER NR NOT REPORTED 1 SW 01 6000C 769 1037 MIXTURE CONTROL AND ALTERNATOR BATTERY AND CABLE ARE TIED TOGETHER. CONTROL AND CABLE CHAFED INSULATION OFF CABLE AND S HORTED TO MIXTURE CABLE, CAUSING MIXTURE CABLE TO FREEZE UP AT ITS CURRENT SETTING. WHEN TYING WIRES AND CABLE AND LINE S OR HOSE TOGETHER USE A STAND OFF FOR SEPARATION BETWEEN THEM. 1 L 7 1 3O 3 O NT A00009CH E1CE 2004071900006 20040719 00006 CE 2004 7 19 2004FA0000567 1 20040601 G 5740 24130023 MOUNT CESSNA 172 172RG 2072438 CE LYC O360 O360* 41514 EA NLG ACTUATOR CRACKED D O OTHER O OTHER NR NOT REPORTED 1 SW 11 9795B 172RG1042 FOUND AT 100 HOUR INSPECTION. NOSE GEAR ACTUATOR MOUNT, CRACKED AFT OF NOSE GEAR ACTUATOR. 1 H 7 1 3O 3 O 3A17 E286 2004071900078 20040719 00078 SO 2004 7 19 2004FA0000568 1 20040226 G 5310 62522000 FITTING PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360* 17025 SO WINDSHIELD FRAME CORRODED D O OTHER O OTHER NR NOT REPORTED 1 EA 03 157BJ 347570282 BOTH LOWER AFT WINDSHIELD FRAME STEEL FITTING VERY CORRODED. WINDSHIELD LEAK AND INSULATION HOLDING MOISTURE ON FITTING . NEED TO BE INSPECTED MORE OFTEN AND CLEANED AND TREATED. 1 L 7 2 3O 3 O A7SO E9CE 2004071900012 20040719 00012 SO 2004 7 19 2004FA0000569 1 20040226 G 5340 6852700 FITTING PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360* 17025 SO WINDSHIELD FRAME CORRODED D O OTHER O OTHER NR NOT REPORTED 1 EA 03 157BJ 347570282 BOTH LOWER AFT WINDSHIELD FRAME STEEL FITTING VERY CORRODED. WINDSHIELD LEAK AND INSULATION HOLDING MOISTURE ON FITTING . NEED TO BE INSPECTED MORE OFTEN AND CLEANED AND TREATED. 1 L 7 2 3O 3 O A7SO E9CE 2004071900013 20040719 00013 EU 2004 7 19 2004FA0000570 1 20040615 G 3610 275503 SHUTOFF VALVE ISRAEL 1124 1124 4500102 EU GARRTT TFE731 TFE731* 01518 WP OXYGEN LEAKING D O OTHER O OTHER NR NOT REPORTED 1 SW 15 79KP 39 262 THIS VALVE INSTALLED PREVIOUSLY TO COMPLY WITH REQURIEMENTS OF AD 2003-11-07. FOUND DURING INSPECTION THAT VALVE WILL N OT SHUT OFF OXYGEN FLOW WHEN TURNED TO CLOSED. REPLACED VALVE WITH NEW PN 27550-3, THIS CORRECTED PROBLEM. 2 M 7 2 4F 4 F A2SW E6WE 2004071900014 20040719 00014 EA 2004 7 19 2004FA0000571 2 20040610 G 7310 25765361 SERVO CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA MCAULY 1A170 1A170E GL ENGINE FUEL INOPERATIVE D O OTHER O OTHER NR NOT REPORTED 1 WP 27 974SP 172S8178 L2893651A TB007 AIRCRAFT WAS REPORTED, ENGINE DIES ON IDLE SPEED, EXCESSIVE RICH MIXTURE, BLACK SMOKE EMITTED FROM EXHAUST. IDLE SPEED AND MIXTURE COULD NOT BE ADJUSTED IAW AD 2001-06-17 INSTRUCTIONS REF D, L, I, THRU 2, 1. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P857 2004071900011 20040719 00011 SO 2004 7 19 2004FA0000572 1 20040510 G 1430 AN546 BOLT PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA DOWNLOCK SWITCH CORRODED D O OTHER O OTHER NR NOT REPORTED 1 NE 01 615SN 3334 318052094 PILOT DECLARED AN EMERGENCY WHEN HE HAD A GEAR UNSAFE LIGHT AFTER THE GEAR EXTENDED. (AC EVENTUALLY LANDED SAFELY). GE AR DOWNLOCK DID NOT GO ALL THE WAY TO THE LOCK POSITION AND ACTIVATE THE SWITCH. (DOWNLOCK WAS FOUND CORRODED TO THE BO LT) MM , PUT A FEW DROPS OF OIL ON THE BOLT AT ANNUAL/100 HOUR. THE PROBLEM IS THE OIL DOES NOT WICK INTO THE AREA WHER E IT PIVOTS. ALSO, HOT ENGINE EXHAUST BLOWING ACROSS THE BOLT EVENTUALLY NEGATES ANY LUBRICATION ACTION. RECOMMEND BOL T, GET CHANGED PERIODICALLY AND PUT NEVER SEIZE ON THE BOLT WHEN INSTALLING. IF NOTHING ELSE, THE (NEVER SEIZE) WOULD K EEP THINGS MOVING! 1 L 7 2 3O 3 O A20SO E14EA 2004071900030 20040719 00030 SO 2004 7 19 2004FA0000573 2 20040602 G 7310 CK002 CLAMP LANCAR LC40 LC40550FG 5150000 NM CONT O550 IO550N 17042 SO FUEL PRESS TRANS CRACKED C O OTHER K FLUID LOSS NR NOT REPORTED 1 GL 03 419JK 7 40020 AD WAS COMPLIED WITH AT 250 HOURS BY INSP AND INSTALLATION OF MFG SERVICE KIT (PN CK-002) (WORM TYPE CLAMP) INSTALLED ON THE FUEL PRESSURE TRANSDUCER. THE CLAMP WAS TORQUED TO THE EXACT TORQUE AS CALLED. 6/2/04-DURING AN OIL CHANGE THE CL AMP SUPPLIED IN KIT CK0002 WAS FOUND CRACKED IN TWO, NO LONGER SECURING THE TRANSDUCER. THE PROBLEM IS CAUSED BY COMMON TYPE STAINLESS HOSE CLAP BEING TIGHTENED AROUND A SQUARE TRANSDUCER BRACKET. THE BRACKET PUTS VERY SHARP STRESS MARKS IN FOUR SPOTS OF THE CLAMP CAUSING IT TO CRACK. RECOMMEND PROMPT REVISION TO AD NOTE. 1 L 7 1 3O 3 O RT A00003SA E3SO 2004071900004 20040719 00004 SW 2004 7 19 2004FA0000574 1 20040611 G 5711 SPAR BBAVIA 7 7GCBC 1220601 SW LYC O320 O320* 41508 EA WING DAMAGED D O OTHER O OTHER NR NOT REPORTED 1 SW 01 50338 107279 TWO SPARS SPLIT AT WING ROOT WING ATTACH FITTINGS, ONE SPAR SPLIT AT WING LIFT STRUT ATTACH FITTING. SPLITS FOUND DURIN G ANNUAL INSPECTION. PROBABLE CAUSE: DRYING AND SHRINKAGE. 1 H 7 1 3O 3 O NC A759 E274 2004071900024 20040719 00024 SO 2004 7 19 2004FA0000575 2 20040624 G 7497 M1740R WIRE HARNESS BEECH 36 A36 1151604 CE CONT O520 IO520BA 17032 SO HARTZL HCC3Y PHCC3YF1 GL NR 4 CYLINDER BROKEN D O OTHER O OTHER NR NOT REPORTED 1 SO 03 9139Q 1093 E249 1214317BA EE557 THE SHIELDING ON THE IGN LEAD ON 4 CYLINDERS AT THE PLUG ENDS FRAYED AND BROKEN ALLOWING IGN NOISE TO BE HEARD OVER AIRC RAFT RADIO. PREVENTS PILOT FROM UNDERSTANDING ATC SHIELDING BROKE RT AT (B) ASSEMBLY. THIS IS THE RED SLICK IGN HARNES S. 1 L 7 1 3O 3 O 3A15 E5CE 5 C P25EA 2004071900008 20040719 00008 CE 2004 7 19 2004FA0000576 1 20040621 G 8010 637817 BEARING BEECH 36 A36 1151604 CE CONT O550 IO550B SO STARTER ADAPTER FAILED D O OTHER O OTHER NR NOT REPORTED 1 WP 27 8190G 1453 E2658 297163R UPON RETURN FROM A TRAINING FLIGHT A LARGE QUANTITY OF OIL WAS FOUND IN THE ENGINE COWL AND ON THE GROUND UNDER THE AIRC RAFT. AFTER WASHING THE ENGINE DOWN, AND AN ENGINE RUN, IT WAS DETERMINED THAT THE OIL WAS COMING FROM THE AIR CONDITIO NING DRIVE SHAFT SEAL IN THE STARTER ADAPTER ASSEMBLY. FURTHER DISASSEMBLY AND INSPECTION REVELED THAT THE BALL BEARING , JUST BEHIND THE SEAL, HAD COME APART. NO METAL WAS FOUND IN THE OIL FILTER OR THE STRAINED ENGINE OIL. INSPECT SEAL AT PREFLIGHT TO DETECT EXCESSIVE LEAKAGE. 1 L 7 1 3O 3 O 3A15 E3SO 2004071900005 20040719 00005 CE 2004 7 19 2004FA0000577 1 20040714 G 7160 SEALANT STCSA4428S CESSNA 172 172M 2072418 CE LYC O360 O360A4M 41514 EA AIR BOX SEPARATED B O OTHER R PARTIAL RPM/PWR LOSS TX TAXI/GRND HDL 1 SO 05 738GV 17269974 L3633336A ACFT HAD LOW POWER DURING TAKE OFF, DURING THE FOLLOW-UP INSPECTION THE MECH. FOUND PIECES OF SILICON MISSING AROUND THE CARB INTAKE SUSPECTED THAT IT WAS INGESTED THROUGH THE CARB DURING TAKE OFF. THIS ACFT HAD STC NR SA4428SW INSTALLED O N 9-16-98 PART OF THIS INSTALLATION WAS TO MOD THE AIR BOX AND INSTALL AN ADAPTER PLATE WITH SILICON SEALANT BETWEEN THE PLATE AND THE AIR BOX A PIECE OF THIS SEALANT WAS MISSING. 1 H 7 1 3O 3 O NT 3A12 E286 2004072100061 20040721 00061 NM 2004 7 21 2004FA0000578 1 20040719 G 6220 900R2101006107 HUB DOUG DOUG MD900 MD900 3027375 NM PWC PW207 PW207E NE MAIN ROTOR CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 11 3PD 91 91 0099990080 9000085 DURING ACCOMPLISHMENT OF A.D. 2002-10-05, (MAIN ROTOR UPPER HUB INSP.) FOUND (2) OUT OF (10) HOLES CRACKED IN UPPER HUB FLANGE AS DEPICTED IN MFG SERVICE BULLETIN 900-072. 1 G 7 2 3U 3 U NC H19NM E42NE 2004072100063 20040721 00063 CE 2004 7 21 2004FA0000580 1 20040714 G 1430 AN37 BOLT CESSNA 210 T210J 2073440 CE CONT O520 TSIO520H 17040 SO THROTTLE MISSING G L ABORTED APPROACH R PARTIAL RPM/PWR LOSS AP APPROACH 1 NM 04 2KD 58 T2100436 501200 WHILE MAKING A APPROACH TO THE AIRPORT FOR LANDING, THE PILOT ADDED POWER WITH NO ENGINE RESPONSE. THE THROTTLE CABLE DI SCONNECTED FROM THE ENGINE CONTROL ARM DUE TO THE THROTTLE ATTACHING BOLT MISSING ALONG WITH THE WASHER, NUT AND COTTER PIN. THROTTLE WORKED FIND WHEN MOVED FROM THE COCKPIT. AIRCRAFT HAD THE ENGINE REMOVED APRIL 04 FOR METAL CONTAMINATION AND REINSTALLED. 1 H 7 1 3O 3 O 3A21 E8CE 2004091500110 20040915 00110 NM 2004 9 15 2004FA0000585 1 20040621 G 5210 AE40142Z006 ACTUATOR AMD FALC50 FALCON2000 2730170 NM PAX DOOR DELAMINATED C O OTHER O OTHER NR NOT REPORTED 1 SW 99 2895 MAIN CABIN DOOR ACTUATOR (WISHBONE) DELAMINATING. 2 K 7 3 4F RT A50NM 2004091500112 20040915 00112 NM 2004 9 15 2004FA0000586 1 20040621 G 5210 AE40142Z006 ACTUATOR AMD FALC50 FALCON2000 2730170 NM PAX DOOR DELAMINATED B O OTHER O OTHER NR NOT REPORTED 1 SW 99 2810 034 MAIN CABIN DOOR ACTUATOR DELAMINATED. 2 K 7 3 4F RT A50NM 2004091500114 20040915 00114 SO 2004 9 15 2004FA0000587 1 20040708 G 2701 CLAMP PIPER PA28 PA28181 7102807 SO LYC O360 O360* 41514 EA CONTROL COLLUMN OUT OF POSITION D K NONE O OTHER IN INSP/MAINT 1 SO 03 81892 288090286 FULL DOWN ELEVATOR WAS NOT ACHIEVED DUE TO THE FACT THAT TEMPORARY YOKE ATTACHMENTS WERE IMPEDING THE MOVEMENT OF THE FO RWARD TRAVEL OF THE YOKE. AFTER A THOROUGH INSPECTION OF THE STABALATOR CONTROL SYSTEM IT WAS FOUND THAT THE CLAMP ON A TTACHMENTS WERE IMPEDING THE TRAVEL. OF COURSE THIS CARRY MUCH POTENTIAL DANGER. 1 L 7 1 3O 3 O 2A13 E286 2004092000087 20040920 00087 GL 2004 9 20 2004FA0000588 1 20040605 G 2823 3F20M SELECTOR VALVE DIAMON DA40 DA40 2990002 GL LYC O360 IO360A1A 41514 EA HARTZL HCC2Y HCC2YR1 GL ZONE 100 SEPARATED B O OTHER O OTHER CR CRUISE 1 SO 15 807ER 282 86 40318 L3114451A CH37371B DURING FLIGHT, THE FLIGHT CREW MADE A FUEL TANK SELECTION CHANGE AND NOTICED THE FUEL WAS BURNING FROM THE PREVIOUS TANK EVEN THOUGH THE SELECTOR HAD BEEN MOVED TO THE NEW TANK. AFTER LANDING, MAINTENANCE PERSONNEL FOUND THE FUEL SELECTOR SHAFT HAD BECOME SEPARATED FROM THE SELECTOR AT THE UNIVERSAL JOINT. THE UNIVERSAL JOINT RETAINING PINS ARE PRESSED INT O THE UNIVERSAL JOINT BODY AND HAD BECOME LOOSE ALLOWING THEM TO FALL OUT. THIS SHAFT IS PART OF THE FUEL SELECTOR ASSE MBLY AND HAS NO UNIQUE P/N. 1 L 7 1 3O 3 O NT A47CE 1E10 5 C P920 2004092000103 20040920 00103 GL 2004 9 20 2004FA0000590 1 20040605 G 2823 3F20M SELECTOR VALVE DIAMON DA40 DA40 2990002 GL LYC O360 IO360A1A 41514 EA HARTZL HCC2Y HCC2YR1 GL FUEL SYS SEPARATED B O OTHER O OTHER CR CRUISE 1 SO 15 807ER 282 86 40318 L3114451A CH37371B DURING FLIGHT, THE FLIGHT CREW MADE A FUEL TANK SELECTION CHANGE AND NOTICED THE FUEL WAS BURNING FROM THE PREVIOUS TANK EVEN THOUGH THE SELECTOR HAD BEEN MOVED TO THE NEW TANK. AFTER LANDING, MAINTENANCE PERSONNEL FOUND THE FUEL SELECTOR SHAFT HAD BECOME SEPARATED FROM THE SELECTOR AT THE UNIVERSAL JOINT. THE UNIVERSAL JOINT RETAINING PINS ARE PRESSED IN TO THE UNIVERSAL JOINT BODY AND HAD BECOME LOOSE ALLOWING THEM TO FALL OUT. THIS SHAFT IS PART OF THE FUEL SELECTOR ASS EMBLY AND HAS NO UNIQUE P/N. 1 L 7 1 3O 3 O NT A47CE 1E10 5 C P920 2004092000104 20040920 00104 GL 2004 9 20 2004FA0000591 1 20040605 G 2823 3F20M SELECTOR VALVE DIAMON DA40 DA40 2990002 GL LYC O360 IO360A1B 41514 EA HARTZL HCC2Y HCC2YR1 GL ZONE 100 SEPARATED B K NONE O OTHER CR CRUISE 1 SO 15 807ER 282 86 40318 L3114451A CH37371B DURING FLIGHT, THE FLT CREW MADE A FUEL TANK SELECTION CHANGE AND NOTICED THE FUEL WAS BURNING FROM THE PREVIOUS TANK EV EN THOUGH THE SELECTOR HAD BEEN MOVED TO THE NEW TANK. AFTER LANDING, MAINTENANCE PERSONNEL FOUND THE FUEL SELECTOR SHAF T HAD BECOME SEPARATED FROM THE SELECTOR AT THE UNIVERSAL JOINT. THE UNIVERSAL JOINT RETAINING PINS ARE PRESSED INTO THE UNIVERSAL JOINT BODY AND HAD BECOME LOOSE ALLOWING THEM TO FALL OUT. THIS SHAFT IS PART OF THE FUEL SELECTOR ASSEMBLY AND HAS NO UNIQUE P/N. 1 L 7 1 3O 3 O NT A47CE 1E10 5 C P920 2004092300055 20040923 00055 GL 2004 9 23 2004FA0000596 1 20040616 G 2823 EA2UJD SHAFT DIAMON DA40 DA40 2990002 GL FUEL SELECTOR MISPINNED B K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 15 807ER 282 86 40318 THIS FLEET OPERATOR OPERATES AIRCRAFT. THERE WAS A PILOT REPORT OF THE FUEL SELECTOR NOT FUNCTIONING PROPERLY, AND NOT A LLOWING THE PILOT TO SELECT THE OTHER TANK. A FLEET INSPECTION WAS INITIATED, AND THIS AIRCRAFT WAS FOUND TO HAVE THE S ELECTOR SHAFT UNIVERSAL JOINTS WITH LOOSE OR MISSING ATTACH PINS. 1 L 7 1 3O NT A47CE 2004092300057 20040923 00057 GL 2004 9 23 2004FA0000597 1 20040616 G 2823 EA2UJD SHAFT DIAMON DA40 DA40 2990002 GL FUEL SELECTOR MISPINNED B K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 15 810ER 291 99 40320 THERE WAS A PILOT REPORT OF THE FUEL SELECTOR NOT FUNCTIONING PROPERLY, AND NOT ALLOWING THE PILOT TO SELECT THE OTHER T ANK. A FLEET INSPECTION WAS INITIATED, AND THIS AIRCRAFT WAS FOUND TO HAVE THE SELECTOR SHAFT UNIVERSAL JOINTS WITH LOO SE OR MISSING ATTACH PINS. 1 L 7 1 3O NT A47CE 2004092300059 20040923 00059 GL 2004 9 23 2004FA0000598 1 20040616 G 2823 EFS20X2 SHAFT DIAMON DA40 DA40 2990002 GL FUEL SELECTOR MISPINNED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 15 802ER 346 48 40306 THERE WAS A PILOT REPORT OF THE FUEL SELECTOR NOT FUNCTIONING PROPERLY, AND NOT ALLOWING THE PILOT TO SELECT THE OTHER T ANK. A FLEET INSPECTION WAS INITIATED, AND THIS AIRCRAFT WAS FOUND TO HAVE THE SELECTOR SHAFT UNIVERSAL JOINTS WITH LOOS E OR MISSING ATTACH PINS. 1 L 7 1 3O NT A47CE 2004092300060 20040923 00060 GL 2004 9 23 2004FA0000599 1 20040616 G 2823 EFS20X2 SHAFT DIAMON DA40 DA40 2990002 GL FUEL SELECTOR MISPINNED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 15 805ER 9 40316 THERE WAS A PILOT REPORT OF THE FUEL SELECTOR NOT FUNCTIONING PROPERLY, AND NOT ALLOWING THE PILOT TO SELECT THE OTHER T ANK. A FLEET INSPECTION WAS INITIATED, AND THIS AIRCRAFT WAS FOUND TO HAVE THE SELECTOR SHAFT UNIVERSAL JOINTS WITH LOOS E OR MISSING ATTACH PINS. 1 L 7 1 3O NT A47CE 2005022200010 20050222 00010 GL 2005 2 22 2004FA0000600 1 20040614 G 3222 FORK AMTR AEROST AEROSTARBIRD 0560582 GL NLG BROKEN G E ENGINE SHUTDOWN O OTHER TX TAXI/GRND HDL 1 GL 07 7022X 70 AS1020 THE PILOT REPORTED THAT WHILE TAXING AFTER A LANDING, THE NOSE GEAR GAVE WAY AND THE AIRCRAFT CAME TO REST ON THE PROPEL LER SPINNER. THIS IS AN AMATEUR BUILT AIRCRAFT. THE AIRCRAFT BUILDER MADE THE NOSE WHEEL FORK THAT BROKE. THEREBY LOSIN G THE NOSE WHEEL AND CAUSING THE NOSE GEAR LEG TO FOLD BACK AND PUTTING THE PROPELLER SPINNER ON THE PAVEMENT. SINCE TH IS PART IS INSTALLED ON AN EXPERIMENTAL AIRCRAFT THERE ARE NO STANDARDS FOR THE AIRCRAFT OR ANY OF THE PARTS. PREVENTI ON/SOLUTION, THE PRESENT OWNER HAS RELATED THE OLD PART WAS MADE UP OF ONE QUARTER INCH 2024 T3 ALUMINUM AND THE NEW PAR T WILL BE ONE EIGHTH INCH 4130 STEEL, BENT TO SHAPE AND THEN HARDENED TO A HARDNESS OF 135-145. 1 M 7 1 EXPA1M71 2004081300055 20040813 00055 GL 2004 8 13 2004FA0000601 1 20040727 G 2844 TEE FITTING DIAMON DA40 DA40 2990002 GL LYC O360 IO360LYC* 41514 EA ENGINE SERVO DAMAGED B O OTHER J WARNING INDICATION CL CLIMB 1 SO 15 809ER 50 40321 L3104651A DURING MANEUVERS, THE FUEL PRESSURE GAUGE AND ENUNCIATOR SYSTEM WARN OF A LOW FUEL PRESSURE PROBLEM. ALL ENGINE INDICAT IONS HOWEVER, SHOW THAT FUEL FLOW AND PRESSURE ARE NORMAL. THIS PROBLEM HAS BEEN EVIDENT IN OTHER AIRCRAFT IN THE FLEET OF 10 DA40 AIRCRAFT. THE MOST SUCCESSFUL METHOD OF ELIMINATING THIS INDICATION PROBLEM IS TO BLEED THE AIR THAT SEEMS TO HAVE ACCUMULATED IN THE TRANSDUCER LINES AND FITTINGS. 1 L 7 1 3O 3 O NT A47CE 1E10 2004082300097 20040823 00097 EA 2004 8 23 2004FA0000602 2 20040726 G 8530 3116 STUD LYC CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA NR 3 CYL ROCKER LOOSE D O OTHER O OTHER NR NOT REPORTED 1 NM 04 7610F 2345 2345 15317 17273268 L699076 NR 3 CYLINDER INTAKE VALVE ROCKER ARM STUD BACKED OUT CAUSING PUSHROD TO BEND AND HYDRAULIC LIFTER FAILURE. 1 H 7 1 3O 3 O NT 3A12 E274 2004083100023 20040831 00023 SW 2004 8 31 2004FA0000603 1 20040729 G 3220 NUT SLINDS 100 10AVOLAIRE 9550104 SW LYC O320 O320* 41508 EA NLG LOOSE G O OTHER O OTHER LD LANDING 1 GL 25 6665D 10A028 SAFETY WIRE BROKE FROM THE NUT THAT RETAINS THE NOSE LANDING GEAR PISTON/PISTON ROD ASSEMBLY INTO THE NOSE STRUT CYLINDE R TUBE ASSEMBLY. THE PISTON/PISTON ROD ASSEMBLY SEPARATED FROM THE STRUT CYLINDER TUBE ASSEMBLY UPON LANDING. SUBSEQUEN TLY THE NOSE GEAR/PISTON ROD ASSEMBLY AND WHEEL ASSEMBLY FOLDED BACK ON IMPACT CAUSING THE AIRCRAFT ROLL OUT TO BE SUPPO RTED BY THE STRUT CYLINDER TUBE ASSEMBLY. THE STRUT CYLINDER TUBE ASSEMBLY LOWER LEADING EDGE WAS GROUND DOWN DURING THE LANDING ROLL OUT. 1 H 7 1 3O 3 O 1A21 E274 2004091400084 20040914 00084 2004 9 14 2004FA0000604 4 20040630 G 2397 S2899L50 CIRCUIT BREAKER CESSNA 525 525A 2076615 CE NAV/COMM SYS ARCED B A UNSCHED LANDING G MULTIPLE FAILURE CL CLIMB 1 CE 07 692JM 1229 525A0004 THE FOLLOWING SYS FAILED IN FLIGHT: NR 1 NAV/COMM/XPDR, CO-PILOTS AUDIO PANEL, RT PITOT HEAT, STANDBY HSI, NR 2 ATTITUD E/HEADING, AUTOPILOT DISENGAGED, LANDING GEAR HYDRAULIC, SYS PRESSURE, LANDING GEAR DOWN AND LOCK INDICATOR LIGHTS, FLIG HT CREW UTILIZED THE EMERGENCY EXTENSION SYSTEM TO EXTEND THE LANDING GEAR. A LOOSE TERMINAL SCREW WAS FOUND ON BUS SIDE OF CB (HC068) LOCATED IN THE LT COCKPIT CB PANEL. TERMINAL SCREW BACKED OUT AND SHORTED TO ADJACENT STRUCTURE. THIS CA USED EMERGENCY POWER CB (HC102) IN AFT JUNCTION BOX TO DISENGAGE. DAMAGED TERMINALS AND CIRCUIT BREAKER (HC068) WERE RE PLACED. ALL WIRING AND TERMINALS IN BOTH COCKPIT CB PANELS WERE INSPECTED FOR LOOSE SCREWS AND CHAFING WIRES. 1 L 7 1 4F RT A1WI 2004091500108 20040915 00108 SO 2004 9 15 2004FA0000605 1 20040729 G 1430 NAS464P427 BOLT PIPER PA44 PA44180 7104402 SO NLG CRACKED B K NONE O OTHER IN INSP/MAINT 1 NM 09 2163N 447995222 DURING INSPECTION FOUND NOSE GEAR TORQUE LINK BOLT PN NAS464P4-27 SHEARED MID SPAN OF BOLT SHANK. NO SIGN OF EXCESSIVE C ORROSION. 1 L 7 2 3O A19S0 2004092300082 20040923 00082 GL 2004 9 23 2004FA0000606 1 20040616 G 2823 EA2UJD SHAFT DIAMON DA40 DA40 2990002 GL LYC O360 IO360A1A 41514 EA FUEL SELECTOR MISPINNED B K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 15 809ER 296 99 40321 THIS FLEET OPERATOR OPERATES 10 DA40 AIRCRAFT. THERE WAS A PILOT REPORT OF THE FUEL SELECTOR NOT FUNCTIONING PROPERLY, A ND NOT ALLOWING THE PILOT TO SELECT THE OTHER TANK. A FLEET INSPECTION WAS INITIATED, AND THIS AIRCRAFT WAS FOUND TO HAV E THE SELECTOR SHAFT UNIVERSAL JOINTS WITH LOOSE OR MISSING ATTACH PINS. 1 L 7 1 3O 3 O NT A47CE 1E10 2004092300069 20040923 00069 CE 2004 9 23 2004FA0000607 1 20040721 G 1430 FN22A524 NUT DUNLOP RAYTHN DH125 HAWKER800XP 7150012 CE GARRTT TFE731 TFE731* 01518 WP NR 4 WHEEL SPLIT C O OTHER O OTHER NR NOT REPORTED 1 SW 11 91HK 1418 ZT111 258578 WHILE CLEANING AIRCRAFT DISCOVERED NR 4 MAIN WHEEL 1 EACH TIE-BOLT NUT SPLIT IN HALF. REPLACED ALL WHEEL TIE BOLTS P/N: EWB22-5-16 AND NUTS P/N: FN22A524 WITH NEW PARTS. TIME ON PART SINCE REPAIR UNKNOWN. 2 L 7 2 4F 4 F RT A3EU E6WE 2004092300094 20040923 00094 SO 2004 9 23 2004FA0000608 1 20040625 G 1410 LINE GULSTM GV GV 3980116 SO RROYCE BR700 BR700710A110 NE SENSE LINE LOOSE C B EMER. DESCENT J WARNING INDICATION CR CRUISE 1 GL 23 300K 587 AT FL 410 RECEIVED A CABIN PRESSURE LOW (RED) MESSAGE ON YTHE CAS. AIRCRAFT INITIATED EDM APPROX. FL 380 CAS MESSAGE EXT INGUISHED LEVELED OFF AT FL 200. UNDECLARED AN EMERGENCY. APPROX. 10 MIN LATER RECEIVED ANOTHER CABIN PRESSURE LOW MESS AGE, DECLARED AN EMERGENCY DIVERTED, LANDED WITHOUT INCIDENT. INSPECTED AIRCRAFT IAW MFG M/M. FOUND PRESSURE REFERENCE S ENSE LINE (B) NUT AND FITTING LOOSE. REMOVED AND REPLACED CPCS IAW M/M 21-31-01. 2 L 7 2 4F 4 F RT A12EA E00057EN 2004090800173 20040908 00173 SO 2004 9 8 2004FA0000614 1 20040326 G 1430 BOLT PIPER PA30 PA30 7103002 SO LYC O320 IO320* 41508 EA STABILATOR CORRODED D Q76E O OTHER O OTHER NR NOT REPORTED 1 SW 15 7192Y 30216 DURING ANNUAL INSPECTION THE STABILATOR WAS REMOVED FOR FURTHER INSPECTION. THIS IS DUE TO PREVIOUS PROBLEMS ON OTHER P A24 AND PA30/39 AIRCRAFT WITH STABILATOR TORQUE TUBE AND ATTACHMENT BOLTS WITH EXCESSIVE CORROSION. BOTH BOLTS AN175C33 A THAT ATTACHES THE STABILATOR HORN ASSY TOT THE TORQUE TUBE WERE SEVERELY CORRODED. ALSO CORRODED WERE THE FOLLOWING B OLTS: AN24-46A (400-932), AN174-22A (402-321). TT 4542 1 L 7 2 3O 3 O A1EA 1E12 2004090800166 20040908 00166 SO 2004 9 8 2004FA0000619 1 20040326 G 1430 AN175C33A BOLT PIPER PA30 PA30 7103002 SO LYC O320 O320* 41508 EA STABILATOR CORRODED D Q76E K NONE O OTHER IN INSP/MAINT 1 SW 15 14A 3681 301208 DURING ANNUAL INSPECTION THE STABILATOR WAS REMOVED FOR FURTHER INSPECTION. THIS IS DUE TO PREVIOUS PROBLEMS ON OTHER P A24 AND PA30/39 AIRCRAFT WITH STABILATOR TORQUE TUBE AND ATTACHMENT BOLTS WITH EXCESSIVE CORROSION. BOTH BOLTS AN175C33 A THAT ATTACHES THE STABILATOR HORN ASSY TO THE TORQUE TUBE WERE SEVERELY CORRODED. ALSO CORRODED WERE THE FOLLOWING BO LTS: AN24-46A (400-932), AN174-22A (402-321).. THE BOLTS ATTACHING THE STABILATOR TO THE TORQUE TUBE WERE ALSO CORRODE D SEVERELY. THE BOLTS HAD TO BE REMOVED BY AN IMPACT TOOL. THESE WERE TO BE REPLACED OR INSPECTED IAW AD 74-13-03. TT 3681. 1 L 7 2 3O 3 O A1EA E274 2004091400118 20040914 00118 SO 2004 9 14 2004FA0000628 1 20040809 G 2840 602501 FLOAT SWITCH PIPER PA46 PA46500TP 7104622 SO PWA PT6 PT6* 52043 EA FUEL SYSTEM FAILED C O OTHER O OTHER NR NOT REPORTED 1 EA 25 901DM 413 4697051 OWNER COMPLAINED RT FUEL PUMP WAS INOPERATIVE. TROUBLESHOOT SYSTEM TO A HEAVY FUEL FLOAT SWITCH P/N 602-501. HEAVY FLOAT CAUSED FUEL PUMP TO BE INOPERABLE WHEN SELECTED IN MANUAL OR AUTOMATIC. 1 L 7 1 3O 3 T RT A25SO E2NE 2004091300193 20040913 00193 SO 2004 9 13 2004FA0000630 1 20040709 G 3213 6531903 STRUT PIPER PA28 PA28140 7102802 SO LYC O320 O320* 41508 EA MLG DAMAGED D O OTHER O OTHER LD LANDING 1 NM 01 98151 2826076 LANDING ON GRASS STRIP WHICH WAS NOT AS SMOOTH AS THE USUAL PAVEMENT. THE STRUT APPEARED TO BE OVER EXTENDED. UPON CLO SER LOOK IT WAS NOTED THAT BOTH ON THE EARS WHICH CONNECT THE TORQUE LINK, HAD BROKEN OFF THE STRUT. CHECKING THE OTHER LANDING GEAR SHOWED CRACKS ALSO IN THE SAME AREA. 1 L 7 1 3O 3 O 2A13 E274 2004092000070 20040920 00070 CE 2004 9 20 2004FA0000631 1 20040623 G 7810 NH100089770 CLAMP CESSNA 340 340A 2076405 CE CONT O520 TSIO520NB 17040 SO TURBO TO EXHAUST CRACKED B W6NR O OTHER O OTHER NR NOT REPORTED 1 GL 25 346FS 340A0790 WHILE DOING THE EXHAUST AD2000-01-16, THE ONE PIECE V CLAMP THAT HOLDS THE EXHAUST TO THE TURBO WAS FOUND CRACKED APPROX 50 PERCENT AROUND, REPLACED CLAMP AND LEAK CHECKED OK. THE CRACKED CLAMP DID NOT APPEAR TO BE OVER TORQUED. 1 L 7 2 3O 3 O 3A25 E8CE 2004091500100 20040915 00100 SO 2004 9 15 2004FA0000632 2 20040615 G 7310 641481 LINE CESSNA 421 421C 2076016 CE CONT O520 GTSIO520N 17032 SO INJECTOR CRACKED B J7BR O OTHER O OTHER NR NOT REPORTED 1 SW 01 421GF 98 421C1110 608045 PILOT EXPERIENCED EGT FLUXUATIONS, MADE PRECAUTIONARY LANDING. INSPECTION REVEALED CYLINDER NR 4 INJECTOR LINE WAS CRAC KED AND LEAKING FUEL AT THE BASE OF THE BRAZED ON SLEEVE BETWEEN THE SLEEVE AND THE BALL END. 1 L 7 2 3O 3 O A7CE E7CE 2004091500094 20040915 00094 SO 2004 9 15 2004FA0000633 1 20040719 G 2730 51757005 CONTROL CABLE PIPER PA31T PA31T2 7103127 SO ELEVATOR DISCONNECTED B GW1R O OTHER O OTHER NR NOT REPORTED 1 EA 03 31JZ 31T8166062 DURING A ROUTINE EVENT NR 1 AIRFRAME INSPECTION, IT WAS DISCOVERED THE (ELEVATOR) PRIMARY TOP CONTROL CABLE (ELEVATOR CA BLE) WAS NOT CONNECTED TO THE ELEVATOR BELLCRANK. THE ELEVATOR CABLE IS SHROUDED BY A CABLE TENSIONER TUBE ASSY. THE E LEVATOR CABLE RETAINING BOLT (PN 400-052) WAS POSITIONED THROUGH THE CABLE TENSIONER TUBE (PN 81950-002) AND THE BELLCRA NK (PN 40307-000), HOWEVER, THE ELEVATOR CABLE (PN 51757-005) WAS NOT SECURED TO THE BELLCRANK, THE ELEVATOR CABLE CLEVI S DISCONNECTED WITHIN THE CABLE TENSIONER. A RETAINING CLIP WITHIN THE SPRING TUBE ASSY. WAS THE ONLY DEVICE PREVENTING LOSS OF ELEVATOR CONTROL. (EA03200405977) 1 L 7 2 3T RT A8EA 2004091500078 20040915 00078 CE 2004 9 15 2004FA0000635 1 20040707 G 5210 05170392 HANDLE CESSNA 206 U206G 2073356 CE CONT O520 IO520* 17032 SO PILOTS DOOR FAILED E SSCA O OTHER O OTHER NR NOT REPORTED 1 SW 03 4736U U20605072 INTERIOR DOOR HANDLE FELL OFF. THE INSERT WHICH HAS THE SPLINE REMAINED ON DOOR. THE DOOR HANDLE IS A NEW STYLE WHICH HAS THE PIN WHICH STOPS THE SPLINE INSERT FROM SPINNING INSIDE THE HANDLE. 1 H 7 1 3O 3 O A4CE E5CE 2004091500111 20040915 00111 EA 2004 9 15 2004FA0000636 2 20040811 G 8500 O320H2AD ENGINE CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA MAKING METAL B VJ0R O OTHER O OTHER NR NOT REPORTED 1 NM 09 75704 17267886 RL122676T FACTORY OVERHAUL FOUND FERROUS METAL FLAKES (SEVERAL HUNDRED) IN OIL FILTER. ENGINE REMOVED AND RETURNED TO MFG. 1 H 7 1 3O 3 O NT 3A12 E274 2004091500079 20040915 00079 CE 2004 9 15 2004FA0000637 1 20040811 G 3230 2400021 BUSHING CESSNA 172 172RG 2072438 CE LYC O360 O360A1D 41514 EA MLG SPLIT D VJ0R O OTHER K FLUID LOSS NR NOT REPORTED 1 NM 09 16ED 172RG1189 DURING 100 HR INSPECTION, FOUND BOTH LT AND RT MLG PIVOT BUSHINGS SPLIT AND LEAKING GREASE. THESE BUSHINGS ARE REQUIRED TO BE INSTALLED IAW AD2001-06-06, SB 90-1, SK 172-151. THE SRM HAS NOT BEEN UPDATED TO SHOW ANY DETAIL OF THIS STYLE B USHING. NO INSPECTION PROCEDURES FOR THIS STYLE BUSHING. PARTS MANUAL ALSO HAS NOT BEE UPDATED. MUCH CONFUSION ABOUND S CONCERNING THESE BUSHINGS. (NM09200412026) 1 H 7 1 3O 3 O 3A17 E286 2004091400140 20040914 00140 CE 2004 9 14 2004FA0000638 1 20040713 G 3240 SM50D7 RELAY BEECH 33 F33A 1151425 CE CONT O520 IO520* 17032 SO DYNAMIC BRAKE INTERMITTENT B VJ3R O OTHER J WARNING INDICATION NR NOT REPORTED 1 WP 07 1570A 272 CE1333 DURING FLIGHT, CREW SELECTED (GEAR UP) AND GEAR FAILED TO RETRACT. AFTER ABOUT ONE MINUTE, THE GEAR RETRACTED. THE DYN AMIC BRAKE RELAY WAS FOUND TO BE OPERATING INTERMITTENTLY. RECOMMEND REPLACEMENT OF RELAY WITH SOLID STATE CIRCUIT BOAR D. 1 L 7 1 3O 3 O 3A15 E5CE 2004112400113 20041124 00113 2004 11 24 2004FA0000639 4 20040606 G 2561 KS9P0101 LIFE VEST EMERGENCY EQUIP FAILED B KQ1R O OTHER O OTHER NR NOT REPORTED 1 EA 07 LIFE PRESERVER FAILED MFG. RECOMMMENDED CELL PRESSURE TEST IAW MM. DOM: OCT 1981. 2004112400135 20041124 00135 NM 2004 11 24 2004FA0000640 1 20040630 G 2435 03600923 BEARING DHAV DHC8 DHC8202 2809007 NM STARTER GEN FAILED B OL3R O OTHER O OTHER NR NOT REPORTED 1 WP 27 1053 97090 STARTER GENERATOR HAD A BEARING FAILURE. 2 H 7 2 4T RT A13NM 2004091400132 20040914 00132 SO 2004 9 14 2004FA0000641 2 20040615 G 8530 CYLINDER CESSNA 182 182A 2072704 CE CONT O470 O470L 17026 SO NR 1 FAILED B CRJR O OTHER L NO TEST NR NOT REPORTED 1 CE 01 6329B 157 34229 069972R DURING ANNUAL INSP, CYLINDERS NR 1 AND NR 2 WERE FOUND TO HAVE A LOW COMPRESSION AND LEAKAGE PAST THE EXHAUST VALVE. EN GINE WAS STILL UNDER WARRANTY AND MFG WAS CONTACTED. MFG REP SUGGESTED TO READ SB03-3 WHICH SUPERSEDES SB84-15. SB03-3 SAYS ANY CYLINDER THAT PASSES COMPRESSION VALUE FOUND WHEN USING THE MASTER ORIFICE CAN BE RETURNED TO SERVICE REGARDLE SS OF WHERE THE LEAKS WERE. SB84-15 SAID LEAKAGE PAST ANY VALVE WAS AN UNACCEPTABLE CONDITION. NR 1 AND NR 2 CYLINDERS WERE REMOVED, CLEANED AND MEASURED. NR 1 EXHAUST VALVE AND GUIDE WERE FOUND TO BE BEYOND SERVICEABLE LIMITS AND WERE R EPLACED WITH NEW PARTS. THE GUIDE AND SEAT WERE FOUND NOT TO BE CONCENTRIC. GUIDE AND SEAT WERE GROUND CONCENTRIC. 1 H 7 1 3O 3 O NT 3A13 E273 2004091400176 20040914 00176 EA 2004 9 14 2004FA0000642 2 20040601 G 7414 IMPULSE COUPLING PIPER PA28 PA28235 7102810 SO LYC O540 O540B4B5 41532 EA MAGNETO BROKEN D O OTHER O OTHER NR NOT REPORTED 1 EA 23 4355F 12113 98060008 287610097 L1299140C IMPULSE COUPLING FAILED LOCKING MAGNETO, RESULTING IN FAILURE OF GEARS IN ACCESSORY CASE, PN 13S18647, 71652 AND LW-1909 6 GEARS. FAILURE OCCURRED WHILE FLYING IN PATTERN. (EA23200400620) 1 L 7 1 3O 3 O 2A13 E295 2004091400185 20040914 00185 2004 9 14 2004FA0000643 4 20040624 G 3457 TNL200A GPS BELL 206 206B 1181511 SW ALLSN 250C 250C* GL COCKPIT FAILED D A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 NM 09 656TL 656 ON A PILOT TRAINING FLIGHT, SMOKE WAS OBSERVED COMING OUT OF GPS FACE-PLATE AND THE DISPLAY WENT BLANK. CB WAS PULLED A ND AIRCRAFT RETURNED TO BASE. AFTER SHUTDOWN, POWER WAS APPLIED TO GPS, OPERATION APPEARED NORMAL, BUT SELF DIAGNOSIS D ISPLAYED A (DATA BASE FAILED) WARNING. 1 G 7 1 3U 3 U H2SW E4CE 2004092000098 20040920 00098 SO 2004 9 20 2004FA0000644 2 20040701 G 7414 ES10357426 DISTRIBUTOR BLK BENDIX CESSNA 172 172M 2072418 CE CONT O360 IO360GB 17025 SO MAGNETO LOOSE D O OTHER O OTHER NR NOT REPORTED 1 NE 02 12585 137 A081296 17262094 352806 REPLACED WORN POINTS IN MAGNETO. ON RUN UP FOUND 500 RPM DROP. REMOVED MAGNETO AND FOUND DISTRIBUTOR BLOCK CONTACT TOW ERS AND DISTRIBUTOR FINGER OIL SOAKED FROM EXCESS LUBRICANT. WHILE INSPECTING FOUND DISTRIBUTOR GEAR BUSHING LOOSE IN D ISTRIBUTOR BLOCK. OVERHAUL SHOULD FOLLOW MANUAL. 1 H 7 1 3O 3 O NT 3A12 E1CE 2004092000074 20040920 00074 EA 2004 9 20 2004FA0000645 2 20040602 G 7314 HOUSING PIPER PA31 PA31350 7103110 SO LYC O540 TIO540* 41532 EA EDP LEAKING C K NONE O OTHER IN INSP/MAINT 1 SO 05 350PC 207 GLN005FP 318152006 DURING ENGINE REMOVAL FOR OVERHAUL, FOUND THE ENGINE DRIVEN FUEL PUMP LEAKING FROM AROUND HOUSING ASSY. (SO05200407947) 1 L 7 2 3O 3 O A20SO E14EA 2004092000100 20040920 00100 EA 2004 9 20 2004FA0000646 2 20040713 G 7414 BEARING HUGHES 269 269B 4470502 WP LYC O360 IO360A1A 41514 EA MAGNETO DAMAGED D O OTHER O OTHER NR NOT REPORTED 1 NM 01 9442F 352 1150213 MAGNETO OVERHAULED, WAS FOUND TO HAVE A LOOSE ROTOR TAB THAT CHEWED UP THE DISTRIBUTOR BLOCK TERMINALS. ALSO AN INNER B EARING RACE WAS LOOSE AND SCORED THE SHAFT AND AN OUTER BEARING RACE WAS LOOSE IN THE CASE AND THE CASE WAS THEREFORE JU NK. 1 G 7 1 3O 3 O 4H12 1E10 2004082300059 20040823 00059 SO 2004 8 23 2004FA0000648 1 20040819 G 3220 6715003 DOWNLOCK PIPER PA28 PA28R200 7102811 SO LYC O360 IO360A1A 41514 EA NLG CRACKED D K NONE N FALSE WARNING IN INSP/MAINT 1 NM 01 8991E 6854 28R7635220 DURING INSPECTION FOR AN INTERMITTENT IN TRANSIT LIGHT, DISCOVERED CRACKED NLG DOWNLOCK ASSY. HALF OF THE IB PERIMETER AROUND ACTUATOR ROD ATTACH POINT WAS BROKEN OFF. REMAINING HALF HAS SEVERAL CRACKS EMANATING FROM BOLT HOLE. SEVERAL M ORE GEAR ACTUATIONS WOULD HAVE RESULTED IN COMPLETE SEPARATION. REPLACED ASSY WITH NEW MFG PART WHICH WAS BEEFIER THAN ORIGINAL. PAY ADDED ATTENTION TO THIS AREA (INCLUDING DRAG BRACE ATTACH AREA) AND DO NOT IGNORE FLICKERING LANDING GEAR INDICATION LIGHTS, INVESTIGATE. 1 L 7 1 3O 3 O 2A13 1E10 2004082300034 20040823 00034 EA 2004 8 23 2004FA0000649 2 20040819 G 8550 SUMP CESSNA 206 206H 2073301 CE LYC O540 IO540AC1A5 EA ENGINE OIL SYS CRACKED B K NONE K FLUID LOSS IN INSP/MAINT 1 NE 05 242ME 20608112 L2724248A DURING AN ANNUAL INSPECTION THE ENGINE OIL SUMP WAS FOUND CRACKED IN THE LT REAR STUD BOSS WHERE THE STUD US THREADED IN TO THE SUMP. 1 H 7 1 3O 3 O RT A4CE 1E4 2004083000065 20040830 00065 WP 2004 8 30 2004FA0000650 2 20040819 G 8520 CONNECTING ROD DHAVXX DH82 DH82AROBRTSN 2801002 WP DHAVXX GIPSY GIPSYMAJOR1C 20004 WP NR 3 CYLINDER BROKEN G C ABORTED TAKEOFF R J PARTIAL RPM/PWR LOSS WARNING INDICATION TO TAKEOFF 1 GL 11 7110S 30 83015 NR 3 CYLINDER CONNECTING ROD BROKE DURING TAKE OFF CAUSING ENGINE DAMAGE. GIPSY MAJOR 1C ENGINE MODEL INSTALLED IN A VIN TAGE EXPERIMENTAL EXHIBITION AIRCRAFT. 1 Q 7 1 3I 3 I A8EU A8EU 2004083000026 20040830 00026 CE 2004 8 30 2004FA0000652 1 20040510 G 2810 121640753 RESERVOIR CESSNA 206 206H 2073301 CE LYC O540 IO540AC1A5 EA MCAULY 3D36C B3D36C432 GL FUEL SYSTEM LEAKING D O OTHER O OTHER NR NOT REPORTED 1 WP 27 72635 950 20608065 L2710448A 000187 RESERVOIR FUEL TANKS BELOW FUEL SELECTOR WAS LEAKING FUEL FROM A SEEM WELD THAT HAD CRACKED. FOUND DURING ROUTINE WALK AROUND INSPECTION. THE LEAK WHEN FIRST NOTICED WILL INDICATE THE FUEL PEDCOK IS LEAKING UNDER THE BELLY OF THE AIRCRAFT FURTHER INSPECTION LEAD YOU TO INSPECT THE TANK BY REMOVING THE FLOOR PANEL ABOVE THE RESERVOIR. THERE ARE TWO RESERVO IR RT/ LT. ADVISE: CLOSER INSPECTION DURING 100 HOURS OR ANNUAL INSPECTION USING A MIRROR AND FLASH LIGHT YOU CAN INSP ECT MOST OF THE RESERVOIR. 1 H 7 1 3O 3 O RT A4CE 1E4 5 C P58GL 2004083000109 20040830 00109 SO 2004 8 30 2004FA0000653 2 20040420 G 7261 530010816 LINE CESSNA 340 340A 2076405 CE CONT O520 TSIO520* 17040 SO OIL PRESSURE CORRODED D O OTHER O OTHER NR NOT REPORTED 1 SO 13 68245 1930 340A1204 OIL PRESSURE HARD LINES LEAKING OIL UNDER CABIN FLOOR AFT OF PILOTS AND COPILOTS SEATS. LINES MAKE A 90 DEGREE TURN FOR WARD AND CONTACT CABIN DUCTWORK. LINE CORRODED AND APPROXIMATELY 2-3 QUARTS OF OIL DISCOVERED IN CABIN BELOW FLOOR. 1 L 7 2 3O 3 O 3A25 E8CE 2004083000130 20040830 00130 SO 2004 8 30 2004FA0000654 1 20040712 G 3213 486604 STRUT PIPER PA25 PA25260 7102508 SO LYC O540 O540* 41532 EA LT MLG FAILED G O OTHER O OTHER NR NOT REPORTED 1 WP 11 4339Y 254833 ON MAKING A SLIP TO A LANDING, THE LT GEAR COLLAPSED. IT WAS FOUND THAT THE (VEE ASSEMBLY) PULLED OUT OF THE FITTING AS SEMBLY OF THE SHOCK STRUT. I RECOMMEND THAT THIS BECOME AN INSPECTION POINT FOR POSSIBLE CRACKS. THESE AIRCRAFT MAKE H UNDREDS OF LANDINGS THAT PLACE HIGH SIDE LOADS AT THIS POINT. 1 L 7 1 3O 3 O 2A10 E295 2004083000128 20040830 00128 CE 2004 8 30 2004FA0000655 1 20040607 G 8011 PM2401 STARTER CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA ENGINE DAMAGED B V9MR O OTHER O OTHER NR NOT REPORTED 1 SO 09 5359K 172S9447 L3100251A STARTER BENDIX FAILED CAUSING DAMAGE TO THE STARTER RING GEAR. THIS IS THE 6TH STARTER BENDIX FAILURE ON THIS AIRCRAFT. 1 H 7 1 3O 3 O NT 3A12 1E10 2004083000110 20040830 00110 CE 2004 8 30 2004FA0000656 1 20040513 G 5322 SUPPORT CESSNA 182 182S 2072701 CE LYC O540 IO540* 41532 EA BATTERY CRACKED B WXHR O OTHER O OTHER NR NOT REPORTED 1 NM 01 7267H 2998 18280591 OB BATTERY SUPPORT ANGLE CRACKED AT BOTH ENDS. THIS IS THE THIRD INSTANCE IN FLEET. THE BATTERY SUPPORT STRUCTURE NEED S TO STRENGTHENED WITH ADDITIONAL STRUCTURE TO PREVENT THIS. (NM01200410074) 1 H 7 1 3O 3 O NT 3A13 1E4 2004091300104 20040913 00104 CE 2004 9 13 2004FA0000659 1 20040630 G 2821 7560052 FUEL STRAINER CESSNA 210 T210M 2073451 CE FUEL SYSTEM LOOSE D O OTHER O OTHER NR NOT REPORTED 1 CE 03 8159M 3667 21062032 AD 2000-06-01 HAS STAND PIPE MEASUREMENT AT 1.68 INCHES. FOUND STAND PIPE LONG AT 1.75.6. REPLACED WITH NEW FUEL STRAI NER WITH STAND PIPE AT 1.68 (AT FLIGHT ICE FOUND STAND PIPE LOOSE ON OTHER AND LIKE AIRCRAFT. AC; 8159 TT 3667. 1 H 7 1 3O 3A21 2004091300180 20040913 00180 SO 2004 9 13 2004FA0000660 1 20040519 G 7160 67775000 DOOR PIPER PA28 PA28R201 7102816 SO LYC O360 IO360C1C6 41514 EA HEAT BOX ASSY INGESTED D O OTHER O OTHER NR NOT REPORTED 1 NM 07 2495M 68 28R7837090 L1110451A PARTIAL LOSS OF ENG PWR OCCURRED JUST AFTER T/O. MANIFOLD PRESS DROPPED TO 15 INCHES HG AND RPM DROPPED TO 1900. PRE T /O ENG RUN UP, ALTERN AIR CHECK WAS REPORTED AS (NORMAL). POST FLT INSP REVEALED THAT ALTERN AIR (HEAT BOX) DOOR HAD SE PARATED FROM ALTERNATE AIR BOX ASSY, WAS INGESTED INTO FUEL SERVO INTAKE, PARTIALLY BLOCKED ENG INDUCT AIR FLOW, RESULTE D IN PARTIAL LOSS OF PWR. MS20470AD3 RIVETS (3EA) THAT SECURE DOOR TO AIR BOX HAD FAILED. IMPROPERLY BUCKED RIVETS DUE TO EXCESS SPRING TENSION DURING ASSY AND/OR TOO MUCH SPRING TENSION FOR RIVETS TO BEAR. HEAT BOX DOOR SHOULD BE TETHER ED IN SUCH WAY, IF HINGE ATTACHMENTS SHOULD FAIL DOOR WON`T BE INGESTED AND/OR SECURED WITH STRONGER FAIL SAFE HDWR. 1 L 7 1 3O 3 O 2A13 1E10 2004083000085 20040830 00085 SO 2004 8 30 2004FA0000661 1 20040819 G 8011 GEAR ELECTROSYS PIPER PA32 PA32R300 7103213 SO LYC O540 IO540K1A5 41532 EA HARTZL HCC2Y HCC2YK1 GL STARTER STRIPPED B FFKR O OTHER O OTHER NR NOT REPORTED 1 SO 05 8209C 203 203 D123607 32R7680082 L732348A CH34426C BENDIX DRIVE GEAR TEETH STRIPPED OUT AFTER ENGAGING STARTER. 1 L 7 1 3O 3 O A3SO 1E4 5 C P920 2004083000122 20040830 00122 CE 2004 8 30 2004FA0000662 1 20040820 G 8011 MMU6001 STARTER CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL ENGINE STICKING D O OTHER R J PARTIAL RPM/PWR LOSS WARNING INDICATION AP APPROACH 1 WP 05 714TW 17 17 15279429 L1338615 R774530 STARTER BENDIX ENGAGED RING GEAR DURING FLIGHT. ENGINE RPM LOSS APPROXIMATELY 300 RPM. AIRCRAFT WOULD NOT IDLE WITHOUT A PPLICATION OF POWER AFTER LANDING. 1 H 7 1 3O 3 O NT 3A19 E223 5 N P50GL 2004083000067 20040830 00067 GL 2004 8 30 2004FA0000663 2 20040228 G 8520 CRANKSHAFT AMTR SF2A SF2A GL AMTR AMTR 4AR1200VOLKS 99999 GL ENGINE FAILED C A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 WP 07 219GK 517 303 DURING CRUISE PHASE OF FLIGHT, WHILE DEPARTING TRAFFIC PATTERN, AIRCRAFT EXPERIENCED SEPARATION FAILURE OF CRANKSHAFT WI TH RESULTING LOSS OF PROPELLER, LOSS OF OIL AND SUBSEQUENT ENGINE FAILURE. ENGINE SPEED APPROX. 3100 RPM, 3700 FT MSL, AIRSPEED APPROX 104 MPH. FAILURE OCCURRED APPROXIMATELY 10 INCHES BEHIND PROPELLER AND AFT OF THE FRONT BEARING. CRAN KSHAFT FAILED DIAGONALLY WITH APPROXIMATE 45 DEGREE BREAK. PROPELLER AND CRANKSHAFT STUB DEPARTED CLEANLY WITH NO RESUL TING DAMAGE TO AIRFRAME. 1 H 7 1 3O 3 O NC EXPA1H71 EXP3O 2004112900153 20041129 00153 NE 2004 11 29 2004FA0000668 2 20040617 G 8520 126209 BOLT PWA PWA R1340 R1340* 52016 NE CRANKSHAFT CRACKED B CP2R O OTHER O OTHER NR NOT REPORTED 1 SW 15 6450 609 20497 4214943 THE CRANKSHAFT THRU BOLT APPEARS TO HAVE FRACTURED IN THE AREA JUST BELOW THE THREADS IN THE NECKED DOWN AREA. THE HEAD OF THE COTTER PIN THAT SAFETY LOCKS THE BOLT WAS FOUND IN THE OIL SUMP. THE ENGINE WAS THEN REMOVED AND DISASSEMBLED. UNKNOWN PROBABLE CAUSE, OTHER THAN POSSIBLE FATIGUE FAILURE AND RESULTED IN FRACTURE OF THE CRANKSHAFT IN THE MATING SP LINES. 3 R 5E2 2004083000069 20040830 00069 NM 2004 8 30 2004FA0000669 1 20040414 G 2912 271N20421 BOWL BOEING BOEING 757 757 UTILUSE NM FILTER CRACKED B IU6R O OTHER K FLUID LOSS NR NOT REPORTED 1 NM 01 0187A FILTER BOWL IS CRACKED AND SEVERED AT THE BOTTOM OF THE THREADED AEA. THIS IS THE THIRD INCIDENT OF THIS PART FOUND IN THE LAST SIX MONTHS. INADEQUATE DESIGN OR MATERIAL TYPE. DESIGN AN NEW FILTER BOWL FROM A BETTER MATERIAL. (JOB NR 18 4025) 2 L 7 2 4F RT A2NM 2004083000073 20040830 00073 SO 2004 8 30 2004FA0000671 2 20040311 G 8520 CRANKSHAFT CONT O300 O300D 17022 SO ENGINE MAKING METAL C YYBR K NONE O OTHER IN INSP/MAINT 1 GL 03 25171D7D ENGINE WAS DISASSEMBLED AND INSPECTED. INSP REVEALED METAL CONTAM OF CRANKSHAFT MAIN, CONNECT ROD BRG INSERTS. ENGINE WAS REASSEMBLE WITH NEW BRG INSERTS AND REPLACEMENT STARTER ADAPTER, WHICH WAS DISASSEMBLED AND INSP BEFORE INSTALLATION ON ENGINE. DISCREPANCIES FOUND DURING INSP OF STARTER ADAPTER THAT CAUSED METAL CONTAM OF ENGINE DURING TEST RUN. BRA SS SHAVINGS IN WINDINGS OF THE STARTER ADAPTER CLUTCH SPRING. STEEL BURRS ON THE CLUTCH SHAFT GEAR SERRATIONS. CLUTCH SHAFT SIZE OF 1.899 WITH A TAPER OF .006. SPRING HAS PREMATURE WEAR PATTERN. NR 1 CONNECT ROD BRG WAS DAMAGED DUE TO METAL CONTAM, CORRESPONDING CONNECT ROD JOURNAL. MATERIAL FOUND IN OIL FEED CHANNEL OF SHAFT GEAR, MORE BRASS AND STEEL. 3 O E253 2004092000069 20040920 00069 NM 2004 9 20 2004FA0000672 1 20040210 G 7120 1692M35P03 BUSHING BOEING 777 777* UTILUSE NM GE GE90 GE9090B NE FWD MNT ASSY MISSING D QEMY K NONE O OTHER IN INSP/MAINT 1 EA 35 27182 17303 900143 DURING SHOP VISIT, IT WAS OBSERVED THAT BUSH CMM REF 71-21-03 FIG 3, ITEM 170 WAS MISSING FROM THE ASSEMBLY OF THE FWD M OUNT. THE LOAD BEARING SHOULDER BOLT WAS SUBJECTED TO A SINGLE SHEAR LOAD AS OPPOSED TO A DOUBLE SHEAR IAW DESIGN INTEN T. SIMILARLY, ONLY ONE HALF OF THE CLEVIS WAS SUPPORTING THE LOAD. THE PLATFORM ITEMS, LT LINK ITEM 145, NUT ITEM 160, AND RETAINER EXHIBITED FRETTAGE ASSOCIATED WITH EXCESSIVE RADIAL MOVEMENT OF THE END OF THE SHOULDER BOLT. IT IS NOTED THAT THE FORWARD MOUNT ASSY OR SUBASSY DID NOT FAIL AND IT FULFILLED ITS FUNCTION OF SUPPORTING THE ENGINE. ALL FWD MO UNT ASSY ON SITE HAVE BEEN INSPECTED WITH NO DEFECTS FOUND. INDICATES ASSY HAS NOT BEEN DISASSEMBLED SINCE NEW. 2 L 7 2 4F 4 F RT T00001SE E00049EN 2004091500098 20040915 00098 CE 2004 9 15 2004FA0000673 1 20040810 G 2510 05142132 CYLINDER CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA SEAT BACK DETACHED B K NONE O OTHER IN INSP/MAINT 1 SO 15 437ER 3047 10 172S8653 L2994351A THE CREW REPORTED A SEAT BACK WHICH WOULD NOT RECLINE PROPERLY. THE MAINTENANCE TECHNICIAN INSPECTED THE SEAT MECHANISM AND FOUND THE SEAT RECLINING ACTUATOR WAS BROKEN AT THE AFT ATTACH POINT. THE BREAKAGE WAS AT THE USAGE POINT. 1 H 7 1 3O 3 O NT 3A12 1E10 2004092000077 20040920 00077 CE 2004 9 20 2004FA0000674 1 20040719 G 2897 WIRE CESSNA 501 551 2076605 CE PWA JT15 JT15D4 52112 NE BOOST PUMP DAMAGED B O OTHER O OTHER NR NOT REPORTED 1 SW 05 828SS 6824 5510205 WHILE PERFORMING, SB550-28-14, THE FUEL BOOST PUMP WIRING INSIDE THE LT AND RT WING TANKS WAS FOUND TO HAVE RUBBED HOLES IN THE FUEL TRANSFER LINES INSIDE THE TANKS AND DAMAGED THE WIRING. THE ABOVE BULLETIN ADDRESSES THIS CONCERN AND PROVI DES INSTRUCTIONS FOR SECURING THE BOOST PUMP WIRING, THIS IS A MANDATORY BULLETIN ONLY. WE HAVE HEARD OF OPERATORS WHO HAVE BEEN UNWILLING TO DO THIS BULLETIN BECAUSE IT IS NOT ASSOCIATED WITH AN AD AT THIS TIME. WE HAVE DIGITAL PICTURES AVAILABLE. 1 L 7 2 4F 4 F A27CE E1NE 2004092000095 20040920 00095 SO 2004 9 20 2004FA0000675 2 20040720 G 8520 631716 CRANKSHAFT CESSNA 210 P210N 2073454 CE CONT O520 TSIO520T 17040 SO MCAULY D3A34 D3A34C402 GL ENGINE BROKEN G A UNSCHED LANDING Y ENGINE STOPPAGE DE DESCENT 1 NM 04 7736K 1776 1776 P21000420 278513R 90DSA10 TSIO-520-T CRANKSHAFT BROKE AT 1776 HOURS SINCE FACTORY REMANUFACTURE. OPERATED BEYOND RECOMMENDED OVERHAUL, CRANK FAILE D CAUSING UNSCHEDULED LANDING THAT RESULTED IN AN AIRCRAFT ACCIDENT. 1 H 7 1 3O 3 O 3A21 E8CE 5 C P47GL 2004092000128 20040920 00128 CE 2004 9 20 2004FA0000676 1 20040806 G 2432 G6381 BATTERY CESSNA 500 500CESSNA 2076602 CE PWA JT15 JT15D1 52060 NE EQUIPMENT BAY EXPLODED B O OTHER O OTHER TX TAXI/GRND HDL 1 SW 05 999AM 86 5000232 WHILE ATTEMPTING TO PERFORM AN ENGINE START A LOUD NOISE WAS HEARD AND THE START WAS ABORTED. AN INVESTIGATION REVEALED THE MAIN BATTERY HAD EXPLODED. SEVEN OF THE TWELVE CELL CAPS WERE BLOWN OFF AND THE TOP COVER WAS BROKEN AND BLOWN OFF . BATTERY ELECTROLYTE HAD TO CLEANED FROM THE REAR EQUIPMENT BAY. A LOCAL BATTERY SHOP INFORMED US THEY HAD SEEN THE S AME PROBLEM WITH THIS TYPE BATTERY SEVERAL TIMES AND THE PROBLEM IS CAUSED BY INTERNAL ARCING IN THE BATTERY CAUSING FUM ES TO BE IGNITED. 1 L 7 2 4F 4 F A22CE E1NE 2004092300086 20040923 00086 SO 2004 9 23 2004FA0000677 2 20040731 G 8530 64680A7 CYLINDER CESSNA 182 182A 2072704 CE CONT O470 O470L 17026 SO MCAULY 2A34C 2A34C66 GL NR 3 CRACKED D A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 WP 03 73C 183 51251 670866L 723440 NR 3 CYLINDER CRACKED CIRCUMFERENTIALLY APPROXIMATELY 4 INCHES BELOW THE HEAD. THE RESULTANT VIBRATION MADE A PRECAUTIO NARY LANDING PRUDENT. UPON REMOVAL AND INSPECTION, THE CRACK APPEARED TO VARY BETWEEN 0.060 INCH AND 0.030 INCH (APPROX IMATE) AS IT PROPAGATED AROUND THE CYLINDER. 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 2004092300061 20040923 00061 WP 2004 9 23 2004FA0000678 1 20040806 G 2782 FUSE PIN DOUG DOUG DC10 DC1030F 3023504 WP GE CF6 CF650C2 30018 NE DROOP MECHANISM SHEARED B K NONE O OTHER IN INSP/MAINT 1 SW 99 322FE 47908 RT WING OB SLAT CONTROL MECHANISM HAS ANTI-DROOP FUSE PIN SHEARED. REFERENCE NON-ROUTINE 39501. 2 L 7 3 4F 4 F RT A22WE E23EA 2004092300071 20040923 00071 WP 2004 9 23 2004FA0000679 1 20040806 G 5341 ANB73111 ATTACH FITTING DOUG DC10 DC1030F 3023504 WP GE CF6 CF650C2 30018 NE WING ROOT CORRODED B K NONE O OTHER IN INSP/MAINT 1 SO 05 322FE 47908 LOWER AFT WING TO CENTER BOX ATTACH SKATE FITTING IS EXFOLIATED, LT WHEEL WELL, FUSELAGE STATION 1366 TO 1381. REFERENC E NON-ROUTINE NR 39431. 2 L 7 3 4F 4 F RT A22WE E23EA 2004090800048 20040908 00048 EA 2004 9 8 2004FA0000680 2 20040802 G 8597 P610072P610113 CONDUIT CESSNA 172 172R 2072401 CE LYC O360 IO360A1A 41514 EA ENGINE CHAFED B Z08R O OTHER O OTHER NR NOT REPORTED 1 CE 07 441CA 17280441 FOUND DURING AN ENGINE CHANGE WHILE INSPECTING THE WIRES IN THE ENGINE COMPARTMENT THE CONVOLUTED TUBING USED TO PROTECT THE WIRES WAS CHAFING INTO THE WIRES. IF LEFT UNATTENDED COULD CAUSE AN OPEN IN WIRES FOR OIL PRESSURE, VACUUM MP AND VARIOUS OTHER WIRES OR COULD CAUSE IMPROPER INDICATION OR NO INDICATION OF SYSTEMS. CORRECTED AS REQUIRED. (CE07200415 499) 1 H 7 1 3O 3 O NT 3A12 1E10 2004090800049 20040908 00049 CE 2004 9 8 2004FA0000681 1 20040802 G 8011 PM2401 STARTER CESSNA 172 172R 2072401 CE LYC O360 IO360A1A 41514 EA ENGINE FAILED B Z08R O OTHER O OTHER NR NOT REPORTED 1 CE 07 465CA 17280465 DURING THE ENGINE START THE STARTER BENDIX STAYED ENGAGE. THIS SHREDDED THE GEARS ON THE STARTER AND DAMAGED THE ENGINE FLYWHEEL, GEARS TO THE POINT WHERE THE FLYWHEEL HAD TO BE REPLACED. ACCORDING TO THE POH THEIR IS NOT REQUIREMENT TO L OOK AT THE AMP GAUGE LIKE THE OLDER MODELS. THIS WOULD HAVE SHOWED AN EXCESSIVE AMP DRAW. THE PILOT REPORTED HE NEVER NOTICED ANY PROBLEMS. NOTE: PIECES OF GEAR FROM THE STARTER AND FLYWHEEL WAS FOUND IN THE ENGINE COWLING AREA. (CE0720 0415498) 1 H 7 1 3O 3 O NT 3A12 1E10 2004090800053 20040908 00053 CE 2004 9 8 2004FA0000682 1 20040802 G 1430 BOLT CESSNA 172 172S 2072439 CE LYC O360 IO360A1A 41514 EA STARTER SHEARED B Z08R O OTHER O OTHER NR NOT REPORTED 1 CE 07 7275R 85044305 172S8026 DURING AN INSPECTION, FOUND 2 OF THE 3 THROUGH BOLTS SHEARED OFF AT THE THREADS, REPLACED THE STARTER. IF LT UNATTENDED WOULD CAUSE THE BACKPLATE OF THE STARTER TO COME OFF. 1 H 7 1 3O 3 O NT 3A12 1E10 2004090800056 20040908 00056 EA 2004 9 8 2004FA0000683 2 20040706 G 8530 EXHAUST VALVE CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA MCAULY 1C160 1C160DTM GL NR 2 CYLINDER STUCK B RL8R O OTHER O OTHER NR NOT REPORTED 1 GL 15 738FZ 3248 1237 17269955 L493076T AIRCRAFT EXPERIENCED POWER LOSS DURING CLIMBOUT. AIRCRAFT CIRCLED AND LANDED AND DEPARTED END OF RUNWAY, ROLLED OUT THR U RUNWAY LIGHTS. PROPELLER STRIKE OF ONE LIGHT. FOUND NR 2 CYLINDER EXHAUST VALVE STUCK AND VALVE GUIDE LOOSE . FURTH ER INSPECTION ALSO FOUND EXHAUST PUSH ROD DAMAGED AND PISTON SLIGHTLY CONTACTED EXHAUST VALVE. REMOVED AND REPLACED CYL INDER ASSY, PUSH RODS, INTAKE AND EXHAUST ROCKERS, AND PUSH ROD TUBES WITH NEW PARTS. RECOMMENDED COMPLIANCE WITH MFG M SB PROP STRIKE INSPECTION BEFORE NEXT FLIGHT. (GL15200412166) (GL15200412587) 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2004092000046 20040920 00046 GL 2004 9 20 2004FA0000684 2 20040830 G 7230 60483 DIFFUSER WILINT FJ44 FJ44 66000 GL FLANGE WELD SEAM CRACKED B WI5R O OTHER O OTHER NR NOT REPORTED 1 GL 23 1003 A CRACK APPROXIMATELY 12 INCHES IN LENGTH WAS FOUND ALONG THE AFT FLANGE WELD SEAM OF THE DIFFUSER ASSY. 4 F E3GL 2004090800057 20040908 00057 SO 2004 9 8 2004FA0000685 2 20040609 G 8530 712ACA CYLINDER HEAD CONT O520 IO520A 17032 SO ENGINE CRACKED B CY4R O OTHER O OTHER NR NOT REPORTED 1 AL 03 240774R HOLE THROUGH HEAD OR EXHAUST SIDE, NR7707-14, NR 7707-5 CRACKED HEAD. EST 500 HOURS SINCE NEW. 3 O E5CE 2004090800058 20040908 00058 EA 2004 9 8 2004FA0000686 2 20040708 G 8550 8526250 OIL COOLER PIPER PA18 PA18150 7101828 SO LYC O320 O320A2B 41508 EA SNSNCH 74D 74DM EA ENGINE FAILED B QB2R O OTHER O OTHER NR NOT REPORTED 1 GL 15 82667 1 187909028 L4855127A A46232 INSTALLED OVERHAULED OIL COOLER, TO AIRCRAFT ON 4/30/04, TACH 2028.5. NO LEAKS AT RUN UP. AFTER INSTALL AND NO LEAKS N OTICED AFTER TAXI TO HANGER. AIRCRAFT WAS FLOWN. OIL COOLER FAILED IN FLIGHT WITH LESS THAN AN HOUR OF FLIGHT TIME. C AUSING TOTAL LOSS OF ENGINE OIL. AIRCRAFT MADE AN EMERGENCY LANDING AT FLYING CLOUD FIELD. ENGINE HAD TO BE DISASSEMBL ED AND INSPECTED. ADDITIONAL INFORMATION WILL BE PROVIDED UPON REQUEST. 1 H 7 1 3O 3 O 1A2 E274 5 N P88614 2004083100004 20040831 00004 2004 8 31 2004FA0000687 4 20040722 G 3442 AV200 RECEIVER CESSNA 337 337 2075702 CE CONT IO360 IO360* 17025 CE WX RADAR SYS INTERFERENCE B LN7R O OTHER O OTHER NR NOT REPORTED 1 EA 13 2131X 3370031 WSI WEATHER RECEIVER CAUSES INTERFERENCE WITH COMS ON FREQS. 126.425 AND 126.450. THIS CONDITION MAY EXIST IN OTHER IN STALLATIONS AND SHOULD BE ADDRESSED IN THE MANUFACTURERS INSTALLATION MANUAL. (EA13200405796) 1 H 7 2 3O 3 O A6CE E1CE 2004092000064 20040920 00064 SO 2004 9 20 2004FA0000688 2 20040724 G 8530 AEC631397 CYLINDER HEAD BEECH 36 A36 1151604 CE CONT O550 IO550B SO MCAULY 3A32C D3A32C* GL NR 4 CYLINDER SEPARATED D O OTHER O OTHER NR NOT REPORTED 1 SO 15 117HB 154 E1316 249196R 881193 PILOT LANDED AIRCRAFT AT LT AFTER EXPERIENCING A ROUGH RUNNING ENGINE. UPON FURTHER INVESTIGATION FOUND THE NR 4 CYLIND ER HEAD SEPARATED FROM THE BARREL. FOUND ALL CYLINDERS TO BE ECI CYLINDERS HAVING ONLY 154.73 HOURS IN SERVICE, ALL CYL INDER REQUIRE REPLACEMENT IAW AD 2004-08-10 AND ECI SB 04-1. OWNER REPORTS THAT SINCE MAY 5, 2004 THE EFFECTIVE DATE OF THE AD, THE AIRCRAFT HAS ONLY FLOWN 21.7 HOURS OF THE 50 THAT THE AD GIVES YOU. 1 L 7 1 3O 3 O 3A15 E3SO 5 C P21EA 2004091500089 20040915 00089 SW 2004 9 15 2004FA0000689 1 20040623 G 6520 24910 SHAFT HYNES B2 B2B 1440506 SW LYC O360 O360A1A 41514 EA T/R GEARBOX FAILED D WHSR O OTHER O OTHER NR NOT REPORTED 1 GL 09 9023Z 352 2021 TAIL ROTOR DRIVE FROM 90 GEARBOX TO TAIL ROTOR GEARBOX FAIL AT ATTACHING POINT IN TAIL ROTOR GEARBOX. BY THE DISCOLORAT ION OF THE BREAK IT APPEARS THAT IT HAD PARTIALLY CRACKED PRIOR TO TOTAL FAILURE. THIS CAUSED LOST OF DIRECTIONAL CONTR OL OF AIRCRAFT. THE INSTALLATION WAS INSTALL BY THE FACTORY AND HAD NOT BEEN WORK ON BY ANY OTHER MAINTENANCE PERSONAL. THIS DID NOT FAIL AT THE ATTACHING BOLT HOLE, WHICH WOULD INDICATE AN ALIGNMENT PROBLEM. WOULD SUGGEST A FLEX COUPLIN G INSTALLATION TO ALLOW FOR MISALIGNMENT AND FLEXING OF THE TAIL BOOM PYLON. 1 G 7 1 3O 3 O 2H2 E286 2004090800020 20040908 00020 SO 2004 9 8 2004FA0000690 2 20040701 G 7414 ESIO357174 POINTS BENDIX CESSNA 337 337H 2075732 CE CONT O360 IO360GB 17025 SO MAGNETO WORN D O OTHER R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 NE 01 1258S 137 A081296 33701894 352806 PILOT REPORTED REAR ENGINE LT MAGNETO INOPERABLE ON RUN-UP. TROUBLESHOT AND FOUND CONTACT POINTS NOT OPENING FAR ENOUGH . NYLON CAM FOLLOWER FOUND MELTED AT CONTACT POINT ARM. CONTACT COMPARTMENT COVER HAS VENT HOLES THAT ARE COVERED BY I NSTRUCTIONS IN MASTER SM X40000 S20/S200 . SUSPECT THAT LACK OF VENTILATION CONTRIBUTED TO SOFTENING OF CAM FOLLOWER EI THER THROUGH IONIZATION AND OR EXCESS HEAT. RECOMMEND OPENING VENT HOLES. 1 H 7 2 3O 3 O A6CE E1CE 2004090800042 20040908 00042 SO 2004 9 8 2004FA0000691 1 20040611 G 5511 6357102 RIB PIPER PA32 PA32R301T 7103220 SO STAB CRACKED D O OTHER O OTHER NR NOT REPORTED 1 WP 28 SE12M 5349 32R8129093 A/C IS IN ANNUAL FOR USA CERT. DURING INSPECTION FOUND STAB LT OUTTER RIB CRACKING AT BALANCE WEIGHT ATTACHMENT POINTS. RIB HAS 3 CRACKS WORKING AFT FROM FORWARD END OF RIB. CRACKS RANGED FROM 12 MM TO 23 MM IN LENGTH. LARGEST TRACKING THROUGH LOWER FORWARD RIVET/NUT FOR BALANCE WEIGHT ATTACHMENT. 1 L 7 1 3O A3SO 2004100100061 20041001 00061 EU 2004 10 1 2004FA0000692 1 20040826 G 2720 A740255N CONTROL CABLE LET L23 L23SUPERBLAN 1360308 EU RUDDER FRAYED B O OTHER O OTHER NR NOT REPORTED 1 GL 25 NEW RUDDER CABLE ASSEMBLY, PURCHASED THRU US IMPORTER/DISTRIBUTOR, FOUND TO HAVE BROKEN AND/OR DISTORTED STRANDS IN NUME ROUS PLACES. 1 K 0 0 G60EU 2004090300005 20040903 00005 NM 2004 9 3 2004FA0000693 1 20040729 G 5753 65B155351 BRACE BOEING 747 747228F 1384895 NM NR 4 CANOE FAIR CRACKED D UIEA K NONE O OTHER IN INSP/MAINT 1 EA 15 809MC 20887 DURING A-CHECK ACCOMPLISHING ATLAS AIR ROUTINE WORK CARD 11FM15002 INSPECTION OF LEFT WING FOUND NR 4 FLAP CANOE FAIRING TO TRACK FORWARD OUTBOARD FITTING CRACKED IN HALF. JETIIIB WORK ORDER 1063 NON-ROUTINE NR 132. 2 L 7 4 4F A20WE 2004090800061 20040908 00061 GL 2004 9 8 2004FA0000694 1 20040831 G 7921 P010904 OIL COOLER AMTR AMD ALARUSCH2T 0033001 GL LYC O235 O235N2C 41505 EA SNSNCH 72C 72CK EA ENGINE CRACKED D A UNSCHED LANDING B K SMOKE/FUMES/ODORS/SPARKS FLUID LOSS CR CRUISE 1 SO 13 669AM 18 201025 L2575915 K8593 AIRCRAFT 10 MILES FROM AIRPORT, TRAINING FLIGHT, PRACTICING FLIGHT MANEUVERS. SMELLED SOMETHING WRONG, SCANNED ENGINE G AUGES. NO OIL PRESSURE, BUT OIL TEMPERATURE WAS IN THE GREEN. DECIDED TO RETURN TO THE AIRPORT AND LANDED UNEVENTFULLY . POST FLIGHT INSPECTION - OIL COVERING THE BELLY, WING ROOT AREA, INSIDE THE COCKPIT ON THE FIREWALL, FRONT CARPET, PI LOT'S SHOES. NO OIL SHOWING ON DIPSTICK. REMOVED COWLING. LEAK APPEARED TO ORIGINATE AT THE OIL COOLER. REMOVED OIL COOLER (MOUNTED TO FIREWALL) AND PRESSURE CHECKED. FOUND CRACK (APPROX 1 INCH LONG) IN END CAP, ALONG THE MIDDLE OF THE BEND RADIUS. 1 L 7 1 3 O EXPA1L71 E223 5 N P9045 2004091700073 20040917 00073 SO 2004 9 17 2004FA0000696 1 20040909 G 3246 40131 WHEEL PIPER PA23 PA23250 7102308 SO LYC O540 TIO540* 41532 EA MLG CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 13 15FG 277554112 DURING AN ANNUAL INSPECTION, WAS UNABLE TO LOOSEN LT MAIN WHEEL AXLE NUT. TIRE PRESSURE WAS FOUND TO BE ABOUT 90 PSI IN STEAD OF RECOMMENDED 32 PSI. TIRE WAS DEFLATED AND AXLE NUT WAS ABLE TO BE REMOVED EASILY. WHEEL DISASSEMBLED AND INSP ECTED. FOUND TO BE CRACKED IN TWO PLACES AROUND ADJACENT NUT PLATES. CRACKS WERE PROBABLY DUE TO OVER INFLATION OF TIR E. RT TIRE PRESSURE FOUND TO BE ABOUT 90 PSI ALSO. BOTH WHEEL ASSEEMBLIES REPLACED WITH NEW. 1 L 7 2 3O 3 O 1A10 E14EA 2004091700077 20040917 00077 SO 2004 9 17 2004FA0000697 2 20040914 G 8550 CH481091 OIL FILTER BEECH 45 A45 1152006 CE CONT O470 O470* 17026 SO ENGINE BLOCKED D E ENGINE SHUTDOWN J WARNING INDICATION NR NOT REPORTED 1 WP 09 41W G127 THE OIL FILTER WAS REPLACED AT THE NORMAL OIL CHANGE INTERVAL. THE ENGINE WAS STARTED TO VERIFY OIL PRESSURE AND LEAK CH ECK. NO LEAKS NOTED BUT OIL PRESSURE WOULD NOT RISE ABOVE 20 PSI. ( THIS IS THE MINIMUM OIL PRESSURE FOR IDLE POWER ). O IL FILTER WAS REMOVED FOR INSPECTION AND COMPARED WITH ANOTHER NEW OIL FILTER. THE RUBBER FLAP INSIDE THE FILTER APPEARE D INSTALLED INCORRECTLY WHEN THE FILTER WAS MANUFACTURED. THE LOW OIL PRESSURE WAS CAUSED BY BLOCKAGE OF THE OIL FLOW IN THE FILTER. ANOTHER FILTER WAS INSTALLED AN THE OIL PRESSURE RETUNED TO NORMAL (50 PSI ). 1 L 7 1 3O 3 O 5A3 E273 2004092000050 20040920 00050 SO 2004 9 20 2004FA0000698 1 20040903 G 3233 455987 ACTUATOR PIPER PA44 PA44180 7104402 SO LYC O360 O360* 41514 EA MLG CRACKED D K NONE O OTHER IN INSP/MAINT 1 WP 13 855ND 6808 4495009 FOUND TWO CRACKS IN HOUSING AT PISTON SHAFT END RETAINING CLIP GROOVE AREA. 1 L 7 2 3O 3 O A19S0 E286 2004092000051 20040920 00051 SO 2004 9 20 2004FA0000699 1 20040903 G 3233 455987 ACTUATOR PIPER PA44 PA44180 7104402 SO LYC O360 O360* 41514 EA MLG CRACKED D K NONE O OTHER IN INSP/MAINT 1 WP 13 855ND 6808 4495009 FOUND TWO CRACKS IN HOUSING AT PISTON SHAFT END RETAINING CLIP GROOVE AREA. 1 L 7 2 3O 3 O A19S0 E286 2004092000052 20040920 00052 EU 2004 9 20 2004FA0000700 1 20040908 G 3350 F5053136501 SIGN AMD FALC50 FALCON50MYST 2730106 EU GARRTT TFE731 TFE731* 01518 WP EMERGENCY LIGHT BURNED B K NONE O OTHER IN INSP/MAINT 1 EA 25 450K 186 SMOKE WAS OBSERVED IN THE CABIN AFTER START OF TAXI TO ACTIVE RUNWAY. THE CREW SHUT DOWN ENGINES, SHUTOFF ALL POWER AND DISCONNECTED BATTERIES. FOUND SOURCE OF SMOKE TO BE FROM A NO SMOKING/SEATBELT SIGN LOCATED IN THE LT SIDE OF CABIN AT FRAME 20. THE AIRCRAFT WAS SECURED AND FERRIED TO A MAINTENANCE BASE AND UPON FURTHER INVESTIGATION WE FOUND NO CONCLU SIVE EVIDENCE BUT SUSPECT THAT THE PROBLEM ORIGINATED AT THE INTERFACE OF THE WIRING TO THE NO SMOKING/SEATBELT SIGN. 2 L 7 3 4F 4 F A46EU E6WE 2004092000057 20040920 00057 GL 2004 9 20 2004FA0000701 1 20040907 G 7810 DA403REVB EXHAUST HEADER DIAMON DA40 DA40 2990002 GL LYC O360 IO360A1A 41514 EA ENGINE BROKEN D K NONE O OTHER IN INSP/MAINT 1 GL 09 858PA 454 40258 L3071651A ON 100 HR INSPECTION FOUND EXHAUST RISER CRACKED AND NEARLY BROKEN AT NR 4 EXHAUST OB MOUNTING BOLT EXTENDING INTO THE W ELD AROUND THE PIPE. 1 L 7 1 3O 3 O NT A47CE 1E10 2004092000058 20040920 00058 GL 2004 9 20 2004FA0000702 1 20040907 G 7810 DA403REVB EXHAUST HEADER DIAMON DA40 DA40 2990002 GL LYC O360 IO360A1A 41514 EA ENGINE BROKEN D K NONE O OTHER IN INSP/MAINT 1 GL 09 858PA 454 40258 L3071651A ON INSTALLATION OF NEW NR 4 EXHAUST PIPE, THE FLANGE WELD BEGAN TO CRACK. THIS WAS WITH LITTLE TORQUE APPLIED THE FLANG E. SUBMITTED REPORT TO MFG AND DISCUSSED WHAT MAY POSSIBLY BE CAUSING THIS PROBLEM. THEY SEEMED TO THINK IT WAS THE US E OF MFG EXHAUST GASKET WITH THE ASBESTOS CENTER CAUSING THE PROBLEMS, THIS IS THE SAME GASKET THAT IS CALLED FOR IN THE IR PARTS MANUAL. THEY RECOMMENDED USING TWO THIN COPPER GASKETS INSTEAD OF THE SINGLE THICKER ASBESTOS/COPPER GASKET. 1 L 7 1 3O 3 O NT A47CE 1E10 2004092000062 20040920 00062 GL 2004 9 20 2004FA0000703 1 20040804 G 7810 DA403REVB EXHAUST HEADER DIAMON DA40 DA40 2990002 GL LYC O360 IO360A1A 41514 EA ENGINE BROKEN D K NONE O OTHER IN INSP/MAINT 1 GL 09 858PA 399 40258 L3071651A ON 100 HOUR INSPECTION FOUND EXHAUST RISER BROKEN AT NR 2 EXHAUST IB MOUNTING BOLT. SUBMITTED REPORT TO MFG. 1 L 7 1 3O 3 O NT A47CE 1E10 2004092000063 20040920 00063 CE 2004 9 20 2004FA0000704 1 20040908 G 2910 HYDRAULIC SYSTEM BEECH B300 B300 1159232 CE CONTAMINATED B K NONE O OTHER IN INSP/MAINT 1 GL 11 74TF 56 FL370 DURING THE INITIAL PHASE 1 AND 2 INSPECTION BEING COMPLETED ON AC, ROUTINE INSPECTION OF HYDRAULIC SYS COMPONENTS REVEAL ED THAT THE HYDRAULIC SYS FILTER HAD RETAINED A LARGE AMOUNT OF RED PLASTIC MATERIAL AND THE (GEAR DOWN) PORT SCREEN WAS FOUND TO BE ALMOST COMPLETELY BLOCKED WITH LARGE PORTIONS OF SAME MATERIAL. PORT SCREEN WAS ITSELF DETACH FROM HOUSING ASSY. PLASTIC MATERIAL APPEARED TO BE CONSISTENT WITH MATERIAL THAT LINE CAPS AND PLUGS ARE MADE OF. REVIEW OF MAINTENA NCE LOG REVEALED THAT NO MAINTENANCE HAD BEEN ACCOMPLISHED ON THE HYDRAULIC SYSTEM SINCE THE AIRCRAFT WAS NEW. THE FOD W AS LIKELY INTRODUCED INTO THE SYSTEM DURING PRODUCTION ASSEMBLY OF THE HYDRAULIC LINES FOR THE LANDING GEAR SYSTEM. 2 L 7 2 4T RT A24CE 2004092000066 20040920 00066 SO 2004 9 20 2004FA0000705 2 20040830 G 8530 ACEC642068SNA CYLINDER UNIVAR 108 1083 9230408 NM CONT O470 O470R 17026 SO ENGINE DEBONDED C K NONE O OTHER IN INSP/MAINT 1 AL 03 114 114 1083716 831281R NICKEL COATING OF INSIDE CYLINDER BARREL PEELING OFF. 1 H 7 1 3O 3 O A767 E273 2004092000067 20040920 00067 NM 2004 9 20 2004FA0000706 1 20040830 G 8011 SPRING CONT O470 UNIVAR 108 1083 9230408 NM CONT O470 O470R 17026 SO STARTER ADAPTER SLIPPED G K NONE O OTHER IN INSP/MAINT 1 AL 03 114 CAS1458 1083716 831281R EXCESSIVE WEAR BETWEEN STARTER ADAPTER SPRING AND DRUM. STARTER DOES NOT ALLOW STARTER ADAPTER TO RELEASE AFTER ENGINE START. 1 H 7 1 3O 3 O A767 E273 2004092000107 20040920 00107 NE 2004 9 20 2004FA0000707 2 20040726 G 7200 8063042 FCU PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE DIAPHRAGM FAILED H E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 NE 03 523JL 515 523 PCEPRO0394 LOSS OF ENGINE POWER AND LOW TORQUE INDICATION. ENGINE SHUT DOWN, PROP FEATHERED, EMERGENCY LANDING EXECUTED. (M) 1 L 7 1 3T 4 T RT A78EU E26NE 2004092000108 20040920 00108 EA 2004 9 20 2004FA0000708 2 20040827 G 8530 CL4P10N CYLINDER PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA ENGINE BROKEN B O OTHER O OTHER NR NOT REPORTED 1 GL 11 4295N 55 288316051 L1345039A DURING FLIGHT ENGINE STARTED RUNNING ROUGH AND WOULD ONLY DEVELOP 1800 RPM. PILOT LANDED WITHOUT INCIDENT. UPON INSPEC TION FOUND NR 3 CYLINER ROCKER SHAFT BOSS BROKEN AND SHAFT AND ROCKERS LAYING LOOSE IN THE ROCKER BOX COVER. THE PUSH R ODS WERE STRAIGHT AND THE VALVES WERE NOT STUCK. (M) 1 L 7 1 3O 3 O 2A13 E274 2004092000109 20040920 00109 CE 2004 9 20 2004FA0000709 1 20040801 G 5320 PANEL BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA FUSELAGE CRACKED B O OTHER O OTHER NR NOT REPORTED 1 SO 05 53CK BB329 CLOSE OUT PANEL ON AFT SIDE OF REAR SPAR CARRY THROUGH. TWO CRACKS IN LOWER BEND RADIUS. FIRST CRACK AT END OF CENTER STRINGER AND LOWER END OF ANGLE STRIP ATTACHED TO PANEL SKIN. SECOND CRACK IS FORWARD OF LEFT OF CENTER STRINGER IN BEN D RADIUS OF PANEL. BOTH CRACKS WERE COVERED BY PRESSURE VESSEL SEALANT. (M) 1 L 7 2 4T 4 T A24CE E4EA 2004092000111 20040920 00111 CE 2004 9 20 2004FA0000710 1 20040609 G 2120 AN737TW107 CLAMP CESSNA 500 S550 2076607 CE ACM LOOSE H O OTHER J WARNING INDICATION CR CRUISE 1 NE 03 999HC S5500030 CLIMBING THROUGH FL27, A POP WAS HEARD FROM THE REAR COMPARTMENT OF AC. INSTANTLY CABIN RATE OF CLIMB WENT TO 4K FPM UP . CLEARED BY ATC, AC DESCENDED TO FL10 AND CONTINUED ON TO LAND AT ITS INTENDED DESTINATION. INVESTIGATION FOUND CLAMP THAT SECURES COUPLING P/N 65153165-202 TO THE PRESSURE SIDE OF AIR CYCLE MACHINE WAS INCORRECTLY PLACED, TORQUED AND IN SPECTED DURING JUST COMPLETED INSPECTION, ALLOWING DUCT TO PART, CAUSING CABIN TO VENT TO ATMOSPHERE. AC WAS REPAIRED A ND RETURNED TO SERVICE WITH NO FURTHER COMPLICATIONS. A REVIEW OF INCIDENT HAS RESULTED IN A MORE AGGRESSIVE INSPECTION AND TRAINING PROGRAM FOCUSING ON SELF INSPECTION AND MORE THROUGH INSPECTION BY TECHNICIANS AND INSPECTORS. (M) 1 L 7 2 4F RT A22CE 2004092000121 20040920 00121 2004 9 20 2004FA0000711 4 20040721 G 2562 450017 ANTENNA PIPER PA24 PA24260 7102406 SO LYC O540 TIO540* 41532 EA ELT FAILED B K NONE O OTHER IN INSP/MAINT 1 WP 01 8900P 244355 DURING AN ANNUAL INSPECTION, THE ELT ANTENNA ON AIRCRAFT WAS DISCOVERED TO HAVE FAILED. THE ANTENNA FAILED AT THE BULKH EAD FITTING. IT APPEARS TO BE SIMPLY GLUED INTO THE FITTING. THIS ANTENNA P/N 450017 HAS BEEN RECENTLY UP GRADED INDIC ATING THE MANUFACTURER KNOWS ABOUT THIS DEFECT. PN 450017 SUPPLIED PRIOR TO JUNE 2004 ARE SUSPECT. A PULL TEST WILL DE TERMINE INTEGRITY. (M) 1 L 7 1 3O 3 O 1A15 E14EA 2004092300054 20040923 00054 CE 2004 9 23 2004FA0000712 1 20040609 G 2120 AN737TW107 CLAMP CESSNA 500 S550 2076607 CE ACM INCORRECT H B EMER. DESCENT W INADEQUATE Q C CR CRUISE 1 NE 03 999HC S5500030 CLIMBING THROUGH FL27, POP WAS HEARD FROM REAR COMPARTMENT OF AIRCRAFT. INSTANTLY CABIN RATE OF CLIMB WENT TO 4K FPM UP . CLEARED, AIRCRAFT DESCENDED TO FL10 AND CONTINUED ON TO LAND AT ITS INTENDED DESTINATION. INVESTIGATION FOUND THAT CLAMP THAT SECURES COUPLING P/N 65153165-202 TO PRESSURE SIDE OF AIR CYCLE MACHINE WAS INCORRECTLY PLACED, TORQUED AND I NSPECTED DURING JUST COMPLETED INSPECTION, ALLOWING DUCT TO PART, CAUSING CABIN TO VENT TO ATMOSPHERE. AIRCRAFT WAS REP AIRED AND RETURNED TO SERVICE WITH NO FURTHER COMPLICATIONS. A REVIEW OF THIS INCIDENT HAS RESULTED IN A MORE AGGRESSIV E INSPECTION AND TRAINING PROGRAM FOCUSING ON SELF INSPECTION, MORE THROUGH INSPECTION BY THE TECH AND INSPECTORS. (M) 1 L 7 2 4F RT A22CE 2004092300016 20040923 00016 EA 2004 9 23 2004FA0000713 2 20040916 G 7322 HA6 CARBURETOR AMRGEN AA5 AA5B 3960105 SO LYC O360 O360* 41514 EA ENGINE BINDS D O OTHER R J PARTIAL RPM/PWR LOSS WARNING INDICATION LD LANDING 1 WP 07 959TE 50 50 10238 ON FINAL APPROACH TO THE AIRPORT, REDUCED POWER AND LOWERED THE FLAPS. TRIED TO ADD POWER, THE THROTTLE BOUND. REMOVED THE THROTTLE CABLE AND IT'S MOVEMENT WAS FREE. THEN ACTUATED THE THROTTLE ARM ON THE CARBURETOR AND BINDING COULD BE FEL T ON THE LAST .333 OF THE MOVEMENT. CALLED THE FACTORY AND THEY SAID THERE WERE OTHER OCCURRENCES OF THIS PROBLEM WITH THIS MODEL CARBURETOR. THIS IS A NEW AIRPLANE WITH A NEW CARBURETOR. 1 L 7 1 3O 3 O A16EA E286 2004092300051 20040923 00051 CE 2004 9 23 2004FA0000715 1 20040826 G 3230 SM50D7 RELAY BEECH 33 F33A 1151425 CE CONT O520 IO520* 17032 SO MLG FAILED B VJ3R O OTHER O OTHER NR NOT REPORTED 1 WP 07 5599P 228 CE1344 LANDING GEAR WOULD NOT RETRACT IN FLIGHT. AIRCRAFT WAS PLACED ON JACKS AND THE LANDING GEAR CYCLED IAW MM. INSPECTION OF THE SYSTEM FOUND THAT THE DYNAMIC RELAY WOULD STICK IN THE DOWN POSITION. A NEW DYNAMIC RELAY WAS INSTALLED AND THE SYSTEM CHECKED NORMAL. SUGGEST REPLACING RELAY WITH SOLID STATE BOARD. 1 L 7 1 3O 3 O 3A15 E5CE 2004092300049 20040923 00049 EU 2004 9 23 2004FA0000717 1 20040727 G 7430 103570101 IGNITION SWITCH GROB 120 G120A 1660208 EU LYC O540 AEIO540* EA CABIN INTERMITTENT B VJ3R O OTHER O OTHER NR NOT REPORTED 1 WP 07 864AF 85004 AFTER INSTALLING IGNITION SWITCH, THE MECHANIC NOTICE THE SWITCH WAS HARD TO PUSH IN AND INTERMITTENT AT THE START POSIT ION. NO PROBABLE CAUSE OR RECOMMENDATIONS AT THIS TIME. 1 L 7 1 3O 3 O RT A49CE 1E4 2004092300038 20040923 00038 CE 2004 9 23 2004FA0000718 1 20040727 G 8011 65556624V STARTER BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO ENGINE FAILED B VJ3R O OTHER O OTHER TX TAXI/GRND HDL 1 WP 07 5540P 252 CE1335 DURING ATTEMPTING TO START THE ENGINE, THE STARTER WOULD NOT TURN ENGINE TO START. MAINTENANCE TECHNICIAN FOUND THAT TH E STARTER WOULD NOT START THE ENGINE. REPLACED STARTER AND ENGINE STARTED. 1 L 7 1 3O 3 O 3A15 E5CE 2004092300046 20040923 00046 SO 2004 9 23 2004FA0000719 2 20040728 G 7261 ES48109 OIL FILTER BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO ENGINE TORN B VJ3R O OTHER O OTHER NR NOT REPORTED 1 WP 07 1563A 50 CE1320 WHILE THE MECHANIC WAS INSPECTING THE FILTER ELEMENT FOR METAL PARTICLES, NOTICED THE FILTER WAS TEARING AT THE SEAMS. PROBABLE CAUSE UNKNOWN, MFG HAS BEEN NOTIFIED. 1 L 7 1 3O 3 O 3A15 E5CE 2004092300039 20040923 00039 EU 2004 9 23 2004FA0000720 1 20040727 G 8011 31B22101 STARTER GROB 120 G120A 1660208 EU LYC O540 AEIO540* EA ENGINE INTERMITTENT B VJ3R O OTHER O OTHER NR NOT REPORTED 1 WP 07 864AF 40 85004 PILOT REPORTED STARTER WOULD NOT ENGAGE, PROBABLE CAUSE AT THIS TIME UNKNOWN. 1 L 7 1 3O 3 O RT A49CE 1E4 2004112900118 20041129 00118 SW 2004 11 29 2004FA0000721 1 20040715 G 6700 MOUNT HUGHES 500N 500N 3027374 SW ALLSN 250C 250C20 03013 GL NOTAR FAN OUT OF POSITION C PO7M O OTHER O OTHER NR NOT REPORTED 1 WP 07 529FB LN0098 AIRCRAFT FOUND TO HAVE CONTACT WITH FAN CONTROL ROD AND FAN DRIVESHAFT, WHICH MAY HAVE BEEN THE CAUSE OF HIGH VIBRATION IN AIRFRAME. MFG CALLED TO CHECK THE ALIGNMENT OF THE FAN MOUNT. SECOND TIME, HAD RUB WITH DRIVESHAFT SINCE AIRCRAFT W AS NEW. 1 G 7 1 3U 3 U NC H3WE E4CE 2004092800062 20040928 00062 SW 2004 9 28 2004FA0000722 1 20040715 G 5302 MOUNT HUGHES 500N 500N 3027374 SW ALLSN 250C 250C20 03013 GL NOTAR FAN G/B OUT OF ADJUST C PO7M O OTHER O OTHER NR NOT REPORTED 1 WP 07 528FB LN0097 AIRCRAFT OVERCOME WITH SEVERE VIBRATION ON THROTTLE ROLL UP FROM GROUND IDLE TO FLIGHT IDLE. FOUND FAN CONTROL ROD MADE CONTACT INSIDE FAN DRIVESHAFT. UPON FURTHER INSPECTION FOUND FAN TRANSMISSION MOUNT AT STATION 150 OUT OF ALIGNMENT. SENDING AIRCRAFT BACK TO MFG FOR REPAIR SECOND TIME WE HAD RUB WITH DRIVESHAFT SINCE AIRCRAFT WAS NEW. 1 G 7 1 3U 3 U NC H3WE E4CE 2004092300041 20040923 00041 CE 2004 9 23 2004FA0000724 1 20040830 G 2710 BEARING CESSNA 177 177 2073704 CE LYC O320 O320* 41508 EA AILERON CONTROL DISLODGED D A UNSCHED LANDING F FLT CONT AFFECTED NR NOT REPORTED 1 GL 07 3202T 2598 17700502 IN FLIGHT, NOTICED THAT LOSS OF AILERON CONTROL INPUT HAD OCCURRED, AND UPON ADDED FORCE TO CONTROL YOKE, DETERMINED THA T TOTAL SEIZURE OF THE AILERONS HAD OCCURRED. LANDED WITH RUDDER CONTROL ONLY. REMOVED TUBE ASSY FROM FIREWALL AND FOU ND SHAFT AND BEARING TO BE SEVERELY WORN, APPARENT NEEDLE BEARING DISLODGING CAUSED INABILITY TO ROTATE YOKE FOR AILERON CONTROL INPUT. 1 H 7 1 3O 3 O NT A13CE E274 2004092300036 20040923 00036 CE 2004 9 23 2004FA0000725 1 20040921 G 3230 24411001 PIVOT ASSY CESSNA 172 172RG 2072438 CE LYC O360 O360* 41514 EA MLG CRACKED B HBKR O OTHER O OTHER NR NOT REPORTED 1 SW 11 9572B 172RG0889 IN FLIGHT THE LT LANDING GEAR WOULD NOT COME DOWN. THE PILOT WAS ABLE TO MANUALLY GET THE GEAR DOWN AND LOCKED FOR LAND ING. UPON INVESTIGATION IT WAS DISCOVERED THAT THE LT MAIN LANDING GEAR PIVOT ASSEMBLY SHAFT WHERE THE ACTUATOR ATTACH ES HAD BROKEN AND WHEN THE GEAR WAS SELECTED TO THE DOWN POSITION THE ACTUATOR COULD NOT MOVE THE LT GEAR. IT APPEARS T HAT THE SHAFT TO CRACK HALF WAY AROUND THE CIRCUMFERENCE OF THE SHAFT OVERTIME WHICH CAUSED THE FINAL FAILURE OF THE SHA FT. AT SOME POINT AND TIME THERE SHOULD BE A REQUIREMENT FOR THE GEAR TO BE REMOVED FOR A DETAILED INSPECTION. THE ARE A IN WHICH THE FAILURE OCCURRED ON THIS PIVOT ASSY COULD ONLY HAVE BEEN SEEN WITH LANDING GEAR REMOVED. 1 H 7 1 3O 3 O 3A17 E286 2004092300042 20040923 00042 GL 2004 9 23 2004FA0000726 3 20040826 G 6111 84334 BLADE HARTZL HCA3V HCA3VF4 GL PROPELLER CRACKED B NWOR O OTHER O OTHER NR NOT REPORTED 1 SW 05 BL290 BLADE CRACKED .7500 AROUND RETENTION AREA. PROP IS BEING USED ON S OR V MODEL. 5 C P6EA5 2004112900041 20041129 00041 GL 2004 11 29 2004FA0000727 3 20040812 G 6114 D2A34C98 HUB MCAULY 2A34C D2A34C98 GL PROPELLER CRACKED B NWOR O OTHER O OTHER NR NOT REPORTED 1 SW 05 744998 CRACKED THRU RETENTION THREADS AT CRANK FLANGE SIDE H1 SOCKET. THIS FAILURE INDICATES THAT THE AD REQUIRING OIL FILLING OF THE HUB IS WORKING. PROP WAS SENT TO PROP SHOP DUE TO RED DYE LEAK. PROP WAS PREVIOUSLY OIL FILLED IAW AD. 5 C P3EA 2004112400154 20041124 00154 GL 2004 11 24 2004FA0000728 3 20040812 G 6114 D2A34C98 HUB MCAULY 2A34C D2A34C98 GL PROPELLER CRACKED B O OTHER O OTHER NR NOT REPORTED 1 SW 05 780317 CRACKED THRU RETENTION THREADS AT CRANK FLANGE SIDE, NR 2 SOCKET. THIS FAILURE INDICATES THAT THE AD REQUIRING OIL FILL ING OF HUB IS WORKING. PROP WAS SENT TO PROP SHOP DUE TO RED DYE LEAK. PROP WAS PREVIOUSLY OIL FILLED IAW AD. 5 C P3EA 2004112400155 20041124 00155 GL 2004 11 24 2004FA0000729 3 20040812 G 6114 D2A34C98 HUB MCAULY 2A34C D2A34C98 GL PROPELLER CRACKED B NWOR O OTHER O OTHER NR NOT REPORTED 1 SW 05 767342 CRACKED THRU RETENTION THREADS AT CRANK FLANGE SIDE OF NR 1 SOCKET. THIS FAILURE INDICATES THAT THE AD REQUIRING OIL FI LLING OF THE HUB IS WORKING. PROP WAS SENT TO PROP SHOP DUE TO RED DYE LEAK. PROP WAS SENT TO PROP SHOP DUE TO RED DYE LEAK. PROP WAS PREVIOUSLY OIL FILLED IAW AD. 5 C P3EA 2004092300045 20040923 00045 EA 2004 9 23 2004FA0000732 2 20040803 G 7322 MA4105217 CARBURETOR PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA ENGINE BURNED G FJPS O OTHER A FLAME/FIRE NR NOT REPORTED 1 SO 03 1307H 281 287716015 THIS AIRCRAFT ENGINE HAS EXPERIENCED TWO FIRES. BOTH OF WHICH WERE CARBURETOR FAILURE. THIS WAS CAUSED BY A SPLIT FLOA T THAT A PREVIOUS AD SHOULD HAVE SOLVED. THE NEW FLOAT SPLIT AND THE FLOAT FILLED WITH FUEL THIS CAUSED THE ENGINE TO Q UIT. THE AIRCRAFT WAS BEING USED AS A INSTRUCTIONAL FLIGHT WITH TWO PILOTS ON BOARD. AT RESTART PROCEDURES WERE BEING CONDUCTED ON THE ACTIVE RUNWAY THE AIRCRAFT CAUGHT FIRE. (SO03200402575) 1 L 7 1 3O 3 O 2A13 E274 2004092800056 20040928 00056 SW 2004 9 28 2004FA0000733 1 20040811 G 5302 MOUNT HUGHES 500N 500N 3027374 SW ALLSN 250C 250C20 03013 GL NOTAR FAN OUT OF POSITION B PO7M O OTHER O OTHER NR NOT REPORTED 1 WP 07 529FB 1543 LN0098 AIRCRAFT FOUND TO HAVE CONTACT WITH FAN CONTROL ROD AND FAN DRIVESHAFT. WHICH MAY HAVE BEEN THE CAUSE OF HIGH VIBRATION IN AIRFRAME. MFG CALLED TO CHECK THE ALIGNMENT OF THE FAN MOUNT. SECOND TIME WE HAD RUB WITH DRIVESHAFT SINCE AIRCRAF T WAS NEW. UPON REMOVAL FOUND PAINT INSIDE MAST BLISTERED AND FALLING DOWN INSIDE M/R GEARBOX. WE HAVE THIS PROBLEM NI NE OTHER TIMES IN LAST 4 YEARS. 1 G 7 1 3U 3 U NC H3WE E4CE 2004101500098 20041015 00098 GL 2004 10 15 2004FA0000734 1 20040922 G 5730 PANEL AMTR LANCAR LANCAIRLEGAY 056141X GL CONT O550 IO550* SO WING MISSING G A UNSCHED LANDING D INFLIGHT SEPARATION CR CRUISE 1 GL 07 103LL 44 44 L2K182 DURING A LT TURN IN A PLEASURE FLIGHT; THE TOP LT IB PANEL FLEW OFF AND THERE WAS LOSS OF LIFT IN LT WING. IN TRYING TO LAND, HAD TO MAINTAIN HIGH AIRSPEED, MADE A HARD LANDING. NOSE WHEEL BROKE OFF, PROPELLER WAS DAMAGED. MISSING PANEL I S JUST OB OF THE FUSELAGE, APPROX. 3 FEET BY 3 FEET, JUST ABOVE THE LT MAIN LANDING GEAR. PANEL IS A CARBON PILE MATERIA L ATTACHED TO STRUCTURE BY THE BONDING OF EPOXY GLUE. PILOT/ BUILDER/ OWNER REPORTED EPOXY WAS A JEFFCO EPOXY, 3176, 30 MINUTES. PANEL ON RT WING WAS FINISHED WITHIN A COUPLE WEEKS OF THE LT WING. IAW OWNER, NO REPAIRS WILL BE STARTED UN TIL LANCAIR HAS INSPECTED THE AIRCRAFT. AS OF THIS DATE THE MISSING PANEL HAS NOT BEEN LOCATED. 1 L 7 1 3O 3 O RT EXPA1L71 E3SO 2004100400074 20041004 00074 CE 2004 10 4 2004FA0000735 1 20040907 G 3246 40170A WHEEL BEECH 90 C90 1152913 CE PWA PT6 PT6* 52043 EA MLG CRACKED D O OTHER O OTHER NR NOT REPORTED 1 CE 07 77HE LJ969 INNER WHEEL HALF OF WHEEL ASSEMBLY PN 40-170A, SN 10, HEAT LOT NR 283 WAS REJECTED DURING EDDY CURRENT INSPECTION FOR CR ACKS IN EXCESS OF 0.010 INCH. INDICATIONS WERE FOUND IN THE AREA OF BEAD SEAT OF THE INNER HALF OF THE WHEEL ASSEMBLY O NLY, NO INDICATIONS WERE FOUND ON THE OUTER WHEEL HALF OF THE ASSEMBLY. 1 L 7 2 3T 3 T 3A20 E2NE 2004100400077 20041004 00077 EU 2004 10 4 2004FA0000736 1 20040913 G 2720 792200200N7134 FORK SOCATA TBM TBM700 8682000 EU PWA PT6 PT6A6 52043 EA RUDDER PEDAL BENT B JULR O OTHER O OTHER NR NOT REPORTED 1 SW 01 220MA 248 LT RUDDER PEDAL WENT TO FLOOR ON TAXI OUT. FOUND FORK END SHEARED AT JAM NUT. WHEN BOLT AND CASTLE NUT WERE REMOVED, C ASTLE NUT WAS EXTREMELY TIGHT AND BOLT COULD NOT ROTATE. THIS COULD BE CAUSE OF THE PROBLEM. RUDDER PEDAL NUT AND BOLT ON OTHER RUDDER PEDAL WAS LOOSE ENOUGH TO ROTATE. OTHER CAUSE COULD BE MFG DEFECT OR FOR SOME REASON THE ROD ON FORK E ND WAS POSSIBLY BENT. 1 L 7 1 3T 3 T RT A60EU E4EA 2004100100119 20041001 00119 SO 2004 10 1 2004FA0000737 1 20040816 G 2497 BATTERY CABLE PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360* 17025 SO BATTERY BAY OVERHEATED D F6FS O OTHER O OTHER TX TAXI/GRND HDL 1 SO 19 467TC 8126 347870006 LT ENGINE HARD STARTING. EXCESSIVE AMPERAGE DRAW THROUGH BATTERY CABLES CAUSING HOT CABLES AND SUBSEQUENT BATTERY FIRE. REPLACED BATTERY POSITIVE AND NEGATIVE CABLES, RT AND LT STARTER CABLES, ENGINE (STARTER) TO GROUND CABLES, MASTER SOL ENOID TO TERMINAL CABLE, AND TERMINAL TO STARTER SOLENOID CABLES. CABLE KIT IS A COMPLETE STC AND CONVERTS FROM ALUMINU M TO COPPER WIRE. OPERATIONAL CHECK AFTER CABLE REPLACEMENT SHOWS ENGINES TURN OVER MUCH FASTER THAN BEFORE. (SO192004 18338) 1 L 7 2 3O 3 O A7SO E9CE 2004100400078 20041004 00078 EA 2004 10 4 2004FA0000738 2 20040909 G 7250 3053094 TURBINE BEECH 200 B200 1152922 CE PWA PT6 PT6A41 52043 EA HOT SECTION SHIFTED D O OTHER O OTHER NR NOT REPORTED 1 GL 19 40PT 258 5032895 BB1291 NEW STYLE PN SEGMENT INSTALLED AT HSI 258 HOURS PRIOR. THIS NEW STYLE SEGMENT SHIFTS AFT RESULTING IN HOT SECTION FAILU RE. VERY COMMON WITH THIS PN SEGMENT, MFG NEEDS TO CHANGE DESIGN. 1 L 7 2 4T 4 T A24CE E4EA 2004092800060 20040928 00060 CE 2004 9 28 2004FA0000739 1 20040812 G 2450 AC2101 CONTROLLER CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA ALTERNATOR FAILED B MYNR O OTHER O OTHER NR NOT REPORTED 1 GL 11 45EF 1765 172S8982 ALTERNATOR VOLTAGE WENT OVER VOLT. OV PROTECTION FAILED AND BUSS VOLTAGE WENT WAY HIGH BURNING UP EVERTHING THAT WAS TU RNED ON INCLUDING NAV LIGHTS, LANDING AND TAXI LIGHTS, ALL RADIOS, MOST INSTRUMENT LIGHTS AND ALL ELEC INSTRUMENTS, ANNU NCIATOR PANEL, INTERCOM. (GL11200413843) 1 H 7 1 3O 3 O NT 3A12 1E10 2004111000070 20041110 00070 CE 2004 11 10 2004FA0000740 1 20040910 G 1430 MS2000626 BOLT BEECH MU300 400BEECH CE PWA JT15 JT15D5 52112 NE MLG WHEEL BROKEN D O OTHER O OTHER NR NOT REPORTED 1 CE 09 598JL MAY8538 RJ19 RT MAIN TIRE SIDEWALL AND TREAD DEPARTED AIRCRAFT ON LANDING ROLLOUT. DETERMINED BROKEN WHEEL THROUGH BOLT DISLODGED IN SIDE WHEEL HALF CAUSED BREAKAGE OF FUSIBLE PLUG AND EVENTUAL DEFLATION OF TIRE DURING FLIGHT. AIRCRAFT LANDED ON DEFLAT ED TIRE. (CE09200404725) 2 H 7 2 4F 4 F RT A16SW E25EA 2004100400094 20041004 00094 CE 2004 10 4 2004FA0000741 1 20040816 G 2701 805241051 BEARING BEECH 36 A36 1151604 CE CONT O550 IO550* SO CONROL YOKE STICKING D X76R O OTHER O OTHER NR NOT REPORTED 1 CE 03 729P 210 E3489 685975 PILOT REPORTS THAT THE AILERON CONTROL LOCKS UP AND WILL NOT TURN IN EITHER DIRECTION AND THEN RELEASES AND RETURNS TO N ORMAL. UPON INSPECTION OF AILERON SYSTEM, IT WAS FOUND THAT THE CONTROL YOKE CONNECTION BEARING WAS STICKING AND WOULD NOT RELEASE UNTIL THE YOKE WAS MOVED EITHER FORWARD OR AFT. MFG TECH SUPPORT, WHO STATED THAT THE BEARING IS A 100 HOUR LUBRICATION ITEM AND THAT LUBRICATION SHOULD CLEAR UP THE PROBLEM. THE PART WAS LUBRICATED AND NO BINDING OF THE CONTR OL COLUMN WAS FOUND. AC RETURNED FOR REPLACEMENT OF BEARING. 1 L 7 1 3O 3 O 3A15 E3SO 2004100400097 20041004 00097 SO 2004 10 4 2004FA0000743 2 20040827 G 8530 654650 CYLINDER CESSNA 182 182Q 2072732 CE CONT O470 O470U 17026 SO NR 6 CRACKED D O OTHER O OTHER NR NOT REPORTED 1 SO 05 735UL 1043 18265694 465734 ON TAKEOFF AT CLIMB OUT, PILOT HEARD LOUD BANG FOLLOWED BY ROUGH ENGINE, DECLARED EMERGENCY AND LANDED WITHOUT FURTHER P ROBLEMS. WITH OIL LEAKING FROM COWL, VISUAL INSPECTION NOTED HEAD SEPARATED FROM NR 6 CYLINDER. WITH COWL REMOVED AND CYLINDER OFF, IT WAS OBVIOUS THE CYLINDER HAD BEEN PARTIALLY CRACKED FOR SOME TIME. (SO05200410648) 1 H 7 1 3O 3 O NT 3A13 E273 2004100100073 20041001 00073 CE 2004 10 1 2004FA0000744 1 20040923 G 2810 C1560030101 CAP CESSNA CESSNA 172 172 2072402 CE LYC O360 O360A1A 41514 EA HARTZL HCC2Y HCC2YK1 GL FUEL TANK CLOGGED B EHHR A UNSCHED LANDING Y J ENGINE STOPPAGE WARNING INDICATION CR CRUISE 1 EA 17 8214X 17248714 L2561736A F766A2 PILOT EXPERIENCED FUEL INTERUPTION. MADE EMERGENCY LANDING IN SOYBEAN FIELD. NO INJURIES OR DAMAGE TO AC. REMOVED AC F ROM FIELD TO LOCAL AIRPORT. DRAINED ALL FUEL FROM WING TANKS. FOUND WHILE DRAINING FUEL WITH FUEL CAPS ON THAT DRAINING FUEL WAS SLOW. REMOVED FUEL CAP, QUICKENED FLOW RATE AT FUEL DRAIN. AFTER CLOSE INSP, FOUND VENT HOLES CLOGGED WITH HARD MUD TYPE SUBSTANCE. ALSO FOUND THE VENT TUBE IN THE LT WING WAS RESTRICTED. BLOWING NITROGEN THROUGH TUBE FREED BLOCKAG E. FRESH FUEL WAS INSTALLED, FUEL CAPS WERE REPLACED WITH NEW. LENGHTY RUNUP WAS PERFORMED WITH NO DEFECTS NOTED. FLIGHT WAS MADE WITHOUT INCIDENT. AFTER ARRIVING, OWNER REQUESTED TO REPLACE THE FUEL SELECTOR AS PRECAUTIONARY MEASURE. 1 H 7 1 3O 3 O NT 3A12 E286 5 C P920 2004100400088 20041004 00088 CE 2004 10 4 2004FA0000745 1 20040424 G 7160 05521644 AIR BOX CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA CARBURETOR DAMAGED D O OTHER R PARTIAL RPM/PWR LOSS TX TAXI/GRND HDL 1 NM 03 5048E 7993 17271699 L217076T DURING RUN-UP, BEFORE DEPARTURE, THE CARBURETOR HEAT WAS CHECKED AT 1000 AND 1700 RPM WITH ABOUT 75 RPM DROP. DURING TH E FLIGHT BACK, IN CRUISE FLIGHT, THE CARB HEAT WAS CHECKED AGAIN AT VARIOUS POWER SETTINGS, WORKING NORMALLY WITH ABOUT A 100 RPM DROP. AFTER ARRIVAL, THE CARBURETOR AIR BOX WAS REMOVED FOR INSPECTION. UPON INSPECTION, 2 EA .7500 IN PIECE S OF THE FLAPPER VALVE SEAL WERE FOUND MISSING ON TWO CORNERS OF THE FLAPPER VALVE. OTHERWISE, THE CARBURETOR AIR BOX A SSY WAS INTACT. 1 H 7 1 3O 3 O NT 3A12 E274 2004092800054 20040928 00054 CE 2004 9 28 2004FA0000746 1 20040802 G 5511 24320004 SPAR CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA HORIZONTAL STAB DAMAGED D O OTHER O OTHER NR NOT REPORTED 1 GL 11 4190V 3164 17280626 DURING INSP, HORIZONTAL STABILIZER WAS FOUND TO BE LOOSE AT BOTH FORWARD SPAR MOUNT HOLES. ENTIRE EMPENNAGE WAS REMOVED FROM AIRFRAME FOR DETAILED INSP. BOTH HOLES AT STABILIZER SPAR AND FORWARD BULKHEAD WERE FOUND TO BE ELONGATED .316 IN CH TO .319 INCH. BOTH SHIMS BETWEEN STAB AND BULKHEAD WERE EXTREMELY ELONGATED AND APPEAR TO HAVE BEEN COUNTERSUNK PRIO R TO INSTALLATION AT FACTORY. BOTH SHIMS REMOVED WERE A THICKNESS OF .080 INCH. BOLTS REMOVED FROM FWD SPAR MOUNTS WER E AN5-6A, WHICH IS CORRECT HARDWARE IAW MM. BOLTS INSTALLED FROM MFG DID NOT HAVE SUFFICIENT GRIP LENGTH TO SUPPORT TOT AL MATERIAL THICKNESS. RECOMMEND REAMING ALL 4 HOLES TO .371 IN TO .374 IN AND INSTALLING AN6-10A BOLTS. 1 H 7 1 3O 3 O NT 3A12 1E10 2004100400076 20041004 00076 EA 2004 10 4 2004FA0000747 2 20040628 G 8550 75141 SUMP PIPER PA28 PA28R200 7102811 SO LYC O360 IO360C1C 41514 EA OIL SYSTEM CORRODED D T56R O OTHER K FLUID LOSS NR NOT REPORTED 1 GL 05 2850T 2853 28R7235146 L2208551A OWNER HAD OIL LEAK, UPON INSPECTION, FOUND OIL DRIPPING FROM OIL SUMP FWD OF RT INTAKE PORT. REMOVED OIL SUMP, FOUND AR EA APPROX. 2.5 INCHES IN DIA. PITTED AND CORRODED. ONE AREA HAD PITTED THROUGH AND LEAKED. ENTIRE AREA WAS CLOSE TO P ITTING THROUGH. IAW MFG TECH, WAS CAUSED BY TOO MUCH TIME ON OIL AND AIRCRAFT NOT FLOWN ENOUGH TO KEEP MOISTURE OUT OF OIL. 1 L 7 1 3O 3 O 2A13 1E10 2004092800059 20040928 00059 EU 2004 9 28 2004FA0000748 1 20040803 G 3340 032452032470 MOUNT AGUSTA A109 A119 0261102 EU PWA PT6 PT6* 52043 EA SPOT LIGHT DAMAGED B EH1R O OTHER O OTHER NR NOT REPORTED 1 EA 13 172P 433 14027 AT 25 HR INSPECTION, MECH HEARD A RATTLING NOISE WHEN INSPECTING NIGHTSUN II. LENS WAS REMOVED, REFLECTION WAS REMOVED. FOUND BOTH MOUNTING PLATES (PN032452, PN 032470) REV X1 BROKEN COMPLETELY OFF AT REFLECTOR BUT STILL SCREWED TO MOUNT. ALSO, BULB SET SCREWS MISSING AND GOUND WIRE TO BULB LOOSE AT ATTACHMENT SCREW. AIRCRAFT IS IN TRACK AND BALANCE, BUT AIR FRAME STILL HAS HIGH LEVEL OF 4 IAW VIBRATION. (EA13200406110) 1 G 7 2 3U 3 T H7EU E2NE 2004100400093 20041004 00093 CE 2004 10 4 2004FA0000749 1 20040728 G 8120 DUCT CESSNA 206 TU206F 2073353 CE CONT O520 TSIO520C 17040 SO TURBOCHARGER LOOSE D O OTHER O OTHER NR NOT REPORTED 1 WP 23 1002V U20602387 501091 SCAT 16 NOSE FROM AIRBOX TO TURBOCHARGER AIR INLET, WIRE INSIDE SCAT 16 NOSE WAS 1 INCH FROM TURBOCHARGER COMPRESSOR WHE EL. WIRE MUST BE SECURED TO OUTSIDE OF AIR DUCTS WITH OEM CLAMPS. 1 H 7 1 3O 3 O A4CE E8CE 2004100400092 20041004 00092 CE 2004 10 4 2004FA0000750 1 20040803 G 1430 BOLT BEECH 36 A36TC 1151603 CE CONT O520 TSIO520* 17040 SO LT WING INCORRECT D O OTHER O OTHER NR NOT REPORTED 1 WP 23 444FC EA257 AFT UPPER LT WING ATTACH BOLT FOUND INSTALLED AND PRESUMABLY TORQUED WITHOUT CHAMFERED WASHER UNDER HEAD. DAMAGE TO BAT HTUB FITTING UNKNOWN AT THIS TIME. 1 L 7 1 3O 3 O 3A15 E8CE 2004100100113 20041001 00113 CE 2004 10 1 2004FA0000751 1 20040803 G 5610 0413419200 WINDSHIELD CESSNA 150 150G 2071816 CE CONT O200 O200* 17020 SO COCKPIT DEPARTED D O OTHER D INFLIGHT SEPARATION NR NOT REPORTED 1 EA 23 4760X 15064810 SECTION OF WINDSHIELD DEPARTED AIRCRAFT IN FLIGHT. WINDSHIELD HAD BEEN REPAIRED 7/15/00 IAW AC43.131B CHAPTER 3 SECTION 4, BUT NO REINFORCEMENT WAS EVIDENT ON PART REMAINING IN AIRCRAFT. HOW WINDSHIELD INSTALLED. THIS COULD HAVE BEEN PRE VENTED IF NEW WINDSHIELD WAS INSTALLED IAW AC 43.13 . 1 H 7 1 3O 3 O 3A19 E252 2004100100117 20041001 00117 CE 2004 10 1 2004FA0000752 1 20040903 G 7120 051313211 BRACKET CESSNA 175 175 2072502 CE LYC O360 O360A1D 41514 EA ENGINE MOUNT CRACKED D J7BR O OTHER O OTHER NR NOT REPORTED 1 SW 01 7487M 3951 55787 L665436 THE FUSELAGE UPPER ENGINE MOUNT BRACKETS WERE DISCOVERED TO BE CRACKED AT MOUNTING HOLES. PN 0513132-11 FOR UPPER LT AN D UPPER RT. NEW REPLACEMENT PARTS WERE NOTED TO BE SLIGHTLY THICKER AND MADE FROM SAME MATERIAL. SUGGEST ENGINE MOUNT REMOVAL FOR INSPECTION PERIODICALLY. 1 H 7 1 3O 3 O NT 3A17 E286 2004100100118 20041001 00118 SO 2004 10 1 2004FA0000753 2 20040723 G 7414 10357487242 VIBRATOR BEECH 95 95B55 1152729 CE CONT O470 IO470L 17026 SO HARTZL HCC3Y PHCC3YF2 GL MAGNETO BURNED C A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 WP 11 88CS 4704 TC723 CS9152146 EB1190557 JUST AFTER DEPARTURE A BURNING ODOR WAS NOTICED FROM THE FRONT OF THE AIRCRAFT. A STANDARD FLIGHT PATTERN BACK TO RUNWA Y WAS EXPEDITED. LATER FINDING THE IGN VIBRATOR HAD STARTED A FIRE IN THE FRONT PILOTS LOWER FIREWALL PANEL. A GEAR UP LANDING BECAME THE RESULT OF THE ELECTRICAL BURN UP. THE FINAL PART OF THE FLIGHT WAS CONDUCTED AS AN EMERGENCY. (WP11 200403343) 1 L 7 2 3O 3 O RT 3A16 3E1 5 C P25EA 2004100100121 20041001 00121 NM 2004 10 1 2004FA0000754 1 20040806 G 7160 DOOR PROPJT 200 200D 0140312 NM CONT O520 IO520* 17032 SO ALTERNATE AIR BROKEN D O OTHER O OTHER NR NOT REPORTED 1 WP 23 49J 352 PILOT COMPLAINED OF STUCK THROTTLE ON GROUND. FOUND ALTERNATE AIR DOOR BROKEN OFF AND WEDGED IN THROTTLE BODY. HINGE A PPEARED TO HAVE WORN COMPLETELY THROUGH. 1 L 7 1 3O 3 O 3A18 E5CE 2004100100122 20041001 00122 SO 2004 10 1 2004FA0000755 1 20040809 G 7120 MOUNT PIPER PA44 PA44180 7104402 SO ENGINE BROKEN D VKPS O OTHER O OTHER NR NOT REPORTED 1 WP 07 53395 4496076 ENGINE MOUNT TUBE BROKEN BELOW TOP RT ISOLATOR. DISCOVERED DURING 100 HR INSPECTION. (WP07200420174) 1 L 7 2 3O A19S0 2004100100123 20041001 00123 SO 2004 10 1 2004FA0000756 2 20040719 G 8520 GEAR CESSNA 180 180 2072602 CE CONT O470 O470K 17026 SO CAMSHAFT FAILED D A UNSCHED LANDING Y J ENGINE STOPPAGE WARNING INDICATION NR NOT REPORTED 1 SW 01 7714A 32611 474576K THIS ENGINE HAD A COMPLETE FAILURE IN FLIGHT, PILOT WAS ABLE TO GLIDE TO AIRPORT. INITIAL INSPECTION FOUND DAMAGE TO CR ANKSHAFT AND CAMSHAFT DRIVE GEARS INSIDE ACCESSORY GEARBOX. INSPECTION WAS NOT COMPLETE TO FIND OUT WHY THIS HAPPENED, DUE TO THE TIME AND AGE OF ENGINE. DECISION MADE TO JUST REPLACE ENGINE. LAST OVERHAULED APRIL 1968. (WO M8766) 1 H 7 1 3O 3 O NC 5A6 E273 2004111000072 20041110 00072 EU 2004 11 10 2004FA0000757 1 20040818 G 2910 95G50 PRESSURE SWITCH AMD FALC90 FALCON900B 2730171 EU GARRTT TFE731 TFE731* 01518 WP NR 2 HYD SYSTEM LEAKING C E A ENGINE SHUTDOWN UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CL CLIMB 1 EA 03 25MB 2773 163 APPROX 5-10 MINUTES AFTER TAKEOFF, PILOTS NOTED NR 2 HYDRAULIC SYSTEM LOSING FLUID. SYSTEM CONTINUED TO LOSE FLUID SO N R 2 ENGINE WAS SHUT DOWN AND AIRCRAFT LANDED. MAINTENANCE FOUND NR 2 HYDRAULIC SYSTEM PRESSURE SWITCH LEAKING. INSTALL ED NEW PRESSURE SWITCH CLEANED AIRCRAFT AFT COMPARTMENT AND TESTED SYSTEM FOR OPERATION AND LEAKS. AIRCRAFT RETURNED TO SERVICE. NEW SWITCH WAS A LATER GENERATION SWITCH (PN 906229). 2 L 7 3 4F 4 F RT E6WE 2004100100065 20041001 00065 CE 2004 10 1 2004FA0000758 1 20040827 G 5540 07126167 BULKHEAD CESSNA 182 182N 2072730 CE CONT O470 O470* 17026 SO RT RUDDER STOP CRACKED D O OTHER O OTHER NR NOT REPORTED 1 SO 05 9078G 4095 18260618 BULKHEAD FOUND CRACKED DURING ANNUAL INSPECTION AT RT RUDDER STOP BOLT. THIS BULKHEAD REQUIRES 1000 HR INSPECTIONS IAW AD72-07-09, WHICH WAS NOT DUE AT THIS TIME. SUSPECT WIND DAMAGE FROM REPEATEDLY STRIKING STOP. (SO05200410568) 1 H 7 1 3O 3 O NT 3A13 E273 2004100100070 20041001 00070 SW 2004 10 1 2004FA0000759 1 20040820 G 2820 18586 LINE AIRPTS A A9B 0144206 SW LYC O540 IO540* 41532 EA MCAULY 1A200 1A200* GL FUEL SYSTEM LEAKING G O OTHER K FLUID LOSS NR NOT REPORTED 1 CE 07 7798V 4340 1551 L763148 103239 IT APPEARS THAT THE FUEL LINE WAS LEAKING FUEL AT THE ATTACH POINT OF THE STEEL BRAIDED LINE TO THE FITTING. THE FUEL L INE IS ATTACHED AT THE FIRE WALL AND GOES TO THE INLET SIDE OF THE ENGINE DRIVEN FUEL PUMP. (CE07200416055) 1 L 7 1 3O 3 O A758 1E4 5 N P874 2004100100056 20041001 00056 EA 2004 10 1 2004FA0000760 2 20040811 G 8530 7580213 CYLINDER HEAD CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA ENGINE CRACKED B MW2R O OTHER O OTHER NR NOT REPORTED 1 GL 17 96507 1163 17276082 L1437139A CYLINDER CRACKED FROM LOWER SPARK PLUG HOLE AROUND OUTSIDE OF EX SEAT TO TOP SPARK PLUG HOLE. JUST LIKE ALL THE OTHER O NES. 1 H 7 1 3O 3 O NT 3A12 E274 2004100100057 20041001 00057 EA 2004 10 1 2004FA0000761 2 20040811 G 8530 STUD PIPER PA28 PA28R200 7102811 SO LYC O360 IO360C1C 41514 EA NR2 CYLINDER FAILED B MW2R O OTHER O OTHER NR NOT REPORTED 1 GL 17 4509X 1000 28R7635067 L705051A NR 2 CYLINDER STUD, 8 O CLOCK POSITION, FAILED. 1 L 7 1 3O 3 O 2A13 1E10 2004100100053 20041001 00053 EA 2004 10 1 2004FA0000762 2 20040922 G 8530 LW13870 CYLINDER GULSTM 500 500B 0141106 SW LYC O540 IO540B1A5 41532 EA NR 1 POSITION SEIZED B G6NR O OTHER O OTHER NR NOT REPORTED 1 CE 09 6154X 500B98324 RL976248 NR CYLINDER ON LT ENGINE SEPARATED BETWEEN CYLINDER BASE AND FIRST SET OF STEEL COOLING FINS. THE CONNECTING ROD WAS TO RN FROM THE CRANKSHAFT. THE SEPARATION ALLOWED THE CYLINDER TO MIGRATE OUTWARD ABOUT 2 INCHES. THE FUEL INJECTION LINE WAS TORN OFF AT FUEL INJECTOR. BOTH PUSH ROD TUBES FELL OUT AND INTAKE TUBE WAS PULLED OUT. PROBABLE CAUSE IS CYLINDE R AND PISTON SEIZED TOGETHER. 1 H 7 2 3O 3 O 6A1 1E4 2004100100068 20041001 00068 EA 2004 10 1 2004FA0000763 2 20040811 G 8530 STUD PIPER PA32 PA32300 7103212 SO LYC O540 IO540K1A5 41532 EA NR 3 CYLINDER FAILED B MW2R O OTHER O OTHER NR NOT REPORTED 1 GL 17 4228T 500 327240046 L472948 NR 3 CYLINDER DECK STUDS FAILED AND CYLINDER DEPARTED ENGINE. 1 L 7 1 3O 3 O A3SO 1E4 2004100100108 20041001 00108 NE 2004 10 1 2004FA0000764 2 20040702 G 8540 BUSHING SCWZER G164 G164A 3952704 EA PWA R1340 R1340* 52016 NE ENGINE OBSTRUCTED G MWRG O OTHER R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 EA 17 915X 434 4210213 ENGINE LOST POWER ON TAKE-OFF. PILOT LANDED IN BOG AND FLIPPED OVER. PRELIMINARY INSPECTION SHOWED DAMAGE TO INDUCTION IMPELLER. TEARDOWN REVEALED IMPELLER SHAFT SUPPORTED BY TWO BRONZE BUSHINGS WHICH ARE LUBRICATED BY AN .1250 INCH HOLE ON BOTH BUSHINGS AND BY A .0625 INCH HOLE ON BOTH BUSHINGS AND BY A .0625 INCH HOLE ON ONE BUSHING. THE .0625 INCH HOL E WAS BLOCKED, UNABLE TO DETERMINE IF BLOCKAGE WAS CAUSE OR CONSEQUENCE OF THE FAILURE, ATTRIBUTED TO LACK OF LUBRICATIO N. 1 Q 7 1 3R 3 R 1A16 5E2 2004100100034 20041001 00034 SO 2004 10 1 2004FA0000765 1 20040802 G 5102 F9B15 VALVE BALWKS FIREFY FIREFLY9 1050124 SO BALLOON DESTROYED C O OTHER O OTHER NR NOT REPORTED 1 GL 05 2189K F9B2004 DURING FLIGHT, 3 OF 4 VALVE WINDOWS FAILED BY SEPARATING AT SEAMS. UPON SEPARATION, REMAINING WINDOW MATERIAL MELTED AW AY, THUS CREATING 3 LARGE HOLES IN THE TOP OF THE BALLOON, WHICH RAISED INTERNAL TEMP, AND CAUS HIGH (EXTREME) FUEL CONS UMPTION AND RENDERED THE AIRCRAFT UNCONTROLABLE AND UNAIRWORTHY. ALL ABOVE WITHIN 42 MINUTES OF FLIGHT. 1 B 0 0 A14SO 2004100100127 20041001 00127 SO 2004 10 1 2004FA0000766 1 20040808 G 5102 F8B15 VALVE BALWKS FIREFY FIREFLY8B15 1050111 SO VALVE WINDOWS DAMAGED C O OTHER O OTHER NR NOT REPORTED 1 GL 05 B820243 F8B2024 NOTICED DURING PREFLIGHT INSPECTION 2 OF 4 VALVE WINDOWS SHOWED CRACKING ON EDGES AND CRACKS. TRANSVERSE PASSED SEAMS I NTO FLIGHT LOAD AREA. FLIGHT ABORTED. 1 B 0 0 A14SO 2004100400072 20041004 00072 SO 2004 10 4 2004FA0000767 1 20040625 G 2741 67201104 CONTROL CABLE PIPER PA28 PA28181 7102807 SO STAB TRIM BROKEN D O OTHER O OTHER NR NOT REPORTED 1 GL 03 5903V 5340 287790511 TRIM CABLE BROKEN (STABILIZER TRIM). FRAYED AND BROKEN AT 2ND PULLEY FROM FRONT. (CLOSER INSPECTION UNDER BAGGAGE AREA) . 1 L 7 1 3O 2A13 2004100400064 20041004 00064 SO 2004 10 4 2004FA0000768 2 20040723 G 7413 10357487242 VIBRATOR BEECH 95 95B55 1152729 CE CONT O470 IO470L 17026 SO LT CTR FIREWALL BURNED D A UNSCHED LANDING B A SMOKE/FUMES/ODORS/SPARKS FLAME/FIRE NR NOT REPORTED 1 WP 11 88CS 4704 TC723 PILOT DEPARTED ON MAINT TEST FLIGHT ON CROSS WIND. PILOT NOTICED BURNING ODOR AS PILOT TURNED BASE LEG TO LAND ON DEPAR TURE RUNWAY, AC HAS SMOKE IN COCKPIT. AC WAS LANDED GEAR UP. AFTER AREA OF PILOT SIDE RUDDER PEDALS WAS NOTICED AND PU T OUT. ON FURTHER INVESTIGATION IT WAS FOUND THAT IGNITION VIBRATOR (10-357487-242) HAD SHORTED OUT AND CAUSED FIRE TH AT BURNED BEHIND INSTRUMENT PANEL. BEEN DETERMINED FROM AC SRM THAT SN TC1 THRU TC1028 HAVE NO CIRCUIT PROTECTION IN IG NITION CIRCUIT. IGNITION VIBRATOR HAS 28V ON IT AT ACC TIMES AND SWITCH PROVIDES GROUND TO COMPLETE CIRCUIT. ANY MALFU NCTION OF SWITCH OR SHORT IN WIRING WOULD CAUSE POINTS TO CLOSE AND IGNITION VIBRATOR TO BE ENGAGED. (WP11200403343) 1 L 7 2 3O 3 O RT 3A16 3E1 2004100100038 20041001 00038 EA 2004 10 1 2004FA0000769 2 20040727 G 7314 200F5003 PUMP PIPER PA31 PA31350 7103110 SO LYC O540 TIO540* 41532 EA ENGINE LEAKING D O OTHER K FLUID LOSS NR NOT REPORTED 1 SO 05 350PC 10 318152006 INSTALLED AN O/H ENGINE ONTO THE RT POSITION. UPON PERFORMING AN OIL FILTER CHECK THE VERY NEXT DAY, AFTER AIRCAFT RUNS ON 7/27/04. FOUND THAT THE ENGINE DRIVEN FUEL PUMP HAD BLUE STAINS AROUND BODY HOUSING AND ALSO NOTICED FUEL LEAKING F ROM DRAIN END OF THE DRIVE SECTION OF THIS FUEL PUMP. (SO05200410029) 1 L 7 2 3O 3 O A20SO E14EA 2004100100039 20041001 00039 CE 2004 10 1 2004FA0000770 1 20040603 G 7160 PLATE CESSNA 210 T210M 2073451 CE CONT O520 TSIO520R 17040 SO MCAULY D3A34 D3A34C402 GL ALT AIR DOOR SEPARATED B NF2R O OTHER C F.O.D. NR NOT REPORTED 1 GL 03 732WP 21061835 512178 776652 ENGINE ALTERNATE AIR DOOR IS HELD CLOSED WITH A MAGNETIC LATCH ORIGINAL PN 1250938-8. THE MAGNETIC LATCH HAS 2 STEEL SM ALL PLATES BONDED TO THE MAGNET THAT MAKE CONTACT WITH THE ALTERNATE AIR DOOR. ONE STEEL PLATE CAME DEBONDED FROM AGE V IBRATION. PLATE WAS INJESTED INTO THE TURBOCHARGER. THE TURBO WAS DESTROYED IN SECONDS CAUSING TOTAL BOOST LOSS AND A RETURN LANDING. THE METAL FROM THE TURBO WAS PASSED THRU THE INDUCTION SYSTEM AND OIL SYSTEM CAUSING MAJOR DAMAGE. HAV E FOUND 2 ADDITIONAL AC WITH THE LATCH ALMOST READY TO FAIL. MFG HAS NEW IMPROVED LATCH THAT WILL NOT ALLOW ANY PARTS T O FALL INTO THE INDUCTION. 1 H 7 1 3O 3 O 3A21 E8CE 5 C P47GL 2004100100126 20041001 00126 EA 2004 10 1 2004FA0000771 2 20040716 G 8530 AEL65102ST041 CYLINDER HEAD CESSNA 172 172L 2072432 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160DTM GL ENGINE FAILED D A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION NR NOT REPORTED 1 WP 05 19674 820 17260657 L3253127A VJ44025 STUDENT AND INSTRUCTOR WERE FLYING, HEARD LOUD BANG. AC SHUTTERED, OIL PRESSURE STABLE, RPM DROPPED TO BOTTOM OF GREEN ARC, OIL PRESSURE STARTED DROPPING ON A PRECAUTIONARY APPROACH. NORMAL LANDING, SHUT ENGINE DOWN AT SOUTH BAY AVIATION. UPON INSP OF ENG IT WAS DETERMINED. NR3 CYLINDER HEAD SEPARATED FROM CYLINDER. REPLACED NR 3 CYLINDER ASSY. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2004100100124 20041001 00124 SO 2004 10 1 2004FA0000772 1 20040714 G 8011 MZ6222 STARTER PIPER PA32 PA32R300 7103213 SO LYC O540 IO540K1A5 41532 EA ENGINE BURNED D GM8T K NONE O OTHER IN INSP/MAINT 1 SW 05 1594X 270 32R7680004 L2313648A STARTER WAS INSTALLED BY FACTORY DURING ENGINE OVERHAUL. STARTER HAS STEADILY WEAKENED SINCE INSTALLATION OF THE ENGINE ON THE AIRCRAFT. OPENED STARTER AND FOUND BRUSHES AND COMMUTATOR SEVERELY BURNED. IT IS THE SUBMITTERS OPINION THAT T HIS PERMANENT MAGNET STARTER IS UNDER DESIGNED TO TURN AN ENGINE WITH 12 VOLTS. 1 L 7 1 3O 3 O A3SO 1E4 2004100100125 20041001 00125 SW 2004 10 1 2004FA0000773 1 20040627 G 2820 LINE BBAVIA 7 7GCBC 1220601 SW LYC O320 O320* 41508 EA FUEL SYSTEM CHAFED D O OTHER K FLUID LOSS NR NOT REPORTED 1 WP 11 86727 65674 IN COMPLIANCE WITH MFG SL NR 419. FOUND FUEL LINE CHAFED OVER .5000 WAY THROUGH TUBE WALL. CAUSED BY FLAP ACTUATOR. C HAFE WAS NOT VISIBLE. FOUND BY FEELING. RECOMMEND MFG RUN LINE STRAIGHT THROUGH FUSELAGE WALL THEN ROUTE AFT. ALSO RE COMMEND MAKING INTO AN AD. 1 H 7 1 3O 3 O NC A759 E274 2004100100114 20041001 00114 SO 2004 10 1 2004FA0000774 2 20040629 G 7261 640756 HOUSING PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360* 17025 SO SCAVANGE PUMP BROKEN B R2JR O OTHER K FLUID LOSS NR NOT REPORTED 1 EA 21 2190K 400 347970096 DURING SEARCH FOR OIL LEAK ONTO ALTERNATOR FOUND. OIL SCAVENGE PUMP HOUSING HAD BROKEN MOUNT LUG. REPLACED WITH NEW PA RT. CAUSE OF FAILURE BELIEVED TO BE WEAK CONSTRUCTION. AIRCRAFT FREON COMPRESSOR MOUNTS HERE. AIRCRAFT HAS HAD DYNAMI C PROP BALANCES. SECOND FAILURE THIS ENGINE WITHIN 400 HOURS. EXTRA WEIGHT OF FREON COMPRESSOR COULD BE FACTOR. THE R T ENGINE WITHOUT COMPRESSOR HAD NO FAILURES YET. 1 L 7 2 3O 3 O A7SO E9CE 2004100400081 20041004 00081 EA 2004 10 4 2004FA0000775 2 20040714 G 8520 IO540 CRANKCASE PIPER PA32 PA32301 7103207 SO LYC O540 IO540K1A5 41532 EA ENGINE CRACKED D O OTHER O OTHER NR NOT REPORTED 1 AL 03 8374T 800 328106058 11379248A CRANK IN CRANKCASE JUST BELOW CYLINDER NR 3 BETWEEN THE BOTTOM CYLINDER HOLD DOWN STUDS AND ROCKER DRAIN NIPPLES. CRACK IS APPROX 2.5 INCHES LONG. (AL03200418212) 1 L 7 1 3O 3 O A3SO 1E4 2004100100062 20041001 00062 SO 2004 10 1 2004FA0000776 2 20040713 G 7414 M3050 IMPULSE COUPLING BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO LT MAGNETO BROKEN B VJ3R O OTHER O OTHER NR NOT REPORTED 1 WP 07 5599P 1383 153 CE1344 825882R PILOT REPORTED EXCESSIVE DROP ON LT MAGNETO ON ENGINE RUN UP. ON FURTHER INVESTIGATION THE MECHANIC FOUND THE IMPULSE C OUPLING SPRING BROKEN. PROBABLE CAUSE AT THIS TIME IN UNKNOWN, AND THERE IS NO RECOMMENDATIONS AT THIS TIME EITHER. 1 L 7 1 3O 3 O 3A15 E5CE 2004100100110 20041001 00110 EA 2004 10 1 2004FA0000777 2 20040914 G 8530 LW19001 VALVE CESSNA 150 150K 2071822 CE LYC O320 O320E2D 41508 EA CYLINDER HEAD STUCK D O OTHER O OTHER NR NOT REPORTED 1 WP 07 6103G 15071603 L4889027A POWER LOSS ON TAKE OFF. UPON INSPECTION, FOUND PUSHROD TUBE BENT. INDICATES STUCK VALVE. DEVELOPMENT NEEDED TO AVOID EXHAUST AND/OR INTAKE VALVES FROM STICKING. (WP07200421112) 1 H 7 1 3O 3 O 3A19 E274 2004100400066 20041004 00066 EA 2004 10 4 2004FA0000778 2 20040923 G 7322 FLOAT PREAIR PIPER PA28 PA28140 7102802 SO LYC O320 O320E3D 41508 EA CARBURATOR LEAKING C O OTHER R J PARTIAL RPM/PWR LOSS WARNING INDICATION DE DESCENT 1 SW 99 ENGINE STARTED FALTERING DURING POWER REDUCTION FOR DESCENT. ENGINE RAN FINE AT CRUISE POWER. UPON INSPECTION OF CARB, ONE OF THE PLASTIC FLOAT CELLS IS FULL OF FUEL. CARB LESS THAN 100 HOURS OUT OF OVERHAUL. 1 L 7 1 3O 3 O 2A13 E274 2004100400067 20041004 00067 EA 2004 10 4 2004FA0000779 2 20040923 G 7322 FLOAT PREAIR PIPER PA28 PA28140 7102802 SO LYC O320 O320E3D 41508 EA CARBURATOR LEAKING C O OTHER R J PARTIAL RPM/PWR LOSS WARNING INDICATION DE DESCENT 1 SW 99 ENGINE STARTED FALTERING DURING POWER REDUCTION FOR DESCENT. ENGINE RAN FINE AT CRUISE POWER. UPON INSPECTION OF CARB, ONE OF THE PLASTIC FLOAT CELLS IS FULL OF FUEL. CARB LESS THAN 100 HOURS OUT OF OVERHAUL. 1 L 7 1 3O 3 O 2A13 E274 2004100400082 20041004 00082 EA 2004 10 4 2004FA0000780 2 20040923 G 7322 MA4SPA CARBURETOR PIPER PA28 PA28140 7102802 SO LYC O320 O320* 41508 EA ENGINE MALFUNCTIONED B O OTHER O OTHER NR NOT REPORTED 1 SO 15 56098 287325571 OVERHAULED ENGINE INSTALLED ON AIRFRAME APPROXMIATELY 75 HRS AND 4 MONTHS AGO,CARBURETOR SET AND ADJUSTED TO SPECS AT IN STALLATION. ENGINE BECAME ERRATIC AND NEAR STALL OUT CONDITION WITHIN THE LAST 1 HOURS. ATTEMPTED TO ADJUST RICH/LEAN SETTING AND IDLE. ENGINE WOULD NOT RESPOND AS NORMAL. REMOVED CARB, DISASSEMBLED, INSPECTED. ONE HALF OF FLOAT NEARLY FULL OF AV 100LL FUEL, SLIGHT SPLIT NOTED AT FLOAT BOND JOINT. FLOAT IS MADE FROM A PLASTIC MATERIAL, CARB SENT FOR RE PAIRS. 1 L 7 1 3O 3 O 2A13 E274 2004100400102 20041004 00102 CE 2004 10 4 2004FA0000781 1 20040923 G 3000 33CB15 CIRCUIT BREAKER RAYTHN 390 390 7150030 CE WING ICE LIGHT WRONG PART B K NONE O OTHER IN INSP/MAINT 1 GL 11 567T 464 RB37 REPORTED THAT THE WING ICE LIGHT C/B SWITCH TRIPS AFTER BEING IN (ON) POSITION FOR 3-4 MINUTES. TROUBLESHOOTING REVEALED THAT A 3 AMP C/B HAD BEEN INSTALLED IN A 7 AMP CIRCUIT AT POSITION 33CB15. INSPECTING THE OTHER C/B SWITCHES REVEALED T HAT POSITION 33CB6, 33CB11 AND 33CB32 WERE ALL WRONG AMPERAGE C/B. THE C/B WERE REMOVED AND REPLACED IN THEIR CORRECT RE SPECTIVE CIRCUITS AND THE SYSTEMS OPERATIONAL CHECKED. RESEARCH OF RECORDS REVEALED NO WORK HAD BEEN ACCOMPLISHED ON THE AFFECTED CIRCUITS AT ANY TIME SINCE THE AIRCRAFT WAS NEW. LEADING TO THE CONCLUSION THAT THE C/B WERE INCORRECTLY INSTA LLED DURING PRODUCTION. MFG TECHNICAL SUPPORT WAS NOTIFIED AND IS CONDUCTING AND INVESTIGATION AT THIS TIME. 1 7 2 3F RT A00010WI 2004102700102 20041027 00102 SO 2004 10 27 2004FA0000782 1 20040923 G 2810 C1560030101 CAP CESSNA PIPER PA28 PA28181 7102807 SO LYC O360 O360A1A 41514 EA HARTZL HCC2Y HCC2YK1 GL FUEL TANK CLOGGED B A UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 EA 17 8214Y 288090362 L2561736A F766A2 PILOT EXPERIENCED FUEL INTERRUPTION TO ENGINE WHILE ENROUTE. SWITCHED FUEL TANKS AND ENGINE QUIT. MADE EMERGENCY LANDING . REMOVED AC FROM FIELD TO LOCAL AIRPORT (N75). DRAINED ALL FUEL FROM WING TANKS. FOUND WHILE DRAINING FUEL WITH FUEL C APS ON THAT DRAINING FUEL WAS SLOW. REMOVING FUEL CAP QUICKENED FLOW RATE AT FUEL DRAIN. AFTER CLOSE INSP FOUND VENT HO LES CLOGGED WITH MUD. FOUND THE VENT TUBE IN LT WING WAS RESTRICTED. BLOWING NITROGEN THROUGH TUBE FREED UP BLOCKAGE. FRESH FUEL WAS INSTALLED IN EACH TANK AND FUEL CAPS WERE REPLACED WITH NEW UNITS. A LENGTHY RUNUP WAS PERFORMED WITH NO DEFECTS NOTED. AFTER ARRIVING, OWNER REQUEST WE REPLACE THE FUEL SELECTOR AS A PRECAUTIONARY MEASURE 1 L 7 1 3O 3 O 2A13 E286 5 C P920 2004102700103 20041027 00103 CE 2004 10 27 2004FA0000783 1 20040923 G 2810 C1560030101 CAP CESSNA CESSNA 172 172 2072402 CE LYC O360 O360A1A 41514 EA HARTZL HCC2Y HCC2YK1 GL FUEL TANK CLOGGED B A UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 EA 17 8214Y 17248714 L2561736A F766A2 PILOT EXPERIENCED FUEL INTERRUPTION TO ENGINE WHILE ENROUTE. SWITCHED FUEL TANKS AND ENGINE QUIT. MADE EMERGENCY LANDIN G. NO INJURIES OR DAMAGE TO AIRCRAFT. REMOVED AC FROM FIELD TO LOCAL AIRPORT (N75). DRAINED ALL FUEL FROM WING TANKS. FO UND WHILE DRAINING FUEL WITH FUEL CAPS ON THAT DRAINING FUEL WAS SLOW. REMOVING FUEL CAP QUICKENED FLOW RATE AT FUEL DRA IN. AFTER CLOSE INSP FOUND VENT HOLES CLOGGED WITH MUD. FOUND VENT TUBE IN LT WING WAS RESTRICTED. BLOWING NITROGEN TH ROUGH TUBE FREED UP BLOCKAGE. FRESH FUEL WAS INSTALLED IN EACH TANK AND FUEL CAPS WERE REPLACED WITH NEW UNITS. A FLIGH T WAS MADE WITHOUT INCIDENT. AFTER ARRIVING, THE OWNER REQUEST WE REPLACE THE FUEL SELECTOR AS A PRECAUTIONARY MEASURE. 1 H 7 1 3O 3 O NT 3A12 E286 5 C P920 2004101500089 20041015 00089 NE 2004 10 15 2004FA0000784 2 20040515 G 8520 270458 CRANKSHAFT AIRTRC AT300 AT301 0390103 SW PWA R1340 R1340AN1 52016 NE HAMSTD 12D 12D40 NE ENGIEN CRACKED G O OTHER O OTHER NR NOT REPORTED 1 CE 07 8561S 3010145 CP513333 AC WAS ON FERRY FLIGHT, PILOT REPORTED GETTING OIL ON WINDSHIELD. OIL BEGAN TO GET WORSE; REDUCED POWER, AC STARTED VIB RATING SEVERELY. POWER WAS REDUCED FURTHER AND VIBRATION ALSO REDUCED. PILOT LANDED AC IN UNPLANTED FIELD. AC SKIPPED OVER TERRACE AS SLOWED TO STOP. TAIL CAME UP AND AC WENT OVER ON NOSE. PROP STRUCK GROUND AND SEPARATED FROM ENGINE. CRANKSHAFT HAD BROKEN IN PROP THRUST BEARING AREA. EXAM OF CRANKSHAFT SHOWS FATIGUE CRACKING. BLADES DAMAGED APPROX 2 5 INCHES FROM TIPS. PROP WAS INSTALLED AFTER BEING O/H. ENGINE RUN AND GROUND CHECKS COMPLETED. PROP WAS IN SERVICE . 5 HOUR BEFORE FAILURE OF CRANKSHAFT. (CE07200414081) 1 L 7 1 3R 3 R A9SW 5E2 5 C P257 2004101800127 20041018 00127 CE 2004 10 18 2004FA0000785 1 20040827 G 6120 C299506B0104 PCU CESSNA 172 R172K 2072431 CE CONT IO360 IO360* 17025 CE PROPELLER FROZEN D O OTHER O OTHER NR NOT REPORTED 1 GL 15 218H 1 R1722840 NEW PROP CONTROL INSTALLED IAW SRM, CONTROL OPERATED FINE, AIRCRAFT WAS FLOWN ONCE AFTER COOL DOWN. PROP CONTROL WAS FR OZEN, WAS ABLE TO BREAK FREE, INSTALLATION AND RIGGING CHECKED, PROP GOVERNOR CHECKED, AIRCRAFT FLOWN AGAIN, PROP CONTRO L FROZEN AGAIN AFTER COOL DOWN, WAS ABLE TO BREAK CONTROL FREE, INSTALLED SECOND NEW CONTROL FROM MFG, THE SAME ABOVE O CCURRED WITH THE SECOND NEW CONTROL. CONTROL SENT TO MFG FOR INSPECTION, CUSTOM CONTROL WAS PURCHASED, FIELD APPROVAL I N PROGRESS. 1 H 7 1 3O 3 O 3A17 E1CE 2004101800182 20041018 00182 EA 2004 10 18 2004FA0000786 2 20040816 G 7414 10382971 BEARING BENDIX CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA MAGNETO OVERHEATED D S43S O OTHER O OTHER NR NOT REPORTED 1 CE 03 2246E 382 GO1AA069 17271203 L647276T DURING FLIGHT, ENGINE BEGAN TO LOOSE POWER, AND AIRCRAFT EXPERIENCED AN OFF-FIELD LANDING. UPON INVESTIGATION INTO THE FAULT, IT WAS DISCOVERED THAT THE MAGNETO BREAKER POINTS WERE NOT OPENING. DISASSEMBLY OF THE MAGNETO REVEALED THAT BEA RING PN 1038297 INSTALLED IN BENDIX MAGNETO PN 10-682555-14, HAD OVERHEATED DUE TO APPARENT INSUFFICENT LUBRICATION CAUS ING RAPID WEAR OF THE BREAKER POINTS CAM FOLLOWERS. (CE03200402198) 1 H 7 1 3O 3 O NT 3A12 E274 2004101800181 20041018 00181 SO 2004 10 18 2004FA0000787 2 20040812 G 8520 648014 VALVE GUIDE CESSNA 182 182P 2075816 CE CONT O470 O470* 17026 SO CYLINDER HEAD WORN D K NONE O OTHER IN INSP/MAINT 1 NM 09 5823J 18263557 ON DOING A COMPRESSION CHECK, 3 OUT OF 6 CYLINDERS HAD VALVES LEAKING. WHEN REMOVED FOR REPAIR, DISCOVERED GUIDES WORN BEYOND MAX SERVICE LIMIT. (NM09200412745) 1 H 7 1 3O 3 O NT TA13 E273 2004101800103 20041018 00103 SO 2004 10 18 2004FA0000788 1 20040501 G 5102 PULLEY BALWKS FIREFY FIREFLY11 1050125 SO ENVELOPE STICKING P O OTHER O OTHER NR NOT REPORTED 1 WP 19 70535 F11005 DEFLATION CWE PULLEY CATCHES ON ENVELOPE THROAT WEBBING AND NOMEX SKIRT CAUSING DEFLATION PANEL TO REMAIN OVEN DURING DE SCENTS AND CAUSES DIFFICULTY RETURNING TO LEVEL FLIGHT WHEN HEATING ENVELOPE. THE PULLEY EVENTUALLY FREES ITSELF WHEN E NOUGH HEAT IS APPLIED AND MORE TENTION IS ADDED TO THE LINE. THE PULLEY RELEASES WITH A SNAP WHICH ALSO JOLTS THE AIRCR AFT AND PASSENGERS. 1 B 0 0 A14SO 2004101800184 20041018 00184 EA 2004 10 18 2004FA0000789 2 20040428 G 7314 62D22569 PUMP PIPER PA23 PA23250 7102308 SO LYC O540 TIO540C1A 41532 EA FUEL SYSTEM FAILED D O OTHER O OTHER NR NOT REPORTED 1 WP 01 54MV 3 277654043 RL1057961A FUEL LEAKING INTO MANIFOLD REFERENCE LINE. PILOT EXPERIENCED INFLIGHT ROUGH ENGINE WHEN AUXILIARY FUEL PUMP WAS TURNED ON. FUEL CONTINUED TO RUN ONTO THE GROUND AFTER ENGINE SHUTDOWN. 1 L 7 2 3O 3 O 1A10 E14EA 2004101800192 20041018 00192 EA 2004 10 18 2004FA0000790 2 20040428 G 7314 RG17980JM PUMP PIPER PA23 PA23250 7102308 SO LYC O540 TIO540C1A 41532 EA ENGINE FAILED D O OTHER O OTHER NR NOT REPORTED 1 WP 01 54MV 20 277654043 RL723861A FUEL LEAKING INTO MANIFOLD REFERENCE LINE. PILOT EXPERIENCED INFLIGHT ROUGH ENGINE WHEN AUXILIARY FUEL PUMP TURNED ON. FUEL CONTINUED TO RUN ON GROUND AFTER ENGINE SHUTDOWN. PROBABLE CAUSE: MFG DEFECT: LEAKING DIAPHRAGM. 1 L 7 2 3O 3 O 1A10 E14EA 2004101500093 20041015 00093 CE 2004 10 15 2004FA0000791 1 20041001 G 5522 96610006617 SKIN BEECH BEECH 58 58 1152740 CE ELEVATOR CRACKED B U5LR O OTHER O OTHER NR NOT REPORTED 1 GL 15 ELEVATOR SKIN CRACKED WHERE CENTER RIB AND TRIM TAB HINGE BRACKET INTERSECT. THESE SKINS ARE MADE FROM MAGNESIUM AND AR E PRONE TO CRACKING IN THIS AREA. THIS REPAIR STATION HAS REPLACED NUMEROUS SKINS DUE TO THIS DEFECT. 1 L 7 2 3O 3A16 2004101800046 20041018 00046 NM 2004 10 18 2004FA0000792 1 20040930 G 2497 WIRE LANCAR LC42 LC42550FG 5150002 NM CONT O550 IO550* SO ALTERNATOR BROKEN B O OTHER H ELECT. POWER LOSS-50 PC NR NOT REPORTED 1 SO 05 65035 136 E022966 42052 PILOT REPORTED LT ALTERNATOR INOPERATIVE. FOUND TERMINAL FOR B+ WIRE BROKEN OFF, WHICH RESULTED IN INTERMITTENT CONTACT CAUSING SEVERE ELECTRICAL ARCING BETWEEN ALTERNATOR AND WIRE TERMINAL END. 1 L 7 1 3O 3 O RT A00003SE E3SO 2004101800120 20041018 00120 NM 2004 10 18 2004FA0000793 1 20041006 G 3220 STRUT LANCAR LC42 LC42550FG 5150002 NM CONT O520 IO520* 17032 SO NLG LOOSE B K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 SO 05 244SC 100 42047 DURING INSPECTION FOUND THE TWO BOLTS/NUTS THAT ATTACH NOSE STRUT TO THE ENGINE MOUNT VERY LOOSE. NOSE STRUT WOBBLES WI TH AIRCRAFT ON JACKS. FOUND SIMILAR SITUATION ON TWO OTHER AIRCRAFT WITH LESS THAN 100 HOURS SINCE NEW. 1 L 7 1 3O 3 O RT A00003SE E5CE 2004101800039 20041018 00039 2004 10 18 2004FA0000794 4 20041008 G 3422 ST3400 INDICATOR BEECH 200 B200 1152922 CE PWA PT6 PT6* 52043 EA TAWS/RMI MALFUNCTIONED B FE6R O OTHER O OTHER NR NOT REPORTED 1 NM 11 2328E BB1608 THE TAWS/RMI SHOWS SIGNIFICANT BEARING ERRORS ON HEADINGS GREATER THAN 350 DEGREES OR LESS THAN 0 DEGREES. THIS PROBLEM WAS DISCOVERED IN FLIGHT AND VALIDATED THROUGH GROUND TESTING OF NUMEROUS UNITS. PROBABLE CAUSE OF MALFUNCTION IS SOFT WARE. THE ST3400 TAWS/RMI IS NOT RECOMMENDED FOR NAVIGATION AT THIS TIME. 1 L 7 2 4T 3 T A24CE E2NE 2004102700080 20041027 00080 CE 2004 10 27 2004FA0000796 1 20040815 G 1430 BOLT BEECH 90 B90 1152912 CE PWA PT6 PT6* 52043 EA WING LOOSE G O OTHER W INADEQUATE Q C NR NOT REPORTED 1 NM 07 148Z LJ472 INSPECTION AFTER TURBULENT AIR, DISCOVERED BOTH UPPER FWD WING BOLTS AND NUTS WERE ONLY INSTALLED HAND TIGHT. REVEALED THAT WING BOLT INSP HAD BEEN COMPLETED 116.8 HOURS BEFORE. WING BOLT RETORQUE CHECK HAD BEEN COMPLIED WITH 72.8 HOURS A FTER THAT. AIRCRAFT HAS WING STRAP INSTALLED. THE STC ICA AND SB ONLY MENTIONS PROCEDURES FOR TORQUEING THE LWR FWD BO LTS. PROCEDURE FOR TORQUEING REMAINDER BOLTS IS LEFT TO MFG SIRM. WING BOLT MAINT, SIRM STATES TO CHK TORQUE IAW FIGUR ES SHOWN. IT APPEARS THAT REQUIRED TORQUE COULD BE MET, EVEN THOUGH NUTS WERE NOT FULLY ENGAGED, OR CORRECTLY TORQUED T O BEGIN WITH, DUE TO DOWNWARD PRESSURE EXERTED ON WING. SIRM STATES (ENSURE WING IS PROPERLY SUPPORTED FOR MAINT). 1 L 7 2 3T 3 T 3A20 E2NE 2004102000201 20041020 00201 EA 2004 10 20 2004FA0000797 2 20040723 G 8520 60009 VALVE LYC BEECH 60 B60 1153605 CE LYC O541 TIO541* 41536 EA CYLINDER BROKEN B WS9R O OTHER O OTHER NR NOT REPORTED 1 NM 07 131MC P392 WITHIN THE LAST 3 TO 3.5 HOURS OF FLIGHT, THE PILOT NOTED THE ENGINES WERE RUNNING ROUGH AND FLEW TO OUR FACILITY FOR DI SCOVERED THAT THE INTAKE VALVE KEEPER KEYS WERE BROKEN, THE NR 6 CYLINDER HAD A STUCK EXHAUST VALVE. THE PILOT REPORTED HAVE THE NR 6 CYLINDER REPLACED WITH A REMANUFACTURED UNIT AT ANOTHER FACILITY FAIRLY RECENTLY. ON THE LT ENGINE, THE NR 4 INTAKE VALVE STEM WAS DISCOVERED TO BE BROKEN. 1 L 7 2 3O 3 O A12CE E10EA 2004102000198 20041020 00198 SO 2004 10 20 2004FA0000798 2 20040901 G 8530 CYLINDER BEECH 36 A36 1151604 CE CONT O550 IO550B SO ENGINE CRACKED B PAIR O OTHER O OTHER NR NOT REPORTED 1 SO 05 23NY E2359 675303R PERFORMED ROUTINE ENGINE CYLINDER COMPRESSION CHECKS AS REQUIRED IAW ANNUAL INSPECTION PROCEDURES. FOUND NR 1 AND 3 CYL INDERS PASSED COMPRESSION MINIMUMS IAW MFG SPEC, IE: NR1 66/80, NR3 51/80. DURING COMPRESSION CK, THE TECH OBSERVED AIR ESCAPING FROM CYL AT AREA OF FUEL INJECTORS AT EACH CYLINDER. UPON FURTHER INSP THE TECH VISUALLY FOUND CRACKS BETWEEN THE BARREL AND THE HEAD OF THE CYLINDERS BETWEEN TWO COOLING FINS. COMPRESSION CHECKS FOR ALL OTHER CYLINDERS PASSED A ND NO EXTERNAL LEAKS NOTED. RESEARCH BY INSPECTION FOUND THAT THIS ENGINE SN WAS NOT COVERED BY AD, WHICH CONTAINS FAIL URES VERY SIMILAR TO THIS FAILURE. AD COVERS SN UP TO 675278, WHICH DOES NOT INCLUDE THIS SN OF 675303. 1 L 7 1 3O 3 O 3A15 E3SO 2004110300129 20041103 00129 GL 2004 11 3 2004FA0000799 1 20040609 G 2810 GASKET AIMM AMT300 AMT300 05607RA GL ROTAX 914 ROTAX914 EU FUEL TANK DETERIORATED B L1MR O OTHER O OTHER NR NOT REPORTED 1 WP 11 117MQ 365 300106 FUEL TANK GASKETS MAY NOT BE COMPATABLE WITH AUTO FUEL. ENGINE IS APPROVED FOR AUTO FUEL. GASKETS WERE FOUND SEVERELY DETERIORATED. (WP11200403100) 1 K 7 1 3I 3 O RT TG00004A EXPE3I 2004102000202 20041020 00202 CE 2004 10 20 2004FA0000800 1 20040603 G 7160 12509388 LATCH CESSNA 210 T210M 2073451 CE CONT O520 TSIO520R 17040 SO ALT AIR DOOR/BOX FAILED B NF2R O OTHER O OTHER NR NOT REPORTED 1 GL 03 7568M 22667 21062021 DURING THE ANNUAL INSPECTION, FOUND THE PN 1250938-8, MAGNET LATCH ON THE ALTERNATE AIR DOOR WITH ONE OF ITS STEEL BONDE D PLATES LOOSE AND READY TO FALL INTO THE TURBO, COULD CAUSE INFLIGHT FAILURE. INSTALLED THE NEW IMPROVED CATCH PN C100 200. RECOMMEND MANDITORY REPLACEMENT OF THE OLD TYPE MAGNETIC LATCH IF TT IS ABOVE 1500 HOURS. 1 H 7 1 3O 3 O 3A21 E8CE 2004101400004 20041014 00004 NM 2004 10 14 2004FA0000801 1 20040413 G 6220 900R2101006107 HUB DOUG MD900 MD900 3027375 NM PWC PW207 PW207E NE MAIN ROTOR CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 11 3PD 102 102 9000085 DURING ACCOMPLISHMENT OF AD 2002-10-05, MAIN ROTOR UPPER HUB INSP. FOUND (3) OUT OF (10) BOLT HOLES CRACKED AS DEPICTED IN SB 900-072. CRACKS START IN BOLT HOLE CHAMFER. PART TOTAL TIME: 102.0 HRS. 1 G 7 2 3U 3 U NC H19NM E42NE 2004101400005 20041014 00005 NM 2004 10 14 2004FA0000802 1 20041012 G 6230 900D2436530101 DRIVE SHAFT DOUG MD900 MD900 3027375 NM PWC PW207 PW207E NE MAIN ROTOR WORN D K NONE O OTHER IN INSP/MAINT 1 EA 11 3PD 1478 300 9000085 DURING ACCOMPLISHMENT OF A 300 HR INSPECTION FOUND MAIN ROTOR DRIVE SHAFT UPPER DRIVE SPLINES WORN BEYOND MAINTENANCE MA NUAL LIMITS. PART TOTAL TIME: 1478.9 HRS. REPLACED DRIVE SHAFT WITH NEW PART. 1 G 7 2 3U 3 U NC H19NM E42NE 2004101500078 20041015 00078 2004 10 15 2004FA0000803 4 20040928 G 6113 TCB35323011 BULKHEAD PIPER PA28 PA28140 7102802 SO LYC O320 O320* 41508 EA SPINNER CHAFED D O OTHER O OTHER NR NOT REPORTED 1 WP 27 8938C 521 287625136 UPON ANNUAL INSPECTION, FOUND AFT SPINNER BULKHEAD (PN TCB36323011) TO BE CHAFFING AGAINST PROPELLER BLADES. ONCE REMOV ED, IT WAS ALSO EVIDENT THAT CORROSION HAD FORMED ON THE PROPELLER TUB. ALSO DISCOVERED WAS MATERIAL FROM THE BULKHEAD HAD TRANSFERRED TO THE PROPELLER. INSPECTION OF THE AFT SPINNER BULKHEAD SHOWED THAT THE BULKHEAD HAD BEEN COMPRESSED, WHICH HAD REDUCED THE TORQUE ON THE MOUNTING BOLTS. (WP27200407907) 1 L 7 1 3O 3 O 2A13 E274 2004101400003 20041014 00003 2004 10 14 2004FA0000804 4 20041013 G 2350 KMA260201 AUDIO PANEL CESSNA 172 172S 2072439 CE COCKPIT SMOKE D O OTHER B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 GL 13 106RA 500 172S8241 THE AUDIO CONTROL PANEL EMITTED SMOKE AND STOPPED OPERATING DURING TAXI PRIOR TO FLIGHT. AIRCRAFT RETURNED TO BASE, MAI NTENANCE REMOVED THE UNIT FROM AIRCRAFT AND VERIFIED AIRCRAFT BUS BAR VOLTAGE WITH ALTERNATOR OPERATING. A WORKING KMA -26 WAS INSTALLED, OPERATION WAS VERIFIED IAW MM AND AIRCRAFT WAS RETURNED TO SERVICE. THE AIRCRAFT/AUDIO CONTROL PANEL HAD NOT COMPLIED RECOMMEND MFG SB03-23-01 AND SB KMA26-5. THE BULLETINS REQUIRE THAT POWER MODULE INSIDE THE KMA-26 BY REPLACED WITH A UPDATED PART NUMBER. THE KMA-26 HAD BOARD TRACE DAMAGE, BELIEVED TO BE CAUSED BY POWER MODULE FAILURE. 1 H 7 1 3O NT 3A12 2004102000197 20041020 00197 CE 2004 10 20 2004FA0000805 1 20041001 G 2121 903840311 BLOWER BEECH 90 F90 1152909 CE PWA PT6 PT6A60 52043 NE CABIN AIR OVERHEATED C O OTHER O OTHER NR NOT REPORTED 1 EA 23 314P LA170 SMOKE COMING FROM UNDER PILOTS FLOORBOARDS. UPON INVESTIGATION FOUND ENVIRONMENTAL BLOWER MOTOR TOO HOT TO TOUCH. AIRC RAFT LANDED SAFE WITH FIRE DEPARTMENT FOLLOWING. INSPECTION FOUND NO TIME LIMIT ON BLOWER OR MOTOR. (EA23200410155) 1 L 7 2 4T 4 T A31CE E4EA 2004110300127 20041103 00127 CE 2004 11 3 2004FA0000806 1 20040930 G 2497 024081000 WIRE HARNESS SAFT LEAR 45 45LEAR 5170805 CE BATTERY MISPINNED D K NONE O OTHER IN INSP/MAINT 1 GL 25 117972 450150 WHILE PERFORMING THE OPERATIONAL CHECKS ON BATTERY, BOTH THE T1 (140 DEGREE) SWITCH AND T2 (160 DEGREE) SWITCH WERE IMPR OPERLY WIRED. TEMP SWITCH T1 WAS WIRED TO PINS C AND D INSTEAD OF PINS C AND E AND SWITCH T2 WAS WIRED TO PINS E AND F I NSTEAD OF PINS D AND F. IN EVENT OF THERMAL RUNAWAY ON THE AC, 160 DEGREE SWITCH NOT ONLY PROVIDES A RED CAS AND CREW M WP BATT OVHT INDICATION BUT ALSO REMOVES THE BATTERY FROM CHARGING CIRCUIT, WITH THIS DEFECTIVE SWITCH HARNESS INSTALLED NOT ONLY WOULD A THERMALLY UNSTABLE BATTERY BE ALLOWED TO CONTINUE TO CHARGE AND RUNAWAY BUT CREW WOULD NOT HAVE INDICA TION THAT EVENT IS TAKING PLACE.IF THEY HAD EICAS CONFIGURED TO VIEW A PAGE OTHER THAN THE SUMMARY OR ELECTRICAL PAGES. 2 L 7 2 4F RT T00008WI 2004102000180 20041020 00180 SO 2004 10 20 2004FA0000807 2 20041017 G 8520 6557718 EXHAUST VALVE CESSNA 210 T210M 2073451 CE CONT O520 TSIO520R 17040 SO ENGINE BURNED C K NONE O OTHER IN INSP/MAINT 1 SO 05 732YK 830 830 21061879 294273R EXHAUST VALVE LEAKAGE ON COMPRESSION CHECK. BURNED VALVE VERIFIED BORESCOPE INSPECTION. VALVE STEM AND GUIDE WORN BEYO ND SERVICE LIMITS. 1 H 7 1 3O 3 O 3A21 E8CE 2004102000181 20041020 00181 EA 2004 10 20 2004FA0000808 2 20041016 G 8530 AEL65102 CYLINDER HEAD PIPER PA28 PA28151 7102805 SO LYC O360 O360A4M 41514 EA SNSNCH 76E 76EM8 EA NR2 CYLINDER DETACHED P B A EMER. DESCENT UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 WP 07 4544X 300 300 287615027 L2033236A 35407K WHILE ON CLIMB-OUT, AT A POINT ABOUT 3 MILES NORTH OF THE AIRPORT AND AT AN ALTITUDE OF ABOUT 2800 FT (1300 FT AGL), HEA RD AND FELT LOUD BANG WITH RESULTING POWER LOSS. INITIATED 180 DEGREE TURN BACK TO AIRPORT WHILE ALERTING TOWER OF EMER GENCY. LANDED WITHOUT FURTHER INCIDENT ALTHOUGH WIND SCREEN WAS TOTALLY COATED WITH OIL PREVENTING FORWARD VISIBILITY. 1 L 7 1 3O 3 O 2A13 E286 5 N P4EA 2004102000182 20041020 00182 EA 2004 10 20 2004FA0000809 2 20041016 G 8530 AEL65102 CYLINDER HEAD PIPER PA28 PA28151 7102805 SO LYC O360 O360A4M 41514 EA SNSNCH 76E 76EM8 EA NR 2 CYLINDER DETACHED P B A EMER. DESCENT UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 WP 07 4544X 300 300 287615027 L2033236A 35407K WHILE ON CLIMB-OUT, AT A POINT ABOUT 3 MILES NORTH OF THE AIRPORT AND AT AN ALTITUDE OF ABOUT 2800 FT (1300 FT AGL), HEA RD AND FELT LOUD BANG WITH RESULTING POWER LOSS. INITIATED 180 DEGREE TURN BACK TO AIRPORT WHILE ALERTING TOWER OF EMER GENCY. LANDED WITHOUT FURTHER INCIDENT ALTHOUGH WIND SCREEN WAS TOTALLY COATED WITH OIL PREVENTING FORWARD VISIBILITY. 1 L 7 1 3O 3 O 2A13 E286 5 N P4EA 2004102000183 20041020 00183 EA 2004 10 20 2004FA0000810 2 20041016 G 8530 AEL65102 CYLINDER HEAD PIPER PA28 PA28151 7102805 SO LYC O360 O360A4M 41514 EA SNSNCH 76E 76EM8 EA 2 CYLINDER DETACHED P B A EMER. DESCENT UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 WP 07 4544X 300 300 287615027 L2033236A 35407K WHILE ON CLIMB-OUT (0715 LOCAL TIME), AT A POINT ABOUT 3 MILE NORTH OF THE AIRPORT AND AT AN ALTITUDE OF ABOUT 2800' (13 00' AGL), HEARD AND FELT LOUD BANG WITH RESULTING POWER LOSS. INITIATED 180 DEGREE TURN BACK TO AIRPORT WHILE ALERTING TOWER OF EMERGENCY. LANDED WITHOUT FURTHER INCIDENT ALTHOUGH WIND SCREEN WAS TOTALLY COATED WITH OIL PREVENTING FORWARD VISIBILITY. 1 L 7 1 3O 3 O 2A13 E286 5 N P4EA 2004102000184 20041020 00184 EA 2004 10 20 2004FA0000811 2 20041016 G 8530 AEL65102 CYLINDER HEAD PIPER PA28 PA28151 7102805 SO LYC O360 O360A4M 41514 EA SNSNCH 76E 76EM8S5 EA NR2 CYLINDER DETACHED P B A EMER. DESCENT UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 WP 07 4544X 300 300 287615027 L2033236A 35407K WHILE ON CLIMB-OUT, AT A POINT ABOUT 3 MILES NORTH OF THE AIRPORT AND AT AN ALTITUDE OF ABOUT 2800 FT (1300 FT AGL), HEA RD AND FELT LOUD BANG WITH RESULTING POWER LOSS. INITIATED 180 DEGREE TURN BACK TO AIRPORT WHILE ALERTING TOWER OF EMER GENCY. LANDED WITHOUT FURTHER INCIDENT ALTHOUGH WIND SCREEN WAS TOTALLY COATED WITH OIL PREVENTING FORWARD VISIBILITY. 1 L 7 1 3O 3 O 2A13 E286 5 N P4EA 2004102000185 20041020 00185 EA 2004 10 20 2004FA0000812 2 20041016 G 8530 AEL65102 CYLINDER HEAD PIPER PA28 PA28151 7102805 SO LYC O360 O360A4M 41514 EA SNSNCH 76E 76EM8 EA NR 2 CYLINDER DETACHED P B A EMER. DESCENT UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 WP 07 4544X 300 300 287615027 L2033236A 35407K WHILE ON CLIMB-OUT, AT A POINT ABOUT 3 MILE NORTH OF THE AIRPORT AND AT AN ALTITUDE OF ABOUT 2800 FT (1300 FT AGL), HEAR D AND FELT LOUD BANG WITH RESULTING POWER LOSS. INITIATED 180 DEGREE TURN BACK TO AIRPORT WHILE ALERTING TOWER OF EMERG ENCY. LANDED WITHOUT FURTHER INCIDENT ALTHOUGH WIND SCREEN WAS TOTALLY COATED WITH OIL PREVENTING FORWARD VISIBILITY. 1 L 7 1 3O 3 O 2A13 E286 5 N P4EA 2004102000186 20041020 00186 EA 2004 10 20 2004FA0000813 2 20041016 G 8530 AEL65102 CYLINDER HEAD PIPER PA28 PA28151 7102805 SO LYC O360 O360A4M 41514 EA SNSNCH 76E 76EM8 EA NR 2 CYLINDER DETACHED P B A EMER. DESCENT UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 WP 07 4544X 300 300 287615027 L2033236A 35407K WHILE ON CLIMB-OUT, AT A POINT ABOUT 3 MILES NORTH OF THE AIRPORT AND AT AN ALTITUDE OF ABOUT 2800 FT (1300 FT AGL), HEA RD AND FELT LOUD BANG WITH RESULTING POWER LOSS. INITIATED 180 DEGREE TURN BACK TO AIRPORT WHILE ALERTING TOWER OF EMER GENCY. LANDED WITHOUT FURTHER INCIDENT ALTHOUGH WIND SCREEN WAS TOTALLY COATED WITH OIL PREVENTING FORWARD VISIBILITY. 1 L 7 1 3O 3 O 2A13 E286 5 N P4EA 2004102000188 20041020 00188 EA 2004 10 20 2004FA0000814 2 20041016 G 8530 AEL65102 CYLINDER HEAD PIPER PA28 PA28151 7102805 SO LYC O360 O360A4M 41514 EA SNSNCH 76E 76EM8 EA NR 2 CYLINDER DETACHED P B A EMER. DESCENT UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 WP 07 4544X 300 300 287615027 L2033236A 35407K WHILE ON CLIMB-OUT, AT A POINT ABOUT 3 MILES NORTH OF THE AIRPORT AND AT AN ALTITUDE OF ABOUT 2800 FT (1300 FT AGL), HEA RD AND FELT LOUD BANG WITH RESULTING POWER LOSS. INITIATED 180 DEGREE TURN BACK TO AIRPORT WHILE ALERTING TOWER OF EMER GENCY. LANDED WITHOUT FURTHER INCIDENT ALTHOUGH WIND SCREEN WAS TOTALLY COATED WITH OIL PREVENTING FORWARD VISIBILITY. 1 L 7 1 3O 3 O 2A13 E286 5 N P4EA 2004110300115 20041103 00115 NE 2004 11 3 2004FA0000815 2 20040730 G 7250 30606944 TRANSITION DUCT AMD FALC50 FALCON50MYST 2730106 EU GARRTT TFE731 TFE73140 29001 NE HP TURBINE FAILED C O OTHER O OTHER NR NOT REPORTED 1 NM 01 38WP 2475 292 P115204 FLIGHT CREW MADE 3 ATTEMPTS TO START NR 3 ENGINE. COCKPIT INDICATION ON N1 AND N2 SHOWED NO ROTATION. 4TH ATTEMPT SHOW ED ROTATION WITH A NORMAL START. DURING FLIGHT BACK, CREW NOTED N2 APPROX 2 PERCENT LOWER AT CRUISE. ITT WAS APPROX 10 0 DEGREES HIGHTER. ALL OTHER PARAMETERS INDICATED NORMAL. MAINTENANCE CARRIED OUT GROUND MOTORING RUNS THAT INDICATED HARD RUB INSIDE ENGINE. COMPUTER DOWNLOAD COMPLIED WITH AND ANALYZED BY MFG AND ECTM CONFIRMING HIGH PRESSURE TURBINE A ND SHROUD FAILURE ENGINE NR 3 REMOVED AND SENT FOR REPAIR. BANK ENGINE INSTALLED AND AC RELEASED FOR SERVICE. (NM12004 11360) 2 L 7 3 4F 4 F A46EU E1NM 2004102700091 20041027 00091 CE 2004 10 27 2004FA0000816 1 20040902 G 5412 07536007 STIFFENER CESSNA 182 182S 2072701 CE LYC O540 IO540* 41532 EA FIREWALL CRACKED D O OTHER O OTHER NR NOT REPORTED 1 NM 01 7267H 3334 18280591 2 INCH LONG CRACK IN LT AREA OF FIREWALL STIFFENER IN AREA OF THE PARKING BRAKE BRACKET MOUNTING. BELIEVED TO BE CAUSED BY FLEXING OF FIREWALL BY APPLICATION OF PARKING BRAKE. THIS IS THE SECOND AC IN FLEET WITH THIS PROBLEM. THIS AREA N EEDS ADDITIONAL REINFORCEMENT TO MINIMIZE FLEXING IN THIS AREA. 1 H 7 1 3O 3 O NT 3A13 1E4 2004102700045 20041027 00045 EU 2004 10 27 2004FA0000817 1 20040923 G 3221 G1092805 MOUNT BRACKET GROB 109 G109 1660204 EU TAIL WHEEL CRACKED G O OTHER O OTHER NR NOT REPORTED 1 WP 11 909G 700 6134 BRACKET WAS CRACKED AND BROKEN, ALLOWING THE BRACKET TO BECOME LOOSE. THE TAIL WHEEL ATTACH STUD CONTACTOR TO ELEVATION TORQUE TUBE DAMAGING THE TUB. RECOMMEND A FLEET WIDE VISUAL INSPECTION FOR CRACKS/ DAMAGE OF BRACKETS/ TORQUE FUSER. 1 K 7 1 3O NC G43EU 2004102700027 20041027 00027 CE 2004 10 27 2004FA0000818 1 20040918 G 2820 S116760180 HOSE CESSNA 175 175C 2072508 CE CONT O300 GO300E 17022 SO CARBURETOR LOOSE G O OTHER O OTHER NR NOT REPORTED 1 SW 11 8323T 17557023 260431E LOST POWER ON TAKE OFF, APPROXIMATELY 100 FT IN THE AIR AT 100 MPH, HALFWAY DOWN RUNWAY. LANDED AT 10 FEET AT END OF RU NWAY. AIRCRAFT TAKEN BACK TO HANGER, REMOVED ENGINE COWL (TOP). NOTE: ENGINE PRIMER LINE TO LEFT AFT CYLINDER BROKEN. HOSE ASSEMBLY (CARBURETOR TO STRAINER) LOOSE AT CARBURETOR SIDE. (SW11200408528) 1 H 7 1 3O 3 O 3A17 E298 2004102700028 20041027 00028 CE 2004 10 27 2004FA0000819 1 20040312 G 5510 12326232 REINFORCEMENT CESSNA 210 T210N 2073456 CE CONT O520 TSIO520* 17040 SO MCAULY D3A34 D3A34C402 GL LT HORZ STAB BROKEN D O OTHER O OTHER NR NOT REPORTED 1 EA 23 6546N 2597 21063102 293534R 775725 FOUND REINFORCEMENT BROKEN AT ANNUAL INSPECTION. BREAK IS AT LOWER OB BOLT HOLE. PROBABLE CAUSE UNKNOWN. RECOMMEND CA REFUL INSPECTION OF AFT HORIZONTAL STABILIZER SPAR REINFORCEMENTS AT EACH 100 HOUR/ ANNUAL INSP. 1 H 7 1 3O 3 O 3A21 E8CE 5 C P47GL 2004102700093 20041027 00093 2004 10 27 2004FA0000820 4 20040903 G 2200 1C7501668P SERVO BEECH 33 F33A 1151425 CE CONT O520 IO520* 17032 SO PITCH BROKEN C O OTHER O OTHER NR NOT REPORTED 1 WP 17 1854N CE975 ONE SIDE OF BRIDLE CABLE BROKE AT CAPSTAN PIN. OTHER SIDE O BRIDLE CABLE BACKLASHED AND TANGLED IN CAPSTAN BRIDLE CABLE GUARD PINS CAUSING RESTRICTION OF UP ELEVATOR CONTROL. CENTURY FLIGHT SYSTEMS SB CSB-2003-01 EXISTS FOR THIS TYPE OF C ONDITION. POSSIBLY AD WOULD ENSURE COMPLIANCE. (WP17200405843) 1 L 7 1 3O 3 O 3A15 E5CE 2004102700072 20041027 00072 SW 2004 10 27 2004FA0000821 1 20040908 G 3233 SHAFT MOONEY M20 M20M 5870222 SW LYC O540 TIO540* 41532 EA MLG ACTUATOR MISINSTALLED D O OTHER O OTHER NR NOT REPORTED 1 EA 07 2231X 270296 GEAR ACTUATOR (CHATTERED) DURING LANDING GEAR RETRACTION CYCLES. FOUND APPROX .020 INCH END PLAY ON DRIVE GEAR ASSY SHA FT. INSPECTION OF RELATED PARTS REVEALED NO EXCESSIVE WEAR. IT APPEARS THAT WITH ONLY 632 HRS TSI ON THE ACTUATOR (WHI CH HAS NEVER BEEN PREVIOUSLY DISASSEMBLED) THAT IT MUST HAVE BEEN IMPROPERLY SHIMMED FROM THE FACTORY. (EA07200405963) 1 L 7 1 3O 3 O RT 2A3 E14EA 2004102700073 20041027 00073 SW 2004 10 27 2004FA0000822 1 20040908 G 3233 CLUTCH SPRING MOONEY M20 M20M 5870222 SW LYC O540 TIO540* 41532 EA MLG ACTUATOR MISSING D O OTHER O OTHER NR NOT REPORTED 1 EA 07 2231X 632 270296 AFTER COMPLIANCE WITH SB M20-282 AND THE CORRESPONDING SI 102000-1901 REV 2 THE NO-BACK CLUTCH SPRING MECHANISM WAS ALLO WING THE ACTUATOR TO (BACK UP) UNDER NORMAL LOADS. IT WAS FOUND THAT EXCESSIVE FRICTION BETWEEN THE INPUT/DRIVE GEAR AS SY AND THE OUTPUT/DRIVEN GEAR ASSY CAUSES THEM TO (LOCK) TOGETHER AND THEREFORE ROTATE SIMULTANEOUSLY. UNDER THIS CONDI TION THE NO-BACK CLUTCH SPRING WILL SLIP AND NOT LOCK PROPERLY. TWO CAUSES OF THE EXCESSIVE FRICTION WERE NOTED. IF TH E POINT OF CONTACT IS A THE LARGER DIAMETER HUBS INSTEAD OF THE SMALLER DIAMETER GEAR SHAFTS. IF GEAR SHAFT ASSY IS PRE LOADED TO THE MAX ACCEPTABLE LIMIT AS DEFINED IN THE ABOVE TWO BULLETINS. 1 L 7 1 3O 3 O RT 2A3 E14EA 2004102700069 20041027 00069 SW 2004 10 27 2004FA0000823 1 20040908 G 3230 CLUTCH SPRING EATON MOONEY M20 M20M 5870222 SW LYC O540 TIO540* 41532 EA GEAR ACTUATOR FAILED D O OTHER O OTHER NR NOT REPORTED 1 EA 07 716PR 145 270305 LANDING GEAR ACT CYCLED ON AND OFF AT 5-10 SECOND INTERVALS IN DOWN POSITION. FOUND NO-BACK CLUTCH SPRING (SLIPPING) WH EN GEAR WAS UNDER PRELOAD IN DOWN OR UP POSITION. SB M20-282 AND SI 102000-1-901 REV2 , INSTALLING NEW NO-BACK CLUTCH S PRING, MECHANISM WAS STILL ALLOWING ACT TO (BACK UP) UNDER NORMAL LOADS. IT WAS FOUND THAT EXCESS FRICTION BETWEEN INPU T/DRIVE GEAR ASSY, OUTPUT/DRIVEN GEAR ASSY CAUSES THEM TO (LOCK) TOGETHER AND ROTATE. NO-BACK CLUTCH SPRING WILL SLIP A ND NOT LOCK PROPERLY. TWO CAUSES WERE NOTED: IF POINT OF CONTACT BETWEEN TWO DRIVE GEAR ASSY IS AT LARGER DIAMETER HUBS INSTEAD OF SMALLER DIAMETER GEAR SHAFTS. IF GEAR SHAFT IS PRELOADED TO MAX ACCEPT LIMIT AS IN ABOVE BULLETINS. 1 L 7 1 3O 3 O RT 2A3 E14EA 2004102700097 20041027 00097 CE 2004 10 27 2004FA0000824 1 20040902 G 5340 07326015 FITTING CESSNA 210 T210G 2073432 CE CONT O520 TSIO520M 17040 SO MCAULY D3A34 D3A34C402 GL TAILCONE DETACHED D ESER O OTHER O OTHER NR NOT REPORTED 1 SO 11 6864R 2473 T2100264 512265 030258 DURING COMPLIANCE WITH SEB88-3 TO REPLACE FORWARD STABILIZER ATTACH FITTINGS PN 0732601-5, IT WAS DISCOVERED THAT THE TO P TWO RIVETS OF BOTH FITTINGS HAD FAILED LEAVING ONLY THE THREE RIVETS IN THE LOWER PORTION OF EACH FITTING. ALL FOUR R IVETS FAILED IN BETWEEN THE STABILIZER AND THE FITTINGS, APPARENTLY IN TENSION, LEAVING THE HEAD AND TAIL OF THE RIVET I N PLACE. THERE WAS NO EVIDENCE OF ANY PROBLEM UNTIL THE FITTINGS WERE DRILLED OFF OF THE STABILIZER. A SUBSTANTIAL AMO UNT OF BLACK ALUMINUM RESIDUE WAS SANDWICHED BETWEEN THE PARTS INDICATING THE PROBLEM HAD BEEN THERE FOR A WHILE. 1 H 7 1 3O 3 O 3A21 E8CE 5 C P47GL 2004102700098 20041027 00098 CE 2004 10 27 2004FA0000825 1 20040923 G 3230 SM50D7 RELAY BEECH 33 F33A 1151425 CE CONT O520 IO520* 17032 SO MLG INTERMITTENT B VJ3R O OTHER O OTHER NR NOT REPORTED 1 WP 07 5519A CE1337 PILOT SELECTED GEAR DOWN AND NOTHING HAPPENED, SELECTED GEAR DOWN AGAIN AND GEAR CAME DOWN. UP ON FURTHER TROUBLESHOOTI NG FOUND RELAY WAS INTERMITTENT, PROBABLE CAUSE AT TIME, UNKNOWN, THIS IS SUPPOSE TO BE AN IMPROVED RELAY SO THERE IS NO RECOMMENDATIONS AT THIS TIME. 1 L 7 1 3O 3 O 3A15 E5CE 2004102600139 20041026 00139 EA 2004 10 26 2004FA0000827 2 20040823 G 8550 ES48110 OIL FILTER PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA SNSNCH 74D 74DM EA ENGINE DEFECTIVE D O OTHER O OTHER NR NOT REPORTED 1 NM 01 53215 2842170 L1969739A A59565 THIS DEFECT WAS FOUND ON 100 HR INSP. HAD RUN AC TO ENSURE CORRECT OPER OF ENG AND AVIONICS, ENABLE OIL TO WARM UP. DR AINED OIL AND WENT TO REMOVE OIL FILTER. AS OIL FILTER CAME OFF, NOTICED THAT OIL FILTER THREADED STUD WAS STILL ENGAGE D AND TIGHT IN ENG SIDE OF OIL FILTER ADAPTOR. IT WAS NOT DIFFICULT TO REMOVE THREADED STUD FROM ENG. ONCE THREADED PO RTION HAD BEEN REMOVED, DRAINED OIL FILTER. OPENED OIL FILTER IN ORDER TO INSPECT FILTER ELEMENT. UPON REMOVAL OF FILT ER HSG, NOTED A DELAMINATION, SEPARATION OF FILTER ELEMENT AT CONNECTING POINT. NOTED THAT THERE WAS EXCESS POTTING COM POUND WITHIN OIL FILTER TO SECURE ELEMENT TO ELEMENT HSG. THIS COMPOUND WAS GOOPY/SOFT. 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 2004110200108 20041102 00108 CE 2004 11 2 2004FA0000828 1 20040622 G 3246 31571299124879 WHEEL CESSNA 560 560XL 2076702 CE PWA 545 PW545A NE MLG DAMAGED L O OTHER O OTHER NR NOT REPORTED 1 WP 25 OEGPA 4876 5605265 LDB545 AC WAS TOWED, WITH BRAKES RELEASED, WITHOUT ANY BRAKING ACTIVITIES BY PILOT, SHEARING NOISE WAS NOTED, TOWING PROCESS W AS STOPPED. HYD FLUID WAS SPILLED OUT FROM LT BRAKE UNIT. FIRST INVESTIGATION OF INSTALLED LT CARBON BRAKE UNIT DID S HOW, THAT ATTACHING SCREW FOR ONE INSERT ON WHEEL ASSY WAS SHEARED OFF, THEN LOOSE INSERT DAMAGED BRAKE UNIT. BRAKE FLU ID SPILLED FROM DAMAGED ACTUATING CYLINDERS, PISTONS. AS EACH INSERT IS ONLY FIXED BY ONE SCREW, INCASE OF A LOOSEN SCR EW CORRESPONDING INSERT WILL SHEAR OFF THIS SCREW. INSERT THEN MOVES OUT OF WHEEL AGAINST BRAKE UNIT. IN CASE OF THIS OCCURRENCE DURING TAKE OFF ROLL, AFTER TOUCH DOWN OR TAXI, UNCONTROLLED AND EVENTFUL BRAKE OUT WOULD BE FORSEEABLE. 2 L 7 2 4F 4 F RT A22CE E00059EN 2004102600142 20041026 00142 GL 2004 10 26 2004FA0000830 2 20040812 G 7230 230397911 ADAPTER ALLSN AGUSTA A109 A109 0260109 EU ALLSN 250C 250C20B 03013 GL NR 2 COMPRESSOR SHEARED D O OTHER O OTHER NR NOT REPORTED 1 EA 35 109WF 2961 CAC39323 7298 CAE834720 DURING FLIGHT PILOT HEARD MUFFLED BANG AND EXPERIENCED YAWING OF FUSELAGE WITH RELATED HIGH TOT INDICATION OF NR 2 ENG. ENGINE SHUT DOWN AND EMERGENCY LANDING CARRIED OUT. AC RECOVERED BY ROAD TO MAINT FACILITY. INVESTIGATION REVEALED MI NOR DEBRIS ON ACCESSORY GB, CHIP DETECTOR AND COMPRESSOR/ POWER TURBINE SPINS FREELY BY HAND BUT, WITH COMPRESSOR TURNIN G ACCESSORY DRIVES DO NOT ROTATE. ENG MODULES SEPARATED AND COMPRESSOR ADAPTOR FOUND SHEARED. ALERT BULLETIN HAS NOT B EEN COMPLIED WITH ON THIS ENGINE AND MFG MAY SET AN OPER TIME LIMIT. 1 G 7 2 3U 3 U H7EU E4CE 2004102600133 20041026 00133 SO 2004 10 26 2004FA0000831 1 20040923 G 2520 51023306 PLATE AMRGEN AG5B AG5B 3990100 SO LYC O360 O360A1D 41514 EA SEAT BELT MISINSTALLED D K NONE O OTHER IN INSP/MAINT 1 EA 09 400LM 10061 WHILE REPLACING REAR PASSENGER SEAT BELTS, IT WAS DISCOVERED THAT PN 51023306 REINFORCEMENT PLATE HAD BEEN INSTALLED ON FWD SIDE OF AFT SEAT BULKHEAD UNDER SEATBELT ATTACH BRACKET. THE -6 PLATE SHOULD HAVE BEEN INSTALLED ON AFT SIDE OF THE BULKHEAD IAW AGAG DRAWING 5102299. MS20364-1032 (THIN SHEER NUT) WAS USED TO SECURE THE AN3-5A RETAINING BOLTS. MS203 65-1032 OR MS21042-3 NUTS SHOULD HAVE BEEN INSTALLED AS CALLED OUT ON THE DRAWING. THIS RESULTS IN REDUCED SEATBELT ATT ACHMENT STRENGTH WHEN COMPARED WITH THE DESIGN CONFIGURATION. THIS AC APPEARED TO HAVE THE ORIGINAL SEATBELTS INSTALLED SO IT IS LIKELY THAT THIS IMPROPER INSTALLATION WAS ACCOMPLISHED DURING ASSEMBLY. (EA07200406183) 1 L 7 1 3O 3 O NT 1L71 E286 2004102600135 20041026 00135 2004 10 26 2004FA0000832 4 20040324 G 3461 4010455000101 DISPLAY DHAV DHC2 DHC2MK1 2800102 EA PWA R985 R985* 52008 NE INSTRUMT PANEL MALFUNCTIONED B O OTHER O OTHER NR NOT REPORTED 1 AL 05 62355 1045 FOLLOWING THE INSTALLATION OF THE EFIS-SV SYSTEM, THE SOFTWARE WAS LOADED ONTO A SMART MEDIA CARD AND THE SMART MEDIA CA RD WAS INSERTED INTO THE INTEGRATED DISPLAY UNIT (IDU). SEVERAL ATTEMPTS WERE MADE TO UPLOAD THE INFORMATION INTO THE S YSTEM. IT WAS DETERMINED THAT THE IDU WOULD NOT READ THE DATA FROM THE CARD, SO THE IDU WAS REPLACED AND THE SOFTWARE U PLOAD WAS COMPLETED SUCCESSFULLY. IDU SN 36244, MFG DATE CODE: 03328 1 H 7 1 3R 3 R A806 5E1 2004102700063 20041027 00063 SO 2004 10 27 2004FA0000833 1 20040331 G 3010 4010455000101 DISPLAY PIPER PA32 PA32300 7103212 SO LYC O540 TIO540* 41532 EA INSTRUMENT PANEL MALFUNCTIONED B O OTHER O OTHER NR NOT REPORTED 1 AL 05 15950 327340075 DURING THE INITIAL GROUND CALIBRATION FOR THE EFIS-SV, THE RT CONTROL KNOB OF THE INTEGRATED DISPLAY UNIT (IDU) WOULD NO T ENTER THE CORRECT DATA WHEN PUSHED. THE IDU WAS REPLACED AND THE CALIBRATION PROCEEDED NORMALLY. IDU SN 34410. 1 L 7 1 3O 3 O A3SO E14EA 2004102600161 20041026 00161 SO 2004 10 26 2004FA0000834 1 20040320 G 2497 CIRCUIT CARD CHELTON PIPER PA31 PA31350 7103110 SO LYC O540 TIO540* 41532 EA IDU MALFUNCTIONED B O OTHER O OTHER NR NOT REPORTED 1 AL 05 3590N 318052148 OPERATOR WAS IN PROCESS OF UPGRADING SOFTWARE FOR EFIS-SV SYSTEM IAW SB WSB IDU-III-6. THE NEW DATA WAS LOADED ONTO THE SMART MEDIA CARDS AND THE CARDS WERE THEN INSTALLED IN THE INTEGRATED DISPLAY UNITS (2EA). UPON INITIALIZATION OF THE SOFTWARE UPLOAD, THE ENTIRE SYSTEM MALFUNCTIONED AND COULD NOT BE REINITIALIZED. THE AC WAS GROUNDED. AFTER SEVERAL UN SUCCESSFUL ATTEMPTS TO RELOAD THE UPGRADE ONTO THE CARDS AND THEN UPLOAD THE INFORMATION INTO THE SYSTEM, THE SMART MEDI A CARDS WERE REPLACED WITH NEW, THE INFORMATION DOWN LOADED ONTO THE CARDS, AND THE SYSTEM SUCCESSFULLY REBOOTED AND FUN CTIONED PROPERLY. 1 L 7 2 3O 3 O A20SO E14EA 2004110300135 20041103 00135 2004 11 3 2004FA0000835 4 20040314 G 2330 CIRCUIT CARD CESSNA 180 180J 2072622 CE CONT O470 IO470* 17026 SO DISPLAY MALFUNCTIONED D O OTHER O OTHER NR NOT REPORTED 1 AL 05 7687K 18052703 THE OPERATOR WAS IN THE PROCESS OF UPGRADING THE SOFTWARE FOR THE EFIS-SV SYSTEM IAW SB WSB IDU-III-6. THE NEW DATA WAS LOADED ONTO THE SMART MEDIA CARDS AND THE CARDS WERE THEN INSTALLED IN THE INTEGRATED DISPLAY UNITS (2 EA.) UPON INITI ALIZATION OF THE SOFTWARE UPLOAD, THE ENTIRE SYSTEM MALFUNCTIONED AND COULD NOT BE REINITIALIZED. THE AIRCRAFT WAS GRO UNDED. AFTER SEVERAL UNSUCCESSFUL ATTEMPTS TO RELOAD THE UPGRADE ONTO THE CARDS AND THEN UPLOAD THE INFORMATION INTO TH E SYSTEM, THE SMART MEDIA CARDS WERE REPLACED WITH NEW, THE INFORMATION DOWNLOADED ONTO THE CARDS, AND THE SYSTEM SUCCES SFULLY REBOOTED AND FUNCTIONED PROPERLY. 1 H 7 1 3O 3 O 5A6 E1CE 2004102700062 20041027 00062 2004 10 27 2004FA0000836 4 20040329 G 3457 84100020301 RECEIVER PIPER PA32 PA32300 7103212 SO LYC O540 IO540* 41532 EA GPS/WAAS MALFUNCTIONED D O OTHER O OTHER NR NOT REPORTED 1 AL 05 8127K 30 327940268 THIS RECEIVER WAS INSTALLED AS PART OF THE EFIS-SV SYSTEM. AFTER APPROXIMATELY 30 HOURS OF OPERATION FOLLOWING THE INST ALLATION, AN LOI MESSAGE DISPLAYED ON THE INTEGRATED DISPLAY UNIT (IDU). THE RECEIVER WAS REPLACED, AND THE ERROR MESSA GE WAS NO LONGER DISPLAYED, AND THE SYSTEM FUNCTIONED NORMALLY. GPS/WAAS RECEIVER, SN 4048218. 1 L 7 1 3O 3 O A3SO 1E4 2004102700085 20041027 00085 EA 2004 10 27 2004FA0000837 2 20040916 G 7322 30804 FLOAT AMRGEN AA1 AA1A 0630710 SO LYC O235 O235K2C 41505 EA CARBURETOR DAMAGED D O OTHER O OTHER NR NOT REPORTED 1 SO 05 9253L 200 AA1A0153 L1051215 ENGINE STALLED WHILE AIRCRAFT WAS ON FINAL APPROACH. DURING TEST RUN, ENGINE PERFORMED NORMALLY DURING RUN UP CHECK, ID LE CHECK AND MIXTURE CHECK AT 1000 RPM. HOWEVER, WHEN THE ENGINE LT AT IDLE (650 RPM) THE ENGINE WOULD BEGIN TO RUN RIC H, LOPE AND QUIT RUNNING AFTER ABOUT 1 TO 2 MINUTES. THE CARBURETOR WAS REMOVED AND INSPECTED. ONE HALF OF THE FLOAT, WHICH IS MADE OF HOLLOW PLASTIC, WAS FILLED WITH FUEL. 1 L 7 1 3O 3 O A11EA E223 2004102700086 20041027 00086 CE 2004 10 27 2004FA0000838 1 20041014 G 5711 58221661 SPAR CAP CESSNA 404 404 2075901 CE WING CORRODED B AK6R O OTHER O OTHER NR NOT REPORTED 1 SW 19 677MF 8000 4040421 DURING OUR INITIAL INSPECTION OF THIS AIRCRAFT, DISCOVERED SEVERE INTERGARNULAR CORROSION ON UPPER AND LOWER REAR SPAR C APS. THE AREA OF CORROSION IS LOCATED INSIDE THE MAIN GEAR WELL ON BOTH LEFT AND RIGHT WINGS. NOTE: AIRCRAFT IS OPERA TED IN A SALT AIR ENVIRONMENT FOR THE LAST YEAR. 1 L 7 2 3O RT A25CE 2004102700088 20041027 00088 CE 2004 10 27 2004FA0000839 1 20041014 G 5711 58221664 SPAR CAP CESSNA 404 404 2075901 CE WING CORRODED B AK6R O OTHER O OTHER NR NOT REPORTED 1 SW 19 677MF 8000 4040421 DURING OUR INITIAL INSPECTION OF THIS AIRCRAFT, DISCOVERED SEVERE INTERGRANULAR CORROSION ON UPPER AND LOWER REAR SPAR C APS. THE AREA OF CORROSION IS LOCATED INSIDE THE MAIN GEAR WELL ON BOTH LEFT AND RT WINGS. NOTE: THIS AIRCRAFT IS OPE RATED IN A SALT AIR ENVIRONMENT FOR THE LAST YEAR. 1 L 7 2 3O RT A25CE 2004102700087 20041027 00087 SO 2004 10 27 2004FA0000840 2 20040707 G 7414 DISTRIBUTOR BLK CESSNA 185 A185F 2072821 CE CONT O520 IO520* 17032 SO MAGNETO BURNED D O OTHER O OTHER NR NOT REPORTED 1 WP 25 24FG 01062608 18504207 ON 5/20/2004 THIS MAGNETO WAS REMOVED, PILOT REPORTED ROUGH ENGINE OPERATION AT ALTITUDES OF 8,000 FT OR HIGHER. PILOT ISOLATED MISFIRING MAGNETO. MAGNETO APPEARED TO BE FUNCTIONING NORMALLY ON GROUND AT SEA LEVEL AND INFLIGHT AT LOWER AL TITUDES. MAGNETO DISASSEMBLED. DIST BLOCK AND GEAR ASSY WERE SEVERELY BURNED AND MELTED. THE CARBON BRUSH WAS GONE, A N THE HIGH TENSION LEAD AREA OF THE COIL WAS BURNED. DUE TO SEVERAL FACTORS: INTERNAL ROUGHNESS OF HOLE IN SHAFT WERE C ARBON BRUSH RIDES, CARBON BRUSHES MFG OF TOO SOFT COMPOUND AND CARBON BUILDUP WHICH CAUSES SHORT. 1 H 7 1 3O 3 O 3A24 E5CE 2004102600144 20041026 00144 SW 2004 10 26 2004FA0000841 1 20041021 G 7603 269A84601 BRACKET HUGHES 269 269C1 8059504 SW LYC O360 HO360* 41514 EA THROTTLE CRACKED B O OTHER O OTHER NR NOT REPORTED 1 WP 27 614TV 2658 35 0035 A STUDENT NOTICED ON PRE-FLIGHT, A CRACK ON THE THROTTLE BELLCRANK SUPPORT BRACKET, (PN 269A8460-1) MOUNTED TO THE CARBU RETOR. THE CRACK WAS LOCATED JUST BELOW THE THROTTLE CONTROL BELLCRANK ATTACH LUG AND WAS NOTICEABLE UPON APPLYING LATER AL PRESSURE TO A LINKAGE TO WHICH THE THROTTLE BELLCRANK IS ATTACHED. THE CRACK WAS APPROX. AROUND 75 PERCENT OF THE WEB . 1 G 7 1 3O 3 O O 4H12 E286 2004102700078 20041027 00078 SW 2004 10 27 2004FA0000842 1 20041021 G 7603 269A84601 BRACKET HUGHES 269 269C1 8059504 SW LYC O360 HO360* 41514 EA THROTTLE CRACKED B O OTHER O OTHER NR NOT REPORTED 1 WP 27 614TV 2658 35 0035 A STUDENT NOTICED ON PRE-FLIGHT A CRACK ON THE THROTTLE BELLCRANK SUPPORT BRACKET, (PN 269A8460-1)MOUNTED TO THE CARBURE TOR. THE CRACK WAS LOCATED JUST BELOW THE THROTTLE CONTROL BELLCRANK ATTACH LUG AND WAS NOTICEABLE UPON APPLYING LATERAL PRESSURE TO A LINKAGE TO WHICH THE THROTTLE BELLCRANK IS ATTACHED. THE CRACK WAS APPROX. AROUND 75 PERCENT OF THE WEB. 1 G 7 1 3O 3 O O 4H12 E286 2004102700079 20041027 00079 CE 2004 10 27 2004FA0000843 1 20041022 G 1410 62402312D0463 HOSE BEECH 90 E90 1152914 CE PWA PT6 PT6A28 EA OIL COOLER DETERIORATED G A UNSCHED LANDING F FLT CONT AFFECTED CL CLIMB 1 GL 15 3741M 7 LW342 DURING CLIMB OUT, OIL PRESSURE ON BOTH ENGINES DROPPED TO APPROXIMATELY 50 PSI WITH SLIGHT SURGING. AUTOFEATHER WAS ENG AGED AT THE TIME. MAINTENANCE FACILITY DISCOVERED THAT BOTH OIL COOLER LONG LINES WERE DETERIORATING INTERNALLY. THE HO SES ARE AEROQUIP HOSES PART NUMBER 033 624023-12D0463. THIS BATCH OF HOSE WAS PRODUCED IN THE 3RD QUARTER OF 2004 AS IN DICATED ON THE DATA TAG. THE HOSES HAD APPROXIMATELY 7 HOURS USE PRIOR TO FAILURE. 1 L 7 2 3T 4 T 3A20 E4EA 2004102700083 20041027 00083 2004 10 27 2004FA0000844 4 20041020 G 2562 ELT CIRRUS SR SR22 2130001 GL CONT O550 IO550* SO CAIBN INCORRECT G K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 05 521JL 0877 DURING A RECENT INSPECTION OF A NEW AC IT WAS NOTED THAT THE ELT SWITCH WAS IN THE OFF POSITION FROM THE MANUFACTURE, UP ON FURTHER INVESTIGATION THE PILOT RECEIVED THE AIRCRAFT FROM THE FACTORY AND WAS NOT INFORMED THAT THE SWITCH WAS OFF D URING HIS FLY-OFF FROM THE FACTORY. 1 L 7 1 3O 3 O NT A00009CH E3SO 2004111000083 20041110 00083 SO 2004 11 10 2004FA0000845 1 20041018 G 2701 6271607 SHAFT PIPER PIPER PA28 PA28R201T 7102813 SO CONT O360 TSIO360F 17025 SO CONTROL COLUMN MISMANUFACTURED D K NONE O OTHER IN INSP/MAINT 1 NM 03 43761 6806 28R7703310 DURING 100 HOUR INSP AT 1V5, LT CONTROL COLUMN, P/N 62834-02, WAS REMOVED FOR REPLACEMENT DUE TO EXCESS PLAY. UPON REMOV AL, CONTROL COLUMN SHAFT, P/N 62716-02, WAS FOUND TO BE DRILLED (FOR AN-386-1-6A TAPER PIN) LESS THAN 0.025 INCH FROM AF T END OF SHAFT. HOLE IS SO CLOSE TO END THAT SHAFT WAS DEFORMED APPROX. .125 INCH BY TAPER PIN. FWD END OF SHAFT WAS IN SERTED APPROX 0.20 INCH BEYOND THE END OF SPROCKET, P/N 62839-00, AND TAPER PIN HOLE IS APPROX. 0.35 INCH FROM FWD END O F SHAFT. REPLACEMENT UNIVERSAL, PMA, P/N CA62834-802, HAS A WITNESS HOLE TO ENSURE SHAFT IS FULLY INSERTED BEFORE DRILL ING. INSPECT SHAFT TO DETERMINE AMOUNT OF PENETRATION, THROUGH SPROCKET, REPLACE SHAFT IF IT PROJECTS BEYOND SPROCKET. 1 L 7 1 3O 3 O 2A13 E9CE 2004111000084 20041110 00084 SO 2004 11 10 2004FA0000846 1 20041018 G 2701 6271607 SHAFT PIPER PIPER PA28 PA28R201T 7102813 SO CONT O360 TSIO360F 17025 SO CONTROL COLUMN MISMANUFACTURED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 03 43761 6806 28R7703310 DURING 100 HR INSP AT 1V5, LT CONTOL COLUMN UNIVERSAL,P/N 62834-02, WAS REMOVED FOR REPLACEMENT DUE TO EXCESS PLAY. CON TROL COLUMN SHAFT, P/N 62716-02, WAS FOUND TO BE DRILLED (FOR THE AN-386-1-6A TAPER PIN) LESS THAN 0.025 INCH FROM AFT E ND OF SHAFT. HOLE IS SO CLOSE TO END THAT SHAFT WAS DEFORMED APPROX .125 INCH BY TAPER PIN. FWD END OF SHAFT WAS INSER TED APPROX 0.20 INCH BEYOND END OF SPROCKET, P/N 62839-00, TAPER PIN HOLE IS APPROX. 0.35 INCH FROM FWD END OF SHAFT. R EPLACEMENT UNIVERSAL, PMA PRODUCTS P/N CA62834-802, HAS A WITNESS HOLE TO ENSURE SHAFT IS FULLY INSERTED BEFORE DRILLING . OPS INSPECT SHAFT TO DETERMINE AMT OF PENETRATION, THROUGH SPROCKET, REPLACE SHAFT IF IT PROJECTS BEYOND SPROCKET. 1 L 7 1 3O 3 O 2A13 E9CE 2004110300005 20041103 00005 SO 2004 11 3 2004FA0000847 1 20040826 G 2750 82905003 BELLCRANK PIPER PA46 PA46350P 7104602 SO TE FLAP SHEARED D O OTHER O OTHER NR NOT REPORTED 1 SW 99 77PK 2538 4622089 RT IB FLAP BELLCRANK SHAFT SHEARED ON APPROACH FOR LANDING CAUSING ASYMMETRICAL FLAP CONDITION. BELLCRANK SHOWED SIGNS OF BEING CRACKED FOR A LONG TIME. FLAP SYSTEM WAS WAY OUT OF RIG. OUT OF RIG PROBLEM CAUSED BY TWISTING OF BELLCRANK S HAFT AND FURTHER ADJUSTMENTS OF ROD END CAUSING UNDUE LOAD. 1 L 7 1 3O RT A25SO 2004110300033 20041103 00033 CE 2004 11 3 2004FA0000848 1 20040916 G 3222 67420861 CAP CESSNA 750 750 2076810 CE ALLSN AE3007 AE3007C GL STRUT UNSCREWED B A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CE 07 953QS 3350 7500153 AT FLIGHT LEVEL 390, THE AIRCRAFT EXPERIENCED A JOLT AND THE LANDING GEAR UNLOCK LIGHT ILLUMINATED. THE PROBLEM WAS CAU SED BY THE NOSE LANDING GEAR DROPPING OUT OF THE UPLOCK HOOK. IT WAS DETERMINED THAT THE NOSE GEAR STRUT WAS OVER EXTEN DED. THE NOSE GEAR WAS DISASSEMBLED AND THE LOWER ORIFICE CAP WAS FOUND TO BE PARTIALLY UNSCREWED. THE SAME PROBLEM HA S OCCURRED ON OTHER AIRCRAFT OF THIS MODEL. 2 L 7 2 4J 4 F RT T00007WI TE6CH 2004110300109 20041103 00109 GL 2004 11 3 2004FA0000849 2 20041018 G 7250 689967 TURBINE WHEEL BELL 206 206B 1181511 SW ALLSN 250C 250C20J 03013 GL ENGINE FAILED D E ENGINE SHUTDOWN T J ENGINE CASE PENETRATION WARNING INDICATION NR NOT REPORTED 1 SW 09 54GL 490 4068 CAE270452 DURING GROUND RUN, AFTER SCHEDULED TURBINE REPLACEMENT, LEAK CHECKS HAD BEEN COMPLETED AT IDLE POWER. WHILE ADDING POWE R, AT ABOUT 85 PERCENT N2 THE NR 3 TURBINE WHEEL EXPERIENCED AN UNCONTAINED FAILUE DESTROYING THE ENGINE AS WELL AS DAMA GING THE COWLING, ROTOR BLADES, AND ENGINE PAN AND STRUCTURE. THE CAUSE IS UNDER INVESTIGATION BY MFG. 1 G 7 1 3U 3 U H2SW E4CE 2004110300110 20041103 00110 GL 2004 11 3 2004FA0000850 2 20041018 G 7250 689967 TURBINE WHEEL BELL 206 206B 1181511 SW ALLSN 250C 250C20J 03013 GL ENGINE FAILED D E ENGINE SHUTDOWN T J ENGINE CASE PENETRATION WARNING INDICATION IN INSP/MAINT 1 SW 09 54GL 490 4068 CAE270452 DURING GROUND RUN, AFTER SCHEDULED TURBINE REPLACEMENT, LEAK CHECKS HAD BEEN COMPLETED AT IDLE POWER. WHILE ADDING POWE R, AT ABOUT 85 PERCENT N2 THE NR3 TURBINE WHEEL EXPERIENCED AN UNCONTAINED FAILURE DESTROYING THE ENGINE AS WELL AS DAMA GING THE COWLING, ROTOR BLADES, AND ENGINE PAN AND STRUCTURE. THE CAUSE IS UNDER INVESTIGATION BY MFG. 1 G 7 1 3U 3 U H2SW E4CE 2004111000077 20041110 00077 CE 2004 11 10 2004FA0000851 1 20040923 G 5610 WINDSCREEN CESSNA 560 560XL 2076702 CE PWA 545 PW545A NE COCKPIT DISTORTED C O OTHER O OTHER NR NOT REPORTED 1 SW 99 5368 ON DELIVERY OF A NEW AIRCRAFT, DAY ACCEPTANCE CHECK CARRIED OUT AND AIRCRAFT ACCEPTED. DURING NIGHT FLYING LT WINDSCREEN OBSERVED TO HAVE PARALLAX DISTORTION ERROR. DAY TESTS CARRIED OUT OF GRID TEST AND WATER TEST. WINDSCREEN CERTIFIED SE RVICEABLE BY VENDOR AND MFG ENGINEERS. PILOTS INSISTED CHECK BE CARRIED OUT AT NIGHT BY TEST PILOT WHO CONFIRMED DEFECT. WINDSCREEN CHANGED. PRESENT DAY TESTS ONLY FOR WINDSCREEN PARALLAX AND DISTORTIONS INADEQUATE TO DETECT THESE FLAWS W HICH CAN ONLY BE DETECTED AT NIGHT. MFG INDICATES THIS IS THE FIRST CASE DETECTED. SINCE THE PRESENT DAY TESTS ONLY CANN OT DETECT THIS FLAW/DEFECT MANY AIRCRAFT MUST BE FLYING WITH THIS DEFECT. 2 L 7 2 4F 4 F RT A22CE E00059EN 2004120700173 20041207 00173 CE 2004 12 7 2004FA0000852 1 20040923 G 5610 WINDSCREEN CESSNA 560 560XL 2076702 CE COCKPIT DISTORTED C O OTHER O OTHER NR NOT REPORTED 1 SW 99 10 5368 ON DELIVERY OF NEW A/C, DAY ACCEPTANCE CHECK CARRIED OUT AND A/C ACCEPTED. DURING NIGHT FLYING LT WINDSCREEN OBSERVED TO HAVE PARALLAX DISTORTION ERROR. DAY TESTS CARRIED OUT OF GRID TEST AND WATER TEST. WINDSCREEN CERTIFIED SERVICEABLE BY VENDOR & MANUFACTURERS ENGINEERS. PILOTS INSISTED CHECK BE CARRIED OUT AT NIGHT BY TEST PILOT, OVERRIDING INSISTENCE BY ENGINEERS ON WINDSCREEN HAVING NO DEFECT & BEING SERVICEABLE. TEST PILOT CONFIRMED DEFECT. WINDSCREEN CHANGED.PRESENT D AY TESTS ONLY FOR WINDSCREEN PARALLAX & DISTORTIONS INADEQUATE TO DETECT THESE FLAWS WHICH CAN ONLY BE DETECTED AT NIGH T. CESSNA INDICATES THIS IS THE FIRST CASE DETECTED. SINCE THE PRESENT DAY TESTS ONLY CANNOT DETECT THIS FLAW/DE 2 L 7 2 4F RT A22CE 2004111000082 20041110 00082 CE 2004 11 10 2004FA0000853 1 20040709 G 3220 08421211 ROD END CESSNA 310 T310Q 2074244 CE NLG BROKEN C O OTHER O OTHER NR NOT REPORTED 1 SW 05 27KC 310Q1134 THE AIRCRAFT DEPARTED. A LARGE NOISE WAS HEARD, COULD NOT EXTEND NOSE GEAR. LANDED WITH AN UNSAFE NOSE GEAR UP, NOSE G EAR COLLAPSED ON LANDING CAUSING DAMAGE. THE ROD END FAILED ON TUBE ASSY. NOTE: THIS IS A COMMON PROBLEM ON THE AK. (SW05200408481) 1 L 7 2 3O 3A10 2004111000076 20041110 00076 NE 2004 11 10 2004FA0000855 1 20041029 G 2910 LINE CONAER LA4 LA4200 5110310 NE LYC O360 IO360A1B 41514 EA HARTZL HCC2Y HCC2YK1 GL HYD SYSTEM CRACKED D A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CR CRUISE 1 EA 25 6691L 454 L747351A DURING FLT, HYD PUMP STARTED TO CYCLE ABNORMALLY. IDENTIFIED HYDRAULIC PRESSURE LOSS TO LANDING GEAR RETRACT CIRCUIT AN D ISOLATED WITH LDG GEAR SELECTOR. GEAR EXTENDED FOR LANDING NORMALLY. DURING POST INSPECTION FOR LEAK, LOCATED HYD TUBE AT AFT BULKHEAD STATION 126, CRACKED .5 INCHES FROM FITTING. LINES WERE BUNDLED TOGETHER WITHOUT PROPER SUPPORT OR SEPA RATION AT FITTINGS. REMOVED FLOOR BOARDS AND ALSO FOUND BROKEN AND INADEQUATE SUPPORT ALLOWING LINES TO VIBRATE AND CHAF E. SECURED ALL LINES AND PROVIDED SEPARATION AT FITTINGS. LOGBOOK INDICATED PREVIOUS HYD TUBE FAILURE ON RT SIDE OF AIR CRAFT. 1 H 7 1 3O 3 O 1A13 1E10 5 C P920 2005030800113 20050308 00113 SW 2005 3 8 2004FA0000858 1 20040827 G 5320 35011007 ANGLE MOONEY M20 M20C 5870208 SW LYC O360 O360* 41514 EA FUSELAGE CORRODED B MYNR K NONE O OTHER IN INSP/MAINT 1 GL 11 6832V 7144 201162 CROSS MEMBER AT STA 103, SUPPORT RUDDER, ELEVATOR PUSH ROD HANGER AND SUPPORTS A HANGER FOR TAIL TRIM TUBE. (GL11200413 706) 1 L 7 1 3O 3 O 2A3 E286 2005030800114 20050308 00114 CE 2005 3 8 2004FA0000859 1 20040827 G 2460 CIRCUIT BREAKER CESSNA 182 T182T 2072738 CE LYC O540 TIO540* 41532 EA ELECTRICAL SYS MISINSTALLED B RSUR K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 21 5107Y T18208099 GPS CIRCUIT BREAKER IS PROVIDING POWER TO MULTIPLE UNITS WHICH IS CONTRARY TO AC20-138A. AC20-138 STATES THAT GPS CIRCU IT BREAKER CAN ONLY POWER GPS. REFERENCE ATTACHED DRAWINGS FROM MFG WIRING DIAGRAM MANUAL. PAGES 34-20-00-01 AND 34-52 -03-01. 1 H 7 1 3O 3 O NT 3A13 E14EA 2004112900164 20041129 00164 2004 11 29 2004FA0000860 4 20040928 G 6113 055032111 BULKHEAD CESSNA 172 172S 2072439 CE PROP SPINNER CRACKED B WIWR O OTHER O OTHER NR NOT REPORTED 1 WP 07 3512T 172S8883 PILOTS REPORTED AFT SPINNER BULKHEAD CRACKED AND SPINNER DOME BENT UP SLIGHTLY. UPON INSPECTION CORNER NUTPLATE FOUND C OMPLETELY BROKEN OFF BULKHEAD. 1 H 7 1 3O NT 3A12 2004111000057 20041110 00057 CE 2004 11 10 2004FA0000861 1 20041031 G 2497 WIRE CESSNA CESSNA 206 206H 2073301 CE LYC O540 IO540AC1A5 EA ALTERNATOR BURNED D D RETURN TO BLOCK H ELECT. POWER LOSS-50 PC TX TAXI/GRND HDL 1 CE 03 21076 332 A173381 20608213 PILOT REPORTED AN ALTERNATOR FAILURE. REMOVED ENGINE COWLING AND FOUND THE POWER WIRE AND THE GROUND WIRE FOR THE ALTER NATOR WERE BROKEN IN HALF ABOUT 3 INCHES FROM THE TERMINALS ON THE ALTERNATOR. THE ENDS OF BOTH WIRES WERE MELTED, SUSP ECTED FROM ARCING. UPON FURTHER INSPECTION, FOUND THE GROUND WIRE TERMINAL STUD WAS BROKEN OFF THE BACK OF THE ALTERNAT OR. WE SUSPECT THE WIRES BROKE BECAUSE OF THE SHARP BEND RADIUS THE WIRES ARE SUBJECTED TO BETWEEN THE ENGINE BAFFLING AND THE ALTERNATOR. 1 H 7 1 3O 3 O RT A4CE 1E4 2004112900037 20041129 00037 NE 2004 11 29 2004FA0000862 2 20040913 G 7320 660526AS TRANSDUCER DHAV DHC2 DHC2MK1 2800102 EA PWA R985 R985AN14B 52008 NE FUEL FLOW MALFUNCTIONED B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 37756 634 2679 1456 2679 REMOVED FUEL FLOW TRANSDUCER PN 660526AS INSTALLED UNDER STC NR SA809GL. UNIT PROVIDING ERRONEOUS FUEL FLOW READINGS AN D CAUSING THE AIR DATA COMPUTER (ADC) ALSO INSTALLED IN THE AIRCRAFT TO FUNCTION IMPROPERLY. AIR DATA COMPUTER INSTALLE D UNDER FLIGHT SYSTEMS EFIS-SV SYSTEM IAW STC NR SA02203AK. 1 H 7 1 3R 3 R A806 5E1 2004112900059 20041129 00059 NE 2004 11 29 2004FA0000863 2 20040913 G 7320 660526AS TRANSDUCER DHAV DHC2 DHC2MK1 2800102 EA PWA R985 R985AN14B 52008 NE FUEL FLOW MALFUNCTIONED B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 67676 601 2680 809 2680 REMOVED FUEL FLOW TRANSDUCER INSTALLED UNDER STC NR SA809GL. UNIT PROVIDING ERRONEOUS FUEL FLOW READINGS AND CAUSING TH E AIR DATA COMPUTER (ADC) ALSO INSTALLED IN THE AIRCRAFT TO FUNCTION IMPROPERLY. AIR DATA COMPUTER INSTALLED, EFIS-SV S YSTEM IAW STC NR SA02206AK. 1 H 7 1 3R 3 R A806 5E1 2004112900079 20041129 00079 NE 2004 11 29 2004FA0000864 2 20040913 G 7320 660526AS TRANSDUCER DHAV DHC2 DHC2MK1 2800102 EA PWA R985 R985AN14B 52008 NE FUEL FLOW MALFUNCTIONED B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 68010 362 2681 1243 2681 REMOVED FUEL FLOW TRANSDUCER, INSTALLED UNDER STC NR SA809GL. UNIT PROVIDING ERRONEOUS FUEL FLOW READINGS AND CAUSING T HE AIR DATA COMPUTER (ADC) ALSO INSTALLED INT THE AIRCRAFT TO FUNCTION IMPROPERLY. AIR DATA COMPURTER (ADC) INSTALLED, EFIS-SV SYSTEM IAW STC NR SA02203AK. 1 H 7 1 3R 3 R A806 5E1 2005022300003 20050223 00003 EA 2005 2 23 2004FA0000870 1 20040730 G 5320 601R35031239 ANGLE CNDAIR CL600 CL6002B19 1900309 EA FUSELAGE CRACKED B O OTHER O OTHER NR NOT REPORTED 1 EA 09 935SW 7725 FLOOR SUPPORT ANGLE AT FS 621, WL 73 OUTBOARD OF LBL AND RBL 27 CRACKED. REPAIR IAW BOMBARDIER AEROSPACE EO NR 601R-53- 61-117. 2 L 7 2 4F RT A21EA 2005022300001 20050223 00001 CE 2005 2 23 2004FA0000871 1 20040801 G 2730 6565007197CR BRIDAL CABLE CESSNA 500 560CESSNA 2076750 CE ELEVATOR FRAYED B O OTHER O OTHER NR NOT REPORTED 1 SO 05 5600028 ELEVATOR AUTO PILOT BRIDAL CABLE FRAYED TO THE POINT OF LOCKING UP CONTROL. DURING LOCATING CONTROL BLOCKAGE CABLE BROK E COMPLETELY INTO AT THE SUPPORT GUIDE PULLEYS. PRE-SB 560-27-07. 2 L 7 2 4F RT A22CE 2005022300002 20050223 00002 CE 2005 2 23 2004FA0000872 1 20040809 G 3240 6242020519 BRAKE CESSNA 650 650 2076802 CE MLG OUT OF ADJUST I A UNSCHED LANDING E VIBRATION/BUFFET DE DESCENT 1 GL 13 260VP 6500190 ON DEPARTURE FROM MKE, CREW NOTED A SHIMMY IN THE NOSE WHEEL AND ABORTED TAKEOFF. INSPECTION FOUND NOSE GEAR FRICTION B RAKE DRAG LOW. ADJUSTED FRICTION BRAKE PER CE650 MM. COMPLETED HIGH SPEED (100 KTS) TAXI CHECK WITH NO SHIMMY EVIDENT. RELEASED AIRCRAFT FOR SERVICE. (M) 2 L 7 2 4F A9NM 2005012700065 20050127 00065 GL 2005 1 27 2004FA0000873 1 20040922 G 2810 FUEL CELL AMTR CHALGR CHALLENGERII 05624JT GL MISMANUFACTURED G A UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 SO 13 2079S 13 CH22017 DURING CRUISE FLIGHT, THE ROTAX ENGINE EXPERIENCED POWER LOSS AND PILOT PERFORMED EMERGENCY LANDING. AIRCRAFT SUSTAINED SUBSTANTIAL DAMAGE AND PILOT WAS SERIOUSLY INJURED. SUBSEQUENT INVESTIGATION REVEALED THAT WATER WAS IN BOTH CARBURETO R FUEL BOWLS, THE FUEL FILTER AND THE FUEL TANK. DISCOVERED THAT THE 10 GALLON PLASTIC FUEL TANK HAD A LOW POINT MOLDED INTO IT FOR COLLECTION OF WATER AND DEBRIS, HOWEVER THERE WAS NO FUEL DRAIN VALVE IN ORDER TO SUMP THE TANK. 1 H 7 1 3I NT EXPA1H71 2004121300001 20041213 00001 SO 2004 12 13 2004FA0000874 2 20041006 G 7414 IMPULSE COUPLING PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360EB 17025 SO MAGNETO MISSING B K NONE O OTHER IN INSP/MAINT 1 SO 06 6935C 1225 1225 D02HA094R 347870167 807783R WHILE PERFORMING AD 96-12-07, THE MECHANIC NOTICED THAT THE STOP PIN FOR THE IMPULSE COUPLING WAS MISSING. INSPECTED TH E ACCESSORY SECTION AND FOUND THE PIN WEDGED BETWEEN THE CRANK CASE AND A GEAR. REMOVED THE PIN, NO FURTHER DAMAGE WAS FOUND. 1 L 7 2 3O 3 O A7SO E9CE 2005022300179 20050223 00179 NM 2005 2 23 2004FA0000876 1 20040719 G 6220 900R2101006107 ROTOR HEAD DOUG DOUG MD900 MD900 3027375 NM PWC PW207 PW207E NE MAIN ROTOR CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 11 3PD 91 91 0099990080 9000085 DURING ACCOMPLISHMENT OF AD 2002-10-05, "MAIN ROTOR UPPER HUB INSP", FOUND (2) OUT OF (10) HOLES CRACKED IN UPPER HUB FL ANGE AS DEPICTED IN MD HELICOPTERS SERVICE BULLETIN 900-072 PART TOTAL TIME: 91.23 HRS. 1 G 7 2 3U 3 U NC H19NM E42NE 2005022300178 20050223 00178 NM 2005 2 23 2004FA0000877 1 20041012 G 6220 ROTOR HEAD DOUG MD900 MD900 3027375 NM PWC PW207 PW207E NE MAIN ROTOR CRACKED D O OTHER E VIBRATION/BUFFET HO HOVERING 1 EA 11 3PD 1478 HAD VIBRATION (.7 IPS) CAUTION ON IDS DURING FLIGHT AND HIGH VIBRATION ON SHUT DOWN BETWEEN 30-40 PERCENT NR. INSPECTED MAIN ROTOR SYSTEM IAW MAINTENANCE MANUAL AND FOUND (3) OUT OF (5) FLEXBEAMS CRACKED. REPLACING FLEXBEAMS WITH NEW UPDA TED FLEXBEAMS. 1 G 7 2 3U 3 U NC H19NM E42NE 2005022300167 20050223 00167 GL 2005 2 23 2004FA0000878 1 20041008 G 3213 AXLE AMTR ZENITH ZENITHCH701 05611WI GL ROTAX 912 ROTAX912UL EU WHEEL ASSEMBLY SEPARATED C O OTHER O OTHER NR NOT REPORTED 1 CE 07 701TD 68 66 73993 4403395 LEFT MAIN AXLE SEPARATED FROM BACKING PLATE AT LANDING CAUSING MAIN SPRING TO DIG IN, WHICH CAUSED THE PLANE TO NOSE OVE R. INSPECTION OF THE AXLE ASSEMBLY REVEALED VERY LITTLE WELD PENETRATION AND THE WHOLE DESIGN WAS VERY INADEQUATE FOR T HE TYPE OF OPERATIONS THAT THIS GEAR ASSEMBLY MARKETED TO. 1 H 7 1 3I 3 O NT EXPA1H71 EXPE3I 2004120600080 20041206 00080 SO 2004 12 6 2004FA0000879 1 20040809 G 8011 MZ6222 STARTER PIPER PA32 PA32300 7103212 SO LYC O540 IO540J4A5 41532 EA ENGINE INTERMITTENT B O OTHER O OTHER TX TAXI/GRND HDL 1 SO 05 833WC 330 330 327640059 L319548 UPON ENGINE START UP, PILOT WENT TO ENGAGE STARTER, STARTER DID NOT ENGAGE. INVESTIGATED STARTER AND FOUND STARTER BEND IX WOULD NOT ENGAGE. SUSPECT FAULTY BENDIX. 1 L 7 1 3O 3 O A3SO 1E4 2004120600085 20041206 00085 EA 2004 12 6 2004FA0000880 2 20040802 G 8520 LW11033 CRANKCASE PIPER PA32 PA32260 7103206 SO LYC O540 O540E4B5 41532 EA ENGINE DAMAGED G B A EMER. DESCENT UNSCHED LANDING E M R VIBRATION/BUFFET OVER TEMP PARTIAL RPM/PWR LOSS CL CLIMB 1 NM 04 3542W 77 32428 L1204540 WHILE CLIMBING OUT FROM RAWLINS, WY ON A FLIGHT TO HOLLISTER, CA., THE ENGINE STARTED TO RUN ROUGH AND THE PILOT NOTICED THAT THE OIL TEMPERATURE WAS RED LINED. THE PILOT RETURNED TO THE AIRPORT FOR EMERGENCY LANDING UNDER PARTIAL ENGINE P OWER. THE AIRCRAFT LANDED WITHOUT FURTHER INCIDENT. THE ENGINE WAS INSPECTED FOR THE ROUGH RUNNING AND IT WAS FOUND TH AT THE CRANKCASE WAS DAMAGED BY THE CRANKSHAFT AT THE REAR OF THE FRONT THRUST BEARING AREA. 1 L 7 1 3O 3 O A3SO E295 2004120600105 20041206 00105 EA 2004 12 6 2004FA0000881 2 20040805 G 8550 29A21372 DRIVE ASSY PIPER PA32 PA32R301T 7103220 SO LYC O540 TIO540* 41532 EA SCAV PUMP LEAKING B O OTHER K FLUID LOSS NR NOT REPORTED 1 CA 325PA 396 3257237 L1096861A PILOT REPORTED OIL LEAKING FROM ENGINE. THE DRIVE ASSEMBLY FOR THE TURBO SCAVENGE PUMP WAS FOUND LEAKING. THE PUMP WAS REMOVED FROM THE ENGINE, REPAIRED AND REINSTALLED. NO LEAKS FOUND AFTER GROUND RUN. 1 L 7 1 3O 3 O A3SO E14EA 2005020200042 20050202 00042 EA 2005 2 2 2004FA0000882 2 20040706 G 7414 BL68256013 MAGNETO PIPER PA32 PA32R300 7103213 SO LYC O540 IO540* 41532 EA ENGINE BROKEN B O OTHER O OTHER NR NOT REPORTED 1 SO 06 333TG 108 108 32R7680320 L2299648A PILOT REPORTED OIL UNDER COWLING AFTER A WEEKEND OVERNIGHT. INVESTIGATED OIL LEAK AND FOUND THE MAGNETO MOUNTING FLANGE CRACKED. MAGNETO WAS PROPERLY TORQUED, SUSPECT MAGNETO HOUSING FATIGUED. 1 L 7 1 3O 3 O A3SO 1E4 2005020200124 20050202 00124 SO 2005 2 2 2004FA0000883 1 20040820 G 8011 MZ6222 STARTER PIPER PA32 PA32300 7103212 SO LYC O540 IO540* 41532 EA ENGINE INTERMITTENT B O OTHER O OTHER TX TAXI/GRND HDL 1 SO 06 833WC 6 6 327640059 L319548 UPON ENGINE START UP, PILOT WENT TO ENGAGE STARTER, STARTER DID NOT ENGAGE. INVESTIGATED STARTER AND FOUND STARTER BEND IX WOULD NOT ENGAGE. SUSPECT FAULTY BENDIX. 1 L 7 1 3O 3 O A3SO 1E4 2004120300043 20041203 00043 SO 2004 12 3 2004FA0000884 1 20041122 G 3230 1159SCL56613 TRUNNION PIN GULSTM GV GV 3980116 SO MLG CORRODED B K NONE O OTHER IN INSP/MAINT 1 GL 15 23M 2281 579 AIRCRAFT IN MAINTENANCE FOR THE SCHEDULED 5 YEAR LANDING GEAR CORROSION INSPECTION, FOUND AFT TRUNNION PINS AND THRU BOL T NAS1962C56 SEVERELY CORRODED. PARTS REPLACED WITH NEW. 2 L 7 2 4F RT A12EA 2004120300044 20041203 00044 CE 2004 12 3 2004FA0000885 1 20041119 G 2722 1900741 SERVO BEECH 200 200BEECH 1152920 CE RUDDER BINDING D K NONE L NO TEST IN INSP/MAINT 1 NM 11 773TP 1594 BB1722 RIGHT RUDDER BOOST SYSTEM DID NOT TEST PROPERLY WHEN THE RIGHT ENGINE WAS BROUGHT UP TO POWER. FOUND THE RIGHT RUDDER B OOST SERVO BELLOWS WAS HANGING UP IN THE SERVO. WOULD NOT RETRACT ALL THE WAY. REPLACED THE SERVO AND SYSTEM OPERATED NORMALLY. 1 L 7 2 4T A24CE 2005020100093 20050201 00093 CE 2005 2 1 2004FA0000887 1 20040726 G 5730 390331204 SKIN RAYTHN 390 390 7150030 CE WILINT FJ44 FJ44 66000 GL RT WINGTIP CRACKED B CGHR K NONE O OTHER IN INSP/MAINT 1 GL 19 88ER 342 RB17 THE RT WINGTIP HAS A CRACK APPROXIMATELY 7 INCHES LONG ON THE FAR OB END, AFT HALF OF THE WINGTIP. THE CRACK RUNS FORE / AFT ON THE WINGTIP. 1 7 2 3F 4 F RT A00010WI E3GL 2005020100127 20050201 00127 SO 2005 2 1 2004FA0000888 1 20040713 G 7603 A9200410 CABLE AMRGEN AG5B AG5B 3990100 SO LYC O360 O360* 41514 EA THROTTLE WORN B IG8R K NONE O OTHER IN INSP/MAINT 1 EA 07 929TE 333 10208 SWEDGED-IN PORTION OF THE CABLE GUIDE DISPLAYED .110 INCH FORE AND AFT PLAY INDICATING IMPENDING FAILURE OF THE SWIVEL J OINT. CABLE WAS REMOVED AND GIVEN FOR EVALUATION. THIS CONDITION WAS APPARENTLY CAUSED BY DIRT CONTAMINATION. (THE PR OTECTIVE RUBBER BOOT OVER THE SWIVEL JOINT HAD CRACKED, ALLOWING DIRT CONTAMINATION OF THE JOINT.) THIS SUBMITTER RECOM MENDS THAT THE THROTTLE CABLE SWIVEL JOINT AND ITS RUBBER BOOT BE CLOSELY INSPECTED AT EACH 100 HOUR AND/OR ANNUAL INSPE CTION TO PREVENT EXCESSIVE WARE AND SUBSEQUENT FAILURE OF THE THROTTLE CABLE. (EA07NEL200405197) 1 L 7 1 3O 3 O NT 1L71 E286 2005030800122 20050308 00122 EA 2005 3 8 2004FA0000889 2 20040909 G 7250 3053094 TURBINE BEECH 200 B200 1152922 CE PWA PT6 PT6A41 52043 EA ENGINE SHIFTED B CGHR K NONE O OTHER IN INSP/MAINT 1 GL 03 40PT 258 BB1291 NEW STYLE, PN SEGMENT INSTALLED AT HSI 258 HRS PRIOR. THIS NEW STYLE SEGMENT SHIFTS AFT RESULTING IN HOT SECTION FAILUR E. VERY COMMON WITH THIS PN SEGMENT 3053094/ MFG NEEDS TO CHANGE DESIGN. 1 L 7 2 4T 4 T A24CE E4EA 2004122100021 20041221 00021 CE 2004 12 21 2004FA0000890 1 20041008 G 5610 10138402521 WINDSHIELD BEECH 300 300BEECH 1152930 CE PWA PT6 PT6* 52043 EA COCKPIT CRACKED B O OTHER O OTHER NR NOT REPORTED 1 GL 21 701FC 749 FC291 THE AIRCRAFT WAS AT 33,000 FT WITH THE WINDSHIELD HEAT OFF, SPEED OF 290 KNOTS AND CABIN PRESSURIZED TO 6.5 PSI WHEN THE WINDSHIELD CRACKED. THEY WERE ALSO IN CLEAR AIR, WITH NO TURBULENCE. (GL21200500727) 2 L 7 2 4T 3 T A24CE E2NE 2004122100054 20041221 00054 GL 2004 12 21 2004FA0000891 1 20040824 G 2720 MS5184422 SLEEVE AMTR LONGEZ LONGEZ 05690Z8 GL LYC O235 O235* 41505 EA RUDDER CABLE FAILED D EIPR O OTHER O OTHER NR NOT REPORTED 1 WP 07 49DW 1 463 NICOPRESS SLEEVE (ZINC PLATED COPPER) WAS INSTALLED ON A .0625 INCH STAINLESS CABLE AND PULLED OUT UNDER FLIGHT LOADS. A TEST WAS MADE USING ANOTER SLEEVE AND THE CABLE ALSO PULLED OUT USING A PULL TEST. A TEST WAS PERFORMED USING THE SAM E CABLE AND A NICOPRESS (NON PLATED COPPER), THE PULL TEST WAS SATISFACTORY. 1 M 7 1 3O 3 O RT EXPA1M71 E223 2004122100055 20041221 00055 EU 2004 12 21 2004FA0000892 1 20040820 G 3220 ES128545 TRUNNION ISRAEL 1124 1124A 4500103 EU GARRTT TFE731 TFE731* 01518 WP NLG CRACKED B IOQR K NONE O OTHER IN INSP/MAINT 1 WP 01 788FS 5649 319 DURING A 1200 HOUR SCHEDULED INSPECTION, THE OUTER STRUT BODY OF THE NOSE LANDING GEAR UPPER TRUNNION WAS FOUND TO HAVE A CRACK IN THE OUTER BARREL STARTING FROM THE UPPER THREAD LOCK BORE EXTENDING DOWN 5.75 INCHES. 2 M 7 2 4F 4 F A2SW E6WE 2004122100083 20041221 00083 EA 2004 12 21 2004FA0000893 2 20041117 G 8550 ES48110 OIL FILTER CESSNA 206 T206H 2073303 CE LYC O540 TIO540AJ1A EA ENGINE SEPARATED D O OTHER O OTHER NR NOT REPORTED 1 CE 03 265TB 48 T20608351 REMOVED THIS FILTER AND CUT OPEN TO INSPECT CONTENTS AS PAR OF A ROUTINE OIL CHANGE. FOUND THE FILTER MEDIA HAD SEPARA TED WHERE THE ENDS ARE CRIMPED TOGETHER. FOUND THE GASKET BETWEEN THE INNER FILTER AND THE END PLATE IMPROPERLY INSTALL ED. THIS GASKET WAS TORN AND HANGING INTO THE FILTER PIC 2,3, AND 4. HAVE CUT OPEN 3 OIL FILTERS THIS BRAND, ALL 3 HA VE SHOWN THE SAME FAILURES. HAVE SENT COPIES OF PICTURES TO MFG ENGINEERING DEPT. NO IMMEDIATE DAMAGE TO THE ENGINE NO TED. THESE FAILURES ARE CAUSING UNFILTERED OIL TO CIRCULATE THROUGH THE ENGINE. 1 H 7 1 3O 3 O RT A4CE E14EA 2004122900152 20041229 00152 SO 2004 12 29 2004FA0000894 1 20041125 G 5753 8290503 BELLCRANK PIPER PA46 PA46350P 7104602 SO TE FLAPS CRACKED D O OTHER F FLT CONT AFFECTED LD LANDING 1 SW 99 DEZPA 1379 4622184 BEFORE LANDING, PILOT SELECTED 10 DEGREES FLAPS & ACFT DRIFTED LT. ABORTED LANDING, RAISED FLAPS & DID A GO AROUND THIN KING, THAT ONE OF THE MLG HAD NOT COME DOWN. AT THE 2ND ATTEMPT, HAD SAME PROBLEM & REALIZED THE PROBLEM WAS NOT THE ML G, BUT THE FLAP SYS. RT FLAP HAD NOT GONE DOWN, RAISED FLAPS AGAIN & LANDED WITHOUT FLAPS. AFTER LDG, A FUNCTIONAL CHE CK OF FLAPS, NO ABNORMALITIES. AFTER INSP, RT FLAP INBOARD BELLCRANK FOUND CRACKED ABOUT 80% OF CIRCUMFERENCE. OTHER B ELLCRANKS OF BOTH FLAPS WERE VISUALLY INSP & NO PROBLEM FOUND. PILOTS STATES, THAT HE & OTHER PILOTS HAVE NEVER LOWERED THE FLAPS AT SPEEDS HIGHER THAN THOSE SPECIFIED IN THE ACFT POH. 1 L 7 1 3O RT A25SO 2004122900163 20041229 00163 EA 2004 12 29 2004FA0000895 1 20041124 G 2710 C6CW10861 CONTROL ROD DHAV DHC6 DHC6 2802606 EA AILERON CONTROL FAULTY B K NONE O OTHER IN INSP/MAINT 1 NM 03 70465 173 173 554 DURING A VISUAL INSPECTION OF THE CONTROL ROD, IT WAS DISCOVERED THE ROD DID NOT HAVE A CRIMPED SLEEVE WHICH IT SHOULD. 1 H 7 2 3T RT A9EA 2004122900165 20041229 00165 EA 2004 12 29 2004FA0000896 1 20041124 G 2710 C6CW10861 CONTROL ROD DHAV DHC6 DHC6 2802606 EA AILERON CONTROL FAULTY B K NONE O OTHER IN INSP/MAINT 1 NM 03 70465 173 173 554 DURING A VISUAL INSPECTION OF THE CONTROL ROD, IT WAS DISCOVERED THE ROD DID NOT HAVE A CRIMPED SLEEVE WHICH IT SHOULD. 1 H 7 2 3T RT A9EA 2004122900188 20041229 00188 CE 2004 12 29 2004FA0000897 1 20041203 G 3222 968200183 RETAINER BEECH 58 58 1152740 CE NLG CRACKED B K NONE O OTHER IN INSP/MAINT 1 SO 05 440BL 4107 TH801 DURING ANNUAL INSPECTION, FOUND UPPER NOSE GEAR STRUT HOUSING RETAINER CRACKED APPX 80% ACROSS. 1 L 7 2 3O 3A16 2004123000014 20041230 00014 GL 2004 12 30 2004FA0000898 1 20041101 G 3220 FAIRING CIRRUS SR SR22 2130001 GL NLG DEPARTED C O OTHER O OTHER NR NOT REPORTED 1 SO 09 1457C 0547 NOSE WHEEL FAIRING DEPARTED AIRPLANE ON CROSSWIND LANDING. HAD SIGNIFICANT SHIMMY IN THE FRONT WHEEL UPON TOUCHDOWN. D ISCOVERED UPON REACHING RAMP AREA OF REAR PART OF FRONT WHEEL FAIRING. 1 L 7 1 3O NT A00009CH 2004123000020 20041230 00020 NM 2004 12 30 2004FA0000902 1 20041119 G 5320 210056033 CHANNEL PIPER PA60 PA60601 7106010 NM ZONE 100 CRACKED D O OTHER O OTHER NR NOT REPORTED 1 SO 09 7529S 3410 61016182 ON INSPECTION, FOUND PART CRACKED AT RIVET HOLES WHERE ATTACHED TO P/N 210056-031 CHANNEL. 1 M 7 2 3O RT A17WE 2005012700052 20050127 00052 SO 2005 1 27 2004FA0000904 1 20041124 G 3710 SHAFT PIPER PA32 PA32R300 7103213 SO LYC O540 LTIO540* 41533 EA VACUUM PUMP SHEARED B FFKR O OTHER J WARNING INDICATION AP APPROACH 1 SO 06 333TG 202 202 C04616 32R7680320 L2299648A AIRCRAFT WAS ON SHORT FINAL WHEN VACUUM PUMP FAILED. AFTER INSPECTION AND REMOVAL OF THE VACUUM PUMP, THE SHEAR SHAFT H AD SHEARED. 1 L 7 1 3O 3 O A3SO E14EA 2005012700053 20050127 00053 SO 2005 1 27 2004FA0000905 1 20041201 G 2910 HYC5005 POWERPACK PIPER PA32 PA32R300 7103213 SO HYD SYSTEM BURNED D O OTHER S J AFFECT SYSTEMS WARNING INDICATION LD LANDING 1 SO 05 898DS 32R7780358 OWNER REPORTED LANDING GEAR WOULD NOT EXTEND. IMPLEMENTED EMERGENCY EXTENSION SUCCESSFULLY. TROUBLESHOOTING REVEALED T HE FOLLOWING: 1) THE HYDRAULIC POWER PACK MOTOR BRUSHES AND COMMUTATOR WERE WORN WELL BEYOND LIMITS. 2) THE VENT HOLE FO R THE POWER PACK WAS BLOCKED BY A FACTORY INSTALLED WASHER (NOT REMOVED ON INSTALLATION) 3) THERE WERE INTERMITTENT CONT ACTS BETWEEN SELECTOR HANDLE WIRING CAUSING THE GEAR MOTOR TO CYCLE INTERMITTENTLY AFTER POWER PACK REPLACEMENT. REPLAC ED THE POWER PACK ASSEMBLY, REPAIRED THE WIRING, AND REMOVED THE VENT HOLE COVER (ON THE NEW POWER PACK). SYSTEM OPS CK S PER MFG SPECS. 1 L 7 1 3O A3SO 2005012700054 20050127 00054 SO 2005 1 27 2004FA0000906 1 20041201 G 2910 HYC5005 POWERPACK PIPER PA32 PA32R300 7103213 SO HYD SYSTEM BURNED D O OTHER S J AFFECT SYSTEMS WARNING INDICATION LD LANDING 1 SO 05 898DS 32R7780358 OWNER REPORTED LANDING GEAR WOULD NOT EXTEND. IMPLEMENTED EMERGENCY EXTENSION SUCCESSFULLY. TROUBLESHOOTING REVEALED T HE FOLLOWING: 1) THE HYDRAULIC POWER PACK MOTOR BRUSHES AND COMMUTATOR WERE WORN WELL BEYOND LIMITS. 2) THE VENT HOLE FO R THE POWER PACK WAS BLOCKED BY A FACTORY INSTALLED WASHER (NOT REMOVED ON INSTALLATION) 3) THERE WERE INTERMITTENT CONT ACTS BETWEEN SELECTOR HANDLE WIRING CAUSING THE GEAR MOTOR TO CYCLE INTERMITTENTLY AFTER POWER PACK REPLACEMENT. REPLAC ED THE POWER PACK ASSEMBLY, REPAIRED THE WIRING, AND REMOVED THE VENT HOLE COVER (ON THE NEW POWER PACK). SYSTEM OPS CK S PER MFG SPECS. 1 L 7 1 3O A3SO 2005020200070 20050202 00070 SO 2005 2 2 2004FA0000907 1 20041109 G 5610 1159SCB310012 WINDOW GULSTM G1159 GIV 3980115 SO COCKPIT OUT OF LIMITS D O OTHER O OTHER NR NOT REPORTED 1 NM 09 941AM 630 1499 PILOT REPORT OF POSSIBLE PROBLEM WITH COPILOT SIDE WINDOW HEAT. TROUBLESHOOTING REVEALED BUSS TO BUSS RESISTANCE TOO HIG H, CAUSE FOR WINDOW REPLACEMENT. WINDOW VERY DIFFICULT TO REMOVE, EXTRAORDINARY MEASURES TAKEN, AS INCORRECT SEALANT WA S APPLIED DURING MANUFACTURE. SEALANT WAS NOT TYPE 1425 OR EQUIVALENT AS CALLED OUT IN MAINTENANCE MANUAL. 2 L 7 2 4F RT A12EA 2005022400146 20050224 00146 EU 2005 2 24 2004FA0000908 1 20041014 G 3010 FAL1005D HOSE AMD FALC10 FALCON10 2730101 EU GARRTT TFE731 TFE73121C NE ANTI-ICE SYS COLLAPSED B PAZR K NONE P NO WARNING INDICATION IN INSP/MAINT 1 GL 03 87TH 427 178 DURING ENGINE RUN-UP, PHYSICALLY CHECKED LEADING EDGE FOR HEAT AND FOUND COLD. RT IB ANTI-ICE FLEXHOSE WAS REMOVED AND VISUALLY INSPECTED. FOUND THE INNER LINING HAD COLLAPSED, BLOCKING AIRFLOW THROUGH HOSE. HOSE WAS REPLACED WITH NEW. FAULTY HOSE WAS MARKED "3Q01". THIS FLEXHOSE, P/N FAL1005D, IS REFERENCED IN DASSAULT SERVICE BULLETIN F10-A246. THIS HOSE WAS LAST REPLACED ON 4/22/2003 AT 6213.2 HRS TTAF AND 5458 TOTAL LANDINGS BY CRS# BONR551C. 2 L 7 2 4F 4 F A33EU E6WE 2005020200100 20050202 00100 NE 2005 2 2 2004FA0000909 2 20041119 G 7230 9204M87P02 RETAINER DOUG DC10 DC1030F 3023504 WP GE CF6 CF650C2 30018 NE NR 3 ENGINE MISLOCATED B K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 99 46917 517228 DURING A ROUTINE "A-CHECK", FINNAIR FAA REPAIR STATION WAS REQUESTED TO PERFORM FAN BLADE LUBRICATION OF POSITION NR 3 E NGINE ON DA-10,N303WL. INSPECTION OF THE FAN BLADES REVEALED THAT ALL FAN BLADE SPACERS WERE IMPROPERLY INSTALLED. THE SPACER RETAINER LIPS WERE HANGING LOOSE, TOWARD THE WEB AREA OF THE FAN DISK, INSTEAD OF UNDER THE SPACERS BENEATH EACH FAN BLADE. IT WAS ALSO NOTED THAT THE STARTERS QUAD-RING WAS NOT SECURED BY A BOLT. ATTACHMENTS TO ORIGINAL REPORT SE NT TO FRANKFURT IFO WERE FORWARDED TO PMI FOR WORLD CARGO. 2 L 7 3 4F 4 F RT A22WE E23EA 2005020200131 20050202 00131 GL 2005 2 2 2004FA0000910 1 20041107 G 5720 AA819 SCREW TCRAFT BC BC12D 8850316 GL WING BROKEN D K NONE O OTHER IN INSP/MAINT 1 SO 11 5031M 1550 10331 WHILE REMOVING THE JURY STRUTS BEFORE REMOVING THE WINGS FOR RECOVER, WHEN THE BOLT HOLDING THE JURY STRUT TO THE ADJUST ING SCREW AT THE FRONT SPAR WAS REMOVED THE ADJUSTING SCREW WAS IN TWO PIECES. THE EAR THAT IS WELDED TO THE SCREW BROK E JUST ABOVE THE WELD. THE DESIGN OF THE ADJUSTING SCREW IS SUCH THAT THE THREADED PART POINTS STRAIGHT UP AND IS OPEN FOR MOISTURE AND/OR DIRT TO ACCUMULATE INSIDE THE SCREW. 1 H 7 1 3O A696 2005031000005 20050310 00005 EU 2005 3 10 2004FA0000911 1 20041125 G 2910 90G229 PRESSURE SWITCH AMD FALC50 FALCON50MYST 2730106 EU NR 1 HYD SYSTEM LEAKING B A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CR CRUISE 1 SW 99 77NT 8871 8871 77 LOSS OF NR 1 HYDRAULICS. INSPECTORS, FOUND HYDRAULIC NR 1 SYSTEM PRESSURE SWITCH LEAKING. PRESSURE SWITCH, HYDRAULIC P UMP NR 1 AND NR 2 REPLACED. 2 L 7 3 4F A46EU 2005030800057 20050308 00057 EU 2005 3 8 2004FA0000912 1 20041022 G 3244 M08401 TIRE AMD FALC50 FALCON50MYST 2730106 EU GARRTT TFE731 TFE73131C 01518 NE MLG DEFORMED E K NONE O OTHER IN INSP/MAINT 1 SO 17 164GB 234 164 THIS TIRE WAS MOUNTED ON THE RIGHT INBOARD SIDE (NR 3). CUPPING WAS NOTICED ON THE INSIDE EDGE OF THE TIRE ALL THE WAY AROUND WITH CORD SHOWING. TIRE WAS REPLACED. CONTACTED FALCON TECH OPS. THEY HAD NOT HEARD OF THIS ITEM AND ASKED ME TO CONTACT THE TIRE MANUFACTURE. CONTACTED MICHELIN, CONFIRMED THE PROBLEM AND SAID THEY WERE WORKING ON IT. 2 L 7 3 4F 4 F A46EU E6WE 2005030800058 20050308 00058 EU 2005 3 8 2004FA0000913 1 20041022 G 3244 M08401 TIRE AMD FALC50 FALCON50MYST 2730106 EU GARRTT TFE731 TFE73131C 01518 NE MLG DEFORMED E K NONE O OTHER IN INSP/MAINT 1 SO 17 164GB 234 164 THIS TIRE WAS MOUNTED ON THE RIGHT INBOARD SIDE (NR 3). CUPPING WAS NOTICED ON THE INSIDE EDGE OF THE TIRE ALL THE WAY AROUND WITH CORD SHOWING. TIRE WAS REPLACED, CONTACTED FALCON TECH OPS. THEY HAD NOT HEARD OF THIS ITEM AND ASKED ME TO CONTACT THE TIRE MANUFACTURE, CONTACTED MICHELIN. THEY CONFIRMED THE PROBLEM AND SAID THEY WERE WORKING ON IT. 2 L 7 3 4F 4 F A46EU E6WE 2005022200280 20050222 00280 SO 2005 2 22 2004FA0000914 2 20041022 G 8530 6399576 ROCKER CONT CESSNA 421 421 2076010 CE CONT O520 GTSIO520D 17032 SO NR 3 CYLINDER BROKEN D E ENGINE SHUTDOWN R PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 GL 07 4068L 3 4210068 1885208D ANNUAL PRE-INSPECTION RUN-UP RAN GOOD. POST INSPECTION RUN-UP RAN ROUGH. SUSPECTED A STICKING VALVE. FURTHER INVESTIG ATION REVEALED A BROKEN EXHAUST ROCKER ARM AND STUCK VALVE FOR NR 3 CYLINDER ON THE LEFT ENGINE. ALSO, NOTED IS AN APPA RENT INCLUSION IN THE BROKEN ROCKER ARM. 1 L 7 2 3O 3 O RT A7CE E7CE 2005030800053 20050308 00053 SO 2005 3 8 2004FA0000915 2 20041022 G 8530 6399576 EXHAUST ROCKER CESSNA 421 421 2076010 CE CONT O520 GTSIO520D 17032 SO NR 3 CYLINDER BROKEN D E ENGINE SHUTDOWN R PARTIAL RPM/PWR LOSS TX TAXI/GRND HDL 1 GL 07 4068L 3 4210068 1885208D ANNUAL PRE-INSPECTION RUN-UP RAN GOOD. POST INSPECTION RUN-UP RAN ROUGH. SUSPECTED A STICKING VALVE. FURTHER INVESTIG ATION REVEALED A BROKEN EXHAUST ROCKER ARM AND STUCK VALVE FOR NR 3 CYLINDER ON THE LEFT ENGINE. ALSO, NOTED IS AN APPA RENT INCLUSION IN THE BROKEN ROCKER ARM. 1 L 7 2 3O 3 O RT A7CE E7CE 2005030800158 20050308 00158 2005 3 8 2004FA0000916 2 20041209 G 7414 M3975 COIL SLICK MAGNETO FAILED B K NONE O OTHER IN INSP/MAINT 1 WP 27 600 600 96100581 MAGNETO IMPULSE COUPLING WEAR & IGNITION COIL FAILURE, FAILED IGNITION COIL: BROKEN HIGH-TENSION SECONDARY WINDINGS RESU LTING IN MISFIRING OF THE SPARK PLUGS, INDUCING MX OF MAGNETO. EXTREME WEAR AROUND MAGNET SHAFT OVER TAPERED PORTION BE TWEEN IMPULSE CAM AND MAIN SHAFT COMPRISING OF A CONDITION WHERE THE HARDENED CAM ASSY HAS COME INTO ANGULAR INTERFERENC E WITH THE (SOFTER) MAGNET SHAFT WHICH IT IS DESIGNED TO MOUNT AROUND. THE CONCENTRIC WEAR ON THE SHAFT INCLUDES A SHARP RAISED EDGE AT THE LARGEST OUTER DIAMETER OF THE MAGNET SHAFT TAPER. POSSIBLE CATASTROPHIC FAILURE OF THE MAGNETO MAY H AVE RESULTED FROM THE SHAFT BREAKING AT THE EDGE NEAREST THE BASE OF THE DISPLACED MATERIAL. 2005030800059 20050308 00059 EU 2005 3 8 2004FA0000917 1 20041103 G 3244 M15101 TIRE AMD FALC50 FALCON50MYST 2730106 EU GARRTT TFE731 TFE73131C 01518 NE MLG DEFORMED E K NONE O OTHER IN INSP/MAINT 1 SO 17 164GB 256 164 THIS MICHELIN TIRE WAS MOUNTED ON THE LEFT INBOARD SIDE (NR 2). CUPPING WAS NOTICED ON THE INSIDE EDGE OF THE TIRE ALL THE WAY AROUND. TIRE WAS REPLACED, THEN CONTACTED FALCON TECH OPS. THIS HAD HAPPENED ON ANOTHER TIRE BUT DIFFERENT PAR T NUMBER (OMB NR 2120-0003). THEY HAD NOT HEARD OF THIS ITEM AND ASKED ME TO CONTACT THE TIRE MANUFACTURE. I THEN CONT ACTED MICHELIN. THEY CONFIRMED THE PROBLEM AND SAID THEY WERE WORKING ON IT. 2 L 7 3 4F 4 F A46EU E6WE 2005022200169 20050222 00169 NM 2005 2 22 2004FA0000918 1 20040728 G 5730 SKIN UNIVAR 415 415CD 0420304 NM WING CORRODED D K NONE O OTHER IN INSP/MAINT 1 GL 15 9474 4851 INSPECTION OF WING CENTER SECTION PER AD 02-26-02 FOUND LIGHT CORROSION ON LOWER SKINS, MODERATE CORROSION ON 3 STIFFENE RS. REPLACED STIFFENERS, CLEANED AND TREATED SKIN. AIRCRAFT WAS OUTSIDE WITHOUT COVER FOR AT LEAST 30 YEARS. 1 L 7 1 3O A718 2005022200170 20050222 00170 NM 2005 2 22 2004FA0000919 1 20040728 G 5730 SKIN UNIVAR 415 415CD 0420304 NM WING CORRODED D K NONE O OTHER IN INSP/MAINT 1 GL 15 9474 4851 INSPECTION OF WING CENTER SECTION PER AD 02-26-02 FOUND LIGHT CORROSION ON LOWER SKINS, MODERATE CORROSION ON 3 STIFFENE RS. REPLACED STIFFENERS, CLEANED AND TREATED SKIN. AIRCRAFT WAS OUTSIDE WITHOUT COVER FOR AT LEAST 30 YEARS. 1 L 7 1 3O A718 2004122900149 20041229 00149 NM 2004 12 29 2004FA0000920 1 20040728 G 5730 SKIN UNIVAR 415 415CD 0420304 NM WING CENTER SECT CORRODED D K NONE O OTHER IN INSP/MAINT 1 GL 15 9474 4851 INSPECTION OF WING CENTER SECTION PER AD 02-26-02 FOUND LIGHT CORROSION ON LOWER SKINS, MODERATE CORROSION ON 3 STIFFENE RS. REPLACED STIFFENERS, CLEANED AND TREATED SKIN. AIRCRAFT WAS OUTSIDE WITHOUT COVER FOR AT LEAST 30 YEARS. 1 L 7 1 3O A718 2005030800063 20050308 00063 SO 2005 3 8 2004FA0000922 1 20041122 G 3211 1159SCL56613 TRUNNION PIN GULSTM GV GV 3980116 SO MLG CORRODED B O OTHER O OTHER NR NOT REPORTED 1 GL 15 300K 2722 587 AIRCRAFT IN MAINTENANCE FOR THE SCHEDULED 5 YEAR LANDING GEAR CORROSION INSPECTION. FOUND AFT TRUNNION PINS AND THRU BO LT PN: NAS1962C56 SEVERELY CORRODED. PART REPLACED WITH NEW. 2 L 7 2 4F RT A12EA 2004122200125 20041222 00125 WP 2004 12 22 2004FA0000923 1 20041214 G 6210 C0162 BLADE ROBSIN R44 R44 7640120 WP MAIN ROTOR DELAMINATED D K NONE O OTHER IN INSP/MAINT 1 WP 17 667SA 775 726 PREFLIGHT INSPECTION FOUND ONE OF THE BLADES APPEARED TO HAVE SKIN SEPARATION AT TRAILING EDGE TIP APPROX 1/4" LONG. SE NT DIGITAL PHOTO TO ROBINSON AND THEY REQUESTED BOTH BLADES BE SENT TO THEM FOR INSPECTION. UPON INSPECTION AT FACTORY BOTH BLADES WERE SCRAPPED DUE TO CORROSION DELAMINATION. SHIP HAS RECENTLY CHANGED OWNERS BUT PRIOR OWNER OPERATED SHIP IN FLORIDA. SHIP WAS MANUFACTURED IN EARLY 2000 AND ONLY HAS 775 HOURS SINCE NEW. ROBINSON DOES NOT CONSIDER THIS A D EFECT BUT CLAIMS THE PROBLEM WAS THE CORROSIVE ENVIRONMENT IT WAS OPERATED IN. 1 G 7 1 3O H11NM 2005012400017 20050124 00017 WP 2005 1 24 2004FA0000924 1 20041116 G 6720 369H753113 TORQUE TUBE HUGHES 369 369D 4470706 WP T/R PEDAL OUT OF LIMITS B K NONE O OTHER IN INSP/MAINT 1 AL 03 CFMAL 611010D FOUND AN AREA ON THE T/R PEDAL TORQUE TUBE THAT WAS DRESSED OUT WAY BEYOND LIMITS NEARLY HALF THE WALL THICKNESS AND THE AREA NOTED COULD NOT BE SEEN CLEARLY UNTILL IT WAS DISASSEMBLED. REPLACED TUBE. 1 G 7 1 3U H3WE 2004122200054 20041222 00054 2004 12 22 2004FA0000925 4 20041221 G 3417 962830A1S8 ADC DHAV DHC2 DHC2* 2800108 EA COCKPIT MALFUNCTIONED B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 47AK 726 DURING GROUND FUNTIONAL TEST OF THE INITIAL INSTALLATION OF AIR DATA COMPUTER (ADC) INSTALLED AS PART OF THE CHELTON FLI GHT SYSTEMS EFIS-SV SYSTEM UNDER STC SA02203AK, ENCOUNTERED 100FT ALTITUDE DRIFT WITHIN 5 MINUTES AFTER BAROMETRIC PRESS URE HAD BEEN SET. 1 H 7 1 3R A806 2005012400046 20050124 00046 WP 2005 1 24 2004FA0000926 1 20041116 G 6700 369H7131503 CYCLIC STICK HUGHES 369 369D 4470706 WP FLIGHT CONTROLS LOOSE B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 CFMAL 611010D DURING ANNUAL INSPECTION IT WAS DISCOVERED THAT THE CYCLIC STICK HAD ABOUT HALF FORE AND AFT PLAY CAUSED BY A LOOSE FIT AT THE CYCLIC PIVOT POINT AT THE CYCLIC TORQUE TUBE. WHEN IT WAS DISASSEMBLED IT WAS FOUND TO HAVE BEEN SHIMMED WITH CO MPRESSOR SHIMS WHICH HAVE AN ID OF .3125 INCH AND THE BOLT IS .250 INCH THE SHIMS BEING TOO BIG, MORE THAN LIKELY, SHIFT ED TO ONE SIDE OR THE OTHER OFF OF THE EDGE OF THE BEARING BUSHING AND GOT HAMMERED AND LOST TENSION THEN IT WAS A MATTE R OF THE BEARINGS GOUGING INTO THE CASTING. 1 G 7 1 3U H3WE 2005020100005 20050201 00005 CE 2005 2 1 2004FA0000927 1 20041221 G 2720 51310103 BRACKET CESSNA 421 421B 2076014 CE CONT O520 GTSIO520C 17032 SO ZONE 300 MISINSTALLED D K NONE W INADEQUATE Q C NR NOT REPORTED 1 NM 11 678DB 4794 4794 421B0876 COMPLIED WITH MFG MEB 00-4 RUDDER BEARING INSPECTION/REPLACEMENT. FOUND RUDDER LOWER HINGE BEARING BRACKET INSTALLED UP SIDE DOWN FROM FACTORY. REPLACEMENT PROCEDURE DESCRIBED IN MEB FOUND ERRONEOUS AND INADEQUATE TO COMPLETE SATISFACTORY REPLACEMENT OF BRACKET. MS 2047AD4-11 AND AD 5-11 RIVETS CALLED OUT IN MEB ARE OF THE INADEQUATE LENGTH. THIS WILL REQ UIRE -12 OR -13 LENGTH RIVETS. REPLACEMENT PN 5131010-3 IS NOT SAME SIZE AS ORIGINAL AND DOES NOT APPEAR TO HAVE ADEQUAT E EDGE DISTANCE FROM RIVET HOLES AS WELL AS CAUSING BULGING OF VERTICAL STABILIZER SKINS BECAUSE IT IS SLIGHTLY TOO WIDE . A MAJOR RE-WRITE OF THIS MEB AND ITS COMPLIANCE INSTRUCTIONS IS NEEDED. 1 L 7 2 3O 3 O A7CE E7CE 2005020100006 20050201 00006 CE 2005 2 1 2004FA0000928 1 20041221 G 5313 1014400311 STRINGER BEECH 200 B200 1152922 CE FUSELAGE CRACKED E K NONE O OTHER IN INSP/MAINT 1 GL 07 200EW 5391 BB1163 STRINGER NR 9 ON THE LT SIDE FOUND CRACKED DURING NON-RELATED MAINTENANCE. 1 L 7 2 4T A24CE 2005020100016 20050201 00016 GL 2005 2 1 2004FA0000931 1 20041216 G 3213 STRUT AMTR CH601 ZODIAC GL ROTAX 912 ROTAX912S2 EU LT MLG BROKEN H O OTHER O OTHER LD LANDING 1 NM 09 601RT 318 100 63314 THE LT MAIN GEAR STRUT FAILED AT THE LOWER WELDMENT WHERE THE STRUT ATTACHES TO THE FORK. THIS DAMAGE HAD PROGRESSED ARO UND THE ATTACHMENT IN THE FORM OF A CRACK UNTIL WEEKEND TO THE POINT OF FAILURE. THIS PART HAD BEEN FABRICATED BY THE KI T MANUFACTURER. 1 L 7 1 3O 3 O NC EXPA1L71 E00051EN 2005031000023 20050310 00023 CE 2005 3 10 2004FA0000932 1 20041213 G 5720 515610211 ANGLE CESSNA 421 421C 2076016 CE LEFT WING CORRODED B O OTHER O OTHER NR NOT REPORTED 1 EA 07 717LR 2300 421C1109 LEFT WING NACELLE, ANGLE JUST AFT OF FIREWALL EXHIBITED SEVERE CORROSION. CORROSION WAS TRANSFERED TO UPPER WING SKIN AN D FUEL CELL. 1 L 7 2 3O A7CE 2005021500142 20050215 00142 SO 2005 2 15 2004FA0000933 1 20041127 G 5610 1159SCB31023 WINDSHIELD GULSTM G1159 GIV 3980115 SO RROYCE TAY TAY6118 EU COCKPIT CRACKED B N38R K NONE O OTHER IN INSP/MAINT 1 EA 05 970SJ 1146 PILOTS WINDSHIELD CRACKED ENROUTE, CREW DIVERTED DUE TO THE FACT THAT MFG SERVICE CENTER THERE. CREW FOLLOWED NORMAL LA NDING PROCEDURES, AND LANDED AIRCRAFT UNEVENTFULLY. 2 L 7 2 4F 4 F RT A12EA E25NE 2005031000033 20050310 00033 NM 2005 3 10 2004FA0000934 1 20041216 G 2810 900P3661120101 FUEL CELL DOUG MD900 MD900 3027375 NM PWC PW207 PW207E NE FUSLEAGE LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 EA 11 902PD 1602 9000084 DURING TROUBLESHOOTING A FUEL LEAK FOUND THAT WHEN THE FUEL CELL WAS FLEXED, FUEL WOULD WEEP FROM EXTERIOR SURFACE. REMO VED FUEL CELL AND SENT OUT FOR TEST AND REPAIR. EVALUATION RESULTS SHOWED WEEPING/ POROUS CONDITION OVER 80 PERCENT OF T HE CELL AND CELL TO BE BEYOND REPAIR. REPLACING CELL WITH SERVICEABLE UNIT. CELL DATE OF MANUFACTURE : 07/99, TOTAL TIME ON AIRCRAFT 1602.2 1 G 7 2 3U 3 U NC H19NM E42NE 2005020100091 20050201 00091 CE 2005 2 1 2004FA0000935 1 20041220 G 5730 10140453S SKIN BEECH 200 B200 1152922 CE LT WING DELAMINATED E K NONE O OTHER IN INSP/MAINT 1 GL 07 200EW 5391 BB1163 SKIN DELAMINATION ON LT WING CENTER SECTION UPPER SURFACE AFT OF THE SPAR NOTICED BY MAINTENANCE CREW, WHILE MAINTENANCE WAS BEING COMPLETED ON A NON-RELATED MATTER. 1 L 7 2 4T A24CE 2005031000041 20050310 00041 SO 2005 3 10 2004FA0000936 2 20041115 G 8520 649990 CRANKSHAFT CONT O550 IO550C SO ENGINE FRACTURED C B EMER. DESCENT Y ENGINE STOPPAGE CR CRUISE 1 EA 23 2316 469 684556 CRANKSHAFT FRACTURED IN FLIGHT BETWEEN THE NR 1 AND 2 CONNECTING ROD JOURNALS. AIRCRAFT MADE A SAFE LANDING. 3 O E3SO 2005031000042 20050310 00042 SO 2005 3 10 2004FA0000937 2 20041115 G 8520 649990 CRANKSHAFT CONT O550 IO550C SO ENGINE FRACTURED C B EMER. DESCENT Y ENGINE STOPPAGE CR CRUISE 1 EA 23 2316 469 684556 CRANKSHAFT FRACTURED IN FLIGHT BETWEEN THE NR 1 AND 2 CONNECTING ROD JOURNALS. AIRCRAFT MADE A SAFE LANDING. 3 O E3SO 2005031000029 20050310 00029 NM 2005 3 10 2004FA0000938 1 20041216 G 6220 900R2101006107 HUB DOUG MD900 MD900 3027375 NM PWC PW207 PW207E NE MAIN ROTOR CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 11 1852 77 9000085 DURING ACCOMPLISHMENT OF AD 2002-10-05 "MAIN ROTOR UPPER HUB INSP" FOUND BOLT HOLES CRACKED AS DEPICTED IN MD HELICOPTER S SERVICE BULLETIN 900-072. PART TOTAL TIME: 1852 HRS 1 G 7 2 3U 3 U NC H19NM E42NE 2005031000032 20050310 00032 NM 2005 3 10 2004FA0000939 1 20041216 G 6220 900R1103001113 BEAM DOUG DOUG MD900 MD900 3027375 NM PWC PW207 PW207E NE M/R HUB CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 11 902PD 1602 100 0099990078 9000084 DURING 100 HOUR INSPECTION, FOUND FLEX BEAM CRACKED IN AREA OF LEG GOING INTO UPPER HUB. REPLACED PART WITH UPDATED SERV ICEABLE PART. 1 G 7 2 3U 3 U NC H19NM E42NE 2005031000031 20050310 00031 NM 2005 3 10 2004FA0000940 1 20041216 G 6220 900R2101006107 HUB DOUG MD900 MD900 3027375 NM PWC PW207 PW207E NE MAIN ROTOR CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 11 902PD 292 100 9000084 DURING ACCOMPLISHMENT OF A.D. 2002-10-05 " MAIN ROTOR UPPER HUB INSP." FOUND (3) OUT OF (10) BOLT HOLES CRACKED AS DEPIC TED IN MD HELICOPTERS SERVICE BULLETIN 900-072. PART TOTAL TIME: 292 HRS 1 G 7 2 3U 3 U NC H19NM E42NE 2005031000047 20050310 00047 CE 2005 3 10 2004FA0000941 1 20041221 G 5313 1014400339 STRINGER BEECH 200 B200 1152922 CE PWA PT6 PT6A60A 52043 NE FUSELAGE CRACKED E K NONE O OTHER IN INSP/MAINT 1 GL 07 200EW 5391 BB1163 STRINGER NR 9 ON THE RT SIDE WAS FOUND CRACKED DURING NON-RELATED MAINTENANCE. 1 L 7 2 4T 4 T A24CE E4EA 2005021500088 20050215 00088 2005 2 15 2004FA0000942 4 20040914 G 3417 962830A1S8 ADC PIPER PA32 PA32300 7103212 SO LYC O540 IO540K1G5 41532 EA COCKPIT MALFUNCTIONED B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 31589 327840135 UNIT REPORTING ERRONEOUS ALTITUDE READINGS UP TO 1000 FEET OFF. (AL05200401238) 1 L 7 1 3O 3 O A3SO 1E4 2005012100158 20050121 00158 EA 2005 1 21 2004FA0000943 1 20040729 G 2820 660526AS TRANSDUCER DHAV DHC2 DHC2MK1 2800102 EA PWA R985 R985AN14B 52008 NE FUEL FLOW INOPERATIVE B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 95DG 100 572 FUEL FLOW TRANSDUCER INOPERATIVE-NOT PROVIDING SIGNAL TO IDU. 1 H 7 1 3R 3 R A806 5E1 2005031100079 20050311 00079 NE 2005 3 11 2005FA0000000 1 20041130 G 6320 643520048101 BEVEL GEAR SKRSKY SKRSKY S64 S64F 8142610 NE PWA JFTD12 JFTD12A4A 52047 NE M/R GEARBOX CRACKED B JYDR K NONE O OTHER IN INSP/MAINT 1 NM 09 159AC 2215 A6125 64084 DURING NDT INSPECTION, GEAR WAS MPI`D AND REJECTED FOR CRACKS. LOCATION OF CRACKS WERE IN ATTACHMENT FLANGE BOLT HOLES (18 EACH). EVERY HOLE HAS APPROXIMATELY .1250 INCH LONG CRACK STARTING ON THE GEAR TO SHAFT ATTACHMENT SIDE EXTENDING D OWN INTO THE HOLE. UPON DISASSEMBLY, FRETTING WAS FOUND ON ATTACHMENT FLANGE OF GEAR. FRETTING BETWEEN GEAR AND SHAFT TYPICALLY CAUSES THIS DEFECT. THIS MGB ASSEMBLY WAS O/H SEVERAL YEARS AGO AND DID NOT INCORPORATE THE REVISED TORQUE PR OCEDURE CURRENTLY USED. A REVISED TORQUE PROCEDURE WITH ENSURING A DRY FIT AT ASSEMBLY HAS REDUCED FRETTING THUS PREVEN TS CRACKING. (NM09200504351) (K) 2 G 7 2 4U 4 U H6EA E15EA 2005031100030 20050311 00030 NE 2005 3 11 2005FA0000001 1 20041130 G 7160 575219 DUCT SKRSKY S64 CH54B 8142610 NE PWA JFTD12 JFTD12A4A 52047 NE ENGINE WRONG PART B JYDR K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 09 158AC 651 64081 DURING TEARDOWN OF F/T ASSEMBLY, A BROKEN EPR PROBE WAS FOUND AND THE INLET DUCT WAS SITTING LOW WHICH WOULD ALLOW MORE AXIAL TRAVEL OF INLET DUCT DURING OPERATION. AFTER REMOVING INLET DUCT, FOUND THE OVERALL HEIGHT OF INLET DUCT TO BE SH ORT. THIS CAUSED WEAR IN THE AFT FLANGE OF THE INLET DUCT AND PUT EXTRA LOAD ON PROBES. THIS INLET DUCT WAS PURCHASED AS A SERVICEABLE PART. HEIGHT IS NOT REQUIRED TO TAKE THIS DIMENSION AT OVERHAUL. IT IS CHECKED WHEN INLET DUCT HAS AN AFT FLANGE REPAIR AND FORWARD SNAP REPAIR BY SUPPLIER. SUPPLIER’S REPAIR RESTORES TO BLUE PRINT HEIGHT OF 7.270 INCH - 7.310 INCH. THE HEIGHT OF THIS INLET DUCT IS 7.250 INCH. CHECK OVERALL HEIGHT OF INLET DUCT. (MDR04-068) (K) 2 G 7 2 4U 4 U H6EA E15EA 2005021500171 20050215 00171 NE 2005 2 15 2005FA0000002 1 20041206 G 6210 151520604000 SPAR SKRSKY S64 S64E 8142604 NE M/R BLADE CRACKED B JYDR O OTHER O OTHER NR NOT REPORTED 1 NM 09 CGESG 5301 64M48515147 64065 BLADE WAS RECEIVED WITH AN UNSERVICEABLE BIM INDICATION. DURING LEAK CHECK, A CHORDWISE CRACK, APPROX .5 INCH LONG WITH A CORROSION PIT IN THE CENTER, WAS FOUND. THE CRACK IS LOCATED APPROX 70.75 INCH FROM TIP END AND 3.25 INCH FROM L/E. CORROSION PIT A CENTER OF CRACK. PREVENT CORROSION PITTING. (K) 2 G 7 2 4U H4EA 2005030800220 20050308 00220 SO 2005 3 8 2005FA0000003 1 20041209 G 5200 DOOR FRAME GULSTM G1159 G1159B 3953535 SO DOOR CRACKED B N38R K NONE O OTHER IN INSP/MAINT 1 EA 05 211SJ 75 DURING AIRCRAFT 4000 LANDING INSPECTION, FOUND APPROX A 1 INCH CRACK AT THE UPPER FORWARD RADIUS OF DOOR FRAME. STOP DR ILLED CRACK AND REPAIRED WITH AN OVERLAY DOUBLER IAW THE SRM. OVERLAY INSTALLED (WET) WITH PRC 1440. (K) 2 L 7 2 4F RT A12EA 2005032800072 20050328 00072 EA 2005 3 28 2005FA0000004 2 20041119 G 7200 INVERTER BEECH 99 99A 1154003 CE PWA PT6 PT6A27 52043 EA RT ENGINE MALFUNCTIONED B TIMR A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 NM 07 326CA U135 ON CLIMB OUT, RT ENGINE TORQUE DROPPED TO 500. AC RETURNED, WHERE THE TORQUE SYSTEM WAS JET CAL, GAUGES SWAPPED SIDE TO SIDE AND ALL SYSTEMS WORKED AS REQUIRED. MAINTENANCE SUSPECTS AN ELECTRICAL SPIKE FROM THE NR 1 INVERTER. THE GAUGES STUCK ON 500 BUT DROPPED TO ZERO WHEN INVERTER NR 2 SELECTED. INVERTER NR 1 AND NR 2 INSPECTED, CONNECTOR PLUG, INSPECT ED THE WIRES, NOTHING WAS FOUND AND MAINTENANCE CANNOT DUPLICATE THE PROBLEM. SWITCH OF INVERTERS PRODUCED NO PROBLEMS WITH TORQUE SYSTEM. (K) 1 L 7 2 3T 4 T A14CE E4EA 2005030800239 20050308 00239 CE 2005 3 8 2005FA0000005 1 20041116 G 5210 CABLE BEECH 1900 1900C 1154161 CE PWA PT6 PT6A27 52043 EA PAX DOOR BROKEN B TIMR C ABORTED TAKEOFF P NO WARNING INDICATION CL CLIMB 1 NM 07 153GA UB34 PCE41706 ON CLIMBOUT THE AIRSTAIR DOOR OPENED. AC RETURNED, WHEN AIRSTAIR DOOR OPENED IN FLIGHT, DOOR DAMPER BROKE AND SUPPORT CHAINS BROKE. CHAIN HIT PROPELLER AND CAUSED NOTICEABLE DAMAGE. DOOR ANNUNCIATOR LIGHT WAS NOT ILLUMINATED SO NO INDIC ATION OF ANY PROBLEM WAS EVIDENT. CAUSE FOR DOOR FAILURE WAS DOOR CABLE WHICH TURNS LOCKING CAMS BROKE WHEN DOOR WAS CL OSED. PILOT NEGLECTED TO CHECK CAM MARKS FOR ALIGNMENT WITH GUN SIGHTS LOCATED ON DOOR FRAME. GROUND PERSONNEL DID NOT REALIZE THE DOOR INSIDE CAM CABLE BROKE, AS A RESULT, HANDLE IS STOWED, DOOR PIN POPS OUT INDICATING DOOR IS CLOSED. B OTH SWITCHES ON THE DOOR FOR THE ANNUNCIATOR MAKE A CLOSED CIRCUIT CAUSING THE LIGHT TO GO OUT. 2 L 7 2 4T 4 T RT A24CE E4EA 2005042100006 20050421 00006 EA 2005 4 21 2005FA0000006 2 20041228 G 7200 31019912 BLADE BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA LT ENGINE BROKEN B TIMR O OTHER O OTHER NR NOT REPORTED 1 NM 07 153GA UB34 AIRCRAFT DEPARTED, AT CRUISE, THE LT ENGINE HAD AN EXPLOSIVE NOISE AND THE LEFT ENGINE SEIZED. PRE INSPECTION OF ENGINE INDICATES LOSS OF CT BLADE. (K) 2 L 7 2 4T 4 T RT A24CE E4EA 2005020100100 20050201 00100 EU 2005 2 1 2005FA0000010 1 20041207 G 7810 FIOA5SCP2013 CLAMP BRAERO DH125 HS125700A 4230170 EU GARRTT TFE731 TFE7315R 01518 WP TAIL PIPE CRACKED B JGVR O OTHER O OTHER NR NOT REPORTED 1 CE 09 224EA 6992 257088 P77269 THE DEFECT IS A FATIGUE CRACK, CAUSED BY BEING OVERSTRESSED DUE TO LOAD LIMITS, POSSIBLE OVERTORQUED. MAYBE THIS PART S HOULD BE MADE STRONGER, TO HANDLE THE STRESS. THIS DEFECT WAS FOUND BY A PENETRANT INSPECTION. THE LOCKING NUT NEEDS TO BE REMOVED, IN THIS CASE THE DEFECT WOULD NOT HAVE BEEN NOTICED IF THE LOCKING NUT HAD NOT BEEN REMOVED. (CE092005019 13) (K) 2 L 7 2 4F 4 F A3EU E6WE 2005021500087 20050215 00087 SO 2005 2 15 2005FA0000011 1 20041206 G 7120 8621202 MOUNT PIPER PA44 PA44180 7104402 SO LYC O360 VO360* 41514 EA RT ENGINE CRACKED B AKGR K NONE O OTHER IN INSP/MAINT 1 CE 05 2234B 2864 447995107 ON COMPLETEING MAINTENANCE ON RT ENGINE, IT WAS NOTICED THAT THE ENGINE MOUNT WAS CRACKED AT A WELD JOINT ABOUT 6 INCHES BELOW THE RT UPPER ISOLATION MOUNT. THE CRACK HAS FOLLOWED THE WELD LAP AND OUT INTO THE TUBE FOR ABOUT TWO THIRDS THE WAY AROUND THE TUBE. 1 L 7 2 3O 3 O A19S0 1E1 2005033000064 20050330 00064 CE 2005 3 30 2005FA0000012 1 20041206 G 6120 1013890293 GOVERNOR BEECH B300 B300 1159232 CE PWA PT6 PT6A60A 52043 NE HARTZL HCB4M HCB4MP3 GL OVERSPEED MALFUNCTIONED B LX5R O OTHER R PARTIAL RPM/PWR LOSS TX TAXI/GRND HDL 1 GL 19 981LL 2435 FL265 PCEPK0267 FWA2851 DURING NORMAL GROUND RUN-UP. THE AIRCRAFT PROPELLER AUTO-FEATHER SYSTEM WAS OPERATIONALLY CHECKED. BOTH LT AND TR PROP ELLER SWITCHES WERE SELECTED AND BOTH PROPELLERS FEATHERED CORRECTLY. WHEN THE SWITCHES WERE RELEASED THE LT PROPELLER DID NOT COME OUT OF THE FEATHERED POSITION BUT THE RT PROPELLER WORKED CORRECTLY. A SERVICEABLE OVERSPEED GOVERNOR WAS INSTALLED IN THE LT POSITION. OPERATIONAL CHECK WAS GOOD AND THE AIRCRAFT WAS RETURNED TO SERVICE. UNKNOWN WHAT CAUSED THE COMPONENT TO FAIL POSSIBLE INTERNAL SWITCH OR SERVO FAILURE, COMPONENT SENT FOR OVERHAUL/ REPAIR. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2005033000065 20050330 00065 CE 2005 3 30 2005FA0000013 1 20041209 G 3230 583800901 MOTOR BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO MLG INTERMITTENT B VJ3R O OTHER J WARNING INDICATION CR CRUISE 1 WP 07 1564A 68 CE1321 830028R DURING FLIGHT OF AIRCRAFT, PILOT REPORTED GEAR WOULD NOT RETRACT. MAINTENANCE TECHNICIAN FOUND LANDING GEAR MOTOR WAS I NTERMITTENT AND SLOW TO RETRACT. NO RECOMMENDATIONS AT THIS TIME. 1 L 7 1 3O 3 O 3A15 E5CE 2005030100044 20050301 00044 SO 2005 3 1 2005FA0000015 1 20041120 G 3233 762365 ROD END PIPER PA23 PA23250 7102308 SO LYC O540 TIO540* 41532 EA LT MLG ACTUATOR BENT C O OTHER O OTHER LD LANDING 1 NE 03 62688 277654144 DURING ROLL-OUT AFTER LANDING, THE LT MAIN GEAR COLLAPSED, INVESTIGATION WHILE THE AIRCRAFT WAS ON JACKS. REVEALED THAT THE ACTUATOR ROD END WAS BENT. (NE03200504405) (K) 1 L 7 2 3O 3 O 1A10 E14EA 2005033000066 20050330 00066 EU 2005 3 30 2005FA0000016 1 20041227 G 5754 FITTING AMD FALC50 FALCON50MYST 2730106 EU GARRTT TFE731 TFE731* 01518 WP SLAT DAMAGED B QU2R K NONE O OTHER IN INSP/MAINT 1 EA 17 56LT 133000 21 FOLLOWING DAMAGE WAS FOUND WHILE LT IB SLAT (PN F50B133B8, SN 133000 WAS AT THIS FACILITY FOR REPAIR. MILLED FITTING, ( PN F50B133014) IS ATTACH POINT FOR NR 4 (OB) RAIL. SIX FASTENERS WERE IMPROPERLY INSTALLED THROUGH INNER SKIN OF SLAT. FOUR BLIND FASTENERS WERE LOCATED THROUGH INNER SKIN INTO EDGE OF MILLED FITTING. ONE SOLID FASTENER WAS THROUGH INN ER SKIN AND FLUSHED ON OUTER SKIN, THIS WAS ALSO DRILLED THROUGH EDGE OF MILLED FITTING. , WHICH CAUSED OUTER SKIN TO BE DISTORTED. ONE SOLID FASTENER WAS COUNTERSUNK ON OUTER SKIN THROUGH THE INNER SKIN. MISDRILLED FASTENERS WERE FOUND D URING PRELIMINARY INSPECTION. DAMAGE TO THE MILLED FITTING WAS FOUND DURING THE TEAR DOWN PHASE OF REPAIR WORK. 2 L 7 3 4F 4 F A46EU E6WE 2005032800083 20050328 00083 SO 2005 3 28 2005FA0000017 1 20041105 G 3230 7642603 DRAG BRACE PIPER PA28 PA28R201 7102816 SO LYC O360 IO360A1A 41514 EA NLG BROKEN B TUDR O OTHER O OTHER CR CRUISE 1 SW 13 1128Q 3172 28R7737027 PILOT REPORTED A LOUD, SHARP (POP) SOUND WHILE IN FLIGHT. PRIOR TO LANDING HE LOWERED THE LANDING GEAR AND MADE A NORMA L LANDING. THE NOSE GEAR UPPER DRAG BRACE WAS BROKEN JUST FORWARD OF THE AREA WHERE THE LANDING GEAR ACTUATOR ATTACHES TO THE BRACE. THERE DID NOT APPEAR TO BE ANY OTHER DAMAGE IN THE AREA. A POSSIBLE CAUSE OF FAILURE IS FATIGUE DUE TO T HE NR OF HOURS OR CYCLES ON THE PART. (SW13200501658) 1 L 7 1 3O 3 O 2A13 1E10 2005020100175 20050201 00175 GL 2005 2 1 2005FA0000018 1 20041111 G 7921 654585 OIL COOLER CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO ENGINE OIL CRACKED B LC1R K NONE K FLUID LOSS IN INSP/MAINT 1 EA 07 1527C 474 0564 THIS AIRCRAFT HAS HAD AN OIL COOLER REPLACED FOR THE SAME DEFECT AT <300 HOURS. THE NEW OIL COOLER IS CRACKED AGAIN AT THE LOWER LT FLANGE AREA. NOTE: MFG HAS A SIX POINT ENGINE MOUNT OPTION AVAILABLE TO REDUCE VIBRATION IN THE AIRCRAFT. THIS AIRCRAFT HAD SUBSTANTIAL VIBRATION AND HAS HAD THAT MOUNT INSTALLED AT THE FIRST OIL COOLER REPLACEMENT AND THE O WNER REPORTS A NOTICEABLE DIFFERENCE IN VIBRATION LEVELS. THIS MAY HAVE CONTRIBUTED TO THE ORIGINAL CRACKING BUT NOT SO MUCH THE 2ND OCCURRENCE. THIS HAS BEEN AREA FLAGGED BY MFG DURING A RECENT SERVICE CENTER MEETING AND IS POSTED ON THE SC WEB SITE. 1 L 7 1 3O 3 O NT A00009CH E3SO 2005031000064 20050310 00064 SO 2005 3 10 2005FA0000021 2 20041224 G 7414 BL68256013 MAGNETO PIPER PA32 PA32R300 7103213 SO LYC 0540 IO540K1G5D 41532 SO HARTZL HCC2Y CHCC2YK1 GL ENGINE CRACKED B FFKR K NONE O OTHER IN INSP/MAINT 1 SO 05 333TG 336 336 32R7680320 L2299648A CH34693B WHEN PERFORMING A VISUAL INSPECTION OF THE ENGINE COMPARTMENT EXCESSIVE OIL WAS FOUND IN THE ENGINE COMPARTMENT. FOUND THE DUEL MAGNETO MOUNTING FLANGE CRACKED. REMOVED MAGNETO, CRACKED MOUNTING FLANGE PIECE FELL OFF OF MAGNETO HOUSING. 1 L 7 1 3O 3 O A3SO 1E4 5 C P920 2005031000057 20050310 00057 CE 2005 3 10 2005FA0000022 1 20041228 G 7111 COWL FLAP CESSNA 337 T337C 2075714 CE INOPERATIVE G O OTHER F FLT CONT AFFECTED CR CRUISE 1 NE 03 2663S 3370963 THE OWNER INSTALLED STC SA01091AT. THIS STC REMOVES THE ELECTRIC COWL FLAP MOTOR, AND INSTALLED A COMPLETELY MECHANICAL SYSTEM. THE OWNER COMPLAINED THAT HE COULD NOT THE CLOSE REAR COWL FLAP IN FLIGHT. 1 H 7 2 3O A6CE 2005020100008 20050201 00008 CE 2005 2 1 2005FA0000031 1 20041012 G 3230 CABLE BEECH MU300 400A 1155402 CE PWA JT15 JT15D5 52112 NE LT MLG BROKEN B E81R K NONE O OTHER IN INSP/MAINT 1 GL 03 494CW RK4 DURING SCHEDULED INSPECTION FOUND LT MAIN GEAR UPLOCK EMERGENCY EXTENSION CABLE BROKEN NEAR OB END. REPLACED CABLE WITH NEW PN128-380021-55 CABLE ASSEMBLY AND RIGGED IAW BE 400/400A, MM 32-30-00. ORIGINAL PN, PART TT NOT SUPPLIED, POSSIBL Y ORIGINAL. ASSEMBLY PN FOR THIS SN RANGE AIRCRAFT HAS BEEN SUPERSEDED TWICE IAW CURRENT BE 400/400A IPC. APPEARS TO H AVE FAILED FROM AGE/TIME IN SERVICE. RECOMMEND ESTABLISHING A LIFE-LIMIT ON THIS CABLE ALSO, OR ISSUE A SB REQUIRING IM PROVED PN CABLE INSTALLATION. TTAF: 5397.4 HRS. 2 H 7 2 4F 4 F RT A16SW E25EA 2005021500076 20050215 00076 2005 2 15 2005FA0000032 4 20041201 G 6113 05522311 BULKHEAD CESSNA 172 172S 2072439 CE LYC O360 IO360B1E 41514 EA MCAULY 1A170 1A170E GL SPINNER CRACKED B WIWR K NONE O OTHER IN INSP/MAINT 1 WP 07 35253 172S8831 DURING 100 HRS INSPECTION, FOUND FWD BULKHEAD OF THE SPINNER CRACKED 4 PLACES AROUND PROPELLER BOLT HOLES. RECOMMENDATI ON: BULKHEAD MATERIAL STRONGER OR THICKER. (WP07200507539) 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P857 2005020100002 20050201 00002 CE 2005 2 1 2005FA0000033 1 20041105 G 3297 SM50D7 RELAY BEECH 33 F33A 1151425 CE CONT O520 IO520* 17032 SO DYNAMIC BREAKER INTERMITTENT B VJ3R O OTHER O OTHER LD LANDING 1 WP 07 5530A CE1342 PILOT SELECTED GEAR DOWN AND NOTHING HAPPENED, SELECTED GEAR DOWN AGAIN AND GEAR CAME DOWN. ON FURTHER TROUBLESHOOTING FOUND RELAY WAS INTERMITTNET, PROBABLE CAUSE AT THIS TIME UNKNOWN, THIS IS SUPPOSE TO BE AN IMPROVED RELAY SO THERE IS N O RECOMMENDATIONS AT THIS TIME. 1 L 7 1 3O 3 O 3A15 E5CE 2005021500093 20050215 00093 CE 2005 2 15 2005FA0000034 1 20041019 G 2750 SM50D7 RELAY BEECH 200 B200C 1152924 CE PWA PT6 PT6A42 52043 NE TE FLAPS FAILED D O OTHER J WARNING INDICATION CR CRUISE 1 WP 19 7232R 69 BL69 WHILE THE AIRCRAFT WAS IN FLIGHT, THE FLAPS FAILED TO EXTEND TO THE SELELCTED APPROACH POSITION. THE PILOT CYCLED THE F LAP SELECT SWITCH TO UP AD BACK TO APPROACH AND THE FLAPS EXTENDED. MAINTENANCE INVESTIGATED THE REPORTED PROBLEM AND W AS ABLE TO DUPLICATE THE PROBLEM ON THE GROUND. WHEN THE FLAPS WERE SELECTED TO APPROACH THE FLAPS MOVED APPROXIMATELY 5 DEGREES AND QUIT MOVING. AFTER ACCESS WAS GAINED TO THE FLAP MOTOR/GEARBOX AND RELAY, A TAP ON THE RELAY RETURNED THE FLAPS TO NORMAL SELECTOR SWITCH RESPONSE OPERATION. INSTALLATION OF A REPLACEMENT RELAY SOLVED THE PROBLEM. THE (FAIL ED ) RELAY HAD 69.0 HOURS. (WP19200503541) 1 L 7 2 4T 4 T A24CE E4EA 2005021500100 20050215 00100 2005 2 15 2005FA0000035 4 20041216 G 2561 GA12P0201 LIFE VEST CABIN FAILED B KO1R O OTHER O OTHER NR NOT REPORTED 1 EA 25 INDIVIDUAL FLOAT DEVICE FAILED CELL PRESSURE TEST DUE TO INFLATION VALVE RUPTURE. DOM: NOV 1981. 2005030200040 20050302 00040 GL 2005 3 2 2005FA0000036 3 20041216 G 6111 C3260 PITCH ROD MCAULY 2AF34C D2AF34C305 GL YOKE CRACKED B ME4R K NONE O OTHER IN INSP/MAINT 1 SO 19 900205 MULTIPLE CRACKS WERE FOUND DURING MAGNAFLUX INSPECTION. BOTTOM AND TOP OF PITCH CHANGE YOKE. EXCESSIVE STRESS MIGHT HA VE BEEN THE CAUSE OF FAILURE. 5 C P5EA 2005021500104 20050215 00104 CE 2005 2 15 2005FA0000038 1 20041102 G 1430 NAS BOLT BBAVIA 7 7KCAB 21101P3 CE LYC O320 IO320* 41508 EA MLG ATTACH IMPROPER PART D K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 17 76ML 44674 DURING ANNUAL INSPECTION, IT WAS FOUND THAT ONE OF THE NAS BOLTS HOLDING THE IB END OF THE LANDING GEAR WAS TOO SHORT AN D DID NOT GO ALL THE WAY THROUGH THE NAS NUT. THESE BOLTS WERE INSTALLED AT THE FACTORY, DURING A REPAIR IN 2001. FAIL URE WOULD RESULT IN ONE LANDING GEAR LEG COLLAPSING. (EA17200504802) 1 H 7 1 3O 3 O A759 1E12 2005033000067 20050330 00067 SO 2005 3 30 2005FA0000039 1 20041207 G 7120 79584008 MOUNT PIPER PA28 PA28140 7102802 SO LYC O320 O320* 41508 EA ENGINE BROKEN B N9VR O OTHER O OTHER LD LANDING 1 SO 03 7063C 3552 287625068 FOLLOW A LANDING, THE FORWARD AND AFT MOUNTING THAT SECURE THE ALTERNATOR TO THE AIR CONDITIONER MOUNT BROKE, ALLOWING T HE ALTERNATOR TO SLIP, STRIKING AND DAMAGING THE LOWER NOSE BOWL. 1 L 7 1 3O 3 O 2A13 E274 2005033000068 20050330 00068 SW 2005 3 30 2005FA0000040 1 20041218 G 2612 1734361600F FIRE DETECTOR SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP RT ENGINE FAILED B OZ5R A UNSCHED LANDING N FALSE WARNING CL CLIMB 1 NM 05 158MC AC726B RT ENGINE FIRE WARNING LIGHT FLICKERED ON AND OFF DURING CLIMB. CREW RETURNED TO STATION. FAILED FIRE DETECTOR PROBE ( CENTER CERAMIC INSULATOR LOOSE). REPLACED FIRE DETECTOR LOCATED BELOW THE OIL COOLER MOUNTED ON THE FIREWALL. (NM052004 00110) (K) 2 L 7 2 4T 4 T RT A8SW E4WE 2005020100066 20050201 00066 SW 2005 2 1 2005FA0000041 1 20041231 G 2150 20475546 ACM SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP RIGHT SEIZED B OZ5R O OTHER B SMOKE/FUMES/ODORS/SPARKS LD LANDING 1 NM 05 430MA 2959 AC710B ON TOUCHDOWN, THE CREW NOTICED AN ACRID SMELL IN THE COCKPIT. THE CREW LANDED AND TAXIED IN WITH NO FURTHER INCIDENT. TROUBLESHOOTING FOUND THE SOURCE TO THE RT ACM. INITALLY DEFERRED ACM IAW MEL, LATER CHANGED THE ACM, MEL WAS CLEARED. (NM05200403534) (K) 2 L 7 2 4T 4 T RT A8SW E4WE 2005033000069 20050330 00069 SW 2005 3 30 2005FA0000042 1 20040303 G 3260 MS246614 SQUAT SWITCH SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP MLG DAMAGED B OZ5R A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 NM 05 159MC AC726B LANDING GEAR WOULD NOT RETRACT DURING CLIMBOUT, WHEN CREW WAS RETURNING FOR LANDING, GPWS GAVE (TO LOW GEAR) ALERT. THE CREW THEN INITIATED A GO-AROUND, ASKED TOWER TO CONFIRM, THREE GEAR DOWN, DID CONFIRM. CREW DECLARED EMERGENCY, MADE N ORMAL LANDING, DURING TAXI, DISCOVERED NOSE WHEEL STEERING WAS INOPERATIVE. MAINTENANCE TO VERIFY DISCREPANCY, GEAR RET RACTED CORRECTLY. FURTHER TROUBLESHOOTING COULD NOT GET GEAR TO FAIL TO OPERATE WHILE ON JACKS. REPLACED LT OB MAIN GE AR SQUAT SWITCH, DUE TO SUSPECTED WATER INGRESSION, CHANGED LANDING GEAR CONTROL HANDLE AND LT LANDING GEAR CONTROL CIRC UIT BREAKER, PRECAUTIONARY ACTION. AC WAS RELEASED AND OPS CHECK FLIGHT WAS PERFORMED WITH NO FURTHER DEFECTS NOTED. 2 L 7 2 4T 4 T RT A8SW E4WE 2005031100073 20050311 00073 SW 2005 3 11 2005FA0000043 1 20040304 G 5270 WARNING SYSTEM SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP CARGO DOOR MALFUNCTIONED B OZ5R O OTHER N FALSE WARNING DE DESCENT 1 NM 05 430MA AC710B CARGO DOOR WARNING LIGHT CAME ON IN FLIGHT DURING THE START OF THE DESCENT TO THE NEXT STATION. ATC WAS NOTIFIED. THE LIGHTS STAYED ON FOR APPROXIMATELY 10 MINUTES. DOOR CLOSING PROCEDURES, DOOR HARD TO CLOSE, DOOR CLICK CLACK RIGGING/LU BRICATION, OR SWITCH RIGGING. ALL CLICK CLACKS AND MICRO SWITCHES. NO DEFECTS NOTED. AN OPERATIONAL CHECK FLIGHT WAS COMPLETED WITH NO DISCREPANCIES. AIRCRAFT WAS RETURNED TO SERVICE. (K) 2 L 7 2 4T 4 T RT A8SW E4WE 2005031100074 20050311 00074 SW 2005 3 11 2005FA0000044 1 20040307 G 6120 8690671 BLOCK FRCHLD SA227 SA227DC 3377521 SW GARRTT TPE331 TPE33112UA 01514 WP BETA SYS LEAKING B OZ5R A UNSCHED LANDING B J SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CL CLIMB 1 NM 05 850LS DC850B AFTER TURNING BLEEDS ON DURING CLIMB, CREW IMMEDIATELY NOTICED AN ODOR AND THEN SAW SMOKE. BLEEDS WERE TURNED OFF, CHEC KLIST ITEMS COMPLETED. CHECKED FOR ANNUNCIATOR LIGHTS, PRESSURE INDICATIONS, AND FIRE LIGHT INDICATIONS, ALL WERE NORMA L. CREW RETURNED TO STATION AND LANDED WITH NO FURTHER INCIDENT. INITALLY SUSPECTED ACM FAILURE, BUT FOUND OIL LEAKING IN THE LT ENGINE SPINNER/ COWL AREA. TIGHTEN FITTING, SAFETIED AND PERFORMED GROUND RUN LEAK CHECK, OPS CHECK GOOD. P ERFORMED OPERATIONAL CHECK FLIGHT, OPS CHECK GOOD. (K) 2 L 7 2 4T 4 T RT A18SW E4WE 2005033000070 20050330 00070 SW 2005 3 30 2005FA0000045 1 20040320 G 5230 DOOR FRCHLD SA227 SA227DC 3377521 SW GARRTT TPE331 TPE33112UA 01514 WP CARGO CLICKCLACK MALFUNCTIONED B OZ5R A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 NM 05 854LS DC854B THE CARGO DOOR WARNING LIGHT CAME ON DURING CLIMBOUT, CREW RETURNED TO THE STATION. ONE OF THE FOLLOWING: DOOR CLOSING PROCEDURES, DOOR HARD TO CLOSE, DOOR CLICK CLACK RIGGING/ LUBRICATION, OR SWITCH RIGGING. ALL SWITCHES AND CLICK CLACK S WERE INSPECTED AND LUBRICATED, NO DEFECTS WERE NOTED. AIRCRAFT GROUND PRESSURIZATION RUN WAS PERFORMED, OPS CHECKED G OOD. (NM05200403789) (K) 2 L 7 2 4T 4 T RT A18SW E4WE 2005033000071 20050330 00071 SW 2005 3 30 2005FA0000046 1 20040322 G 5230 27240050027 DOOR SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP CARGO OUT OF ALIGNMENT B OZ5R A UNSCHED LANDING O OTHER CL CLIMB 1 NM 05 159MC AC728B CARGO DOOR WARNING LIGHT CAME ON AS POWER WAS BEING APPLIED FOR TAKEOFF, CREW DISCONTINUED TAKEOFF ROLL AND RETURNED TO GATE. ONE OF THE FOLLOWING: DOOR CLOSING PROCEDURES, DOOR HARD TO CLOSE, DOOR CLICKCLACK RIGGING/ LUBRICATION, OR SWITC H RIGGING. CLICK CLACKS, BAYONET PINS, MICROSWITCHES WERE CLEANED AND LUBED. DOOR OPS CHECK GOOD, FLIGHT CONTINUED WIT H NO FURTHER DOOR PROBLEMS. 2 L 7 2 4T 4 T RT A8SW E4WE 2005033000072 20050330 00072 SW 2005 3 30 2005FA0000047 1 20040407 G 2435 23079010 STARTER GEN FRCHLD SA227 SA227DC 3377521 SW GARRTT TPE331 TPE33111U 01514 WP RIGHT FAILED B OZ5R O OTHER J WARNING INDICATION DE DESCENT 1 NM 05 453LA DC852B ON DESCENT RT GENERATOR FAILED, CREW TRIED TO RESET GEN, AS CREW WAS FOLLOWING PROCEDURES TO DETERMINE SOURCE OF MALFUNC TION, LT GEN TRIPPED OFFLINE, POSSIBLY DUE TO LOAD. LT GEN WAS RESET AND STAYED ON LINE BRIEFLY, THEN TRIPPED OFFLINE A GAIN. CREW WAS IN VFR CONDITIONS WITH AIRPORT IN SIGHT, LANDED WITHOUT INCIDENT. SUSPECTED GEN PARALLELING CIRCUIT PRO BLEM, GCU OR STARTER GEN PROBLEM. AFTER EXTENSIVE TROUBLESHOOTING, DETERMINED THAT GENERATOR FUNCTION OF RT STARTER GEN ERATOR HAD FAILED. IT IS SUSPECTED THAT THER IS AN INTERNAL PROBLEM WITH STATOR WINDINGS. BRUSHES AND COMMUTER WERE IN SPECTED AND FOUND IN GOOD SERVICEABLE CONDITION. START GEN TEARDOWN EVALUATION HAS BEEN REQUESTED. 2 L 7 2 4T 4 T RT A18SW E4WE 2005021500136 20050215 00136 SW 2005 2 15 2005FA0000048 1 20040503 G 5230 HANDLE SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP CARGO DOOR INCORRECT B OZ5R O OTHER J WARNING INDICATION CL CLIMB 1 NM 05 159MC AC728B THE CARGO DOOR WARNING LIGHT CAME ON DURING CLIMBOUT, CREW RETURNED TO STATION. ONE OF THE FOLLOWING: DOOR CLOSING PRO CEDURES, DOOR HARD TO CLOSE, DOOR CLICKCLACK RIGGING/ LUBRICATION, OR SWITCH RIGGING. MAINTENANCE FOUND HANDLE NOT FULL Y ROTATED TO CLOSED POSITION, CHECKED DOOR AND CLICKCLACKS, RECLOSED THE DOOR AND STOWED THE HANDLE, NO FURTHER PORBLEMS NOTED. CREW CONTINUED FLIGHT WITH NO FURTHER INCIDENTS. (NM05200404459) (K) 2 L 7 2 4T 4 T RT A8SW E4WE 2005021500079 20050215 00079 2005 2 15 2005FA0000051 4 20041226 G 3421 5040030911 INDICATOR SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP ATTITUDE MALFUNCTIONED B OZ5R A UNSCHED LANDING O OTHER CR CRUISE 1 NM 05 60NE 760B NOTE: WRITTEN UP BY CREW AS DG PRECESSING. VERIFIED WITH MAINTENANCE THAT THE ATTITUDE INDICATOR WAS PRECESSING. BAD A TTITUDE INDICATOR. REMOVED AND REPLACED FO ATTITUDE INDICATOR. NO OTHER DEFECTS NOTED. 2 L 7 2 4T 4 T RT A8SW E4WE 2005021500153 20050215 00153 SW 2005 2 15 2005FA0000052 1 20040515 G 2100 22008681 VANE SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP CABIN AIR FAILED B OZ5R O OTHER B SMOKE/FUMES/ODORS/SPARKS LD LANDING 1 NM 05 60NE AC760B MRR-M04-10, AIRCRAFT FILLED WITH SMOKE DURING LANDING. CREW TAXIED IN WITH NO FURTHER INCIDENT. SUSPECT ACM COOLING T URBINE FAILURE. INITIALLY DEFERRED THE NR 1 ACM, DURING TROUBLESHOOTING, FOUND THE DESWIRL VANE CENTER SUPPORT STRUTS H AD ALL FAILED. REPLACED ACM ASSEMBLY, DUE TO FAILURE OF THE INLET AIR DESWIRL VANE SUPPORT STRUTS. THE CENTER CONE HAD SHIFTED DUE TO THE BROKEN SUPPORT STRUTS. THIS CAUSED DECREASED AIRFLOW, LEADING TO HIGHER TEMPERATURES, CAUSING SMOKE IN THE CABIN. THIS PART IS A LOW FAILURE ITEM. THE NEW PART USED TO REPLACE IS A PMA PART THAT IS ALUMINUM, NOT THE C OMPOSITE COMPOSITION OF THE OLD PART. (K) 2 L 7 2 4T 4 T RT A8SW E4WE 2005021500169 20050215 00169 WP 2005 2 15 2005FA0000053 2 20040602 G 7310 31024692 LINE SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP MANIFOLD LEAKING B OZ5R C ABORTED TAKEOFF K J FLUID LOSS WARNING INDICATION TO TAKEOFF 1 NM 05 159MC AC728B MRR-M04-11, ENGINE RPM ONLY WENT TO 97 PERCENT DURING TAKEOFF ROLL AND TORQUE WAS ALSO LOW, ALSO, THERE WAS LITTLE RESPO NSE TO POWER LEVER MOVEMENT. CREW ABORTED TAKEOFF AND RETURNED TO THE GATE. INITIALLY SUSPECTED FCU FAILURE, BUT UPON INSPECTION FOUND FCU INPUT ARM ROD END DISCONNECTED. RECONNECTED ROD END AND SAFETIED. A FUEL LEAK WAS NOTED WHEN COWL ING WAS OPENED, AND WAS FOUND TO BE COMING FROM THE SECONDARY FUEL MANIFOLD LOCATED AT THE 8:00 O’CLOCK POSITION. THE F UEL MANIFOLD LINE WAS REPLACED. MR`S WERE ISSUED TO INSPECT ALL OTHER AIRCRAFT FUEL MANIFOLD LINES, FUEL NOZZLE TASK CA RD WAS ISSUED TO INCLUDE INSPECTION OF THE MANIFOLD LINES AT EACH INSPECTION. 2 L 7 2 4T 4 T RT A8SW E4WE 2005033000073 20050330 00073 SW 2005 3 30 2005FA0000054 1 20040811 G 5230 2724052005 SEAL FRCHLD SA227 SA227DC 3377521 SW GARRTT TPE331 TPE33112UA 01514 WP CARGO DOOR PINCHED B OZ5R O OTHER J WARNING INDICATION CL CLIMB 1 NM 05 853LS DC853B MRR-M04-12, CARGO DOOR WARNING LIGHT ON ANNUNCIATOR AND SECONDARY DOOR UNSAFE WARNING ON SIDE PANEL BOTH CAME ON DURING CLIMBOUT. CREW FOLLOWED PROCEDURES, RETURNED. CREW CHECKED CARGO DOOR HANDLE, FOUND FULLY STOWED UPON RETURN. RIGGING OR ADJUSTMENT OF DOOR. FOUND DOOR SEAL SHIMMED TO TIGHTLY AT DOOR LWR EDGE OPENING, CAUSING DOOR TO BE HARD TO CLOSE. SEAL WAS SHIMMED THIS TIGHTLY IN PART DUE TO SEAL NOT INFLATING TO FULL PRESSURE, DUE TO INFLATION LINE NOT BEING FULLY ALIGNED WITH FEED THROUGH FOR IT IN THE DOOR FRAME. DOOR SEAL WAS REPLACED, MAINTAINING ALIGNMENT OF SEAL. DOOR SEAL S WITCHES WERE ADJUSTED. CARGO DOOR WARNING SYS AND LATCH SYS WAS OPS CHECKED AND OPERATED CORRECTLY. 2 L 7 2 4T 4 T RT A18SW E4WE 2005033000074 20050330 00074 SW 2005 3 30 2005FA0000055 1 20041010 G 3230 246006 SELECTOR VALVE SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP MLG FAILED B OZ5R O OTHER J WARNING INDICATION DE DESCENT 1 NM 05 27465 613 AC755B MRR-M04-14, THE LANDING GEAR FAILED TO EXTEND USING NORMAL OR ALTERNATE BUSS, CREW FOLLOWED EMERGENCY CHECKLIST AND EXTE NDED GEAR USING MANUAL GEAR EXTENSION SYSTEM. THE CREW LANDED WITH NO FURTHER INCIDENT. FAILED HYDRAULIC LANDING GEAR SELECTOR VALVE. INITIALLY REPOSITIONED AIRCRAFT UNDER A SPECIAL FERRY PERMIT TO MAINTENANCE BASE, THEN CHANGED THE GEAR SELECTOR VALVE. GEAR OPS CHECKED GOOD. (NM0520050916) (K) 2 L 7 2 4T 4 T RT A8SW E4WE 2005033000075 20050330 00075 SW 2005 3 30 2005FA0000056 1 20041014 G 2910 LINE FRCHLD SA227 SA227DC 3377521 SW GARRTT TPE331 TPE33112UA 01514 WP HYDRAULIC SYS FAILED B OZ5R O OTHER J WARNING INDICATION CR CRUISE 1 NM 05 1119K DC830B MRR-M04-15, BOTH HYDRAULIC PRESSURE LOW LIGHTS CAME ON INFLIGHT. CREW CHECKED GAGE AND FOUND HYDRAULIC PRESSURE AT (0). HYDRAULIC FLUID LOSS DO TO SYSTEM LEAK. REPLACED LINE IN LEFT WHEEL WELL. LEAK CHECKED ALL SYSTEM LINES AFTER REPAIR , NO ADDITIONAL LEAKS NOTED. (NM05200502367) (K) 2 L 7 2 4T 4 T RT A18SW E4WE 2005033000076 20050330 00076 SW 2005 3 30 2005FA0000057 1 20041114 G 2910 27810321857 LINE SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP HYDRAULIC SYS PIN HOLE B OZ5R O OTHER J WARNING INDICATION CR CRUISE 1 NM 05 27465 AC755B MRR-M04-16, DURING CRUISE, CREW NOTED LOSS OF HYDRAULIC PRESSURE, ENROUTE TO NEXT STATION. HYDRAULIC LINE LEAK. REPLAC ED HYDRAULIC GEAR UP LINE LOCATED UNDER THE FLOORBOARDS IN THE CABIN ON LT SIDE OF THE AIRCRAFT. (NM05200502368) (K) 2 L 7 2 4T 4 T RT A8SW E4WE 2005033000077 20050330 00077 SW 2005 3 30 2005FA0000058 1 20041123 G 2910 LINE SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP HYDRAULIC SYS LEAKING B OZ5R O OTHER J WARNING INDICATION CL CLIMB 1 NM 05 27465 AC755B MRR-M04-17, DURING CLIMBOUT, CREW NOTED LOSS OF HYDRAULIC PRESSURE ENROUTE TO NEXT STATION. HYDRAULIC LINE LEAK. REPLA CED NOSE GEAR UP HYDRAULIC LINE, LEAK CHECK AND OPS CHECK GOOD. (NM05200502369) (K) 2 L 7 2 4T 4 T RT A8SW E4WE 2005031100047 20050311 00047 SW 2005 3 11 2005FA0000059 1 20041203 G 2621 3030020 FIRE BOTTLE SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP EMPTY B OZ5R O OTHER J WARNING INDICATION CR CRUISE 1 NM 05 3114G AC583 MRR-M04-18, DURING FLIGHT THE LT FIRE EXTINGUISHER (E) LIGHT CAME ON BRIEFLY SEVERAL TIMES. THE CREW MONITORED THE LIGH T AND THE FLIGHT WAS CONTINUED TO THE DESTINATION WITH NO INCIDENT. FIRE EXTINGUISHER (E) LIGHT WAS FOUND ON, AND THE F IRE EXTINGUISHER BOTTLE WAS FOUND EMPTY DURING TROUBLESHOOTING BY MAINTENANCE. THE SQUIB HAD BEEN FIRED. REPLACED FIRE EXTINGUISHER BOTTLE AND SQUIB HAD BEEN FIRED. REPLACED FIRE EXTINGUISHER BOTTLE AND SQUIB. FIRE BOTTLE PN: 3030020, S N 05782B1 OH 7-14-04, INSTALLED 7-19-04. NO DEFECTS WERE NOTED DURING TROUBLESHOOTING OR PARTS CHANGES. PRESS TO TEST FUNCTION AND ALL OTHER FUNCTION CHECKS WERE GOOD. (K) 2 L 7 2 4T 4 T RT A8SW E4WE 2005033000078 20050330 00078 SW 2005 3 30 2005FA0000060 1 20041205 G 2120 SMOKE SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP COCKPIT DETECTED B OZ5R B EMER. DESCENT B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 NM 05 3114G AC583 MRR-M04-19, CREW NOTICED SMOKE IN COCKPIT AS THEY WERE CLIMBING THROUGH 12,000 FT, DESCENDED TO 10,000 FT, DEPRESSURIZED , TURNED OFF BLEEDS, AND CONTINUED TO STATION UNPRESSURIZED. SUSPECTED ACM FAILURE OR BLEED HEAT CNTRL VALVE FAILURE. RAN BOTH ENG FOR 20 MIN, NO SMOKE NOTICABLE IN CABIN. INSPECTED LT AND TR TEMP CNTRL VALVES, WITH NO DEFECTS NOTED. IN SPECTED LT AND RT ACMS, WITH NO DEFECTS NOTED. SERVICED BOTH ACMS AND REMOVED, CLEANED, REINSTALLED WATER SOCKS. RAN E NG SECOND TIME WITH NO DEFECTS NOTED. COULD NOT DUPL ORIGINAL WRITE-UP. WATER SEPARATOR ICED UP, AND WHEN IT WARMED U P, STEAM CAME THROUGH, MIMICING SMOKE. (NM05200502386) (K) 2 L 7 2 4T 4 T RT A8SW E4WE 2005033000079 20050330 00079 SW 2005 3 30 2005FA0000061 1 20041219 G 2910 LINE SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP HYDRAULIC SYS CRACKED B OZ5R O OTHER J WARNING INDICATION CR CRUISE 1 NM 05 27465 AC755B MRR-M04-20, DURING CRUISE, CREW NOTED LOSS OF HYDRAULIC PRESSURE ENROUTE TO NEXT STATION. THEY DIVERTED TO AN AIRPORT W ITH BETTER RUNWAYS FOR LANDING FLAPS UP AND WITH NO NOSE WHEEL STEERING. CREW MANUALLY EXTENDED THE GEAR, THE LANDED FL APS UP AND WITHOUT NOSE WHEEL STEERING. CREW LANDED WITH NO FURTHER INCIDENT. HYDRAULIC LINE LEAK. REPLACED HYDRAULIC GEAR UP LINE IN THE COCKPIT, LEAK CHECK AND OPS CHECK GOOD. CRACK OR EROSION IN THE BEND RADIUS SEEMS TO ORIGINATE AT TOOLING MARKS IN THE OUTSIDE OF THE CURVE. THIS IS A MFG (FACTORY) MADE LINE. LINE WAS REPLACED, BOTH HYD PUMPS AND FI LTER WERE REPLACED DUE TO BEING RUN MORE THAN 20 MIN W/O HYDRAULIC FLUID. SYSTEM OPS CHECKED GOOD. (NM05200502387) (K) 2 L 7 2 4T 4 T RT A8SW E4WE 2005031100038 20050311 00038 SW 2005 3 11 2005FA0000062 1 20041222 G 5230 HANDLE SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP CARGO DOOR OUT OF RIG B OZ5R B EMER. DESCENT J WARNING INDICATION CR CRUISE 1 NM 05 60NE AC760B CARGO DOOR WARNING LIGHT CAME ON IN FLIGHT, CREW DESCENDED AND DEPRESSURIZED, AND THE LIGHT WENT OUT. CREW LANDED AT CL OSEST AIRPORT. FOUND CARGO DOOR HANDLE NOT COMPLETELY STOWED WHEN CHECK AT ARRIVAL. INSPECTED CARGO DOOR AND LATCHES, CLEANED AND LUBED SWITCHES. DOOR OPS CHECK GOOD. NO FURTHER PROBLEMS NOTED WITH THE DOOR. (NM05200502388) (K) 2 L 7 2 4T 4 T RT A8SW E4WE 2005031100043 20050311 00043 SW 2005 3 11 2005FA0000063 1 20041225 G 3233 2752010003 ACTUATOR SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP NLG FAILED B OZ5R A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 NM 05 27465 57 755B RED GEAR NOSE UNSAFE LIGHT CAME ON IN FLIGHT. LANDED, CHECKED NOSE GEAR WELL NOTICED RT GEAR ACTUATOR BROKE. FORWARD E ND OF ACTUATOR BROKE OFF. AIRCRAFT BROUGHT BACK, BROKEN ACTUATOR REMOVED AND BRACE MFG AND INSTALLED IAW SFP. UPON RE TURN, NLG STRUT AND WHEEL WELL WERE INSPECTED FOR DAMAGE WITH NO DEFECTS NOTED. AN OVERHAULED ACTUATOR WAS INSTALLED, R IGGED, AND A LEAK AND OPERATION CHECKS WERE PERFORMED WITH NO OTHER DEFECTS NOTED. (K) 2 L 7 2 4T 4 T RT A8SW E4WE 2005031100039 20050311 00039 WP 2005 3 11 2005FA0000064 2 20041206 G 7261 31080261 SCAVENGE PUMP SWRNGN SA227 SA227* SW GARRTT TPE331 TPE33111U 01514 WP NR 2 ENGINE FAILED B OZ5R E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 NM 05 430MA AC710B MRR-M04-23, NR 2 ENGINE OIL PRESSURE LIGHT CAME ON AS FLIGHT LEVELED OUT IN CRUISE, OIL PRESSURE GAUGE WAS CHECKED AND F OUND PRESSURE DROPPING. CREW DID A PRECAUTIONARY INFLIGHT SHUTDOWN, AND RETURNED TO STATION. LOSS OF OIL PRESSURE DUE TO LOSS OF OIL FRM REAR SCAVANGE PUMP AREA. REMOVED ENGINE, REPLACED SCAVANGE PUMP AND REINSTALLED ENGINE. MFG HAS CHA NGED PUMP DESIGN TO DECREASE REAR SCAVANGE PUMP FAILURES. (K) 2 L 7 2 4T 4 T RT A5SW E4WE 2005032800094 20050328 00094 CE 2005 3 28 2005FA0000068 1 20041202 G 5312 BULKHEAD CESSNA 206 P206 2073304 CE CONT O520 IO520* 17032 SO FUSELAGE CRACKED C K NONE O OTHER IN INSP/MAINT 1 SO 09 2527X P2060027 WHILE PERFORMING INSPECTION PORTION OF AD PERTAINING TO THE AFT VERTICAL FIN ATTACHMENT BULKHEAD, ONE CRACK WAS FOUND I N EACH OF LOWER IB PORTIONS OF THE RUDDER CABLE CUTOUTS AT APPROXIMATELY THE 4 O`CLOCK POSITION ON THE LT CUTOUT AND THE 8 O`CLOCK POSITION ON THE RT CUTOUT. CRACKS WERE EACH APPROX .2500 INCH LONG, ORIGINATING AT THE EDGE OF THE CUTOUT AN D TRAVELING IN A DIRECTION PERPENDICULAR TO GANGENT OF RADIUS OF CUTOUT AT POINT OF ORIGIN. ALL OTHER AREAS OF INSP PRE SCRIBED BY AD WERE FOUND TO BE WITHIN LIMITS AND NO OTHER DISCREPANCIES WERE FOUND. NO OBVIOUS REASON FOR CRACKS IN THI S LOCATION UNLESS POINTS OF CONCENTRATED STRESS CAUSED BY RUDDER DEFLECTION. (SO09200502375) (SO09200502381) (K) 1 H 7 1 3O 3 O A4CE E5CE 2005021500125 20050215 00125 NE 2005 2 15 2005FA0000069 2 20040913 G 7320 660526AS TRANSDUCER DHAV DHC2 DHC2* 2800108 EA PWA R985 R985AN14B 52008 NE FUEL FLOW MALFUNCTIONED B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 1018A 551 178 REMOVED FUEL FLOW TRANSDUCER (PN 660526AS) INSTALLED UNDER STC NR SA809GL. UNIT PROVIDING ERRONEOUS FUEL FLOW READINGS AND CAUSING THE AIR DATA COMPUTER (ADC) ALSO INSTALLED IN THE AIRCRAFT TO FUNCTION IMPROPERLY. AIR DATA COMPUTER INSTAL LED UNDER IAW STC NR SA02203AK. 1 H 7 1 3R 3 R A806 5E1 2005021500137 20050215 00137 NE 2005 2 15 2005FA0000070 2 20040913 G 7320 660526AS TRANSDUCER DHAV DHC2 DHC2MK1 2800102 EA PWA R985 R985AN14B 52008 NE FUEL FLOW MALFUNCTIONED B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 67673 651 1284 REMOVED FUEL FLOW TRANSDUCER (PN 660526AS) INSTALLED UNDER STC SA809GL. UNIT PROVIDING ERRONEOUS FULE FLOW READINGS AND CAUSING THE AIR DATA COMPUTER (ADC) ALSO INSTALLED IN THE AC TO FUNCTION IMPROPERLY. AIR DATA COMPUTER INSTALLED IAW S TC SA02203AK. (K) 1 H 7 1 3R 3 R A806 5E1 2005021500135 20050215 00135 2005 2 15 2005FA0000072 4 20040715 G 2320 9903333142 AUDIO CONTROL AMD FALC50 FALCON50MYST 2730106 EU GARRTT TFE731 TFE73140 29001 NE COCKPIT INOPERATIVE B GJQR O OTHER B SMOKE/FUMES/ODORS/SPARKS AP APPROACH 1 NM 01 39WP 294 FLIGHT CREW REPORTED ACRID SMELL IN THE COCKPIT ON APPROACH TO LANDING. NR 2 VHF COMM NOT FUNCTION REPORTED BY FLIGHTCR EW. INSPECTION DID CONFIRM NR 2 COMM TRANSCEIVER WAS INOPERATIVE. REMOVED AND REPLACED WITH SERVICEABLE UNIT. ADDITIO NAL TROUBLESHOOTING AND INSPECTION TO AIRFRAME AND AVIONICS RELATED COMPONENTS DID REVEAL THE AUDIO CONTROL PANEL (PN990 -3333-142) NR 2 VHF COMM TRANSCEIVER. AUDIO CONTROL PANEL RETURNED FOR INSPECTION, REPAIR AND RETURNED TO SERVICE. (NM 01200501124) (K) 2 L 7 3 4F 4 F A46EU E1NM 2005033000122 20050330 00122 GL 2005 3 30 2005FA0000081 3 20040901 G 6111 84334 BLADE HARTZL HCA2V HCA2VF2 GL PROPELLER CRACKED B NWOR O OTHER O OTHER NR NOT REPORTED 1 SW 05 Y2155 PROPELLER BLADE CRACKED .33 OF DIAMETER AT RETENTION GROVE. (K) 5 C P24EA 2005033000123 20050330 00123 2005 3 30 2005FA0000082 1 20040722 G 1430 SL12596 BOLT CONNECTING ROD MISMANUFACTURED B YYBR O OTHER O OTHER NR NOT REPORTED 1 GL 03 THE CONNECTING ROD BOLT, PN SL12596, LOT NR 575765, WAS FOUND TOO SHORT FOR PROPER INSTALLATION. THE FREE LENGTH OF THE BOLTS IN QUESTION WERE 2.2485 TO 2.2491. MFG SL1458B REQUIRES A TWO STEP TORQUE PROCESS. FIRST, TORQUE BOLTS TO 35 FT LBS AND MEASURE, IF THE BOLT IS SHORTER THAN 2.255, THE BOLT IS REJECTED. SECOND, THE BOLT MUST NOT EXCEED LENGTH OF 2 .256 AT THE FINAL TORQUE OF 55 FT LBS. THE SUSPECT BOLTS WOULD NOT ATTAIN REQUIRED LENGTH AT 35 FT LBS. THE DEFECT IS CAUSED BY GRINDING THE BOLT TOO SHORT OF A DIMENSION AT MFG. AN INSPECTION RATE WOULD NEED TO BE INREASED TO A LEVEL TH AT WOULD ENSURE PROPER QUALITY CONTROL. (K) 2005030100043 20050301 00043 CE 2005 3 1 2005FA0000085 1 20041214 G 2820 151613621 FUEL LINE CESSNA 337 P337H 2075731 CE CONT O470 TSIO470* 17026 SO FUEL SYSTEM SPLIT D A UNSCHED LANDING K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 NE 05 991 1006 P3370350 AIRCRAFT DEPARTED BGR, TEMPERATURE THE PREVIOUS RIGHT AND DAY WERE CLOSE TO FREEZING. AIRCRAFT RETURNED WITH FUEL SMELL IN COCKPIT. INVESTIGATION FOUND LT FUEL CROSSFEED LINE HAD SPLIT. UPON REMOVAL OF LINE, PRESENCE OF WATER WAS FOUND. PROBABLE CAUSE WAS WATER FROZEN IN LINE. THERE ARE NO PROVISIONS OR PROCEDURES TO DRAIN THIS OR THE RT CROSSFEED LINES . (NE05200503189) (K) 1 H 7 2 3O 3 O A6CE 3E3 2005030100023 20050301 00023 CE 2005 3 1 2005FA0000086 1 20041217 G 2721 PIN CESSNA 182 182T 2072703 CE LYC O540 IO540* 41532 EA COCKPIT OUT OF ADJUST D K NONE O OTHER NR NOT REPORTED 1 SW 13 72KF 32 18281361 TRANSIT CUSTOMER HAD RUDDER TRIM STICK IN FULL RT TRIM CONDITION AND COULD NOT TRIM LT. FOUND THAT IF TRIMMED TOO FAR T O RT. THE INDICATOR PIN WOULD JUMP OUT OF TRIM WHEEL TRACK AND COULD LOCK TRIM WHEEL. WE READJUSTED INDICATOR PIN AND CENTERED CONTROLS. THIS IS THE 2ND INCIDENT. (K) 1 H 7 1 3O 3 O NT 3A13 1E4 2005030100053 20050301 00053 GL 2005 3 1 2005FA0000087 1 20040430 G 2497 VM1000DPU WIRE AVIAT A1 A1B 2210406 GL LYC O360 O360A1D 41514 EA ELECTRICAL SYS LOOSE D K NONE O OTHER IN INSP/MAINT 1 NE 05 36HY 117 2154 DURING TROUBLESHOOTING OF WIRES IN VM1000 SYSTEM, WIRE J4-13, VOLTAGE SENSE, CAME LOOSE AND SHORTED TO GROUND. THIS WIR E IS CONNECTED DIRECTLY TO BUS WITH NO CIRCUIT PROTECTION. LATER MODEL AIRCRAFT DO INCORPORATE CIRCUIT PROTECTION IAW M FG. RECOMMEND EARLIER AIRCRAFT BE RETRO-FITTED WITH NEW DESIGN. WIRE IS HELD IN WITH SCREW CLAMP TYPE TERMINAL. IF TH IS HAD COME LOOSE IN FLIGHT AND IN-FLIGHT FIRE COULD HAVE OCCURRED. (K) 1 H 7 1 3O 3 O NC A22NM E286 2005033000126 20050330 00126 EU 2005 3 30 2005FA0000088 1 20041209 G 2450 HOLDER BRAERO 1000 BAE1251000A 1500104 EU PWA 305 PW305 NE ELECTRICAL FUSE DESTROYED B R14R O OTHER O OTHER NR NOT REPORTED 1 EA 17 533QS 259033 AIRCRAFT WAS SQUAWKED WITH NR 1 ALTERNATOR DROPPING OFF IN FLIGHT. DURING TROUBLESHOOTING THE TECHNICIAN FOUND SMOKE TR AILS ON THE GG PANEL. LOCATED ON THE AFT SIDE OF THE REAR FACE OF THE PRESSURE BULKHEAD. A MORE CLOSE INSPECTION REVEA LED A DESTROYED FUSE HOLDER WITH ACCOMPANING WIRE DAMAGE, GCU AND LINE CONTACTOR DAMAGE, AND A HOLE BURNED THROUGH THE G G PANEL ITSELF AT THE FUSE HOLDER LOCATION. THE DAMAGE WAS CENTERED UNDER THE LEFT SIDE OF THE FUSE BLOCK WHICH HAD DES INTERGRATED. IT WAS UNDETERMINED AS TO WHICH COMPONENT INITIATED THE DAMAGE. (EA17200504804) 2 L 7 2 4F 4 F RT A3EU E35NE 2005030100046 20050301 00046 CE 2005 3 1 2005FA0000089 1 20041202 G 2421 ARMATURE BEECH 95 95 1153402 CE LYC O360 O360A4A 41514 EA GENERATOR FAILED D O OTHER M OVER TEMP NR NOT REPORTED 1 NM 01 21JC 10887 TD224 L1071836AC THE GENERATOR WAS JUST O/H, WITHOUT DISASSEMBLING THE GENERATOR, LOOKING IN TO PULLEY SIDE, YOU COULD SEE THAT THE ARMAT URE HAD PARTIALLY UNWOUND. TO THE POINT WHERE ONE ARMATURE WIRE WAS RUBBING LARGE AMOUNTS OF FIELD COVERING OFF. THIS CAUSED THE ARMATURE WIRE TO BREAK. THIS FIELD COVERING FOD CIRCULATED THROUGH THE COMMUTATOR/BRUSHES TO DISINTEGRATE. THINK THEY AREN’T WINDING THE ARMATURES TIGHT ENOUGH. (NM01199419959) (K) 1 L 7 2 3O 3 O 3A16 E286 2005030100033 20050301 00033 EA 2005 3 1 2005FA0000090 2 20041106 G 7322 MA3A105199 CARBURETOR PIPER PA38 PA38112 7103812 SO LYC O235 O235L2C 41505 EA SNSNCH 72C 72CK EA ENGINE CONTAMINATED D A UNSCHED LANDING O OTHER CR CRUISE 1 SO 15 2534N 3879A0903 L1913615 4333 ENGINE QUIT DURING FLIGHT DUE TO CARBURETOR MALFUNCTION 4 MILES SOUTHEAST OF AIRPORT, MAKING AN EMERGENCY LANDING WITHOU T DAMAGE TO AIRCRAFT, PILOT OR PASSENGER. CARBURETOR WAS REMOVED FROM AIRCRAFT AND SENT FOR OVERHAUL. (WO NR 88013). AIRCRAFT HAD BEEN SETTING FOR A LONG PERIOD OF TIME, WITH FUEL TANKS HALF FULL, MAKING MOISTURE IN THE FUEL SYSTEM. REC OMMENDATION FOR OWNERS, DRAIN FUEL SYSTEM AND RUN THE ENGINE AT LEAST ONCE A WEEK FOR AIRCRAFT TIE DOWN OUTSIDE OF HANGA R. (SO15200509104) (K) 1 L 7 1 3O 3 O A18SO E223 5 N P9045 2005030100056 20050301 00056 2005 3 1 2005FA0000091 4 20041114 G 2300 SMOKE CESSNA 172 172N 2072434 CE LYC O320 O320* 41508 EA COCKPIT DETECTED G O OTHER B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 SO 05 75776 17267942 PILOT REPORTED SMOKE IN THE COCKPIT. INVESTIGATION FOUND THE (AUDIO AMP) CIRCUIT BREAKER POPPED. COULD NOT FIND THE DI RECT CAUSE. HOWEVER, THE RADIOS ARE ORIGINAL EQUIPMENT, WHICH MAY HAVE CAUSED THE SMOKE IN THE COCKPIT. (SO05200504849 ) 1 H 7 1 3O 3 O NT 3A12 E274 2005032800095 20050328 00095 SO 2005 3 28 2005FA0000092 2 20041117 G 8530 655783 INTAKE VALVE CESSNA 421 421C 2076016 CE CONT O520 GTSIO520* 17032 SO NR 4 CYLINDER BROKEN B VA1R A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 SW 19 111KJ 492 421C1230 INTAKE VALVE IN NR 4 CYLINDER FAILED IN FLIGHT. THE VALVE FACE BROKE IN 3 PIECES. THE QUILL SHAFT BROKE AND SHUTDOWN T HE ENGINE. THIS IS 3RD ONE SEEN WITH 400-500 HOURS IN SERVICE. (K) 1 L 7 2 3O 3 O A7CE E7CE 2005030100050 20050301 00050 SO 2005 3 1 2005FA0000094 2 20041127 G 7322 NA53A1 CARBURETOR AMTR STCROX PIETENPOLAIR 7040363 GL CONT A65 A658 17003 SO ENGINE OBSTRUCTED G B A EMER. DESCENT UNSCHED LANDING C R F.O.D. PARTIAL RPM/PWR LOSS CR CRUISE 1 SO 05 899JP 0101 3537658 PILOT REPORTED POWER LOSS IN CRUISE FLIGHT AND COULD NOT MAINTAIN ALTITUDE. PRECAUTIONARY LANDING WAS MADE ON HIGHWAY, MINOR DAMAGE TO AIRCRAFT; NO INJURIES TO PILOT. INVESTIGATION REVEALED A WAS OF STEEL WOOL IN THE VENTURI OF THE CARBUR ETOR. STEEL WOOL HAD BEEN PLACED IN THE HEAT MUFFS TO INCREASE HEAT TRANSFER. THE STEEL WOOL EXITED THE SMALL HOLE IN THE MUFF, WENT THROUGH THE SCAT HOSE AND INTO THE CARBURETOR CAUSING THE POWER LOSS. (SO05200505084) (K) 1 H 7 1 3I 3 O NC EXPA1H71 E205 2005032800088 20050328 00088 CE 2005 3 28 2005FA0000095 1 20041203 G 2435 23046110 BEARING SUPPORT MTSBSI MU2 MU2B40 5780440 CE GARRTT TPE331 TPE331* 01514 WP BEARING LOOSE B R2JR K NONE O OTHER IN INSP/MAINT 1 EA 21 361MA 11412 429SA DURING 400 HOUR SPECIAL ENGINE INSPECTION OF STARTER GENERATOR THE AFT BEARING RETAINER SCREWS WERE FOUND BACKED OUT, WH ICH CAUSED AFT BEARING TO BE LOOSE. BEARING FAILURE CAN CAUSE CATASTROPHIC FAILURE OF STARTER GENERATOR. 4 MS3526543 S CREWS HOLD RETAINER TO FRAME. THE SCREWS HAVE HOLES IN HEAD FOR SAFTEY WIRE, BUT WERE NOT SAFTIED. THE AVAILABLE CMM F OR THE S/G DOES NOT MENTION SAFTEYING THESE SCREWS. SCREWS TIGHTENED AND SAFTIED AND UNIT PUT BACK IN SERVICE. SUGGEST OPERATORS OF AIRCRAFT PERIODICALLY REMOVE UNIT AND COOLING FAN COVER AND ENSURE BEARING RETAINER IS SECURE. (K) 1 H 7 2 3T 3 T RT A10SW E2WE 2005033000128 20050330 00128 CE 2005 3 30 2005FA0000096 1 20041206 G 1430 26520023 BOLT LEAR 35 35A 5170602 CE GARRTT TFE731 TFE731* 01518 WP ENG MOUNT CORRODED B DELR K NONE O OTHER IN INSP/MAINT 1 CE 03 431AS 10723 431 BOLT SHEARED AT THREADS DURING REMOVAL. SIGNS OF INTERNAL CORROSION ON BOLT. 2 L 7 2 4F 4 F A10CE E6WE 2005030100055 20050301 00055 CE 2005 3 1 2005FA0000097 1 20041115 G 5610 10138402521 WINDSHIELD BEECH 300 300BEECH 1152930 CE COCKPIT CRACKED D O OTHER O OTHER NR NOT REPORTED 1 NM 02 20NK 1858 FA51 LT POSITION, INNER PLY OF WINDSHIELD SHATTERED AT 29 K, -38 DEGREE C, 8-10 SECONDS AFTER THE RT WINDSHIELD. INNER PLY H AD SHATTERED. RECOMMEND SUBSEQUENT SCHEDULED WINDSHIELD RETORQUES BE CAREFULLY PREFORMED TO ENSURE ORIGINAL CONTOUR OF WINDSHIELD INSTALLATION PER KIT 101-5043-3 IS NOT ALTERED RESULTING IN POSSIBLE STRESS LOCATIONS IN WINDSHIELD FRAME. 2 L 7 2 4T A24CE 2005021500114 20050215 00114 CE 2005 2 15 2005FA0000098 1 20041107 G 3244 5004549E HEAT SHIELD GOODYEAR CESSNA 500 500CESSNA 2076602 CE PWA JT15 JT15D1 52060 NE LT MLG TIRE DAMAGED B J0UR O OTHER O OTHER LD LANDING 1 SO 09 567EA NOV77761 5000067 PILOT REPORTED, HE HAD HIT AN OBJECT ON RUNWAY DUE TO IMPACT SOUND HEARD ON LT SIDE OF AC AND BRAKE ANTI-SKID FAIL INDIC ATION. INVESTIGATED LT WHEEL AREA AND DISCOVERED THAT TIRE HEAT SHIELD HAD PARTIALLY DISLOGED FROM WHEEL ASSY. INSPECT ED AREA AND FOUND PART OF HEAT SHIELD HAD TORN AWAY CUTTING BRAKE ANTI-SKID WIRE HARNESS, BENDING GEAR DOOR ROD, AND DEN TING IB AREA OF LT LANDING LIGHT HSG. INSPECTED RT TIRE HEAT SHIELD AND FOUND IT LOOSE ALSO. INSP FOUND RT SHIELD TO B E INSTALLED CORRECTLY IAW MFG MM. DECISION WAS MADE TO REPLACE RT SHIELD. TIRE HEAT SHIELD HAS NOT HARD MOUNT ATTACHME NT TO WHEEL ASSY. UPGRADING AC TO NEW STYLE WHEEL/BRAKE ASSY IS THE ONLY VIABLE FIX TO PREVENT THIS FROM HAPPENING. 1 L 7 2 4F 4 F A22CE E1NE 2005021500118 20050215 00118 2005 2 15 2005FA0000099 4 20041215 G 6113 05522311 BULKHEAD CESSNA 172 172S 2072439 CE SPINNER CRACKED B WIWR K NONE O OTHER IN INSP/MAINT 1 WP 07 5023J 97 172S8964 DURING A 100 HR INSPECTION THE FORWARD SPINNER BULKHEAD WAS FOUND TO BE CRACKED AROUND 4 OF THE 6 BOLT HOLES. THINK THAT THE CAUSE OF THE PROBLEM IS THAT THE TORQUE OF THE PROP WAS RAISED AND THE NEW TORQUE IS NOT ENOUGH TO CAUSE THE BULKHE AD AROUND THE BOLT HOLES TO BE PULLED INTO THE CHAMFERED AREA OF THE PROPELLER BOLT HOLES. THIS STRESSES THE BULKHEAD A ND ALLOWS CRACKS TO START. TO PREVENT THIS PROBLEM POSSIBLY CONSIDER MAKING THE BULKHEAD OF THICKER MATERIAL OR REDESIG NING THE PART SO THAT WHEN IT IS TORQUED THERE IS STRESS RELIEF AROUND THE BOLT HOLES SO THAT THE BULKHEAD SITS FLAT. (K ) 1 H 7 1 3O NT 3A12 2005021700006 20050217 00006 EA 2005 2 17 2005FA0000101 2 20040712 G 8530 LW19001 EXHAUST VALVE CESSNA 182 182T 2072703 CE LYC O540 IO540AB1A5 EA NR 3 CYLINDER SEIZED D C ABORTED TAKEOFF R PARTIAL RPM/PWR LOSS TO TAKEOFF 1 NM 01 102LP 1159 18281121 L2837148A UPON TAKEOFF, PILOT REPORTED POWER LOSS AND ROUGH RUNNING ENGINE. INVESTIGATION FOUND NR 3 CYLINDERS EXHAUST VALVE SEIZ ED. THIS WAS 4TH OCCURENCE SINCE NEW (1999). INSTITUTED 300 HOUR VALVE GUIDE REAM AND 25 HOUR OIL CHANGE. MFG DENIED REQUEST TO INCREASE VALVE GUIDE CLEARANCE. 1 H 7 1 3O 3 O NT 3A13 1E4 2005030200028 20050302 00028 SO 2005 3 2 2005FA0000103 1 20040902 G 5730 1159W2000510 SKIN GULSTM G1159 G1159 3953505 SO RROYCE SPEY SPEY5118 54523 EU RT WING CORRODED B GR4R K NONE O OTHER IN INSP/MAINT 1 SO 11 826GW 210 DURING WING (RIGHT) NOT INSPECTION, EXFOLIATION CORROSION NOTED ON WING UPPER PLANK AND FRONT BEAM BETWEEN RBS 284 THRU 375. EXFOLIATION CORROSION REMOVED IAW SRM. REPAIRS COMPLETED. 2 L 7 2 4F 4 F RT A12EA E2EU 2005021700007 20050217 00007 SO 2005 2 17 2005FA0000104 1 20040902 G 5414 1159P203263 COWLING GULSTM G1159 G1159 3953505 SO RROYCE SPEY SPEY5118 54523 EU LT NACELLE CORRODED B GR4R K NONE O OTHER IN INSP/MAINT 1 SO 11 826GW 7997 210 DURING LT ENGINE MID-LIFE UPDATES, LT FIXED COWL WAS INSPECTED AND CORROSION WAS NOTED. FIXED COWL WAS REPAIRED. 2 L 7 2 4F 4 F RT A12EA E2EU 2005021700008 20050217 00008 2005 2 17 2005FA0000105 4 20041212 G 3418 SLZ9692 PROBE GULSTM G1159 G1159B 3953535 SO NR 2 AOA BROKEN B N38R A UNSCHED LANDING N FALSE WARNING CR CRUISE 1 EA 05 4NR 255 NR 2 STICK SHAKER AND PUSHER ACTIVATED IN FLIGHT. ENROUTE, CREW ENCOUNTERED ABOVE MENTIONED ISSUE. CREW DIVERTED, DECL ARED AN EMERGENCY. LANDING WAS UNEVENTFUL. MAINTENANCE DEPARTMENT WAS NOTIFIED IMMEDIATELY. REMOVED AND REPLACED NR A OA PROBE, PN ON SLZ9692, SN ON LH1250B. OPS CHECKED SATISFACTORY. 2 L 7 2 4F RT A12EA 2005030200031 20050302 00031 CE 2005 3 2 2005FA0000106 1 20040924 G 2435 23080023 STARTER GEN LEAR 35 31A 5170531 CE GARRTT TFE731 TFE73123B WP RT ENGINE FAILED B EPDR E ENGINE SHUTDOWN E J VIBRATION/BUFFET WARNING INDICATION CR CRUISE 1 NM 13 901P 914 199 P99524 PILOT REPORTED VIBRATION, FOLLOWED BY RT GENERATOR INOPERATIVE LIGHT. PRECAUTIONARY ENGINE SHUTDOWN WAS DONE. REPLACED STARTER GEN, OPS NORMAL. A TEARDOWN REPORT WILL BE REQUESTED FROM VENDOR. (K) 2 L 7 2 4F 4 F RT A10CE E6WE 2005030200032 20050302 00032 CE 2005 3 2 2005FA0000107 1 20041111 G 7830 2550012513 IDLER LINK BEECH MU300 400A 1155402 CE PWA JT15 JT15D5 52112 NE THRUST REVERSER FAILED B FGQR K NONE O OTHER IN INSP/MAINT 1 SO 01 101CC 1783 RK277 THE UPPER IDLER LINK PN 202-0008-1, FAILED AT THE DOOR END PREVENTING THE THRUST REVERSER TO STOW PROPERLY AND DAMAGED T HE SUPPORT ASSY. PILOT`S WERE UNAWARE OF THE PROBLEM UNTIL THE T/R DOORS WERE NOTICED TO NOT BE FULLY STOWED ON WALK AR OUND. (K) 2 H 7 2 4F 4 F RT A16SW E25EA 2005033000143 20050330 00143 EU 2005 3 30 2005FA0000111 1 20041117 G 3710 1U128006 PUMP GROB 120 G120A 1660208 EU LYC O540 AEIO540D4D5 EA VACUUM SYS SHEARED B VJ3R O OTHER O OTHER TX TAXI/GRND HDL 1 WP 07 862AF 447 85002 DURING RUN-UP OF AIRCRAFT PILOT REPORTED LOST OF INSTRUMENT VACUUM SUCTION. MAINTENANCE TECHNICIAN FOUND VACUUM PUMP HA D A BROKEN SHAFT. UPON REPLACEMENT OF VACUUM PUMP INSTRUMENT SUCTION WAS FOUND TO BE OK. RECOMMEND FINDING A REPLACEME NT THAT IS MORE DURABLE. (K) 1 L 7 1 3O 3 O RT A49CE 1E4 2005033000146 20050330 00146 CE 2005 3 30 2005FA0000113 1 20041019 G 3213 60411022 PISTON LEAR 60 60LEAR 5170707 CE PWA 305 PW305A 52128 NE RT MLG STRUT DAMAGED B WVER K NONE O OTHER IN INSP/MAINT 1 EA 09 248FX 4051 035 188 DURING 3000 LANDING INSPECTION OF MLG UPPER BEARINGS AND RETENSION PINS, FOUND RT MLG PISTON TO HAVE A SECTION OF CHROME MISSING APPROX .250 INCH X .10 INCH AND AREA WHERE THE CHROME HAS CIRCUMFERENCE CRACKS MEASURING AN AREA OF APPROX 3.0 INCH X 1.0 INCH. MANUFACTURE TO EVALUATE. (K) 2 L 7 2 4F 4 F RT A10CE E35NE 2005033000148 20050330 00148 EU 2005 3 30 2005FA0000114 1 20041113 G 5610 350A25900400 WINDSHIELD UROCOP EC130 EC130B4 8680989 EU TMECA ARRIEL ARRIEL2B NE COCKPIT CRACKED B MHIR O OTHER O OTHER LD LANDING 1 EA 25 456AE 3492 DURING DESCENT TO LANDING, PILOT NOTED CENTER WINDSHIELD CRACKED FROM JOGGLE POINT ACROSS LOWER WINDSCREEN. REPAIRED WI NDSCREEN IAW SRM FOR FLIGHT MAINTENANCE. REPLACED WINDSCREEN WITH NEW. CENTER WINDSCREEN HAS PROBLEMS WITH CRACKING DU RING TEMPERATURE CHANGES (COLD WEATHER). (K) (RECORD NR 98050) 1 G 7 2 3U 3 U H9EU E00054EN 2005033000149 20050330 00149 EU 2005 3 30 2005FA0000115 1 20041119 G 6310 365A32653000 COUPLING AEROSP AS365 AS365N2 8680815 EU TMECA ARRIEL ARRIEL1 60030 NE ENG TO MR GB CRACKED B MHIR K NONE O OTHER IN INSP/MAINT 1 EA 25 886TW 6413 DURING INSPECTION FOUND RT FORWARD ENGINE/ MGB DRIVE FLEX COUPLING CRACKED. REPLACED WITH NEW. (RECORD NR 98086) (K) 1 G 7 2 3U 3 U RT H10EU E19EU 2005030100059 20050301 00059 NE 2005 3 1 2005FA0000121 2 20040903 G 8520 LW13683 BEARING PIPER PA31 PA31 7103102 SO LYC O540 TIO540J2B NE ENGINE FAILED C K NONE O OTHER IN INSP/MAINT 1 CE 07 7436L 1000 317400994 RT REAR MAIN BEARING BEGAN TO SHRED METAL INTO OIL FILTER AFTER LANDING. OIL CHANGE AND FILTER CUT OPEN. THIS WAS FOUN D ON A PRE-BUY. LETTER TO FAA SENT SEPT 03, 2005, BUT NO REPLY. (K) 1 L 7 2 3O 3 O A20SO E14EA 2005032800097 20050328 00097 EA 2005 3 28 2005FA0000123 2 20041116 G 8530 CYLINDER MOONEY M20 M20J 5870219 SW LYC O360 IO360A3B6 41514 EA NR 2 FAILED B AW4R A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 WP 11 3925H 240903 PILOT REPORTED THAT ENGINE BEGAN RUNNING ROUGH. READINGS FORM THE ENGINE MONITOR SHOWED THAT NR 2 CYLINDER FAILED. PIL OT ELECTED TO LAND. INVESTIGATION SHOWED THAT BOTH UPPER THROUGH BOLTS AND BOTH UPPER CYLINDER ATTACH STUDS FOR NR 2 CY LINDER HAD FAILED AT THE CYLINDER FLANGE. THE LOWER AT THROUGH BOLT FOR NR 1 CYLINDER WAS ALSO FOUND FAILED AT THE CYLI NDER FLANGE. ALL 4 CYLINDERS HAD BEEN REPLACED 205.2. HOURS PREVIOUSLY AT 4177.7 HOURS. FAILURE OF THE STUDS AND BOLT S APPEARS TO BE CONSISTENT WITH EITHER UNDER TORQUE OR OVER-TORQUE OF THE NUTS AT INSTALLATION. (K) 1 L 7 1 3O 3 O 2A3 1E10 2005033000168 20050330 00168 SO 2005 3 30 2005FA0000125 2 20041202 G 8520 TCM652832 CRANKSHAFT CESSNA 421 421B 2076014 CE CONT O520 GTSIO520C 17032 SO ENGINE BROKEN B VA1R K NONE O OTHER IN INSP/MAINT 1 SW 19 210FC 421B0908 CRANKSHAFT BROKE AT NR 2 MAIN. NO SIGNS OF OIL STARVATION. NO SIGNS OF CASE FRETTING. CASE WAS DAMAGED BEYOND REPAIR. (K) 1 L 7 2 3O 3 O A7CE E7CE 2005033000169 20050330 00169 SO 2005 3 30 2005FA0000126 1 20041129 G 5740 62701153 CONTROL CABLE PIPER PA44 PA44180 7104402 SO LYC O360 O360* 41514 EA STABILATOR CORRODED B E85R K NONE O OTHER IN INSP/MAINT 1 SO 15 8086Z 447995329 AIRCRAFT EXPERIENCED COMPLETE STABILATOR PRIMARY CONTROL FAILURE. CAUSE OF FAILURE WAS DETERMINED TO BE CORROSION OF LO WER STABILATOR CONTROL CABLE FORWARD CABLE END JUST T/E OF BARREL. ESTABLISH A TIME LIFE REPLACEMENT OF CONTROL CABLE. PROBLEM IS NOT DETECTABLE DURING PERIODIC INSP IAW MM. (K) 1 L 7 2 3O 3 O A19S0 E286 2005030100058 20050301 00058 CE 2005 3 1 2005FA0000127 1 20041025 G 3020 24648000 HEATER CESSNA 210 P210N 2073454 CE CONT O520 TSIO520* 17040 SO ENGINE INLET CRACKED D K NONE B SMOKE/FUMES/ODORS/SPARKS DE DESCENT 1 NM 07 43CE 552 P21000703 PILOT REPORTED SMELLING A BURNED ODOR WHILE DESCENDING IN SEVERE ICING CONDITIONS. ON A POST FLIGHT INSPECTION OF THE A IRCRAFT A V SHAPED CRACK WITH THE TIP MISSING WAS FOUND IN THE ENGINE INLET HEATER. IT APPEARS THAT PART OF THE HEATER HAS SHORTED OUT CAUSING THIS PART TO CRACK. THE HEATER WAS TESTED AND WAS STILL OPERATIONAL. (K) 1 H 7 1 3O 3 O 3A21 E8CE 2005030100028 20050301 00028 SO 2005 3 1 2005FA0000128 2 20041222 G 8520 292266R CRANKCASE CESSNA 421 421C 2076016 CE CONT O520 GTSIO520* 17032 SO ENGINE CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 05 885C 421C0406 ENGINE CASE CRACK BY NR 3 FORWARD CYLINDER UPPER THROUGH BOLT RADIATING DOWNWARD SEVERAL INCHES. AD ADDRESSES THIS PROB LEM, BUT THESE MODEL NR ENGINE ARE NOT INCLUDED. THIS HAS HAPPENED TO THIS ENGINE ONCE BEFORE, 2 YEARS AGO. (K) 1 L 7 2 3O 3 O A7CE E7CE 2005030100062 20050301 00062 SO 2005 3 1 2005FA0000129 1 20041221 G 5751 8656206 SKIN PIPER PA44 PA44180 7104402 SO LYC O320 O320* 41508 EA LT AILERON CRACKED B A5OR K NONE O OTHER IN INSP/MAINT 1 SO 09 3047U 7707 447995262 DURING AN ANNUAL INSPECTION OF THE AIRCRAFT THE LT AILERON ASSEMBLY WAS FOUND TO HAVE A CRACK IN THE OB SKIN. PROBABLE CAUSE OF CRACKING OF THE LT AILERON ASSEMBLY IS UNKNOWN. AILERON REMOVED FOR MAINTENANCE AND REPAIRED BY REPLACING DAMA GED PART. (K) 1 L 7 2 3O 3 O A19S0 E274 2005030100065 20050301 00065 SO 2005 3 1 2005FA0000130 1 20041221 G 5751 8656206 SKIN PIPER PA44 PA44180 7104402 SO LYC O360 O360* 41514 EA LT AILERON CRACKED B A5OR K NONE O OTHER IN INSP/MAINT 1 SO 09 2202X 8034 447995278 DURING AN ANNUAL INSPECTION OF THE AIRCRAFT THE LT AILERON ASSEMBLY WAS FOUND TO HAVE A CRACK IN THE OB SKIN. PROBABLE CAUSE OF CRACKING OF THE LT AILERON ASSEMBLY IS UNKNOWN. AILERON REMOVED FOR MAINTENANCE AND REPAIRED BY REPLACING DAMA GED PART. (K) 1 L 7 2 3O 3 O A19S0 E286 2005030100067 20050301 00067 SO 2005 3 1 2005FA0000131 1 20041221 G 5751 8656206 SKIN PIPER PA44 PA44180 7104402 SO LYC O360 O360* 41514 EA LT AILERON CRACKED B A5OR K NONE O OTHER IN INSP/MAINT 1 SO 09 2247B 8022 447995108 DURING AN ANNUAL INSPECTION OF THE AIRCRAFT THE LT AILERON ASSEMBLY WAS FOUND TO HAVE A CRACK IN THE OB SKIN. PROBABLE CAUSE OF CRACKING OF THE LT AILERON ASSEMBLY IS UNKNOWN. AILERON REMOVED FOR MAINTENANCE AND REPAIRED BY REPLACING DAMA GED PART. (K) 1 L 7 2 3O 3 O A19S0 E286 2005040100025 20050401 00025 2005 4 1 2005FA0000133 1 20040919 G 2434 ALK1242AAS2 HOUSING ELECTROSYS ALTERNATOR MISREPAIRED B KC2R K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 03 E020668 IN PREPARING ALTERNATOR FOR INSTALLATION. CLOSE INSPECTION REVEALED THAT LIGHT PRESSURE ON NEGATIVE DIODE CAUSED DIODE TO BECOME UNSEATED FROM BORE IN HOUSING. INSPECTION OF BORE SHOWED THAT THE BORE WAS OVERSIZED AND HAD BEEN PAINTED DUR ING OVERHAUL. DIODE BORE DIMENSION (.499 INCH +/- .001 INCH) IS CRITICAL TO RELIABLE OPERATION OF THE ALTERNATOR. (THE DIODES RELY ON A PRESS FIT TO MAINTAIN ADEQUATE HEAT DISSIPATION AND CURRENT FLOW AND SHOULD NOT BE INSTALLED IN A BORE THAT HAS PAINT OR ANY OTHER ELECTRICALLY RESISTIVE MATERIAL IN IT.) THIS FAILURE IS EXACTLY THE SAME AT THE UNIT THAT W AS BEING REPLACED, HAVE SEEN NUMEROUS OTHER (LOOSE DIODES), RETURNED TO FACTORY FOR WARRANTY. 2005030100060 20050301 00060 EU 2005 3 1 2005FA0000135 1 20041001 G 3411 PITOT TUBE PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE PITOT/STATIC SYS OUT OF POSITION D K NONE O OTHER NR NOT REPORTED 1 CE 07 527PB 114 527 PILOT LOST AIRSPEED INDICATION ON A POST 91 FLIGHT. AIRCRAFT RETURNED, FOUND PITOT TUBE SLIPPED OUT FROM B-NUT AT T-FIT TING, BEHIND INTERIOR PANEL ON RT SIDE, APPROXIMATELY AT FRAME 23. SUSPECT TUBING INSERT WAS NOT INSERTED FAR ENOUGH IN TO TUBING DURING MANUFACTURE. (K) 1 L 7 1 3T 4 T RT A78EU E26NE 2005030100019 20050301 00019 EA 2005 3 1 2005FA0000144 2 20040814 G 8540 70384 GEAR SHAFT LYC O540 O540E4B5 41532 EA ENGINE BROKEN D K NONE O OTHER IN INSP/MAINT 1 AL 05 765 L1019440 AT AIRCRAFT 100 HOUR ENGINE WAS FOUND WITH TIGHT SPOT. REMOVED ENGINE ACCYS AND FOUND GOVERNOR SHAFT NOT TURNING DISASS EMBLED ENGINE. FOUND GOVERNOR IDLER GEAR SHAFT (PN 70384) BROKEN IN 3 PARTS; ALL GOV GEARS HAD RG TEETH, 1 OF 2 KNOWN F AILURES, ON SHAFT (PN 70384) WITH SAME SERIAL/ BATCH NUMBERS. 3 O E295 2005030200029 20050302 00029 2005 3 2 2005FA0000145 4 20041210 G 6113 05522311 BULKHEAD CESSNA 172 172S 2072439 CE LYC O360 IO360A1A 41514 EA PROP SPINNER CRACKED B WIWR K NONE O OTHER IN INSP/MAINT 1 WP 07 796WW 172S8635 DURING ANNUAL INSPECTION FOUND FWD BULKHEAD OF THE SPINNER CRACKED 5 PLACES AROUND PROPELLER BOLT HOLES. RECOMMEND: BUL KHEAD MATERIAL STRONGER OR THICKER. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 2005041500182 20050415 00182 2005 4 15 2005FA0000146 4 20041216 G 6113 05522311 BULKHEAD CESSNA 172 172S 2072439 CE LYC O360 IO360A1A 41514 EA MCAULY 1A170 1A170E GL PROP SPINNER CRACKED B WIWR K NONE O OTHER IN INSP/MAINT 1 WP 07 154ME 172S8534 DURING 100 HOURS INSPECTION, FOUND PROP SPINNER FWD BULKHEAD CRACKED SEVERAL PLACES. LOWER PROP BOLTS TORQ SETTING OR M AKE BULKHEAD STRONGER. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P857 2005040100075 20050401 00075 2005 4 1 2005FA0000147 4 20041222 G 6113 05522311 BULKHEAD CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA PROP SPINNER CRACKED B WIWR K NONE O OTHER IN INSP/MAINT 1 WP 07 2134M 172S9552 DURING ANNUAL INSPECTION, FOUND PROP SPINNER FWD BULKHEAD CRACKED AROUND 2 BOLT HOLES. RECOMMENDATION: MANUFACTURE BULK HEAD STRONGER OR THICKER. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 2005030100051 20050301 00051 SO 2005 3 1 2005FA0000148 2 20041120 G 8530 CYLINDER UNIVAR 415 415C 0420302 NM CONT C85 C8512 17008 SO MCAULY 1B90 1B90* GL ENGINE FAILED D K NONE O OTHER NR NOT REPORTED 1 WP 09 2919H 24 3544 29175712 19046 CYLINDER AND ROD FAILURE RESULTED IN CASE FAILURE CAUSING CYLINDER TO COME OF ENGINE. CAUSE UNKNOWN. NR 4 PISTON (AE-C 530348) FAILURE. (WP09200502317). (K) 1 L 7 1 3O 3 O A718 E233 5 N P842 2005032800110 20050328 00110 EU 2005 3 28 2005FA0000150 1 20041124 G 3220 120A5211 SWIVEL GROB 120 G120A 1660208 EU NLG CRACKED B VJ3R K NONE O OTHER IN INSP/MAINT 1 WP 07 863AF 1761 85003 INSPECTION OF NOSE GEAR UPPER TRUNNION BOLTS FOUND CRACKS AROUND WELDS AND ON THE EARS FOR THE SWIVEL TUBE. PROBABLE C AUSE EXCESSIVE STRESSES IN THIS AREA. AT THIS TIME NO RECOMMENDATION UNTIL MFG MAKES DETERMINATION OF CAUSES. (K) 1 L 7 1 3O RT A49CE 2005040400089 20050404 00089 EU 2005 4 4 2005FA0000151 1 20041124 G 3220 120A5211 SWIVEL GROB 120 G120A 1660208 EU NOSE GEAR CRACKED B VJ3R K NONE O OTHER IN INSP/MAINT 1 WP 07 864AF 1665 85004 INSPECTION OF NOSE GEAR UPPER TRUNNION BOLTS FOUND CRACKS AROUND WELDS AND ON THE EARS FOR THE SWIVEL TUBE. PROBABLE CA USE EXCESSIVE STRESSES IN THIS AREA. AT THIS TIME NO RECOMMENDATION UNTIL MFG MAKES DETERMINATION OF CAUSES. (K) 1 L 7 1 3O RT A49CE 2005040400004 20050404 00004 EU 2005 4 4 2005FA0000152 1 20041124 G 3210 BOLT GROB 120 G120A 1660208 EU NLG TRUNNION CRACKED B VJ3R K NONE O OTHER IN INSP/MAINT 1 WP 07 867AF 85007 INSPECTION OF NOSE GEAR UPPER TRUNNION BOLTS FOUND CRACKS AROUND WELDS AND ON THE EARS FOR THE SWIVEL TUBE. PROBABLE CA USE EXCESSIVE STRESSES IN THIS AREA. AT THIS TIME NO RECOMMENDATION UNTIL MFG MAKES DETERMINATION OF CAUSES. (K) 1 L 7 1 3O RT A49CE 2005040100028 20050401 00028 EU 2005 4 1 2005FA0000153 1 20041124 G 3220 120A5211 SWIVEL GROB 120 G120A 1660208 EU NLG CRACKED B VJ3R K NONE O OTHER IN INSP/MAINT 1 WP 07 862AF 1755 85002 INSPECTION OF NOSE GEAR UPPER TRUNNION BOLTS, FOUND CRACKS AROUND WELDS AND ON THE EARS FOR THE SWIVEL TUBE. PROBABLE C AUSE EXCESSIVE STRESSES IN THIS AREA. AT THIS TIME NO RECOMMENDATION UNTIL MFG MAKES DETERMINATION OF CAUSES. (K) 1 L 7 1 3O RT A49CE 2005030100020 20050301 00020 CE 2005 3 1 2005FA0000157 1 20041123 G 3213 0541124 AXLE CESSNA 170 170A 2072304 CE CONT C145 C145* 17012 SO LT MLG BROKEN D K NONE O OTHER IN INSP/MAINT 1 GL 11 5430C 2871 19560 LT MAIN GEAR WHEEL AXLE BROKE BETWEEN GEAR LEG AND WHEEL RACE. (GL11200505686) (K) 1 H 7 1 3O 3 O A799 E253 2005030100106 20050301 00106 CE 2005 3 1 2005FA0000158 1 20041101 G 2434 991059111RX ALTERNATOR CESSNA 182 182S 2072701 CE LYC O540 IO540AB1A5 EA MCAULY 3D36C B3D36C431 GL ENGINE FAILED B AIHR O OTHER H J ELECT. POWER LOSS-50 PC WARNING INDICATION CR CRUISE 1 GL 11 801AL 417 18280767 L2749848A 000544 PILOT DECLARED EMERGENCY, TOTAL ELECTRICAL FAILURE. DIAGNOSTIC INSPECTION REVEALED ALTERNATOR FAILURE. PILOT FAILED TO SEE WARNING LIGHT; DISCHARGE ON AMMETER AND LOW VOLT READING ON VOLT METER. (GL11200505028) (K) 1 H 7 1 3O 3 O NT 3A13 1E4 5 C 2005030100018 20050301 00018 SO 2005 3 1 2005FA0000159 1 20041026 G 5320 6345100 SUPPORT PIPER PA32 PA32R300 7103213 SO LYC O540 TIO540* 41532 EA RUDDER PEDAL DAMAGED D K NONE O OTHER NR NOT REPORTED 1 NE 01 7665F 32R7780075 RUDDER PEDAL FLEXING DURING BRAKING ACTION. (K) 1 L 7 1 3O 3 O A3SO E14EA 2005031100008 20050311 00008 NE 2005 3 11 2005FA0000160 1 20041101 G 6320 51635200582 RING GEAR SKRSKY SKRSKY S58T S58JT 8141807 NE PWA PT6T PT6T3 52045 EA GEAR TEETH DAMAGED B JTKR K NONE O OTHER IN INSP/MAINT 1 GL 03 827MW 1902 S58H17561084 58827 RING GEAR DAMAGED. 2 G 7 2 4U 4 U 1H11 E22EA 2005030200065 20050302 00065 EU 2005 3 2 2005FA0000162 1 20041020 G 4920 A4504174 COMPRESSOR WHEEL HAMSTD BRAERO DH125 BAE125800A 1500285 EU GARRTT TFE731 TFE7315R 01518 WP APU DAMAGED B OTUR K NONE O OTHER IN INSP/MAINT 1 CE 03 48Y 258009 RECENTLY EXPERIENCED A PROBLEM WITH A RELATIVELY LOW TIME COMPRESSOR WHEEL. THIS NEW STYLE COMPRESSOR WHEEL IS A REPLAC EMENT WHEEL TO SUPPORT AD NR20021502. THE WHEEL IN QUESTION LOST A LARGE INDUCER TIP THAT PENETRATED, AND CAME VERY CLO SE TO EXITING THE AIR INLET HOUSING. THIS WHEEL WAS INSTALLED 20 MONTHS AGO. AT THE TIME OF THIS EVENT IT HAD ACCUMULA TED 265.1 HOURS AND 660 CYCLES. BESIDES THE MISSING INDUCER TIP, SEVERAL BLADES EXHIBIT INDUCER BLADE CRACKS CLOSE TO T HE WHEEL BORE. THERE WAS NO INDICATION OF BEARING FAILURE, FOD, OR IMPACT WITH THE AIR INLET. 2 L 7 2 4F 4 F RT A3EU E6WE 2005040100077 20050401 00077 EA 2005 4 1 2005FA0000163 2 20041020 G 8520 72877 TAPPET LYC SOCATA TB20 TB20TRINIDAD 8680695 EU LYC O540 IO540C4D5 41532 EA HARTZL HCC3Y HCC3YR GL ENGINE MISSING D K NONE O OTHER IN INSP/MAINT 1 EA 25 882 L2821948A 2161 L282A48A DY5166B ON ANNUAL 100 HR INSP, OIL STRAINER CLEANED, METAL PIECE FOUND IN STRAINER, METAL PIECE SENT TO MFG FOR ANALYSIS, REPORT INDICATED. PIECE FROM TAPPET BODY. CYCLE REDUCED, INSP OF TAPPPET BODIES, FOUND NIS INLET, BODY WITH PIECE MISSING FR OM SURFACE, PROBABLE CAUSE MFG DEFECT. ALSO NOTICED, ON CYLINDER REMOVAL, SEVERE CORRODION OF 4 CYLS, WHICH RESULTED IN CYLS, WHICH RESULTED IN CYL BEING SCRAP. (K) 1 L 7 1 3O 3 O RT A51EU 1E4 5 C P25EA 2005040100078 20050401 00078 SO 2005 4 1 2005FA0000164 2 20041105 G 8520 653387788 LIFTER CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO ENGINE CORRODED B LC1R O OTHER O OTHER NR NOT REPORTED 1 EA 07 956C 308 0387 686694 DURING A RECENT MFG SYMPOSIUM, THE PROBLEM OF UNAIRWORTHY LIFTERS IN MFG ENGINES DISCUSSED. MFG ENGINE HAVE BEEN NOT HO LDING UP WELL IN THESE AREAS AND MANY SC`S ARE RECOMMENDING AN INSPECTION OF THE LIFERS DURING SCHEDULED MAINTENANCE. T HIS AC WAS UNDERGOING AN ANNUAL INSPECTION AND THE OWNERS AGREED TO HAVE THE LIFTERS CHECKED AS THE WARRANTY PERIOD ENDS THIS MONTH. WITH 308.5 HOURS TSN, WE FOUND 3 LIFTERS SPALLED AND PITTED. IT IS MY EXPERIENCE THAT THE CAUSE FOR THIS IS THE USE OF A MULTI-VISCOSITY OIL SINCE NEW. RECOMMEND STRAIGHT WEIGHT OILS ALWAYS ESPECIALLY IN THESE ENGINES. ALS O RECOMMEND 25 HOUR OIL CHANGES REGARDLESS OF THE USAGE OF THE AIRCRAFT. (EA07200501466) 1 L 7 1 3O 3 O NT A00009CH E3SO 2005030800271 20050308 00271 SO 2005 3 8 2005FA0000165 2 20041029 G 7321 6329168 FMU CESSNA 402 402CESSNA 207590K CE CONT O520 TSIO520E 17040 SO MCAULY 3AF32C 3AF32C* GL LT ENGINE OUT OF ADJUST D O OTHER R PARTIAL RPM/PWR LOSS AP APPROACH 1 WP 19 3278Q 1053 816 4020078 502452 941052 LT ENGINE LOST POWER ON FINAL APPROACH DUE TO THE FUEL METERING UNIT BECOMING OUT OF ADJUSTMENT. UNIT WAS ADJUSTED IAW CSM AND ENGINE FUEL PRESSURES AND FLOWS WERE ADJUSTED IAW MFG SB97-3. GROUND RUN WAS PERFORMED AND FLIGHT TEST CONDUCTE D. NO DEFECTS WERE NOTED WITH EITHER ACTION. NO RECOMMENDATIONS FOR NON-RECURRENCE AS THE FUEL SETTINGS CHANGE WITH TH E CHANGE IN CONSULTED ON THIS BY THIS COMPANY AND OTHERS WITH THE ONLY RECOMMENDATION THAT PRESSURES AND FLOWS BE ADJUST ED AT SEASONAL CHANGE. (WP19200504117) 1 L 7 2 3O 3 O A7CE E8CE 5 C P22EA 2005030800273 20050308 00273 SO 2005 3 8 2005FA0000166 2 20040712 G 8520 649895 CRANKSHAFT CESSNA 414 414A 2075907 CE CONT O520 TSIO520* 17040 SO ENGINE CRACKED D O OTHER O OTHER CR CRUISE 1 GL 09 36934 768 414A0486 208086J CRANKSHAFT CRACKED 1 L 7 2 3O 3 O A7CE E8CE 2005033000049 20050330 00049 EA 2005 3 30 2005FA0000167 2 20041026 G 8530 STUD PIPER PA28 PA28R200 7102811 SO LYC O360 IO360C1C 41514 EA NR 2 CYLINDER FAILED B MW2R K NONE O OTHER IN INSP/MAINT 1 GL 17 33129 850 28R7535124 RL870551A (4) EA DECK STUDS ON NR 2 CYLINDER, FAILED. 1 L 7 1 3O 3 O 2A13 1E10 2005030800275 20050308 00275 SO 2005 3 8 2005FA0000168 2 20041026 G 8520 STUD CESSNA 206 P206 2073304 CE CONT O520 IO520A 17032 SO ENGINE FAILED B MW2R K NONE O OTHER IN INSP/MAINT 1 GL 17 2625X 433 P2060125 112599R (2) EA DECK STUDS ON NR 1 CYLINDER FAILED. (K) 1 H 7 1 3O 3 O A4CE E5CE 2005040100036 20050401 00036 SO 2005 4 1 2005FA0000169 2 20041025 G 8520 653877 LIFTER CESSNA 210 210N 2073453 CE CONT O520 IO520L 17032 SO ENGINE SPALLED B LX5R K NONE O OTHER IN INSP/MAINT 1 GL 19 6484A 884 21063535 295048 DURING SCHEDULED OIL CHANGE, METAL WAS FOUND IN THE FILTER. FURTHER INVESTIGATION DISCOVERED THE TAPPETS STARTING TO FA IL. THIS CONDITION CAN BE A RESULT OF IMPROPER HEAT-TREATING. WITHOUT BEING FAMILIAR WITH MFG PROCESS, CAN NOT RECOMME ND A PLAN FOR PREVENTIVE ACTION. (K) 1 H 7 1 3O 3 O 3A21 E5CE 2005030800280 20050308 00280 SO 2005 3 8 2005FA0000170 2 20041105 G 7314 65335385 PUMP DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240B 17063 SO ENGINE DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 EA 05 977DC 43 C0177 FUEL PUMP FAILS TO HOLD PROPER PRESSURES. SAME PROBLEM WITH ORIGINAL PUMP. CHANGED PUMP, SET PRESSURES IAW SI 097-3B. PRESSURES TO BE RE-ADJUSTED APPROXIMATELY ONCE EVERY 2-3 WEEKS. NOTICED PRESSURES CHANGE WITH SEASON TEMPERATURES. (K) 1 L 7 1 3O 3 O NT TA4CH E7SO 2005030800109 20050308 00109 SO 2005 3 8 2005FA0000172 1 20041026 G 3213 2705301 STRUT PIPER PA24 PA24260 7102406 SO LYC O540 IO540* 41532 EA RT MLG CORRODED D K NONE K FLUID LOSS IN INSP/MAINT 1 WP 07 9014P 244475 PERFORMING ROUTINE SERVICE, THE RT MLG STRUT WAS FOUND LEAKING 5606 HYDRAULIC FLUID. DISCOVERED THAT THE STEEL (4130) A TTACHMENT FOR THE GEAR DOOR HAD CREATED DISSIMILAR METAL CORROSION AND CREATED A PIN HOLE LEAK. THIS PART NEEDS TO BE R EMOVED AND CHECKED TO PREVENT THIS FROM RE-OCCURRING. 1 L 7 1 3O 3 O 1A15 1E4 2005032800082 20050328 00082 SO 2005 3 28 2005FA0000173 1 20041012 G 3220 472681 LINK PIPER PA18 PA18150 7101828 SO LYC O320 O320* 41508 EA TAIL WHEEL FAILED G O OTHER O OTHER LD LANDING 1 SO 15 1121C 182221 ON LANDING ROLLOUT, AIRCRAFT DRIFTED TO THE LT AND WENT INTO SOFT GROUND, COMING TO REST ON IT`S NOSE. FOUND LINK (PN 4 72681) PARTIALLY STRAIGHTENED, CAUSING THE RT TAIL WHEEL SPRING ASSY TO FAIL. (K) 1 H 7 1 3O 3 O 1A2 E274 2005040400065 20050404 00065 SO 2005 4 4 2005FA0000185 1 20040806 G 2140 94E421 PRESSURE SWITCH PIPER PA31 PA31350 7103110 SO HEATER CLOSED B IS4R K NONE O OTHER IN INSP/MAINT 1 SO 09 CUSTOMER BOUGHT EXCHANGE HEATER. CORE RETURNED TO US HAD A DISTORTED COMBUSTION TUBE. FOUND COMBUSTION AIR PRESSURE SW ITCH 94E42-1 CLOSED AT ALL TIMES. THIS PARTICULAR SWITCH IS A NORMALLY OPEN SWITCH. SWITCH CLOSES WHEN COMBUSTION AIR PRESSURE INCREASES AND TELLS THE HEATER IT HAS COMBUSTION AIR. THE COMBUSTION AIR BLOWER QUIT (FAILED) AND THIS SWITCH DID NOT SENSE THIS LACK OF COMBUSTION AIR PRESSURE AND CONTINUED TO SUPPLY FUEL TO THE HEATER. BAD, BAD, BAD. THIS SWI TCH DOES NOT GET TESTED IAW AD 96-20-07. THIS FR65D79-3EL HEATER WAS BUILT IN OCTOBER 1997. (K) 1 L 7 2 3O A20SO 2005040400072 20050404 00072 SO 2005 4 4 2005FA0000186 1 20040813 G 2140 94E423 PRESSURE SWITCH PIPER PA34 PA34200T 7103406 SO HEATER CLOSED D IS4R K NONE O OTHER IN INSP/MAINT 1 SO 09 76 A02020068 CUSTOMER WAS CHECKING HEATER IAW AD96-20-07 EVEN THOUGH HE WASN’T REQUIRED TO DO SO, AND FOUND THE COMBUSTION AIR PRESSU RE SWITCH CLOSED AT ALL TIMES. THIS IS A NORMALLY OPEN SWITCH. CUSTOMER INFORMED US THAT THE HEATER HAS 76 HRS. TT. T HIS WAS A WARRANTY CLAIM. UPON RECEIPT OF THE DEFECTIVE SWITCH, CONCLUDED THAT THE SWITCH WAS CLOSED AT ALL TIMES. THI S SWITCH (AND HEATER) IS NOT REQUIRED TO BE TESTED IAW AD 96-20-07. THE HEATER, THIS SWITCH IS INSTALLED ON IS PN FR90D 38-1EL AND WAS BUILT IN FEBRUARY 2002. TO PREVENT RECURRENCE, HAVE OPERATORS CHECK HEATERS AND SWITCHES WITH A SB OR AD . (K) 1 L 7 2 3O A7SO 2005033000027 20050330 00027 NM 2005 3 30 2005FA0000189 1 20040613 G 5711 41513027 SPAR CAP UNIVAR 415 415C 0420302 NM CONT A75 A75* 17005 SO WING CORRODED B A5OR K NONE O OTHER IN INSP/MAINT 1 SO 09 3620H 958 4245 WHILE PERFORMING A 3 YEAR INSPECTION OF THE WING CENTER SECTION IAW AD, NOTE: 2002-26-02 AND MFG SB NR 31, THE FORWARD U PPER SPAR CAPSTRIP, PN 415-13027 WAS FOUND TO HAVE AN AREA OF INTERGRANULAR (IG) CORROSION NEAR THE UPPER WING ATTACH FI TTING. THE CORROSION WAS BARELY VISIBLE WITH THE WING CENTER SECTION INSTALLED ON THE AIRCRAFT. THE FULL EXTENT OF THE IG CORROSION WAS NOT KNOWN TILL THE WING CENTER SECTION SPAR WAS REMOVED FROM THE AIRCRAFT, STRIPPED OF PAINT AND THORO UGHLY CLEANED. INITIALLY THE AREA OF CORROSION APPEARED TO LOOK LIKE PEALING PAINT. CLOSER INSPECTION REVEALED AN AREA .6250 WIDE X 6 INCHES LONG X .1875 INCH DEEP. RECOMMEND A CLOSE AND THOROUGH INSPECTION OF WING CENTER INSPECTION FOR 1 L 7 1 3O 3 O A718 E213 2005042500194 20050425 00194 EU 2005 4 25 2005FA0000206 1 20041014 G 2910 M20R751802A2 LINE AMD FALC20 FALCONF 2720306 EU GARRTT TFE731 TFE731* 01518 WP HYD SYSTEM CHAFED B UO2R K NONE O OTHER IN INSP/MAINT 1 GL 19 132EP 4397 463 2 HYDRAULIC PIPES WERE CHAFING AGAINST EACH OTHER IN THE RT ENGINE PYLON. THE 2 PIPES WERE REMOVED AND REPLACED, ENSURI NG NO CONTACT BETWEEN THEM. (GL19200501324) (K) (NR1 OF 2 ) 2 L 7 2 4F 4 F A7EU E6WE 2005040400100 20050404 00100 CE 2005 4 4 2005FA0000207 1 20041017 G 5755 24920016KIT PANEL LEAR 60 60LEAR 5170707 CE RT WING SPOILER DAMAGED B WVER K NONE O OTHER IN INSP/MAINT 1 EA 09 228FX 132 WHILE PERFORMING SCHEDULED INSPECTION THE RT SPOILER PANEL WAS FOUND TO BE DAMAGED AT THE FORWARD IB CORNER. THIS SPOIL ER PANEL WAS PREVIOUSLY INSTALLED AT THIS STATION ON 9/29/2002 AT TT:3939.5 & TC:2774. SB 60-27-2 WAS USED TO INSTALL A ND TRIM THE PANEL AT INSTALLATION. THE SB TRIM CLEARANCE FOR THIS PANEL IS .030 INCH TO .060 INCH, MFG MM 27-60-01 TRIM CLEARANCE IS .050 INCH TO .080 INCH. THE PANEL CLEARANCE WAS FOUND TO BE AT .040 INCH WHICH WAS TOO TIGHT WHEN USED AS SPOILERONS IN FLIGHT. INCORRECT TRIM GAP IN SB 27-60-2. MFG EVALUATE AND MAKE CHANGE. (EA09200500519) (K) 2 L 7 2 4F RT A10CE 2005040400090 20050404 00090 CE 2005 4 4 2005FA0000208 1 20041006 G 5755 2422510 PANEL LEAR 60 60LEAR 5170707 CE LT WING SPOILER DAMAGED B WVER K NONE O OTHER IN INSP/MAINT 1 EA 09 240FX 167 AIRCRAFT ARRIVE WITH LT SPOILER PANEL DAMAGE AT THE IB FWD EDGE CORNER. AN INSPECTION WAS ACCOMPLISHED WITH NEGATIVE RE SULTS. THIS SPOILER PANEL WAS PREVIOUSLY INSTALLED AT THIS STATION ON 9/16/2004 FOR A SIMULAR DEFECT AT TT: 4277.5 AND TC: 2923. SB 60-27-2 WAS USED TO INSTALL AND TRIM THE PANEL AT INSTALLATION. THE SB TRIM CLEARANCE FOR THIS PANEL IS .0 30 INCH TO .060 INCH, MFG MM 27-60-01 TRIM CLEARANCE IS .050 INCH TO .080 INCH. THE PANEL CLEARANCE WAS FOUND TO BE AT .040 INCH WHICH WAS TOO TIGHT WHEN USED AS SPOILERONS IN FLIGHT. INCORRECT TRIM GAP IN SB 27-60-2. MFG TO EVALUATE AND MAKE CHANGE. (EA09200500525) (K) 2 L 7 2 4F RT A10CE 2005042500195 20050425 00195 WP 2005 4 25 2005FA0000209 2 20041026 G 7200 STATOR LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE7312 01518 WP ENGINE ERODED B WVER K NONE O OTHER IN INSP/MAINT 1 EA 09 422FX 135 P116281 DURING 600/1200 HOUR INSPECTION, FOUND (9) NINE BY PASS STATOR BLADES WITH EROSION DAMAGE ON THE LEADING EDGE. BLADES W ERE REMOVED AND REPALCED IAW MM. PROBABLE CAUSE: DESIGN ENGINEERING EVALUATE. (EA09200500613) (K) 2 L 7 2 4F 4 F RT T00008WI E6WE 2005040400074 20050404 00074 EU 2005 4 4 2005FA0000210 1 20041229 G 3000 7847232 ANTI-ICE VALVE AMD FALC90 FALCON900B 2730171 EU GARRTT TFE731 TFE731* 01518 WP FAILED B UO2R K NONE O OTHER IN INSP/MAINT 1 GL 19 203CW 1181 33 DURING TROUBLESHOOTING FOR (HIGHER THAN NORMAL) GASPER AIR TEMPERATURE, FOUND THE TURBOFAN TURBINE ANIT-ICE VALVE DISASS EMBLED BETWEEN THE VALVE AND THE MOTOR. NO DAMAGE CAN BE SEEN ON THE VALVE. THE 2 THREADED PARTS WERE FOUND UNTHREADED . THE DYSFUNCTIONAL PART WAS REMOVED AND REPLACED WITH A NEW VALVE PN 784723-3. REF AMM 21-512. (K) 2 L 7 3 4F 4 F RT E6WE 2005040400078 20050404 00078 CE 2005 4 4 2005FA0000211 1 20041229 G 7921 10046A OIL COOLER BEECH 60 B60 1153605 CE LYC O541 TIO541* 41536 EA RT ENGINE CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 19 2025P P476 COOLER SPLIT AT WELD ON END OF COOLER. SPLIT WAS 2+ INCHES LONG RIGHT DOWN THE CENTER OF THE WELD. (GL19200501920) (GL 19200502021) (K) 1 L 7 2 3O 3 O A12CE E10EA 2005040400006 20050404 00006 NE 2005 4 4 2005FA0000225 2 20041025 G 8500 50B043 ROD PWA 4060 PW4060 52119 NE LPC MODULE NICKED D O OTHER O OTHER NR NOT REPORTED 1 NE 03 P724153 ENGINE WAS RECEIVED FOR PHASE III MODEL CONVERSION. DURING TEARDOWN SEVERAL TIE RODS WERE FOUND WITH NICKED DOWN AREA I N THREADS. PARTS WERE SENT TO T.C. HOLDER FOR INVESTIGATION. REF RMR NR 31481. 4 F E24NE 2005040400069 20050404 00069 EU 2005 4 4 2005FA0000227 1 20041014 G 2910 M20R751804A1 PIPE AMD FALC20 FALCONF 2720306 EU GARRTT TFE731 TFE731* 01518 WP HYD SYSTEM CHAFED B UO2R K NONE O OTHER IN INSP/MAINT 1 GL 19 132EP 4397 463 2 HYDRAULIC PIPES WERE CHAFING AGAINST EACH OTHER IN THE RT ENGINE PYLON. THE 2 PIPES WERE REMOVED AND REPLACED ENSURIN G NO CONTACT BETWEEN THEM. (GL19200501324). (K) (NR 2 OF 2) 2 L 7 2 4F 4 F A7EU E6WE 2005042500200 20050425 00200 CE 2005 4 25 2005FA0000228 1 20041022 G 2697 P133 WIRE HARNESS LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE731* 01518 WP RT FIRE DETECT CHAFED B WVER O OTHER N FALSE WARNING AP APPROACH 1 EA 09 418FX 120 RT ENGINE FAIL CAS AMBER LIGHT ILLUMINATED AND RT ENGINE FIRE RED WARNING LIGHT ILLUMINATED IN FLIGHT ON FINAL APPROACH TO PNE. PROBLEM: SEVERAL WIRES WERE CHAFED THOUGH ON THE P133 WIRING HARNESS. FOUND CHAFED ON FRAME NEAR THE TAIL CONE RELAY PANEL. REPAIRED WIRES IAW MM. OPERATIONAL CHECKED OK. PROBABLE CAUSE: IMPROPER WIRE ROUTING/PROTECTION. (EA09 200500610) (K) 2 L 7 2 4F 4 F RT T00008WI E6WE 2005040100109 20050401 00109 EU 2005 4 1 2005FA0000229 1 20040624 G 2910 723088325 TUBE ISRAEL 1124 1124A 4500103 EU GARRTT TFE731 TFE731* 01518 WP NOSE WHEEL WELL LEAKING G UG1R K NONE K FLUID LOSS IN INSP/MAINT 1 SW 03 437SJ 437 TUBE LEAKING THRU SEVERAL PIN HOLES, SUSPECT INTERNAL CORROSION. SLOW EVACUATION OF HYDRAULIC FLUID PREVENTED ACTUATION OF HYDRAULIC FUSE. TAKEOFF WITH GEAR (UP) SELECTION REVEALED SLOW ACTUATION AND A RETURN TO BASE. GEAR (DOWN) SLOW BU T CAME DOWN AND LOCKED. LAND WITHOUT INCIDENT. (EA03200405351) 2 M 7 2 4F 4 F A2SW E6WE 2005040100110 20050401 00110 EU 2005 4 1 2005FA0000230 1 20040908 G 3320 F5053136501 SIGN AMD FALC50 FALCON50MYST 2730106 EU GARRTT TFE731 TFE731* 01518 WP LT CABIN BURNED B QU2R D RETURN TO BLOCK B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 EA 17 450K 9437 186 SMOKE WAS OBSERVED IN THE CABIN AFTER START OF TAXI TO ACTIVE RUNWAY, THE CREW SHUT DOWN ENGINES, SHUT OFF ALL POWER AND DISCONNECTED BATTERY. FOUND SOURCE OF SMOKE TO BE FROM A NO SMOKING/SEATBELT SIGN LOCATED IN THE LT SIDE OF CABIN AT F RAME 20. THE AIRCRAFT WAS SECURED AND FERRYED TO A MAINTENANCE BASE. UPON FURTHRE INVESTIAGTION, FUND NO CONCLUSIVE EV IDENCE BUT SUSPECT PROBLEM ORIGINATED AT THE INTERFACE OF THE WIRING TO THE NO SMOKING/SEATBELT SIGN. 2 L 7 3 4F 4 F A46EU E6WE 2005032800091 20050328 00091 SW 2005 3 28 2005FA0000232 1 20040808 G 3260 V31 WARNING SWITCH MOONEY M20 M20F 5870214 SW LYC O360 IO360A1A 41514 EA MLG LOOSE D K NONE O OTHER IN INSP/MAINT 1 NM 07 6344Q 670427 LANDING GEAR WARNING SWITCH FOUND LOOSE ON THE ATTACH AREA OF THROTTLE CABLE CAUSING INTERMITTENT OPERATION OF HORN. SC REWS WERE TIGHTENED AND SYSTEM OPERATES NORMALLY.(K) 1 L 7 1 3O 3 O 2A3 1E10 2005042500211 20050425 00211 NM 2005 4 25 2005FA0000233 1 20041105 G 3246 WHEEL BOEING 737 7373H4 1384600 NM CFMINT CFM56 CFM563B1US GL MLG CRACKED B SWAX K NONE O OTHER IN INSP/MAINT 1 SW 29 322SW 23343 WHEEL/ TIRE ASSY WENT FLAT. SHOP FINDINGS THROWN TREAD AND 4 BROKEN WHEEL TIE BOLTS. (K) 2 L 7 2 4F 4 F RT A16WE E2GL 2005042500212 20050425 00212 CE 2005 4 25 2005FA0000234 1 20041026 G 8011 642083A12 ADAPTER BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO STARTER SLIPPED B VJ3R K NONE O OTHER IN INSP/MAINT 1 WP 07 1556A CE1318 INSTALLED NEW ENGINE IN AIRCRAFT AND PERFORMING ENGINE SET UP. MAINTENANCE CREW NOTICED STARTER ADAPTOR SLIPPING. NEW PART SO REMOVED FOR WARRANTY. NO RECOMMENDATION AT THIS TIME. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2005040400108 20050404 00108 CE 2005 4 4 2005FA0000235 1 20041112 G 7810 LW12126 EXHAUST RISER CESSNA 310 T310R 2074246 CE CONT O520 TSIO520* 17040 SO LT ENGINE CRACKED B CTUR K NONE O OTHER IN INSP/MAINT 1 GL 21 3731G 310R0906 FOUND LT ENGINE OB EXHAUST RISER CRACKED WHILE PERFORMING A 50 HOUR EXHAUST INSPECTION IAW AD 00-01-16. (GL21200500869) (K) 1 L 7 2 3O 3 O 3A10 E8CE 2005031100063 20050311 00063 SW 2005 3 11 2005FA0000236 1 20041021 G 5230 DOOR FRAME SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE331* 01514 WP CARGO DOOR CRACKED B Q8LR K NONE O OTHER IN INSP/MAINT 1 NM 11 160WA TC399 DURING A FLUORESCENT PENETRANT INSPECTION OF (CARGO DOOR FRAME LOWER END FORE AND AFT NEAR BAYONET PIN). (FC STUN-M00-2- 1-1) A CRACK OF APPROXIMATELY 0.250 INCH WAS DETECTED. THE PROBABLE CAUSE IS SERVICE INDUCED FATIGUE CRACKING. AREA OF CONCERN HAS ALREADY BEEN REINFORCED WITH DOUBLER PLATE AND ADDITIONAL RIVETS. STOP HOLE WILL BE DRILLED AT CRACK END T O PREVENT FURTHER LENGTHENING. 2 L 7 2 4T 3 T RT A8SW E2WE 2005040400010 20050404 00010 2005 4 4 2005FA0000237 4 20041026 G 6113 05522311 BULKHEAD CESSNA 172 172S 2072439 CE LYC O360 IO360A1A 41514 EA MCAULY 1A170 1A170E GL SPINNER CRACKED B WIWR K NONE O OTHER IN INSP/MAINT 1 WP 07 796WW 393 172S8635 DURING 100 HOUR INSPECTION OF THE PROPELLER, CRACKS NOTED AROUND ALL BOLT HOLES OF THE FWD BULKHEAD. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P857 2005040100111 20050401 00111 NM 2005 4 1 2005FA0000238 1 20041118 G 7500 CLAMP AMD FALC50 FALCON2000 2730170 NM CFE CFE73811B NE BLEED AIR LOOSE B BTVR O OTHER O OTHER NR NOT REPORTED 1 GL 23 248JF 11 CLIMBING THROUGH 27,000 FT THE RT GENERATOR WENT OFFLINE, SHORTLY AFTERWARDS, LT GENERATOR WENT OFFLINE, AN EMERGENCY WA S DECLARED AND THE AC LANDED WITH NO FURTHER INCIDENT, INVESTIGATION FOUND A LOOSE CLAMP CONNECTING A BLEED AIR DUCT TO THE CABIN COLD TEMPERATURE CONTROL VALVE. IT IS SUSPECTED THAT BLEED AIR LEAKING AT THIS AREA CAUSED THE GENERATOR CONT ROL UNITS TO STOP WORKING DUE TO OVERHEATING. THE CLAMP WAS TIGHTENED AND A LEAK CHECK PERFORMED. A FUNCTIONAL CHECK O F THE GENERATOR SYS PERFORMED. NO DISCREPANCIES WERE NOTED. GENERATOR CNTRL UNITS WERE REPLACED AS A PRECAUTIONARY MEA SURE GCU`S WERE SENT TO THE MFG AND FOUND TO FUNCTION IAW DESIGN SPECIFICATION. (K) 2 K 7 3 4F 4 F RT A50NM E44NE 2005030800279 20050308 00279 NM 2005 3 8 2005FA0000239 1 20041027 G 7810 EXHAUST PIPE AERORS J2 J2 5500604 NM LYC O360 O360* 41514 EA ENGINE BROKEN G A UNSCHED LANDING S AFFECT SYSTEMS CL CLIMB 1 SW 11 62SJ 091 (ACCIDENT NR DFW05CA024) ON TAKEOFF CLIMB, EXHAUST PIPE BROKE AND WENT THROUGH 4 BLADED PROPELLER, SHEARING OFF ONE PRO PELLER BLADE. EXHAUST PIPE STRUCK RT TAILBOOM, DOING STRUCTURAL DAMAGE TO TAILBOOM. (SW11200502888) (K) 1 G 7 1 3O 3 O NC H6WE E286 2005040400020 20050404 00020 CE 2005 4 4 2005FA0000240 1 20041109 G 3240 PEDAL CESSNA 206 T206H 2073303 CE LYC O540 TIO540* 41532 EA BRAKE MISALIGNED D K NONE O OTHER IN INSP/MAINT 1 WP 19 808DT T20608278 RT SIDE BRAKE PEDALS: DURING A FLT CHECK, THE INSTRUCTOR FOUND HE RARELY HAD BRAKES DUE TO TOE PEDALS GOING OVER TOO FA R, HIS FOOT COULD NOT GO OVER ANYMORE TO STOP THE AIRCRAFT. DURING OK OUT, SEEMS THE LINKAGE ON PEDALS IS MISALIGNED AL LOWING THE PDEALS TO GO OVER TOO FAR, JUST ABOUT TO FIREWALL. (K) 1 H 7 1 3O 3 O RT A4CE E14EA 2005040100076 20050401 00076 EA 2005 4 1 2005FA0000241 2 20040915 G 7414 S4LN20105136029 MAGNETO PIPER PA28 PA28180 7102808 SO LYC O360 O360A4A 41514 EA RIGHT LOOSE D K NONE O OTHER IN INSP/MAINT 1 NM 08 9198B 351 283857 OVERHAUL DATE, MFG, 5-2001 - GEAR FAILURE (PN AB-357584) ELECTRODE BRASS FINGRE ON NYLON GEAR WAS LOOSE AND CONTRACTED B RASS ELECTRODES. ON PN 10-357424 DISTRIBUTOR BLOCK FILLING BLOCK WITH CONDUCTIVE PARTICLES WHICH ENDED UP SHORTING OUT ONE IGNITION LEAD CAUSING ROUGH RUNNING ENGINE. (K) 1 L 7 1 3O 3 O 2A13 E286 2005040400052 20050404 00052 CE 2005 4 4 2005FA0000242 1 20041115 G 5610 10138402522 WINDSHIELD BEECH 300 300BEECH 1152930 CE PWA PT6 PT6A60A 52043 NE COCKPIT BROKEN D A UNSCHED LANDING O OTHER CR CRUISE 1 NM 13 20NK FA51 INNER PLY OF WINDSHIELD SHATTERED AT 29,000, -38 DEGREES C., RT HAND POSITION. THEN 8-10 SECONDS LATER LT WINDSHIELD SH ATTERED. RECOMMEND SUBSEQUENT SCHEDULED WINDSHIELD RETORQUES BEING CAREFULLY PERFORMED TO ENSURE ORIGINAL CONTOUR OF WS INSTALLATION IAW KIT 101-50433 IS NOT ALTERED RESULTING IN STRESS LOCATIONS IN WINDSHELL FRAME. (NM13200500756) (NM132 00501246) (K) 2 L 7 2 4T 4 T A24CE E4EA 2005031100006 20050311 00006 EU 2005 3 11 2005FA0000243 1 20041109 G 2121 900A6047 FAN SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE AIR CONDITIONER MISMANUFACTURED B D94R K NONE O OTHER IN INSP/MAINT 1 SW 13 204TX 322 3711 LOCKING SET SCREW MISSING FROM FAN, FAN DETATCHED FROM MOTOR. UPON RECEIPT OF NEW FAN, FOUND SET SCREW ALSO MISSING. (K ) 1 G 7 1 3U 3 U H9EU E19EU 2005040400060 20050404 00060 CE 2005 4 4 2005FA0000244 1 20041103 G 2520 551900921 FRAME CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE SEAT CRACKED B LQUR K NONE O OTHER IN INSP/MAINT 1 WP 09 219MS 5500180 UPPER CHAIR BASE ASSEMBLY CRACKED AT CHAIR BACK ATTACH POINTS. CHAIR WAS REPAIRED IAW STO1042WI STRUCTURAL SEAT REPAIR. (K) 1 L 7 2 4F 4 F A22CE E1NE 2005040400082 20050404 00082 CE 2005 4 4 2005FA0000245 1 20041103 G 2520 551900922 FRAME CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE SEAT CRACKED B LQUR K NONE O OTHER IN INSP/MAINT 1 WP 09 219MS 5500180 UPPER CHAIR BASE ASSEMBLY CRACKED AT CHAIR BACK ATTACH POINTS. CHAIR WAS REPAIRED IAW STO1042WI STRUCTURAL SEAT REPAIR. (K) 1 L 7 2 4F 4 F A22CE E1NE 2005040400002 20050404 00002 CE 2005 4 4 2005FA0000246 1 20041103 G 2520 551900932 FRAME CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE SEAT CRACKED B LQUR K NONE O OTHER IN INSP/MAINT 1 WP 09 219MS 5500180 UPPER CHAIR BASE ASSEMBLY CRACKED AT CHAIR BACK ATTACH POINTS. ALSO, PREVIOUS INAPPROPRIATE REPAIR. CHAIR WAS REPAIRED IAW STO1042WI STRUCTURAL SEAT REPAIR. (K) 1 L 7 2 4F 4 F A22CE E1NE 2005042600016 20050426 00016 EA 2005 4 26 2005FA0000254 2 20041225 G 7322 6230103 GASCOLATOR PIPER PA28 PA28180 7102808 SO LYC O360 O360* 41514 EA BOWL CONTACT INOPERATIVE D K NONE O OTHER IN INSP/MAINT 1 SO 15 75EH 2895 282121 SURFACE AREA WHERE BOWL ASSEMBLY (63479-00) CONTACTS THE FRAME (COVER 14428-00) OF THE FUEL FILTER BENDS AS WIRE ASSEMBL Y (BAIL 494-644) IS TIGHTENED. OVER THE YEAR THE FORCE OF THE BAIL ACTUALLY BENDS THE FRAME TO WHERE THE GASKET WILL NO LONGER SEAL AND FUEL WILL SEEP BY THE GASKET WHEN THE BOWL IS CROCKED FORWARD AND AFT. 90 DEGREES TO THE LOCATIO OF TH E BAIL ASSEMBLY. THE ONLY OPTION TO REMEDY THE SITUATION IS TO REPLACE WITH FACTORY NEW OR STC REPLACEMENT. (SO152005 14114) 1 L 7 1 3O 3 O 2A13 E286 2005042600017 20050426 00017 EA 2005 4 26 2005FA0000256 2 20041225 G 8550 CH48110 OIL FILTER PIPER PA28 PA28181 7102807 SO LYC O360 O360* 41514 EA ENGINE MISMANUFACTURED D K NONE O OTHER IN INSP/MAINT 1 SO 15 2166L 287990259 WHEN OIL FILTER WAS CUT OPEN FOR INSPECTION, A PIECE OF STRING WAS DISCOVERED WRAPPED AROUND THE FILTER MEDIUM. NO OTHE R PROBLEM WAS DISCOVERED AT THIS TIME. BETTER Q.C. IN MFG WILL CORRECT SITUATION. (SO15200514115) 1 L 7 1 3O 3 O 2A13 E286 2005040400094 20050404 00094 EU 2005 4 4 2005FA0000260 1 20041209 G 2450 ALTERNATOR BRAERO 1000 BAE1251000A 1500104 EU PWA 305 PW305 NE NR 1 FAILED B R14R K NONE O OTHER IN INSP/MAINT 1 EA 17 533QS 259033 AIRCRAFT WAS SQUAWKED WITH NR 1 ALTERNATOR DROPPING OFF IN FLIGHT. DURING TROUBLESHOOTING THE TECHNICIAN FOUND SMOKE TR AILS ON THE (GG PANEL), LOCATED ON THE AFT SIDE OF THE REAR FACE OF THE PRESSURE BULKHEAD. A MORE CLOSE INSPECTION REV EALED A DESTROYED FUSE HOLDER, WITH ACCOMPANYING WIRE DAMAGE, GCU AND LINE CONTACTOR DAMAGE. THERE WAS A HOLE BURNED TH ROUGH THE (GG PANEL) ITSELF AT THE FUSE HOLDER LOCATION. THE DAMAGE WAS CENTERED UNDER THE LT SIDE OF THE FUSE BLOCK, W HICH HAD DESINTEGRATED. IT WAS UNDETERMINED AS TO WHICH COMPONENT INITIATED THE DAMAGE. (EA17200504804) 2 L 7 2 4F 4 F RT A3EU E35NE 2005040400092 20050404 00092 CE 2005 4 4 2005FA0000261 1 20040805 G 3220 MECHANISM CESSNA 177 177RG 2073709 CE LYC O360 IO360A1B6 41514 EA NLG FAILED G O OTHER J WARNING INDICATION AP APPROACH 1 NM 05 1840Q 177RG0240 NOSE LANDING GEAR FAILED TO EXTEND DURING APPROACH 8/5/04. NOSE GEAR WAS CONFIRMED TO NOT BE EXTENDED BY COCKPIT INDICA TION AND WING MOUNTED MIRROR. SEVERAL ATTEMPTS WERE MADE TO EXTEND NOSE GEAR, TO NO AVAIL. MANUAL NOSE GEAR EXTENSION WAS ALSO ATTEMPTED, EMERGENCY CK LIST, TO NO AVAIL. EMERGENCY DECLARED, AC LANDED NOSE GEAR UP. WHEN AC WAS LIFTED, NO SE GEAR DOORS FELL OPEN, NOSE GEAR WAS ABLE TO BE PUMPED DOWN. INSP, NO OBVIOUS CAUSAL FACTOR OF INCIDENT COULD BE DETE RMINED. AC TO BE REPAIRED. (1ST OCCURRENCE. JULY, 2000 SAME AS ABOVE, NO SINGLE CAUSE IDENTIFIED. AC REPAIRED, FLOWN APPROX 700 HRS TIL THIS INCIDENT.) (NM05200400085) (K) 1 H 7 1 3O 3 O A20CE 1E10 2005032800102 20050328 00102 CE 2005 3 28 2005FA0000262 1 20041004 G 5753 RIB CESSNA 182 TR182 2072735 CE LYC O540 O540* 41532 EA LT FLAP TRACK CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 07 210BB R18201430 LT WING IB FLAP TRACK RIB ASSY, PN 1221010-15, HAS 2 BRACKETS RIVETED TO EITHER SIDE OF IT TO ATTACH FLAP TRACK RIB ASSY TO WING LOWER IB T/E SKIN, REF TO AS FLAP WELL SKIN) PN 0720601-101. ONE OF BRACKETS HAD CRACKED ALLOWING BRACKET TO T WIST SLIGHTLY, DECREASING CLEARANCE BETWEEN BRACKET AND FLAP ROLLER SLOT IN FLAP TRACK RIB ASSY. ON GROUND, PILOT TRIED TO RAISE FLAPS. FRONT OF LT FLAP IB SUPPORT ARM RIB ASSY CAUGHT ON CRACKED AND TWISTED BRACKET JAMMING IB END OF FLAP. NORMALLY THERE IS ABOUT .1250 INCH CLEARANCE BETWEEN THE BRACKET AND FRONT OF FLALP SUPPORT ARM. FLAP MOTOR CONTINUED TO RUN, TRYING TO RETRACT FLAPS, CAUSING SUBSTANTIAL DAMAGE TO JAMMED LT FLAP. REPLACED CRACKED BRACKET, LT FLAP. (K) 1 H 7 1 3O 3 O 3A13 E295 2005042600020 20050426 00020 2005 4 26 2005FA0000265 1 20040802 G 2910 LINE HYD SYSTEM UNSERVICEABLE D K NONE O OTHER IN INSP/MAINT 1 GL 25 78 HAD 3 HYDRAULIC LINE FAILURES CAUSING LOSS OF LANDING GEAR OPERATION WITHIN 70 HOURS. 2 FAILURES WERE DUE TO LOOSE B-NU TS, 1 WAS FAILURE OF LINE AT FLARE. LINES ARE SOFT ALUMINUM, THIN WALL TUBING WITH NO SPEC NUMBER APPEARS TO BE 3003-0 USED FOR AIR AND VACUUM LINES. SHOULD BE 5052-0 FOR GEAR HYDRAULIC SYSTEM. 2005031100071 20050311 00071 SO 2005 3 11 2005FA0000267 1 20040902 G 5312 1159B2156225 BULKHEAD GULSTM G1159 G1159 3953505 SO RROYCE SPEY SPEY5118 54523 EU FUSELAGE CRACKED B GR4R K NONE O OTHER IN INSP/MAINT 1 SO 11 826GW 7997 210 DURING COMPLIANCE OF NDT EDDY CURRENT INSP OF FS-793.75 BULKHEAD, CAP ANGLE WAS FOUND CRACKED. NEW CAP ANGLE WAS INSTAL LED IAW DWG NR SE20000210, REV. D. 2 L 7 2 4F 4 F RT A12EA E2EU 2005040400091 20050404 00091 SO 2005 4 4 2005FA0000268 1 20040902 G 5730 1159W200059 PANEL GULSTM G1159 G1159 3953505 SO RROYCE SPEY SPEY5118 54523 EU LT WING CORRODED B GR4R K NONE O OTHER IN INSP/MAINT 1 SO 11 826GW 210 DURING WIG (LT) NDT INSPECTION EXFOLIATION CORROSION NOTED ON WING UPPER PLANK AND FRONT BEAM BETWEEN RBS 284 THRU 375. REMOVED EXFOLIATION CORROSION IAW SRM. REPAIRS COMPLETED. 2 L 7 2 4F 4 F RT A12EA E2EU 2005031100069 20050311 00069 SO 2005 3 11 2005FA0000269 1 20040902 G 5414 1159P203264 COWLING GULSTM G1159 G1159 3953505 SO RROYCE SPEY SPEY5118 54523 EU RT NACELLE CORRODED B GR4R K NONE O OTHER IN INSP/MAINT 1 SO 11 826GW 7997 210 DURING RT ENGINE MID-LIFE UPDATES, RT FIXED COWL WAS INSPECTED AND CORROSION WAS NOTED. FIXED COWL WAS REPAIRED. 2 L 7 2 4F 4 F RT A12EA E2EU 2005031400093 20050314 00093 SO 2005 3 14 2005FA0000270 2 20040928 G 8530 649358CN CYLINDER HEAD BLANCA 17 1730A 1220433 GL CONT O520 IO520K 17032 SO HARTZL HCC3Y HCC3YF1 GL ENGINE SEPARATED B K NONE O OTHER IN INSP/MAINT 1 SW 05 28127 817 8030972 224129R EC1592A AIRCRAFT ANNUAL INSP- 2 WEEKS PRIOR- REPLACED EXHAUST AND INTAKE VALVES ON NR 2 CYLINDER DUE TO LOW COMPRESSION. FLEW 6 HOURS PRIOR TO INCIDENT. IN CRUISE FLIGHT, ENGINE SUDDENLY RAN VERY ROUGH WITH VIBRATION. VFR WITH FLIGHT FOLLOWING. DECLARED EMERGENCY AND LANDED AT NEAREST AIRPORT(3F3), 18 MILES AWAY. POST FLIGHT INSPECTION: NR 2 CYLINDER BROKE INT O 2 PIECES- SEPARATED AT TOP OF BARREL AND JUNCTURE OF HEAD. HEAD WAS HELD ON BY VALVE COVER AND PUSH RODS. THIS CYLIN DER IS REPORTEDLY NOT SUBJECT TO EXISTING ADS OR MANDATORY SB THAT COVER OTHER ECI CYLINDERS WITH SIMILAR PROBLEMS. (SW 05200502730) 1 L 7 1 3O 3 O A18CE E5CE 5 C P25EA 2005032800078 20050328 00078 SO 2005 3 28 2005FA0000272 1 20041124 G 3246 40120C WHEEL PIPER PA32 PA32R300 7103213 SO LYC O540 TIO540* 41532 EA LT MLG CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 05 898DS 32R7780358 OWNER REPORTED AIRCRAFT HARD TO TOW. UPON INSPECTION, FOUND LT MLG WHEEL (ASSY 40-120C) BINDING. REMOVED LT MLG WHEEL AND FOUND INNER WHEEL HALF FLANGE WITH APPROXIMATELY 5 INCH CRACK. FLANGE HAD SEPARATED ENOUGH TO BIND ON BRAKE ASSY BA CKING PLATE. REPLACED WHEEL ASSY WITH NEW. REMOVED AND INSPECTED RT MLG WHEEL ASSY. NO DEFECTS NOTED. AC RETURNED TO SERVICE. (SO05200405828) 1 L 7 1 3O 3 O A3SO E14EA 2005031000090 20050310 00090 2005 3 10 2005FA0000274 1 20041222 G 2922 RC914UK096 BYPASS SWITCH PALL FILTER SHEARED D O OTHER K FLUID LOSS NR NOT REPORTED 1 SW 99 4550 1 OF THE SREWS (P/N AA-2100-11D99)HAD THE HEAD SHEAR OFF JUST UNDER THE HEAD. THIS SCREW, 1 OF 4 HOLD THE FILTER BYPASS DIFFERENTIAL PRESSURE INDICATOR TO THE TOP OF THE FILTER ASSEMBLY. THE AFFECTED SYSTEM WAS THE RUDDER STANDBY. HYDRAULIC FLUID WAS LEAKING STATICLY WITH THE SYSTEM DEPRESSURIZED. 2005040400073 20050404 00073 SO 2005 4 4 2005FA0000279 2 20041213 G 8520 653877 LIFTER CONT O550 IO550C SO ENGINE SPALLED B E81R K NONE O OTHER IN INSP/MAINT 1 GL 03 600 ON 6 DIFFERENT ENGINES DURING OIL CHANGES OR TROUBLESHOOTING FOR LOW OIL PRESSURE, HAVE FOUND A SPALLED LIFTER. ONLY ON CE WAS THE PROBLEM WAS THE PROBLEM CAUGHT EARLY ENOUGH THAT THE CAMSHAFT WAS NOT DAMAGED AND NEEDING REPLACEMENT. (K) ( 1 OF 2) 3 O E3SO 2005033000031 20050330 00031 SO 2005 3 30 2005FA0000280 2 20041213 G 8520 653888 LIFTER CONT O550 IO550C SO ENGINE SPALLED B E81R K NONE O OTHER IN INSP/MAINT 1 GL 03 600 ON 6 DIFFERENT ENGINES DURING OIL CHANGES OR TROUBLESHOOTING FOR LOW OIL PRESSURE, HAVE FOUND A SPALLED LIFTER. ONLY ON CE WAS THE PROBLEM CAUGHT EARLY ENOUGH THAT THE CAMSHAFT WAS NOT DAMAGED AND NEEDING REPLACEMENT. (K) (2 OF 2) 3 O E3SO 2005031100080 20050311 00080 EU 2005 3 11 2005FA0000281 1 20040809 G 5753 RIB SOCATA TBM TBM700 8682000 EU TE FLAP FAILED C K NONE O OTHER IN INSP/MAINT 1 EA 05 1607 SC205 THE BONDED INSERTS WHICH PROVIDE THE ATTACH POINTS FOR THE METAL CARRIAGE ASSEMBLY TO THE HONEYCOMB FLAP END-RIB HAVE FA ILED. INSPECTION OF THE INSERTS REVEALS THAT THE SEAL BETWEEN THE BONDED INSERT AND THE HONEYCOMB STRUCTURE BECOMES COM PROMISED. WATER IS INTRODUCED INTO THE HONEYCOMB END-RIB AND THE HONEYCOMB STRUCTURE FAILS. IMMEDIATELY INSPECT THE IN TEGRITY OF THE IB AND OB FLAP ATTACH POINTS. ANY MOVEMENT NOTED BETWEEN THE FLAP CARRIAGE ASSY AND THE FLAP END-RIB (IB AND OB) SHOULD REQUIRE REMOVAL OF THE FLAP FOR FURTHER INSPECTION OF THE BONDED INSERTS. MFG NOTIFIED. (K) 1 L 7 1 3T RT A60EU 2005031100082 20050311 00082 EU 2005 3 11 2005FA0000282 1 20040809 G 5753 RIB SOCATA TBM TBM700 8682000 EU TE FLAP FAILED C K NONE O OTHER IN INSP/MAINT 1 EA 05 3090 SC224 BONDED INSERTS WHICH PROVIDE THE ATTACH POINTS FOR THE METAL CARRIAGE ASSY TO THE HONEYCOMB FLAP END-RIB HAVE FAILED. INSPECTION OF THE INSERTS REVEALS THAT THE SEAL BETWEEN THE BONDED INSERT AND THE HONEYCOMB STRUCTURE BECOMES COMPROMISE D. WATER IS INTRODUCED INTO THE HONEYCOMB END-RIB AND THE HONEYCOMB STRUCTURE FAILS. IMMEDIATELY INSPECT THE INTEGRITY OF THE IB AND OB FLAP ATTACH POINTS. ANY MOVEMENT NOTED BETWEEN THE FLAP CARRIAGE ASSEMBLY AND THE FLAP END-RIB (IB AN D OB) SHOULD REQUIRE REMOVAL OF THE FLAP FOR FURTHER INSPECTION OF THE BONDED INSERTS. MFG HAS BEEN CONTACTED. 1 L 7 1 3T RT A60EU 2005031100084 20050311 00084 EU 2005 3 11 2005FA0000283 1 20040809 G 5753 RIB SOCATA TBM TBM700 8682000 EU TE FLAP FAILED C K NONE O OTHER IN INSP/MAINT 1 EA 05 3797 SC149 BONDED INSERTS WHICH PROVIDE THE ATTACH POINTS FOR THE METAL CARRIAGE ASSY TO THE HONEYCOMB FLAP END-RIB HAVE FAILED. INSPECTION OF THE INSERTS REVEALS THAT THE SEAL BETWEEN THE BONDED INSERT AND THE HONEYCOMB STRUCTURE BECOMES COMPROMISE D. WATER IS INTRODUCED INTO THE HONEYCOMB END-RIB AND THE HONEYCOMB STRUCTURE FAILS. IMMEDIATELY INSPECT THE INTEGRITY OF THE IB AND OB FLAP ATTACH POINTS. ANY MOVEMENT NOTED BETWEEN THE FLAP CARRIAGE ASSY AND THE FLAP END-RIB (IB AND OB ) SHOULD REQUIRE REMOVAL OF THE FLAP FOR FURTHER INSPECTION OF THE BONDED INSERTS. MFG HAS BEEN CONTACTED.(K) 1 L 7 1 3T RT A60EU 2005031100085 20050311 00085 EU 2005 3 11 2005FA0000284 1 20040809 G 5753 RIB SOCATA TBM TBM700 8682000 EU TE FLAP FAILED C K NONE O OTHER IN INSP/MAINT 1 EA 05 3797 SC141 BONDED INSERTS WHICH PROVIDE THE ATTACH POINTS FOR THE METAL CARRIAGE ASSY TO THE HONEYCOMB FLAP END-RIB HAVE FAILED. INSPECTION OF THE INSERTS REVEALS THAT THE SEAL BETWEEN THE BONDED INSERT AND THE HONEYCOMB STRUCTURE BECOMES COMPROMISE D. WATER IS INTRODUCED INTO THE HONEYCOMB END-RIB AND THE HONEYCOMB STRUCTURE FAILS. IMMEDIATELY INSPECT THE INTEGRITY OF THE IB AND OB FLAP ATTACH POINTS. ANY MOVEMENT NOTED BETWEEN THE FLAP CARRIAGE ASSEMBLY AND THE FLAP END-RIB (IB AN D OB) SHOULD REQUIRE REMOVAL OF THE FLAP FOR FURTHER INSPECTION OF THE BONDED INSERTS. MFG HAS BEEN CONTACTED. (K) 1 L 7 1 3T RT A60EU 2005031100081 20050311 00081 EU 2005 3 11 2005FA0000285 1 20040809 G 5753 RIB SOCATA TBM TBM700 8682000 EU TE FLAPS FAILED C K NONE O OTHER IN INSP/MAINT 1 EA 05 4562 SC127 BONDED INSERTS WHICH PROVIDE THE ATTACH POINTS FOR THE METAL CARRIAGE ASSY TO THE HONEYCOMB FLAP END-RIB HAVE FAILED. INSPECTION OF THE INSERTS REVEALS THAT THE SEAL BETWEEN THE BONDED INSERT AND THE HONEYCOMB STRUCTURE BECOMES COMPROMISE D. WATER IS INTRODUCED INTO THE HONEYCOMB END-RIB AND THE HONEYCOMB STRUCTURE FAILS. IMMEDIATELY INSPECT THE INTEGRITY OF THE IB AND OB FLAP ATTACH POINTS. ANY MOVEMENT NOTED BETWEEN THE FLAP CARRIAGE ASSEMBLY AND THE FLAP END-RIB (IB AN D OB) SHOULD REQUIRE REMOVAL OF THE FLAP FOR FURTHER INSPECTION OF THE BONDED INSERTS. MFG HAS BEEN CONTACTED. (K) 1 L 7 1 3T RT A60EU 2005031100083 20050311 00083 EU 2005 3 11 2005FA0000286 1 20040809 G 5753 RIB SOCATA TBM TBM700 8682000 EU TE FLAP FAILED C K NONE O OTHER IN INSP/MAINT 1 EA 05 2988 SC193 BONDED INSERTS WHICH PROVIDE THE ATTACH POINTS FOR THE METAL CARRIAGE ASSY TO THE HONEYCOMB FLAP END-RIB HAVE FAILED. INSPECTION OF THE INSERTS REVEALS THAT THE SEAL BETWEEN THE BONDED INSERT AND THE HONEYCOMB STRUCTURE BECOMES COMPROMISE D. WATER IS INTRODUCED INTO THE HONEYCOMB END-RIB AND THE HONEYCOMB STRUCTURE FAILS. IMMEDIATELY INSPECT THE INTEGRITY OF THE IB AND OB FLAP ATTACH POINTS. ANY MOVEMENT NOTED BETWEEN THE FLAP CARRIAGE ASSY AND THE FLAP END-RIB (IB AND OB ) SHOULD REQUIRE REMOVAL OF THE FLAP FOR FURTHER INSPECTION OF THE BONDED INSERTS. MFG HAS BEEN CONTACTED. (K) 1 L 7 1 3T RT A60EU 2005040400063 20050404 00063 EU 2005 4 4 2005FA0000287 1 20040809 G 5753 T700A5755000000 CARRIAGE SOCATA TBM TBM700 8682000 EU TE FLAP FAILED C K NONE O OTHER IN INSP/MAINT 1 EA 05 3561 BONDED INSERTS WHICH PROVIDE THE ATTACH POINTS FOR METAL CARRIAGE ASSY (PN TO THE HONEYCOMB FLAP END-RIB HAVE FAILED. INSPECTION OF THE INSERTS REVEALS THAT THE SEAL BETWEEN THE BONDED INSERT AND THE HONEYCOMB STRUCTURE BECOMES COMPROMISE D. WATER IS INTRODUCED INTO THE HONEYCOMB END-RIB AND THE HONEYCOMB STRUCTURE FAILS. IMMEDIATELY INSPECT THE INTEGRITY OF THE IB AND OB FLAP ATTACH POINTS. ANY MOVEMENT NOTED BETWEEN THE FLAP CARRIAGE ASSY AND THE FLAP EN-RIB (IB AND OB) SHOULD REQUIRE REMOVAL OF THE FLAP FOR FURTHER INSPECTION OF THE BONDED INSERTS. MFG HAS BEEN CONTACTED. (K) 1 L 7 1 3T RT A60EU 2005031100086 20050311 00086 EU 2005 3 11 2005FA0000288 1 20040809 G 5753 RIB SOCATA TBM TBM700 8682000 EU TE FLAP FAILED C K NONE O OTHER IN INSP/MAINT 1 EA 05 3647 SC134 BONDED INSERTS WHICH PROVIDE THE ATTACH POINTS FOR THE METAL CARRIAGE ASSY TO THE HONEYCOMB FLAP END-RIB HAVE FAILED. I NSPECTION OF THE INSERTS REVEALS THAT THE SEAL BETWEEN THE BONDED INSERT AND THE HONEYCOMB STRUCTURE BECOMES COMPROMISED . WATER IS INTRODUCED INTO THE HONEYCOMB END-RIB AND THE HONEYCOMB STRUCTURE FAILS. IMMEDIATELY INSPECT THE INTEGRITY OF THE IB AND OB FLAP ATTACH POINTS. ANY MOVEMENT NOTED BETWEEN THE FLAP CARRIAGE ASSY AND THE FLAP END-RIB (IB AND OB) SHOULD REQUIRE REMOVAL OF THE FLAP FOR FURTHER INSPECTION OF THE BONDED INSERTS. MFG HAS BEEN CONTACTED. (K) 1 L 7 1 3T RT A60EU 2005040100035 20050401 00035 CE 2005 4 1 2005FA0000289 1 20041109 G 2897 EE366L WIRE BEECH 90 C90A 1152911 CE PWA PT6 PT6* 52043 EA HEAT FUEL VENT INOPERATIVE B K NONE O OTHER IN INSP/MAINT 1 SO 13 100RU LJ1433 HEAT ELEMENT INOPERATIVE DUE TO BROKEN WIRE AT TIME VENT TUBE WHERE IS IS GROUNDED. IT IS CAUSED BY IMPROPER PROTECTIVE COATING ON WIRES. IT WEAR OFF AND OPENS THE WIRE FROM GROUND. (K) 1 L 7 2 3T 3 T RT 3A20 E2NE 2005040100026 20050401 00026 CE 2005 4 1 2005FA0000290 1 20041109 G 2897 WIRE BEECH 90 C90A 1152911 CE PWA PT6 PT6* 52043 EA HEATED FUEL VENT BROKEN B K NONE O OTHER IN INSP/MAINT 1 SO 13 100RU LJ1433 HEAT ELEMENT INOPERATIVE, DUE TO BROKEN WIRE AT TIP OF VENT TUBE WHERE IT IS GROUNDED. IT IS CAULED BY IMPROPER PROTECT IVE COATING ON THE WIRE. THE COATING WEARS OFF AND OPENS THE WIRE FROM GROUND. (K) 1 L 7 2 3T 3 T RT 3A20 E2NE 2005040400025 20050404 00025 2005 4 4 2005FA0000315 4 20040505 G 2564 S8012 CYLINDER LIFE RAFT FAILED B O OTHER O OTHER NR NOT REPORTED 1 SO 19 F46392 DURING RECEIVING INSPECTION OF LIFE RAFT (PN RA4610220, SN F46392) IT WAS FOUND THAT THE CYLINDER (PN S-801-2, SN 55396P , DATE OF MFG. 10-1973 WAS CHARGED AND INSTALLED ON THE LIFE RAFT. THE CYLINDER WHICH IS A DOT 3HT 3000 RATED CYLINDER HAD PAST ITS 24 YEAR SERVICE LIFE ON 10-1997 AND WAS HYDROSTATICALLY RETESTED ON 12-98 AND 12-02 BY REG NR PMMC AS SHOW N (STAMPED) ON THE CROWN OF THE CYLINDER. ONCE A DOT 3HT3000 RATED CYLINDER REACHES ITS 24 YEAR SERVICE LIFE IT CANNOT BE HYDROSTATICALLY RETESTED AND MUST BE REMOVED FROM SERVICE. THE COMPANY THAT SERVICE THE LIFE RAFT LAST, FAILED TO CO MPLY THE REGULATIONS FOR SERVICING THE CYLINDER. 2005032800114 20050328 00114 SW 2005 3 28 2005FA0000316 1 20040927 G 3220 206020110103 SKID BELL 407 407 1182206 SW ALLSN 250C 250C47B GL VERTICAL FIN FRACTURED B KBTR K NONE O OTHER IN INSP/MAINT 1 NM 07 407MH 4517 53100 DURING PRE-FLIGHT INSPECTION, FOUND TAIL SKID LOOSE IN VERTICAL FIN. UPON CLOSER EXAMINATION, TAIL SKID PULLED OUT FROM FIN ASSEMBLY. THE TAIL SKID HAD CRACKED COMPLETELY AROUND AND THROUGH AT THE ATTACHMENT BOLT HOLE. BY APPEARANCE OF T HE BROKEN ENDS OF THE TUBE, THIS CRACK PROPAGATION WAS SLOW. NO OTHER DAMAGE, OR DEFORMATION OF TAIL SKID NOTED DURING REPLACEMENT OF THE NEW TAIL SKID. HISTORY, AC WAS INVOLVED IN A HARD LANDING/ TAIL ROTOR SUDDEN STOPPAGE.(K) 1 G 7 1 3U 3 U O H2SW E1GL 2005042700015 20050427 00015 2005 4 27 2005FA0000317 4 20040415 G 2565 C19347101 FRANGIBLE LINK AIRCRUISERS EVAC SLIDE INCORRECT B PN8D K NONE O OTHER IN INSP/MAINT 1 SO 19 0324RP RECEIVED EVACUATION SLIDE FOR RECERTIFICATION. DURING DISASSY EACH FRANGIBLE LINKS (PNC19347-101, 4EA, PN C19347-102,1E A, PN C19347-105,2EA) WERE FOUND WITH (4) STRANDS OF BLACK NYLON THREAD SECURING EACH HALF OF FRANGIBLE LINK TOGETHER. FRANGIBLE LINKS WERE PREVIOUSLY BROKEN, REUSED BY SECURING HALVES TOGETHER WITH BLACK NYLON THREAD. NORMAL OR UNUSED FR ANGIBLE LINKS ARE TWO LOOPS SECURED WITH STRANDS OR BREAKING WIRES, HAVING A SPECIFIC BREAKING STRENGTH WHICH ARE COVERE D WITH HEAT SHRINK TUBING. IF SLIDE WAS DEPLOYED WITH MODIFIED FRANGIBLE LINKS, SLIDE WOULD POSSIBLY EXTEND RAPIDLY, TO E END OF SLIDE WOULD EXTEND UNDER THE AC. ONCE FRANGIBLE LINKS ARE BROKEN, REQUIRED TO BE REPLACED WITH NEW. (1 OF 3) 2005032800040 20050328 00040 2005 3 28 2005FA0000318 4 20040415 G 2565 C19347102 LINK AIRCRUISERS SLIDE BROKEN B PN8D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 19 0324RP RECEIVED EVACUATION SLIDE FOR RECERTIFICATION. DURING DISASSY, EACH FRANGIBLE LINK (PN C19347-101, 4EA, PN C19347-102, 1EA, PN C19347-105, 2EA), WERE FOUND WITH (4) STRANDS OF BLACK NYLON THREAD SECURING EACH HALF OF FRANGIBLE LINK TOGETHE R. FRANGIBLE LINKS WERE PREVIOUSLY BROKEN, REUSED BY SECURING HALVES TOGETHER WITH BLACK NYLON THREAD. NORMAL OR UNUSE D FRANGIBLE LINKS HAVE TWO LOOPS SECURED WITH STRANDS OF BREAKING WIRES HAVING SPECIFIC BREAKING STRENGTH WHICH ARE COVE RED WITH HEAT SHRINK TUBING. IF SLIDE WAS DEPLOYED WITH MODIFIED FRANGIBLE LINKS, SLIDE WOULD POSSIBLE EXTEND RAPIDLY A ND TOE END OF SLIDE WOULD EXTEND UNDER AC. ONCE FRANGIBLE LINKS ARE BROKEN, REQUIRED TO BE REPLACED WITH NEW. (2 OF 3) 2005040100068 20050401 00068 2005 4 1 2005FA0000319 4 20040415 G 2565 C19347105 LINK AIRCRUISERS ECAPE SLIDE INCORRECT B PN8D K NONE O OTHER IN INSP/MAINT 1 SO 19 0324RP RECEIVED EVACUATION SLIDE FOR RECERTIFICATION. DURING DISASSY EACH FRANGIBLE LINKS (PN C19347-101, 4EA, PN C19347-102, 1EA, PN C19347-105, 2EA) WERE FOUND WITH (4) STRANDS OF BLACK NYLON THREAD SECURING EACH HALF OF FRANGIBLE LINK TOGETHER . FRANGIBLE LINKS WERE PREVIOUSLY BROKEN, REUSED BY SECURING HALVES TOGETHER WITH BLACK NYLON THREAD. NORMAL OR UNUSED FRANGIBLE LINKS ARE TWO LOOPS SECURED WITH STRANDS OR BRAKING WIRES, HAVING SPECIFIC BREAKING STRENGTH WHICH ARE COVERE D WITH HEAT SHRINK TUBING. IF SLIDE WAS DEPLOYED WITH MODIFIED FRANGIBLE LINKS, SLIDE WOULD POSSIBLY EXTEND RAPIDLY, TO E END OF SLIDE WOULD EXTEND UNDER THE AC. ONCE FRANGIBLE LINKS ARE BROKEN, REQUIRED TO BE REPLACED WITH NEW. (3 OF 3) 2005042700016 20050427 00016 2005 4 27 2005FA0000320 4 20040415 G 2565 C19347101 FRANGIBLE LINK EVAC SLIDE INCORRECT B K NONE O OTHER IN INSP/MAINT 1 SO 19 0258RP RECEIVED EVACUATION SLIDE FOR RECERTIFICATION. DURING DISASSY EACH FRANGIBLE LINKS (PN C19347-101, 4EA, PN C19347-102, 1EA, PN C19347-105, 2EA) WERE FOUND WITH (4) STRANDS OF BLACK NYLON THREAD SECURING EACH HALF OF FRANGIBLE LINK TOGETHER . FRANGIBLE LINKS WERE PREVIOUSLY BROKEN, REUSED BY SECURING HALVES TOGETHER WITH BLACK NYLON THREAD. NORMAL OR UNUSED FRANGIBLE LINKS ARE TWO LOOPS SECURED WITH STRANDS OR BRAKING WIRES, HAVING A SPECIFIC BRAKING STRENGTH WHICH ARE COVER ED WITH HEAT SHRINK TUBING. IF SLIDE WAS DEPLOYED WITH MODIFIED FRANGIBLE LINKS, SLIDE WOULD POSSIBLE EXTEND RAPIDLY, T OE END OF SLIDE WOULD EXTEND UNDER THE AC. ONCE FRANGIBLE LINKS ARE BROKEN, REQUIRED TO BE REPLACED WITH NEW. (1 OF 3) 2005040100043 20050401 00043 2005 4 1 2005FA0000321 4 20040415 G 2565 C19347102 LINK ESCAPE SLIDE INCORRECT C PN8D K NONE O OTHER IN INSP/MAINT 1 SO 19 RECEIVED EVACUATION SLIDE FOR RECERTIFICATION. DURING DISASSY EACH FRANGIBLE LINKS (PN C19347-101, 4EA, PN C19347-102, 1EA, PN C19347-105, 2EA) WERE FOUND WITH (4) STRANDS OF BLACK NYLON THREAD SECURING EACH HALF OF FRANGIBLE LINK TOGETHER . FRANGIBLE LINKS WERE PREVIOUSLY BROKEN, REUSED BY SECURING HALVES TOGETHER WITH BLACK NYLON THREAD. NORMAL OR UNUSED FRANGIBLE LINKS ARE 2 LOOPS SECURED WITH STRANDS OR BRAKING WIRES, HAVING A SPECIFIC BREAKING STRENGTH WHICH ARE COVERE D WITH HEAT SHRINK TUBING. IF SLIDE WAS DEPLOYED WITH MODIFIED FRANGIBLE LINKS, SLIDE WOULD POSSIBLY EXTEND RAPIDLY, TO E END OF SLIDE WOULD EXTEND UNDER THE AC. ONCE FRANGIBLE LINKS ARE BROKEN, REQUIRED TO BE REPLACED WITH NEW (2 OF 3) 2005042700017 20050427 00017 2005 4 27 2005FA0000322 4 20040415 G 2565 C19347105 FRANGIBLE LINK EVAC SLIDE INCORRECT B PN8D K NONE O OTHER IN INSP/MAINT 1 SO 19 0324RP RECEIVED EVACUATION SLIDE FOR RECERTIFICATION. DURING DISASSY EACH FRANGIBLE LINKS (PN C19347-101, 4EA, PN C19347-102, 1EA, PN C19347-105, 2EA) WERE FOUND WITH (4) STRANDS OF BLACK NYLON THREAD SECURING EACH HALF OF FRANGIBLE LINK TOGETHER . FRANGIBLE LINKS WERE PREVIOUSLY BROKEN, REUSED BY SECURING HALVES TOGETHER. FRANGIBLE LINKS WERE PREVIOUSLY BROKEN, REUSED BY SECURING HALVES TOGETHER WITH BLACK NYLON THREAD. NORMAL OR UNUSED FRANGIBLE LINKS ARE 2 LOOPS SECURED WITH S TRANDS OR BREAKING WIRES, HAVING A SPECIFIC BREAKING STRENGTH WHICH ARE COVERED WITH HEAT SHRINK TUBING. IF SLIDE WAS D EPLOYED WITH MODIFIED FRANGIBLE LINKS, SLIDE WOULD POSSIBLY EXTEND RAPIDLY, TO END OF SLIDE WOULD EXTEND UNDER THE AC. 2005042700019 20050427 00019 SW 2005 4 27 2005FA0000323 1 20040927 G 7500 44C13 CLAMP SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP P3 BLEED AIR LOOSE B OZ5R J A DUMP FUEL UNSCHED LANDING E B J VIBRATION/BUFFET SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CL CLIMB 1 NM 05 60NE AC760B AFTER TAKEOFF, AT ABOUT 400 FT, NR 2 ENG FIRE WARNING LIGHT CAME ON. ENG PARAMETERS CHECKED NORMAL. CREW FOLLOWED EMER GENCY PROCEDURES, RETURNED TO FIELD. AFTER LANDING, ENGINE WAS SHUTDOWN BY USING THE STOP AND FEATHER BUTTON. CREW DIS CHARGED ENGINE FIRE EXTING BOTTLE. AFTER DEPLANING PASSENGERS, CREW PERFORMING WALKAROUND, OBSERVED FLAMES COMING OUT O F ENG INTAKE AND TAILPIPE, DISCHARGED CABIN FIRE EXTING DOWN ENG INLET. FOUND BROKEN BLEED AIR CLAMP IN COWLING WHEN CO WLING WAS OPENED. BROKEN CLAMP ALLOWED BLEED AIR TO TURN ON THE FIRE WARNING LIGHT, INTERNAL ENG FIRE WAS CAUSED BY MAL FUNCTION IN FUEL SHUTOFF. (NM05200500912) (K) 2 L 7 2 4T 4 T RT A8SW E4WE 2005033000019 20050330 00019 SW 2005 3 30 2005FA0000324 1 20040406 G 7921 20163A OIL COOLER SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP NR 2 ENGINE BLOCKED B OZ5R E A ENGINE SHUTDOWN UNSCHED LANDING N FALSE WARNING CL CLIMB 1 NM 05 459AM AC700 P44628 ON CLIMBOUT, NR 2 ENG OIL TEMP WENT UP TO RED LINE, OIL PRESSURE DROPPED. LOW OIL PRESSURE LIGHT HAD NOT COME ON. CREW MADE PRECAUTIONARY SHUTDOWN ON NR 2 ENG, LANDED BACK AT BASE WITH NO FURTHER INCIDENT. OIL WAS FOUND IN TAILPIPE OF NR 2 ENG, NO OIL FOUND IN ENG INLET. REAR CARBON SEAL HAD FAILED DUE TO EROSION, VIBRATION, OR COMB. OIL COOLER WAS REPL ACED, OIL TEMP RETURNED TO NORMAL RANGES. INTERNAL PARTIAL BLOCKAGE IS SUSPECTED. TEARDOWN, EVALUATION OF OIL COOLER R EQUESTED. BORESCOPE OF HOT SECTION DISTRESS, CK OF GEARBOX OIL FOR CONTAMINATION, IF ANYTHING FOUND, REAR CARBON SEAL W ILL BE REPLACED. (NM052004040470) (K) 2 L 7 2 4T 4 T RT A8SW E4WE 2005042700020 20050427 00020 EU 2005 4 27 2005FA0000325 1 20041105 G 1430 A10212D BOLT AIRBUS A330 A330* EU BYPASS VALVE CRACKED Z K NONE O OTHER IN INSP/MAINT 1 SW 99 FRO99BD DOOR BYPASS VALVE WAS RETURNED FOR INVESTIGATION. REASON FOR RETURN WAS ON PUSHBACK, FLIGHT CREW REPORTED GREEN RESERVO IR LOW LEVEL, WHERE THE INVESTIGATION FOUND A LEAK ON DOOR BYPASS VALVE. IDENTIFIED THAT BOLT HAD SHEARED. INVESTIGATI ON AT MFG INDICATED THAT INITIATING FORCE HAD RESULTED IN CRACK THAT PROPAGATED ACROSS BOLT SECTION, RESULTING IN FAILUR E. BOLTS COULD BE YIELDED WHEN TIGHTENED. ALSO AFFECTED IS DOOR BYPASS VALVE. (K) 2 L 7 2 4F RT A46NM 2005032800098 20050328 00098 EU 2005 3 28 2005FA0000326 1 20041105 G 5210 FRM530014D BYPASS VALVE AIRBUS A330 A330* EU DOOR LEAKING Z K NONE O OTHER IN INSP/MAINT 1 SW 99 A DOOR BYPASS VALVE WAS RETURNED FOR INVESTIGATION. THE REASON FOR RETURN WAS ON PUSHBACK, FLIGHT CREW REPORTED GREEN R ESERVOIR LOW LEVEL, WHERE THE INVESTIGATION FOUND A LEAK ON THE DOOR BYPASS VALVE. INVESTIGATION IDENTIFIED THAT BOLT HAD SHEARED. FURTHER INVESTIAGATION AT MFG, THAT AN INITIATING FORCE HAD RESULTED IN A CRACK THAT PROPAGATED ACROSS THE BOLT SECTION, RESULTING IN FAILURE. BOLTS COULD BE YIELDED WHEN TIGHTENED.(K) 2 L 7 2 4F RT A46NM 2005032800099 20050328 00099 EU 2005 3 28 2005FA0000327 1 20041105 G 5210 HTE960023053 BOLT AIRBUS A330 A330* EU BYPASS VALVE CRACKED Z K NONE O OTHER IN INSP/MAINT 1 SW 99 FR099BD A DOOR BYPASS VALVE WAS RETURNED FOR INVESTIAGTION. THE REASON FOR RETURN WAS ON PUSHBACK, FLIGHT CREW REPORTED GREEN R ESERVOIR LOW LEVEL, WHERE THE INVESTIGATION FOUND A LEAK ON THE DOOR BYPASS VALVE. INVESTIGATION IDENTIFIED THAT BOTL H AD SHEARED. FURTHER INVESTIAGTION INDICATED THAT INITAIATING FORCE HAD RESULTED IN A CRACK THAT PROPAGATED ACROSS THE B OLT SECTION, RESULTING IN FAILURE. THE BOLTS COULD BE YIELDED WHEN TIGHTENED.(K) 2 L 7 2 4F RT A46NM 2005040400077 20050404 00077 EU 2005 4 4 2005FA0000328 1 20041105 G 1430 BOLT AIRBUS A330 A330* EU BYPASS VALVE CRACKED Z K NONE O OTHER IN INSP/MAINT 1 SW 99 A DOOR BYPASS VALVE WAS RETURNED FOR INVESTIAGTION. THE REASON FOR RETURN WAS ON PUSHBACK, FLIGHT CREW REPORTED GREEN R ESERVOIR LOW LEVEL, WHERE THE INVESTIGATION FOUND A LEAK ON THE DOOR BYPASS VALVE. THE INVESTIGATION IDENTIFIED THAT BO LT HAD SHEARED. FURTHER INVESTIAGTION AT MFG INDICATED THAT INITIATING FORCE HAD RESULTED IN A CRACK THAT PROPAGATED AC ROSS THE BOLT SECTION, RESULTING IN FAILURE. THE BOLTS COULD BE YIELDED WHEN TIGHTENED. (K) 2 L 7 2 4F RT A46NM 2005040400026 20050404 00026 2005 4 4 2005FA0000329 2 20041105 G 7314 568128300100 PUMP AIRBUS A330 A330* EU FUEL SYS CORRODED Z K NONE O OTHER IN INSP/MAINT 1 SW 99 A FUEL PUMP SHOWS EVIDENCE OF CAVITATIONAL EROSION ON A STRUCTURAL PILLAR WITHIN THE PUMP. THIS PILLAR CONTAINS A PASSA GEWAY FOR ELECTRICAL WIRES, WHICH FORMS PART OF THE MOTOR EXPLOSION CONTAINMENT ZONE. THERE IS A CONCERN THAT THE EROSI ON COULD MIGRATE TO THE PASSAGEWAY AND THEREFORE BREACH THE EXPLOSION CONTAINMENT ZONE. MFG IS COMMUNITATING WITH AC MF G. (K) 2 L 7 2 4F RT A46NM 2005040100099 20050401 00099 SO 2005 4 1 2005FA0000330 1 20040806 G 3246 551792 WHEEL PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA SNSNCH 74D 74DM EA NLG BROKEN D O OTHER O OTHER NR NOT REPORTED 1 EA 25 8252Z 7639 288116011 L913639A NOSE WHEEL FLANGE BROKE OFF DURING TAXI. CLOSE INSPECTION SHOW CRACK MIGHT HAVE STARTED FROM CORROSION UNDER THE FLANGE WHICH IS THE THINNEST PART OF THE WHEEL ASSY. RECOMMEND INSPECTION ON HIGH TIME WHEELS. ESPECIALLY ON AIRCRAFT WHICH DO NOT FLY FREQUENTLY. (EA25200408022) 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 2005042700021 20050427 00021 CE 2005 4 27 2005FA0000331 1 20040928 G 7500 973800011 SLEEVE BEECH 200 200BEECH 1152920 CE LYC O320 O320* 41508 EA LT BLEED AIR DETERIORATED D K NONE O OTHER IN INSP/MAINT 1 NE 05 13061 BP38 BLEED AIR COUPLING FAILED LT ENGINE NACELLE. THIS PART IS ATHE FIRST COUPLING DOWN STREAM OF THE FLOW PAC. THE HEAT GO T TO IT, AGING AC ISSUE, 1983 MFG DATE. 1 L 7 2 4T 3 O A24CE E274 2005042700022 20050427 00022 GL 2005 4 27 2005FA0000332 1 20041221 G 7810 EXHAUST PIPE CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO ENGINE CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 05 990P 254 0945 917219 AIRCRAFT OWNER SQUAWKED MANIFOLD PRESSURE AT 11 PERCENT. FOUND EXHAUST CRACKED AT NR 5 CYLINDER EXHAUST PORT. CRACK EM INATES FROM REAR OF MOUNTING FLANGE AND SPIRALS DOWN COUNTER CLOCKWISE SEVERAL INCHES FROM THERE. 1 L 7 1 3O 3 O NT A00009CH E3SO 2005042700025 20050427 00025 EU 2005 4 27 2005FA0000333 1 20041209 G 1420 3722514110 CONNECTOR AGUSTA A109 A109A2 0260120 EU DME R/T VIBRATION D K NONE O OTHER IN INSP/MAINT 1 SW 07 VIBRATION PROBLEM HAS BEEN IDENTIFIED WITH THE DISTANCE MEASURING EQUIPMENT (DME) RECEIVER-TRANSMITTER (RT) INSTALLED ON THE AIRCRAFT. THIS PROBLEM RESULTS IN INTERMITTENT DME DISPLAY OR LOSS OF POWER TO THE DME INDICATOR. THIS FAILURE OC CURS AFTER APPROX EVERY 400 HOURS OF OPERATION AND IS THE RESULT OF VIBRATION BETWEEN THE DME RT UNIT AND THE ROTORCRAFT MOUNTING SURFACE. THE DME RT UNIT IS HARD MOUNTED ON AN AVIONICS SHELF LOCATED IN THE TAILBOOM, AFT OF THE REAR BAGGAG E COMPARTMENT. VIBRATION BETWEEN THE AC HARNESS PLUG CONNECTOR AND THE DME RT MATING CONNECTOR RESULTS IN LOSS OF ELECT RICAL CONTACT BETWEEN SOME OF THE CONNECTOR PINS. PROBLEM CAN BE CORRECTED BY MOUNTING THE DME RT ON VIBRATION ISOLATOR 1 G 7 2 3U H7EU 2005040100060 20050401 00060 2005 4 1 2005FA0000334 4 20041014 G 2562 BATTERY CESSNA 172 172 2072402 CE CONT O300 O300* 17022 SO ELT CORRODED D K NONE O OTHER IN INSP/MAINT 1 NM 11 6735A 28835 FOUND D (LARGE) SIZE DURACELL BATTERIES USED IN ELT`S EXPELLING AND CORRODED. EXPIRATION DATE 2008 1 H 7 1 3O 3 O NT 3A12 E253 2005033000033 20050330 00033 2005 3 30 2005FA0000335 1 20041004 G 2410 ES4307 ROTOR ELECTROSYS ALTERNATOR DEFECTIVE B KC2R K NONE O OTHER IN INSP/MAINT 1 GL 03 E074260 ALTERNATOR DEFECTIVE AS RECEIVED FROM MFG, ROTOR RUBBING ON STATOR WINDINGS. THIS CONDITION COULD EASILY BE FLET WHEN T URNING ALTERNATOR DRIVE SHAFT BY HAND. (K) 2005033000053 20050330 00053 NM 2005 3 30 2005FA0000336 1 20040203 G 2913 624022 ADAPTER VICKERS BOEING 747 747* NM HYD PUMP ERODED D IU6R K NONE O OTHER IN INSP/MAINT 1 NM 01 MX535816 EROSION AROUND STROKING PISTON PORT. FLUID FLOW AGAINST SOFT METAL. STRONGER MATERIAL FOR HOUSING. (MECHANIC - BSI, JO B 192845) (K) 2 L 7 4 4F RT A20WE 2005040100063 20050401 00063 CE 2005 4 1 2005FA0000349 1 20041220 G 7430 103572001 IGNITION SWITCH BEECH 33 F33A 1151425 CE CONT O520 IO520* 17032 SO COCKPIT CARBONED D O OTHER O OTHER NR NOT REPORTED 1 SW 05 3132W 2377 CE477 ENGINE STOPPED RUNNING DURING TAXI TO RUNWAY. INVESTIGATION SHOWED A LOT OF CARBON IN SWITCH CONTACTS. (SW05200506081) 1 L 7 1 3O 3 O 3A15 E5CE 2005042700064 20050427 00064 CE 2005 4 27 2005FA0000362 1 20041117 G 3230 SM50D7 RELAY BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO MLG INTERMITTENT B VJ3R O OTHER J WARNING INDICATION NR NOT REPORTED 1 WP 07 1570A 245 CE1333 830089R PILOT SELECTED GEAR UP AND NOTHING HAPPENED. LANDING GEAR WOULD NOT RETRACT. MAINTENANCE TECHNICIAN TROUBLESHOOT GEAR SYSTEM AND FOUND THAT THE DYNAMIC RELAY WAS INTERMITTNET. NO RECOMMENDATION AT THIS TIME. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2005040100094 20050401 00094 CE 2005 4 1 2005FA0000365 1 20041215 G 5711 052340050 SPAR CESSNA 172 R172E 2072413 CE CONT O360 IO360D 17025 SO LT WING CRACKED G K NONE O OTHER IN INSP/MAINT 1 SO 09 7892N 15628 R1720283 01080462 WHILE REPLACING THE FLAP TRACK ASSY, A CRACK APPROXIMATELY 2 INCHES IN LENGTH AND RUNNING THROUGH THE LOWER RIVET HOLES WAS FOUND UNDER THE LT IB FLAP TRACK. PROBABLE CAUSE WAS A FLAP OVERSPEED DURING FLIGHT. (SO09200502861) 1 H 7 1 3O 3 O 3A17 E1CE 2005040100062 20050401 00062 CE 2005 4 1 2005FA0000367 1 20041129 G 5753 052323113 FLAP TRACK CESSNA 172 R172E 2072413 CE CONT O360 IO360D 17025 SO MCAULY 1P235 1P235* GL LT WING WORN D O OTHER O OTHER CL CLIMB 1 SO 09 7892N R1720283 553125D LF001 WHILE FLAPS WERE BEING RETRACTED, THE LT IB FLAP ATTACH BRACKET CAUGHT ON THE WING COVE PANEL SUPPORT. THIS CAUSED SUBS TANTIAL DAMAGE TO THE COVE PANEL SUPPORT AS WELL AS THE ATTACH BRACKET. CAUSE WAS DETERMINED TO BE WORN FLAP TRACKS. T HE FLAP TRACKS AND ROLLERS WERE REPLACED WITH NEW PARTS AND THE LT FLAP WAS REPLACED WITH A SERVICEABLE ASSY DUE TO LACK OF PART AT THE MFG FOR REPAIR. SINCE MFG DOES NOT HAVE LIMITATIONS ON THEIR FLAP TRACKS, SUGGEST THAT THEY BE REMOVED AND REPLACED AT 5,000 HOUR INTERVALS. (K) 1 H 7 1 3O 3 O 3A17 E1CE 5 N P12EA 2005042700069 20050427 00069 CE 2005 4 27 2005FA0000368 1 20040928 G 7110 055036125 SPRING CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA ALT AIR DOOR MISSING D O OTHER R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 SO 15 53570 743 172S9397 ON RETURN TO BASE, PILOT REPORTED WHEN CLIMING TO 8000 PT ENGINE SURGED/POWER DROP 2 TIMES. AIRCRAFT WAS DUE A PHASE 1 INSPECTION. WHILE INSPECTING THE ALT AIR DOOR, NOTICED THE DOOR STUCK IN THE OPEN POSITION. FURTHER INSPECTION REVEALE D THE SPRING THAT CONTROLS THE DOOR WAS MISSING FROM THE HINGE ASSY. INSPECTED INSIDE OF SERVO. NO DAMAGE BUT DID NOT LOCATE THE SPRING. THE DOOR SHOWS SIGNS OF WEAR ON SEALING EDGES. FEEL THE SYSTEM IS WEAK AND NEEDS TO BE IMPROVED. ( K) 1 H 7 1 3O 3 O NT 3A12 1E10 2005040100095 20050401 00095 2005 4 1 2005FA0000370 1 20041101 G 3246 9543426 WHEEL AMD STC STCFALC50 GARRTT TFE731 TFE7312B WP NLG CRACKED D O OTHER O OTHER NR NOT REPORTED 1 NM 01 38WP 292 MAINTENANCE CREW FIRST NOTICED TIRE SERVICE BECOMING MORE FREQUENT OVER THE PERIOD OF 2 OR 3 DAYS. TIRE PRESSURES WERE DROPPING APPROX 10 PERCENT TO 15 PERCENT OVERNIGHT. SUBSEQUENT INSPECTION OF THE TIRE AND WHEEL ASSY REVEALED AIR ESCA PING THROUGH THE CASTING ADJACENT THE RAISED VALVE CORE BOSS. LIQUID LEAK DETECTOR ALSO CONFIRMED THE LEAK AND LOCATION . NOTE: SECOND WHEEL TO DEVELOP A LEAK IN SAME AREA, WAS RETURNED FOR EVALUATION INSPECTION AND THE DISPOSITION OF THIS WHEEL IS NOT KNOWN AT THIS TIME. (K) 2 L 7 2 4F 4 F A46EU E6WE 2005040400017 20050404 00017 NM 2005 4 4 2005FA0000371 1 20041019 G 2910 4AS7118102503 B-NUT GULSTM 200 200 4500308 NM LT HYD SYS SPLIT B K5SR K NONE O OTHER IN INSP/MAINT 1 NM 07 363GA 438 063 LT HYDRAULIC PRESSURE LINE IN AFT EQUIPMENT BAY SPLIT AT AFT B-NUT FITTING. INSTALLATION WAS POST SB. PROBABLE CAUSE W AS STRESSED INSTALLATION AND VIBRATION. (K) 2 L 7 2 4F RT A53NM 2005033000036 20050330 00036 EU 2005 3 30 2005FA0000372 1 20041121 G 3213 ES12858501 HOUSING ISRAEL 1124 1124 4500102 EU NLG STRUT CRACKED C GONR K NONE O OTHER IN INSP/MAINT 1 SW 01 730CA 8017 295 AFTER LANDING, TAXIIED TO REPAIR SERVICE, THE NOSE STRUT BOTTOMS OUT, STOPPED AT RAMP. EXITED AC, NOTED A LARGE PUDDLE OF HYDRAULIC FLUID AROUND NLG. JACKED AC UP, NOTICED THE LARGE CRACK IN THE LOWER STRUT HOUSING, STARTING FROM BACK SID E OF TORQUE KNEE ATTACH FITTING ON THE LOWER STRUT BODY. REMOVED NLG ASSY, DISASSEMBLED, INSP PN E51L858501 INNER BODY AND PN 52 NBC2064YZP BEARING CRACKED. THE CRACKS LOOKED LIKE THEY HAD STARTED BEFORE. PROBABLE CAUSE: NOT DISCONNECTIN G SICCORS PRIOR TO TOWING AC. (SW01200502590) 2 M 7 2 4F A2SW 2005040400061 20050404 00061 SO 2005 4 4 2005FA0000373 1 20041015 G 5541 2072904 RIB PIPER PA24 PA24260 7102406 SO LYC O540 TIO540* 41532 EA RUDDER CORRODED D HQ8S K NONE O OTHER IN INSP/MAINT 1 WP 07 8544P 7000 244001 DURING AN ANNUAL INSPECTION, MORE THAN NORMAL SURFACE CORROSION WAS FOUND ON THE RUDDER TAIL POST. UPON DISASSEMBLY OF THE RUDDER, DISSIMILAR METAL CORROSION WAS PRESENT WHERE THE STEEL STIFFENER ATTACHES TO THE LOWER RIB (PN 2072904). ( WP07200505592) (K) 1 L 7 1 3O 3 O 1A15 E14EA 2005033000011 20050330 00011 SO 2005 3 30 2005FA0000374 1 20041015 G 5541 2072910 SPAR PIPER PA24 PA24260 7102406 SO LYC O540 TIO540* 41532 EA RUDDER CRACKED D HQ8S K NONE O OTHER IN INSP/MAINT 1 WP 07 8544P 244001 DURING SERVICE OF AIRCRAFT THE RUDDER WAS REMOVED. NOTHING WAS FOUND ABNORMAL. REMOVAL OF THE UPPER RUDDER HINGE (PN 2 018300. CRACKS WERE FOUND AT THE HINGE ATTACH POINT OF THE RUDDER SPAR (2072910). (WP07200505589) (K) 1 L 7 1 3O 3 O 1A15 E14EA 2005040100096 20050401 00096 SO 2005 4 1 2005FA0000375 1 20041015 G 5541 2072910 SPAR PIPER PA24 PA24260 7102406 SO LYC O540 TIO540* 41532 EA RUDDER CRACKED D HQ8S K NONE O OTHER IN INSP/MAINT 1 WP 07 9180P 244670 DURING SERVICE OF THE AIRCRAFT THE RUDDER WAS REMOVED. NOTHING WAS FOUND ABNORMAL. REMOVAL OF THE UPPER RUDDER HINGE ( PN 2018300). CRACKS WERE FOUND AT THE HINGE ATTACH POINT OF THE RUDDER SPAR (2072910). (K) 1 L 7 1 3O 3 O 1A15 E14EA 2005040100039 20050401 00039 SO 2005 4 1 2005FA0000378 1 20041124 G 2497 WIRE GULSTM G1159 GIV 3980115 SO RROYCE SPEY SPEY51114 54523 EU CABIN CB PANEL PINCHED B ACNR K NONE O OTHER IN INSP/MAINT 1 WP 01 477JB 1214 UPON REPLACEMENT/ UPGRADE OF A CIRCUIT BREAKER IN THE CABIN SERVICES CIRCUIT BREAKER PANEL, IN THE RT RADIO RACK AT FS 1 10, A 20 GA WIRE WAS FOUND PINCHED AND HAD PREVIOUSLY SHORTED TO THE FACE PLATE LEAVING A SCORCH MARK ABOUT THE SIZE OF A DIME. THE WIRE WAS SUBSEQUENTLY REPAIRED, PROPERLY STOWED AND UNIT APPROVED FOR RETURN TO SERVICE. REF GAC DWG NR LC 41 390035-01 - L MAIN UNSEITCHED WIRE NR 1XX102D12 FROM TB1. SUGGEST TECH TAKE EXTRA CARE IN THE RE-MOUNTING OF THIS SE RVICE PANEL TO AVOID CATCHING WIRES ON THE AFT SUPPORT BRACKETS. (K) 2 L 7 2 4F 4 F RT A12EA E2EU 2005040100100 20050401 00100 CE 2005 4 1 2005FA0000379 1 20040928 G 5511 08322502 SPAR CESSNA 310 310R 2074245 CE STAB CORRODED D K NONE O OTHER IN INSP/MAINT 1 NE 01 3556G 5067 310R0869 FOUND THE MAIN (REAR) STABILIZER SPAR WITH SEVERE CORROSION AT THE LOCATIONS WHERE THE BONDING SCREWS WERE ATTACHED. (K) 1 L 7 2 3O 3A10 2005040400095 20050404 00095 SO 2005 4 4 2005FA0000380 1 20041215 G 3220 487484 SPRING PIPER PA28 PA28R200 7102811 SO LYC O360 IO360A1A 41514 EA NLG MISSING D O OTHER O OTHER NR NOT REPORTED 1 NM 07 32749 28R7535085 SPRINGS (PN487-484 AND PN 487-483) ON THE NOSE GEAR RETRACTION LINK ASSY FAILED, LETTING THE ARM ASSY SWING AROUND AND J AM BETWEEN THE DOWNLOCK PIN AND THE MUFFLER. (NM07200502447) 1 L 7 1 3O 3 O 2A13 1E10 2005040400044 20050404 00044 SO 2005 4 4 2005FA0000381 1 20041215 G 3220 487483 SPRING PIPER PA28 PA28R200 7102811 SO LYC O360 IO360A1A 41514 EA NLG MISSING D O OTHER O OTHER NR NOT REPORTED 1 NM 07 32749 28R7535085 SPRINGS (PN487-484 AND PN487-483) ON THE NOSE GEAR RETRACTION LINK ASSY FAILED, LETTING THE ARM ASSY SWING AROUND AND JA M BETWEEN THE DOWNLOCK PIN AND THE MUFFLER. (NM07200502447) (K) 1 L 7 1 3O 3 O 2A13 1E10 2005042700089 20050427 00089 SO 2005 4 27 2005FA0000391 1 20041221 G 5350 8644606 SKIN PIPER PIPER PA44 PA44180 7104402 SO LYC O360 O360* 41514 EA NOSE CONE CRACKED B A5OR K NONE O OTHER IN INSP/MAINT 1 SO 09 2202X 8034 8644638 447995278 DURING AN ANNUAL INSPECTION OF THE AIRCRAFT THE NOSE CONE ASSY WAS FOUND TO HAVE A CRACK IN THE TOP SKIN. PROBABLE CAUS E OF CRACKING OF THE NOSE CONE ASSY IS UNKNOWN. THE NOSE CONE WAS REPAIRED AND AIRCRAFT RETURNED TO SERVICE. OF 3 AIRC RAFT INSPECTED, ALL 3 HAD CRACKS IN THE SAME SKIN IN THE SAME LOCATION. (SO09200503396) (K) 1 L 7 2 3O 3 O A19S0 E286 2005040100069 20050401 00069 SO 2005 4 1 2005FA0000392 1 20041221 G 5350 8644606 SKIN PIPER PA44 PA44180 7104402 SO LYC O360 O360* 41514 EA NOSE CONE CRACKED B A5OR K NONE O OTHER IN INSP/MAINT 1 SO 09 2247B 447995108 DURING AN ANNUAL INSPECTION OF THE AIRCRAFT, THE NOSE CONE ASSY WAS FOUND TO HAVE A CRAK IN THE TOP SKIN. PROBABLE CAUS E OF CRACKING OF THE NOSE CONE ASSY IS UNKNOWN. THE NOSE CONE WAS REPAIRED AND AIRCAFT RETURNED TO SERVICE. (SO0920050 3394) (K) 1 L 7 2 3O 3 O A19S0 E286 2005042700090 20050427 00090 SO 2005 4 27 2005FA0000393 1 20041221 G 5350 8644606 SKIN PIPER PIPER PA44 PA44180 7104402 SO LYC O320 O320* 41508 EA NOSE CONE CRACKED B A5OR K NONE O OTHER IN INSP/MAINT 1 SO 09 3047U 7707 8644638 447995262 DURING AN ANNUAL INSPECTION OF THE AIRCRAFT THE NOSE CONE ASSY WAS FOUND TO HAVE A CRACK IN THE TOP SKIN. PROBABLE CAUS E OF CRACKING OF THE NOSE CONE ASSY IS UNKNOWN. THE NOSE CONE WAS REPAIRED AND AIRCRAFT RETURNED TO SERVICE. (SO092005 03395) (K) 1 L 7 2 3O 3 O A19S0 E274 2005032800037 20050328 00037 EA 2005 3 28 2005FA0000411 2 20041031 G 8520 SL3601SC PISTON RING PIPER PA28 PA28151 7102805 SO LYC O320 O320D3G 41508 EA ENGINE BROKEN H K NONE O OTHER IN INSP/MAINT 1 SO 19 4238F 287715010 ON NIGHT IFR FLIGHT, DEPARTED WITH 7.5 QTS OF OIL IN THE ENGINE. WHEN ARRIVED AT DESTINATION 1.4 HOURS LATER AND PERFOR MED A POST FLIGHT INSPECTION, FOUND THAT THE CRANKCASE WAS DOWN 4 QUARTS OF OIL AND THERE WAS NO SIGN OF AN OIL LEAK. U PON INSPECTION, FOUND THE NR 3 CYLINDER TO BE HEAVILY CONTAMINATED WITH OIL. THE CYLINDER WAS REMOVED AND FOUND THAT TH E OIL CONTROL RING WAS BROKEN. THE CYLINDER WAS INSPECTED NEW RINGS WERE INSTALLED AND THE AIRCRAFT WAS RETURNED BACK T O SERVICE. NOW THIS SHOULDN`T HAPPEN ON BRAND NEW CYLINDERS WITH 200 HOURS ON THEM. THE CYLINDERS WERE BY MFG, ALSO RI GS WERE PN SL-3601-SC, MFG DATE 10/1/2002. (K) 1 L 7 1 3O 3 O 2A13 E274 2005040400034 20050404 00034 EA 2005 4 4 2005FA0000412 2 20041226 G 8520 SL3601SC PISTON RING PIPER PA28 PA28151 7102805 SO LYC O320 O320D3G 41508 EA ENGINE BROKEN C O OTHER O OTHER NR NOT REPORTED 1 SO 19 4238F 287715010 CROSS COUNTRY FLT, HEADED TO 2ND FUEL STOP, HEARD A SLIGHT RPM CHANGE IN ENGINE THAT WAS INTERMITTENT. UPON LANDING, PE RFORMED MAG CHECK AND ONE MAG WAS A LITTLE ROUGH, HAD THE PLUGS PULLED AND FOUND THAT THE PLUG ON NR 4 CYLINDER WAS FOUL ED WITH TRACES OF OIL AND LEAD. PLUGS WERE CLEANED AND REINSTALLED. TO BE ON SAFE SIDE, JUST IN CASE HAD A 2ND OIL RIN G FAILURE, CHANGED FLIGHT TO CHECK OIL CONSUMPTION. UPON LANDING, FOUND IT HAD CONSUMED OVER 3 QUARTS OF OIL. HAD CYL INDER PULLED AND FOUND THE OIL CONTROL RING BROKEN. THIS WAS 2ND RING TO FAIL IN LESS THAN 220 HOURS. RING WAS THE SAM E MANDATE AS THE PREVIOUS RING THAT FAILED. BELIEVE BAD BATCH OF RINGS LUCKY IT WAS CAUGHT BEFORE ENG FAILURE. (K) 1 L 7 1 3O 3 O 2A13 E274 2005040100105 20050401 00105 NE 2005 4 1 2005FA0000422 2 20040819 G 7261 51G186 CARBON SEAL BOEING 747 747* NM PWA PW4062 PW4062 NE ENGINE FAILED B P0ER K NONE O OTHER IN INSP/MAINT 1 NE 03 26 729183 FAILED CARBON SEAL, RESULTING IN LOSS OF OIL, IFSD AND ATB. (NE03200504012) 2 L 7 4 4F 4 F RT A20WE E24NE 2005040400093 20050404 00093 CE 2005 4 4 2005FA0000423 1 20041217 G 8011 S24432 CONTACTOR CESSNA 206 U206G 2073356 CE CONT O520 TSIO520M 17040 SO STARTER FAILED B RDDR O OTHER J WARNING INDICATION CL CLIMB 1 WP 21 PKMPZ 27 0428008 U20606130 STARTER CONTACTOR DID NOT DISENGAGE AFTER ENGINE START. THIS RESULTED IN FAILURE OF THE STARTER AS WELL. SITUATION DID NOT BECOME APPARENT UNTIL AFTER TAKEOFF. PERHAPS BECAUSE AT HIGH POWER SETTINGS THE ALTERNATOR PRODUCED MAXIMUM POWER AND AT HIGH SPEED THE STARTER MOTOR WOULD DRAW FEWER AMPS THAN AT LOW SPEED, ALLOWING THE BUS VOLTAGE TO RISE AND ILLUMI NATE THE LAMP BRIGHTER. MFG HAS BEGUN SUPPLYING A COMPACT, LIGHTWEIGHT STARTER ON NEW ENGINE. THIS AC HAD FACTORY NEW ENGINE INSTALLED 21.7 HOURS PRIOR TO FAILURE. INVESTIGATION INDICATES LIGHTWEIGHT STARTERS HAVE HIGHER CURRENT DRAW THA N LARGER STARTER USED PREVIOUSLY. MFG CONTACTOR CAN NOT HANDLE LOAD. REMOVED AND REPLACED STARTER CONTACTORS. (K) 1 H 7 1 3O 3 O A4CE E8CE 2005042700128 20050427 00128 CE 2005 4 27 2005FA0000424 1 20041217 G 8011 S24432 CONTACTOR CESSNA 206 U206G 2073356 CE CONT O520 TSIO520M 17040 SO STARTER FAILED B RDDR O OTHER J WARNING INDICATION CL CLIMB 1 WP 23 PKMAU 23 U20606365 STARTER CONTACTOR DID NOT DISENGAGE AFTER ENGINE START. RESULTED IN STARTER FAILURE. SITUATION DID NOT BECOME APPARENT UNTIL AFTER TAKEOFF. STARTER ENGAGED WARNING LIGHT INSTALLED BUT DID NOT INDICATE CLEARLY UNTIL AFTER TAKEOFF. BECAU SE AT HIGH POWER SETTINGS ALTERNATOR PRODUCED MAXIMUM PWR & AT HIGH SPEED STARTER MOTOR WOULD DRAW FEWER AMPS THAN AT LO W SPEED, ALLOWING BUSS VOLTAGE TO RISE AND ILLUMINATE THE LAMP BRIGHTER. MFG HAS BEGUN SUPPLYING COMPACT, LIGHTWEIGHT S TARTER ON NEW ENGINES. ENGINE INSTALLED 23.7 HOUR PRIOR. INVESTIGATION INDICATES LIGHTWEIGHT STARTERS HAVE A HIGH CURR ENT DRAW THAN LARGER STARTER. SUSPECT MFG CONTACTOR CANNOT HANDLE LOAD. REMOVED AND REPLACED STARTER CONTACTORS. (K) 1 H 7 1 3O 3 O A4CE E8CE 2005042700130 20050427 00130 2005 4 27 2005FA0000426 1 20040511 G 6100 B4460 PIN MCAULY 3A32C 3A32C76 GL PROPELLER BROKEN D O OTHER O OTHER NR NOT REPORTED 1 SW 99 801412 ON MAY 17, 2004, AUTHORIZED BY NTSB TO DO A TEARDOWN ONLY ON PROPELLER. UPON WHICH (PN 134460) ACTUATING PIN, WAS FOUND BROKEN IN HALF; START OF THREADS. PARTS INVOLVED WERE TAKEN BY FSDO. FSDO FORWARDED THEM TO NTSB FOR INVESTIGATION. CANNOT COMMENT ON PROBABLE CAUSE. 5 C P21EA 2005033000041 20050330 00041 GL 2005 3 30 2005FA0000434 2 20041031 G 7200 ENGINE HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL MAKING METAL B EOOR A UNSCHED LANDING E R J VIBRATION/BUFFET PARTIAL RPM/PWR LOSS WARNING INDICATION NR NOT REPORTED 1 AL 03 C6PHC 180257D CAE833793 PILOT HAD ENGINE CHIP LIGHT ILLUMINATION FOLLOWED ALMOST IMMEDIATELY WITH A NOISE/VIBRATION, THEN A POWER LOSS/ DECEL. AC LANDED WITHOUT INCIDENT AND PILOT HAD TO SHUT OFF THE ENGINE. CHIP PLUGS AND OIL FILTERS WERE CONTAMINATED WITH META L. DISASSEMBLY OF ENGINE AND ENGINE GEARBOX REVEALED A FAILURE OF THE 2.5 BEARING TO A POINT THAT .33 THE CIRCUMFERENCE OF THE SAG SHAFT, INNER RACE, WAS GOUGED TO AN APPROX DEPTH OF .040 INCH TO .045 INCH. NO OTHER SOURCE OF METAL WAS FO UND. 1 G 7 1 3U 3 U H3WE E4CE 2005033000042 20050330 00042 2005 3 30 2005FA0000435 4 20041021 G 3420 8350006213 AHRS PIPER PA32 PA32300 7103212 SO LYC O540 TIO540* 41532 EA COCKPIT FAILED D K NONE O OTHER IN INSP/MAINT 1 AL 05 4485X 783 327640026 THE AHRS INSTALLED AS PART OF THE FLIGHT SYSTEMS, EFIS-SV STC NR SA02203AK FAILED- WAS PROVIDING NO HEADING INFORMATION. THE CIRCUIT BREAKER HAD TO BE PULLED TO KEEP THE GPS ON LINE. (AL05200500173) (K) 1 L 7 1 3O 3 O A3SO E14EA 2005033000043 20050330 00043 2005 3 30 2005FA0000436 4 20041028 G 3417 962830A1S8 ADC PIPER PA32 PA32300 7103212 SO LYC O540 IO540K1A5 41532 EA COCKPIT MALFUNCTIONED D K NONE O OTHER IN INSP/MAINT 1 AL 05 4485X 174 327640026 AIR DATA COMPUTER REPORTING 300 FEET & ERROR. UNIT INSTALLED AS PART OF FLIGHT SYSTEMS, INC STC NR SA02203AK. (AL0520 0500176) (K) 1 L 7 1 3O 3 O A3SO 1E4 2005033000045 20050330 00045 2005 3 30 2005FA0000437 4 20040816 G 3417 962830A1S8 ADC CESSNA 185 A185E 2072818 CE CONT O520 IO520* 17032 SO COCKPIT MALFUNCTIONED D O OTHER O OTHER NR NOT REPORTED 1 AL 05 1999U 563 18501768 ADC PROVIDING ERRONEOUS HEADING AND ALTITUDE READINGS. ADC INSTALLED AS PART OF FLIGHT SYSTEM EFIS-SV SYSTEM. UNDER ST C NR SA02203AK. (K) 1 H 7 1 3O 3 O 3A24 E5CE 2005033000035 20050330 00035 2005 3 30 2005FA0000438 4 20040616 G 3420 8350006214 AHRS PIPER PA32 PA32301 7103207 SO LYC O540 IO540K1G5 41532 EA COCKPIT MALFUNCTIONED D O OTHER O OTHER NR NOT REPORTED 1 AL 05 8200M 328006048 AHRS REPORTING TO IDU WANDERING HEADING AND ERRONEOUS ACCELL/DECELERATION. UNIT INSTALLED AS PART OF FLIGHT SYSTEMS, IN C EFIS-SV SYSTEM. (K) 1 L 7 1 3O 3 O A3SO 1E4 2005040100011 20050401 00011 2005 4 1 2005FA0000439 4 20041110 G 3417 962830A1S8 ADC CESSNA 206 U206E 2073350 CE CONT O520 IO520F 17032 SO COCKPIT MALFUNCTIONED D O OTHER O OTHER NR NOT REPORTED 1 AL 05 9417G 1043 U20601617 ALTITUDE WAS 100 FEET OFF. UNIT INSTALLED AS PRAT OF THE FLIGHT SYSTEM, INC EFIS-SV IAW STC NR SA02203AK. (AL052005001 75) (K) 1 H 7 1 3O 3 O A4CE E5CE 2005040100073 20050401 00073 2005 4 1 2005FA0000440 4 20041028 G 3417 962830A1S8 ADC CESSNA 208 208B 2073701 CE PWA PT6 PT6* 52043 EA COCKPIT MALFUNCTIONED D O OTHER O OTHER NR NOT REPORTED 1 AL 05 331AK 690 208B0739 NR 2 ADC UNIT REPORTING 350 FEET ERROR. UNIT INSTALLED AS PART OF THE FLIGHT SYSTEMS, INC EFIS-SV SYSTEM UNDER STC NR S A02203AK. (AL05200500174) (K) 1 H 7 1 3T 3 T A37CE E2NE 2005040400037 20050404 00037 SO 2005 4 4 2005FA0000441 1 20040915 G 3110 401405000101 DISPLAY PIPER PA32 PA32300 7103212 SO LYC O540 IO540K1G5 41532 EA INTRUMENT PANEL INOPERATIVE D O OTHER O OTHER NR NOT REPORTED 1 AL 05 8127Q 291 327940269 THE INSTRUMENT DISPLAY UNIT (IDU) PRIMARY FLIGHT DISPLAY INSTALLED AS PART OF FLIGHT SYSTEM, INC EFIS-SV SYSTEM FAILED. DURING BOOT-UP, THE DISPLAY SHOWED VERTICAL LINES ACROSS THE SCREEN. (K) 1 L 7 1 3O 3 O A3SO 1E4 2005040100103 20050401 00103 CE 2005 4 1 2005FA0000442 1 20041108 G 5330 SKIN BEECH 58 58 1152740 CE FUSLAGE CORRODED B VIBR O OTHER O OTHER NR NOT REPORTED 1 SO 13 1648W TH251 PERFORMED INCOMING INSPECTION OF AC FOR REPAIR OF CORROSION AT DOORWAY ENTRY. UPON INSPECTION, EXTENSIVE CORROSION WAS FOUND AT VARIOUS LOCATIONS WHERE INSULATION WAS FACTORY INSTALLED. THIS INSULATION WAS FOUND TO BE DAMP AND HAD EXPOSED EDGES. THIS RESULTED IN MAY STRINGERS BEING REPLACED ALONG THE SIDES OF THE FUSELAGE AS WELL AS FUSELAGE SKINS FOR AN AREA OF ABOUT 3 FT X 3 FT ON EACH SIDE OF THE AIRCRAFT. EXTENSIVE CORROSION WAS FOUND AT THE AFT WING SPAR CARRY-THROUG H STRUCTURE AND THE CO-PILOTS ENTRY DOOR FRAME. 1 L 7 2 3O 3A16 2005040100108 20050401 00108 SO 2005 4 1 2005FA0000444 2 20041223 G 8530 637781 EXHAUST VALVE CONT CESSNA 210 T210M 2073451 CE CONT O520 TSIO520R 17040 SO NR 1 CYLINDER BROKEN B I3PD O OTHER O OTHER NR NOT REPORTED 1 NM 03 761QK 4182104 21062432 512584 PILOT REPORTED HEARING A BANG AND NOTICED AN ENGINE VIBRATION AND REDUCTION IN TEMPERATURE ON HIS ENGINE MONITOR. PILOT REPORTED AN EMERGENCY TO ATC AND MADE A SAFE LANDING AT AIRPORT. MAINTENANCE PERFORMED AN ENGINE COMPRESSION TEST AND FOUND CYLINDER NR 1 HAD -0-(ZERO) COMPRESSION. REMOVED CYLINDER NR1 AND FOUND EXHAUST VALVE HEAD MISSING APPROX 40 PERC ENT. THE MISSING PIECE OF THE EXHAUST VALVE WAS FOUND IN THE INTAKE TUBE AND HAD CONTACTED THE TOP OF THE PISTON AND TO P OF THE CYLINDER HEAD. PROBABLE CAUSE OF FAILURE IS UNDETERMINED. 1 H 7 1 3O 3 O 3A21 E8CE 2005040100038 20050401 00038 EU 2005 4 1 2005FA0000460 1 20040517 G 2497 WIRE HARNESS ISRAEL 1124 1124 4500102 EU COCKPIT ENTRY ARCED B XZAR K NONE O OTHER IN INSP/MAINT 1 EA 17 900VP 289 FOUND WIRE HARNESS CHAFFING AND ARCING IN THE AREA OF THE COCKPIT ENTRANCE OVERHEAD. THIS PROBLEM HAS BEEN ADDRESSED BY SB 1124-24A-154. CONSIDERATION SHOULD BE GIVEN TO MAKE THIS AD. DUE TO POTENTIAL OF IN-FLIGHT SMOKE AND FIRE HAZZARD. (K) 2 M 7 2 4F A2SW 2005050300258 20050503 00258 CE 2005 5 3 2005FA0000477 1 20041122 G 3233 ACTUATOR CESSNA 500 550 2076604 CE PWA JT15 JT15* 52060 NE NOSE GEAR WORN B MDOR K NONE O OTHER IN INSP/MAINT 1 CE 07 228CC 5500133 RECEIVED SECOND NLG TO REPLACE THE FIRST ONE SENT TO US OUT OF LIMITS AND FOUND THE SAME PROBLEM. FOUND TO HAVE EXCESSI VE IN LINE MOVEMENT OF THE LOCKING MECHANISM. MOVEMENT IN EXCESS OF .1250 INCH, MAX ALLOWED .035. (K) 1 L 7 2 4F 4 T A22CE E1NE 2005041400105 20050414 00105 SO 2005 4 14 2005FA0000489 1 20041215 G 1430 RIVET GULSTM G1159 G1159B 3953535 SO FUSELAGE LOOSE B N38R O OTHER O OTHER NR NOT REPORTED 1 EA 05 211SJ 75 UPON X-RAY INSPECTION OF AIRCRAFT FOR A 4000 LANDING INSPECTION, FOUND SEVERAL WORKING RIVETS AROUND CABIN WINDOWS AS IN DICATED. LT NR 3 WINDOW; ONE (1) WORKING RIVET, LT NR 4 WINDOW; FOUR (4) WORKING RIVETS, LT NR 5 WINDOW, ONE (1) WORKIN G RIVET, RT NR 3 WINDOW, TWO (2) WORKING RIVETS; RT NR 4 WINDOW, ONE (1) WORKING RIVET; RT NR 5 WINDOW, TWO (2) WORKING RIVETS. ALL DISCREPANT RIVETS WERE EITHER REPLACED OR REBUCKED FOR SATISFACTORY SECURITY. (K) 2 L 7 2 4F RT A12EA 2005050500067 20050505 00067 SO 2005 5 5 2005FA0000522 1 20041107 G 8011 DRIVE ASSY PIPER PA28 PA28161 7102803 SO STARTER FAILED D O OTHER L NO TEST TX TAXI/GRND HDL 1 EA 15 151LH 451 326 D0701748112 2842194 STARTER FAILED AFTER 326.8 HRS SINCE REPAIR. THIS IS THE THIRD TIME THIS S/N STARTER HAS FAILED, INCLUDING BEING REPAIRE D. SAME FAILURE EACH TIME- BENDIX DRIVE JAMS. 1 L 7 1 3O 2A13 2005050500071 20050505 00071 SO 2005 5 5 2005FA0000534 1 20040911 G 8011 DRIVE ASSY PIPER PA28 PA28161 7102803 SO STARTER FAILED D O OTHER L NO TEST TX TAXI/GRND HDL 1 EA 15 152LH 248 248 D081443112 2842195 NEW STARTER FAILED AFTER 248.9 HOURS- BENDIX DRIVE JAMS. 1 L 7 1 3O 2A13 2005050500061 20050505 00061 SO 2005 5 5 2005FA0000536 1 20040212 G 8011 MHB6016 STARTER PIPER PA28 PA28161 7102803 SO LYC O320 O320* 41508 EA ENGINE FAILED D O OTHER L NO TEST TX TAXI/GRND HDL 1 EA 11 151LH 125 48 2842194 STARTER FAILED AFTER 48.1 HOURS SINCE REPAIR FOR SB A-112. 1 L 7 1 3O 3 O 2A13 E274 2005050400085 20050504 00085 SO 2005 5 4 2005FA0000538 1 20041118 G 8011 MZ6222 STARTER PIPER PA28 PA28R201 7102816 SO LYC O360 IO360C1C6 41514 EA ENGINE FAILED D K NONE L W NO TEST INADEQUATE Q C TX TAXI/GRND HDL 1 EA 15 146LH 76 76 2844102 L3109151A NEW REPLACEMENT STARTER FAILED 76.4 HOURS AFTER INSTALLATION. BENDIX DRIVE JAMS, STARTER WILL NOT OPERATE. STARTER IS NO T EFFECTED BY SB A-112. 4TH STARTER CHANGE ON AIRPLANE, 3RD DUE TO MECHANICAL FAILURE ALL WITHIN 205 HOURS (APPROX. 1 YE AR). REVERTED TO HEAVY STARTER MODEL P/N MZ-4222. 1 L 7 1 3O 3 O 2A13 1E10 2005050400077 20050504 00077 SO 2005 5 4 2005FA0000561 1 20040224 G 8011 MZ6222 STARTER PIPER PA28 PA28R201 7102816 SO LYC O360 IO360C1C6 41514 EA ENGINE FAILED D K NONE W L INADEQUATE Q C NO TEST TX TAXI/GRND HDL 1 EA 15 146LH 123 52 2844102 L3109151A STARTER REPAIRED W/O 6883 SB A-112. FAILED IN SERVICE 52.1 HOURS LATER. FAILURE DUE TO PARTS. 1 L 7 1 3O 3 O 2A13 1E10 2005052500040 20050525 00040 EU 2005 5 25 2005FA0000659 1 20040810 G 6410 355A12003108 BLADE SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE TAIL ROTOR DELAMINATED B EHAR K NONE O OTHER IN INSP/MAINT 1 AL 03 353EV 531 2444 DURING A ROUTINE ALF INSPECTION, THE MECHANIC DISCOVERED DELAMINATION ON THE TAILROTOR BLADE. THE DELAMINATED TRIM TAB WAS APPROX 3 INCHES LONG AND 2 INCHES IB OF THE TRIM TAB RIVET. THE TAILROTOR ASSY WAS REMOVED AND SENT TO A BLADE REPA IR FACILITY FOR EVALUATION AND REPAIR. (K) 1 G 7 1 3U 3 U H9EU E19EU 2005052500041 20050525 00041 EU 2005 5 25 2005FA0000660 1 20040912 G 6410 355A12003108 BLADE SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE TAIL ROTOR CRACKED B EHAR K NONE O OTHER IN INSP/MAINT 1 AL 03 350EV 2697 2961 9034 TAIL ROTOR BLADE, FOUND CRACK APPROX 3.2500 INCH LONG, RUNNING PARALLEL TO TRIM TAB. (K) 1 G 7 1 3U 3 U H9EU E19EU 2005052500044 20050525 00044 EU 2005 5 25 2005FA0000661 1 20040913 G 6410 355A12003108 BLADE SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE TAIL ROTOR DELAMINATED B EHAR K NONE O OTHER IN INSP/MAINT 1 AL 03 350EV 2697 2961 DURING A ROUTINE ALF INSPECTION, THE MECHANIC DISCOVERED DELAMINATION ON THE TAILROTOR BLADE. THE TAILROTOR SHOWED NO S IGNS OF IMPACT. THE DELAMINATED TRIM TAB WAS APPROXIMATELY 3 INCHES LONG AND 2 INCHES IB OF THE TRIM TAB RIVET. THE TA ILROTOR ASSY WAS REMOVED AND SENT TO MFG FOR EVALUATION AND REPAIR. (K) 1 G 7 1 3U 3 U H9EU E19EU 2005052500140 20050525 00140 GL 2005 5 25 2005FA0000676 3 20041110 G 6114 DOWEL PIN CESSNA 421 421C 2076016 CE MCAULY 3FF32 3FF32C501 GL PROPELLER HUB SHEARED B VA1R K NONE O OTHER IN INSP/MAINT 1 SW 19 620ZE 3670 421C0301 771538 PROPELLER OVERHAULED AND REINSTALLED. TEST FLIGHT REVEALED VIBRATION. DETERMINED TO BE SHEARED DOWEL PINS CAUSING LOOS E PROPELLER TO CRANK PROP DRIVE SHAFT. (K) 1 L 7 2 3O A7CE 5 C P45GL 2005052500170 20050525 00170 SO 2005 5 25 2005FA0000677 2 20041110 G 8520 TCM634503 MAIN BEARING CESSNA 421 421B 2076014 CE CONT O520 GTSIO520* 17032 SO NR 2 DELAMINATED B VA1R K NONE O OTHER IN INSP/MAINT 1 SW 19 9SD 321 421B0888 235244L BEARING CRACKED AND DELAMINATED IN NR2 MAIN BEARING SADDLE. HEATED CRACKS IN NR2 MAIN JOURNAL. THIS HAS BEEN NOTED ON OTHER ENGINES WE HAVE DISASSEMBLED. BEARING BORN DATE 10-02. THIS WAS A NEW CASE AND NO SIGNS OF FRETTING ON THE CASE HALF. (K) 1 L 7 2 3O 3 O A7CE E7CE 2005052500177 20050525 00177 SO 2005 5 25 2005FA0000678 2 20041227 G 7414 4720N107891 MAGNETO NAMER F51 P51D 6402304 WP PCKARD V1650 V1650* 49001 SO LT FAILED G K NONE O OTHER IN INSP/MAINT 1 EA 17 51JB 4473029A LT MAGNETO FAILED CAUSING ENGINE DETONATION. SUGGEST CLOSER INSPECTION, INTERVAL OF MAGNETO`S OPERATION. (K) 1 L 7 1 4V 4 V L113 EXP4V 2005052500178 20050525 00178 2005 5 25 2005FA0000679 4 20041220 G 2561 GA12P0201 LIFE VEST CABIN FAILED B KQ1R K NONE O OTHER IN INSP/MAINT 1 EA 07 INDIVIDUAL FLOAT DEVICE FAILED. MFG RECOMMENDED CELL PRESSURE TEST. DOM: MAY 1981. (K) 2005052500180 20050525 00180 NM 2005 5 25 2005FA0000681 1 20041229 G 3213 STRUT LANCAR LC42 LC42550FG 5150002 NM CONT O550 IO550* SO NLG LOOSE B W6NR K NONE O OTHER IN INSP/MAINT 1 GL 25 191DW 127 42022 DURING INSPECTION OF NOSE GEAR STRUT HARDWARE IT WAS FOUND TO HAVE LOOSE STRUT MOUNTING HARDWARE. (K) 1 L 7 1 3O 3 O RT A00003SE E3SO 2005052500193 20050525 00193 EU 2005 5 25 2005FA0000683 1 20041124 G 7600 DHS77240030 SWITCH SNIAS 350 AS350B3 8680954 EU TMECA ARRIEL ARRIEL2B NE COCKPIT BINDING D A UNSCHED LANDING O OTHER CR CRUISE 1 SW 17 747R 3341 SWITCH DOES NOT FULLY EXTEND, CAUSING ENGINE TO REMAIN AT IDLE AFTER TWIST GRIP IS PLACE BACK INTO THE (VOL) POSITION DU RING IN-FLIGHT EMERGENCY PROCEDURE TRAINING. REMOVED FROM SERVICE, REPLACED WITH NEW. (K) 1 G 7 1 3U 3 U H9EU E00054EN 2005052500194 20050525 00194 CE 2005 5 25 2005FA0000684 1 20041111 G 2910 AE1011923H0152 HOSE CESSNA 750 750 2076810 CE ALLSN AE3007 AE3007C GL HYDRAULIC SYS RUPTURED B CNQ3 O OTHER K FLUID LOSS LD LANDING 1 GL 13 521FP 2892 7500016 HYDRAULIC HOSE RUPTURED IN AREA ADJACENT TO SLEEVE ALLOWING LOSS OF HYDRAULIC FLUID TO (SYSTEM A). HOSE BEING SENT TO M FG FOR EVALUATION. (GL13200505055) (K) 2 L 7 2 4J 4 F RT T00007WI TE6CH 2005052500195 20050525 00195 EA 2005 5 25 2005FA0000685 2 20041217 G 8520 LW10346 CRANKSHAFT PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA ENGINE FAILED B MW2R K NONE O OTHER IN INSP/MAINT 1 GL 17 525AA 225 318052111 CRANKSHAFT BROKEN AT NR3 MAIN, THEN AT 2 OTHER PLACES. (K) 1 L 7 2 3O 3 O A20SO E14EA 2005052500199 20050525 00199 CE 2005 5 25 2005FA0000688 1 20041222 G 3233 9581001727 ACTUATOR BEECH 58 58 1152740 CE MLG LEAKING B E81R K NONE O OTHER IN INSP/MAINT 1 GL 03 23PC 152 TH2071 DURING FIRST ANNUAL INSPECTION, NOTED OIL PUDDLED UNDER LANDING GEAR ACTUATOR ASSY AND ACTUATOR OIL LEVEL LOW. REMOVED ACTUATOR ASSY FOR LEAK INVESTIGATION AND FOUND SCREWS SECURING UPPER AND LOWER ACTUATOR HOUSINGS TOGETHER LOOSE (WERE AB LE TO LOOSEN WITH FINGER PRESSURE ONLY). MINIMAL SEALANT NOTED ON ACTUATOR HOUSING MATING SURFACES, MOSTLY BARE METAL. ALSO FOUND SECTOR GEAR STOP NOT SEALED TO HOUSING, OIL APPEARS TO HAVE GOTTEN BETWEEN STOP AND MINIMAL SEALANT APPLIED. REASSEMBLED ACTUATOR ASSY IAW SRM, ACTUATOR O/H INSTRUCTIONS, NO EXTERNAL LEAKAGE NOTED. (K) 1 L 7 2 3O 3A16 2005052500200 20050525 00200 CE 2005 5 25 2005FA0000689 1 20041222 G 5343 9511003119 SUPPORT ANGLE BEECH 58 58 1152740 CE MLG CRACKED B E81R K NONE O OTHER IN INSP/MAINT 1 GL 03 23PC 152 TH2071 DURING ANNUAL INSPECTION FOUND SUPPORT ANGLE WHERE LT IB MAIN GEAR DOOR AFT HINGE IS ATTACHED, CRACKED. PROBLEM NOTED O N OTHER LOW-TIME LATE SERIAL NUMBER BE 58 SERIES AIRCRAFT. PROBLEM SEEMS TO BE RELATED TO CHANGE TO ONE-PIECE MACHINED IB DOORS DUE TO STIFFNESS OF NEWER STYLE DOORS COMPARED TO THE OLDER BUILT-UP RIVETED SHEET METAL CONSTRUCTION DOORS. S TRESS FROM DOOR AIR LOADS AND/OR RETRACTED POSITION TENSION SEEMS TO BE BEING TRANSFERRED INTO IB DOOR HINGE SUPPORT STR UCTURE. (K) 1 L 7 2 3O 3A16 2005052500201 20050525 00201 CE 2005 5 25 2005FA0000690 1 20041222 G 5343 9511003119 SUPPORT ANGLE BEECH 58 58 1152740 CE CONT O550 IO550* SO MLG CRACKED B E81R K NONE O OTHER IN INSP/MAINT 1 GL 03 158WC 219 TH2008 DURING ANNUAL INSPECTION FOUND SUPPORT ANGLE WHERE LT IB MAIN GEAR DOOR HINGE IS ATTACHED, CRACKED. PART WAS REPLACED 2 YEARS PREVIOUSLY FOR SAME OCCURRENCE. ALSO FOUND ANGLE ON ADJACENT LT IB DOOR HINGE SUPPORT CRACKED, AS WELL AS SUPPOR T ANGLES FOR RT MAIN GEAR DOOR HINGE BRACKETS. PROBLEM SEEMS TO BE RELATED TO CHANGE TO 1-PIECE MACHINED IB DOORS DUE T O STIFFNESS OF NEWER STYLE DOORS COMPARED TO THE OLDER BUILT-UP RIVETED SHEET METAL CONSTRUCTION DOORS, STRESSES SEEM TO BE TRANSFERRED INTO IB DOOR HINGE SUPPORT STRUCTURE. (K) 1 L 7 2 3O 3 O 3A16 E3SO 2005052600071 20050526 00071 SW 2005 5 26 2005FA0000694 1 20041105 G 5712 RIB BBAVIA 7 7AC 2110102 SW LT WING CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 11 83258 1922 THE FIRST WING RIB LOCATED IB OF THE AILERONS WAS FOUND CRACKED ALONG THE RADIUS OF THE ATTACH TAB WHERE THE RIB IS SECU RED TO THE AFT SPAR. THIS AIRCRAFT WAS SUBJECTED TO YEARS OF PREVAILING WINDS QUARTERING AGAINST THE T/E OF THE LT AILE RON. NO GUST LOCKS WERE UTILIZED. THE RIBS WERE REPAIRED AND THE WINGS RECOVERED. THE OWNER HAS ERECTED A MORE SUITAB LE SHELTER. (GL11200505059) (K) 1 H 7 1 3O A759 2005052600079 20050526 00079 CE 2005 5 26 2005FA0000695 1 20040608 G 5711 5147 SPAR BBAVIA 11 11CC 9140404 CE RT WING CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 05 4159E 835 11CC64 A CRACK IN THE REAR SPAR OF THE RT WING WAS FOUND. THIS CRACK IS RUNNING WITH THE WOOD GRAIN, AND APPROX 13 INCHES LON G. THE CRACK IS EMANATING LT AND RT OF CENTER FROM THE UPPER BOLT HOLE OF THE MOST IB COMPRESSION STRUT. AFTER DISASSE MBLY IT WAS DETERMINED THAT THE COMPRESSION STRUT MOUNT BOLT WAS PREVIOUSLY OVER TIGHTENED, CAUSING CRUSHING OF THE SPAR WOOD, WHICH PRECIPITATED THE CRACK IN THE SPAR. 1 H 7 1 3O A796 2005052600083 20050526 00083 CE 2005 5 26 2005FA0000696 1 20041215 G 5712 052340050 SPAR CESSNA 172 R172E 2072413 CE LT WING IB CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 09 7892N 15628 R1720283 WHILE REPLACING THE FLAP TRACK ASSY, A CRACK APPROX 2 INCHES IN LENGTH AND RUNNING THROUGH THE LOWER RIVET HOLES, WAS FO UND UNDER THE LT IB FLAP TRACK. PROBABLE CAUSE WAS A FLAP OVERSPEED DURING FLIGHT. (K) 1 H 7 1 3O 3A17 2005052600084 20050526 00084 CE 2005 5 26 2005FA0000697 1 20041214 G 2930 98807101 PRESSURE SWITCH CESSNA CESSNA 210 T210L 2073449 CE CONT O520 TSIO520* 17040 SO HYD PWR PACK FAILED D O OTHER J WARNING INDICATION CL CLIMB 1 WP 25 2164S 195 219 21061125 LANDING GEAR FAILED TO FULLY RETRACT AFTER TAKEOFF. FOUND THAT THE WIRE SOLDERED TO THE HYDRAULIC POWER PACK PRESSURE S WITCH HAD CORRODED BENEATH THE HEAT-SHRINK TUBING, NEAR THE SOLDER JOINT. SUSPECTED: THE MFG OF THE PRESSURE SWITCH AS SY USED ACID CORE SOLDER TO ATTACH THE WIRE LEADS TO THE SWITCH. (K) 1 H 7 1 3O 3 O 3A21 E8CE 2005052600085 20050526 00085 CE 2005 5 26 2005FA0000698 1 20041101 G 3340 MS357561 KEY GRIMES CESSNA 425 425 2076018 CE PWA PT6 PT6A60A 52043 NE LANDING LIGHT MISSING B R1JR K NONE O OTHER IN INSP/MAINT 1 SO 15 10RM 5591 4250074 THE RT WING RETRACTABLE LANDING LIGHT WAS FAILED, REMOVED, SENT OUT FOR O/H. RETURNED FROM O/H, INSTALLED 8/6/04 AND OP S CHECKED OK. UNIT FAILED 11/1/04 AND WAS REMOVED. UNITS MOTOR WORM GEAR WAS ACCESSED, REMOVED AND THE MECHANIC DETECT ED NO WOODRUFF KEY WAS INSTALLED AND ONLY SET SCREWS WERE DRIVING THE GEAR STRIPPING THE PARTS. A NEW WORM GEAR AND WOO DRUFF KEY FURNISHED BY THE O/H AGENCY WERE DELIVERED, AND INSTALLED IAW STANDARD PRACTICES. RECOMMEND CLOSER INSPECTIO N. 1 L 7 2 3T 4 T RT A7CE E4EA 2005052600086 20050526 00086 CE 2005 5 26 2005FA0000699 1 20041101 G 3340 A6582 WORM GEAR GRIMES CESSNA 425 425 2076018 CE PWA PT6 PT6A60A 52043 NE LANDING LIGHT MISSING B R1JR K NONE O OTHER IN INSP/MAINT 1 SO 15 10RM 5591 4250074 THE RT WING RETRACTABLE LANDING LIGHT WAS FOAIED, REMOVED, SENT OUT FOR O/H. RETURNE FROM O/H, INSTALLED 8/6/04 AND OPS CHECKED OK. UNIT FAILED 11/1/04 AND WAS REMOVED. UNITS MOTOR WORM GEAR WAS ACCESSED, REMOVED AND THE MECHANIC DETECTE D NO WOODRUFF KEY WAS INSTALLED AND ONLY SET SCREWS WERE DRIVING THE GEAR, STRIPPING THE PARTS. A NEW WORM GEAR AND WO ODRUFF KEY FRUNISHED BY THE O/H AGENCY WERE DELIVERED, AND INSTALLED IAW STANDARD PARCTICES. RECOMMEND CLOSER INSPECTIO N. (K) 1 L 7 2 3T 4 T RT A7CE E4EA 2005052600097 20050526 00097 CE 2005 5 26 2005FA0000702 1 20041217 G 2740 NUT BEECH MU300 400A 1155402 CE JACKSCREW WORN B MGOR K NONE O OTHER IN INSP/MAINT 1 CE 09 400HD 756 921009 RK191 DURING A AND B INSPECTION NOTICED CLUNK IN PITCH TRIM. FOUND ACTUATOR IN FULL NOSE DOWN POSITION CONTACTING VERTICAL F IN CAP SUPPORT. UPON FURTHER INVESTIGATION FOUND JACKSCREW FREEPLAY MEASURED .075 MAX ALLOWABLE FREEPLAY IS .020. ACTU ATOR OVERHAUL INTERVAL IS 1800 HOURS. THIS ACTUATOR WAS O/H 11/21/2000 WITH 756.2 TSO. NEXT SCHEDULED O/H DUE IN 1043. 8 HOURS. FRAME CONTACT MAY HAVE HAD EFFECT ON PREMATURE WEAR. (K) 2 H 7 2 4F RT A16SW 2005052600098 20050526 00098 CE 2005 5 26 2005FA0000703 1 20041217 G 3230 35823071 CONNECTOR BEECH MU300 400A 1155402 CE PWA JT15 JT15* 52060 NE MLG LOOSE B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 712TA RK186 INVESTIGATED LANDING GEAR RETRACT SYSTEM FAULT (LANDING GEAR WOULD NOT RETRACT WHEN GEAR HANDLE SELECTED (UP) AFTER TAKE OFF) FOUND P162 CONNECTOR LOOSE, NOT FULLY SEATED ON A162 PC BOARD ASSY. J1 CONNECTOR, RESEATED P162 CONNECTOR TO A162J 1 CONNECTOR, LANDING GEAR RETRACT/EXTENSION SYSTEM OPERATIONS NORMAL DURING 10 RETRACT/EXTENSION CYCLES. (K) 2 H 7 2 4F 4 T RT A16SW E1NE 2005052600099 20050526 00099 SO 2005 5 26 2005FA0000704 2 20041112 G 8520 634503 MAIN BEARING CESSNA 421 421C 2076016 CE CONT O520 GTSIO520* 17032 SO ENGINE DELAMINATED B VA1R K NONE O OTHER IN INSP/MAINT 1 SW 19 10FF 421C0082 NR 3 MAIN BEARING APPEARED TO DELAMINATE. ALL THE BRASS OR BRONZE SEPARATED FORM THE BEARING SHELL. THE CRANKSHAFT, NR 3 JOURNAL DOES NOT SHOW SIGNS OF OIL STARVATION. (K) 1 L 7 2 3O 3 O A7CE E7CE 2005052600119 20050526 00119 SO 2005 5 26 2005FA0000708 1 20041208 G 2140 94E42 PRESSURE SWITCH JANITROL PIPER PA31T PA31T1 7103126 SO PWA PT6 PT6A60A 52043 NE HEATER BROKEN D K NONE O OTHER IN INSP/MAINT 1 SW 01 250CT 276 A96100018 3177820011 HEATER SHOWED SIGNS OF ABNORMAL COMBUSTION IE. SOOT TRAIL FROM FUEL DRAIN VENT. UPON INVESTIGATION. FOUND COMBUSTION A IR BLOWER FAN WHEEL ASSY HAD COME APART AND FODED HEATER. FAN MOTOR WOULD STILL RUN. AIR PRESSURE SWITCH HAD FAILED IN CLOSED POSITION IAW AD, SWITCH DOESN`T NEED OPS TESTING. RECOMMENDED THAT ALL COMBUSTION AIR PRESSURE SWITCHES, BE TES TED AND THAT THE COMBUSTION AIR FAN WHEEL ASSY BE INSPECTED AT SAME INTERVALS AS IN AD. (K) 1 L 7 2 3T 4 T A8EA E4EA 2005052600121 20050526 00121 SO 2005 5 26 2005FA0000709 1 20041208 G 2140 B07D67 BLOWER JANITROL PIPER PA31T PA31T1 7103126 SO PWA PT6 PT6A60A 52043 NE HEATER BROKEN D K NONE O OTHER IN INSP/MAINT 1 SW 01 250CT 276 A96100018 31T7820011 HEATER SHOWED SIGNS OF ABNORMAL COMBUSTION IE. SOOT TRAIL FROM FUEL DRAIN VENT. UPON INVESTIGATION, FOUND COMBUSTION AI R BLOWER FAN WHEEL ASSY HAD COME APART AND FOD`D HEATER. FAN MOTOR WOULD STILL RUN AIR PRESSURE SWITCH HAD FAILED IN CL OSED POSITION. IAW AD AIR PRESSURE SWITCH DOESN`T NEED OPS TESTING. RECOMMEND THAT ALL COMBUSTION AIR PRESSURE SWITCHE S BE TESTED AND THAT THE COMBUSTION AIR FAN WHEEL ASSY BE INSPECTED AT SAME INTERVALS AS CALLED FOR BY AD. (K) 1 L 7 2 3T 4 T A8EA E4EA 2005060100212 20050601 00212 SO 2005 6 1 2005FA0000755 2 20041220 G 8530 501868 ROCKER CESSNA 421 421B 2076014 CE CONT O520 GTSIO520* 17032 SO NR 1 CYLINDER BROKEN D E ENGINE SHUTDOWN O OTHER NR NOT REPORTED 1 GL 17 CGDMD 10 421B0917 ENGINE BECAME ROUGH IN FLIGHT ENGINE SHUTDOWN FOUND RT ENGINE NR 1 CYLINDER EXHAUST ROCKER ARM BROKEN. (K) 1 L 7 2 3O 3 O A7CE E7CE 2005060200008 20050602 00008 CE 2005 6 2 2005FA0000759 1 20041006 G 3232 221302214 ACTUATOR CESSNA 182 R182 2072734 CE LYC O540 O540* 41532 EA NLG OBSTRUCTED B OMKR O OTHER O OTHER LD LANDING 1 NM 03 756TK R18201150 AC NOSE DAMAGE DUE TO FAILURE OF NOSE GEAR TO EXTEND FOR LANDING. PROP LINKAGE RUNS DOWN OUTSIDE NLG TUNNEL, IS ATTACHE D TO IT IN 2 PLACES WITH ADEL CLAMPS, STANDOFFS, AND AN3 BOLTS. AFT ATTACH HOLE IS DIRECTLY IN LINE WITH NOSE DOOR ACT ARM, WHICH IS HOLLOW SINCE ITS A WELD ASSY MADE OF STEEL TUBING. AC HAD AFT AN3 BOLT INSTALLED WITH THREADS AND NUT FAC ING OR PROTRUDING INTO WHEEL WELL. BOLT END HAS HIT ACT ARM EACH GEAR RETRACTION UNTIL IT BECAME LOOSE ENOUGH TO POP OV ER INTO END OF HOLLOW ACT ARM TUBE. THIS NOW LOCKED ACT ARM INTO POSITION, LOCKED GEAR DOORS CLOSED, PREVENTING GEAR EX TENSION. LT TUNNEL SIDE WAS REPLACED W/FACTORY PN, BOLT HOLE COMES PREDRILLED. NO REF TO PROP CABLE ROUTING. (K) 1 H 7 1 3O 3 O RT 3A13 E295 2005062800171 20050628 00171 SO 2005 6 28 2005FA0000809 1 20041108 G 5711 6707002 SPAR PIPER PA28 PA28140 7102802 SO LYC O320 O320* 41508 EA WING CORRODED B N2YR O OTHER O OTHER NR NOT REPORTED 1 WP 23 8740N 2825555 UPPER SPAR CAP WAS FOUND WITH SEVERE EXFOLIATION CORROSION BEHIND THE FUEL TANK. TANK WAS PULLED TO COMPLY WITH SB. TH ERE WAS NO INDICATION OF CORROSION SWELLING ON THE SURFACE OF THE WING. THE AREA WHERE THE CORROSION OCCURRED IS NOT VI SIBLE FROM INSPECTION PANEL ACCESS AND REQUIRES THAT THE FUEL TANKS BE PULLED FOR INSPECTION OF THIS AREA. MFG HAS ADDR ESSED THIS IN SB. (K) 1 L 7 1 3O 3 O 2A13 E274 2005071900023 20050719 00023 SO 2005 7 19 2005FA0000946 2 20040428 G 7314 6559211A2 PUMP MOONEY M20 M20R 5870225 SW CONT O550 IO550G 17042 SO MCAULY 2A34C 2A34C203 GL ENGINE FUEL FAILED P O OTHER Y J ENGINE STOPPAGE WARNING INDICATION LD LANDING 1 SO 11 10368 156 290286 684961 002495 ENGINE FAILED ON FINAL APPROACH. WAS ABLE TO RESTART AFTER LANDING BUT HAD TO PULL THE MIXTURE CONTROL LEAN ABOUT 1INCH TO KEEP IT RUNNING. AFTER COOLDOWN, MIXTURE WAS OK AGAIN. THIS IS THE FIRST OF 3 FUEL PUMP FAILURES ON THIS AIRCRAFT/ ENGINE IN APPROX 90 HOURS. THIS FUEL PUMP WAS INSTALLED ON THE ENGINE AT THE FACTORY WHEN THIS NEW ENGINE WAS BUILT. N EITHER MFG HAS BEEN ABLE TO DETERMINE THE CAUSE OF ANY OF THE PUMP FAILURES. 1 L 7 1 3O 3 O RT 2A3 E3SO 5 C P3EA 2005080300013 20050803 00013 CE 2005 8 3 2005FA0001081 1 20041115 G 3233 78820152 ACTUATOR CESSNA 172 172RG 2072438 CE LYC O360 O360* 41514 EA LT MLG CRACKED B BNZR O OTHER O OTHER NR NOT REPORTED 1 GL 19 9988B 1407 172RG1108 PILOT REPORTED LT MAIN LANDING GEAR WOULD NOT FULLY RETRACT. FOUND LT ACTUATOR CRACKED AT FORWARD BOLT HOLE. (GL192005 04417) (K) 1 H 7 1 3O 3 O 3A17 E286 2005081700147 20050817 00147 SO 2005 8 17 2005FA0001118 2 20040930 G 8500 ENGINE CESSNA 421 421C 2076016 CE CONT O520 GTSIO520L 17032 SO RT MAKING METAL D O OTHER O OTHER NR NOT REPORTED 1 NM 09 76MJ 108 421C1204 604158 DURING OIL CHANGE (ROUTINE) FOUND BEARING MATERIAL COMING OUT OF SUMP PLUG. PIECES APPROX. .1250-.2500 INCH WIDE, .5 IN CH LONG AND VARIOUS SMALLER PIECES. ENGINE WAS OVERHAULED 12/01/03: OWNER COMPLAINED OF VIBRATION FROM START. O/H SAI D NORMAL. AFTER ENGINE CHANGE, VIBRATION WENT AWAY. (NM09200414007) (K) 1 L 7 2 3O 3 O A7CE E7CE 2005082200078 20050822 00078 CE 2005 8 22 2005FA0001119 1 20041101 G 2700 065001790100 ROLL SERVO BEECH 58 58 1152740 CE FLT CONTROLS BINDING B FTUR K NONE O OTHER IN INSP/MAINT 1 NE 05 658RA 1027 TH1892 FOUND FLIGHT CONTROLS BINDING WHEN YOKE TURNED. BINDING WAS CAUSED BY PARTIALLY SEIZED OUTPUT BEARING IN AUTOPILOT ROLL SERVO. FOUND BEARING AND MOTOR DEFECTIVE. INSTALLED EXCHANGE SERVO. (K) 1 L 7 2 3O 3A16 2005082200080 20050822 00080 CE 2005 8 22 2005FA0001120 1 20041111 G 2700 065001790100 ROLL SERVO BEECH 58 58 1152740 CE FLT CONTROLS DEFECTIVE B FTUR O OTHER F FLT CONT AFFECTED CR CRUISE 1 NE 05 658RA 3 TH1892 AIRCRAFT WENT INTO UNCOMMANDED TURN WITH AUTOPILOT ENGAGED. REMOVED DEFECTIVE ROLL SERVO KS271C WITH 3.4 HOURS ON IT SI NCE OVERHAUL BY MFG. (K) 1 L 7 2 3O 3A16 2005081600222 20050816 00222 NM 2005 8 16 2005FA0001121 1 20041112 G 3411 STATIC PORT ISRAEL 1125 1125 NM GARRTT TFE731 TFE731* 01518 WP LT FWD CLOGGED B LN7R O OTHER O OTHER NR NOT REPORTED 1 EA 13 50TQ 065 AIRSPEED DISPARITY DURING IFR APPROACH, WATER IN LT STATIC PORT. FIRST TIME OCCURRENCE W/ THIS AC OUTSIDE DURING RAINST ORM LASTING 3 HOURS. STATIC DRAINS DRY, WATER ACCUMULATED JUST INSIDE STATIC PORT. DID NOT KNOW WHY STATIC PORT HEATER DID NOT REMOVE THE MOISTURE. RESULT OF PROBLEM: AIRSPEED DISPARITY/ EFIS AIR DATA CHECK SOM ERROR/ PILOTS ABORTED APPR OACH AND PERFORMED MISSED/ RETURNED TO DEPARTURE. BLEW OUT STATIC PORT, SUBSEQUENT FLIGHTS, OPS CHECKED GOOD. (K) 2 L 7 2 4F 4 F RT A16NM E6WE 2005081600224 20050816 00224 EU 2005 8 16 2005FA0001122 1 20041104 G 3210 S20 BEARING GROB GROB 120 G120A 1660208 EU LYC O540 AEIO540* EA RT MLG TRUNION FAILED B VJ3R K NONE O OTHER IN INSP/MAINT 1 WP 07 864AF 85004 DURING INSPECTION OF MAIN LANDING GEAR, DISCOVERED EXCESSIVE FORE AND AFT PLAY IN RT MLG LEG. RT MAIN LEG COULD MOVE FO RE AND AFT 4MM OR MORE. GEAR LEG WAS REMOVED. INSPECTION OF THE AFT TRUNION ASSY REVEALED THAT THE BEARING HAD FAILED AND HAD EXCESSIVE PLAY IN IT. UPON REMOVING THE BEARING, IT WAS DISCOVERED THAT IT APPEARS TO BE CONSTRUCTED FROM DIFFE RENT MATERIAL THAN THE OTHER BEARINGS ALTHOUGH ALL BEARINGS HAVE THE SAME PN. THIS BEARING SEEMS TO HAVE A BRASS OR BRO NZE INNER RACE WHICH HAS BECOME LOOSE AND IS CAPABLE OF MOVING WITHIN THE STEEL OUTER RACE. OTHER BEARINGS OF SAME PN I N AC LANDING GEAR SYS HAVE A STEEL INNER AND OUTER RACE. THIS BRG HAS BEEN RETURNED TO MFG FOR FURTHER INVESTIGATION. 1 L 7 1 3O 3 O RT A49CE 1E4 2005081600218 20050816 00218 EA 2005 8 16 2005FA0001123 2 20041108 G 7320 RSA5AD1 SERVO GROB 120 G120A 1660208 EU LYC O540 AEIO540D4D5 EA FUEL INJECTOR INOPERATIVE B VJ3R O OTHER J WARNING INDICATION TO TAKEOFF 1 WP 07 863AF 196 85003 PILOT REPORTED LOW FUEL FLOW ON TAKEOFF, UPON FURTHER INVESTIGATION THE MECHANIC FOUND THE FUEL FLOW WAS AT 149 PPH UNTI L THE ENGINE GOT HOT THEN THE FUEL FLOW DROPPED DOWN TO 142-144 PPH. NO RECOMMENDATION AT THIS TIME. (K) 1 L 7 1 3O 3 O RT A49CE 1E4 2005082200082 20050822 00082 CE 2005 8 22 2005FA0001124 1 20041101 G 8011 642083A10R ADAPTER BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO ENGINE STARTER FAILED B VJ3R K NONE O OTHER IN INSP/MAINT 1 WP 07 5581T 87 CE1350 DURING ATTEMPTING TO START THE ENGINE. THE STARTER WOULD NOT TURN ENGINE TO START. MAINTENANCE TECHNICIAN FOUND THAT T HE STARTER ADAPTER WOUD NOT ENGAGE TO START THE ENGINE DUE TO STARTER ADAPTER SLIPPING. REPLACED START ADAPTER AND ENGI NE STARTED GOOD. NO RECOMMENDATION AT THIS TIME. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2005082200084 20050822 00084 CE 2005 8 22 2005FA0001125 1 20040923 G 3234 551417527 HANDLE CESSNA 500 S550 2076607 CE PWA JT15 JT15D4 52112 NE LANDING GEAR LACK OF LUBE B XZAR O OTHER W INADEQUATE Q C NR NOT REPORTED 1 EA 17 97SK 4416 S5500127 LANDING GEAR WOULD NOT EXTEND WITH ACTUATION OF SELECTOR HANDLE DOWN. EMERGENCY EXTENSION WAS ACTIVATED, AND AIRCRAFT LANDED WITHOUT INCIDENT. AFTER JACKING AND INSPECTING SYS, IT WAS FOUND THAT THE LANDING GEAR HANDLE WOULD MOVE UP AND DOWN, BUT THE SPRING LOADED IN AND OUT MOTION WAS STUCK OUT. THIS CAUSED THE DOWN SWITCH NOT TO MAKE CONTACT WITH THE H ANDLE, NOT ALLOWING THE LANDING GEAR TO EXTEND. LUBRICATION OF THE SPRING AND SLIDER PORTION OF THE SELECTOR HANDLE WIT H SPRAY LUBRICANT FREED UP THE MECHANISM AND ALLOWED CONTACT BETWEEN SWITCH AND HANDLE. ONLY REQUIRED LUBRICATION IS DU RING INSTALLATION. 1 L 7 2 4F 4 F RT A22CE E1NE 2005082200085 20050822 00085 SO 2005 8 22 2005FA0001126 1 20041015 G 5541 2072907 RIB PIPER PA24 PA24260 7102406 SO LYC O540 TIO540* 41532 EA RUDDER CRACKED D UVNR O OTHER O OTHER NR NOT REPORTED 1 WP 07 9180P 3900 244670 CRACK WAS FOUND IN THE RIB THAT ATTACHES THE RUDDER COUNTER WEIGHTS. THIS HAS BEEN NOTICED IN THE PAST, THE FIX IS TO R EPLACE RIB. PARTS NO LONGER AVAILABLE. NOTICED THIS ON AIRFRAMES WITH MORE THAN 4000 HOURS. (K) 1 L 7 1 3O 3 O 1A15 E14EA 2005081700183 20050817 00183 EU 2005 8 17 2005FA0001127 1 20041015 G 3350 ELW3039010201 LIGHT AMD FALC90 FALCON900EX 2730009 EU GARRTT TFE731 TFE731* 01518 WP CABIN DAMAGED B UO2R O OTHER O OTHER NR NOT REPORTED 1 GL 19 900Q 89 10 THE AIRCRAFT WAS ON MFG SPI RAMP. THE CABIN LED LIGHT STRIP IN AFT CABIN BECAME WARM CAUSING HEAT DAMAGE TO THE LIGHT S TRIP. THE LIGHT BOARD WAS SENT TO EMTEQ LIGHTING FOR EVALUATION. EMTEQ DETERMINED THE CAUSE OF THE FAILURE TO BE ELECT RO STATIC DISCHARGE DAMAGE. MFG REP TRAVELED TO FACILITY TO INSPECT INSTALLED CABIN LED BOARDS. NO DEFECTS WERE FOUND ON ANY OF THE CABIN LED LIGHT BOARDS OR THE INSTALLATION OF THE SYS. MFG IS WORKING ON PLAN TO PREVENT THIS FROM HAPPEN ING IN THE FUTURE. (K) 2 L 7 3 4F 4 F RT A46EU E6WE 2005082400096 20050824 00096 SW 2005 8 24 2005FA0001205 1 20041229 G 5343 9981002815 ATTACH FITTING BBAVIA 7 7ECA 21101NN SW LYC O235 O235* 41505 EA RT MLG CRACKED D K NONE O OTHER IN INSP/MAINT 1 NE 03 982G 7ECA321 A CRACK WAS FOUND IN THE TORQUE KNEE ATTACH LUG (UPPER RADIUS) ON THE RT MAIN LANDING GEAR BRACE ASSEMBLY. 1 H 7 1 3O 3 O A759 E223 2005092000072 20050920 00072 EU 2005 9 20 2005FA0001254 1 20041205 G 3241 95426531 TRANSDUCER AMD FALCON FALCON20 2730103 EU GARRTT TFE731 TFE731* 01518 WP ANTI SKID SYS FAILED C O OTHER O OTHER NR NOT REPORTED 1 SW 11 82TN 384 NORMAL APPROACH WITH A GOOD ANTI-SKID CK, AC WENT OFF END OF 6000 FT WET RUNWAY. INSP OF TIRE MARKS AFTER ACCIDENT, NO EVID OF BRAKING ACTION. NO CAUSE OF FAILURE. ON TEST FLT AFTER REPAIR, RT ANTI-SKID WOULD NOT TEST IN AIR. ANTI-SKID WAS LEFT ON LANDING, BRAKING OPERATED NORMALLY. TAXING AFTER LANDING, RT BRAKES QUIT WORKING WHILE ANTI-SKID WAS ON. L T AND RT BRAKES WORKED NML WHEN ANTI SKID WAS TURNED OFF. TESTED ALL OF ANTI-SKID TRANSMITTERS, FOUND NR 3 TRANSMITTER TO HAVE AN OPEN CIRCUIT IN 70 PERCENT OF ITS TRAVEL. MM TEST SPECIFIES TO HOLD BOTH BRAKE PEDALS, SPIN ONE TRANSDUCER W HICH SHOULD CAUSE ALL BRAKES TO RELEASE. THIS TEST PERFORMED AFTER ACCIDENT, BEFORE TEST FLT, CHECKED OK BOTH TIMES. 2 L 7 2 4F 4 F RT A7EU E6WE 2005090800077 20050908 00077 CE 2005 9 8 2005FA0001268 1 20041020 G 2510 STRUCTURE CESSNA CESSNA 501 501 2076603 CE SEAT BASE CRACKED C GVRR O OTHER O OTHER NR NOT REPORTED 1 CE 05 7700T 5010248 UPPER CHAIR BASE ASSEMBLY CRACKED AT CHAIR BACK ATTACH POINTS. STRESS ON CHAIR BACK AND METAL FATIGUE PROBABLE CAUSE. CHAIR WAS REPAIRED IAW STRUCTURAL SEAT REPAIR. (K) 1 L 7 2 4F A27CE 2005090800076 20050908 00076 GL 2005 9 8 2005FA0001269 1 20041118 G 3213 40005401 CYLINDER AMTR AEROST AEROSTARBIRD 0560582 GL LYC O540 TIO540* 41532 EA MLG CRACKED D O OTHER O OTHER NR NOT REPORTED 1 SO 15 7411S 3968 60001627 COLLAR SEPARATING FROM TUBE DUE TO INSUFFICIENT PENETRATION WHEN PART WAS FURNACE BRAZED OR SILVER SOLDERED TOGETHER-WOR KING COLLAR CAUSED PART TO WORK AND CRACK BOSS. (K) 1 M 7 1 3 O EXPA1M71 E14EA 2005090800075 20050908 00075 GL 2005 9 8 2005FA0001270 1 20041118 G 3213 40005401 CYLINDER AMTR AEROST AEROSTARBIRD 0560582 GL LYC O540 TIO540* 41532 EA MLG CRACKED D O OTHER O OTHER NR NOT REPORTED 1 SO 15 7411S 3968 60001627 COLLAR SEPARATING FROM TUBE DUE TO INSUFFICIENT PENETRATION WHEN PART WAS FURNACE BRAZED OR SILBER SOLDERED TOGETHER- WO RKING COLLAR CAUSED PART TO WORK AND CRACK BOSS. RECOMMEND INSPECTION OF COLLAR AT BOTTOM OF GEAR STRUT FOR ANY MOVEMEN T OR WORKING BETWEEN COLLAR AND THE STRUT CYLINDER ASSEMBLY- DYE CHECK COLLAR WHERE PART IS MACHINED FOR CLEARANCE ON TO RQUE LINKS. (K) 1 M 7 1 3 O EXPA1M71 E14EA 2005092000020 20050920 00020 NM 2005 9 20 2005FA0001271 1 20041118 G 3213 COLLAR PIPER PA60 PA60601P 7106012 NM MLG STRUT SEPARATED D O OTHER O OTHER NR NOT REPORTED 1 SO 15 91VK 4148 61P06157963 COLLAR SEPARATING FROM TUBE DUE TO INSUFFICIENT PENETRATION WHEN PART WAS FURNACE BRAZED OR SILVER SOLDERED TOGETHER, WO RKING COLLAR CAUSED PART TO WORK AND CRACKED BOSS. RECOMMEND INSPECTION OF COLLAR AT BOTTOM OF GEAR STRUT FOR ANY MOVE MENT OR WORKING BETWEEN COLLAR AND THE STRUT CYLINDER ASSY - DYE CHECK WHERE PART IS MACHINED FOR CLEARANCE ON TORQUE LI NKS. (K) 1 M 7 2 3O RT A17WE 2005091500018 20050915 00018 EA 2005 9 15 2005FA0001273 1 20041015 G 2797 WIRE CNDAIR CL601 CL6013A 8070802 EA VERTICAL STAB SHORTED B RO3R K NONE O OTHER IN INSP/MAINT 1 CE 03 5175 WHILE TROUBLESHOOTING INTERMITTENT UPPER BEACON CIRCUIT BREAKER FAULT, DISCOVERED LT ELEVATOR CONTROL CABLE HAD TORN THR OUGH WIRING CONDUIT IN VERTICAL STABILIZER. THE CABLE WORE THROUGH THE CONDUIT AND SHORTED OUT THE WIRING FOR THE UPPER BEACON. REPAIRED WIRING CONDUIT, REPLACED WIRING AND REPLACED CONTROL CABLE IAW MFG INSTRUCTIONS. REPAIR OF CONDUIT A LLOWED SUFFICIENT CLEARANCE BETWEEN CABLE AND CONDUIT. UNCLEAR IF CONDUIT WAS INSTALLED AT FACTORY OR AT TIME OF COMPLE TION. SUGGEST INSPECTION OF THIS AREA ON OTHER SIMILAR AIRCRAFT. DEFECT DIFFICULT TO NOTICE DUE TO ACCESSIBILITY OF AR EA IN TAIL. (K) 2 L 7 2 4F RT A21EA 2005091900216 20050919 00216 CE 2005 9 19 2005FA0001298 1 20041209 G 2420 DOF10300B ALTERNATOR CESSNA 210 T210M 2073451 CE CONT O520 TSIO520* 17040 SO ENGINE FAILED C O OTHER H ELECT. POWER LOSS-50 PC CR CRUISE 1 SW 15 732YK 351 21061879 OVERHAULED ALTERNATOR FAILED IN FLIGHT AFTER 351 HOURS IN SERVICE. 1 H 7 1 3O 3 O 3A21 E8CE 2005103100158 20051031 00158 GL 2005 10 31 2005FA0001397 1 20041104 G 7603 THROTTLE CABLE DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240A SO ENGINE FAILED B FE4R O OTHER O OTHER NR NOT REPORTED 1 AL 03 102U 622 C0205 THROTTLE CABLE BROKEN INSIDE OF CABLE HOUSING 26 INCHES FROM CABLE END. NOTED THAT CABLE ASSEMBLY MAKES TIGHT RADIUS BE ND BEHIND INSTRUMENT PANEL, JUST AFT OF FIREWALL. (K) 1 L 7 1 3O 3 O NT TA4CH E7SO 2005031000030 20050310 00030 CE 2005 3 10 2005R0037 1 20041216 G 3242 1338932 BRAKE DISC BFGOODRICH CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE MLG BRAKE CRACKED B K NONE O OTHER IN INSP/MAINT 1 SW 01 2663Y 194 194 0110 5500602 BRAKE ASSEMBLY P/N: 2-1528-6, S/N'S: 0110 AND 1390. BOTH OF THESE BRAKES ARE IN COMPLIANCE WITH MFG SB 2-1528-32-2, REV 5, DATED 3 APR, 2003. BOTH BRAKES WERE UNDERGOING VISUAL INSPECTION AT 202 LANDINGS AND 194.7 HRS SINCE OVERHAUL. BOT H BRAKES HAD STATORS P/N: 133-893-2 CHG D, WITH CRACKS IN THE STOP HOLE AREA OF THE LONG EXPANSION SLOTS. 1 L 7 2 4F 4 F A22CE E1NE 2007013000182 20070130 00182 EU 2007 1 30 2007FA0000089 1 20040706 G 2711 1075010 O-RING FOKKER F28 F28MK4000 4990810 EU AILERON TAB LEAKING D A UNSCHED LANDING K FLUID LOSS NR NOT REPORTED 1 GL 23 159AD 11227 AT 1004Z, AIRCRAFT DEPARTED, APPROX 30 MIN INTO FLIGHT, PILOTS CALL PTK OPS RADIO AND REPORTED TOTAL LOSS OF NR 2 HYD SY STEM FLUID. AIRCRAFT RETURNED TO DEPARTURE. AFTER ARRIVING, THE FLIGHT MECHANIC INSPECTED THE AIRCRAFT AND FOUND THE R T AILERON TAB LOCK OUT ACTUATOR FILTER O-RING HAD RUPTURED. (K) 2 L 7 2 4F RT A20EU 2007061300216 20070613 00216 CE 2007 6 13 2007FA0000421 1 20040205 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 9318 3323 WHILE PREFORMING SCHEDULED MAINTENANCE,REMOVED EXHAUST STACKS TO FACILTATE INSPECTING THE EXHAUST DUCT.A CRACK WAS FOUND IN THE SKI SLOPE.POWER SECTION WAS REMOVED FOR REPAIR. 1 L 7 2 4T 4 T A24CE E4EA 20081028 SO 2008 10 28 2008F00023 2 20041007 G 8520 PUSHROD CESSNA 402 402B 207590P CE CONT O520 IO520* 17032 SO ENGINE FAILED E A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION NR NOT REPORTED 1 SW 05 5421M 402B0021 ENGINE HAD MANIFOLD AND FUEL PRESSURE VARIATION IN FLT, THE ACFT BEGAN TO VIBRATE AND THE PILOT SHUTDOWN ENGINE. THE NR 1 AND NR 2 ROD`S FAILED AND SEPARATED FROM THE CRANKSHAFT AND CREATED (2) LARGE HOLES IN THE CASE AND KNOCKING BOTH MAG NETOS LOOSE. THERE ARE SIGNS OF OIL STARVATION ON THE CRANK AND OVERHEATING ASIGNS ON THE CRANKSHAFT. REMOVAL OF OTHER CYLINDERS INDICATED OIL STARVATION ON THE NR (6) AND (5) ROD`S ALSO. OVERHEATING OF THE CRANK AT THOSE LOCATIONS IS EV IDENT. PILOT VERIFIED LOSING OIL PRESSURE BEFORE SHUTTING THE ENGINE. (K) 1 L 7 2 3O 3 O A7CE E5CE 20081028 SW 2008 10 28 2008FA0000711 1 20041003 G 5620 33036710 WINDOW GULSTM 690TP 690C 7630517 SW CABIN CRACKED B TKTR A UNSCHED LANDING D J INFLIGHT SEPARATION WARNING INDICATION NR NOT REPORTED 1 WP 11 XBDMT 380 11360 ACFT LOST PRESSURIZATION. AFTER LANDING THE RT CABIN WINDOW WAS FOUND CRACKED. AFTER REMOVAL THE CRACK WAS FOUND TO EXTE ND FROM THE TOP OF THE WINDOW INTO MOUNTING SCREW HOLE NR 22 AFT OF THE FRONT OF THE WINDOW THEN FWD 14 INCHES THROUGH 1 3 MOUNTING HOLES. THE CRACK THEN TURNED DOWN AND CONTINUED ACROSS THE TOP FWD CORNER OF THE WINDOW FOR 10 MORE INCHES IN TO MOUNTING HOLE NR 5 FROM THE TOP ON THE FWD EDGE OF THE WINDOW. (K) 1 H 7 2 3T 2A4 20081028 CE 2008 10 28 2008FA0000713 1 20041013 G 2510 05140778 SEAT FRAME CESSNA 172 172M 2072418 CE LYC O320 O320* 41508 EA COCKPIT CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 99 20454 5822 17261300 DURING A ROUTINE 100 HOUR INSPECTION IT WAS DISCOVERED THAT THE PILOTS FULLY ADJUSTABLE SEAT FRAME WAS CRACKED IN SEVERA L PLACES. SOME AREAS WERE COVERED UP BY THE UPHOLSTERY WHICH IS GLUED TO THE FRAME IN THAT AREA. OTHER AREAS OF CONCERN WERE INCOMPLETE WELDS DONE AT THE FACTORY. (3) OUT OF (4) SUPPORT LEGS WERE CRACKED AT THE WELD AND AT THE ATTACHMENT P OINT TO THE BOTTOM SEAT ASSY. (K) 1 H 7 1 3O 3 O NT 3A12 E274 20081028 CE 2008 10 28 2008FA0000714 1 20041009 G 2420 53954732 V-BELT BEECH 33 35C33 1151408 CE CONT O470 O470N 17026 SO ALTERNATOR DEPARTED G A UNSCHED LANDING D INFLIGHT SEPARATION NR NOT REPORTED 1 SO 19 55FL CD996 PILOT REPORTED LOSS OF ELECTRICAL POWER IN CRUISE FLIGHT DURING NIGHT VFR. V-BELT OBSERVED MISSING FROM ACCESSORY CASE A BSENT FROM ALTERNATOR PULLEY. V-BELT APPARENTLY LOST IN FLIGHT THROUGH OPENING IN LOWER COWLING. OWNER REPORTS THAT ONLY 25-30 HOURS WAS PUT ON THIS COMPONENT. (K) 1 L 7 1 3O 3 O 3A15 E273 20081028 GL 2008 10 28 2008FA0000716 1 20040929 G 5100 SPAR DIAMON DA20 DA20C1 2990001 GL CONT O200 O200* 17020 SO DELAMINATED D K NONE O OTHER IN INSP/MAINT 1 SW 99 885CT C0085 DURING THE 6000 HR INSPECTION, DELAMINATION FOUND IN THE TOP AFT CORNERS OF THE SPAR BRIDGE, BOTH SIDES. AFTER FURTHER I NVESTIGATION BY FACTORY PERSONNEL, CRACKS WERE FOUND DOWN THROUGH THE DIFFERENT LAYERS OF GLASS NOT THROUGH THE CARBON F IBER. RECOMMEND THAT THE AREA BE THOROUGHLY INSPECTED DURING THE 1000 HR INSPECTIONS. BRIGHT LIGHTS AND A MAGNIFYING GLA SS MUST BE USED. THESE CRACKS AND DELAMINATION ARE IN PROHIBITED AREA ACCORDING TO CHAPTER 51-00 STANDARD PRACTICES AND STRUCTURES. (K) 1 L 7 1 3O 3 O NT TA4CH E252 2004050600028 20040506 00028 CE 2004 5 6 206040204 1 20040402 G 7820 12502505 MUFFLER CESSNA 206 206CESSNA 2073302 CE CONT O520 IO520* 17032 SO ENGINE BULGED B JBZR K NONE O OTHER IN INSP/MAINT 1 WP 27 5224U 2060224 WHILE PERFORMING A ROUTINE PREFLIGHT INSPECTION, MECHANIC LOOKED UP TAILPIPES OF EXHAUST SYSTEM AND NOTICED SILENCER CON E HAD EXTENDED TO POSITION THAT WAS JUST SHORT OF CLOSING OFF EXHAUST PATH. THIS CONDITION OCCURRED OVER A PERIOD OF LE SS THAN 50 HOURS WHEN SAME MECHANIC HAD PERFORMED SAME VISUAL INSPECTION AND NOTED NO UNUSUAL CONDITIONS. 1 H 7 1 3O 3 O A4CE E5CE 2005022300198 20050223 00198 NE 2005 2 23 2104 2 20041015 G 7200 ENGINE BOEING 767 767300 1385204 NM GE CF6 CF680C2B7 NE NR 1 VIBRATION H E A ENGINE SHUTDOWN UNSCHED LANDING E J VIBRATION/BUFFET WARNING INDICATION CR CRUISE 1 EA 15 VPBAZ 30111 704956 NR 1 ENGINE SHUT DOWN DURING FLIGHT DUE TO VIBRATION. 2 L 7 2 4F 4 F RT A1NM E13NE 2005052000072 20050520 00072 GL 2005 5 20 21200003A 1 20040519 G 2410 ALTERNATOR CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO ENGINE LOOSE B DEBR H DEACTIVATE SYST/CIRCUITS J WARNING INDICATION NR NOT REPORTED 1 SW 99 449CD 1320 917617 THIS ACFT HAD A ALTERNATOR NR 1 FAIL LIGHT. UPON TROUBLE SHOOTING IT WAS FOUND THAT THE AFT HOUSING OF THE ALTERNATOR WA S LOOSE. FOUR SCREWS ATTACHING THE HOUSING WERE STILL SAFETY WIRED. IT DOES NOT APPEAR THAT SCREWS HAD LOOSENED OR THA T THE FORWARD HOUSING THREADS WERE DAMAGED. IT IS OUR OPION THAT AT ASSEMBLY THE ALTERNATOR FROM TELEDYNE CONTINENTAL MO TORS MANFACTUER WAS TORQUED AND SEFETY WIRED AND THAT THE AFT HOUSING WAS NOT FULLY SEATED TO THE FRONT HOUSING DUE TO I NTERFERENCE FROM THE INTERNAL PARTS OF THE ALTERNATOR. THIS IS THE THIRD ALTERNATOR WITH A LOOSE AFT HOUSING. FAILURE TO TAL TIMES OF THE THREE ALTERNATORS RANGE FROM 79.6 HOURS TO 232.2 HOURS. WE ARE AWARE OF AT LEAST 10-12 TOTAL FAILURES 1 L 7 1 3O 3 O NT A00009CH E3SO 2004122700001 20041227 00001 SO 2004 12 27 21200003AA 1 20041107 G 3210 653193 CYLINDER PIPER PIPER PA28 PA28180 7102808 SO RT MLG BROKEN C K NONE P NO WARNING INDICATION LD LANDING 1 GL 03 4830L 4797 284173 ON FINAL LANDING AFTER SEVERAL TOUCH AND GO`S, STUDENT PILOT AND CFI THOUGHT THAT THEY BLEW THE LT TIRE BECAUSE THE RT W ING CAME UP. AFTER FULL STOP, NOTED THAT THE UPPER TORQUE LINK ATTACH LUGS OF THE RT MLG CYLINDER HAD BOTH BROKEN OFF, DISCONNECTING THE TORQUE LINK ASSY ALLOWING THE STRUT TO FULLY OPEN AND MISALIGNING THE WHEEL. OTHER THAN THE CYLINDER ASSY, NO OTHER DAMAGE INCURRED. THE LT MLG CYLINDER WAS DYE PENETRATED AND BOTH ATTACH LUGS HAD CRACKS PRESENT. VISUAL LY LOOKING AT WHERE THE BREAK OCCURED, IT WAS APPARENT THAT THE CRACKS HAD BEEN THERE FOR SOMETIME AND THAT CORROSION HA D OCCURRED. BOTH CYLINDERS WILL BE REPLACED. PIPER SERVICE BULLETIN NR 1131 DATED AUGUST 2003 WAS NOT COMPLIED WITH. 1 L 7 1 3O 2A13 2004100400150 20041004 00150 SW 2004 10 4 21200003EAI 1 20040923 G 2150 35BD219DUM BEARING AIRCOM BELL 412 412EP 1182205 SW PWA PT6T PT6T3 52045 EA ACM FAILED B O OTHER O OTHER NR NOT REPORTED 1 SO 03 64 36333 DURING FIRST GROUND RUN AFTER INSTALLATION OF AIRCOM CABIN AIR CONDITIONING SYSTEM (P/N 412AC-106-2 - STC SR00066DE) A M ECHANIC INSPECTING THE SYSTEM NOTICED THE IDLER PULLY ON P/N 412AC-3036-1 SHAFT ASSEMBLY WAS NO LONGER IN ALIGNMENT WITH THE MAIN DRIVE PULLY & COMPRESSOR. AFTER ENGINE SHUTDOWN AND FURTHER INSPECTION IT WAS DETERMINED THAT THE IDLER PULLE Y BEARING ASSEMBLY HAD FAILED WITH THE BEARING SEAL AND MOST OF THE BALL BEARINGS MISSING. AFTER REMOVAL AND INSPECTION THERE WAS NO EVIDANCE OF ANY INTERNAL BEARING LUBRICATION. LESS THAN 5 BALL BEARINGS WERE RECOVERED (ON THE AIRCRAFT R OOF AND ON THE GROUND AROUND THE AIRCRAFT). AFTER FURTHER INSPECTION THERE WAS NO EVIDANCE OF FOD DAMAGE TO THE ENGINES 1 G 7 2 4U 4 U H4SW E22EA 2004030300188 20040303 00188 2004 3 3 21200004 4 20040221 G 2210 55X AUTOPILOT SYS CESSNA 210 T210L 2073449 CE CONT O520 TSIO520* 17040 SO COCKPIT DEFECTIVE C H DEACTIVATE SYST/CIRCUITS F FLT CONT AFFECTED CR CRUISE 1 NM 10 2084S 700 21061050 AIRCRAFT PORPOISES WHILE IN ALTITUDE HOLD MODE. DISABLE ALTITUDE HOLD MODE. MAINTENANCE CONFIRMS DEFECTIVE UNIT BY MAN UFACTURER. MANUFACTURER UNABLE TO SUPPLY REPLACEMENT PART. 1 H 7 1 3O 3 O 3A21 E8CE 2004101800092 20041018 00092 GL 2004 10 18 22010904 1 20041004 G 7160 AN334 BOLT CIRRUS CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO HARTZL HCJ3Y PHCJ3YF1 GL ALT AIR DOOR CHAFED B K NONE O OTHER IN INSP/MAINT 1 GL 15 968BG 205 0968 DURING REMOVAL AND REPLACEMENT OF THE P/N 15708-001 INDUCTION DUCT ASSY. IT WAS NOTED THAT THE INDUCTION DUCT WAS CRACK ED IN AREA OF AN3-34 BOLT WHICH SERVES AS HINGE POINT FOR ALTERNATE AIR DOOR. AFTER REMOVING BOLT IT WAS FOUND TO HAVE A GROOVE WORN INTO BOLT SHANK ALL THE WAY AROUND (360 DEGREES). IT APPEARS THAT INDUCTION DUCT SUPPORT BRACKET P/N 15671 -002, MADE OF STAINLESS STEEL, IS WEARING INTO BOLT. IT IS VERY DIFFICULT TO TELL IF THERE IS CRACKING ON DUCT (CRACKING LOCATED AT BOTTOM OF DUCT) WITHOUT REMOVING IT. THE CONDITION OF THE BOLT CANNOT BE VERIFIED UNLESS IT IS REMOVED. TH IS MODEL AIRCRAFT, WITH THE PLASTIC TYPE INDUCTION DUCTS SHOULD BE INSPECTED FOR THIS CONDITION AS SOON AS POSSIBLE. 1 L 7 1 3O 3 O NT A00009CH E3SO 5 C P36EA 2005022300124 20050223 00124 GL 2005 2 23 2201092004 1 20041004 G 1430 AN334 BOLT CIRRUS CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO INDUCTION DUCT CHAFED B YD5R K NONE O OTHER IN INSP/MAINT 1 GL 15 968BG 205 0968 DURING REMOVAL AND REPLACEMENT OF THE P/N 15708-001 INDUCTION DUCT ASSY IT WAS NOTED THAT DUCT WAS CRACKED IN THE AREA O F THE AN3-34 BOLT THAT SERVES AS THE HINGE POINT FOR THE ALTERNATE AIR DOOR. AFTER REMOVING THE BOLT IT WAS FOUND TO BE CHAFFED ALL THE WAY AROUND THE SHANK (360 DEGREES). IT APPEARS THE INDUCTION DUCT SUPPORT BRACKET P/N 15671-002, MADE O F STAINLESS STEEL, IS WEARING IT'S WAY INTO THE BOLT SHANK. SEVERAL OTHER AIRCRAFT WERE INSPECTED AND WERE FOUND TO HAVE BOLT WEAR AND/OR CRACKING OF THE DUCT IN THE SAME AREA. THE CRACKING OF THE DUCT IS VERY DIFFICULT TO SEE WITHOUT REMO VING THE ASSY AND THE CHAFFING OF THE BOLT CANNOT BE SEEN WITHOUT REMOVING IT. 1 L 7 1 3O 3 O NT A00009CH E3SO 2004102700101 20041027 00101 GL 2004 10 27 220192004 1 20041004 G 1430 AN334 BOLT CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO HARTZL HCJ3Y PHCJ3YF1 GL ALT AIR DOOR CHAFED B K NONE O OTHER IN INSP/MAINT 1 GL 15 968BG 205 0968 DURING REMOVAL AND REPLACEMENT OF PN 15708-001 INDUCTION DUCT ASSY IT WAS NOTED THAT INDUCTION DUCT WAS CRACKED IN AREA OF AN3-34 BOLT WHICH SERVES AS HINGE POINT FOR ALTERNATE AIR DOOR. AFTER REMOVING BOLT IT WAS FOUND TO HAVE A GROOVE WO RN INTO BOLT SHANK ALL THE WAY AROUND (360 DEGREES). IT APPEARS THAT INDUCTION DUCT SUPPORT BRACKET PN 15671-002, STAIN LESS STEEL, IS WEARING IT'S WAY INTO BOLT. OTHER AC WERE INSPECTED IN THIS AREA AND ALL WERE FOUND TO HAVE SOME DEGREE OF WEAR ON BOLT AND CRACKING ON THE DUCT ASSY IN SAME AREA. IT IS VERY DIFFICULT TO TELL IF THERE IS CRACKING ON DUCT (C RACKING LOCATED AT BOTTOM OF DUCT) WITHOUT REMOVING IT. CONDITION OF THE BOLT CANNOT BE VERIFIED UNLESS IT IS REMOVED. 1 L 7 1 3O 3 O NT A00009CH E3SO 5 C P36EA 2004122900154 20041229 00154 SO 2004 12 29 2304 1 20041105 G 2910 HYDRAULIC SYSTEM GULSTM G1159 GIV 3980115 SO LEAKING H A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CR CRUISE 1 SW 99 VPBSH 1466 APPROX 3.5 HR INTO FLIGHT, RETURN TO BLOCK DUE TO HYD FLUID LOSS. 2 L 7 2 4F RT A12EA 2004123000057 20041230 00057 GL 2004 12 30 24041004 1 20041028 G 7160 15671002 BRACKET CIRRUS CIRRUS SR SR22 2130001 GL INDUCTION DUCT CHAFED B YD5R K NONE O OTHER IN INSP/MAINT 1 GL 15 787CD 0918 THE INDUCTION DUCT SUPPORT BRACKET P/N 15671-002 HAS BEEN FOUND TO BE CHAFING INTO THE ALTERNATE AIR DOOR PIVOT BOLT P/N AN3-34. REPORTED THIS CONDITION BEFORE. A CHECK OF MULTIPLE AIRCRAFT HAVE SHOWED SIGNS OF CHAFFING AT THIS LOCATION. SUGGEST CLOSE LOOK AT THIS AREA WHEN PERFORMING MAINTENANCE. IT IS NECESSARY TO REMOVE THE DUCT ASSY P/N 15708-001 TO PERFORM THIS INSPECTION. 1 L 7 1 3O NT A00009CH 2005020200099 20050202 00099 GL 2005 2 2 24331 1 20041102 G 1430 AN334 BOLT CIRRUS SR SR22 2130001 GL ALT AIR DOOR CHAFED B YD5R K NONE O OTHER IN INSP/MAINT 1 GL 15 361CD 312 0885 THE BOLT (P/N AN3-34) THAT SERVES AS THE PIVOT FOR THE ALTERNATE AIR DOOR IN THE INDUCTION DUCT ASSEMBLY (P/N 15708-001) IS BEING CHAFFED BY THE INDUCTION DUCT SUPPORT BRACKET (P/N 15671-002). IN ADDITION TO THE CHAFFED BOLT THE INDUCTION DUCT ASSY IS SUSCEPTIBLE TO CRACKING. ALSO INSPECTED 14 OTHER AIRCRAFT WITH COMPARABLE TIME OR LESS AND FOUND SIGNS OF CHAFFING AND/OR INDUCTION DUCT CRACKING REQUIRING REPLACEMENT OF THE INDUCTION DUCT ASSY. THIS CONDITION IS VERY DIFFIC ULT TO INSPECT WITHOUT REMOVING THE INDUCTION DUCT ASSY. 1 L 7 1 3O NT A00009CH 2004120900119 20041209 00119 GL 2004 12 9 25921104 1 20041129 G 1430 AN334 BOLT CIRRUS SR SR22 2130001 GL ALR AIR DOOR CHAFED B YD5R K NONE O OTHER IN INSP/MAINT 1 GL 15 302CD 158 1076 THE BOLT (P/N AN3-34) THAT SERVES AS THE PIVOT FOR THE ALTERNATE AIR DOOR IN THE INDUCTION DUCT ASSY (P/N 15708-001) IS BEING CHAFED BY THE INDUCTION SUPPORT BRACKET (P/N 15671-002). IN ADDITION TO THE CHAFED BOLT THE PLASTIC DUCT IS SUSCEP TIBLE TO CRACKING AROUND THE PIVOT BOLT ON THE BOTTOM OF THE DUCT ASSY. THIS AREA IS VERY DIFFICULT TO INSPECT WITHOUT R EMOVING THE DUCT ASSEMBLY. ALSO, IT IS NECESSARY TO REMOVE THE NUT AND SUPPORT BRACKET TO INSPECT THE BOLT FOR CHAFFING. 1 L 7 1 3O NT A00009CH 2005012600166 20050126 00166 GL 2005 1 26 26251204 1 20041203 G 1430 AN334 BOLT CIRRUS CIRRUS SR SR22 2130001 GL ALT AIR DOOR CHAFED E YD5R K NONE O OTHER IN INSP/MAINT 1 GL 15 822TW 128 1066 THE BOLT (P/N 3-34) THAT SERVES AS THE PIVOT FOR THE ALTERNATE AIR DOOR IN THE INDUCTION DUCT ASSY (P/N 15708-001) IS BE ING CHAFED BY THE INDUCTION DUCT SUPPORT BRACKET (P/N 15671-002). IN ADDITION TO THE CHAFFED BOLT THE PLASTIC DUCT IS S USCEPTIBLE TO CRACKING AROUND THE PIVOT BOLT ON THE BOTTOM OF THE DUCT ASSY. THIS AREA IS VERY DIFFICULT TO INSPECT WIT HOUT REMOVING THE DUCT ASSY. ALSO, IT IS NECESSARY TO REMOVE THE NUT AND SUPPORT BRACKET TO INSPECT THE BOLT FOR CHAFFI NG. 1 L 7 1 3O NT A00009CH 2004092000027 20040920 00027 CE 2004 9 20 2688200400001 1 20040903 G 7800 2254008 CROSSOVER TUBE CESSNA 182 TR182 2072735 CE LYC O540 O540L3C5 41532 EA EXHAUST SYS CRACKED C K NONE O OTHER IN INSP/MAINT 1 WP 27 5091T 1400 R18201814 DURING ANNUAL INSPECTION, DISCOVERED CRACK APPROXIMATELY 1.5 INCHES IN LENGTH AROUND THE LT CROSSOVER ASSEMBLY (PN 22540 08). UPON REMOVAL, ALSO FOUND DETERIORATION IN THE SLIP JOINT CONNECTING THE RT CROSSOVER ASSEMBLY (PN 2254013). REPLA CED BOTH PARTS WITH FACTORY NEW. 1 H 7 1 3O 3 O 3A13 E295 2004092000028 20040920 00028 CE 2004 9 20 2688200410001 1 20040903 G 7800 2254008 CROSSOVER TUBE CESSNA 182 TR182 2072735 CE LYC O540 O540L3C5 41532 EA EXHAUST SYS CRACKED C K NONE O OTHER IN INSP/MAINT 1 WP 27 5091T 1400 R18201814 DURING ANNUAL INSPECTION, DISCOVERED CRACK APPROXIMATELY 1.5 INCHES IN LENGTH AROUND THE LT CROSSOVER ASSEMBLY (PN 22540 08). UPON REMOVAL, ALSO FOUND DETERIORATION IN THE SLIP JOINT CONNECTING THE RT CROSSOVER ASSEMBLY (PN 2254013). REPLA CED BOTH PARTS WITH FACTORY NEW. 1 H 7 1 3O 3 O 3A13 E295 2004091700067 20040917 00067 CE 2004 9 17 2689200410001 1 20040902 G 7810 2254008 CROSSOVER TUBE CESSNA 182 TR182 2072735 CE LYC O540 O540L3C5 41532 EA RT ENGINE CRACKED C K NONE O OTHER IN INSP/MAINT 1 WP 27 5091T 1400 R18201814 DURING ANNUAL INSPECTION, DISCOVERED CRACK APPROXIMATELY 1.5 INCHES IN LENGTH AROUND THE LT CROSSOVER ASSEMBLY. UPON RE MOVAL, ALSO FOUND DETERIORATION IN THE SLIP JOINT CONNECTING THE RT CROSSOVER ASSEMBLY (PN 2254013). REPLACED BOTH PART S WITH FACTORY NEW. 1 H 7 1 3O 3 O 3A13 E295 2005031000054 20050310 00054 GL 2005 3 10 270112 1 20041223 G 1430 AN334 BOLT CIRRUS CIRRUS SR SR22 2130001 GL ALR AIR DOOR CHAFED E YD5R K NONE O OTHER IN INSP/MAINT 1 GL 15 308CD 147 1026 THE BOLT (P/N 3-34) THAT SERVES AS THE PIVOT FOR THE ALTERNATE AIR DOOR IN THE INDUCTION DUCT ASSY (P/N 15708-001) IS BE ING CHAFFED BY THE INDUCTION DUCT SUPPORT BRACKET P/N 15671-002. IN ADDITION TO THE CHAFFED BOLT THE PLASTIC DUCT IS SUS CEPTABLE TO CRACKING AROUND THE PIVOT BOLT ON THE BOTTOM OF THE DUCT ASSY. THIS AREA IS VERY DIFFICULT TO INSPECT WITHOU T REMOVING THE DUCT ASSY. ALSO, IT IS NECCESSARY TO REMOVE THE NUT AND SUPPORT BRACKET TO VISUALLY INSPECT THIS AREA. 1 L 7 1 3O NT A00009CH 2005031000052 20050310 00052 GL 2005 3 10 27011204 1 20041223 G 1430 AN334 BOLT CIRRUS CIRRUS SR SR22 2130001 GL ALR AIR DOOR CHAFED E YD5R K NONE O OTHER IN INSP/MAINT 1 GL 15 308CD 147 1026 THE BOLT (P/N 3-34) THAT SERVES AS THE PIVOT FOR THE ALTERNATE AIR DOOR IN THE INDUCTION DUCT ASSY (P/N 15708-001) IS BE ING CHAFED BY THE INDUCTION DUCT SUPPORT BRACKET P/N 15671-002. IN ADDITION TO THE CHAFED BOLT THE PLASTIC DUCT IS SUSCE PTABLE TO CRACKING AROUND THE PIVOT BOLT ON THE BOTTOM OF THE DUCT ASSY. THIS AREA IS VERY DIFFICULT TO INSPECT WITHOUT REMOVING THE DUCT ASSY. ALSO, IT IS NECCESSARY TO REMOVE THE NUT AND SUPPORT BRACKET TO VISUALLY INSPECT THIS AREA. 1 L 7 1 3O NT A00009CH 2004092000060 20040920 00060 CE 2004 9 20 2724 1 20040816 G 3244 301361311 TIRE BEECH B300 B300 1159232 CE PWA PT6 PT6A6 52043 EA MLG DEFECTIVE B K NONE O OTHER IN INSP/MAINT 1 NE 03 350NY FL283 PROBLEM FOUND DURING NORMAL WORN TIRE REPLACEMENT. CORD (WIRE LIKE MATERIAL) WAS NOT DEEP ENOUGH IN THE RUBBER OF THE T IRE SEAT AREA WHICH LEFT A GROOVE (MIRROR IMAGE OF THE CORD) IN THE NR 3 MAIN WHEEL RIMS (INNER AND OUTER HALVES). THE GROOVES COVERED MORE THAN HALF THE DIAMETER OF THE OF THE WHEEL RIMS TO A MAX DEPTH OF JUST UNDER .020 INCH. BECAUSE OF THE LENGTH OF THE GROOVES, THE WHEEL ASSEMBLY REQUIRED REPLACEMENT. (WHEEL P/N 101-8001-47) 2 L 7 2 4T 3 T RT A24CE E4EA 2005031000053 20050310 00053 GL 2005 3 10 27641204 1 20041223 G 2425 116118001 BRACKET CIRRUS CIRRUS SR SR22 2130001 GL RT INST PANEL CHAFED E YD5R O OTHER O OTHER CR CRUISE 1 GL 15 581MD 157 1098 THE PILOT REPORTED A LOSS OF VOLTAGE INDICATION ON THE MFD WITH ALL OTHER SYSTEMS OPERATING NORMALLY. THROUGH TROUBLESHO OTING IT WAS DISCOVER THAT WIRE #ANEN983-22 WAS CHAFFED THROUGH THE INSULATION (THE AREA IN QUESTION IS LOCATED ABOVE T HE CO-PILOTS KICK PANEL AND BEHIND THE RIGHT HAND INSTRUMENT PANEL). THE AIRCRAFT RECENTLY HAD THE X-M WEATHER KIT OPTIO N INSTALLED. IT APPEARS THAT WHEN THE KIT IS INSTALLED IT IS POSSIBLE FOR THE WIRE HARNESS TO BE MOVED TO THE POINT WHER E IT CAN CHAFFE ON THE X-M AFT MOUNTING BRACKET. SINCE THIS IS DIFFICULT TO SEE ANTI-CHAFFE MATERIAL SHOULD BE INSTALLED ON THE AFT BRACKET TO ELIMINATE THE POSSIBILITY OF THIS CONDITION. 1 L 7 1 3O NT A00009CH 2005030800056 20050308 00056 EU 2005 3 8 2961 1 20041022 G 3244 M08401 TIRE AMD FALC50 FALCON50MYST 2730106 EU GARRTT TFE731 TFE73131C 01518 NE MLG DEFORMED E K NONE O OTHER IN INSP/MAINT 1 SO 05 164GB 234 164 THIS TIRE WAS MOUNTED ON THE RIGHT INBOARD SIDE (NR 3). CUPPING WAS NOTICED ON THE INSIDE EDGE OF THE TIRE ALL THE WAY AROUND WITH CORD SHOWING. TIRE WAS REPLACED. CONTACTED FALCON TECH OPS. HAD NOT HEARD OF THIS ITEM AND ASKED ME TO CON TACT THE TIRE MANUFACTURE. CONTACTED MICHELIN, CONFIRMED THE PROBLEM AND SAID THEY WERE WORKING ON IT. 2 L 7 3 4F 4 F A46EU E6WE 2004092000089 20040920 00089 EA 2004 9 20 2AUG04 1 20040802 G 3244 256K433 TIRE CNDAIR CL600 CL6002B16 1900305 EA GE CF34 CF343A 30015 NE MLG SEPARATED C C ABORTED TAKEOFF O OTHER TO TAKEOFF 1 GL 23 710VF 45 5050 APPROXIMATELY 1 TO 2 SECONDS BEFORE TAKEOFF, PILOT REPORTED A SLIGHT FORWARD LURCH TO AIRCRAFT AS IF IT WAS GOING THROUG H A PUDDLE. CHECK ALL FLT PARAMETERS NO ABNORMALITIES NOTED. CALL TOWER TO ASK FOR RUNWAY INSPECTION, GROUND PERSONNEL REPORTED FINDING PIECES OF TIRE AND WHAT LOOKED LIKE AN ANTENNA (IT WAS THE IB WOW INPUT PROX SWITCH). THE ENTIRE TREAD SEPARATED FROM THE CASING AND CAUSED CONSIDERABLE DAMAGE TO AIRCRAFT. 2 L 7 2 4F 4 F RT A21EA E15NE 2004042900032 20040429 00032 EU 2004 4 29 314431004 1 20040310 G 6220 350A31191600 STARFLEX SNIAS 350 AS350B3 8680954 EU MAIN ROTOR CRACKED E S4WA K NONE O OTHER IN INSP/MAINT 1 WP 07 5226R 1047 3144 STARFLEX BUSHING CRACKED AT BONDING JOINT, INDICATING SEPARATION. 1 G 7 1 3U H9EU 2004072100057 20040721 00057 EA 2004 7 21 32029A 1 20040715 G 7910 CABLE WACO UPF7 UPF7 9601302 EA OIL TANK BROKEN B W2OR K NONE O OTHER IN INSP/MAINT 1 GL 09 32029 5500 5660 CABLE ASSEMBLY THAT SECURES THE OIL TANK BROKE ON REINSTALLATION OF THE OIL TANK. ON FIRST LOOK, THE CABLE ENDS APPEARED TO BE THE OLD STYLE WOVEN CABLE SPLICE. AFTER THE CABLE BROKE WHILE TIGHTENING THE TURNBUCKLE, IT WAS FOUND THE CABLE W AS WRAPPED AROUND THE THIMBLE, SAFETY WIRE WAS WRAPPED AROUND THE TWO PIECES OF CABLE, AND THE JOINT SOLDERED. THE AIRCR AFT WAS REBUILT IN 1987. THE LOGBOOK ENTRIES DO NOT INDICATE WHETHER THE CABLE WAS CHANGED. HAD THE CABLE FAILED, THE OI L TANK WOULD HAVE NOT BEEN RESTRAINED AND FREE TO MOVE ON THE TUBING MOUNT. THIS TYPE OF CABLE SPLICE IS UNAIRWORTHY AND PRESENTED A SIGNIFICANT SAFETY HAZARD. NICOPRESS SLEEVES WOULD HAVE BEEN THE APPROPRIATE METHOD TO FABRICATE THE CABLE. 1 Q 7 1 3R A642 2004072100056 20040721 00056 EA 2004 7 21 32029B 1 20040715 G 3242 CABLE WACO UPF7 UPF7 9601302 EA BRAKE SYS DEFECTIVE B W2OR K NONE S AFFECT SYSTEMS IN INSP/MAINT 1 GL 09 32029 5660 CABLE ASSY CONNECT BRAKE PEDALS TO MASTER CYLINDERS WERE INSPECTED UNDER MORE SCRUTINY AFTER FINDING DEFECTIVE CABLE SEC URING OIL TANK. CABLE ENDS APPEARED TO BE OLD STYLE WOVEN CABLE SPLICE. FOUND CABLE WAS WRAPPED AROUND THIMBLE, SAFETY W IRE WAS WRAPPED AROUND TWO PIECES OF CABLE, JOINT SOLDERED. CORROSION PRESENT IN SOLDERED SAFETY WIRE EVIDENCED AS A GR EENISH, WHITE POWDER. CABLES HAVE BURNED LOOKING AREAS AT SOLDERED AREA THAT MAY HAVE BEEN CAUSED BY TORCH USED TO HEAT AREA. AC WAS REBUILT IN 1987. LOGBOOK ENTRIES DO NOT INDICATE CABLES WERE CHANGED. HAD CABLE FAILED, BRAKES WOULD BECOME INOPERATIVE. CABLE SPLICE IS UNAIRWORTHY. AC SHOULD NOT HAVE PASSED ANNUAL INSPECTIONS WITH THESE CABLES INSTALLED. 1 Q 7 1 3R A642 2004050300184 20040503 00184 2004 5 3 32404 4 20040308 G 2350 0110040110 AUDIO PANEL CIRRUS SR SR22 2130001 GL FAILED G A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 NM 01 8160N 57 0734 DURING CRUISE, PILOT NOTED FAILURE OF AUDIO SYSTEM. ELECTRICAL BURNING ODOR ACCOMPANIED SYSTEM FAILURE. PILOT ELECTED TO SHUT DOWN ELECTRICAL POWER AND MAKE A PRECAUTIONARY LANDING. EVALUATION OF AIRCRAFT FOUND FAILURE OF AUDIO PANEL. 1 L 7 1 3O NT A00009CH 2004050300151 20040503 00151 SO 2004 5 3 3M57931704 1 20040317 G 2742 5913114 RESOLVER GULSTM GV GULFSTREAMGV 3980116 SO RROYCE BR700 BR700710A110 NE STAB ACTUATOR INACCURATE B LD2R O OTHER J WARNING INDICATION CL CLIMB 1 GL 15 23M 2780 400 579 11261262 FLAP STAB MISCOMPARE CAS MESSAGE. STAB ACTUATOR HAS BAD RESOLVER. 2 L 7 2 4F 4 F RT A12EA E00057EN 2005012600187 20050126 00187 CE 2005 1 26 4001 1 20041207 G 8011 PM2401 STARTER CESSNA 172 172S 2072439 CE ENGINE CRACKED D O OTHER O OTHER TX TAXI/GRND HDL 1 SW 99 53564 916 172S9442 BENDIX DRIVE HOUSING CRACKED AND BROKE OFF OF STARTER. 1 H 7 1 3O NT 3A12 2004092000054 20040920 00054 EU 2004 9 20 4007053 1 20040225 G 2720 8011540140140 RUDDER PEDAL PIAGIO P180 P180 6960204 EU PWA PT6 PT6* 52043 EA COCKPIT LOOSE B K NONE O OTHER IN INSP/MAINT 1 NE 03 109MS 2672 1008 THE RUDDER PEDAL FOOT ASSEMBLIES ARE MADE UP OF A FOOT PEDAL WHICH SLIPS INTO A TUBE AND RIVETED TOGETHER WITH 6 BLIND R IVETS. (FOOT PEDAL IS OFFSET FROM THE TUBE, SO THE PEDAL WANTS TO ROTATE IN THE TUBE WHEN PUSHING FORWARD ON THE PEDAL) THE RIVETS WERE LOOSE IN BOTH PILOT'S RUDDER PEDAL ASSEMBLIES AND THE COPILOT'S RIGHT ASSEMBLY. OLD RIVETS WERE REMOVE D, PARTS ASSEMBLED WITH LIGHT COAT OF STRUCTURAL ADHESIVE, AND NEW RIVETS INSTALLED AS RECOMMENDED BY TECHNICAL SUPPORT. 1 H 7 2 3O 3 T RT A59EU E2NE 2004030400071 20040304 00071 CE 2004 3 4 40188138 1 20040226 G 5520 556555026 BRACKET CESSNA 500 500CESSNA 2076602 CE PWA JT15 JT15D1 52060 NE BALANCE WEIGHT CRACKED B K NONE O OTHER IN INSP/MAINT 1 GL 09 26NS 7280 5000340 BALANCE WEIGHT ARM FOR ELEVATOR CONTROL SYSTEM IS CRACKED. 1 L 7 2 4F 4 F A22CE E1NE 2004092000055 20040920 00055 EU 2004 9 20 4046 1 20040910 G 2720 8011540140102 RUDDER PEDAL PIAGIO P180 P180 6960204 EU PWA PT6 PT6* 52043 EA COCKPIT LOOSE B K NONE O OTHER IN INSP/MAINT 1 NE 03 122PA 453 1038 THE RUDDER PEDAL FOOT ASSEMBLIES ARE MADE UP OF A FOOT PEDAL WHICH SLIPS INTO A TUBE AND RIVETED TOGETHER WITH 6 BLIND R IVETS. (FOOT PEDAL IS OFFSET FROM THE TUBE, SO THE PEDAL WANTS TO ROTATE IN THE TUBE WHEN PUSHING FORWARD ON THE PEDAL) THE RIVETS WERE LOOSE IN BOTH PILOT'S AND BOTH COPILOT'S RUDDER PEDAL ASSEMBLIES. TO REPAIR: OLD RIVETS WERE REMOVED, PA RTS ASSEMBLED WITH LIGHT COAT OF STRUCTURAL ADHESIVE, AND NEW RIVETS INSTALLED AS RECOMMENDED BY TECHNICAL SUPPORT. 1 H 7 2 3O 3 T RT A59EU E2NE 2004050700004 20040507 00004 CE 2004 5 7 40590 1 20040420 G 2731 BEARING CESSNA 414 414A 2075907 CE ELE TRIM TAB CORRODED B K NONE O OTHER IN INSP/MAINT 1 GL 09 6815T 3846 414A0645 DURING ANNUAL INSPECTION FOUND THE ELEVATOR TRIM TAB HORN BEARING FROZEN. WHEN HORN WAS REMOVED TO REPLACE THE BEARING THE 2 ATTACHMENT SCREWS IN THE FORWARD HOLES OF THE BEARING WERE FOUND SEVERELY CORRODED. MORE THAN 50 PERCENT OF THE O RRIGINAL DIAMETER WAS ERODED AWAY. 1 L 7 2 3O A7CE 2004071900029 20040719 00029 CE 2004 7 19 409798 1 20040629 G 3246 NUT CESSNA 500 550 2076604 CE WHEEL BEARING LOOSE B K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 09 669B 269 5501060 WHEN REMOVING WHEEL FOR TIRE CHANGE FOUND THE LT MAIN WHEEL NUT HAD NOT BEEN TIGHTENED CAUSING RUINED BEARING SEALS. TH IS WAS THE FIRST ACCESS SINCE THE AIRCRAFT WAS DELIVERED NEW FROM THE FACTORY. 1 L 7 2 4F A22CE 2004092000059 20040920 00059 CE 2004 9 20 4101 1 20040816 G 3244 301361311 TIRE BEECH B300 B300 1159232 CE PWA PT6 PT6A6 52043 EA MLG GROOVED B O OTHER O OTHER NR NOT REPORTED 1 NE 03 350NY FL283 PROBLEM FOUND DURING NORMAL WORN TIRE REPLACEMENT. CORD (WIRE LIKE MATERIAL) WAS NOT DEEP ENOUGH IN THE RUBBER OF THE T IRE SEAT AREA WHICH LEFT A GROOVE (MIRROR IMAGE OF THE CORD) IN THE NR 4 MAIN WHEEL RIMS (INNER AND OUTER HALVES). THE GROOVES COVERED A THIRD OF THE DIAMETER OF THE WHEEL RIMS TO A MAX DEPTH OF JUST UNDER .018 INCH. BECAUSE OF THE LENGTH OF THE GROOVES, THE WHEEL ASSEMBLY REQUIRED REPLACEMENT. (WHEEL P/N 101-8001-47). 2 L 7 2 4T 3 T RT A24CE E4EA 2004110300119 20041103 00119 SO 2004 11 3 417011 1 20041015 G 5730 ACCESS PANEL PIPER PA46 PA46500TP 7104622 SO PWA PT6 PT6* 52043 EA WING DEBONDED B K NONE O OTHER IN INSP/MAINT 1 GL 09 767TP 617 4697036 WING FUEL PANELS HAVE A FOAM FILLER BLOCK AND SEALANT TO PREVENT WATER FROM BEING TRAPPED AT PANELS. THE SEALANT HAD TO RN FREE AND THE FOAM BLOCK WAS FLOATING LOOSE IN THE TANK FROM ONE PANEL AND WAS LOOSE FROM A SECOND PANEL BUT WAS NOT F REE IN THE TANK YET. THESE PIECES ARE ABOUT 5 INCHES LONG, 3 INCHES WIDE AND .5 INCH THICK. PANELS WERE REPAIRED AND R EINSTALLED IAW MM. 1 L 7 1 3O 3 T RT A25SO E2NE 2005012700068 20050127 00068 CE 2005 1 27 418611 1 20041111 G 2121 EM6039 BLOWER BEECH 90 E90 1152914 CE COCKPIT FAILED B A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 GL 09 999SE LW344 SMOKE IN COCKPIT CAUSED BY FAILED ELECTRICAL MOTOR ON VENT BLOWER ASSEMBLY. LOG BOOK WAS NOT AVAILABLE AT TIME OF INSTA LLATION, SO TOTAL TIME OF PART IS UNKNOWN. 1 L 7 2 3T 3A20 2005020100015 20050201 00015 CE 2005 2 1 4356 1 20041221 G 8011 EBB131A STARTER CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA ENGINE DESTROYED C O OTHER O OTHER TX TAXI/GRND HDL 1 NM 03 195 17274489 2115 ON ENGINE START, STARTER BENDIX DID NOT DISENGAGE. ALL BENDIX DRIVE ENGAGEMENT TEETH SHEARED AND DAMAGED ENGINE STARTER RING GEAR. TIME SINCE OVERHAUL BY KELLY AEROSPACE 195.0 1 H 7 1 3O 3 O NT 3A12 E274 2004051200028 20040512 00028 EA 2004 5 12 5040050504A 1 20040505 G 3241 6002504 SENSOR CNDAIR CL600 CL6002B16 1900305 EA WHEEL SPEED FAILED E S4WA K NONE L NO TEST IN INSP/MAINT 1 WP 07 807Z 5201 5040 OB FAIL LIGHT STAYED ON DURING ANTI-SKID TEST. TEST BOX SHOWED OUT LO FAIL. 2 L 7 2 4F RT A21EA 2004051200025 20040512 00025 EA 2004 5 12 5040050504B 1 20040505 G 5610 6003303025 WINDSHIELD CNDAIR CL600 CL6002B16 1900305 EA COCKPIT DELAMINATED E S4WA O OTHER O OTHER NR NOT REPORTED 1 WP 07 807Z 1104 5040 LT FWD WINDSHIELD DELAMINATED. 2 L 7 2 4F RT A21EA 2004050700003 20040507 00003 CE 2004 5 7 5266S 1 20040317 G 7830 2660016507 SUPPORT BEAM LEAR 60 60LEAR 5170707 CE THRUST REVERSER CRACKED B K NONE O OTHER IN INSP/MAINT 1 NM 07 601GG 192 LT AND RT THRUST REVERSER, THE SUPPORT BEAMS, ALSO KNOWN AS BIRD CAGES PN 266-0016-507 ARE CRACKING AT THE GUIDE ROD FEE D THROUGHS. THIS DISCREPANCY HAS BEEN OBSERVED ON THE FOLLOWING N620JF, 60-074, N114PJ, 60-114, N600GG 60-115, N91772 60-053, N60UU 60-007, N603SC 60-096, N415NP 60-024, N43NR 60-043, N601GG 60-192. AFTER INSTALLING THE NEW REPLACEMENT S UPPORT BEAM PN 288-0019-1 WE HAVE DISCOVERED NO CRACKS AT THE GUIDE ROD FEED THROUGHS 2 L 7 2 4F RT A10CE 2004091400182 20040914 00182 SW 2004 9 14 535062004 1 20040702 G 3510 CONTROL CABLE MOONEY M20 M20M 5870222 SW OXYGEN SYSTEM OBSTRUCTED B K NONE O OTHER IN INSP/MAINT 1 SW 17 12XL 270325 A RIVE NUT ON THE BRACKET HOLDING THE O2 CONTROL CABLE HAS CAUSED THE O2 CONTROL TO FAIL TO REACH ITS (FULL ON) POSITION . IF THE O2 CONTROL CABLE IS NOT SET AT (FULL ON) OR (FULL OFF) (IN OTHER WORDS, WHEN THE CONTROL IS IN-BETWEEN EITHER SETTING) THERE IS A LIKELIHOOD OF THE O2 BOTTLE EMPTYING ITS CONTENTS INTO THE TAILCONE IN A SHORT PERIOD OF TIME. THE C RUX OF THIS PROBLEM IS A RIVNUT PREVENTING FULL TRAVEL OF THE O2 CONTROL. THIS DEFECT COULD AFFECT MORE THAN ONE AIRCRAF T. 1 L 7 1 3O RT 2A3 2004022500024 20040225 00024 WP 2004 2 25 54017 2 20040112 G 7200 31026131 PLENUM DORNER DO228 DO228* EU GARRTT TPE331 TPE3315 01514 WP ENGINE CRACKED B DSCR K NONE O OTHER IN INSP/MAINT 1 GL 25 P39350 FOUND CRACKED AT IGNITER BOSS LOCATION. 1 H 7 2 4T 4 T RT A16EU E4WE 2004022500027 20040225 00027 WP 2004 2 25 54140 2 20040119 G 7200 310166811 PLENUM LEAR 35 31 5170530 CE GARRTT TPE331 TPE33110UG 01514 WP ENGINE CRACKED B DSCR K NONE O OTHER IN INSP/MAINT 1 GL 25 CGEMQ P63118 FOUND CRACKED AT THE PRIMARY FUEL NOZZLE BOSS. 2 L 7 2 4F 4 T RT A10CE E4WE 2004022500029 20040225 00029 WP 2004 2 25 54140A 2 20040119 G 7200 310166811 PLENUM JETAIR JETSTM JETSTM4101 1500501 EU GARRTT TPE331 TPE33110UG 01514 WP ENGINE CRACKED B DSCR K NONE O OTHER IN INSP/MAINT 1 GL 25 FOUND CRACKED AT DRAIN. 2 L 7 2 4T 4 T RT A41NM E4WE 2004050300162 20040503 00162 WP 2004 5 3 54148 2 20040119 G 7230 310166811 PLENUM GARRTT TPE331 TPE33110UG 01514 WP ENGINE CRACKED B DSCR K NONE O OTHER IN INSP/MAINT 1 GL 25 FOUND CRACKED AT DRAIN BOSS. 4 T E4WE 2004091400147 20040914 00147 2004 9 14 54951 4 20040720 G 3417 8220842421 ADC CNDAIR CL604 CL604 1900301 EA NR 2 FAILED C D RETURN TO BLOCK J WARNING INDICATION TX TAXI/GRND HDL 1 GL 17 495BA 13 5495 NR 2 AIR DATA COMPUTER (ADC) FAILED SHOWING ALTITUDE FLAG AND VERTICAL SPEED FLAG. MDC CODES 350-000812 AND 351-080112 , 351-0106F2. 2 L 7 2 4F RT A21EA 2005052400252 20050524 00252 EU 2005 5 24 62GX20281 1 20041122 G 3411 ST600R STATIC PORT ISRAEL GALAXY GALAXY 4500307 EU FUSLEAGE CORRODED D QRRR K NONE O OTHER IN INSP/MAINT 1 EA 13 62GX 2028 031 AIRCRAFT ADC (AIR DATA COMPUTER) - 200 FT SPLIT ON APPROACH TO LAND IN HEAVY RAIN. FOUND MOISTURE IN STATIC PORTS (4 EA ) DURING POST FLIGHT INSPECTION. CLOSER INSPECTION REVEALED CORROSION ON THE INTERIOR OF THE STATIC PORTS. EXISTING ST ATIC PORTS (ST600R) HAVE LARGER DIAMETER HOLES THAN THE REPLACEMENT STATIC PORTS WHICH MAY ALLOW WATER ENTRY. REPLACED STATIC PORTS WITH NEW ONES. NO FURTHER DEFECTS. (EA13200504025) (K) 2 L 7 2 4F RT A53NM 2004071900025 20040719 00025 CE 2004 7 19 6346753 1 20040707 G 2510 081278216 FRAME CESSNA 441 441 2076020 CE GARRTT TPE331 TPE33110 29053 NE MCAULY 4HFR34 4HFR34C660 NE SEAT BROKEN B K NONE O OTHER IN INSP/MAINT 1 NM 07 800AB 7844 4410162 CO-PILOTS BOTTOM WAS BROKEN IN THE REAR AT BOTH .2500 INCH AND .5000 INCH TUBES ON THE RT AND LT SIDE WHERE THE SIDE TUB ES ATTACH TO THE REAR CROSS PIECE AT THE GUSSETS. FORWARD CROSS PIECE TUBING WAS BROKEN AT THE LT SEAT ADJUSTMENT BRACKE TS AND CRACKED HALF WAY THROUGH AT THE RT ADJUSTMENT BRACKETS. 1 L 7 2 3T 4 T RT A28CE E4WE 5 C 3PNE 2004030100160 20040301 00160 CE 2004 3 1 6521 1 20040217 G 5420 505403042 BEAM CESSNA 421 421C 2076016 CE NACELLE CRACKED B K NONE O OTHER IN INSP/MAINT 1 SO 11 3922C 9480 93 421C0419 DURING VISUAL INSPECTION OF BOTH LT AND RT NACELLE STRUCTURES, CRACKS WERE OBSERVED ON BOTH NACELLE, AFT BEAMS ON THE TO P AND AFT, OB AREAS. FOLLOWING EVALUATION OF THIS STRUCTURE BY THIS INSPECTION CREW AND A LOCAL DER, IT WAS DETERMINED T HAT REPAIR OF THIS STRUCTURE IS NOT ECONOMICALLY FEASIBLE AND REQUIRES REPLACEMENT OF BOTH LT AND RT BEAM ASSEMBLIES, PR OVIDED BY MFG. CLOSE ATTENTION TO THIS AREA IS RECOMMENDED DURING AIRCRAFT INSPECTION. 1 L 7 2 3O A7CE 2004030100114 20040301 00114 CE 2004 3 1 6604 1 20040212 G 5343 07436062 FITTING CESSNA 182 182P 2075816 CE CONT O470 O470* 17026 SO NLG BROKEN B C ABORTED TAKEOFF E VIBRATION/BUFFET TO TAKEOFF 1 GL 11 7371Q 2737 18261011 ABORTED TAKEOFF AFTER LOUD NOISE HEARD ON TAKEOFF AND RUDDER KICKED FULL DEFLECTION. FOUND NOSE GEAR LOWER FITTING BROK EN IN TWO, INSPECT THIS FITTING CLOSELY AT ANNUAL. 1 H 7 1 3O 3 O NT TA13 E273 2004011200206 20040112 00206 GL 2004 1 12 7011203 1 20040106 G 2820 51020001 CONNECTOR CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO HARTZL HCJ3Y PHCJ3YF1 GL FUEL HOSE LOOSE B K NONE O OTHER IN INSP/MAINT 1 GL 15 975CW 124 0424 686724 FP1958B AIRCRAFT WAS IN FOR AN ANNUAL INSPECTION. A FUEL LEAK WAS NOTED AS A DISCREPANCY. FURTHER INVESTIGATION REVEALED THAT TH E ORIGIN OF THE LEAK WAS COMING FROM A HOSE/BULKHEAD FITTING CONNECTION ON THE FIREWALL. THE HOSE B-NUT WAS FOUND TO BE FINGER TIGHT. THE FITTING HAD BEEN TORQUE STRIPED BUT THE STRIPE WAS BROKEN. MAINTENANCE LOGS WERE REVIEWED BUT SHOWED N O WORK PERFORMED ON THE FUEL SYSTEM, HOWEVER A STARTER ADAPTOR HAD BEEN RECENTLY REPLACED. IMMEDIATE INVESTIGATION OF AN Y FUEL LEAK CANNOT BE OVERSTATED. THIS AIRCRAFT ALSO HAD A LOOSE FUEL PUMP ADJUSTMENT SCREW JAMB NUT. 1 L 7 1 3O 3 O NT A00009CH E3SO 5 C P36EA 2004051400112 20040514 00112 2004 5 14 705050704 4 20040504 G 3414 26465933 INDICATOR ISRAEL 1124 1124 4500102 EU GARRTT TFE731 TFE7313 01518 WP AIRSPEED ERRATIC E C ABORTED TAKEOFF M OVER TEMP TO TAKEOFF 1 SO 35 705AC 870 870 209 AIRCRAFT ABORTED TAKEOFF DUE TO A AIRSPEED INDICATION ANOMALY. BRAKES EXPERIENCED AN OVERHEAT. 2 M 7 2 4F 4 F A2SW E6WE 2004122900153 20041229 00153 NM 2004 12 29 7529S 1 20041119 G 5320 210056033 CHANNEL PIPER PA60 PA60601 7106010 NM FUSLEAGE CRACKED D O OTHER O OTHER NR NOT REPORTED 1 SO 19 7529S 3410 61016182 ON INSPECTION, FOUND PART CRACKED AT RIVET HOLES WHERE ATTACHED TO P/N 210056-031 CHANNEL. 1 M 7 2 3O RT A17WE 2004030400098 20040304 00098 CE 2004 3 4 8570000 1 20040227 G 2731 S3280 GEAR BEECH 1900 1900D 1154162 CE PWA PT6 PT6* 52043 EA ELEVATOR TRIM SLIPPED A JJBA K NONE O OTHER IN INSP/MAINT 1 EA 01 857CA 5662 UE403 WHILE CHECKING ELEVATOR TRIM FOR FCD BE2703 DISCOVERED ELEVATOR TAB DIAL MECHANISM MOUNT ASSY HAD SLIPPED CAUSING THE TR IM INDEX MARK CALIBRATION TO CHANGE. UPON FURTHER INSPECTION IT WAS DISCOVERED THAT THE SLIPPAGE WAS CAUSED BY A PRESSED ON GEAR IN THE ELEVATOR TAB DIAL MECHANISM MOUNT ASSY THAT HAD SLIPPED ON ITS SHAFT. 2 L 7 2 4T 3 T RT A24CE E2NE 2005011300062 20050113 00062 WP 2005 1 13 872SJ001 1 20041021 G 5330 SKIN DOUG DC8 DC871F 302199D WP ZONE 100 CORRODED B GKZR K NONE O OTHER IN INSP/MAINT 1 SW 11 872SJ 46040 LAV ACCESS SERVICE PANEL HAS CORROSION UNDER PAINT GBAMC NR 04161 AND NR 04185 UPON INVESTIGSTION FOUND SKIN TO BE OUT O F LIMITS BELOW LIP ON ACCESS DOOR, REMOVED DAMAGED SKIN AREA OF 1.75X9.00 FABED FILLER,FABED FINGER DOUBLER FOR BACK, FA B DOUBLER FOR EXTERNAL, INSTALLED SPLICE, INSIDE DOUBLER& OUTSIDE DOUBLER IAW COTNEY AEROSPACE DWG W93-RO3 REV.IR-CLOSED - 2 L 7 4 4F RT 4A25 2005011300041 20050113 00041 WP 2005 1 13 872SJ002 1 20041021 G 5330 SKIN DOUG DC8 DC871F 302199D WP FUSELAGE CORRODED B GKZR K NONE O OTHER IN INSP/MAINT 1 SW 11 872SJ 46040 A/C COMP AREA INTERIOR A/C OUTFLOW DUCT HAS CORROSION GBAMC NR 04160 CLEANED CORRISON ON INTERIOR A/C OUTFLOW DUCT PANEL IAW DC-8 SRM 51-1-8,CORRISON FOUND TO BE OUT OF LIMITS IAW DC-8 SRM 53-2-0. MATERIAL THICKNESS.130,MATERIAL LOSS .104 F ABED DOUBLER IAW COTNEY AEROSPACE INC. DWG W93-R02 REV IR AND INSTALLED DOUBLER AT STA 35 TO 55 AND L28R TO TO L30R IAW DC-8 SRM 51-1-21 SUPPORTED BY 8110-3. -CLOSED- 2 L 7 4 4F RT 4A25 2005022200226 20050222 00226 WP 2005 2 22 872SJ003 1 20041022 G 5248 DOOR DOUG DC8 DC871F 302199D WP CARGO BAY CORRODED B GKZR K NONE O OTHER UK UNKNOWN 1 SW 11 872SJ 46040 D-PIT, AFT BULKHEAD DOOR 645 CORRODED GBAMC NR#04172 CUT OUT DAMAGED MATERIAL ON D PIT DOOR AFT BULKHEAD DOOR 645 IAW DC -8 SRM 52-2-0 FIG 4 SHEET 2. FABRICATED DOUBLER PATCH OUT OF 7075T6 .032 AND INSTALLED DOUBLER PATCH ON D-PIT BULKHEAD DOOR IAW DC-8 SRM 52-2-0 FIG 4 SHEET 2. 2 L 7 4 4F RT 4A25 2004111000014 20041110 00014 WP 2004 11 10 872SJ004 1 20041022 G 5320 FLOOR SUPPORT DOUG DC8 DC871F 302199D WP FUSELAGE CORRODED B GKZR O OTHER O OTHER NR NOT REPORTED 1 SW 11 872SJ 46040 LT W/W LT SIDE UPPER, SECOND FLOOR SUPPORT HAS CORROSION ON LOWER SIDE. GBAMC NR04176 -OPEN- 2 L 7 4 4F RT 4A25 2004111000050 20041110 00050 WP 2004 11 10 872SJ005 1 20041022 G 5330 FINGER DOUBLER DOUG DC8 DC871F 302199D WP FUSELAGE CORRODED B GKZR O OTHER O OTHER NR NOT REPORTED 1 SW 11 872SJ 46040 CARGO AREA RT SIDE STA 960 HAS CORROSION UNDER FINGER DOUBLER UNDER FLOORBOARD. GBAMC NR04182 -OPEN- 2 L 7 4 4F RT 4A25 2004111000049 20041110 00049 WP 2004 11 10 872SJ006 1 20041027 G 5330 FINGER DOUBLER DOUG DC8 DC871F 302199D WP FUSELAGE CORRODED B GKZR K NONE O OTHER IN INSP/MAINT 1 SW 11 872SJ 46040 LT OB TOP SIDE OF WHEEL WELL PRESSURE DOGHOUSE BETWEEN STA 960 AND 980, FINGER DOUBLER HAS CORROSION ON FWD UNDERSIDE. G BAMC NR304186 -OPEN- 2 L 7 4 4F RT 4A25 2004111000048 20041110 00048 WP 2004 11 10 872SJ007 1 20041022 G 5310 STRUCTURE DOUG DC8 DC871F 302199D WP LT MLG WW CORRODED B GKZR K NONE O OTHER IN INSP/MAINT 1 SW 11 872SJ 46040 LT WW UPPER LT SIDE FWD AND AFT OF NR 6 FLOOR SUPPORT HAS CORROSION. GBAMC NR04178 -OPEN- 2 L 7 4 4F RT 4A25 2005022200267 20050222 00267 WP 2005 2 22 872SJ008 1 20041102 G 5320 GUSSET DOUG DC8 DC871F 302199D WP FUSELAGE CRACKED B GKZR K NONE O OTHER UK UNKNOWN 1 SW 11 872SJ 46040 RT UPPER GUSSET CRACKED AT STA XW5.000 GBAMC NR#04187. STOP DRILLED, FAB`D DOUBLER IAW DC-8 SRM. INSTALLED TOP AND BO TTOM DOUBLER IAW DC-8 SRM 51-1-21 AT STA XW5.000 2 L 7 4 4F RT 4A25 2004070600129 20040706 00129 CE 2004 7 6 A001ABB 1 20040618 G 2730 55653421 PUSHROD CESSNA 500 550 2076604 CE RT ELEVATOR BENT B DYCR K NONE O OTHER IN INSP/MAINT 1 GL 07 840MQ 427 RIGHT ELEVATOR PUSH ROD WAS INITIALLY REMOVED FROM THE AIRCRAFT WHEN IT WAS DISCOVERED DURING AN INSPECTION TASK THAT TH IS ROD WAS ASSEMBLED USING ALUMINUM RIVETS, SHOULD BE MONEL RIVETS PER THE TASK. UPON REMOVAL, INSPECTION PERSONNEL DIS COVERED THAT THIS ROD WAS BENT. REMOVAL OF LEFT ELEVATOR PUSHROD REVEALED THAT IT TOO WAS BENT - CORRECT RIVETS WERE IN STALLED. BENDS IN THESE RODS WERE NOT READILY APPARENT UNTIL REMOVAL FROM AIRCRAFT. TWO NEW RODS WERE ORDERED FROM CES SNA. ONE ROD ROLLED PERFECTLY STRAIGHT ON A SURFACE PLATE, THE OTHER APPEARED TO BE MIS-MANUFACTURED. THIS ROD WHILE N OT OBVIOUSLY BENT, OSCILLATED WHEN ROLLED ON THE SURFACE PLATE. THE FORMED END WITH A CLEVIS FORK INSTALLED WAS NOT FORM 1 L 7 2 4F A22CE 2005020800092 20050208 00092 GL 2005 2 8 AE0R200400002 2 20041221 G 7250 23076976 TURBINE BLADES EMB 145 EMB145LR 3260212 SO ALLSN AE300 AE3007A GL ENGINE FRACTURED B CHQA A UNSCHED LANDING Y ENGINE STOPPAGE NR NOT REPORTED 1 SO 03 279SK 591 145379 CAE311220 ENGINE S/N CAE311220 WAS DELIVERED TO SHOP FOR REPAIR 11/03/04 DUE TO IN-FLIGHT SHUTDOWN. DURING DISASSEMBLY, DAMAGE WA S NOTED TO THE TURBINE. ONE 1ST STAGE TURBINE BLADE WAS FRACTURED BELOW THE PLATFORM. 2 L 7 2 4T 4 F RT T00011AT TE6CH 2004122200169 20041222 00169 EU 2004 12 22 AE1 1 20041210 G 5520 STRUCTURE PILATS PC6T PC6B2H2 7090213 EU PWA PT6 PT6A27 52043 EA HARTZL HCB3T HCB3TN3 GL ELEVATOR FAILED P A UNSCHED LANDING O OTHER CL CLIMB 1 EA 25 7391U 15954 2028 PCE40186 BOA19977 FAILURE OF ELEVATOR ATTACH POINT AND OR HARDWARE. ACTUAL CAUSE IS UNKNOWN BECAUSE THE ELEVATOR HAS NOT BEEN LOCATED FOR RECOVERY. 1 H 7 1 3T 4 T 7A15 E4EA 6 C P15EA 2005081700058 20050817 00058 EU 2005 8 17 AE110304 1 20041103 G 2822 9A2045 CARTRIDGE UROCOP EC135 EC135P1 8680990 EU FUEL PUMP CRACKED B E80R O OTHER O OTHER NR NOT REPORTED 1 SW 07 THE PUMP WAS RECEIVED FROM THE OVERHAUL FACILITY TO THIS REPAIR STATION WITH THE IMPELLER CRACKED AND CRUSHED TO WHERE T HE PRESSURE AND FLOW OF THE FUEL WOULD BE DEGRADED. OTHER PUMPS RECEIVED HAD FOREIGN MATERIAL IN THE IMPELLER (DEBRIS A ND INSECT PARTS). QUALITY DEPARTMENT HAS BEEN NOTIFIED. (K) 1 G 7 2 3U O H88EU 2005022200016 20050222 00016 SW 2005 2 22 ALGA095160 1 20040607 G 6210 206015001119 BLADE BELL 206 206L1 1182107 SW MAIN ROTOR CORRODED B ALGA O OTHER O OTHER NR NOT REPORTED 1 AL 03 40LP 1162 45233 DURING ROUTINE A/F INSPECTION, CORROSION AND SEPARATION WAS NOTED ON LOWER SURFACE SKIN/SPAR INTERFACE IMMEDIATELY O/B O F GRIPFINGER. REPLACED W/SERVICABLE PART. 1 G 7 1 3U H2SW 2005021700127 20050217 00127 SW 2005 2 17 ALGA098260 1 20041206 G 6300 406310405101 UNIVERSAL BELL 407 407 1182206 SW M/R DRIVE WORN B ALGA O OTHER O OTHER NR NOT REPORTED 1 SW 03 457AL 666 53151 UNIVERSAL BEARING HAS AXIAL PLAY BEYOND LIMITS. REPLACED WITH NEW BY FIELD MAINTENANCE. 1 G 7 1 3U O H2SW 2005021700128 20050217 00128 SW 2005 2 17 ALGA098261 1 20041206 G 6300 406310405101 UNIVERSAL BELL 407 407 1182206 SW M/R DRIVE WORN B ALGA O OTHER O OTHER NR NOT REPORTED 1 SW 03 457AL 666 53151 UNIVERSAL HAS AXIAL PLAY BEYOND LIMITS. REPLACED WITH NEW BY FIELD MAINTENANCE. 1 G 7 1 3U O H2SW 2004051300025 20040513 00025 CE 2004 5 13 AMCR200400001 1 20040407 G 1420 MS3106E10SL3S CONNECTOR CESSNA 525 525A 2076615 CE WILINT FJ44 FJ44 66000 GL STROBE BURNED B AMCR K NONE O OTHER IN INSP/MAINT 1 GL 09 179DV 13 20122 525A0172 LT WINGTIP STROBE ASSEMBLY WAS INSTALLED 13 HOURS PRIOR IAW SB525A-33-02. WHEN STROBE FAILURE WAS NOTED, FOUND CONNECTOR SEVERELY BURNED, WITH ONE PIN COMPLETELY BURNED AWAY (ON POWER SUPPLY SIDE). POWER SUPPLY FAILED ALSO (MFG:FLIGHT COMPO NENTS AG). CHANGED POWER SUPPLY AND STROBE UNIT. 1 L 7 1 4F 4 F RT A1WI E3GL 2004083000046 20040830 00046 SO 2004 8 30 AMCR200400003 1 20040820 G 3250 41001 SOLENOID GULSTM GULSTM G1159 GIV 3980115 SO RROYCE TAY TAY6118 EU MLG SHORTED B AMCR O OTHER J WARNING INDICATION TX TAXI/GRND HDL 1 GL 09 251DV 19 505B 1522 UPON LOWERING THE LANDING GEAR, TWO CIRCUIT BREAKERS POPPED FOR THE NOSE STEERING. INVESTIGATION FOUND A SHORTED SOLENO ID VALVE IN THE STEERING SYSTEM. THE SOLENOID WAS SHORTED TO GROUND INTERNALLY. 2 L 7 2 4F 4 F RT A12EA E25NE 2004092000056 20040920 00056 EU 2004 9 20 AMCR200400004 1 20040909 G 3246 FUSIBLE PLUG AMD FALC90 FALCON900B 2730171 EU GARRTT TFE731 TFE7315BR WP WHEEL LEAKING B AMCR K NONE O OTHER IN INSP/MAINT 1 GL 09 523AC 3158 139 DURING A PREFLIGHT, FOUND TIRE PRESSURE TO BE DOWN SIGNIFICANTLY. INVESTIGATION FOUND ONE WHEEL FUSE PLUG TO BE LEAKING. WHEN FUSE WAS REMOVED, THERE APPEARED TO BE A SLIGHT DENT ON THE FACE OF THE FUSE, SIMILAR TO HANDLING DAMAGE. HISTORY SHOWS THIS TO BE AN ORIGINAL FUSE SINCE THE WHEEL WAS NEW. 2 L 7 3 4F 4 F RT E6WE 2004122900151 20041229 00151 SO 2004 12 29 AMCR200400005 1 20041103 G 2750 ROLLER GULSTM GV GULFSTREAMGV 3980116 SO RROYCE BR700 BR700710A110 NE TE FLAPS OUT OF POSITION B AMCR K NONE S AFFECT SYSTEMS LD LANDING 1 GL 09 524AC 686 AFTER LANDING, THE PILOT WAS NOT ABLE TO RAISE THE FLAPS FROM THE 39 DEGREE POSITION AND HAD ASSOCIATED CAS MESSAGES CON CERNING THE FLAP SYSTEM. VISUAL INSPECTION REVEALED THE FLAPS TO BE OVER-EXTENDED WHICH CAUSED EACH OB ROLLER TO BE OUT BEYOND THE FLAP TRACK. THE FLAP SHIFTED SLIGHTLY AND THE ROLLERS JAMMED BEHIND THE TRACK. BESIDES SOME ROLLERS EXHIBIT ING SOME WEAR, NO DAMAGE WAS FOUND. THE FLAPS WERE FULLY RIGGED IAW THE MM AND RETURNED TO SERVICE. NOTE: THE FLAP SYS TEM WAS PREVIOUSLY RIGGED A FEW WEEKS PRIOR FOR A CONDITION IN WHICH THE FLAPS APPEARED NOT TO FULLY STOW. 2 L 7 2 4F 4 F RT A12EA E00057EN 2005020100007 20050201 00007 SO 2005 2 1 AMCR200400006 1 20041213 G 2730 1159H4002811 ACTUATOR GULSTM G1159 GIV 3980115 SO HYD SYSTEM BYPASSING B AMCR O OTHER K J FLUID LOSS WARNING INDICATION CR CRUISE 1 GL 09 528GA 44 1528 JUST BEFORE DESCENT, CREW GOT A 3 BONG ANNUNCIATION "LOW COMBINED FLUID". ON HYDRAULICS SYNOPTIC PAGE, CREW NOTICED FLUI D MIGRATION FROM COMBINED SIDE TO FLIGHT SIDE, WITH "COMBINED" SYSTEM LOW AND "FLIGHT" SYSTEM HIGH. AN UNEVENTFUL LANDI NG TOOK PLACE, UPON SHUTDOWN, "FLIGHT" SYSTEM DUMPED FLUID OVERBOARD. INVESTIGATION TURNED UP NOTHING AND NUMEROUS CHE CKS WERE ACCOMPLISHED WITH NO MIGRATION NOTED. AIRCRAFT THEN FLEW BACK TO MANUFACTURER AND FLUID MIGRATION WAS NOTED AG AIN. MANUFACTURER FOUND THE 'ELEVATOR SERVO' ACTUATOR WAS BYPASSING INTERNALLY, AS WAS THE RT 'GROUND SPOILER' ACTUATOR AND 'FLIGHT POWER SHUTOFF VALVE' ALSO. AIRCRAFT WAS RETURNED TO SERVICE WITH NO FURTHER HYDRAULIC SYSTEM ANOMALIES. 2 L 7 2 4F RT A12EA 2004050300121 20040503 00121 2004 5 3 ANCF200400008 4 20040414 G 3436 4059845911 COMPUTER DOUG MD80 MD83 3023681 NM WINDSHEAR/GUIDAN INOPERATIVE W ANCF C ABORTED TAKEOFF J WARNING INDICATION TO TAKEOFF 1 SO 23 583AN 1635 53183 WINDSHEAR ALERT WAS PRESENTED TWO TIMES DURING TAKE OFF BEFORE REACHING 60 KTS. WINDSHEAR COMPUTER WAS REPLACED IAW AM M 34-47-00 PAG 201. TEST WINDSHEAR AND GUIDANCE SYSTEM WAS PERFORMED IAW AMM 34-47-00 PAG 201. 2 L 7 2 4F RT 2004081800171 20040818 00171 2004 8 18 ANCF200400027 4 20040812 G 3413 4067241863 INDICATOR DOUG MD80 MD83 3023681 NM PWA JT8 JT8D219 52053 NE RATE OF CLIMB FAILED W A UNSCHED LANDING O OTHER CL CLIMB 1 SO 23 632CT 49632 AFTER T/O THE LT RATE OF CLIMB IND FAIL. IAW AMM 34-14-01/201 THE VERTICAL SPEED INDICATOR LT POS. WAS REMOVED AND REPL ACED. OPS CHECKED ON GROUND, SATISFACTORY. 2 L 7 2 4F 4 F RT E9NE 2004102900005 20041029 00005 SO 2004 10 29 AOC04001 2 20040712 G 8530 AEC631397SN2A CYLINDER CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO ENGINE DAMAGED B R29R O OTHER J WARNING INDICATION CR CRUISE 1 SW 19 9802Z 23 U20606667 291297R FOLLOWING SEVERAL WRITE UPS CONCERNING HIGH CYLINDER TEMP, THE CYLINDERS WERE REMOVED AFTER EXTENSIVE TROUBLESHOOTING RE VEALED NO DEFECT. UPON INSPECTION OF THE CYLINDERS, IT WAS NOTED THAT THREE CYLINDERS HAD UNUSUAL CIRCULAR MARKS ON THE CYLINDER WALLS. ONE CYLINDER HAD CRACKING IN THE NICKEL PLATING AROUND ONE OF THE MARKS. NEW CONTINENTAL STEEL CYLINDERS WERE INSTALLED AND CYLINDER TEMP RETURNED TO NORMAL. REMOVED CYLINDERS SENT BACK TO MANUFACTURER. 1 H 7 1 3O 3 O A4CE E5CE 2004092000086 20040920 00086 SO 2004 9 20 AOC04002 2 20040721 G 8530 AEC631397SN2A CYLINDER CESSNA 206 TU206F 2073353 CE CONT O520 TSIO520C 17040 SO ENGINE DAMAGED B R29R O OTHER R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 SW 19 3160L 223 U20602815 217211R FOLLOWING SEVERAL WRITE UPS CONCERNING HIGH CYLINDER TEMP, THE CYLINDERS WERE REMOVED AFTER PREVIOUS LIKE PROBLEMS WITH ANOTHER AIRCRAFT. UPON INSPECTION OF THE CYLINDERS, IT WAS NOTED THAT THREE CYLINDERS HAD UNUSUAL CIRCULAR MARKS ON THE CYLINDER WALLS. NEW ECI CYLINDERS WERE INSTALLED AND CYLINDER TEMP RETURNED TO NORMAL. REMOVED CYLINDERS SENT BACK TO MA NUFACTURER. 1 H 7 1 3O 3 O A4CE E8CE 2004090800161 20040908 00161 CE 2004 9 8 AOC04003 1 20040722 G 2421 F424R ALTERNATOR CESSNA 206 U206G 2073356 CE ENGINE WORN B R29R K NONE O OTHER IN INSP/MAINT 1 SW 19 9938Z 170 U20606757 PILOT REPORTED ALTERNATOR SYSTEM FAILURE. FOUND ALTERNATOR FAN AND PULLEY TO HAVE EXCESSIVE SIDE PLAY AS WELL AS FORE AN D AFT PLAY ON THE ALTERNATOR SHAFT. SUSPECT FRONT BEARING FAILURE. 1 H 7 1 3O A4CE 2004083000202 20040830 00202 SO 2004 8 30 AOC04004 2 20040720 G 8530 AEC631397SN2A CYLINDER CESSNA 206 206CESSNA 2073302 CE CONT O520 IO520* 17032 SO ENGINE DAMAGED B R29R O OTHER M OVER TEMP CR CRUISE 1 SW 19 9811Z 34 U20606674 245523 AFTER REPORTS OF HIGH CYLINDER TEMP, CYLINDERS WERE REMOVED FOR INSPECTION. THREE CYLINDERS FOUND TO HAVE UNUSUAL MARKS ON THE ECI CYLINDER WALLS, SIMILAR TO TWO OTHER ENGINES WITH THE SAME PROBLEMS. CYLINDERS REPLACED WITH NEW ECI CYLINDER S AND CYLINDER TEMP RETURNED TO NORMAL. 1 H 7 1 3O 3 O A4CE E5CE 2004082300095 20040823 00095 SO 2004 8 23 AOC04005 2 20040728 G 8530 AEC631397SN71 CYLINDER CESSNA 206 206CESSNA 2073302 CE CONT O520 IO520A 17032 SO ENGINE CHIPPED B R29R K NONE O OTHER IN INSP/MAINT 1 SW 19 UPON RECEIVING INSPECTION OF NEW ECI CYLINDERS, ONE CYLINDER WAS FOUND TO HAVE THE NICKEL PLATING CHIPPED (.7500 INCH LO NG X .0312 INCH WIDE) AT THE BASE OF THE CYLINDER SKIRT. PACKAGING APPEARED TO BE ADEQUATE AND THE CYLINDER WAS NOT DROP PED. SUSPECT PROBLEM WITH NICKEL PLATING PROCESS. 1 H 7 1 3O 3 O A4CE E5CE 2005022200205 20050222 00205 CE 2005 2 22 AOC04006 1 20040818 G 2110 1015552119 COMPRESSOR BEECH 300 B300C 1152933 CE AIR CONDITIONER DAMAGED B R29R O OTHER O OTHER NR NOT REPORTED 1 SW 19 8230Q 81 FM3 PILOT REPORTED FREON AIR CONDITIONING SYSTEM INOPERATIVE FOLLOWING A FLIGHT. FOUND COMPRESSOR CLUTCH PLATE HAS SEPARATE D FROM THE COMPRESSOR AND WAS FOUND IN THE LOWER ENGINE COWL. FIRE SLEEVE ON OIL LINE FROM THE OIL COOLER HAD IMPACT DA MAGE (SLEEVE CUT) BUT NO DAMAGE TO THE OIL LINE. NO OTHER DAMAGE NOTED. 2 L 7 2 4T RT A24CE 2004033000163 20040330 00163 EU 2004 3 30 AUS20040001 1 20040103 G 3231 5322112082 ROD PILATS PC12 PC12 7090550 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL MLG DOOR SHEARED W O OTHER J WARNING INDICATION CL CLIMB 1 AU S (AUS) LT NOSE LANDING GEAR DOOR OPERATING ROD BROKEN IN AREA LOCATEDADJACENT TO LOWER WITNESS HOLES. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004033000164 20040330 00164 GL 2004 3 30 AUS20040002 3 20040104 G 6111 CLIP MCAULY CESSNA 206 U206F 2073333 CE CONT O520 IO520F 17032 SO MCAULY D3A34 D3A34C404 GL PROPELLER BLADE SEPARATED W K NONE O OTHER IN INSP/MAINT 1 AU S 1280 (AUS) PROPELLER BLADE ROOT CIRCLIP AND ASSOCIATED SHIMS SEPARATED. 1 H 7 1 3O 3 O A4CE E5CE 5 C P47GL 2004033000165 20040330 00165 NE 2004 3 30 AUS20040003 3 20040106 G 6110 4HFR34C652 PROPELLER SWRNGN SWRNGN SA227 SA227* SW GARRTT TPE331 TPE3312U 01514 WP MCAULY 4HFR34 4HFR34C652 NE PROPELLER LIGHTNING STRIKE W O OTHER C F.O.D. CR CRUISE 1 AU S 944 DC873B (AUS) LIGHTNING STRIKE ON RT PROPELLER AND RT FUSELAGE ADJACENT TO SAS VANE. SAS CIRCUIT BREAKER POPPED. DAMAGE TO RT P ROPELLER AND RT FUSELAGE CONSISTENT WITH LIGHTNING STRIKE. 2 L 7 2 4T 3 T RT A5SW E3WE 6 C 3PNE 2004033000166 20040330 00166 2004 3 30 AUS20040004 4 20040104 G 2210 4051601937 CONTROL PANEL BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU AUTOPILOT SYSTEM FAILED W O OTHER F FLT CONT AFFECTED CL CLIMB 1 AU S 90101410 (AUS) AUTOPILOT MODE CONTROL PANEL FAILED. 2 L 7 2 4F 4 F RT A16WE E21EU 2004033000167 20040330 00167 EA 2004 3 30 AUS20040005 2 20040104 G 7322 NEEDLE PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA SNSNCH 74D 74DM EA CARBURETOR STICKING W O OTHER E Y B VIBRATION/BUFFET ENGINE STOPPAGE SMOKE/FUMES/ODORS/SPARKS LD LANDING 1 AU S (AUS) FIRE IN ENGINE COWLS. SUSPECT CAUSED BY STICKING CARBURETOR NEEDLE AND SEAT CAUSING FLOODING OF ENGINE. EXCESS FUEL LEAKED INTO COWLS AND IGNITED. 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 2004033000169 20040330 00169 CE 2004 3 30 AUS20040006 1 20040107 G 5341 BB148 WASHER BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL LT & RT WING WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) LT AND RT WING LOWER ATTACHMENT BOLT WASHERS INCORRECTLY FITTED. DAMAGE TO BATHTUB FITTING. PERSONNEL/MAINTENANC E ERROR. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2004033000170 20040330 00170 EA 2004 3 30 AUS20040007 2 20040108 G 7414 103827991 ROTOR BENDIX BEECH 76 76 1153005 CE LYC O360 LO360A1G6 41514 EA HARTZL HCM2Y HCM2YR GL MAGNETO FAULTY W O OTHER O OTHER NR NOT REPORTED 1 AU S 274 9032476 (AUS) RT ENGINE MAGNETO ROTATING MAGNETIC SLIPPED ON SHAFT BY APPROXIMATELY 25 DEGREES. 1 L 7 2 3O 3 O A29CE 1E10 5 C P43GL 2004033000171 20040330 00171 NE 2004 3 30 AUS20040008 1 20040108 G 3230 2071235 BEARING RACE SKRSKY S76 S76C 8143008 NE TMECA ARRIEL ARRIEL1S 60030 NE MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LANDING GEAR INTERCONNECT ROD SPHERICAL BEARING INNER RACE CRACKED. FOUND DURING INSPECTION IAW AD/S-76/66 PT4. 1 G 7 2 3U 3 U NC H1NE E19EU 2004033000172 20040330 00172 CE 2004 3 30 AUS20040009 1 20040105 G 7120 26011895 SUPPORT CESSNA 208 208B 2073701 CE PWA PT6 PT6A114A 52043 NE HARTZL H3B3M HCB3M GL ENGINE MOUNT FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ENGINE SUPPORT HOUSING FOR AIR CONDITIONER DRIVE LEAKING OIL. INVESTIGATION FOUND THE SUPPORT HOUSING ALIGNMENT SP IGOT TO BE TOO LONG TO FIT INTO THE RECESS IN THE ENGINE MOUNT PAD. THESPIGOT BOTTOMS OUT ON THE SEAL CARRIER CAUSING A 0.33MM (0.013IN) GAP ON THE GASKET FLANGE. THE SPIGOT BOTTOMING ON THE PAD CAUSES EXCESSIVE WEAR ON THE DRIVE SHAFT SPLI NES PN 2601267-2 AND THE INTERNAL SPLINES ON THE DRIVE GEAR PNO 3100450-01. 1 H 7 1 3T 3 T A37CE E4EA 5 C P9NE 2004033000173 20040330 00173 NE 2004 3 30 AUS20040010 1 20040108 G 6210 7615009043050 CAP SKRSKY S76 S76C 8143008 NE TMECA ARRIEL ARRIEL1S 60030 NE MAIN ROTOR BLADE CRACKED W O OTHER O OTHER NR NOT REPORTED 1 AU S (AUS) MAIN ROTOR BLADE TIP CAP TOP SKIN CRACKED IN AREA ADJACENT TO THE ATTACHMENT DOUBLER. CRACK LENGTH 270MM (10.62IN) . TIP CAP HAD DISBONDED INTERNALLY FROM THE METAL DOUBLER ASSEMBLY AND THE KEVLAR SKIN HAD CRACKED AND DELAMINATED. 1 G 7 2 3U 3 U NC H1NE E19EU 2004033000174 20040330 00174 EU 2004 3 30 AUS20040011 1 20040110 G 5740 SD3230488XA ATTACH FITTING STBROS SD3 SD360 8100606 EU PWA PT6 PT6A67R 52043 NE HARTZL HCA6A HCA6A3 NE LT WING CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT WING STRUT FORWARD LOWER STRUT TO STUB WING ATTACHMENT LUG CORRODED ON AFT FACE. DEPTH OF CORROSION 3.327MM (0. 131IN) WHICH IS APPROXIMATELY 13 PERCENT OF THE FITTING THICKNESS. FOUND DURING INSPECTION IAW AD/SD3-60/48 AMDT2. 2 H 7 2 4T 4 T A41EU E26NE 6 C P14NE 2004033000175 20040330 00175 NM 2004 3 30 AUS20040012 1 20040101 G 2742 4012373817 ACTUATOR DHAV DHC8 DHC8202 2809007 NM PWA 120 PW123D 52152 NE HAMSTD 14SF 14SF23 NE STABILIZER FAULTY W O OTHER O OTHER NR NOT REPORTED 1 AU S (AUS) YAW DAMPER LINEAR ACTUATOR FAULTY. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004033000176 20040330 00176 EU 2004 3 30 AUS20040013 2 20040105 G 7200 CFM563C1 ENGINE BOEING 737 737376 NM CFMINT CFM56 CFM563C 13802 EU OVERHEATED W O OTHER M OVER TEMP NR NOT REPORTED 1 AU S 724786 (AUS) ENGINE EXCEEDED EGT LIMITS. EGT REACHED 938 DEGREES C. 2 L 7 2 4F 4 F RT A16WE E21EU 2004033000177 20040330 00177 NM 2004 3 30 AUS20040014 1 20040105 G 2781 189929 PROXIMITY SWITCH BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU SLATS FAULTY W O OTHER N FALSE WARNING CR CRUISE 1 AU S 196670 (AUS) NR 3 LEADING EDGE SLAT PROXIMITY SWITCH FAULTY. 2 L 7 2 4F 4 F RT A16WE E21EU 2004033000178 20040330 00178 2004 3 30 AUS20040015 4 20040114 G 6113 05502636 SUPPORT MCAULY CESSNA 172 172H 2072424 CE CONT O300 O300C 17022 SO MCAULY 1C172 1C172EM GL SPINNER CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 30 (AUS) PROPELLER SPINNER FORWARD SUPPORT CRACKED AROUND PROPELLER BOLT ATTACHMENT HOLES. SUPPORT HAD BEEN FITTED 30 HOU RS AGO DUE TO THE SAME PROBLEM WITH THE PREVIOUS SUPPORT. 1 H 7 1 3O 3 O NT 3A12 E253 5 N P910 2004033000186 20040330 00186 NM 2004 3 30 AUS20040016 1 20040113 G 3230 161A661143 SPRING BOEING 737 7377Q8 1384418 NM GE CFM56 CFM567B24 NE MLG UPLOCK MISSING W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT MAIN LANDING GEAR AFT UPLOCK SPRING MISSING. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004042900003 20040429 00003 NE 2004 4 29 AUS20040018 2 20040112 G 7210 5074T51G10 GEARBOX SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE ROTOL R375 R3754123F21 NE ENGINE UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) PROPELLER GEARBOX BYPASS PIN ACTIVATED. FOUND DURING INSPECTION IAW AD/CT7/10 (SB CT7-72-0453). METAL CONTAMINAT ION OF CHIP DETECTOR ALSO PRESENT. 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P17NE 2004042900004 20040429 00004 NM 2004 4 29 AUS20040019 1 20040114 G 2910 AN81510D COUPLING DHAV DHC8 DHC8315 2809010 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE HYD MANIFOLD FRACTURED W O OTHER K FLUID LOSS DE DESCENT 1 AU S (AUS) NR 2 HYDRAULIC SYSTEM PRESSURE MANIFOLD INLET UNION FRACTURED. LOSS OF HYDRAULIC FLUID. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004042900005 20040429 00005 SO 2004 4 29 AUS20040020 1 20040115 G 5540 63502000 HINGE PIPER PA28 PA28151 7102805 SO LYC O320 O320E3D 41508 EA MCAULY 1C160 1C160EGM GL RUDDER CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) UPPER RUDDER HINGE BRACKET CONTAINED SEVERE CORROSION EXTENDING TO APPROXIMATELY 50 PERCENT OF THE DEPTH OF THE BR ACKET. 1 L 7 1 3O 3 O 2A13 E274 5 N P910 2004042900006 20040429 00006 SO 2004 4 29 AUS20040021 1 20040115 G 7120 J961340 MOUNT PIPER PA28 PA28151 7102805 SO LYC O320 O320E3D 41508 EA MCAULY 1C160 1C160EGM GL ENGINE LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT LOWER ENGINE MOUNT LOOSE. 1 L 7 1 3O 3 O 2A13 E274 5 N P910 2004042900007 20040429 00007 NM 2004 4 29 AUS20040022 1 20040106 G 2621 EXTINGUISHER BOEING 747 747438 NM RROYCE RB211 RB211524G19 NE LAVATORY MISSING W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) CS41B TOILET WASTE DISPOSAL SYSTEM BUILT IN FIRE EXTINGUISHER MISSING. 2 L 7 4 4F 4 F RT A20WE E30NE 2004042900008 20040429 00008 NM 2004 4 29 AUS20040023 1 20040108 G 3397 J1 CONNECTOR BOEING 747 747438 NM RROYCE RB211 RB211524G19 NE OEU ARCED W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 AU S (AUS) OVERHEAD ELECTRONICS UNIT (OEU) 1-2-1 D7466 LOCATED AT DL2 HAD A DAMAGED J1 CONNECTOR. OVERHEATING OF UNIT CAUSED PLASTIC CONNECTOR TO MELT CAUSING SHORT CIRCUIT WITH ARCING AND SPARKING. 2 L 7 4 4F 4 F RT A20WE E30NE 2004042900009 20040429 00009 NM 2004 4 29 AUS20040024 1 20040118 G 3244 275Q221 TIRE BOEING 737 7377BX 13844D2 NM GE CFM56 CFM567B24 NE MLG SEPARATED W C ABORTED TAKEOFF O OTHER TO TAKEOFF 1 AU S (AUS) LT NOSE WHEEL TIRE TREAD SEPARATED. TCAS ANTENNA COVER RIPPED OFF AND FOUND ON RUNWAY. DAMAGE CAUSED TO NLG AIR/ GROUND SENSOR, BRACKETRY AND WIRING CONDUIT. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004042900010 20040429 00010 2004 4 29 AUS20040025 4 20040116 G 2210 AUTOPILOT SYS BOEING 737 737800* NM GE CFM56 CFM567B24 NE COCKPIT FAULTY W O OTHER F J FLT CONT AFFECTED WARNING INDICATION CR CRUISE 1 AU S (AUS) NEITHER AUTOPILOT WOULD TRIM THE AIRCRAFT. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004042900011 20040429 00011 EU 2004 4 29 AUS20040026 1 20040116 G 5270 WARNING LIGHT AIRBUS 330 A300* EU GE CF6 CF680 30025 NE CARGO DOOR ILLUMINATED W O OTHER J WARNING INDICATION CL CLIMB 1 AU S (AUS) FORWARD CARGO DOOR MESSAGE. LIMITED INFORMATION PROVIDED. 2 L 7 2 4F 4 F RT A26NM E13NE 2004042900012 20040429 00012 EU 2004 4 29 AUS20040027 1 20040118 G 2120 UNKNOWN AIRBUS 330 A330300 EU GE CF6 CF680 30025 NE GALLEY FUMES W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S (AUS) PLASTIC SMELLING FUMES IN REAR GALLEY. INVESTIGATION COULD FIND NO CAUSE FOR THE FUMES. 2 L 7 2 4F 4 F RT E13NE 2004042900013 20040429 00013 NM 2004 4 29 AUS20040028 1 20040118 G 5523 65C2638415A TRIM TAB BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU ELEVATOR LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ELEVATOR TAB FREE PLAY EXCEEDED MAXIMUM LIMIT OF 0.9144MM (0.036IN). FREE PLAY MEASURED 1.143MM (0.045IN). FOUND DURING INSPECTION IAW AD/B737/175 AND EI 737-55-12R5. 2 L 7 2 4F 4 F RT A16WE E21EU 2004042900014 20040429 00014 WP 2004 4 29 AUS20040029 2 20040119 G 7210 PLANETARY GEAR ISRAEL 1125 ASTRASPX 4500205 EU GARRTT TFE731 TFE7314R 01518 WP ENGINE VIBRATES W O OTHER E F VIBRATION/BUFFET FLT CONT AFFECTED DE DESCENT 1 AU S (AUS) RT ENGINE VIBRATION. INVESTIGATION FOUND THE VIBRATION CAME FROM THE PLANETARY GEARSET. 2 L 7 2 4F 4 F RT A16NM E6WE 2004042900015 20040429 00015 2004 4 29 AUS20040030 4 20040103 G 3418 C809072 TRANSDUCER DHAV DHC8 DHC8202 2809007 NM PWA 120 PW123D 52152 NE HAMSTD 14SF 14SF23 NE STALL WARNING FAILED W C ABORTED TAKEOFF F J FLT CONT AFFECTED WARNING INDICATION TO TAKEOFF 1 AU S (AUS) STALL WARNING VANE FAILED DUE TO FAULTY TRANSDUCER. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004042900016 20040429 00016 NM 2004 4 29 AUS20040031 1 20040120 G 2910 HOSE BOEING 737 737376 NM GE CFM56 CFM563B1 13802 NE HYD SYSTEM BURST W O OTHER K J FLUID LOSS WARNING INDICATION LD LANDING 1 AU S (AUS) LT MAIN LANDING GEAR DOWNLOCK ACTUATOR HYDRAULIC HOSE BURST. LOSS OF HYDRAULIC FLUID. 2 L 7 2 4F 4 F RT A16WE E2GL 2004042900017 20040429 00017 WP 2004 4 29 AUS20040032 1 20040120 G 3260 SWITCH GOVT N22 N24A 3880104 WP MLG FAILED W C ABORTED TAKEOFF O OTHER TO TAKEOFF 1 AU S (AUS) LT MAIN LANDING GEAR SWITCH FAILED AND WIRES BROKEN. LANDING GEAR OVERRAN EXTENSION AND JAMMED PREVENTING LANDING GEAR FROM BEING RETRACTED. 1 H 7 2 3T A7PC 2004042900018 20040429 00018 CE 2004 4 29 AUS20040033 1 20040120 G 3230 EVE4001 MOTOR BEECH 76 76 1153005 CE LYC O360 O360A1G6D EA HARTZL HCM2Y HCM2YR GL HYD PUMP FAULTY W O OTHER O OTHER LD LANDING 1 AU S 108 (AUS) LANDING GEAR HYDRAULIC PUMP ELECTRIC MOTOR FAULTY. INVESTIGATIONFOUND BROKEN WIRE IN THE MOTOR WINDINGS. 1 L 7 2 3O 3 O A29CE E286 5 C P43GL 2004042900019 20040429 00019 NE 2004 4 29 AUS20040034 3 20040118 G 6114 8173891 SEAL HAMSTD DHAV DHC8 DHC8202 2809007 NM PWA 120 PW123D 52152 NE HAMSTD 14SF 14SF23 NE PROP HUB FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S MFG950719 (AUS) PROPELLER HUB NR 3 BLADE SEAL LEAKING DUE TO FRACTURE OF SEALSPRING IN THE AREA ADJACENT TO THE WELDMENT. NR 2 BL ADE SEAL WAS ALSO REPLACED AS A PRECAUTION. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004042900020 20040429 00020 NM 2004 4 29 AUS20040035 1 20040121 G 2824 MA20A10011 ACTUATOR BOEING 737 737* NM GE CFM56 CFM567B24 NE FUEL TRANSFER STICKING W O OTHER J WARNING INDICATION CL CLIMB 1 AU S (AUS) FUEL CROSSFEED VALVE ACTUATOR FAILED. CROSSFEED VALVE STUCK IN THE OPEN POSITION. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004042900021 20040429 00021 SO 2004 4 29 AUS20040036 1 20040120 G 3241 396512 VALVE EMB 120 EMB120 3260201 SO PWA 118 PW118A NE HAMSTD 14SF 14SF9 NE ANTISKID SYS FAULTY W O OTHER O OTHER LD LANDING 1 AU S (AUS) LT IB BRAKE ANTISKID VALVE SUSPECT FAULTY. BRAKE LOCKED ON LANDING CAUSING FAILURE OF BRAKE UNIT AND DEFLATION OF MAIN WHEEL TIRE. 2 L 7 2 4T 4 T RT A31SO E20NE 6 N P11NE 2004042900022 20040429 00022 CE 2004 4 29 AUS20040037 1 20040121 G 5744 58244659 BRACKET CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCB3T HCB3TN5 GL AILERON CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT WING OB AILERON ATTACHMENT BRACKET CRACKED. INVESTIGATION FOUND INDICATIONS OF SURFACE INTERGRANNULAR CORROSIO N AND CONFIRMATION OF A CRACK LOCATED APPROXIMATELY 3.175MM (0.125IN) BEHIND THE BEARING HOUSING. CRACK LENGTH APPROXIMA TELY 12.7MM (0.5IN). 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P15EA 2004042900023 20040429 00023 NM 2004 4 29 AUS20040038 1 20040122 G 2752 7341529001 ACTUATOR BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL TE FLAP FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) TRAILING EDGE FLAP POWER DRIVE UNIT BYPASS VALVE ROTARY ACTUATOR FAULTY. INVESTIGATION FOUND THE ROTARY ACTUATOR PURPLE INDICATION ARM PIVOT RETAINING PIN ADRIFT AND CAUSING INTERFERENCE BETWEEN THE ACTUATOR DRIVE AND ACTUATOR HOUSIN G. 2 L 7 2 4F 4 F RT A1NM E23EA 2004042900024 20040429 00024 NM 2004 4 29 AUS20040039 1 20040123 G 7830 CF680C2 THRUST REVERSER BOEING 747 747438 NM GE CF6 CF680C2* GL ENGINE FAILED W O OTHER E VIBRATION/BUFFET LD LANDING 1 AU S (AUS) NR 3 AND NR 4 ENGINE THRUST REVERSERS FAILED TO OPERATE. SUSPECT CAUSED BY FROZEN LINE TO PILOT VALVE. LOCAL TEMP ERATURE WAS 15 DEGREES F (-9.5 DEGREES C). BOTH THRUST REVERSERS OPERATED SATISFACTORY FOLLOWING HEATING AND RECYCLING OF CIRCUIT BREAKER. NR 1 ENGINE THRUST REVERSER WAS ALREADY LOCKED OUT. 2 L 7 4 4F 4 F RT A20WE E23EA 2004042900025 20040429 00025 2004 4 29 AUS20040040 4 20040123 G 2215 6225734002 SERVO EMB 120 EMB120 3260201 SO PWA 118 PW118A NE HAMSTD 14RF 14RF9 NE AUTOPILOT FAULTY W O OTHER F FLT CONT AFFECTED DE DESCENT 1 AU S 3902 (AUS) AUTOPILOT CAUSED AIRCRAFT TO PITCH UP ON APPROACH. INVESTIGATION FOUND ELEVATOR AUTOPILOT SERVO FAULTY. RT ENGIN E OVERTORQUED TO 134 PERCENT AND LT ENGINE OVERTORQUED TO 125 PERCENT DURING RECOVERY FROM AUTOPILOT MALFUNCTION. 2 L 7 2 4T 4 T RT A31SO E20NE 6 C P11NE 2004042900026 20040429 00026 NM 2004 4 29 AUS20040041 1 20040124 G 2710 256T34304 GEARBOX BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL AILERON CONTROL FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 7860 (AUS) RT INBOARD AILERON ANGLE GEARBOX FAULTY. 2 L 7 2 4F 4 F RT A1NM E23EA 2004042900027 20040429 00027 NM 2004 4 29 AUS20040042 1 20040122 G 2781 SENSOR BOEING 737 737376 NM GE CFM56 CFM563B1 13802 NE LE SLATS OUT OF ADJUST W O OTHER F J FLT CONT AFFECTED WARNING INDICATION AP APPROACH 1 AU S (AUS) LEADING EDGE FLAP NR 2 EXTEND SENSOR OUT OF ADJUSTMENT. 2 L 7 2 4F 4 F RT A16WE E2GL 2004031500001 20040315 00001 NM 2004 3 15 AUS20040043 1 20040117 G 5210 723D1009 ACTUATOR BOEING 747 747438 NM RROYCE RB211 RB211524* NE PAX DOOR INTERMITTENT W O OTHER J WARNING INDICATION CR CRUISE 1 AU S 34991 (AUS) RT UPPER DECK DOOR FLIGHT LOCK ACTUATOR INTERMITTENT IN OPERATION. ACTUATOR INTERMITTENTLY UNLOCKS DOOR HANDLE. 2 L 7 4 4F 4 F RT A20WE E12EU 2004031500006 20040315 00006 CE 2004 3 15 AUS20040044 1 20040127 G 5740 35115050602 ATTACH FITTING BEECH 36 A36 1151604 CE CONT O520 IO520B 17032 SO MCAULY 2A36C 2A36C23 GL RT WING CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT WING UPPER AFT ATTACHMENT FITTING CORRODED. MAXIMUM DEPTH OF CORROSION 1.27MM (0.050IN). FOUND DURING INSPECT ION IAW AD. 1 L 7 1 3O 3 O 3A15 E5CE 5 C P880 2004031500007 20040315 00007 NM 2004 3 15 AUS20040045 1 20040123 G 5210 PIN BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL PAX DOOR OUT OF ADJUST W O OTHER J WARNING INDICATION CR CRUISE 1 AU S (AUS) L1 FORWARD ENTRY DOOR CRACKED OPEN IN FLIGHT WITH HANDLE MOVING APPROXIMATELY HALF WAY UP. INVESTIGATION FOUND T HE DOOR LOCK SENSOR LATCH PIN TO BE 0.762MM (0.030IN) OUT OF LIMITS. 2 L 7 2 4F 4 F RT A1NM E23EA 2004031500008 20040315 00008 2004 3 15 AUS20040046 4 20040122 G 3418 C809072 TRANSDUCER DHAV DHC8 DHC8202 2809007 NM PWA 120 PW123D 52152 NE HAMSTD 14SF 14SF23 NE STALL WARNING STICKING W O OTHER N FALSE WARNING TO TAKEOFF 1 AU S (AUS) RT STALL WARNING SYSTEM TRANSDUCER STICKING IN FORWARD POSITION. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004031500009 20040315 00009 SW 2004 3 15 AUS20040047 1 20040130 G 5330 2722197002 DOUBLER SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP HARTZL HCB3T HCB3TN5 GL FUSELAGE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE DOUBLER LOCATED AT RT EMERGENCY EXITS, BADLY CORRODED. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P15EA 2004031500010 20040315 00010 NM 2004 3 15 AUS20040048 1 20040129 G 5310 65056131 DOOR FRAME BOEING 727 7272J4 1384006 NM PWA JT8 JT8D17 52049 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) AFT CARGO DOOR CUTOUT FRAME LOCATED AT BS 1090 RIB BL28 CRACKED. CRACK LENGTH 8.255MM (0.325IN). 2 L 7 3 4F 4 F RT A3WE E2EA 2004061000075 20040610 00075 GL 2004 6 10 AUS20040050 2 20040129 G 7250 6890040 SHIELD ALLSN 250C20R HUGHES 369 369E 4470707 WP ALLSN 25OC 250C20R GL TURBINE SECTION CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 1231 CAT36291 (AUS) FIRST STAGE TURBINE NOZZLE SHIELD CRACKED AROUND 90 PERCENT OF RADIUS. ONE PIECE OF SHIELD ABOUT THE SIZE OF A 50 CENT PIECE DISLODGED AND WAS FOUND SITTING IN THE BOTTOM OF THE COMBUSTION LINER. 1 G 7 1 3U 3 U H3WE E4CE 2004061000076 20040610 00076 SW 2004 6 10 AUS20040052 1 20040125 G 6320 70061L275W210A HOSE BELL 412 412 1182202 SW PWA PT6T PT6T3B 52045 NE MAIN ROTOR GB LEAKING W O OTHER K J FLUID LOSS WARNING INDICATION DE DESCENT 1 AU S (AUS) MAIN TRANSMISSION OIL HOSE LEAKING. FURTHER INVESTIGATION FOUND THE HOSE WAS CHAFING IN THE AREA UNDER THE IDENTIF ICATION TAG. 1 G 7 2 4U 4 U H4SW E22EA 2004061000081 20040610 00081 NE 2004 6 10 AUS20040053 2 20040128 G 7261 4074T58P09 O-RING SAAB SF340 SF340A 7850100 EU GE CT7TP CT75A2 30030 NE ROTOL R375 R3754123F21 NE ENGINE OIL LEAKING W O OTHER K J FLUID LOSS WARNING INDICATION CL CLIMB 1 AU S 853 (AUS) LT ENGINE POWER TURBINE (C) SUMP COVER O-RING SEAL LEAKING. 2 L 7 2 4T 4 T RT A52EU E8NE6 6 C P17NE 2004061000093 20040610 00093 CE 2004 6 10 AUS20040054 1 20040114 G 2910 P40791 VALVE LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE731* 01518 WP HYD SYS FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT HYDRAULIC SHUTOFF VALVE FAULTY. INVESTIGATION FOUND DIODE SPLICE D5100 OPEN CIRCUITED. 2 L 7 2 4F 4 F RT T00008WI E6WE 2004061000108 20040610 00108 GL 2004 6 10 AUS20040055 2 20040128 G 7200 695686 ENGINE BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL RIGHT FAILED W O OTHER E VIBRATION/BUFFET NR NOT REPORTED 1 AU S 6242 (AUS) RT ENGINE FAILED TO START. FURTHER INVESTIGATION FOUND N2 SHAFT NOT BEING DRIVEN BY N2 GEARBOX. INVESTIGATION IS CONTINUING. 2 L 7 2 4F 4 F RT A1NM E23EA 2004061000109 20040610 00109 CE 2004 6 10 AUS20040056 1 20040123 G 3252 35825145 DAMPER BEECH 76 76 1153005 CE LYC O360 O360A1G6D EA HARTZL HCM2Y HCM2YR GL NLG FAULTY W O OTHER F FLT CONT AFFECTED LD LANDING 1 AU S 478 (AUS) NOSE WHEEL SHIMMY DAMPER END CAP RETAINING CIRCLIP MISSING. 1 L 7 2 3O 3 O A29CE E286 5 C P43GL 2004061000110 20040610 00110 CE 2004 6 10 AUS20040058 1 20040202 G 5554 10164001417 HINGE BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA HARTZL HCB4M HCB4MP3 GL RUDDER TAB CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RUDDER CENTER HINGE CONTAINED EXFOLIATION CORROSION IN THE HINGE BRACKET WEB. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2004061000111 20040610 00111 2004 6 10 AUS20040059 4 20040203 G 3416 5934PAM1 ALTIMETER REIMS 406 F406 7535723 EU PWA PT6 PT6A112 52043 NE MCAULY 3G34C7 3GFR34C701 GL COCKPIT FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ALTIMETER FITTED TO AIRCRAFT WITH INCORRECT ALTITUDE RANGE. PERSONNEL/MAINTENANCE ERROR. 1 L 7 2 3T 3 T RT A54EU E4EA 5 C P60GL 2004061000112 20040610 00112 2004 6 10 AUS20040060 4 20040203 G 3416 5035P ALTIMETER REIMS 406 F406 7535723 EU PWA PT6 PT6A112 52043 NE MCAULY 3G34C7 3GFR34C701 GL COCKPIT FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ALTIMETER FITTED TO AIRCRAFT WITH INCORRECT ALTITUDE RANGE. PERSONNEL/MAINTENANCE ERROR. 1 L 7 2 3T 3 T RT A54EU E4EA 5 C P60GL 2004061000113 20040610 00113 EU 2004 6 10 AUS20040061 1 20040203 G 3610 3925308 VALVE FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE PNEUMATIC SYS FAULTY W O OTHER O OTHER CL CLIMB 1 AU S 1884 (AUS) PNEUMATIC SYSTEM SHUTOFF VALVE FAULTY. LIMITED INFORMATION PROVIDED. 2 L 7 2 4F 4 F RT E25NE 2004061000114 20040610 00114 CE 2004 6 10 AUS20040062 1 20040116 G 2910 S217840095A HOSE CESSNA 210 210M 2073450 CE CONT O520 IO520L 17032 SO MCAULY D3A34 D3A34C404 GL MLG DOOR ACT FAILED W O OTHER K FLUID LOSS LD LANDING 1 AU S (AUS) NOSE LANDING GEAR DOOR ACTUATOR HOSE FAILED. LOSS OF HYDRAULIC FLUID. 1 H 7 1 3O 3 O 3A21 E5CE 5 C P47GL 2004061000115 20040610 00115 EA 2004 6 10 AUS20040063 2 20040128 G 8530 EXHAUST VALVE NEWZE FU24 FU24954 6280102 WP LYC O720 IO720A1B 41546 EA HARTZL HCC3Y HCC3YR GL ENGINE STICKING W O OTHER E K VIBRATION/BUFFET FLUID LOSS CR CRUISE 1 AU S 1367 (AUS) NR 2 CYLINDER REAR PUSHROD COVER BENT AND LEAKING OIL. SUSPECT CAUSED BY STICKING EXHAUST VALVE. 1 L 7 1 3O 3 O A9PC 1E15 5 C P25EA 2004061000116 20040610 00116 CE 2004 6 10 AUS20040064 1 20040203 G 1420 606171 CONNECTOR BEECH 76 76 1153005 CE LYC O360 O360A1G 41514 EA HARTZL HCM2Y HCM2YR GL ENGINE CONTAMINATED W O OTHER E VIBRATION/BUFFET CL CLIMB 1 AU S (AUS) RT ENGINE INSTRUMENT CLUSTER CONNECTOR CONTAMINATED. 1 L 7 2 3O 3 O A29CE E286 5 C P43GL 2004061000117 20040610 00117 EU 2004 6 10 AUS20040065 1 20040205 G 2612 HARNESS BAG BAE146 BAE146300A 1500267 EU LYC ALF502 ALF502* 41580 EA FIRE DETECTION FAULTY W O OTHER N FALSE WARNING CL CLIMB 1 AU S (AUS) NR 4 ENGINE FIRE WARNING SYSTEM WIRING HARNESS FAULTY. 2 H 7 4 4F 4 F RT A49EU E6NE 2004061000118 20040610 00118 EU 2004 6 10 AUS20040066 1 20040203 G 7931 IPTE1191000200D1 SENSOR SAAB SF340 SF340A 7850100 EU GE CT7TP CT75A2 30030 NE ROTOL R389 R3894123F25 NE ENGINE OIL PRESS FAULTY W O OTHER N FALSE WARNING CL CLIMB 1 AU S (AUS) LT ENGINE PROPELLER GEARBOX OIL PRESSURE SENSOR FAULTY. 2 L 7 2 4T 4 T RT A52EU E8NE6 6 C P30NE 2004061000119 20040610 00119 EU 2004 6 10 AUS20040067 1 20040202 G 3710 687751710 HOSE PARTEN P68 P68B 6780104 EU LYC O360 IO360A1G6 41514 EA HARTZL HCC2Y HCC2YK2 GL VACUUM DIST DISTORTED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) VACUUM HOSE KINKED. DISTORTION WAS LOCATED ON FRAME F AT THE TOP FRONT LT DOOR FRAME AND WAS CAUSED BY THE BEND RA DIUS BEING TOO SMALL AFTER PASSING OVER THE FRAME. PERSONNEL/MAINTENANCE ERROR. 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 2004061000120 20040610 00120 NE 2004 6 10 AUS20040068 2 20040205 G 7261 311136401 PLUG DHAV DHC8 DHC8201 2809001 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE ENGINE OIL MISSING W O OTHER B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 AU S (AUS) NR 2 ENGINE BREATHER IMPELLER SHAFT COUPLING STOP/PLUG ASSEMBLYAND RETAINING RING MISSING. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004061000121 20040610 00121 CE 2004 6 10 AUS20040069 1 20040113 G 3411 FITTING CESSNA 206 U206A 2073316 CE CONT O520 IO520F 17032 SO MCAULY 3A32C D3A32C90 GL PITOT/STATIC SYS IMPROPER PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) STATIC SYSTEM T FITTING UNAPPROVED PART. FITTING WAS A COMMERCIAL PRODUCT. PERSONNEL/MAINTENANCE ERROR. UNAPPROV ED PART. 1 H 7 1 3O 3 O A4CE E5CE 5 C P21EA 2004061000122 20040610 00122 2004 6 10 AUS20040070 4 20040204 G 3452 8221338002 TRANSPONDER BOEING 737 7377BX 13844D2 NM GE CFM56 CFM567B24 NE ATC FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ATC TRANSPONDER FAILED SELF TEST. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004061000123 20040610 00123 2004 6 10 AUS20040071 4 20040125 G 2300 TH2507JJ1 CONTROLLER REIMS 406 F406 7535723 EU PWA PT6 PT6A112 52043 NE MCAULY 3G34C7 3GFR34C701 GL COMMUNICATIONS FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S (AUS) COMMUNICATION SYSTEM CONTROL BOX FAILED. 1 L 7 2 3T 3 T RT A54EU E4EA 5 C P60GL 2004061000124 20040610 00124 2004 6 10 AUS20040072 4 20040104 G 2565 BATTERY BOEING 767 767* NM RROYCE RB211 RB211524* NE ESCAPE SLIDE DISCHARGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NR 3R DOOR ESCAPE SLIDE EMERGENCY LIGHTING FAILED TO ILLUMINATE. INVESTIGATION FOUND THE BATTERY FLAT. 2 L 7 2 4F 4 F RT A1NM E12EU 2004061000125 20040610 00125 CE 2004 6 10 AUS20040073 1 20040210 G 5753 052390114 ARM CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA MCAULY 1C160 1C160DTM GL TE FLAP CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FLAP SUPPORT ARM TO FLAP SUPPORT ARM RIB RIVETS MISSING DUE TO CORROSION. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2004061000126 20040610 00126 CE 2004 6 10 AUS20040074 1 20040105 G 8011 DRIVE GEAR CESSNA 150 A152 2071836 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL ENGINE STARTER STRIPPED W K NONE O OTHER IN INSP/MAINT 1 AU S 154 (AUS) ENGINE STARTER MOTOR DRIVE GEAR TEETH STRIPPED. 1 H 7 1 3O 3 O 3A19 E223 5 N P50GL 2004061000127 20040610 00127 EA 2004 6 10 AUS20040075 2 20040205 G 7322 105267 CARBURETOR CESSNA 150 A152 2071836 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL FUEL CONTROL FAULTY W O OTHER E VIBRATION/BUFFET CL CLIMB 1 AU S 62 (AUS) CARBURETOR FAULTY. 1 H 7 1 3O 3 O 3A19 E223 5 N P50GL 2004061000128 20040610 00128 CE 2004 6 10 AUS20040076 1 20040211 G 5711 SPAR CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCB3T HCB3TN5 GL LT WING DEBONDED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT WING SPAR WEB DISBONDED IN AREA LOCATED AT CWS 57. 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P15EA 2004061000129 20040610 00129 CE 2004 6 10 AUS20040077 1 20040205 G 2497 WIRE HARNESS CESSNA 210 210M 2073450 CE CONT O520 IO520L 17032 SO MCAULY D3A34 D3A34C404 GL DC POWER DISTRIB BURNED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WIRING LOOM CHAFED AND BURNED BY ELEVATOR COUNTERWEIGHT. 1 H 7 1 3O 3 O 3A21 E5CE 5 C P47GL 2004061000130 20040610 00130 CE 2004 6 10 AUS20040078 1 20040211 G 3210 12411171 LANDING GEAR CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO MCAULY 3A32C D3A32C90 GL MAINS COLLAPSED W O OTHER O OTHER TX TAXI/GRND HDL 1 AU S (AUS) LT MAIN LANDING GEAR LEG COLLAPSED. THE LEG WAS A NEWLY FITTED ITEM AND FAILED 530MM (20.8IN) FROM THE IB TIP OF THE LEG. AIRCRAFT TAILPLANE, ELEVATOR, WINGTIP AND POD DAMAGED. 1 H 7 1 3O 3 O A4CE E5CE 5 C P21EA 2004061000131 20040610 00131 NM 2004 6 10 AUS20040080 1 20040206 G 2910 HYDRAULIC SYSTEM BOEING 737 737376 NM GE CFM56 CFM563B1 13802 NE HYDRAULIC SYSTEM LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S (AUS) HYDRAULIC SYSTEM LEAKING. 2 L 7 2 4F 4 F RT A16WE E2GL 2004061000132 20040610 00132 EA 2004 6 10 AUS20040081 2 20040210 G 7322 MA4SPA CARBURETOR LYC PIPER PA28 PA28151 7102805 SO LYC O320 O320D3G 41508 EA SNSNCH 74DM M74DM EA FUEL CONTROL ICED W O OTHER E Y VIBRATION/BUFFET ENGINE STOPPAGE LD LANDING 1 AU S DC2950 (AUS) ENGINE FAILED DURING LANDING. SUSPECT CAUSED BY CARBURETOR ICING. 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 2004061000133 20040610 00133 CE 2004 6 10 AUS20040082 1 20040203 G 2434 DOFF10300B ALTERNATOR CESSNA 150 A152 2071836 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL DC SYSTEM FAILED W O OTHER H ELECT. POWER LOSS-50 PC CL CLIMB 1 AU S 207 (AUS) ALTERNAOR FAILED. 1 H 7 1 3O 3 O 3A19 E223 5 N P50GL 2004061000134 20040610 00134 SO 2004 6 10 AUS20040083 1 20040204 G 2710 3866003 FITTING PIPER PIPER PA44 PA44180 7104402 SO LYC O360 O360E1A6 41514 EA HARTZL HCC2Y HCC2YR2 GL AILERON CONTROL LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S NA (AUS) LT AND RT AILERON CONTROL ROD ATTACHMENT FITTINGS, LOOSE. 1 L 7 2 3O 3 O A19S0 E286 5 C P920 2004061000136 20040610 00136 EA 2004 6 10 AUS20040084 2 20040207 G 8520 LW11997 SEAL HUGHES 269 269C 4470504 WP LYC O360 HIO360C1A 41514 EA CRANKSHAFT WORN W K NONE E K VIBRATION/BUFFET FLUID LOSS CR CRUISE 1 AU S (AUS) ENGINE CRANKSHAFT SEAL LEAKING. INVESTIGATION FOUND SEAL HAD DISINTEGRATED AROUND THE SEALING LIP. 1 G 7 1 3O 3 O 4H12 1E10 2004061000137 20040610 00137 EA 2004 6 10 AUS20040085 2 20040208 G 8520 LW11997 SEAL HUGHES 269 269C 4470504 WP LYC O360 HIO360D1A 41514 EA CRANKSHAFT WORN W O OTHER E K VIBRATION/BUFFET FLUID LOSS CR CRUISE 1 AU S (AUS) ENGINE CRANKSHAFT SEAL LEAKING. INVESTIGATION FOUND SEAL HAD DISINTEGRATED AROUND THE SEALING LIP. THIS IS A REPLA CEMENT SEAL AFTER THE SEAL FAILURE IN MDR 04/0084. 1 G 7 1 3O 3 O 4H12 1E10 2004061000146 20040610 00146 NM 2004 6 10 AUS20040086 1 20040206 G 2740 AR6460M2 ACTUATOR BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU STAB CONTROL FAULTY W O OTHER F J FLT CONT AFFECTED WARNING INDICATION CR CRUISE 1 AU S (AUS) STABILIZER TRIM ACTUATOR FAULTY. 2 L 7 2 4F 4 F RT A16WE E21EU 2004061000148 20040610 00148 EU 2004 6 10 AUS20040087 1 20040205 G 6123 1310176 VALVE SAAB SF340 SF340A 7850100 EU GE CT7TP CT75A 30030 NE ROTOL R354 R3544123F13 NE PROP FEATHERING FAULTY W C ABORTED TAKEOFF E J VIBRATION/BUFFET WARNING INDICATION TO TAKEOFF 1 AU S (AUS) RT ENGINE PROPELLER FEATHER SOLENOID VALVE FAULTY. VALVE WAS SLOWLY BLEEDING PCU PRESSURE. 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P61GL 2004061000149 20040610 00149 EU 2004 6 10 AUS20040088 1 20040211 G 3242 1597400 ROTOR CLEVELAND PILATS PC12 PC12 7090550 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL BRAKE BROKEN W O OTHER O OTHER TX TAXI/GRND HDL 1 AU S 1229 (AUS) RT BRAKE ROTOR BROKEN INTO TWO PIECES WITH ONE PIECE LODGING BETWEEN THE BRAKE ASSEMBLY AND WHEEL. ON DISASSEMBLY IT WAS NOTED THAT THE ROTOR HAD BEEN BROKEN FOR SOME TIME. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004061000150 20040610 00150 NE 2004 6 10 AUS20040089 3 20040206 G 6110 4HFR34C652 PROPELLER SWRNGN SA227 SA227* SW GARRTT TPE331 TPE33112UHR WP MCAULY 4HFR34 4HFR34C652 NE LT & RT FAULTY W O OTHER O OTHER NR NOT REPORTED 1 AU S (AUS) LT AND RT PROPELLERS FAULTY. BOTH ENGINES OVERTEMPED. 2 L 7 2 4T 4 T RT A5SW E4WE 6 C 3PNE 2004061000152 20040610 00152 CE 2004 6 10 AUS20040090 1 20040102 G 8011 643109 SPRING CONT CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO MCAULY 3A32C D3A32C90 GL ENGINE STARTER BROKEN W O OTHER O OTHER NR NOT REPORTED 1 AU S (AUS) ENGINE STARTER ADAPTER CLUTCH SPRING TANG BROKEN OFF CAUSING SPRING TO SLIP ON GEAR. BROKEN PIECE OF SPRING FOUN D IN BASE OF STARTER ADAPTER. 1 H 7 1 3O 3 O A4CE E5CE 5 C P21EA 2004061000153 20040610 00153 EU 2004 6 10 AUS20040091 1 20040209 G 3246 5006227 WHEEL SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE ROTOL R375 R3754123F21 NE NLG VIBRATES W O OTHER E VIBRATION/BUFFET NR NOT REPORTED 1 AU S (AUS) NOSE LANDING GEAR WHEELS VIBRATING. INVESTIGATION COULD FIND NO OBVIOUS DEFECTS BUT REPLACED THE NOSE WHEELS AND SERVICED THE SHIMMY DAMPER. THE AIRCRAFT WAS THEN RETURNED TO SERVICE WITH NO FURTHER DEFECTS REPORTED. 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P17NE 2004061000154 20040610 00154 CE 2004 6 10 AUS20040092 1 20040203 G 5730 8135105 SKIN BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A42 52043 NE HARTZL HCD4N3 HCD4N3A GL LT WING DELAMINATED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT WING INNER LEADING EDGE SKIN DELAMINATING IN AREA LOCATED ABOVE THE BYPASS DUCT. 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2004061000155 20040610 00155 CE 2004 6 10 AUS20040093 1 20040205 G 3230 CIRCUIT BREAKER BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A42 52043 NE HARTZL HCD4N3 HCD4N3A GL MLG TRIPPED W O OTHER J WARNING INDICATION DE DESCENT 1 AU S (AUS) RT MAIN LANDING GEAR WOULD NOT EXTEND. CIRCUIT BREAKER (60AMP)FOUND TRIPPED. CB RESET AND RETRACTION TESTS CARRI ED OUT WITH NO REOCCURANCE. 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2004061000156 20040610 00156 2004 6 10 AUS20040094 4 20040210 G 6122 661001002 GOVERNOR SAAB SF340 SF340A 7850100 EU GE CT7TP CT75A 30030 NE ROTOL R354 R3544123F13 NE PROPELLER FAULTY W O OTHER J WARNING INDICATION NR NOT REPORTED 1 AU S (AUS) RT PROPELLER OVERSPEED GOVERNOR HAD AN INTERMITTENT FAULT. 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P61GL 2004061000157 20040610 00157 EU 2004 6 10 AUS20040095 1 20040212 G 2450 6TC210 CIRCUIT BREAKER BAC 146 146100A 1500260 EU LYC ALF502 ALF502R5 41580 NE AC POWER FAILED W O OTHER H B ELECT. POWER LOSS-50 PC SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S (AUS) RT WINDSCREEN HEAT CIRCUIT BREAKER OVERHEATED CAUSING LOSS OF AC POWER AND SMOKE IN THE COCKPIT. WIRING, BUSBAR AND CB LA5 LOCATED ADJACENT TO CB ALSO REPLACED DUE TO DAMAGE. 2 H 7 4 4F 4 F RT A49EU E6NE 2004061000158 20040610 00158 CE 2004 6 10 AUS20040096 1 20040206 G 5311 FRAME BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A42 52043 NE HARTZL HCB3T HCB3TN3 GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE FRAME LOCATED AT RF 265-760 CRACKED IN AREA ADJACENT TO FLOORBEAM. FOUND DURING INSPECTION IAW AD/BEECH 200/65. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2004061000159 20040610 00159 NM 2004 6 10 AUS20040097 1 20040209 G 2761 65448517 ACTUATOR BOEING 737 737376 NM GE CFM56 CFM563B1 13802 NE DRAG CONTROL CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S (AUS) NR 4 GROUND SPOILER OB ACTUATOR BODY CRACKED AND LEAKING IN AREA NEXT TO RETRACT FITTING. 2 L 7 2 4F 4 F RT A16WE E2GL 2004061000160 20040610 00160 NM 2004 6 10 AUS20040098 1 20040210 G 2730 BEARING BOEING 737 737376 NM GE CFM56 CFM563B1 13802 NE ELEVATOR CONTROL SEIZED W K NONE F FLT CONT AFFECTED IN INSP/MAINT 1 AU S (AUS) ELEVATOR CONTROL CENTERING UNIT MOUNT BEARING SEIZED. 2 L 7 2 4F 4 F RT A16WE E2GL 2004061000161 20040610 00161 EU 2004 6 10 AUS20040099 1 20040212 G 7712 02597 SWITCH FOKKER F27 F27MK500 4990629 EU RROYCE DART DART531 EU ROTOL R4304 R1934304 EU ENGINE FAULTY W O OTHER E J VIBRATION/BUFFET WARNING INDICATION CR CRUISE 1 AU S 736 (AUS) RT ENGINE LOW TORQUE SWITCH FAULTY. WORKSHOP INVESTIGATION FOUND THE FOLLOWING DEFECTS WITH THE SWITCH: SLIGHT DISTORTION ON SWITCH BASE SWITCH CAP O'RING GROOVES SCORED. PIN TERMINAL ASSEMBLY HAD CORROSION ON PINS. 2 H 7 2 4T 4 T A817 E297 6 C P899 2004061500019 20040615 00019 NE 2004 6 15 AUS20040100 2 20040214 G 7200 3038400 ENGINE DHAV DHC8 DHC8202 2809007 NM PWA 120 PW123D 52152 NE HAMSTD 14SF 14SF23 NE LEFT LEAKING W O OTHER K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 AU S PCE123314 (AUS) LT ENGINE OIL LEAK EVIDENT IN P2.5 CAVITY. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004061000178 20040610 00178 NE 2004 6 10 AUS20040101 2 20040216 G 7230 3035569 IMPELLER EMB 120 EMB120 3260201 SO PWA 118 PW118A NE HAMSTD 14RF 14RF9 NE ENG COMPRESSOR DAMAGED W O OTHER E B VIBRATION/BUFFET SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 AU S (AUS) LT ENGINE LP IMPELLER BADLY DAMAGED. FURTHER INSPECTION ALSO FOUND SEVERE DAMAGE TO THE HP IMPELLER AS WELL AS TH E GAS GENERATOR CASE AND THE LP DIFFUSER CASE. A DENT WAS ALSO FOUND IN THE COMBUSTION CHAMBER OUTER LINER. SUSPECT CA USED BY FOD. 2 L 7 2 4T 4 T RT A31SO E20NE 6 C P11NE 2004061000179 20040610 00179 NE 2004 6 10 AUS20040102 2 20040211 G 7250 3053094CL SHROUD BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A42 52043 NE MCAULY 4HFR34 4HFR34C754 NE TURBINE SECTION DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT ENGINE TURBINE SHROUD AND BLADES DAMAGED. 1 L 7 2 4T 4 T A24CE E4EA 6 C 3PNE 2004061000180 20040610 00180 SO 2004 6 10 AUS20040103 1 20040205 G 5312 62444005 BULKHEAD PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA SNSNCH 74D 74DM EA FUSELAGE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE BULKHEAD CORRODED IN AREA BENEATH VERTICAL FIN FRONT ATTACHMENT PLATE AND STRINGER HAT ASSEMBLY ATTACHMEN T AREA. 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 2004061000181 20040610 00181 SO 2004 6 10 AUS20040104 1 20040205 G 3222 35123002 FORK PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA SNSNCH 74D 74DM EA NLG CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NOSE LANDING GEAR FORK CONTAINED INTERGRANNULAR CORROSION IN ATTACHMENT AREA. 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 2004061000184 20040610 00184 SW 2004 6 10 AUS20040105 1 20040122 G 5711 129579 SPAR BBAVIA 7 7EC 2110120 SW LYC O235 O235C1 41505 EA AMTR C8289 C8289 GL RT WING CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT WING FRONT AND REAR SPARS CRACKED. CRACKS APPEAR TO ALIGN WITH THE ATTACHMENT FITTING BOLT HOLES. SPARS ARE CO NSTRUCTED FROM TIMBER. FOUND DURING INSPECTION IAW AD/CHA/23 AMDT4. 1 H 7 1 3O 3 O A759 E223 5 N EXPP5N 2004061000185 20040610 00185 EU 2004 6 10 AUS20040106 1 20040217 G 2434 5243212137 DRIVE SHAFT PILATS PC12 PC12 7090550 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL DC GENERATOR WORN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NR 2 GENERATOR DRIVESHAFT WORN AT INNER (FORWARD) BEARING AREA. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004061000186 20040610 00186 SW 2004 6 10 AUS20040107 1 20040102 G 5302 SKIN BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL TAILBOOM CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) TAILBOOM CRACKED IN LOWER SKIN TO UPPER SKIN ATTACHMENT RIVET LINE LOCATED ON AFT RT SIDE. 1 G 7 1 3U 3 U H2SW E4CE 2004061500020 20040615 00020 NM 2004 6 15 AUS20040108 1 20040211 G 4930 82830105139 PIPE DHAV DHC8 DHC8202 2809007 NM PWA 120 PW123D 52152 NE HAMSTD 14SF 14SF23 NE APU FUEL WORN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) APU GRAVITY FUEL FEED LINE CHAFED. DEPTH OF DAMAGE 0.0508MM (0.002IN). FOUND DURING INSPECTION IAW AD/DHC-8/093 ( SB8-49-019). 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004061000187 20040610 00187 EU 2004 6 10 AUS20040109 1 20040213 G 2910 1379305A155 HOSE BAG JETSTM JETSTM3201 1500217 EU GARRTT TPE331 TPE33112UA 01514 WP MCAULY 4HFR34 4HFR34C653 NE HYD SYSTEM FAILED W O OTHER K F FLUID LOSS FLT CONT AFFECTED DE DESCENT 1 AU S (AUS) RT MAIN LANDING GEAR UPLOCK FLEXIBLE HOSE FAILED. LOSS OF HYDRAULIC FLUID. 2 L 7 2 4T 4 T RT A56EU E4WE 6 C 3PNE 2004061000189 20040610 00189 NM 2004 6 10 AUS20040111 1 20040213 G 5270 SWITCH BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE DOOR WARNING SYS OUT OF ADJUST W O OTHER N FALSE WARNING NR NOT REPORTED 1 AU S (AUS) MAIN CARGO DOOR NR 1 AND NR 7 LATCH INDICATOR MICROSWITCHES OUT OF ADJUSTMENT. 2 L 7 3 4F 4 F RT A3WE E2EA 2004061000191 20040610 00191 EU 2004 6 10 AUS20040112 1 20040215 G 2120 ODOR AIRBUS A330 A330* EU GE CF6 CF680 30025 NE CABIN DETECTED W O OTHER B SMOKE/FUMES/ODORS/SPARKS DE DESCENT 1 AU S (AUS) ELECTRICAL ODOR IN CABIN IN AREA OF SEAT 48JK. INVESTIGATION CONTINUING. 2 L 7 2 4F 4 F RT A46NM E13NE 2004061000192 20040610 00192 EU 2004 6 10 AUS20040113 1 20040219 G 6730 SC5072 SERVO SNIAS 350 AS350B 8680801 EU TMECA ARRIEL ARRIEL1D NE TAIL ROTOR FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 200 (AUS) TAIL ROTOR SERVO FAULTY. INVESTIGATION FOUND ALTHOUGH FULL TAIL ROTOR PEDAL CONTROL WAS AVAILABLE, THE ACTUATOR G AVE LIMITED OUTPUT. 1 G 7 1 3U 3 U H9EU E19EU 2004061000193 20040610 00193 CE 2004 6 10 AUS20040114 1 20040213 G 8011 D083645 GEAR LYC CESSNA 150 A152 2071836 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL ENGINE STARTER BROKEN W O OTHER O OTHER NR NOT REPORTED 1 AU S D083645 (AUS) STARTER MOTOR BENDIX DRIVE GEAR DISINTEGRATED. ENGINE RING GEAR TEETH DAMAGED. 1 H 7 1 3O 3 O 3A19 E223 5 N P50GL 2004061000205 20040610 00205 CE 2004 6 10 AUS20040115 1 20040218 G 5311 10144009133 FRAME BEECH 200 B200C 1152924 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE FRAMES (3OFF) LOCATED AT STN 285.188, STN 278.5 AND STN291.875 CRACKED. FRAME PART NUMBERS PN 101-440091- 33, PN 101-440090-27 AND PN 101-440092-31. FOUND DURING INSPECTION IAW AD. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2004061000206 20040610 00206 CE 2004 6 10 AUS20040116 1 20040216 G 8011 PM2401H MOTOR LYC CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA MCAULY IC235 IC235LFA7570 EA ENGINE STARTER FAILED W O OTHER O OTHER NR NOT REPORTED 1 AU S 85035913 (AUS) ENGINE STARTER MOTOR BENDIX DRIVE WOULD NOT ENGAGE. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P12EA 2004061000208 20040610 00208 EA 2004 6 10 AUS20040118 2 20040220 G 7313 73772 NOZZLE LYC PARTEN P68 P68B 6780104 EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YR2 GL FUEL INJECTOR BLOCKED W O OTHER O OTHER CR CRUISE 1 AU S (AUS) NR 4 CYLINDER FUEL INJECTOR NOZZLE BLOCKED. 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 2004061000209 20040610 00209 NM 2004 6 10 AUS20040119 1 20040224 G 6310 A1902 DRIVE BELT ROBSIN R22 R22BETA 7640110 NM LYC O320 O320B2C 41508 EA ENGINE/XMSN DISTORTED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ENGINE TO TRANSMISSION DRIVE BELTS STRETCHED. 1 G 7 1 3O 3 O H10WE E274 2004061000210 20040610 00210 CE 2004 6 10 AUS20040120 1 20040202 G 5312 8050 STRUCTURE BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A42 52043 NE MCAULY 4HFR34 4HFR34C754 NE BULKHEAD CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) REAR PRESSURE BULKHEAD CLEAT LOCATED AT STRINGER 7L AND BULKHEAD BEAM AT STRINGER 6L CRACKED. FOUND DURING INSPECT ION IAW AD. 1 L 7 2 4T 4 T A24CE E4EA 6 C 3PNE 2004061000212 20040610 00212 SW 2004 6 10 AUS20040121 1 20040220 G 2731 2742004003 ACTUATOR SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP HARTZL HCB3T HCB3TN5 GL ELEVATOR TAB FAULTY W O OTHER O OTHER NR NOT REPORTED 1 AU S (AUS) PITCH TRIM ACTUATOR SLIPPING. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P15EA 2004061000213 20040610 00213 SW 2004 6 10 AUS20040122 1 20040224 G 2740 27043062009 BRACKET SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP HARTZL HCB3T HCB3TN5 GL STABILIZER CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) HORIZONTAL STABILIZER PITCH TRIM ACTUATOR UPPER ATTACHMENT BRACKET CRACKED. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P15EA 2004061000214 20040610 00214 NM 2004 6 10 AUS20040123 1 20040224 G 3230 BACH8A06EE0260T HOSE BOEING 737 737376 NM GE CFM56 CFM563B1 13802 NE MLG LEAKING W O OTHER K FLUID LOSS NR NOT REPORTED 1 AU S (AUS) RT MAIN LANDING GEAR ACTUATOR UP LINE LEAKING DUE TO CHAFING ON B SYSTEM LOW PRESSURE RETURN LINE. ENGINE DRIVEN PUMP FAILED AND RETURN FILTERS CONTAMINATED. 2 L 7 2 4F 4 F RT A16WE E2GL 2004061000216 20040610 00216 SW 2004 6 10 AUS20040124 1 20040224 G 2752 2736053001 ACTUATOR SWRNGN SA227 SA227* SW GARRTT TPE331 TPE33112UHR WP MCAULY 4HFR34 4HFR34C652 NE TE FLAPS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT WING TRAILING EDGE FLAP ACTUATOR HOUSING CRACKED AND LEAKING FROM A HAIRLINE FRACTURE AT THE END OF THE HOUSING . 2 L 7 2 4T 4 T RT A5SW E4WE 6 C 3PNE 2004061000217 20040610 00217 CE 2004 6 10 AUS20040125 1 20040219 G 2497 WIRE CESSNA 310 310R 2074245 CE CONT O520 IO520M 17032 SO MCAULY 3AF32C 3AF32C87 GL LT WING MISROUTED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WIRING IN BOTH LT AND RT WINGS CONTACTING FUEL VENT LINES LOCATED AT WS 145. PERSONNEL/MAINTENANCE ERROR. 1 L 7 2 3O 3 O 3A10 E5CE 5 C P22EA 2004061000218 20040610 00218 EA 2004 6 10 AUS20040126 2 20040224 G 7322 105235 VALVE LYC O540J3C5 CESSNA 182 R182 2072734 CE LYC O540 O540J3C5 41532 EA MCAULY 2D34C B2D34C214 GL FUEL CONTROL SEPARATED W K NONE O OTHER IN INSP/MAINT 1 AU S 75113808 (AUS) CARBURETOR ACCELERATOR PUMP DISCHARGE CHECK VALVE LOOSE AND SEPARATED. 1 H 7 1 3O 3 O RT 3A13 E295 5 C P7EA 2004061000220 20040610 00220 NM 2004 6 10 AUS20040127 1 20040224 G 2120 61B600051155 BLANKET BOEING 747 747338 NM RROYCE RB211 RB211524D419 54555 NE AIR DISTRIBUTION DETERIORATED W K NONE B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S (AUS) APU DUCT INSULATION BLANKET BURNED AND IN POOR CONDITION. 2 L 7 2 4F 4 F RT A20WE E12EU 2004061000225 20040610 00225 CE 2004 6 10 AUS20040128 1 20040224 G 3260 SWITCH CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCB3T HCB3TN5 GL MLG OUT OF ADJUST W O OTHER N FALSE WARNING CL CLIMB 1 AU S (AUS) LT MAIN LANDING GEAR UPLOCK SWITCH OUT OF ADJUSTMENT. MICROSWITCH WAS SWITCHING OFF LOADING VALVE BUT NOT THE IN TRANSIT LIGHT. INVESTIGATION FOUND SOME WEAR IN THE SWITCH WHICH AFFECTED ADJUSTMENT. 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P15EA 2004061000226 20040610 00226 EU 2004 6 10 AUS20040129 1 20040226 G 1430 HC554H0074000 BOLT BAG BAE146 BAE146300A 1500267 EU LYC ALF502 ALF502R5 41580 NE RUDDER STRUCTURE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RUDDER FIXED HINGE BOLT CRACKED UNDER BOLT HEAD. BOLT IS LOCATED AT VERTICAL STABILISER RIB 5. CRACK LENGTH 2.2 86MM (0.090IN). FOUND DURING NDT INSPECTION. 2 H 7 4 4F 4 F RT A49EU E6NE 2004061000227 20040610 00227 NE 2004 6 10 AUS20040130 1 20040225 G 7170 0174078010 DRAIN VALVE SKRSKY S76 S76C 8143008 NE TMECA ARRIEL ARRIEL1S 60030 NE ENGINE LEAKING W O OTHER K FLUID LOSS LD LANDING 1 AU S (AUS) ENGINE START DRAIN VALVE LEAKING DUE TO ORING SEAL FAILURE. 1 G 7 2 3U 3 U NC H1NE E19EU 2004061000229 20040610 00229 CE 2004 6 10 AUS20040131 1 20040225 G 2910 4529101060001 PIPE LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE7312 01518 WP HYDRAULIC SYSTEM FRACTURED W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S (AUS) HYDRAULIC PRESSURE LINE LOCATED IN RT ENGINE PYLON AREA FRACTURED AND LEAKING IN AREA OF RINGLOK SWAGE ON UPPER EN D OF THE LINE. 2 L 7 2 4F 4 F RT T00008WI E6WE 2004061000238 20040610 00238 NM 2004 6 10 AUS20040132 1 20040226 G 7120 UL22991 LINK RROYCE RB211524G BOEING 747 747438 NM RROYCE RB211 RB211524G19 NE ENGINE MOUNT DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) AFT ENGINE FAIL SAFE LINK ASSEMBLY DAMAGED. RT AFT ATTACHMENT HARDWARE VERY LOOSE AND NUT WAS NOT SECURED BY SPLIT PIN. FOLLOWING DISASSEMBLY OF THE FAIL SAFE LINK IT WAS FOUND THAT THE LP TURBINE SUPPORT TO WHICH THE LINK WAS ATTACHE D WAS ALSO DAMAGED WITH THE ATTACHMENT HOLE BEING ELONGATED AND FRETTING DAMAGE CAUSED BY THE LINK. ATTACHMENT BUSHING A ND BOLT BOTH BADLY WORN. 2 L 7 4 4F 4 F RT A20WE E30NE 2004061000239 20040610 00239 EU 2004 6 10 AUS20040133 1 20040206 G 5711 SPAR CAP PARTEN P68 P68B 6780104 EU LYC O360 IO360A1G6 41514 EA HARTZL HCC2Y HCC2YK2 GL LT WING CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) REAR WING SPAR BOTTOM SPAR CAP CRACKED IN AREA OF LT SIDE WING ATTACHMENT. CRACK LENGTH 6MM (0.236IN). FOUND DURIN G EDDY CURRENT INSPECTION. 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 2004061000240 20040610 00240 CE 2004 6 10 AUS20040134 1 20040114 G 3230 50450107 TORQUE TUBE CESSNA 310 310Q 2074242 CE CONT O470 IO470V 17026 SO MCAULY 3AF32C 3AF32C87 GL MLG BROKEN W O OTHER O OTHER LD LANDING 1 AU S (AUS) LT MAIN LANDING GEAR TORQUE TUBE BROKEN. 1 L 7 2 3O 3 O 3A10 3E1 5 C P22EA 2004061000241 20040610 00241 SO 2004 6 10 AUS20040135 1 20040228 G 2721 6345703 ARM PIPER PA32 PA32300 7103212 SO LYC O540 IO540K1A5 41532 EA HARTZL HCC3Y HCC3YR GL RUDDER TAB CRACKED W O OTHER F FLT CONT AFFECTED NR NOT REPORTED 1 AU S (AUS) RUDDER TRIM ARM ASSEMBLY SEPARATED FROM RUDDER PEDAL BAR. 1 L 7 1 3O 3 O A3SO 1E4 5 C P25EA 2004061000243 20040610 00243 EA 2004 6 10 AUS20040136 2 20040227 G 7322 252434710 FUEL CONTROL HUGHES 269 269C 4470504 WP LYC O360 HIO360D1A 41514 EA ENGINE FAULTY W O OTHER E Y VIBRATION/BUFFET ENGINE STOPPAGE DE DESCENT 1 AU S 272 (AUS) ENGINE FUEL CONTROL UNIT FAULTY. INVESTIGATION FOUND PRESSURE ON THE MIXTURE ARM CHANGED THE FUEL FLOW RATE CAUSI NG THE ENGINE TO STOP. 1 G 7 1 3O 3 O 4H12 1E10 2004061400001 20040614 00001 2004 6 14 AUS20040137 4 20040229 G 2215 065001501 SERVO REIMS 406 F406 7535723 EU PWA PT6 PT6A112 52043 NE MCAULY 3G34C7 3GFR34C701 GL AUTOPILOT SYS FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) AUTOPILOT ROLL SERVO CAPSTAN FOUND IN PIECES ON AIRCRAFT FLOOR. SIX FASTENEING SCREWS FOUND IN CLOSE PROXIMITY TO THE SERVO MOUNT. 1 L 7 2 3T 3 T RT A54EU E4EA 5 C P60GL 2004061400002 20040614 00002 SO 2004 6 14 AUS20040138 1 20040222 G 5313 LONGERON PIPER PA18 PA18150 7101828 SO LYC O320 O320A2B 41508 EA SNSNCH 74DM M74DM EA FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) UPPER LT LONGERON TUBE CRACKED IN AREA BETWEEN FORWARD WELD OF LT REAR STABILIZER SUPPORT AND FORWARD WELD OF CROS S BRACE TUBE. 1 H 7 1 3O 3 O 1A2 E274 5 N P88614 2004061400003 20040614 00003 NE 2004 6 14 AUS20040139 3 20040223 G 6111 8173881 SEAL HAMSTD DHAV DHC8 DHC8315 2809010 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE PROPELLER BLADE UNSERVICEABLE W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 20030212 (AUS) RT PROPELLER NR 3 BLADE SEAL BADLY SPLIT AND SPRING DISTORTED. NR 1 AND NR 4 BLADE SEALS BROKEN WITH SIGNS OF DIS TORTION. SEALS WERE FOUND TO HAVE INCORRECT SPRINGS FITTED. LT PROPELLER NR 2 AND NR 3 BLADE SEALS ALSO DAMAGED DUE TO F IT OF INCORRECT SPRINGS. UNAPPROVED PART. PERSONNEL/MAINTENANCE ERROR. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004061400004 20040614 00004 NM 2004 6 14 AUS20040140 1 20040228 G 3244 277A6000454 TIRE BOEING 737 737* NM GE CFM56 CFM563B1 13802 NE NLG SEPARATED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT NOSE WHEEL TIRE TREAD SEPARATING. APPROXIMATELY 100MM (4IN) OF TREAD SEPARATED. 2 L 7 2 4F 4 F RT A16WE E2GL 2004061400005 20040614 00005 NM 2004 6 14 AUS20040141 1 20040229 G 2824 405744 ACTUATOR BOEING 737 737376 NM CFMINT CFM56 CFM563C 13802 EU TRANSFER VALVE FAILED W K NONE K J FLUID LOSS WARNING INDICATION IN INSP/MAINT 1 AU S 3842 (AUS) FUEL CROSSFEED VALVE ACTUATOR FAILED. 2 L 7 2 4F 4 F RT A16WE E21EU 2004061400006 20040614 00006 EA 2004 6 14 AUS20040142 2 20040302 G 7414 10400553 BEARING CONT SOCATA TB10 TB10TOBAGO 8680696 EU LYC O360 O360A1A 41514 EA HARTZL HCC2Y HCC2YK1 GL MAGNETO FAILED W O OTHER E VIBRATION/BUFFET TX TAXI/GRND HDL 1 AU S B259305G (AUS) MAGNETO DRIVE SHAFT OUTER BEARING COMPLETELY DESTROYED. BEARING HAD BEEN RUNNING DRY FOR SOME TIME. SUSPECT MAGN ETO ASSEMBLED WITHOUT GREASE IN THE BEARING. PERSONNEL/MAINTENANCE ERROR. 1 L 7 1 3O 3 O RT A51EU E286 5 C P920 2004061400007 20040614 00007 NE 2004 6 14 AUS20040143 2 20040301 G 7210 CPGB1384 GEARBOX BELL 412 412 1182202 SW PWA PT6T PT6T3B 52045 NE ENGINE CONTAMINATED W O OTHER J WARNING INDICATION NR NOT REPORTED 1 AU S 2983 CPGB1384 (AUS) COMBINING GEARBOX CHIP DETECTOR METAL CONTAMINATION. 1 G 7 2 4U 4 U H4SW E22EA 2004061400008 20040614 00008 2004 6 14 AUS20040144 4 20040219 G 6122 8210263 GOVERNOR MCAULY SWRNGN SA227 SA227* SW GARRTT TPE331 TPE33112UHR WP MCAULY 4HFR34 4HFR34C652 NE PROPELLER FAILED W O OTHER E VIBRATION/BUFFET NR NOT REPORTED 1 AU S 813 (AUS) LT ENGINE PROPELLER GOVERNOR FAILED. WORKSHOP INVESTIGATION AND DISASSEMBLY OF THE GOVERNOR FOUND A NUMBER OF FAU LTS WITH THE UNIT, HOWEVER THE MAIN FAILURE MODE WAS DUE TO THE FLYWEIGHT HEAD ASSEMBLY MISSING ALL TRIGGER TEETH, CAUSE D BY CONTACT WITH THE MONOPOLE DURING ROTATION OF THE FLYWEIGHT HEAD. THE MONOPOLE HAD RECENTLY BEEN ADJUSTED AS A FAUL T FINDING ACTION FOR THE EGT FLUCTUATIONS. IT IS BELIEVED THAT THIS ADJUSTMENT CAUSED THE REDUCTION IN SETUP GAP BETWEE N THE MONOPOLE AND THE FLYWEIGHT TEETH. ALL OTHER DAMAGE TO THE GOVERNOR FOUND DURING DISSASSEMBLY WAS SUBSEQUENT AND D UE TO THE INITIAL DAMAGE. PERSONNEL/MAINTENANCE ERROR. 2 L 7 2 4T 4 T RT A5SW E4WE 6 C 3PNE 2004061400009 20040614 00009 CE 2004 6 14 AUS20040145 1 20040223 G 3230 131378252CL LINK BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL NLG MISINSTALLED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) NOSE WHEEL RETRACTION CHAIN CONNECTING LINK INCORRECTLY FITTED. PERSONNEL/MAINTENANCE ERROR. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2004061400010 20040614 00010 WP 2004 6 14 AUS20040146 1 20040301 G 1430 AN626 BOLT 245109 FLTCHR 24 FU24AAIRPTS 3530204 WP LYC O720 IO720A1B 41546 EA HARTZL HCC3Y HCC3YR GL MLG FAILED W O OTHER O OTHER NR NOT REPORTED 1 AU S (AUS) RT MAIN LANDING GEAR TOP TORQUE LINK BOLT FAILED. 1 L 7 1 3O 3 O 4A12 1E15 5 C P25EA 2004061400011 20040614 00011 EU 2004 6 14 AUS20040148 1 20040303 G 5523 HC552H0321001 PLATE BAG BAE146 BAE146300A 1500267 EU LYC ALF502 ALF502R5 41580 NE ELEVATOR TAB CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT ELEVATOR TAB NR 1 HINGE UPPER REINFORCEMENT PLATE CONTAINED LEVEL 2 CORROSION. CORROSION DIMENSIONS WERE 25.4M M (1IN) BY50.8MM (2IN) AND PENETRATING TO FULL DEPTH. 2 H 7 4 4F 4 F RT A49EU E6NE 2004061400012 20040614 00012 SW 2004 6 14 AUS20040149 1 20040302 G 2913 99101371 PUMP GULSTM G73 G73 3951802 SW PWA PT6 PT6A34 52043 EA HARTZL HCB3T HCB3TN3 GL HYDRAULIC SYS FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 291 (AUS) RT HYDRAULIC PUMP FAILED. INVESTIGATION FOUND A FINE BROWN COATING OVER THE SURFACE OF THE PUMP. SUSPECT PUMP OVE RHEATED. 1 H 7 2 3R 4 T A783 E4EA 6 C P15EA 2004061400013 20040614 00013 CE 2004 6 14 AUS20040150 1 20040218 G 2612 473275 FIRE DETECTOR BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL LT ENGINE FAULTY W O OTHER N FALSE WARNING CL CLIMB 1 AU S 1527 (AUS) LT ENGINE FORWARD UPPER FIRE DETECTOR SUSPECT FAULTY. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2004061500022 20040615 00022 NE 2004 6 15 AUS20040151 2 20040301 G 7200 PT6A42 ENGINE BEECH 200 B200C 1152924 CE PWA PT6 PT6A42 52043 NE MCAULY 4HFR34 4HFR34C754 NE LEFT FLUCTUATES W O OTHER R J PARTIAL RPM/PWR LOSS WARNING INDICATION DE DESCENT 1 AU S (AUS) LT ENGINE FUEL FLOW AND ENGINE TORQUE FLUCTUATING BEFORE ENGINE STARTED TO ROLLBACK. INVESTIGATION COULD FIND NO CAUSE FOR THE DEFECT. THE ENGINE WAS GROUND RUN AND THEN TEST FLOWN WITH NO FURTHER REOCCURRENCE. 1 L 7 2 4T 4 T A24CE E4EA 6 C 3PNE 2004061400014 20040614 00014 EU 2004 6 14 AUS20040152 1 20040302 G 3610 JR28930A DUCT FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE PNEUMATIC SYS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NR 2 BLEED AIR SYSTEM BIFURCATED DUCT CRACKED IN AREA OF SUPPORT ATTACHING BRACKET ADJACENT TO THE PRSOV. CRACK LE NGTH APPROXIMATELY 25MM (0.984IN). 2 L 7 2 4F 4 F RT E25NE 2004061400015 20040614 00015 NM 2004 6 14 AUS20040153 1 20040302 G 1430 26084383 RIVET HONEYWELL BOEING 717 717200 1383700 NM RROYCE BR700 BR700715A130 NE BRAKE FAILED W O OTHER O OTHER LD LANDING 1 AU S B0367 (AUS) RT MAIN LANDING GEAR NR 3 BRAKE ASSEMBLY BRAKE PADS LOCATED BETWEEN NR 2 AND NR 3 ROTORS HAD SEPARATED AND JAMMED THE BRAKE UNIT. INVESTIGATION FOUND PAD SEPARATION WAS DUE TO RIVET FAILURE. 2 L 7 2 4F 4 F TR A6WE E00061EN 2004061400016 20040614 00016 CE 2004 6 14 AUS20040154 1 20040303 G 3221 5842000213 TRUNNION CESSNA 310 310R 2074245 CE CONT O520 IO520M 17032 SO MCAULY 3AF32C 3AF32C87 GL NLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S PN5842000216 (AUS) NOSE LANDING GEAR TRUNNION CRACKED IN RADIUS LOCATED ON LOWER SIDE OF THE LT ATTACHMENT LUG. CRACK LENGTH APPROXIM ATELY 12MM(0.472IN). THE TRUNNION WAS THE EARLIER PN 5842000-213 WITH SMALLER DIAMETER ATTACHMENT LUGS. FOUND DURING INS PECTION IAW MFG SB MEB 88-5 REV2. 1 L 7 2 3O 3 O 3A10 E5CE 5 C P22EA 2004061400017 20040614 00017 SW 2004 6 14 AUS20040155 1 20040303 G 7921 8538100 OIL COOLER BELL 412 412 1182202 SW PWA PT6T PT6T3B 52045 NE ENGINE LEAKING W O OTHER K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS LD LANDING 1 AU S (AUS) ENGINE/TRANSMISSION OIL COOLER INTERNAL LEAK. THE LEAK ALLOWED TRANSMISSION OIL TO ENTER THE COMBINING GEARBOX OIL SYSTEM UNDERPRESSURE AND OVERFILL THE COMBINING GEARBOX WHICH THEN VENTED THROUGH THE BREATHER. 1 G 7 2 4U 4 U H4SW E22EA 2004061400018 20040614 00018 SO 2004 6 14 AUS20040156 1 20040220 G 2810 FUEL TANK PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL RT ENGINE CONTAMINATED W O OTHER R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 AU S (AUS) RT ENGINE MISFIRING IN FLIGHT. INVESTIGATION FOUND CONTAMINATION IN THE LT FUEL TANK. A HAIR LIKE FIBER WAS FOUN D IN THE FUEL FILTERS AND INJECTOR NOZZLES. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004061400019 20040614 00019 NM 2004 6 14 AUS20040157 1 20040305 G 2910 O-RING BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE HYDRAULIC SYS FAILED W O OTHER K J FLUID LOSS WARNING INDICATION CR CRUISE 1 AU S (AUS) HYDRAULIC SYSTEM A PRESSURE MODULE SUPPLY LINE O-RING SEAL FAILED. LOSS OF HYDRAULIC FLUID. 2 L 7 3 4F 4 F RT A3WE E2EA 2004061400020 20040614 00020 CE 2004 6 14 AUS20040159 1 20040302 G 8011 D104103 GEAR LYC CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA MCAULY 1C160 1C160DTM GL ENGINE STARTER BROKEN W O OTHER O OTHER NR NOT REPORTED 1 AU S D104103 (AUS) STARTER BENDIX DRIVE GEAR DISINTEGRATED DURING ENGINE START. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2004061400021 20040614 00021 NM 2004 6 14 AUS20040160 1 20040228 G 3412 102LA2AG PROBE BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL OUTSIDE AIR TEMP FAILED W O OTHER O OTHER NR NOT REPORTED 1 AU S 3458 (AUS) TAT PROBE FAILED. 2 L 7 2 4F 4 F RT A1NM E23EA 2004061400022 20040614 00022 EA 2004 6 14 AUS20040161 2 20040228 G 8530 LW12416 CYLINDER GULSTM STC STCAA5 LYC O320 O320E2G 41508 EA MCAULY 1C172 1C172* GL ENGINE WORN W K NONE O OTHER IN INSP/MAINT 1 AU S 1001 L4190629A (AUS) NR 1 CYCLINDER WORN. PISTON, RING, & BARREL CLEARANCES EXCESSIVE. 1 L 7 1 3O 3 O A16EA E274 5 N P910 2004061400023 20040614 00023 2004 6 14 AUS20040162 4 20040209 G 3416 AW2835AB06 ALTIMETER BOEING 737 7377BX 13844D2 NM GE CFM56 CFM567B24 NE COCKPIT OUT OF ADJUST W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) CABIN ALTIMETER OUT OF CALIBRATION. FOUND DURING INSPECTION IAW AD/INST/9. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004061400024 20040614 00024 2004 6 14 AUS20040163 4 20040209 G 3416 WL102AM53 ALTIMETER BOEING 737 7377BX 13844D2 NM GE CFM56 CFM567B24 NE COCKPIT FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) STANDBY ALTIMETER/AIRSPEED INDICATOR FAULTY. BENCH TESTING FOUNDTHE LIGHTING UNSERVICEABLE, EXCESSIVE FRICTION AND THE STOP AND JUMP TEST OUTSIDE LIMITS. FOUND DURING INSPECTION IAW AD/INST/9 AND BENCH TEST IAW CMM 34-10-61 REV9. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004061400025 20040614 00025 EA 2004 6 14 AUS20040164 2 20040224 G 8520 LW13908 CAMSHAFT PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL LT ENGINE SPALLED W K NONE O OTHER IN INSP/MAINT 1 AU S L640561A (AUS) LT ENGINE CAMSHAFT LOBE NR 2 BADLY SPALLED. METAL CONTAMINATION OF OIL SYSTEM. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004061400026 20040614 00026 CE 2004 6 14 AUS20040165 1 20040306 G 7931 1013890235 TRANSDUCER BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA HARTZL HCB4M HCB4MP3 GL ENG OIL PRESS UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT ENGINE OIL PRESSURE TRANSDUCER FAULTY. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2004061400027 20040614 00027 GL 2004 6 14 AUS20040166 2 20040308 G 7261 AN8334J FITTING BELL 206 206B3 1181506 SW ALLSN 250C 250C20B 03013 GL ENG OIL PRESS SEPARATED W O OTHER K J FLUID LOSS WARNING INDICATION CR CRUISE 1 AU S CAG30074BA (AUS) ENGINE TURBINE OIL PRESSURE FITTING PN AN833-4J SEPARATED FROM GEARBOX COVER PN 6898569 ALLOWING ENGINE OIL TO BE PUMPED OVERBOARD. SUSPECT CAUSED BY B NUT VIBRATING LOOSE ALLOWING THE FITTING TO FRET IN THE COVER. REDUCED OIL FLOW ( AND COOLING) TO THE TURBINE DAMAGED THE TURBINE BEARINGS. BEARING DEBRIS COLLECTED ON THE FORWARD CHIP PLUG. 1 G 7 1 3U 3 U H2SW E4CE 2004061400028 20040614 00028 EU 2004 6 14 AUS20040167 1 20040225 G 6123 30048000011 AUTOFEATHER SYS FOKKER F27 F27MK50 EU PWA PWA120 PW125B NE ROTOL R352 R3526123F1 GL PROPELLER FAULTY W O OTHER J WARNING INDICATION NR NOT REPORTED 1 AU S (AUS) AUTOFEATHER UNIT SUSPECT FAULTY. INVESTIGATION COULD FIND NO FAULTS BUT THE LT AND RT AUTOFEATHER UNIT PLUGS WERE CLEANED AND FUNCTIONAL TESTS CARRIED OUT. 2 H 7 2 4T 4 T RT A817 E20NE 6 C P16NG 2004061400029 20040614 00029 CE 2004 6 14 AUS20040168 1 20040309 G 5320 12131842 TUNNEL WALL CESSNA 210 210R 2073458 CE CONT O520 IO520L 17032 SO MCAULY D3A34 D3A34C404 GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT SIDE NOSE LANDING GEAR TUNNEL WALL CRACKED IN AREA NEAR RT NOSE LANDING GEAR TORQUE TUBE STIFFENER PN 1213801-2 . FURTHER INVESTIGATION OF THE STRUCTURE FOUND CRACKS IN THE LT AND RT NOSE GEAR TUNNEL WALLS LOCATED AT THE LOWER END OF THE FORWARD ENGINE SHOCK MOUNT ASSEMBLY CHANNEL. CRACKS WERE ALSO FOUND IN THE STIFFENERS PN 1213195-1 AND PN 1213195 -2). AREA HAD BEEN MODIFIED IAW STC NO SA00796AT. 1 H 7 1 3O 3 O RT 3A21 E5CE 5 C P47GL 2004061400030 20040614 00030 CE 2004 6 14 AUS20040169 1 20040309 G 5320 12131842 TUNNEL WALL CESSNA 210 210N 2073453 CE CONT O520 IO520L 17032 SO MCAULY D3A34 D3A34C404 GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT SIDE NOSE LANDING GEAR TUNNEL WALL CRACKED IN AREA NEAR RT NOSE LANDING GEAR TORQUE TUBE STIFFENER PN 1213801-2 . AREA HAD BEEN MODIFIED IAW STC NO SA00796AT. CRACKING WAS FOUND DURING INSPECTION FOLLOWING DISCOVERY OF SIMILAR CR ACKING AS REPORTED IN MDR 04/0168. 1 H 7 1 3O 3 O 3A21 E5CE 5 C P47GL 2004061400031 20040614 00031 NM 2004 6 14 AUS20040170 1 20040307 G 2761 252T13013 ACTUATOR BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL DRAG CONTROL CRACKED W O OTHER K J FLUID LOSS WARNING INDICATION CL CLIMB 1 AU S 47713 (AUS) NR 6 SPOILER POWER CONTROL ACTUATOR FILTER HOUSING SPLIT. LOSS OF HYDRAULIC FLUID. 2 L 7 2 4F 4 F RT A1NM E23EA 2004061400032 20040614 00032 NM 2004 6 14 AUS20040171 1 20040216 G 2170 M01AB010102E HUMIDIFIER BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL COCKPIT FAULTY W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S 463 (AUS) HUMIDIFIER FAILED. BURNING ODOR ON FLIGHTDECK. 2 L 7 2 4F 4 F RT A1NM E23EA 2004061400033 20040614 00033 NM 2004 6 14 AUS20040172 1 20040307 G 2823 737M28500011 VALVE BOEING 737 737376 NM GE CFM56 CFM563B1 13802 NE NR 2 ENGINE FAILED W O OTHER O OTHER NR NOT REPORTED 1 AU S (AUS) NR 2 ENGINE FUEL SYSTEM SPAR VALVE FAILED. 2 L 7 2 4F 4 F RT A16WE E2GL 2004080600018 20040806 00018 CE 2004 8 6 AUS20040173 1 20040223 G 5597 WIRE BEECH 55 95C55 1152708 CE CONT O520 IO520C 17032 SO MCAULY 3AF32C 3AF32C75 GL ELEVATOR TAB ST WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) RT ELEVATOR TRIM TAB HINGE WIRE MANUFACTURED FROM MILD STEEL. RT TRIM TAB FREEPLAY 7.366MM (0.290IN) AND LT TRIM T AB FREEPLAY 9.829MM (0.387IN). MAXIMUM FREEPLAY 2.133MM (0.084IN). PERSONNEL/MAINTENANCE ERROR. UNAPPROVED PART. 1 L 7 2 3O 3 O 3A16 E5CE 5 C P22EA 2004061400034 20040614 00034 NM 2004 6 14 AUS20040174 1 20040309 G 3231 4000894E BELLCRANK PIPER PA60 PA60601P 7106012 NM LYC O540 IO540S1A5 41532 EA HARTZL HCC3Y HCC3YR2 NE RT MLG DOOR BROKEN W O OTHER O OTHER NR NOT REPORTED 1 AU S R133819 (AUS) RT MAIN LANDING GEAR DOOR BELLCRANK LUG BROKEN. 1 M 7 2 3O 3 O RT A17WE 1E4 5 C P25EA 2004061400035 20040614 00035 EU 2004 6 14 AUS20040175 1 20040311 G 3260 5EN16 SWITCH BAG JETSTM JETSTM3201 1500217 EU GARRTT TPE331 TPE33112UHR WP MCAULY 4HFR34 4HFR34C653 NE MLG FAULTY W O OTHER O OTHER NR NOT REPORTED 1 AU S (AUS) NOSE LANDING GEAR SQUAT SWITCH FAULTY. INVESTIGATION FOUND THE CONTACTS HAD HIGH RESISTANCE. 2 L 7 2 4T 4 T RT A56EU E4WE 6 C 3PNE 2004061400036 20040614 00036 CE 2004 6 14 AUS20040176 1 20040307 G 2820 10138901157 CHECK VALVE BEECH 200 B200C 1152924 CE PWA PT6 PT6A42 52043 NE MCAULY 4HFR34 4HFR34C754 NE FUEL DIST FAULTY W O OTHER O OTHER NR NOT REPORTED 1 AU S 6425 (AUS) FUEL SYSTEM CHECK VALVE SUSPECT FAULTY. 1 L 7 2 4T 4 T A24CE E4EA 6 C 3PNE 2004061400037 20040614 00037 2004 6 14 AUS20040177 4 20040308 G 3461 1714970501 FMC BOEING 737 737800* NM GE CFM56 CFM567B24 NE FLT MANAGEMENT FAULTY W O OTHER O OTHER NR NOT REPORTED 1 AU S (AUS) DUEL FLIGHT MANAGEMENT COMPUTER (FMC) FAILURE. INVESTIGATION FOUND THAT BOTH FMCS EXPERIENCED A RESTART DUE TO AN UNHANDLED SOFTWARE EXCEPTION (SOFTWARE PROGRAM ERROR). 2 L 7 2 4F 4 F RT A16WE E00055EN 2004061400038 20040614 00038 SO 2004 6 14 AUS20040178 1 20040304 G 1420 CONNECTOR EMB 120 EMB120 3260201 SO PWA 118 PW118A NE HAMSTD 14RF 14RF9 NE RT ENGINE EEC FAULTY W O OTHER O OTHER NR NOT REPORTED 1 AU S (AUS) RT ENGINE ELECTRONIC ENGINE CONTROL (EEC) AND TORQUE SIGNAL CONDITIONER CONNECTOR PLUGS SUSPECT FAULTY/CONTAMINATE D. 2 L 7 2 4T 4 T RT A31SO E20NE 6 C P11NE 2004061400039 20040614 00039 NM 2004 6 14 AUS20040179 1 20040312 G 2450 P18 PANEL BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE AC POWER FAULTY W O OTHER B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 AU S (AUS) SMOKE AND BURNING ODOR COMING FROM TOP SECTION OF P18 CIRCUIT BREAKER PANEL. 2 L 7 3 4F 4 F RT A3WE E2EA 2004061400040 20040614 00040 EA 2004 6 14 AUS20040180 2 20040315 G 7414 6089188 IMPULSE COUPLING SLICK PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA AMTR C8289 C8289 GL MAGNETO LOOSE W O OTHER R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 AU S 6089188 (AUS) LT MAGNETO IMPULSE COUPLING LOOSE ON SHAFT. FURTHER INVESTIGATION FOUND THE IMPULSE COUPLING LOCATION KEY SHEARED . 1 L 7 1 3O 3 O 2A13 E274 5 N EXPP5N 2004080600020 20040806 00020 CE 2004 8 6 AUS20040181 1 20040310 G 1430 SCREW BEECH 35 S35 1151532 CE CONT O520 IO520B 17032 SO MCAULY 2A36C 2A36C23 GL FUSELAGE FLOOR WRONG PART W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ELEVATOR CONTROL CABLE RUBBING ON SCREW. INVESTIGATION FOUND (A LONGER THAN NORMAL) SCREW HOLDING THE FORWARD CAB IN FLOOR IN POSITION. INCORRECT SCREW HAD BEEN FITTED DURING REUPHOLSTERING CARRIED OUT APPROXIMATELY TWO WEEKS PREVIOUS LY. UNAPPROVED PART. PERSONNEL/MAINTENANCE ERROR. 1 L 7 1 3O 3 O 3A15 E5CE 5 C P880 2004061400041 20040614 00041 NM 2004 6 14 AUS20040182 1 20040309 G 5210 PIN BOEING 737 737376 NM GE CFM56 CFM563B1 13802 NE PAX DOOR SEPARATED W O OTHER O OTHER NR NOT REPORTED 1 AU S (AUS) L2 OUTER DOOR HANDLE MOVED TO VERTICAL POSITION AFTER DEPARTURE. DURING INVESTIGATION, THE WHOLE HANDLE AND SHAFT ASSEMBLY CAME AWAY FROM THE DOOR. A LOOSE CASTELLATED NUT AND SHIMS WERE FOUND IN THE HOUSING ASSEMBLY. FURTHER INVES TIGATION FOUND A DEFORMED SPLIT PIN IN THE BOTTOM OF THE DOOR STRUCTURE. 2 L 7 2 4F 4 F RT A16WE E2GL 2004061400042 20040614 00042 CE 2004 6 14 AUS20040183 1 20040308 G 2910 572700223 PIPE CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCB3T HCB3TN5 GL HYDRAULIC SYS CRACKED W O OTHER K J FLUID LOSS WARNING INDICATION TX TAXI/GRND HDL 1 AU S (AUS) HYDRAULIC PIPE CRACKED AND LEAKING. LOSS OF HYDRAULIC FLUID. PIPE IS LOCATED IN RT WING LEADING EDGE. INVESTIGAT ION FOUND TOOLING MARKS ON THE PIPE IN THE AREA OF THE PIPE BEND. 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P15EA 2004061400043 20040614 00043 NM 2004 6 14 AUS20040184 1 20040309 G 5311 FRAME BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE FRAME LOCATED AT BS 663.75 STRINGER 3R-3L CRACKED AT S1AND S2R FASTENER HOLES. FOUND DURING EDDY CURRENT INSPECTION. 2 L 7 2 4F 4 F RT A16WE E21EU 2004061400044 20040614 00044 SW 2004 6 14 AUS20040185 1 20040314 G 6220 471401341 CLAMP BELL 47 47G5A 1181034 SW LYC O435 VO435B1A 41516 EA MAIN ROTOR HEAD CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) MAIN ROTOR STABILIZER BAR CLAMP CRACKED. 1 G 7 1 3O 3 O 2H3 E279 2004061400045 20040614 00045 EU 2004 6 14 AUS20040186 1 20040311 G 3260 213NW447AB SWITCH STBROS SD3 SD360 8100606 EU PWA PT6 PT6A67R 52043 NE HARTZL HCA6A HCA6A3 NE MLG FAULTY W O OTHER O OTHER NR NOT REPORTED 1 AU S (AUS) NOSE LANDING GEAR DOWNLOCK SWITCH FAULTY. 2 H 7 2 4T 4 T A41EU E26NE 6 C P14NE 2004061400046 20040614 00046 NE 2004 6 14 AUS20040187 2 20040315 G 7200 CFM567B26 ENGINE BOEING 737 737* NM GE CFM56 CFM567B24 NE NR 1 CONTAMINATED W K NONE J WARNING INDICATION IN INSP/MAINT 1 AU S (AUS) NR 1 ENGINE GEARBOX CHIP DETECTOR CONTAMINATED. INVESTIGATION SUSPECTS THAT DEBRIS IS M50 BEARING MATERIAL. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004061400047 20040614 00047 EA 2004 6 14 AUS20040188 2 20040316 G 7322 252429111 FCU MUDRY 10 CAP10B 0950102 EU LYC O360 AEIO360B2F 41514 EA HOFMAN HO29 HO29HM180 EU ENGINE CONTAMINATED W O OTHER J WARNING INDICATION LD LANDING 1 AU S (AUS) FUEL CONTROL UNIT FINGER FILTER CONTAMINATED. WORKSHOP INSPECTION FOUND A FINE HAIR LIKE SUBSTANCE. 1 L 7 1 3O 3 O A36EU 1E10 5 N P3EU 2004061400048 20040614 00048 EA 2004 6 14 AUS20040189 3 20040312 G 6111 72CK056 BLADE PIPER PA38 PA38112 7103812 SO LYC O235 O235L2C 41505 EA SNSNCH 72C 72CK EA PROPELLER CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 788 (AUS) PROPELLER BLADES CONTAINED SEVERE INTERGRANNULAR CORROSION. 1 L 7 1 3O 3 O A18SO E223 5 N P9045 2004061400049 20040614 00049 EA 2004 6 14 AUS20040190 3 20040315 G 6111 72CK056 BLADE PIPER PA38 PA38112 7103812 SO LYC O235 O235L2C 41505 EA SNSNCH 72C 72CK EA PROPELLER CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 1079 (AUS) PROPELLER BLADES CONTAINED SEVERE INTERGRANNULAR CORROSION. 1 L 7 1 3O 3 O A18SO E223 5 N P9045 2004061400050 20040614 00050 2004 6 14 AUS20040191 4 20040225 G 3497 WIRE CESSNA 402 402B 207590P CE CONT O520 TSIO520VB 17040 SO MCAULY 3AF32C 3AF32C93 GL ATC TRANSPONDER FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) TRANSPONDER WIRING SUSPECT FAULTY. TRANSPONDER AND GPS WIRING PARALLEL WHICH CAN CAUSE INACCURATE ALTITUDE READING S. 1 L 7 2 3O 3 O A7CE E8CE 5 C P22EA 2004061400058 20040614 00058 2004 6 14 AUS20040192 4 20040311 G 3414 2083111 INDICATOR BOEING 737 737376 NM CFMINT CFM56 CFM563C 13802 EU AIRSPEED FAILED W O OTHER O OTHER NR NOT REPORTED 1 AU S 2027 (AUS) FIRST OFFICER'S AIRSPEED INDICATOR/MACHMETER FAILED. 2 L 7 2 4F 4 F RT A16WE E21EU 2004061400060 20040614 00060 NM 2004 6 14 AUS20040193 1 20040123 G 2121 6066223 FAN BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL AIR DISTRIBUTION FAULTY W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S 24556 1072073 (AUS) CABIN RECIRCULATING FAN FAULTY. SMOKE AND FUMES IN COCKPIT ANDCABIN. 2 L 7 2 4F 4 F RT A1NM E23EA 2004061400062 20040614 00062 NM 2004 6 14 AUS20040194 1 20040303 G 2121 7322591E FAN BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL AIR DISTRIBUTION FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S 9138 (AUS) FORWARD EQUIPMENT COOLING FAN SEIZED. FUMES IN COCKPIT. 2 L 7 2 4F 4 F RT A1NM E23EA 2004061400065 20040614 00065 SO 2004 6 14 AUS20040195 1 20040316 G 3213 20029 PIN MESSIER EMB 120 EMB120 3260201 SO PWA 118 PW118A NE HAMSTD 14RF 14RF9 NE MLG STRUT STICKING W O OTHER J WARNING INDICATION DE DESCENT 1 AU S 244 (AUS) RT MAIN LANDING GEAR DRAG BRACE STRUT PIVOT PIN BINDING. 2 L 7 2 4T 4 T RT A31SO E20NE 6 C P11NE 2004061400066 20040614 00066 NE 2004 6 14 AUS20040196 2 20040211 G 7297 6068T54P01 WIRE HARNESS SAAB SF340 SF340A 7850100 EU GE CT7TP CT75A 30030 NE ROTOL R354 R3544123F13 NE RT ENGINE FAULTY W O OTHER O OTHER NR NOT REPORTED 1 AU S (AUS) RT ENGINE W4 (YELLOW) WIRING HARNESS FAULTY. 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P61GL 2004061400068 20040614 00068 GL 2004 6 14 AUS20040197 3 20040313 G 6110 BLADE BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL PROPELLER LIGHTNING STRIKE W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT PROPELLER BLADE EXHIBITED LIGHTNING EXIT MARKS. FURTHER INVESTIGATION FOUND BOTH LT AND RT PROPELLERS MAGNETISE D BEYOND LIMITS. LT ENGINE POWER SECTION MAGNETISM BEYOND LIMITS. LIGHTNING EXIT MARKS FOUND ON LT ELEVATOR OB TRAILIN G EDGE. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2004061400069 20040614 00069 NM 2004 6 14 AUS20040198 1 20040121 G 2910 HYDRAULIC SYSTEM BOEING 737 737376 NM GE CFM56 CFM563B1 13802 NE A-SYSTEM CONTAMINATED W O OTHER K J FLUID LOSS WARNING INDICATION NR NOT REPORTED 1 AU S (AUS) HYDRAULIC SYSTEM A FAULTY. ENGINEERING INVESTIGATION SUSPECTS AIR IN HYDRAULIC SYSTEM. LT MAIN LANDING GEAR HYDRA ULIC HOSE HAD BEEN REPLACED ON THE PREVIOUS DAY. 2 L 7 2 4F 4 F RT A16WE E2GL 2004061400071 20040614 00071 2004 6 14 AUS20040199 4 20040319 G 2213 4051601935 PANEL BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU FLT CONTROLLER FAULTY W O OTHER F FLT CONT AFFECTED CR CRUISE 1 AU S (AUS) AUTOPILOT MODE CONTROL PANEL FAULTY. 2 L 7 2 4F 4 F RT A16WE E21EU 2004061400072 20040614 00072 2004 6 14 AUS20040200 4 20040123 G 2215 6225734002 SERVO EMB 120 EMB120 3260201 SO PWA 118 PW118A NE HAMSTD 14RF 14RF9 NE AUTOPILOT MAIN FAILED W O OTHER F FLT CONT AFFECTED DE DESCENT 1 AU S 3902 (AUS) ELEVATOR AUTOPILOT SERVO FAILED. LOSS OF AUTOPILOT CAUSED AIRCRAFT TO PITCH UP. RT ENGINE OVERTORQUED TO 134 PERCE NT AND LT ENGINE OVERTORQUED TO 125 PERCENT. OVERTORQUE INSPECTION ON ENGINES AND PROPELLERS FOUND NO DAMAGE. 2 L 7 2 4T 4 T RT A31SO E20NE 6 C P11NE 2004061400074 20040614 00074 NM 2004 6 14 AUS20040201 1 20040309 G 2750 CONTROL SYSTEM BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL TE FLAPS FAULTY W O OTHER F FLT CONT AFFECTED AP APPROACH 1 AU S (AUS) FLAPS FAILED TO MOVE FROM 20 TO 30. 2 L 7 2 4F 4 F RT A1NM E23EA 2004061400076 20040614 00076 SO 2004 6 14 AUS20040202 1 20040316 G 5711 67069003 SPAR PIPER PA28 PA28R200 7102811 SO LYC O360 IO360C1C 41514 EA HARTZL HCC2Y HCC2YK1 GL WING CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WING SPAR CORRODED. FOUND FOLLOWING REMOVAL OF FUEL TANK FOR STRUCTURAL DEFECT REPAIR. CORROSION WAS SEVERE ENOUGH TO HAVE COMPROMISED STRUCTURAL INTEGRITY. 1 L 7 1 3O 3 O 2A13 1E10 5 C P920 2004061400078 20040614 00078 EU 2004 6 14 AUS20040203 1 20040305 G 3222 RING PILATS PC12 PC12 7090550 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL NLG WORN W K NONE O OTHER IN INSP/MAINT 1 AU S 1542 (AUS) NOSE LANDING GEAR OVEREXTENDED. INVESTIGATION FOUND THE OLEO GUIDE RING WORN AND DAMAGED ALLOWING THE RETAINING P INS TO MIGRATE OUT DISCONNECTING THE GUIDE TUBE FROM THE NOSE FORK. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004061400079 20040614 00079 SO 2004 6 14 AUS20040204 1 20040225 G 3230 8623853 TUBE PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360E 17025 SO HARTZL HCC2Y BHCC2YF2 GL MLG WORN W O OTHER O OTHER LD LANDING 1 AU S (AUS) NOSE LANDING GEAR EXTENSION HYDRAULIC PIPE WORN THROUGH BY CONTACT WITH THE NLG BRAKE FLUID COVER ASSEMBLY. LOSS OF HYDRAULIC FLUID. 1 L 7 2 3O 3 O A7SO E9CE 5 C P920 2004061400080 20040614 00080 NM 2004 6 14 AUS20040205 1 20040311 G 5311 65B0175424 FRAME BOEING 747 747438 NM RROYCE RB211 RB211524G19 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE FRAME PN 65B01754-24 AND FRAME DOUBLER PN 65B26275-34 CRACKED. INVESTIGATION FOUND CRACKING WAS DUE TO TH E USE OF A SPLICE PLATE OF THE INCORRECT MATERIAL AS STATED IN BSB 747-53-2483. 2 L 7 4 4F 4 F RT A20WE E30NE 2004061400081 20040614 00081 GL 2004 6 14 AUS20040206 1 20040318 G 3220 AN442 BOLT AMTR JABIRU JABIRUSK 05602CU GL AMTR CHEVY8 CHEVYV8 GL AMTR C8289 C8289 GL NLG SHEARED W O OTHER O OTHER NR NOT REPORTED 1 AU S (AUS) NOSE LANDING GEAR TRAILING LINK PIVOT BOLT FAILED AT LT PIVOT POINT. 1 H 7 1 3I 3 V NC EXPA1H71 EXPE3V 5 N EXPP5N 2004061400082 20040614 00082 CE 2004 6 14 AUS20040207 1 20040317 G 5514 04320049 BRACKET CESSNA 150 A152 2071836 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL HORIZONTAL STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) HORIZONTAL STABILIZER STEEL BRACKET CRACKED. CRACK LENGTH 10MM(0.393IN). 1 H 7 1 3O 3 O 3A19 E223 5 N P50GL 2004061400083 20040614 00083 SW 2004 6 14 AUS20040208 1 20040318 G 3260 SWITCH SWRNGN SA227 SA227* SW GARRTT TPE331 TPE33112UHR WP MCAULY 4HFR34 4HFR34C652 NE MLG STICKING W O OTHER N FALSE WARNING CL CLIMB 1 AU S (AUS) RT MAIN LANDING GEAR MICROSWITCH STICKING. 2 L 7 2 4T 4 T RT A5SW E4WE 6 C 3PNE 2004061400084 20040614 00084 NE 2004 6 14 AUS20040209 3 20040309 G 6114 660714259 HUB SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE ROTOL R390 R3904123F27 NE PROPELLER CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 7004 (AUS) LT PROPELLER HUB CRACKED IN ATTACHMENT BOLT HOLE. FOUND DURING NDT INSPECTION IAW AD/PR/33. 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P31NE 2004061400086 20040614 00086 NM 2004 6 14 AUS20040210 1 20040318 G 2912 271T00424 FILTER BOEING 767 767* NM RROYCE RB211 RB211524* NE HYDRAULIC SYS FAILED W O OTHER K J FLUID LOSS WARNING INDICATION NR NOT REPORTED 1 AU S (AUS) NR 1 HYDRAULIC SYSTEM FILTER MODULE PRESSURE FILTER BOWL SHEARED OFF. LOSS OF HYDRAULIC FLUID. 2 L 7 2 4F 4 F RT A1NM E12EU 2004061400087 20040614 00087 NM 2004 6 14 AUS20040211 1 20040319 G 1430 AN3167R NUT BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE TE FLAPS MISSING W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT IB FLAP CARRIAGE DEAD WEIGHT ROLLER NUT AND LOCK WASHER MISSING. BOLT WAS STARTING TO MIGRATE FROM POSITION. SU SPECT CAUSED BY FAILURE OF LOCK WASHER TAB. 2 L 7 3 4F 4 F RT A3WE E2EA 2004061400088 20040614 00088 2004 6 14 AUS20040212 4 20040214 G 6122 661001002 GOVERNOR SAAB SF340 SF340A 7850100 EU GE CT7TP CT75A 30030 NE ROTOL R354 R3544123F13 NE PROPELLER FAULTY W O OTHER O OTHER NR NOT REPORTED 1 AU S 26765 (AUS) RT PROPELLER OVERSPEED GOVERNOR FAULTY. 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P61GL 2004061400089 20040614 00089 CE 2004 6 14 AUS20040213 1 20040312 G 2824 10138901157 VALVE BEECH 200 B200C 1152924 CE PWA PT6 PT6A42 52043 NE MCAULY 4HFR34 4HFR34C754 NE FUEL TRANSFER FAULTY W O OTHER O OTHER NR NOT REPORTED 1 AU S (AUS) DEFECT REPORT NR WAS CREATED IN LIEU OF DATA BEING ATTACHED TO MDR 04/0176. CANCELLED, DATED 25TH MARCH 2004. 1 L 7 2 4T 4 T A24CE E4EA 6 C 3PNE 2004061400090 20040614 00090 EU 2004 6 14 AUS20040214 1 20040320 G 6123 3012534 CLAMP REIMS 406 F406 7535723 EU PWA PT6 PT6A112 52043 NE MCAULY 3G34C7 3GFR34C701 GL PROPELLER FAILED W O OTHER O OTHER NR NOT REPORTED 1 AU S (AUS) LT ENGINE PROPELLER REVERSING LEVER CABLE CLAMP BOLT FAILED ALLOWING PROPELLER REVERSING PY LEVER TO DISCONNECT FR OM PUSH/PULL CABLE. 1 L 7 2 3T 3 T RT A54EU E4EA 5 C P60GL 2004061400092 20040614 00092 CE 2004 6 14 AUS20040215 1 20040322 G 5740 50110242 FITTING CESSNA 402 402C 207590R CE CONT O520 TSIO520VB 17040 SO MCAULY 3AF32C 3AF32C87 GL WING CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT WING AFT LOWER ATTACHMENT FITTING PN 5011024-2, LT WING AFT UPPER ATTACHMENT FITTING PN 5011023-1, RT WING AFT LOWER FITTING PN 5011024-2 AND RT WING AFT UPPER FITTING PN 5011023-1 ALL CONTAINED INTERGRANNULAR CORROSION. 1 L 7 2 3O 3 O A7CE E8CE 5 C P22EA 2004061400093 20040614 00093 EA 2004 6 14 AUS20040216 2 20040323 G 7421 URHB32E SPARK PLUG PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) SPARK PLUG CRACKED IN AREA BETWEEN HEXAGONAL BODY AND FLANGE AT UPPER THREADED AREA. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004061400094 20040614 00094 EA 2004 6 14 AUS20040217 2 20040319 G 8520 LW10292 GEAR PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA HARTZL HCE3Y HCE3YR2 GL ENGINE FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 492 (AUS) CRANKSHAFT IDLER GEAR FRACTURED. DAMAGE CAUSED TO SHAFT SUPPORT HOLE IN CRANKCASE. METAL CONTAMINATION OF OIL SY STEM. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004061400095 20040614 00095 CE 2004 6 14 AUS20040218 1 20040322 G 8011 85073009 GEAR LAMAR CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA MCAULY IC235 IC235LFA7570 EA ENGINE STARTER BROKEN W O OTHER O OTHER NR NOT REPORTED 1 AU S 85073009 (AUS) STARTER MOTOR BENDIX DRIVE GEAR DISINTEGRATED. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P12EA 2004061400096 20040614 00096 NM 2004 6 14 AUS20040219 1 20040229 G 4920 P6452 APU BOEING 737 737800* NM GE CFM56 CFM567B24 NE APU BAY CONTAMINATED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) APU FILTER INDICATOR ACTIVATED. INSPECTION FOUND METAL CONTAMINATION OF MAGNETIC PLUG. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004061400097 20040614 00097 WP 2004 6 14 AUS20040220 2 20040324 G 7261 31035781 PIPE SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP ROTOL R321 R321482F8 GL ENGINE OIL WORN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ENGINE REAR BEARING OIL SUPPLY PIPE CHAFING ON NTS OIL PIPE. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P61GL 2004061400098 20040614 00098 GL 2004 6 14 AUS20040221 3 20040324 G 6111 891286 LATCH MCAULY CESSNA 404 404CESSNA 2075901 CE CONT O520 GTSIO520M 17032 SO MCAULY 3FF32 3FF32C501 GL PROPELLER BLADE FAILED W O OTHER O OTHER NR NOT REPORTED 1 AU S 891286 (AUS) PROPELLER EXPERIENCED UNCOMMANDED FEATHER FOLLOWING GROUND RUN. SUSPECT CAUSED BY FAILURE OF THE LOW PITCH STOP LA TCH PINS. 1 L 7 2 3O 3 O A25CE E7CE 5 C P45GL 2004061400099 20040614 00099 CE 2004 6 14 AUS20040222 1 20040323 G 3230 1018100211 SHAFT BEECH 200 B200C 1152924 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL MLG FAILED W O OTHER O OTHER CL CLIMB 1 AU S (AUS) LT MAIN LANDING GEAR RETRACTION DRIVE TUBE FAILED DUE TO INTERFERENCE WITH PNEUMATIC DUCTING CLAMP. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2004061400100 20040614 00100 EA 2004 6 14 AUS20040223 3 20040319 G 6111 72CK056 BLADE PIPER PA38 PA38112 7103812 SO LYC O235 O235L2C 41505 EA SNSNCH 72C 72CK EA PROPELLER CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 732 (AUS) PROPELLER BLADES CONTAINED SEVERE INTERGRANNULAR CORROSION. 1 L 7 1 3O 3 O A18SO E223 5 N P9045 2004061400102 20040614 00102 SW 2004 6 14 AUS20040224 1 20040322 G 2740 3064307 SWITCH SWRNGN SA227 SA227* SW GARRTT TPE331 TPE33112UHR WP MCAULY 4HFR34 4HFR34C652 NE STAB CONTROL MISINSTALLED W O OTHER W INADEQUATE Q C NR NOT REPORTED 1 AU S (AUS) PITCH TRIM SWITCH INSTALLED INCORRECTLY. SWITCH HAD BEEN REFITTED FOLLOWING REPAIRS TO THE PILOTS CONTROL YOKE. PERSONNEL/MAINTENANCE ERROR. 2 L 7 2 4T 4 T RT A5SW E4WE 6 C 3PNE 2004061400103 20040614 00103 SW 2004 6 14 AUS20040225 1 20040326 G 2897 WIRE SWRNGN SA227 SA227* SW GARRTT TPE331 TPE33112UHR WP MCAULY 4HFR34 4HFR34C652 NE FUEL BOOST PUMP CHAFED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT MAIN FUEL BOOST PUMP WIRING CHAFED. 2 L 7 2 4T 4 T RT A5SW E4WE 6 C 3PNE 2004061400105 20040614 00105 CE 2004 6 14 AUS20040227 2 20040322 G 7314 BEARING CONT PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360RB 17025 CE MCAULY 3AF32C 3AF32C* GL ENGINE FUEL PUMP FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 1446 B01AA428 (AUS) ENGINE DRIVEN FUEL PUMP FAULTY. PUMP CONTAMINATED WITH A BLACK CARBON POWDER TYPE SUBSTANCE. POOR PUMP LUBRICATION CAUSED EXCESSIVE BEARING WEAR. 1 L 7 2 3O 3 O A7SO E9CE 5 C P22EA 2004061400106 20040614 00106 CE 2004 6 14 AUS20040228 1 20040321 G 3297 WIRE CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE MLG BROKEN W O OTHER O OTHER NR NOT REPORTED 1 AU S (AUS) RT MAIN LANDING GEAR DOWNLOCK SWITCH WIRE BROKEN. 1 L 7 2 4F 4 F A22CE E1NE 2004061400107 20040614 00107 NE 2004 6 14 AUS20040229 2 20040318 G 7220 311467901 CASE BEECH 300 300BEECH 1152930 CE PWA PT6 PT6A60A 52043 NE HARTZL HCB4M HCB4MP3 GL ENGINE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT AND RT ENGINE AIR INLET CASES CORRODED IN AREA WHERE THE INLET CASE MATES WITH THE COMPRESSOR SHROUD. AIR INLE T CASE IS MANUFACTURED FROM MAGNESIUM ALLOY. 2 L 7 2 4T 4 T A24CE E4EA 6 C P56GL 2004061400108 20040614 00108 NM 2004 6 14 AUS20040230 1 20040324 G 2823 737M28500011 VALVE BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU FUEL SELECTOR STICKING W O OTHER O OTHER NR NOT REPORTED 1 AU S 20216 3377 (AUS) NR 1 ENGINE FUEL SHUTOFF VALVE STICKING. 2 L 7 2 4F 4 F RT A16WE E21EU 2004061400111 20040614 00111 NE 2004 6 14 AUS20040231 2 20040327 G 7200 ENGINE BOEING 747 747438 NM RROYCE RB211 RB211524G19 NE NR 4 FIRE W O OTHER A FLAME/FIRE NR NOT REPORTED 1 AU S (AUS) NR 4 ENGINE FAILED TO START. TAILPIPE FIRE OCCURRED DUE TO A LARGE AMOUNT OF RESIDUAL FUEL IN THE ENGINE. 2 L 7 4 4F 4 F RT A20WE E30NE 2004061400112 20040614 00112 NM 2004 6 14 AUS20040232 1 20040318 G 2810 2670137101 CHECK VALVE BOEING 737 737800* NM FUEL STORAGE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WING REFUELING MANIFOLD CHECK VALVE DAMAGED. CHECK VALVE HAD DAMAGE ON THE VALVE BODY, SPRING AND FLAPPERS. WEAR ALSO FOUND ON THE FLAPPER ATTACHMENT LUGS AND THE LUGS ON THE VALVE BODY WHICH HOLDS THE FLAPPER PIN. THE FLAPPER SEPARA TED FROM THE VALVE AND WAS FOUND IN THE CENTER FUEL TANK. FOD. 2 L 7 2 4F RT A16WE 2004061400113 20040614 00113 GL 2004 6 14 AUS20040233 2 20040321 G 7250 TURBINE BOEING 747 747 UTILSYS NM AMTR CHEVY8 CHEVYV8 GL NR 2 ENGINE FAILED W O OTHER E F VIBRATION/BUFFET FLT CONT AFFECTED NR NOT REPORTED 1 AU S (AUS) NR 2 ENGINE VIBRATION LEVELS HIGH. VISUAL INSPECTION OF THE TAIL PIPE FOUND CATASTROPHIC TURBINE FAILURE. RT COR E COWL HOLED. LPT CASE CONTAINED HOLES AND CRACKING. AIRCRAFT IS FOREIGN REGISTERED. 2 L 7 4 4F 3 V RT A20WE EXPE3V 2004061400114 20040614 00114 SW 2004 6 14 AUS20040234 1 20040328 G 2720 2770066001 GUST LOCK SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP HARTZL HCB3T HCB3TN5 GL RUDDER CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RUDDER GUSTLOCK CRACKED. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P15EA 2004061400115 20040614 00115 EU 2004 6 14 AUS20040235 1 20040324 G 2820 SEAL CASA C212 C212 2410200 EU GARRTT TPE331 TPE3311 01514 WP ROTOL R334 R334482F13 GL FUEL DIST FAULTY W O OTHER O OTHER NR NOT REPORTED 1 AU S (AUS) REFUEL/DEFUEL VALVES NOT CLOSING CORRECTLY ALLOWING AIR TO BE DRAWN INTO ENGINE FUEL SYSTEM. INVESTIGATION FOUND T HE SEALINGWASHERS INSIDE THE VALVE ASSEMBLIES TO BE DEFECTIVE. 2 H 7 2 4T 3 T A43EU E3WE 6 C P61GL 2004061400121 20040614 00121 GL 2004 6 14 AUS20040236 2 20040317 G 7323 22397 SHAFT BENDIX HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL TURBINE GOVERNOR WORN W O OTHER O OTHER NR NOT REPORTED 1 AU S 493 22397 (AUS) POWER TURBINE GOVERNOR DRIVESHAFT FAILED. INVESTIGATION FOUND THE DRIVESHAFT COUPLING SPINNING FREELY ON THE DRI VESHAFT. 1 G 7 1 3U 3 U H3WE E4CE 2004061400126 20040614 00126 EU 2004 6 14 AUS20040237 1 20040331 G 2750 HC579L1309000 PIN BAG BAE146 BAE146300A 1500267 EU LYC ALF502 ALF502R5 41580 NE TE FLAPS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FAIL SAFE PIN ASSEMBLY OF THE RT FLAP TAB NR 2 HINGE BOLT CRACKED. FOUND DURING NDT INSPECTION. 2 H 7 4 4F 4 F RT A49EU E6NE 2004061400129 20040614 00129 CE 2004 6 14 AUS20040238 2 20040322 G 7314 6543511 PUMP PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360RB 17025 CE MCAULY 3AF32C 3AF32C* GL ENGINE FUEL CONTAMINATED W K NONE O OTHER IN INSP/MAINT 1 AU S 1780 (AUS) INSPECTION OF ENGINE DRIVEN FUEL PUMP FOLLOWING STRIP FOR OVERHAUL. THE PUMP WAS FOUND TO CONTAMINATED WITH WHAT APPEARS TO BE CARBON POWDER. PUMP SHAFT BUSHING CONTAMINATED, CAUSING PUMP ROTATION TO BE RESTRICTED. 1 L 7 2 3O 3 O A7SO E9CE 5 C P22EA 2004061500024 20040615 00024 CE 2004 6 15 AUS20040239 1 20040302 G 5311 FRAME BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A42 52043 NE HARTZL HCB3T HCB3TN3 GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE FRAMES CRACKED. CRACKS FOUND IN THE FOLLOWING AREAS:-1. INTERCOSTAL CRACKED AT STRINGER NR 72. FUSELAGE F RAME CRACKED AT STATION 326.75, STRINGER NO8 AND NO9 3. FUSELAGE FRAME CRACKED AT STATION 337.75, AT STRINGER NR 9, NR 10 AND NR 114. LT STRINGER NR 9 CRACKED AT REAR PRESSURE BULKHEAD 5. ATIGUE CRACKS TO SKIN AND STRINGERS AT FUSELAGE STA TION 326.75 TO 337.75 AND STRINGER NR 9, REAR PRESSURE BULKHEAD 6. MULTIPLE CRACKS IN FUSELAGE SKIN LT SIDE LOWER FRAME STATION 337.5. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2004061500025 20040615 00025 NM 2004 6 15 AUS20040240 1 20040107 G 2497 WIRE BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL AC GENERATOR CHAFED W O OTHER H J ELECT. POWER LOSS-50 PC WARNING INDICATION CR CRUISE 1 AU S 2145 (AUS) RT INTEGRATED DRIVE GENERATOR (IDG) FAILED DUE TO A WIRE CHAFING ON THE STATOR HOUSING. SUSPECT INSUFFICIENT INSUL ATION SLEEVING ON THE WIRE. DURING RECTIFICATION OF THE PROBLEM THE FIREWALL FEED THROUGH CONNECTOR BACKSHELL WAS FOUND TO BE LOOSE. 2 L 7 2 4F 4 F RT A1NM E23EA 2004061500026 20040615 00026 EU 2004 6 15 AUS20040241 1 20040331 G 5730 HC571H0236 SKIN BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE WING CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WING TOP SKIN SUSPECT CORRODED. REMOVAL OF PAINT FINISH AND FURTHER INSPECTION FOUND THE SKIN TO BE SERVICEABLE WI TH NO CORROSION OR CRACKING EVIDENT. INSPECTION CARRIED OUT IAW AD/BAE146/61 AMDT2. 2 H 7 4 4F 4 F A49EU E6NE 2004061500027 20040615 00027 EU 2004 6 15 AUS20040242 1 20040330 G 2910 1379305A155 HOSE BAG JETSTM JETSTM3201 1500217 EU GARRTT TPE331 TFE33112UHR WP MCAULY 4HFR34 4HFR34C653 NE HYD SYSTEM FAILED W O OTHER K FLUID LOSS DE DESCENT 1 AU S (AUS) RT MAIN LANDING GEAR RADIUS ROD UP HYDRAULIC HOSE FAILED. LOSS OF HYDRAULIC FLUID. 2 L 7 2 4T 4 T RT A56EU E4WE 6 C 3PNE 2004061500028 20040615 00028 CE 2004 6 15 AUS20040243 1 20040327 G 3297 WIRE CESSNA 340 340CESSNA 2076404 CE CONT O520 TSIO520K 17040 SO MCAULY 3AF32C 3AF32C87 GL DOWNLOCK SWITCH BROKEN W O OTHER O OTHER LD LANDING 1 AU S (AUS) RT MAIN LANDING GEAR DOWNLOCK SWITCH WIRE BROKEN IN AREA APPROXIMATELY 763MM (3IN) FROM SWITCH. 1 L 7 2 3O 3 O 3A25 E8CE 5 C P22EA 2004061500029 20040615 00029 WP 2004 6 15 AUS20040244 2 20040319 G 7210 310703411 TORQUE RING SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP ROTOL R321 R321482F8 GL RT ENGINE FAILED W O OTHER E VIBRATION/BUFFET CR CRUISE 1 AU S (AUS) RT ENGINE TORQUE RING BRIDGES FAILED. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P61GL 2004061500030 20040615 00030 CE 2004 6 15 AUS20040246 1 20040329 G 3213 358152607 STRUT BEECH 58 58 1152740 CE CONT O550 IO550* SO MCAULY 3AF32C 3AF32C512 GL MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 12 (AUS) MAIN LANDING GEAR STRUT SLIDING MEMBER CRACKED CIRCUMFERENTIALLYAROUND THE LOWER SECTION. 1 L 7 2 3O 3 O 3A16 E3SO 5 C P22EA 2004061500031 20040615 00031 SW 2004 6 15 AUS20040247 1 20040331 G 1430 NAS130427D BOLT SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP ROTOL R321 R321482F8 GL MLG BROKEN W O OTHER J WARNING INDICATION CL CLIMB 1 AU S (AUS) RT MAIN LANDING GEAR UPLOCK ROLLER BOLT BROKEN. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P61GL 2004080600109 20040806 00109 NM 2004 8 6 AUS20040248 1 20040331 G 2530 8202017 INSERT BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE GALLEY WRONG PART W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S (AUS) INCORRECT OVEN INSERT (TRAYS) USED IN NO4 OVEN. INSERT DID NOTHAVE A HEAT/PROTECTIVE SHIELD FITTED AT THE REAR ALL OWING THE MEAL PACKAGING TO CONTACT HEATING ELEMENTS. UNAPPROVED PART.PERSONNEL/MAINTENANCE ERROR. 2 L 7 2 4F 4 F RT A16WE E2GL 2004062100174 20040621 00174 NM 2004 6 21 AUS20040249 1 20040401 G 3150 WARNING SYSTEM BOEING 737 737* NM GE CFM56 CFM567B24 NE COCKPIT FAULTY W O OTHER N FALSE WARNING NR NOT REPORTED 1 AU S (AUS) CENTRAL WARNING SYSTEM SUSPECT FAULTY. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004060900135 20040609 00135 EU 2004 6 9 AUS20040251 1 20040329 G 3244 12480131 BALANCE WEIGHT GOODYEAR PILATS PC12 PC12 7090550 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL TIRE SEPARATED W O OTHER O OTHER CL CLIMB 1 AU S 12480131 (AUS) RT MAIN LANDING GEAR TIRE BALANCE WEIGHT SEPARATED. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004060900136 20040609 00136 CE 2004 6 9 AUS20040252 1 20040331 G 2720 1015242653 PUSHROD BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A42 52043 NE MCAULY 4HFR34 4HFR34C754 NE RUDDER CONTROL CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RUDDER PUSHROD CONTAMINATED WITH WATER CAUSING CORROSION OF THE INTERNAL BORE. 1 L 7 2 4T 4 T A24CE E4EA 6 C 3PNE 2004060900137 20040609 00137 EU 2004 6 9 AUS20040253 1 20040316 G 5311 FRAME BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE FRAME 29 RHS CRACKED FROM RIVET IN AREA LOCATED ABOVE STRINGER NR 13. 2 H 7 4 4F 4 F A49EU E6NE 2004060900138 20040609 00138 SO 2004 6 9 AUS20040254 2 20040401 G 7322 25765407 SERVO CONT PIPER PA34 PA34220T 7103420 SO CONT O360 LTSIO360RB SO MCAULY 3AF32C 3AF32C* GL FUEL CONTROL CONTAMINATED W O OTHER E VIBRATION/BUFFET CL CLIMB 1 AU S 70470306 (AUS) RT ENGINE FCU REGULATOR AIR SECTION CONTAMINATED WITH OIL. 1 L 7 2 3O 3 O A7SO E9CE 5 C P22EA 2004060900139 20040609 00139 CE 2004 6 9 AUS20040255 2 20040322 G 7322 25765407 SERVO CONT PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360RB 17025 CE MCAULY 3AF32C 3AF32C* GL FUEL CONTROL LEAKING W O OTHER E VIBRATION/BUFFET LD LANDING 1 AU S 70470304 (AUS) ENGINE FCU SERVO STEM SEAL LEAKING FUEL. FURTHER INVESTIGATION FOUND THAT THERE WERE MANY SMALL PARTS OF BLUE RUBB ER THROUGH OUT THE UNIT. THESE RUBBER PARTS HAD COME FROM A POSSIBLE DAMAGED O RING SEAL DURING ASSEMBLY. ON TOTAL STRIP OF THE UNIT NONE OF THE O RINGS SHOWED SIGNS OF DAMAGE INDICATING THAT THE DAMAGED ORING MAY HAVE BEEN CHANGED BUT THE RUBBER NOT REMOVED. 1 L 7 2 3O 3 O A7SO E9CE 5 C P22EA 2004060900140 20040609 00140 EU 2004 6 9 AUS20040256 1 20040325 G 2510 959300111 SEAT PILATS PC12 PC12 7090550 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL COCKPIT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) PILOTS SEAT BACKREST ASSEMBLY CRACKED IN TWO PLACES. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004060900141 20040609 00141 CE 2004 6 9 AUS20040257 1 20040407 G 1420 MS20470AD3 RIVET CESSNA 182 182P 2075816 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C203 GL FUSELAGE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE SKIN RIVET HEADS CORRODED AND MISSING. RIVETS ARE LOCATED IN THE AREA UNDER THE BELLY OF THE AIRCRAFT AN D ATTACH THE MAIN LANDING GEAR CASTINGS PNO 0741627-1 AND PNO 0741627-2 TO THE FUSELAGE BELLY SKIN. 1 H 7 1 3O 3 O NT TA13 E273 5 C P3EA 2004060900142 20040609 00142 NM 2004 6 9 AUS20040258 1 20040407 G 3610 8021709 VALVE BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL PNEUMATIC SYS FAULTY W C ABORTED TAKEOFF J WARNING INDICATION TO TAKEOFF 1 AU S 5669 940627 (AUS) LT ENGINE PRESSURE REGULATING VALVE (PRV) FAULTY. 2 L 7 2 4F 4 F RT A1NM E23EA 2004060900143 20040609 00143 EU 2004 6 9 AUS20040259 1 20040404 G 4920 38004545 APU AIRBUS A330 A330* EU GE CF6 CF680 30025 NE APU BAY FAILED W O OTHER E VIBRATION/BUFFET TX TAXI/GRND HDL 1 AU S 3723 (AUS) APU FAILED TO START DURING TAXI. 2 L 7 2 4F 4 F RT A46NM E13NE 2004060900144 20040609 00144 NM 2004 6 9 AUS20040260 1 20040405 G 5210 STOP BOEING 737 737376 NM GE CFM56 CFM563B1 13802 NE PAX DOOR FAULTY W O OTHER O OTHER CL CLIMB 1 AU S (AUS) FOLLOWING LOUD CRACKING NOISES IN FLIGHT AN INSPECTION OF THE DOOR AND DOOR CUTOUT AREA WAS CARRIED OUT. I NVESTIG ATION FOUND THE DOOR STOPS HEAVILY WORN AND DRY. 2 L 7 2 4F 4 F RT A16WE E2GL 2004060900145 20040609 00145 CE 2004 6 9 AUS20040261 1 20040408 G 3230 AS119E10C000 HOSE LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE7312 01518 WP MLG RUPTURED W O OTHER K FLUID LOSS CL CLIMB 1 AU S (AUS) NOSE LANDING GEAR RETRACTION SYSTEM HYDRAULIC HOSE RUPTURED. LOSS OF HYDRAULIC FLUID. 2 L 7 2 4F 4 F RT T00008WI E6WE 2004061000001 20040610 00001 CE 2004 6 10 AUS20040262 1 20040408 G 8011 D112530 GEAR LYC CESSNA 172 172RG 2072438 CE LYC O360 O360F1A6 41514 EA MCAULY 2D34C B2D34C220 GL ENGINE STARTER DISINTEGRATED W O OTHER E VIBRATION/BUFFET NR NOT REPORTED 1 AU S D112530 (AUS) STARTER BENDIX DRIVE GEAR DISINTEGRATED ON START. 1 H 7 1 3O 3 O 3A17 E286 5 C P7EA 2004061000002 20040610 00002 NE 2004 6 10 AUS20040263 1 20040414 G 2612 7630607902103 FIRE DETECTOR SKRSKY S76 S76C 8143008 NE TMECA ARRIEL ARRIEL1S 60030 NE NR 2 ENGINE FAULTY W O OTHER E B N VIBRATION/BUFFET SMOKE/FUMES/ODORS/SPARKS FALSE WARNING CR CRUISE 1 AU S (AUS) NR 2 ENGINE FLAME DETECTOR FAULTY. 1 G 7 2 3U 3 U NC H1NE E19EU 2004061000003 20040610 00003 EA 2004 6 10 AUS20040264 2 20040406 G 7322 70274603 SERVO LYC CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA MCAULY IC235 IC235LFA7570 EA FUEL CONTROL FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 70274603 (AUS) FUEL CONTROL UNIT AIR CHAMBER CONTAMINATED WITH FUEL. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P12EA 2004061000004 20040610 00004 CE 2004 6 10 AUS20040265 1 20040411 G 2434 10300B ALTERNATOR CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA MCAULY 1C160 1C160DTM GL DC SYSTEM FAILED W O OTHER H ELECT. POWER LOSS-50 PC CR CRUISE 1 AU S 260 (AUS) ALTERNATOR FAILED IN FLIGHT. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2004061000005 20040610 00005 SW 2004 6 10 AUS20040266 1 20040410 G 2150 434422123 SWITCH SWRNGN SA227 SA227* SW GARRTT TPE331 TPE33112UA 01514 WP MCAULY 4HFR34 4HFR34C663 NE CABIN COOLING FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LEADING EDGE DUCT THERMAL SWITCH FAULTY. 2 L 7 2 4T 4 T RT A5SW E4WE 6 C 3PNE 2004061000006 20040610 00006 EA 2004 6 10 AUS20040267 2 20040326 G 7313 252405411 INJECTOR PARTEN P68 P68B 6780104 EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YR2 GL FUEL SYSTEM CONTAMINATED W O OTHER E VIBRATION/BUFFET CR CRUISE 1 AU S 1184 (AUS) RT ENGINE FUEL INJECTORS CONTAMINATED BY SMALL FERROUS (RUST) PARTICLES. 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 2004061000007 20040610 00007 NE 2004 6 10 AUS20040268 2 20040411 G 7200 ENGINE DHAV DHC8 DHC8202 2809007 NM PWA 120 PW123D 52152 NE HAMSTD 14SF 14SF23 NE RIGHT OVERTORQUED W O OTHER J WARNING INDICATION CL CLIMB 1 AU S (AUS) RT ENGINE OVERTORQUED TO 155 PERCENT. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004061000008 20040610 00008 NM 2004 6 10 AUS20040269 1 20040407 G 2421 761574B IDG BOEING 737 737* NM GE CFM56 CFM567B24 NE AC GENERATOR FAILED W O OTHER J WARNING INDICATION CR CRUISE 1 AU S (AUS) NR 2 ENGINE INTEGRATED DRIVE GENERATOR (IDG) PRESSURE RELIEF REGULATING VALVE RETAINING COVER SCREW SHEARED. COVE R, POPPET VALVE AND SPRING SEPARATED FROM IDG RESULTING IN LOSS OF OIL INTO FAN COWL. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004061000009 20040610 00009 EU 2004 6 10 AUS20040270 1 20040408 G 2434 5243212137 DRIVE SHAFT PILATS PC12 PC12 7090550 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL DC GENERATOR SHEARED W O OTHER H ELECT. POWER LOSS-50 PC TX TAXI/GRND HDL 1 AU S (AUS) NR 2 GENERATOR DRIVESHAFT SHEARED. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004061000010 20040610 00010 2004 6 10 AUS20040271 4 20040414 G 2215 065005656 SERVO PILATS PC12 PC12 7090550 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL AUTOPILOT SYS FAULTY W O OTHER F FLT CONT AFFECTED CL CLIMB 1 AU S (AUS) AUTOPILOT ROLL SERVO FAULTY. INVESTIGATION FOUND THAT THE SCREWS HOLDING THE CLUTCH HAD LOOSENED ALLOWING THE CLU TCH TO REMAIN ENGAGED WHEN THE AUTOPILOT WAS DISENGAGED. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004061000011 20040610 00011 WP 2004 6 10 AUS20040272 2 20040416 G 7210 GEAR BAG JETSTM JETSTM3201 1500217 EU GARRTT TPE331 TPE33112UHR WP MCAULY 4HFR34 4HFR34C653 NE RT ENGINE FAILED W O OTHER E VIBRATION/BUFFET DE DESCENT 1 AU S (AUS) RT ENGINE SUFFERED AN UNCONTAINED GEARBOX FAILURE. DEBRIS FROM THE FAILED GEAR IMPACTED ON THE RT SIDE OF THE AIRC RAFT CABIN. 2 L 7 2 4T 4 T RT A56EU E4WE 6 C 3PNE 2004061000012 20040610 00012 2004 6 10 AUS20040273 4 20040416 G 2310 14809 ANTENNA SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE ROTOL R390 R3904123F27 NE HF COMMUNICATION FAILED W O OTHER D C INFLIGHT SEPARATION F.O.D. NR NOT REPORTED 1 AU S (AUS) HF ANTENNA BROKEN AT VERTICAL STABILIZER. SAFETY RESTRAINING DEVICE FAILED TO RETAIN THE BROKEN CABLE AS THE CABLE HAD FAILED ON BOTH SIDES OF THE RESTRAINT CLAMP. THE BROKEN ANTENNA CAUSED NO DAMAGE TO THE AIRFRAME HOWEVER THE SAFETY RESTRAINT, COMPRISING A BOLTED TEFLON FITTING SECURED BY NYLON TAPE, HAD REPEATEDLY IMPACTED THE VERTICAL STABILIZER SI DE PANEL RESULTING IN DELAMINATION, ABRASION AND CRACKING OF THE OUTER SKIN AND DAMAGE TO THE ALUMINUM HONEYCOMB CORE. 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P31NE 2004061000013 20040610 00013 EU 2004 6 10 AUS20040274 1 20040408 G 2823 7913003K SHUTOFF VALVE BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE FUEL SELECTOR FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NR 1 ENGINE FUEL SHUTOFF VALVE FAILED TO OPERATE WHEN THE FIRE HANDLE WAS PULLED. 2 H 7 4 4F 4 F A49EU E6NE 2004061000014 20040610 00014 NM 2004 6 10 AUS20040275 1 20040415 G 2810 FUEL TANK BOEING 737 7377Q8 1384418 NM GE CFM56 CFM567B24 NE LT WING LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S (AUS) LT WING FUEL TANK LEAKING INTO DRY BAY AT WBL 616.75 LOWER AFT CORNER. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004061000015 20040610 00015 EA 2004 6 10 AUS20040276 2 20040416 G 7313 252405411 INJECTOR PARTEN P68 P68B 6780104 EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YR2 GL RT ENGINE FAULTY W C ABORTED TAKEOFF E VIBRATION/BUFFET TO TAKEOFF 1 AU S 37 (AUS) RT ENGINE FUEL INJECTOR FLOW ERRATIC. 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 2004061000016 20040610 00016 WP 2004 6 10 AUS20040277 1 20040420 G 6310 A1902 DRIVE BELT ROBSIN R22 R22ALPHA 7640104 WP LYC O320 O320B2C 41508 EA ENGINE/XMSN DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ENGINE TO TRANSMISSION DRIVE BELTS STRETCHED AND WORN. 1 G 7 1 3O 3 O H10WE E274 2004061000017 20040610 00017 EA 2004 6 10 AUS20040278 2 20040420 G 7414 E02HA23B DISTRIBUTOR BLK CONT ROBSIN R22 R22BETA 7640110 NM LYC O360 HO360* 41514 EA MAGNETO LOOSE W O OTHER E VIBRATION/BUFFET CR CRUISE 1 AU S E02HA23B (AUS) LT MAGNETO DISTRIBUTOR BLOCK LOOSE IN HOUSING. 1 G 7 1 3O 3 O H10WE E286 2004061000018 20040610 00018 EU 2004 6 10 AUS20040279 1 20040405 G 7110 SKIN BAC 146 AVRO146RJ70A 1500095 EU LYC LF507 LF5071F NE ENGINE COWLING CHAFED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ENGINE REAR COWLING SKIN CHAFING IN AREA LOCATED JUST BENEATH THE REAR ATTACHMENT/HINGE POINT. CHAFING EVIDENT ON ALL EIGHT REAR COWLING DOORS. 2 H 7 4 4F 4 F RT A49EU E6NE 2004061000020 20040610 00020 2004 6 10 AUS20040280 4 20040419 G 2350 M1035AAABJLB2 PANEL SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP HARTZL HCB3T HCB3TN5 GL AUDIO FAULTY W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S 41 (AUS) COPILOTS AUDIO PANEL FAULTY. SMOKE AND ODOR IN COCKPIT. SMOKE AND ODOR DISSIPATED WHEN CIRCUIT BREAKER POPPED. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P15EA 2004061000021 20040610 00021 EU 2004 6 10 AUS20040281 1 20040317 G 5343 HC537L0002006 DIAPHRAGM BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE MLG ACT MOUNT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NOSE LANDING GEAR ACTUATOR MOUNTING BOSS DIAPHRAGM CRACKED. FOUND DURING INSPECTION IAW AD/BAE146/71. 2 H 7 4 4F 4 F A49EU E6NE 2004061000025 20040610 00025 NM 2004 6 10 AUS20040282 1 20040416 G 3242 26123121 BRAKE BOEING 737 737* NM GE CFM56 CFM567B24 NE RT MLG WORN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT OB BRAKE WORN BEYOND LIMITS. BRAKE SEIZED ON WHEEL. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004061000026 20040610 00026 NM 2004 6 10 AUS20040283 1 20040402 G 2750 FLAP BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU TRAILING EDGE FAULTY W O OTHER F J FLT CONT AFFECTED WARNING INDICATION AP APPROACH 1 AU S (AUS) AIRCRAFT HAD AN ASSYMETRIC FLAP INDICATION DURING SELECTION. THE AIRCRAFT HAS HAD A TOTAL OF FOUR SIMILAR OCCURRE NCES DURING A TWO WEEK PERIOD. INVESTIGATION IS CONTINUING. 2 L 7 2 4F 4 F RT A16WE E21EU 2004061000027 20040610 00027 NE 2004 6 10 AUS20040284 2 20040319 G 7220 311467901 CASE BEECH 300 300BEECH 1152930 CE PWA PT6 PT6A60 52043 NE HARTZL HCB4M HCB4MP3 GL RT ENGINE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT ENGINE AIR INLET CASE CORRODED. 2 L 7 2 4T 4 T A24CE E4EA 6 C P56GL 2004061000031 20040610 00031 NM 2004 6 10 AUS20040285 1 20040417 G 2611 473054 SMOKE DETECTOR DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE CARGO BAY FAULTY W O OTHER N FALSE WARNING CR CRUISE 1 AU S (AUS) BAGGAGE COMPARTMENT SMOKE DETECTOR UNIT FAULTY. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004061000032 20040610 00032 NM 2004 6 10 AUS20040286 1 20040408 G 2820 GASCOLATOR ROBSIN R22 R22BETA 7640110 NM LYC O320 O320B2C 41508 EA FUEL SYS CONTAMINATED W O OTHER E Y VIBRATION/BUFFET ENGINE STOPPAGE LD LANDING 1 AU S (AUS) ENGINE FAILED. INVESTIGATION FOUND WATER AND RUST IN THE AIRCRAFT FUEL FILTER GASCOLATOR AND CARBURETOR. 1 G 7 1 3O 3 O H10WE E274 2004061000034 20040610 00034 EU 2004 6 10 AUS20040287 1 20040420 G 7120 001322603 MOUNT SAAB SF340 SF340A 7850100 EU ENGINE INCORRECT W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FORWARD LOWER ENGINE MOUNT CANISTER ASSEMBLIES (7OFF) RECEIVED AS REPLACEMENT PARTS WERE PRE MODIFICATION ITEMS. CANISTERS DID NOT COMPLY WITH AD/SF340/68. 2 L 7 2 4T RT A52EU 2004061000035 20040610 00035 SW 2004 6 10 AUS20040289 1 20040416 G 6710 B542DD BEARING BELL 206 206B3 1181506 SW ALLSN 250C 250C20B 03013 GL MAIN ROTOR LACK OF LUBE W O OTHER F FLT CONT AFFECTED DE DESCENT 1 AU S (AUS) COLLECTIVE JACKSHAFT SUPPORT BEARING FAULTY. INVESTIGATION FOUND THAT THE BEARING LUBRICANT HAD DRIED OUT. 1 G 7 1 3U 3 U H2SW E4CE 2004061000036 20040610 00036 NM 2004 6 10 AUS20040290 1 20040416 G 5753 65C344836 SPINDLE BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU TE FLAPS FRACTURED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT OB MID FLAP CARRIAGE SPINDLE SUSPECT CRACKED. FOUND DURING ULTRASONIC INSPECTION IAW EI 737-57-72R2. 2 L 7 2 4F 4 F RT A16WE E21EU 2004061000037 20040610 00037 EU 2004 6 10 AUS20040291 1 20040422 G 5730 SKIN FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE WING CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WING STRUCTURE CONTAINED LEVEL 3 CORROSION IN THE FOLLOWING AREAS: CORROSION FOUND ON FORWARD FACE OF FORWARD MAIN SPAR AT RIB STATION 129752. ACCESS PANEL Z536FB MOUNTING FLANGE HAD EVIDENCE OF SURFACE AND DEEPER CORROSION AT RIB 11 974-12795. FORWARD FACE OF LT SPAR HAS CORROSION AT STATION 11460. CORROSION FOUND ON FORWARD FACE OF MAIN SPAR AT WING STATION 106505 LT OB AILERON TAB HINGE ARM EXFOLIATION CONTAINED. 2 L 7 2 4F 4 F RT E25NE 2004061000038 20040610 00038 2004 6 10 AUS20040292 4 20040217 G 2213 0119244TF CONTROLLER BNORM BN2 BN2B20 1520302 EU LYC O540 IO540K1B5 41532 EA HARTZL HCC2Y HCC2YK2 GL AUTOPILOT FAULTY W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S (AUS) AUTOPILOT BURNED OUT. ROLL SERVO ALSO BURNED OUT. 1 H 7 2 3O 3 O A17EU 1E4 5 C P920 2004061000039 20040610 00039 NM 2004 6 10 AUS20040293 1 20040416 G 2731 6355B000103 MOTOR BOEING 737 7377Q8 1384418 NM GE CFM56 CFM567B24 NE ELEVATOR TAB FAULTY W O OTHER F J FLT CONT AFFECTED WARNING INDICATION CR CRUISE 1 AU S (AUS) STABILIZER ELECTRIC TRIM MOTOR FAULTY. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004061000040 20040610 00040 SW 2004 6 10 AUS20040294 1 20040415 G 2435 95066 BEARING LUCAS SWRNGN SA227 SA227* SW GARRTT TPE331 TPE33112UHR WP MCAULY 4HFR34 4HFR34C652 NE STARTER GEN FAILED W O OTHER H ELECT. POWER LOSS-50 PC NR NOT REPORTED 1 AU S 586 95066 (AUS) RT ENGINE STARTER-GENERATOR BEARING FAILED. 2 L 7 2 4T 4 T RT A5SW E4WE 6 C 3PNE 2004061000041 20040610 00041 EU 2004 6 10 AUS20040295 1 20040423 G 2701 GA827302343 BUSHING GIPPLD GA8 GA8 3900102 EU CONTROL COLUMN GALLED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) CONTROL WHEEL SHAFT BUSHING GALLED AGAINST WELD PENETRATION ON INNER FACE OF CONTROL COLUMN SLEEVE. 1 H 7 1 3O NT 2004061000042 20040610 00042 NM 2004 6 10 AUS20040296 1 20040418 G 1430 BACB30US16K47 BOLT BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL FUSELAGE FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT AND RT VERTICAL FIN FORWARD ATTACHMENT BOLTS FAILED TORQUE TEST. 2 L 7 2 4F 4 F RT A1NM E23EA 2004061000043 20040610 00043 NM 2004 6 10 AUS20040297 1 20040420 G 5220 H2052K3833 LATCH BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL EMERGENCY EXITS FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S PH0225 (AUS) LT OFFWING SLIDE DOOR NR 3 LATCH GUIDE PIN, BUSH AND SPRING MISSING. 2 L 7 2 4F 4 F RT A1NM E23EA 2004061000044 20040610 00044 NE 2004 6 10 AUS20040298 1 20040318 G 2720 ROD END CONAER LA4 LA4200 5110310 NE LYC O360 IO360A1B 41514 EA HARTZL HCC2Y HCC2YK1 GL RUDDER CONTROL FAILED W O OTHER F FLT CONT AFFECTED LD LANDING 1 AU S 40 (AUS) RUDDER CONTROL ROD BALL JOINT SEIZED AND ROD END FAILED. THE SEIZED BALL JOINT ALLOWED THE CONTROL ROD END TO BEND UP AND DOWN DURING RUDDER APPLICATIONS UNTIL FINAL FAILURE. 1 H 7 1 3O 3 O 1A13 1E10 5 C P920 2004061000045 20040610 00045 EU 2004 6 10 AUS20040300 1 20040428 G 2730 D19202001 BRACKET FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE ELEVATOR CONTROL MISINSTALLED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) LT ELEVATOR CONTROL ROD LOCK BRACKET INCORRECTLY INSTALLED AND FOULING ON LT ELEVATOR ROD CAUSING RESTRICTION IN E LEVATOR MOVEMENT. PERSONNEL/MAINTENANCE ERROR. 2 L 7 2 4F 4 F RT E25NE 2004061000046 20040610 00046 EU 2004 6 10 AUS20040301 1 20040428 G 5310 DOOR FRAME FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE FUSELAGE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) SERVICE DOOR FRAME CONTAINED LEVEL 3 CORROSION LOCATED AT THE BOTTOM FORWARD CORNER. 2 L 7 2 4F 4 F RT E25NE 2004061000047 20040610 00047 EU 2004 6 10 AUS20040302 1 20040424 G 3242 1090300 PAD CLEVELAND PILATS PC12 PC12 7090550 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL BRAKE SEPARATED W O OTHER O OTHER TX TAXI/GRND HDL 1 AU S 2050 1200 (AUS) BRAKE ASSEMBLY WEAR PAD SEPARATED FROM BRAKE DISC ROTOR AND DAMAGED FOUR MORE PADS CAUSING THE BRAKE UNIT TO LOCK UP. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004061000048 20040610 00048 SO 2004 6 10 AUS20040303 1 20040415 G 3520 11900301 PBE EMB 120 EMB120 3260201 SO PAX OXYGEN FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) PASSENGER BREATHING EQUIPMENT (PBE) UNITS FAULTY. PBE STORAGE BAGS HAD LOST VACUUM AND ITEMS WERE CHAFED IN CONTA INMENT BOX. 2 L 7 2 4T RT A31SO 2004061000049 20040610 00049 SW 2004 6 10 AUS20040304 1 20040310 G 3411 STATIC PORT SWRNGN SA227 SA227* SW GARRTT TPE331 TPE33112UHR WP MCAULY 4HFR34 4HFR34C652 NE PITOT/STATIC SYS BLOCKED W O OTHER W INADEQUATE Q C CL CLIMB 1 AU S (AUS) PITOT/STATIC INSTRUMENTS FAILED TO OPERATE FOLLOWING TAKEOFF. INVESTIGATION FOUND CLEAR PLASTIC TAPE OVER AFT STAT IC VENT PORTS. TAPE HAD BEEN LEFT ON FOLLOWING PITOT/STATIC CHECK. PERSONNEL/MAINTENANCE ERROR. 2 L 7 2 4T 4 T RT A5SW E4WE 6 C 3PNE 2004061000050 20040610 00050 NE 2004 6 10 AUS20040305 2 20040429 G 7261 OIL SYSTEM BAC 146 146100A 1500260 EU LYC ALF502 ALF502R5 41580 NE ENGINE FAILED W O OTHER E K J VIBRATION/BUFFET FLUID LOSS WARNING INDICATION CR CRUISE 1 AU S (AUS) ENGINE SHUTDOWN DUE TO LOW OIL PRESSURE WARNING AND ZERO OIL QUANTITY. INVESTIGATION CONFIRMED ENGINE OIL TANK CON TENTS EMPTY BUT COULD NOT FIND ANY SOURCE OF LEAKAGE. ENGINE WAS REMOVED DUE TO FAILING WINDMILL CRITERIA. 2 H 7 4 4F 4 F RT A49EU E6NE 2004061000051 20040610 00051 CE 2004 6 10 AUS20040306 1 20040428 G 5511 053200199 RIB CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA MCAULY IC235 IC235LFA7570 EA HORIZONTAL STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) HORIZONTAL STABILIZER RIB CRACKED AROUND CIRCUMFERENCE OF AFT ATTACHMENT HOLES. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P12EA 2004061000052 20040610 00052 WP 2004 6 10 AUS20040307 1 20040422 G 1430 STD1419 BOLT ROBSIN R44 R44 7640120 WP LYC O540 O540F1B5 41532 EA ENGINE MISSING W O OTHER K B J FLUID LOSS SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CL CLIMB 1 AU S (AUS) CRANKCASE BOLT MISSING. OIL LEAKING FROM CRANKCASE. ENGINE HAD JUST BEEN FITTED AND AIRCRAFT WAS ON TEST FLIGHT. PERSONNEL/MAINTENANCE ERROR. 1 G 7 1 3O 3 O H11NM E295 2004061000053 20040610 00053 NE 2004 6 10 AUS20040308 2 20040414 G 7200 ENGINE BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A42 52043 NE HARTZL HCD4N3 HCD4N3A GL NR 2 SURGES W O OTHER E VIBRATION/BUFFET NR NOT REPORTED 1 AU S (AUS) NR 2 ENGINE POWER SURGE. DURING GROUND RUN TORQUE BLED OFF. INVESTIGATION FAILED TO FIND ANY CAUSE AND THE ENGINE WAS REMOVED. 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2004061000055 20040610 00055 EU 2004 6 10 AUS20040309 1 20040420 G 2910 SA7670006131 HOSE BAC 146 146100A 1500260 EU LYC ALF502 ALF502R5 41580 NE DRAG CONTROL ACT RUPTURED W O OTHER K J FLUID LOSS WARNING INDICATION CL CLIMB 1 AU S (AUS) ROLL SPOILER ACTUATOR PRESSURE HOSE RUPTURED. LOSS OF YELLOW HYDRAULIC SYSTEM FLUID. 2 H 7 4 4F 4 F RT A49EU E6NE 2004061000056 20040610 00056 CE 2004 6 10 AUS20040310 1 20040414 G 3610 12945085021 MANIFOLD LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE731* 01518 WP PNEUMATIC DIST CRACKED W O OTHER J WARNING INDICATION CR CRUISE 1 AU S (AUS) LT ENGINE HP SERVO PRESSURE SUPPLY TUBE TO MANIFOLD WELDED JOINT CRACKED. 2 L 7 2 4F 4 F RT T00008WI E6WE 2004061000057 20040610 00057 2004 6 10 AUS20040311 4 20040429 G 2210 FCS80 AUTOPILOT SYS SWRNGN SA227 SA227AT 8780610 SW GARRTT TPE331 TPE33111U 01514 WP ROTOL R321 R321482F8 GL COCKPIT FAULTY W O OTHER F FLT CONT AFFECTED CR CRUISE 1 AU S (AUS) AUTOPILOT FAULTY. 2 L 7 2 4T 4 T RT A5SW E4WE 6 C P61GL 2004061000058 20040610 00058 NM 2004 6 10 AUS20040312 1 20040427 G 1430 BOLT BOEING 737 737376 NM GE CFM56 CFM56* 13802 NE PAX SEAT SEPARATED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) PASSENGER SEAT SUPPORT BEAM TO AISLE SIDE LEG STRUCTURE BOLTS SEPARATED AND FOUND UNDER SEAT 12 DEF. 2 L 7 2 4F 4 F RT A16WE E2GL 2004061000059 20040610 00059 NM 2004 6 10 AUS20040313 1 20040426 G 7830 BRAKE ASSY GE BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL THRUST REVERSER FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT ENGINE THRUST REVERSER LT AND RT ELECTROMECHANICAL BRAKES FAILED SYSTEM TORQUE CHECK. FOUND DURING INSPECTION IAW AD/B767/182 AND AD/B767/83. 2 L 7 2 4F 4 F RT A1NM E23EA 2004061000060 20040610 00060 NM 2004 6 10 AUS20040314 1 20040415 G 1420 MS3470L1412P CONNECTOR LUCAS DHAV DHC8 DHC8315 2809010 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE AC GENERATOR FAILED W O OTHER H ELECT. POWER LOSS-50 PC CL CLIMB 1 AU S 5966 Y10007 (AUS) NR 2 AC GENERATOR FAILED. REPLACED IAW MANUFACTURERS MM. INVESTIGATION FOUND PHASE IMBALANCE PROTECTION CIRCUITRY WIRE CHAFED INSIDE GENERATOR UNIT. CONNECTOR CONTAMINATED WITH OIL. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004061000073 20040610 00073 EU 2004 6 10 AUS20040315 2 20040429 G 7210 332BF6 NUT SNIAS AS332 AS332L 8680809 EU TMECA MAKILA MAKILA1A 60040 EU NR 1 ENG FLANGE MISMANUFACTURED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NR 1 ENGINE OUTPUT DRIVESHAFT TO OUTPUT FLANGE ATTACHMENT NUTS FAULTY. MATING SURFACE OF NUTS MISALIGNED. NUTS AR E PART OF BOLT SET PN 332BF6. SUSPECT MANUFACTURING ERROR. 2 G 7 2 4U 4 U H4EU E12NE 2004061000074 20040610 00074 EU 2004 6 10 AUS20040316 1 20040430 G 2822 229945 PUMP FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE FUEL BOOST BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT AFT BOOST PUMP INLET CHECK VALVE FLAP SEPARATED AT PIVOT POINT. 2 L 7 2 4F 4 F RT E25NE 2004080600010 20040806 00010 EU 2004 8 6 AUS20040317 1 20040427 G 3241 SHAFT BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE ANTISKID SYS WRONG PART W O OTHER W INADEQUATE Q C LD LANDING 1 AU S (AUS) NR 1 MAIN WHEEL TIRE DAMAGED AND DEFLATED. INVESTIGATION FOUND THAT THE TIRE DEFLATED DUE TO WHEEL LOCKUP ON LANDI NG ROLL. THE WHEEL LOCKUP WAS CAUSED BY A BENT ANTI-SKID TRANSDUCER DRIVESHAFT WHICH CAUSED THE ANTI-SKID SYSTEM ON THIS WHEEL POSITION TO BE NON-OPERATIVE. THE BENT TRANSDUCER SHAFT ALSO CAUSED DAMAGE TO SEVERAL OTHER COMPONENTS NAMELY THE BRAKE COOLING FAN MOTOR, FAN DUCT, AND DEBRIS SCREEN COVER. THE BENT ANTI-SKID DRIVE SHAFT APPEARS TO BE CAUSED BY INCO RRECT FIT OF SHAFT INTO DEBRIS SCREEN SPLINED DRIVE BEARING AT LAST WHEEL INSTALLATION. PERSONNEL/MAINTENANCE ERROR. 2 H 7 4 4F 4 F A49EU E6NE 2004080600011 20040806 00011 EU 2004 8 6 AUS20040318 1 20040429 G 1430 A203612 BOLT HARTZL WSK M18 M18DROMADER 9810102 EU GARRTT TPE331 TPE33111U 01514 WP HARTZL HCB5M HCB5MP3 GL PROPELLER BLADE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S EVA2790 (AUS) PROPELLER COUNTERWEIGHT TO BLADE CLAMP ATTACHMENT BOLTS (2OFF10) CRACKED. 1 L 7 1 3O 4 T A47EU E4WE 6 C P44GL 2004080600012 20040806 00012 EA 2004 8 6 AUS20040319 2 20040430 G 7314 LW15473 PUMP ROBSIN R44 R44 7640120 WP LYC O540 IO540* 41532 EA ENGINE FUEL LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S (AUS) AIRCRAFT MOUNTED ENGINE FUEL PUMP LEAKING. 1 G 7 1 3O 3 O H11NM 1E4 2004080600013 20040806 00013 2004 8 6 AUS20040320 4 20040427 G 6122 923309D SHAFT WOODWARD BNORM BN2 BN2A26 1520226 EU LYC O540 O540E4C5 41532 EA HARTZL HCC2Y HCC2YK2 GL PROP GOVERNOR SHEARED W O OTHER E VIBRATION/BUFFET CR CRUISE 1 AU S 923309D (AUS) RT ENGINE PROPELLER GOVERNOR DRIVESHAFT SHEARED IN AREA LEVEL WITH THE MOUNTING FACE. 1 H 7 2 3O 3 O A17EU E295 5 C P920 2004080600014 20040806 00014 EU 2004 8 6 AUS20040321 1 20040501 G 5711 AV50903 SUPPORT ANGLE PARTEN P68 P68B 6780104 EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YK2 GL WING SPAR CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WING SPAR STRAP SUPPORT FORWARD AND AFT ANGLES CRACKED ALONG RIVET LINE. 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 2004080600015 20040806 00015 EU 2004 8 6 AUS20040322 1 20040319 G 2910 4204001 PTU BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE HYDRAULIC SYSTEM SEIZED W O OTHER J WARNING INDICATION DE DESCENT 1 AU S 7184 (AUS) HYDRAULIC POWER TRANSFER UNIT (PTU) SEIZED. 2 H 7 4 4F 4 F A49EU E6NE 2004080600016 20040806 00016 NM 2004 8 6 AUS20040323 1 20040409 G 4950 DUCT BOEING 747 747438 NM RROYCE RB211 RB211524G19 NE APU BLEED AIR LEAKING W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 AU S (AUS) BURNING ODOR IN CABIN. SUSPECT CAUSED BY APU BLEED AIR DUCT LEAK. 2 L 7 4 4F 4 F RT A20WE E30NE 2004080600017 20040806 00017 CE 2004 8 6 AUS20040324 1 20040427 G 2897 99104207 WIRE CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCB3T HCB3TN5 GL FUEL INDICATING WORN W K NONE O OTHER IN INSP/MAINT 1 AU S 21310 (AUS) RT FUEL TANK QUANTITY WIRE CHAFED ON STRINGERS LOCATED AT STATION PWS 61.80. 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P15EA 2004080600044 20040806 00044 CE 2004 8 6 AUS20040325 1 20040421 G 3230 57411541 SPACER CESSNA 441 441 2076020 CE HARTZL HCB3T HCB3TN5 GL MLG WORN W O OTHER J WARNING INDICATION CL CLIMB 1 AU S (AUS) MAIN LANDING GEAR UPLOCK HOOK ROLLER SPACER WORN. 1 L 7 2 3T RT A28CE 6 C P15EA 2004080600045 20040806 00045 CE 2004 8 6 AUS20040326 1 20040405 G 5551 21320082 WEB CESSNA 210 210R 2073458 CE CONT O520 IO520L 17032 SO MCAULY D3A34 D3A34C404 GL HORIZONTAL STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 7977 (AUS) TAILPLANE ATTACHMENT WEB CRACKED. 1 H 7 1 3O 3 O RT 3A21 E5CE 5 C P47GL 2004080600046 20040806 00046 WP 2004 8 6 AUS20040327 2 20040424 G 7261 31032174 PUMP CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCB3T HCB3TN5 GL ENGINE OIL CRACKED W O OTHER E K VIBRATION/BUFFET FLUID LOSS NR NOT REPORTED 1 AU S (AUS) ENGINE OIL PUMP HOUSING CRACKED. 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P15EA 2004080600047 20040806 00047 NM 2004 8 6 AUS20040328 1 20040501 G 2120 ODOR BOEING 737 737800* NM GE CFM56 CFM567B24 NE CABIN DETECTED W O OTHER B SMOKE/FUMES/ODORS/SPARKS LD LANDING 1 AU S (AUS) STRONG BURNING ODOR ON FLIGHT DECK AND IN CABIN. EXTENSIVE INVESTIGATION COULD FIND NO CAUSE FOR THE PROBLEM OR A NY EVIDENCE OF BURNING. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004080600048 20040806 00048 NM 2004 8 6 AUS20040329 1 20040408 G 3244 161U000115 TIRE BOEING 747 747438 NM RROYCE RB211 RB211524G19 NE MLG DEFLATED W O OTHER O OTHER LD LANDING 1 AU S (AUS) TIRE DEFLATED DURING FLIGHT. 2 L 7 4 4F 4 F RT A20WE E30NE 2004080600059 20040806 00059 2004 8 6 AUS20040330 4 20040502 G 2210 R1053M182 FORCE LIMITER BOEING 737 737376 NM GE CFM56 CFM563B1 13802 NE AUTOPILOT SYSTEM FAULTY W O OTHER F FLT CONT AFFECTED CL CLIMB 1 AU S (AUS) AUTOPILOT WOULD NOT ENGAGE. SUSPECT FAULTY FORCE LIMITER. 2 L 7 2 4F 4 F RT A16WE E2GL 2004080600060 20040806 00060 NM 2004 8 6 AUS20040331 1 20040426 G 2761 LINE BOEING 737 737* NM GE CFM56 CFM567B24 NE SPOILER ACTUATOR LOOSE W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 AU S (AUS) OB SLAT ACTUATOR HYDRAULIC LINE LOOSE AND LEAKING. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004080600061 20040806 00061 NM 2004 8 6 AUS20040332 1 20040420 G 2752 413T1001 MOTOR BOEING 747 747438 NM GE CF6 CF680C2* GL TE FLAPS SEIZED W K NONE O OTHER IN INSP/MAINT 1 AU S 3843 (AUS) OB TRAILING EDGE FLAP ELECTRIC MOTOR SEIZED. 2 L 7 4 4F 4 F RT A20WE E23EA 2004080600062 20040806 00062 WP 2004 8 6 AUS20040333 2 20040421 G 7320 69254313 VALVE CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCB3T HCB3TN5 GL FUEL CONTROL LEAKING W O OTHER K FLUID LOSS NR NOT REPORTED 1 AU S (AUS) START FUEL VALVE LEAKING BETWEEN VALVE BODY AND SOLENOID. 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P15EA 2004080600063 20040806 00063 NE 2004 8 6 AUS20040334 1 20040504 G 5280 7620902019043 FITTING SKRSKY S76 S76C 8143008 NE TMECA ARRIEL ARRIEL1S 60030 NE MLG DOOR CRACKED W O OTHER O OTHER LD LANDING 1 AU S 7087 (AUS) LT MAIN LANDING GEAR DOOR HINGE FITTING FAILED. 1 G 7 2 3U 3 U NC H1NE E19EU 2004080600064 20040806 00064 NM 2004 8 6 AUS20040335 1 20040501 G 2421 IDG BOEING 737 73776N 13844CH NM GE CFM56 CFM567B24 NE AC GENERATOR FAULTY W O OTHER H J ELECT. POWER LOSS-50 PC WARNING INDICATION TX TAXI/GRND HDL 1 AU S (AUS) NR 2 INTEGRATED DRIVE GENERATOR (IDG) SUSPECT FAULTY. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004080600065 20040806 00065 NM 2004 8 6 AUS20040336 1 20040425 G 2910 BACC27AC10061006 FITTING BOEING 737 737800* NM GE CFM56 CFM567B24 NE HYDRAULIC SYSTEM CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S (AUS) FOUR WAY HYDRAULIC FITTING CRACKED AND LEAKING. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004080600066 20040806 00066 NM 2004 8 6 AUS20040337 1 20040403 G 2751 900040813 TRANSDUCER BOEING 747 74748E 2FOR NM GE CF6 CF680C2* GL TE FLAPS FAULTY W O OTHER F J FLT CONT AFFECTED WARNING INDICATION CL CLIMB 1 AU S (AUS) LT IB TRAILING EDGE FLAP ROTARY VOLTAGE DIFFERENTIAL TRANSDUCER (RVDT) FAULTY. 2 L 7 2 4F 4 F RT A20WE E23EA 2004080600074 20040806 00074 EU 2004 8 6 AUS20040339 1 20040505 G 5310 PLATE BAG BAE146 BAE146300A 1500267 EU LYC ALF502 ALF502R5 41580 NE FUSELAGE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) INSP OF REAR CABIN WET AREA AT FLOOR LEVEL FOUND CORROSION IN FOLLOWING PLATES: SHEAR PLATE PN HC538H1183-000 LOC ATED ON TOP OF LONGITUDINAL BEAM FRAME 43 RBL 34. CORROSION WAS LOCATED ON UPPER SURFACE MEASURING 17.018MM (0.67IN) LE NGTH, 16.002MM (0.63IN) WIDTH AND 0.508MM (0.020IN) DEPTH. TOP PLATE PN HC 538J0584-203 LOCATED ON TOP OF LONGITUDINAL RAIL FROM FRAME 41 TO 43 RBL 21. CORROSION LOCATED ON LOWER SURFACE MEASURING 24MM (0.944IN) LENGTH, 18MM (0.708IN) WI DTH AND 0.838MM (0.033IN) DEPTH. TOP PLATE PN HC538J1361-000 OF LATERAL FLOOR SUPPORT BEAM AT FRAME 40 BETWEEN LBL 20 + RBL 20. CORROSION LOCATED ON THE UPPER SURFACE MEASURING 250MM (9.8IN) LENGTH, 45MM 040339 5. 2 H 7 4 4F 4 F RT A49EU E6NE 2004080600075 20040806 00075 NM 2004 8 6 AUS20040340 1 20040426 G 2410 B1773 SEAL BOEING 737 737400 138449A NM CFMINT CFM56 CFM563C 13802 EU CSD LEAKING W O OTHER H ELECT. POWER LOSS-50 PC CR CRUISE 1 AU S 14217 (AUS) NR 2 CONSTANT SPEED DRIVE (CSD) GENERATOR DRIVE SEAL WORN AND LEAKING. 2 L 7 2 4F 4 F RT A16WE E21EU 2004080600076 20040806 00076 NM 2004 8 6 AUS20040341 1 20040407 G 2751 INDICATOR BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL TE FLAP FAULTY W O OTHER F J FLT CONT AFFECTED WARNING INDICATION AP APPROACH 1 AU S (AUS) TRAILING EDGE FLAP DISAGREE INDICATION. 2 L 7 2 4F 4 F RT A1NM E23EA 2004080600077 20040806 00077 NM 2004 8 6 AUS20040342 1 20040418 G 2131 1305026 SELECTOR BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL CABIN PRESSURE FAULTY W O OTHER J WARNING INDICATION DE DESCENT 1 AU S 18643 (AUS) CABIN PRESSURE SELECTOR FAULTY. 2 L 7 2 4F 4 F RT A1NM E23EA 2004080600078 20040806 00078 EU 2004 8 6 AUS20040343 1 20040429 G 6420 1053040212 FITTING BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE T/R GEARBOX CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) TAIL ROTOR GEARBOX MOUNT CRACKED FROM BOLT HOLE. 1 G 7 2 3U 3 U H13EU E5NE10 2004080600079 20040806 00079 EA 2004 8 6 AUS20040344 2 20040501 G 7414 BEARING PIPER PA32 PA32300 7103212 SO LYC O540 IO540K1A5 41532 EA HARTZL HCC2Y HCC2YK1 GL MAGNETO SEIZED W O OTHER E VIBRATION/BUFFET TX TAXI/GRND HDL 1 AU S 919 (AUS) MAGNETO REAR BEARING SEIZED. CONTACT BREAKERS MELTED. 1 L 7 1 3O 3 O A3SO 1E4 5 C P920 2004080600080 20040806 00080 EU 2004 8 6 AUS20040345 1 20040506 G 1430 HC536B0475000 BOLT BAG BAE146 BAE146300A 1500267 EU LYC ALF502 ALF502R5 41580 NE FUSELAGE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FORWARD OUTER ATTACHMENT SPECIAL BOLT SHAFT CORRODED AND PLATING MISSING. CORROSION WAS LOCATED APPROXIMATELY 12.7 MM (0.5IN) DOWN FROM THE BOLT HEAD. AREA OF CORROSION 25.4MM (1IN) IN LENGTH BY 9.39MM (0.370IN) IN WIDTH BY0.127MM (0. 005IN) DEPTH.BOLTS ARE LOCATED IN ZONE 161, FRAME 29 STN 539-4. 2 H 7 4 4F 4 F RT A49EU E6NE 2004080600081 20040806 00081 EU 2004 8 6 AUS20040346 1 20040506 G 5710 SKIN FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE WING CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WING TRAILING EDGE CONTAINED CORROSION ON BOTH SIDES. 2 L 7 2 4F 4 F RT E25NE 2004080600082 20040806 00082 EU 2004 8 6 AUS20040347 1 20040506 G 5315 FLOORBEAM FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE FUSELAGE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) CABIN FLOOR PANEL SUPPORT BEAMS (2OFF) CORRODED. SUSPECT CAUSED BY INCORRECT REMOVAL OF FLOOR PANEL AND GAP SEALAN T USING A SHARP EDGED TOOL WHICH SCORED THE BEAMS. CORROSION INITIATED AT THE SCORE MARKS. PERSONNEL/MAINTENANCE ERROR. 2 L 7 2 4F 4 F RT E25NE 2004080600083 20040806 00083 EU 2004 8 6 AUS20040348 1 20040506 G 5313 STRINGER FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE FUSELAGE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) CENTER CARGO COMPARTMENT CORRODED ON FORWARD FACE OF DOOR SILL BEAM AND LOWER SHELL STRINGERS. 2 L 7 2 4F 4 F RT E25NE 2004080600084 20040806 00084 NM 2004 8 6 AUS20040349 1 20040421 G 2130 CABIN PRESSURE BOEING 767 767238 1385114 NM PWA JT9 JT9D7R4E 52054 NE MALFUNCTIONED W O OTHER O OTHER DE DESCENT 1 AU S (AUS) CABIN DIFFERENTIAL PRESSURE STUCK AT 8.6 PSI. 2 L 7 2 4F 4 F RT A1NM E3NE 2004080600085 20040806 00085 2004 8 6 AUS20040350 4 20040423 G 3418 60150301 STRIP REIMS 406 F406 7535723 EU PWA PT6 PT6A112 52043 NE MCAULY 3G34C7 3GFR34C701 GL STALL WARNING SY SEPARATED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) STALL STRIP MISSING. 1 L 7 2 3T 3 T RT A54EU E4EA 5 C P60GL 2004080600086 20040806 00086 EU 2004 8 6 AUS20040351 1 20040506 G 5347 SEAT TRACK BAG BAE146 BAE146300A 1500267 EU LYC ALF502 ALF502R5 41580 NE FUSELAGE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) SEAT TRACKS CORRODED. PN HC538J0343-001 RT IB SEAT TRACK FOUND CORRODED ON UPPER SURFACE. CORROSION MEASURES 106 .68MM (4.2IN) LENGTH, 24.13MM (0.95IN) WIDTH WITH DEPTH OUT OF LIMITS. LOCATION, ZONE 251, FRAME 40, RBL 21 RT. REPOR TED CAUSE OF DEFECT, LAVATORY/GALLEY SPILL. PN HC539J0395 LT OB SEAT TRACK FOUND CORRODED ON THE UPPER SURFACE. CORROSI ON MEASURES 38.1MM (1.5IN) LENGTH, 21.7MM (0.856IN) WIDTH AND 1.803MM (0.071) DEPTH. LOCATION - ZONE 251 STA 867 AND 8 54 LBL 43. REPORTED CAUSE OF DEFECT - DISSIMILAR METALS OF THE SEAT TRACK AND THE STEEL FEET OF THE MEAL TROLLEY REAR ST OWAGE UNIT IN A DAMP ENVIRONMENT. PN HC538J0343-000 LT IB SEAT TRACK FOUND CORRODED ON. 2 H 7 4 4F 4 F RT A49EU E6NE 2004080600087 20040806 00087 NM 2004 8 6 AUS20040352 1 20040427 G 3350 BPS73 BATTERY BOEING 767 767338 1385151 NM RROYCE RB211 RB211524* NE EMERGENCY LIGHT FAULTY W K NONE L NO TEST IN INSP/MAINT 1 AU S (AUS) EMERGENCY LIGHTING SYSTEM POWER SUPPLY AND BATTERY M1395 FAULTY. 2 L 7 2 4F 4 F RT A1NM E12EU 2004080600088 20040806 00088 NM 2004 8 6 AUS20040353 1 20040416 G 7797 WIRE BOEING 747 747338 NM RROYCE RB211 RB211524* NE ENGINE BROKEN W O OTHER E VIBRATION/BUFFET CR CRUISE 1 AU S (AUS) ENGINE AIRBORNE VIBRATION MONITOR INDICATION MODULE SELECTOR SWITCH WIRE FROM PIN 19 OF CONNECTOR DM162 BROKEN. 2 L 7 2 4F 4 F RT A20WE E12EU 2004080600089 20040806 00089 EU 2004 8 6 AUS20040354 1 20040506 G 5730 SKIN FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE WING CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT WING TIP TRAILING EDGE CORRODED. CORROSION ALSO FOUND UNDERSTATIC DISCHARGER BASE. 2 L 7 2 4F 4 F RT E25NE 2004080600090 20040806 00090 EU 2004 8 6 AUS20040355 1 20040506 G 5714 STRINGER FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE CENTER WING CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WING CENTER SECTION EXTERNAL LOWER SURFACE Z SECTION STRINGERS CONTAINED LEVEL 3 CORROSION. 2 L 7 2 4F 4 F RT E25NE 2004080600091 20040806 00091 EU 2004 8 6 AUS20040356 1 20040506 G 5752 D18016 BRACKET FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE AILERON TAB CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) AILERON TAB BEARING BRACKET CONTAINED LEVEL 3 CORROSION. 2 L 7 2 4F 4 F RT E25NE 2004080600092 20040806 00092 EU 2004 8 6 AUS20040357 1 20040505 G 5311 HC536H1050200 FRAME BAG BAE146 BAE146300A 1500267 EU LYC ALF502 ALF502R5 41580 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) CABIN CROWN FRAME TO SKIN STRUCTURE ANGLE CLEATS (8OFF) CRACKED FROM BEND RADIUS EDGE. THE ANGLE CLEATS ARE LOCATE D IN FOLLOWING AREAS: FRAME 19A BETWEEN STRINGERS 1 AND 2 LT. FRAME 19A BETWEEN STRINGERS 2 AND 3 LT 3. FRAME 19B BETW EEN STRINGERS 1 AND 2 LT. FRAME 19B BETWEEN STRINGERS 2 AND 3 LT. FRAME 19C BETWEEN STRINGERS 1 AND 2 LT. FRAME 19 C BETWEEN STRINGERS 2 AND 3 LT. FRAME 19D BETWEEN STRINGERS 1 AND 2 LT. FRAME 19D BETWEEN STRINGERS 2 AND 3 LT THE C RACKS RANGED IN LENGTH BETWEEN 2.5MM (0.1IN) AND 22.8MM(0.9IN). 2 H 7 4 4F 4 F RT A49EU E6NE 2004080600093 20040806 00093 CE 2004 8 6 AUS20040358 1 20040505 G 5511 053200199 ANGLE CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA MCAULY IC235 IC235LFA7570 EA HORIZONTAL STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT HORIZONTAL STABILIZER AFT RIB ATTACHMENT ANGLE CRACKED. A GAP BETWEEN THE AFT RIB ATTACHMENT ANGLE AND SPAR CAU SES CRACKING OF THE ANGLE WHEN THE ATTACHMENT BOLTS ARE TENSIONED. ON REMOVAL OF THE FORWARD STABILIZER ATTACHMENT BOLTS FRETTING WAS EVIDENT AND THE BOLTS WERE SHANK BOUND. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P12EA 2004080600094 20040806 00094 NM 2004 8 6 AUS20040359 1 20040427 G 5754 SKIN BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL RT SLAT DELAMINATED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT LE SLAT T/E WEDGE DELAMINATED ON IB END UPPER FACE. AREA OF DELAMINATION APPROXIMATELY 70 SQ IN. FOUND DURING INSPECTION IAW AD/767/73. 2 L 7 2 4F 4 F RT A1NM E23EA 2004080600095 20040806 00095 SO 2004 8 6 AUS20040360 2 20040505 G 8550 IO520MB OIL SYSTEM CESSNA 310 310R 2074245 CE CONT O520 IO520M 17032 SO MCAULY 3AF32C 3AF32C87 GL ENGINE CONTAMINATED W O OTHER E K VIBRATION/BUFFET FLUID LOSS DE DESCENT 1 AU S 6 565592 (AUS) METAL CONTAMINATION OF RT ENGINE OIL SYSTEM. THREE PIECES OF 0.812 MM (0.032IN) LOCKWIRE FOUND IN OIL FILTER. TW O MORE PIECES OF LOCKWIRE FOUND IN OIL PRESSURE RELIEF VALVE. ENGINE HAD 6 HOURS OPERATION SINCE OVERHAUL. PERSONNEL/MA INTENANCE ERROR. 1 L 7 2 3O 3 O 3A10 E5CE 5 C P22EA 2004080600096 20040806 00096 SO 2004 8 6 AUS20040361 2 20040501 G 7310 S112940150 HOSE CESSNA 210 210M 2073450 CE CONT O520 IO520L 17032 SO MCAULY D3A34 D3A34C404 GL FUEL DISTRIBUTIO LOOSE W O OTHER K J FLUID LOSS WARNING INDICATION CR CRUISE 1 AU S 60 (AUS) ENGINE FUEL HOSE LEAKING AT CONNECTION TO CHECK VALVE. FUEL LEAKING INTO ENGINE BAY. HOSE HAD NOT BEEN TIGHTENED DURING MAINTENANCE. PERSONNEL/MAINTENANCE ERROR. 1 H 7 1 3O 3 O 3A21 E5CE 5 C P47GL 2004080600097 20040806 00097 SW 2004 8 6 AUS20040362 1 20040406 G 6320 206040662101 GEAR BELL BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL M/R GEARBOX WORN W K NONE O OTHER IN INSP/MAINT 1 AU S BKW11161 (AUS) MAIN TRANSMISSION SUN GEAR PN 206-040-662-101 AND SUN GEAR SHAFT PN 206-040-040-005 WORN BEYOND LIMITS IN SPLINED AREAS. INVESTIGATION FOUND THE SUN GEAR UPPER O RING PN M83248/1-228 WAS TORN AND SLICED IN SEVERAL AREAS AND THE SUN G EAR LOWER O-RING PN M83248/1-232 WAS ILL FITTING AND COULD BE REMOVED WITH LITTLE EFFORT. SUSPECT WEAR WAS CAUSED BY CO NTAMINATION OF THE SUN GEAR SPLINE LUBRICATION GREASE BEING CONTAMINATED WITH TRANSMISSION LUBRICATING OIL DUE TO DAMAGE D AND ILL FITTING O-RINGS. 1 G 7 1 3U 3 U H2SW E4CE 2004080600098 20040806 00098 EA 2004 8 6 AUS20040363 2 20040424 G 7414 2202 BEARING BENDIX BL6006163 ROBSIN R44 R44 7640120 WP LYC O540 O540F1B5 41532 EA MAGNETO FAILED W O OTHER E F VIBRATION/BUFFET FLT CONT AFFECTED DE DESCENT 1 AU S 420 E03DA06012 (AUS) LT MAGNETO BEARING FAILED. 1 G 7 1 3O 3 O H11NM E295 2004080600099 20040806 00099 NM 2004 8 6 AUS20040364 1 20040429 G 7921 BOLT BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL FUEL/OIL COOLER LOOSE W O OTHER K J FLUID LOSS WARNING INDICATION DE DESCENT 1 AU S (AUS) LT TANK FUEL QUANTITY APPROXIMATELY 800 KILOGRAMS LOWER THAN RT TANK. INVESTIGATION FOUND THE FUEL/OIL COOLER FORW ARD BASKET BOLTS LOOSE BUT ASCERTAINED THIS WAS NOT THE CAUSE OF THE APPARENT FUEL LOSS. INVESTIGATION CONTINUING. 2 L 7 2 4F 4 F RT A1NM E23EA 2004080600100 20040806 00100 NM 2004 8 6 AUS20040365 1 20040506 G 2530 GENM2585015 OVEN BOEING 737 737376 NM GE CFM56 CFM563B1 13802 NE GALLEY FAULTY W O OTHER B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 AU S 90022634 (AUS) AFT GALLEY OVEN ELECTRICAL FAULT. INVESTIGATION FOUND FILTERBOARD CAUGHT FIRE DUE TO THE FORMATION OF DRY SOLDER JOINTS ON INDUCTOR CONTACTS. 2 L 7 2 4F 4 F RT A16WE E2GL 2004080600101 20040806 00101 NM 2004 8 6 AUS20040366 1 20040505 G 2510 PANEL BOEING 747 747438 NM RROYCE RB211 RB211524G19 NE COCKPIT INCORRECT W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) COCKPIT IB DECORATIVE PANEL FORWARD EDGE OVERLAPPING CAUSING CAPTAINS RUDDER PEDALS TO BIND DURING FULL TRAVEL CON TROL CHECK. REPOSITIONING PANEL PREVENTED FURTHER BINDING PROBLEMS. 2 L 7 4 4F 4 F RT A20WE E30NE 2004080600102 20040806 00102 2004 8 6 AUS20040367 4 20040503 G 2565 737M25651017 SLIDE BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU L2 DOOR FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) DOOR 2L ESCAPE SLIDE LIGHTS FAILED TO ILLUMINATE FOLLOWING SLIDED EMPLOYMENT. SUSPECT FLAT BATTERY. 2 L 7 2 4F 4 F RT A16WE E21EU 2004080600103 20040806 00103 CE 2004 8 6 AUS20040368 1 20040429 G 3010 27S70510904 BOOT CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCB3T HCB3TN5 GL DEICE SYS FAILED W O OTHER O OTHER CL CLIMB 1 AU S (AUS) RT WING OUTER DE-ICE BOOT BURST AT THE UPPER SEAM AND SPLIT FOR THE ENTIRE LENGTH FROM THE OB RT NACELLE TO THE WI NGTIP. 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P15EA 2004080600104 20040806 00104 EA 2004 8 6 AUS20040369 2 20040503 G 8520 L421861A ENGINE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL LEFT MAKING METAL W K NONE O OTHER IN INSP/MAINT 1 AU S L421861A (AUS) LT ENGINE METAL CONTAMINATION. METAL PARTICLES IN FILTER WERE NON-FERROUS FLAKES WITH THE LARGEST FLAKES APPROXIM ATELY 6MM BY 4MM (0.236IN BY 0.157IN). SUSPECT BEARING MATERIAL. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004080600105 20040806 00105 EU 2004 8 6 AUS20040370 1 20040510 G 2810 TANK FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE FUEL STORAGE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT WING FUEL SYSTEM COLLECTOR TANK CONTAINED LEVEL 3 CORROSION ON LOWER INTERNAL SURFACE. 2 L 7 2 4F 4 F RT E25NE 2004080600106 20040806 00106 EU 2004 8 6 AUS20040371 1 20040510 G 2810 TANK FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE FUEL STORAGE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT WING FUEL SYSTEM COLLECTOR TANK CONTAINED LEVEL 3 CORROSION ON LOWER INTERNAL SURFACE. 2 L 7 2 4F 4 F RT E25NE 2004080600107 20040806 00107 EU 2004 8 6 AUS20040372 1 20040507 G 5320 HC538H0125007 ANGLE BAG BAE146 BAE146300A 1500267 EU LYC ALF502 ALF502R5 41580 NE FUSELAGE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT REAR ENTRY SILL PLATE ATTACHMENT ANGLE CONTAINED LEVEL 2 CORROSION ON THE UPPER SURFACE. AREA OF CORROSION 48 .26MM (1.9IN) LONG BY 20.8MM (0.82IN) WIDE AND 0.584MM (0.023IN) DEEP. LOCATION OF CORROSION, ZONE 252 STRINGER 19, BET WEEN FRAMES 41AND 43, BL44 RT. 2 H 7 4 4F 4 F RT A49EU E6NE 2004080600108 20040806 00108 CE 2004 8 6 AUS20040373 1 20040507 G 5511 1016200143 SPAR CAP BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL HORIZONTAL STAB CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT HORIZONTAL STABILISER UPPER REAR SPAR CAP CONTAINED SEVERE INTERGRANNULAR CORROSION. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2004080600110 20040806 00110 EU 2004 8 6 AUS20040374 1 20040507 G 2797 A157BA2579920 WIRE REIMS 406 F406 7535723 EU PWA PT6 PT6A112 52043 NE MCAULY 3G34C7 3GFR34C701 GL TE FLAPS BROKEN W O OTHER F FLT CONT AFFECTED TO TAKEOFF 1 AU S (AUS) FLAP CONTROL SYSTEM WIRE BROKEN. FAULT TRACE TO BROKEN WIRE A157B-A25799200 TO FLAP UP CONTROL SWITCH. 1 L 7 2 3T 3 T RT A54EU E4EA 5 C P60GL 2004080600111 20040806 00111 CE 2004 8 6 AUS20040375 1 20040505 G 3232 6632303003001 ACTUATOR LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE7312 01518 WP MLG DOOR DAMAGED W O OTHER K FLUID LOSS LD LANDING 1 AU S (AUS) LT MAIN LANDING GEAR IB DOOR ACTUATOR DAMAGED. ACTUATOR HOUSING END CAP SEPARATED FROM HOUSING DUE TO SHEARING OF THE FOUR END CAP BOLT HEADS. LOSS OF HYDRAULIC FLUID. 2 L 7 2 4F 4 F RT T00008WI E6WE 2004080600112 20040806 00112 NM 2004 8 6 AUS20040376 1 20040428 G 2750 BEARING BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE TE FLAPS SEIZED W O OTHER F FLT CONT AFFECTED DE DESCENT 1 AU S (AUS) IB FLAP SELECTOR VALVE INPUT ROD SELF ALIGNING BEARING BINDING DUE TO LACK OF LUBRICATION. 2 L 7 3 4F 4 F RT A3WE E2EA 2004080600113 20040806 00113 CE 2004 8 6 AUS20040377 1 20040424 G 5340 26111441 SUPPORT CESSNA 208 208B 2073701 CE PWA PT6 PT6A114A 52043 NE MCAULY 3AF34C 3GFR34C703 GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FLAP ACTUATOR SUPPORT ASSEMBLY CRACKED. 1 H 7 1 3T 3 T A37CE E4EA 5 C P60GL 2004092300111 20040923 00111 EU 2004 9 23 AUS20040378 1 20040503 G 1420 51224133 CONNECTOR STBROS SD3 SD360 8100606 EU PWA PT6 PT6A67R 52043 NE HARTZL HCA6A HCA6A3 NE FIRE DETECTOR CORRODED W O OTHER E B J VIBRATION/BUFFET SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION TO TAKEOFF 1 AU S (AUS) LT ENGINE FIRE WIRE CONNECTOR CORRODED. CONNECTOR IS LOCATED AT THE REAR FIREWALL POSITION. 2 H 7 2 4T 4 T A41EU E26NE 6 C P14NE 2004092300112 20040923 00112 EU 2004 9 23 AUS20040379 1 20040505 G 5347 SEAT TRACK BAG BAE146 BAE146300A 1500267 EU LYC ALF502 ALF502R5 41580 NE FUSELAGE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) CABIN FLOOR STRUCTURE CONTAINED LEVEL 2 CORROSION IN THE FOLLOWING AREAS: PN HC536H1063-001 RT OB SEAT TRACK END ON UPPER SURFACE. AREA OF CORROSION MEASURED 38.1MM (1.5IN) IN LENGTH BY 12.7MM (0.5IN) IN WIDTH WITH A DEPTH OF 2.54M M (0.10IN). CORROSION LOCATED IN ZONE 222 AT FRAME 18 BETWEEN STATIONS 216.6 AND 240 RT BL43 RT. REPORTED CAUSE OF DAM AGE LAVATORY/GALLEY SPILL. PN HC536H1063-002 LT OB SEAT TRACK ON UPPER SURFACE AT FORWARD END. AREA OF CORROSION MEA SURED 25.4MM (1IN) IN LENGTH BY 6.35MM (0.250IN) IN WIDTH WITH A DEPTH OF 1.066MM (0.042IN). CORROSION LOCATED IN ZONE 221 ON FRAME 18 AT BL 42 LT. REPORTED CAUSE OF DAMAGE LAVATORY/GALLEY SPILL. 2 H 7 4 4F 4 F RT A49EU E6NE 2004092300113 20040923 00113 EU 2004 9 23 AUS20040380 1 20040510 G 5280 D26323007 ROLLER FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE MLG DOOR MISMANUFACTURED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) MAIN DOOR LOCKING ROLLER INTERNAL DIAMETER WAS TOO SMALL TO FIT OVER THE STEEL STUD IN THE DOOR FRAME. ROLLER WAS A NEW ITEM AND WAS BEING FITTED TO THE DOOR. SUSPECT FAULTY MANUFACTURE. 2 L 7 2 4F 4 F RT E25NE 2004080500080 20040805 00080 EU 2004 8 5 AUS20040381 1 20040507 G 5313 STRINGER68 STRINGER FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) STRINGER 68 CRACKED. 2 L 7 2 4F 4 F RT E25NE 2004072800201 20040728 00201 NM 2004 7 28 AUS20040382 1 20040503 G 3244 165T0100530 TIRE BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL LT MLG DEFLATED W K NONE O OTHER IN INSP/MAINT 1 AU S 1581 QF15102 (AUS) LT MAIN LANDING GEAR NR 5 TIRE DEFLATED. NO DAMAGE TO TIRE EVIDENT. 2 L 7 2 4F 4 F RT A1NM E23EA 2004072800202 20040728 00202 EA 2004 7 28 AUS20040383 2 20040503 G 8530 LW19339 SCREW CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL ENGINE CRACKED W O OTHER E VIBRATION/BUFFET CL CLIMB 1 AU S 591 (AUS) EXHAUST VALVE ROCKER ADJUSTMENT SCREW CRACKED ALLOWING LOCKNUT TO LOOSEN AND ADJUST VALVE CLEARANCE. 1 H 7 1 3O 3 O NT 3A19 E223 5 N P50GL 2004072800203 20040728 00203 NM 2004 7 28 AUS20040384 1 20040426 G 2751 2061141 INDICATOR BOEING 737 737376 NM GE CFM56 CFM563B1 13802 NE TE FLAPS FAULTY W O OTHER F J FLT CONT AFFECTED WARNING INDICATION AP APPROACH 1 AU S 25055 (AUS) FLAP POSITION INDICATOR FAULTY. 2 L 7 2 4F 4 F RT A16WE E2GL 2004072800204 20040728 00204 2004 7 28 AUS20040385 4 20040414 G 2211 065006401 COMPUTER REIMS 406 F406 7535723 EU PWA PT6 PT6A112 52043 NE MCAULY 3G34C7 3GFR34C701 GL AUTOPILOT FAULTY W O OTHER F FLT CONT AFFECTED CR CRUISE 1 AU S (AUS) AUTOPILOT COMPUTER FAULTY. 1 L 7 2 3T 3 T RT A54EU E4EA 5 C P60GL 2004072800205 20040728 00205 SW 2004 7 28 AUS20040386 1 20040504 G 6320 2060400209 GEAR BELL BELL 206 206L1 1182107 SW ALLSN 250C 250C30 03013 GL M/R GEARBOX FAILED W O OTHER J WARNING INDICATION LD LANDING 1 AU S 554 BMB45250 (AUS) MAIN ROTOR TRANSMISSION INPUT PINION GEAR FAILED. GEAR TEETH STARTING TO BREAK DOWN WITH DISTINCT WEAR PATTERN AN D PITTING ON THE FLANK OF ALL GEAR TEETH AND ADVANCED BREAKING DOWN OF SOME OF THE TEETH. METAL CONTAMINATION OF TRANSM ISSION. 1 G 7 1 3U 3 U H2SW E1GL 2004072800206 20040728 00206 NM 2004 7 28 AUS20040387 1 20040429 G 2701 CONTROL COLUMN BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU COCKPIT BINDING W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FIRST OFFICER'S CONTROL COLUMN ELL FITTING CHAFING ON TRANSFER MECHANISM FORK. TRANSFER MECHANISM WAS FOUND TO HAV E A PRESERVICE BULLETIN FORK FITTED INSTEAD OF A POST SERVICE BULLETIN FORK. 2 L 7 2 4F 4 F RT A16WE E21EU 2004072900001 20040729 00001 NM 2004 7 29 AUS20040388 1 20040509 G 2420 GENERATOR BOEING 737 737376 NM GE CFM56 CFM563B1 13802 NE APU FAILED W K NONE H ELECT. POWER LOSS-50 PC IN INSP/MAINT 1 AU S (AUS) APU GENERATOR FAILED. 2 L 7 2 4F 4 F RT A16WE E2GL 2004072900020 20040729 00020 NM 2004 7 29 AUS20040389 1 20040511 G 2797 TB262XA3 TERMINAL BOEING 737 737* NM GE CFM56 CFM567B24 NE RUDDER CONTROL FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) STANDBY RUDDER SHUTOFF VALVE WILL NOT CLOSE ON SELECTION. INVESTIGATION FOUND WIRES W2212-0521-20 AND W5170-0505-2 0 TOTB262-XA3 NOT LOCKED INTO POSITION CAUSING OPEN CIRCUIT. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004072900021 20040729 00021 NM 2004 7 29 AUS20040390 1 20040506 G 1430 BOLT BOEING 747 747338 NM RROYCE RB211 RB211524D419 54555 NE MLG INCORRECT W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT WING LANDING GEAR TO LANDING GEAR DOOR TIE ROD BOLTS INCORRECTLY FITTED. BOLTS WERE FITTED UPSIDE DOWN. PERSO NNEL/MAINTENANCE ERROR. 2 L 7 2 4F 4 F RT A20WE E12EU 2004072900022 20040729 00022 NM 2004 7 29 AUS20040391 1 20040510 G 5410 311T106535 DOOR BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL NACELLE MISSING W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NR 2 ENGINE NACELLE/STRUT OB ACCESS DOOR MISSING. 2 L 7 2 4F 4 F RT A1NM E23EA 2004072900023 20040729 00023 CE 2004 7 29 AUS20040392 1 20040113 G 5312 0513006103 BULKHEAD CESSNA 182 182B 2072706 CE CONT O470 O470* 17026 SO HARTZL HC82X HC82XF1 GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE BULKHEAD CRACKED IN AREA DESCRIBED IN AD/CESSNA180/75AMDT2. CRACK LENGTH APPROXIMATELY 38.1MM (1.5IN). AD IS NOT APPLICABLE TO THIS MODEL AIRCRAFT. 1 H 7 1 3O 3 O NT 3A13 E273 5 C P878 2004072900024 20040729 00024 EA 2004 7 29 AUS20040393 2 20040511 G 7414 10682014 GEAR PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL MAGNETO FAULTY W O OTHER O OTHER NR NOT REPORTED 1 AU S GOIJA088R (AUS) MAGNETO DISTRIBUTOR GEAR FINGER INCORRECTLY FITTED. FINGER WAS LOCATED APPROXIMATELY 180 DEGREES FROM LOCATING LU GS. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004072900025 20040729 00025 NM 2004 7 29 AUS20040394 1 20040506 G 5511 SPAR BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU HORIZONTAL STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) HORIZONTAL STABILIZER REAR SPAR SUSPECT CRACKED. EDDY CURRENT INSPECTION CONFIRMED THE FOLLOWING CRACKS. STABILI ZER REAR SPAR RT FORWARD FACE OF TOP WEB ASSEMBLY. CRACK INDICATION CONFIRMED. CRACK LENGTH 10.16MM (0.400IN)OUT OF FAS TENER HOLE. HORIZONTAL STABILIZER CENTER SECTION REAR SPAR RT HOLE. EDDY CURRENT INSPECTION CARRIED OUT. WEB CRACKE D 6 O’CLOCK POSITION. 2 L 7 2 4F 4 F RT A16WE E21EU 2004072900026 20040729 00026 2004 7 29 AUS20040395 4 20040511 G 2564 710FAUL2901104 LIFE RAFT CABIN DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LIFERAFT HOLED IN TOP, ROOF AND FLOOR CHAMBERS. INVESTIGATION FOUND THE HOLES HAD OCCURRED DURING INITIAL PACKING ATMANUFACTURE. 2004072900027 20040729 00027 WP 2004 7 29 AUS20040396 1 20040511 G 7810 D3171 SHIELD ROBSIN R44 R44 7640120 WP LYC O540 IO540* 41532 EA EXHAUST SEPARATED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) EXHAUST SHIELD MISSING. ATTACHMENT TABS REMAINED ON EXHAUST ASSEMBLY. 1 G 7 1 3O 3 O H11NM 1E4 2004072900028 20040729 00028 NM 2004 7 29 AUS20040397 1 20040510 G 2150 213A10031 SEPARATOR BOEING 737 7377Q8 1384418 NM GE CFM56 CFM567B24 NE CABIN COOLING SY CONTAMINATED W O OTHER B SMOKE/FUMES/ODORS/SPARKS DE DESCENT 1 AU S (AUS) AIR CONDITIONING SYSTEM DUCTING, WATER SEPARATORS AND COALESCER BAGS CONTAMINATED WITH OIL. SUSPECT CAUSED BY OVER FILLING OF APU OIL SYSTEM. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004072900029 20040729 00029 WP 2004 7 29 AUS20040398 2 20040506 G 8550 H40671B2 SCAVENGE PUMP DHAV DHC1 DCH1CHIPMUNK 2801704 GL DHAVXX GIPSY GIPSYMAJOR1 20004 WP AMTR C8289 C8289 GL ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 48 (AUS) ENGINE OIL SCAVENGE PUMP CRACKED. 1 L 7 1 3O 3 I EXPA1L71 A8EU 5 N EXPP5N 2004072900030 20040729 00030 SW 2004 7 29 AUS20040399 1 20040503 G 7712 31080811 PIPE SWRNGN SA227 SA227* SW GARRTT TPE331 TPE33112UHR WP MCAULY 4HFR34 4HFR34C663 NE TORQUE SENSOR CRACKED W O OTHER E K VIBRATION/BUFFET FLUID LOSS CL CLIMB 1 AU S (AUS) LT ENGINE NEGATIVE TORQUE SENSOR (NTS) OIL PIPE CRACKED IN FLARE. 2 L 7 2 4T 4 T RT A5SW E4WE 6 C 3PNE 2004072900031 20040729 00031 NE 2004 7 29 AUS20040400 2 20040512 G 7250 312313102 TURBINE BLADES BEECH 200 B200C 1152924 CE PWA PT6 PT6A42 52043 NE MCAULY 3G34C7 3GFR34C701 GL TURBINE SECTION CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S PCE94722 (AUS) COMPRESSOR TURBINE BLADES (3 OFF) CRACKED. CRACKS EMANATE FROM BLADE TIP RADIALLY TOWARDS BLADE ROOT. CRACK LENGT HS UP TO APPROXIMATELY 7MM (0.27IN). FOUND DURING BOROSCOPE INSPECTION. 1 L 7 2 4T 4 T A24CE E4EA 5 C P60GL 2004072900032 20040729 00032 EU 2004 7 29 AUS20040401 1 20040517 G 2761 P308450102ISS2 ACTUATOR BAG BAE146 BAE146300A 1500267 EU LYC ALF502 ALF502R5 41580 NE DRAG CONTROL SEIZED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT NR 2 LIFT SPOILER ACTUATOR SPINDLE SEIZED IN LOCKED POSITION WITH THE ACTUATOR EXTENDED. FOUND DURING INSPECTI ON IAW AD/BA6-27-60-16D BAE MANDATORY ISB 27-137. 2 H 7 4 4F 4 F RT A49EU E6NE 2004072900033 20040729 00033 CE 2004 7 29 AUS20040402 1 20040514 G 5511 053200199 RIB CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA MCAULY IC235 IC235LFA7570 EA HORIZONTAL STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH HORIZONTAL STABILIZER RIB AFT ATTACHMENT ANGLE CRACKED. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P12EA 2004072900034 20040729 00034 SW 2004 7 29 AUS20040403 1 20040516 G 3230 OAS55015 DRAG BRACE SWRNGN SA227 SA227* SW GARRTT TPE331 TPE33112UHR WP MCAULY 4HFR34 4HFR34C652 NE MLG FRACTURED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT MAIN LANDING GEAR UPPER DRAG BRACE UPLOCK LUGS FRACTURED. CAUSED BY DRAG BRACE OUT OF ADJUSTMENT. 2 L 7 2 4T 4 T RT A5SW E4WE 6 C 3PNE 2004072900035 20040729 00035 SW 2004 7 29 AUS20040404 1 20040516 G 2752 2736053003 ACTUATOR SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TFE33112UHR WP ROTOL R321 R321482F8 GL TE FLAPS LEAKING W O OTHER K J FLUID LOSS WARNING INDICATION CR CRUISE 1 AU S 1433 (AUS) RT TRAILING EDGE FLAP ACTUATOR LEAKING FLUID FROM AROUND THE ACTUATOR RAM. LOSS OF HYDRAULIC FLUID. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P61GL 2004072900036 20040729 00036 EU 2004 7 29 AUS20040405 1 20040517 G 5311 HC538H0136002 FRAME BAG BAE146 BAE146300A 1500267 EU LYC ALF502 ALF502R5 41580 NE FUSELAGE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT FUSELAGE FRAME 43 CONTAINED LEVEL 2 CORROSION ON THE FORWARD FACE AT FLOOR LEVEL. DAMAGE WAS LOCATED AT ZONE 20 FRAME 43 STA 726.9 AND WAS 38.1MM (1.5IN) LONG BY 38.1MM (1.5IN) WIDE AND 4.546MM (0.179IN) DEEP. CAUSE OF DAMAGE WAS A SSESSED AS ENVIRONMENTAL. 2 H 7 4 4F 4 F RT A49EU E6NE 2004072900037 20040729 00037 NM 2004 7 29 AUS20040406 1 20040423 G 2910 DSC1896 VALVE DHAV DHC8 DHC8315 2809010 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE HYD SYSTEM FAILED W O OTHER K FLUID LOSS LD LANDING 1 AU S 99999 (AUS) NR 2 HYDRAULIC SYSTEM CHECK VALVE FAILED. LOSS OF HYDRAULIC FLUID. INVESTIGATION FOUND THE CHECK VALVE HAD SUFFERE D METAL FATIGUE FAILURE OF THE VALVE BODY WITH THE BODY CRACKING FULLY AROUND THE CIRCUMFERENCE OF THE VALVE BODY. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004072900057 20040729 00057 NE 2004 7 29 AUS20040407 3 20040512 G 6111 8173881 SEAL HAMSTD DHAV DHC8 DHC8315 2809010 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE PROPELLER BLADE INCORRECT W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 99999 (AUS) LT PROPELLER NR 4 BLADE SEAL FAILED. INSPECTION OF THE REMOVED SEAL REVEALED THE SEAL TO BE A SEAL FOR A 14SF TYP E PROPELLER WITH A 14RF TYPE PROPELLER GLAND SPRING SUPPLIED. THE 14RF GLAND SPRING IS OF A SMALLER DIAMETER WHEN COMPA RED TO THE 14SF GLAND SPRING. UNAPPROVED PART. PERSONNEL/MAINTENANCE ERROR. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004072900058 20040729 00058 NE 2004 7 29 AUS20040408 3 20040516 G 6111 8173881 SEAL HAMSTD DHAV DHC8 DHC8315 2809010 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE PROPELLER BLADE INCORRECT W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 99999 (AUS) LT PROPELLER NR 4 BLADE SEAL FAILED. INSPECTION OF THE REMOVED SEAL REVEALED THE SEAL TO BE A SEAL FOR A 14SF TYP E PROPELLER WITH A 14RF TYPE PROPELLER GLAND SPRING SUPPLIED. THE 14RF GLANDSPRING IS OF A SMALLER DIAMETER WHEN COMPARE D TO THE 14SF GLAND SPRING. UNAPPROVED PART. PERSONNEL/MAINTENANCE ERROR. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004072900059 20040729 00059 NM 2004 7 29 AUS20040409 1 20040427 G 7997 WIRE DHAV DHC8 DHC8315 2809010 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE OIL PRESS IND WORN W D RETURN TO BLOCK E K J VIBRATION/BUFFET FLUID LOSS WARNING INDICATION TX TAXI/GRND HDL 1 AU S (AUS) NR 2 ENGINE LOW OIL PRESSURE WARNING LIGHT SWITCH WIRE CHAFED AND SHORT CIRCUITING TO GROUND. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004072900060 20040729 00060 EU 2004 7 29 AUS20040410 1 20040517 G 5320 HC538J1324000 INTERCOSTAL BAG BAE146 BAE146300A 1500267 EU LYC ALF502 ALF502R5 41580 NE FUSELAGE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) AFT CABIN FLOOR INTERCOSTAL CONTAINED LEVEL 2 CORROSION ON THESIDE AND UPPER SURFACES. THE INTERCOSTAL DAMAGE WAS LOCATED INZONE 251 BETWEEN FRAMES 41 AND 53 AT BL9 LH. AREA OF CORROSION MEASURED 38.1MM (1.5 IN) IN LENGTH BY 3.175MM ( 0.125 IN) IN WIDTH AND 0.558MM (0.022 IN) DEPTH. 2 H 7 4 4F 4 F RT A49EU E6NE 2004072900061 20040729 00061 SW 2004 7 29 AUS20040411 1 20040405 G 6720 476221651 BRACKET BELL 47 47G3B1 1181028 SW LYC O435 TVO435B1A 41516 EA TAIL ROTOR MISSING W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) DUAL TAIL ROTOR CONTROL PEDAL SYSTEM INTERFERENCE BRACKET NOT FITTED. AD/BELL47/69 REQUIRES THE BRACKET TO BE FITT ED TO DUALCONTROL BELL/AGUSTA 47 SERIES AIRCRAFT. THE BRACKET PREVENTS INCORRECT FITMENT OF THE DUAL PEDAL CONTROLS. PER SONNEL/MAINTENANCE ERROR. 1 G 7 1 3O 3 O 2H3 1E13 2004072900062 20040729 00062 CE 2004 7 29 AUS20040412 1 20040427 G 2910 248000131 PIPE CESSNA 172 172RG 2072438 CE LYC O360 O360F1A6 41514 EA MCAULY 2D34C B2D34C220 GL HYD POWER PACK CORRODED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S (AUS) LANDING GEAR UP PIPE FROM GEAR SELECTOR HANDLE VALVE TO HYDRAULIC POWER PACK CORRODED WITH A SMALL PINHOLE LEAK. A FINE SPRAY OF HYDRAULIC FLUID CONTAMINATED THE REAR OF THE ADF RACK. 1 H 7 1 3O 3 O 3A17 E286 5 C P7EA 2004072900063 20040729 00063 WP 2004 7 29 AUS20040413 1 20040514 G 1430 NAS130310D BOLT HUGHES 269 269C 4470504 WP LYC O360 HIO360D1A 41514 EA FUEL CONTROL SEPARATED W O OTHER E J VIBRATION/BUFFET WARNING INDICATION CR CRUISE 1 AU S (AUS) GOVERNOR LINKAGE BOLT SEPARATED. LOSS OF ENGINE CONTROL RESULTED IN AUTO ROTATION AND HEAVY LANDING WITH SOME MIN OR DAMAGE TO THE AIRCRAFT. 1 G 7 1 3O 3 O 4H12 1E10 2004072900064 20040729 00064 EU 2004 7 29 AUS20040414 1 20040515 G 3233 750470706 SEAL BAG BAE146 BAE146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE MLG ACTUATOR LEAKING W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT MAIN LANDING GEAR ACTUATOR RESTRICTOR SEAL LEAKING. 2 H 7 4 4F 4 F RT A49EU E6NE 2004072900065 20040729 00065 NM 2004 7 29 AUS20040415 1 20040513 G 2752 65503245 DRIVE SHAFT BOEING 737 737376 NM GE CFM56 CFM563B1 13802 NE TE FLAP DRIVE WORN W K NONE O OTHER IN INSP/MAINT 1 AU S 45797 40216A (AUS) NR 4 TRAILING EDGE FLAP TRANSMISSION UNIVERSAL DRIVESHAFT WORN AXIALLY BEYOND LIMITS. END FLOAT WAS APPROXIMATELY 0.406MM(0.016IN) AT OUTPUT END. 2 L 7 2 4F 4 F RT A16WE E2GL 2004072900066 20040729 00066 CE 2004 7 29 AUS20040416 1 20040519 G 2761 6627602001005 ACTUATOR LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE731* 01518 WP DRAG CONTROL LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S (AUS) LT WING SPOILER ACTUATOR PRESSURE SWIVEL FAILED. LOSS OFHYDRAULIC FLUID. 2 L 7 2 4F 4 F RT T00008WI E6WE 2004072900067 20040729 00067 NM 2004 7 29 AUS20040417 1 20040516 G 3242 26123121 BRAKE BOEING 737 737800* NM GE CFM56 CFM567B24 NE RT MLG FAULTY W O OTHER O OTHER NR NOT REPORTED 1 AU S 553 (AUS) RT MAIN LANDING GEAR IB BRAKE FAULTY. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004072900068 20040729 00068 NM 2004 7 29 AUS20040418 1 20040515 G 7830 BLOCKER DOOR RROYCE BOEING 747 747438 NM RROYCE RB211 RB211524* NE THRUST REVERSER SEPARATED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NR 1 ENGINE THRUST REVERSER NR 9 BLOCKER DOOR DAMAGED. CONTROL LINKAGE, FITTING AND APPROXIMATELY 40 PERCENT OF T HE BLOCKER DOOR MISSING. 2 L 7 4 4F 4 F RT A20WE E12EU 2004072900069 20040729 00069 NM 2004 7 29 AUS20040419 1 20040404 G 2920 571488 SEAL DHAV DHC8 DHC8202 2809007 NM PWA 120 PW123D 52152 NE HAMSTD 14SF 14SF23 NE HYD SYSTEM FAILED W O OTHER K J FLUID LOSS WARNING INDICATION CR CRUISE 1 AU S (AUS) NR 2 HYDRAULIC STANDBY POWER UNIT DRIVESHAFT SEAL FAILED. LOSS OF HYDRAULIC FLUID. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004072900070 20040729 00070 NM 2004 7 29 AUS20040420 1 20040421 G 3397 2067051 CONNECTOR DHAV DHC8 DHC8315 2809010 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE LIGHTS BURNED W K NONE L NO TEST IN INSP/MAINT 1 AU S (AUS) RH OVERHEAD LIGHTING TERMINAL 7 CONNECTOR BURNED AND DAMAGED.ADJACENT TERMINAL 6 ALSO HEAT DAMAGED. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004072900071 20040729 00071 NM 2004 7 29 AUS20040422 1 20040514 G 3244 TIRE BOEING 737 737376 NM GE CFM56 CFM563B1 13802 NE NLG DAMAGED W C ABORTED TAKEOFF C F.O.D. TO TAKEOFF 1 AU S (AUS) RT NOSE LANDING GEAR TIRE DAMAGED BY DEBRIS ON RUNWAY. TIRE SHREDDED AND CAUSED DAMAGE TO FORWARD LOWER FUSELAGE SKIN. FOD WAS IDENTIFIED AS THRUST REVERSER BLOCKER DOOR PARTS. 2 L 7 2 4F 4 F RT A16WE E2GL 2004072900072 20040729 00072 2004 7 29 AUS20040423 4 20040517 G 2210 AUTOPILOT SYS BOEING 737 737376 NM GE CFM56 CFM563B1 13802 NE COCKPIT FAILED W O OTHER F FLT CONT AFFECTED CL CLIMB 1 AU S (AUS) DUAL AUTOPILOT MALFUNCTION. LIMITED INFORMATION PROVIDED. 2 L 7 2 4F 4 F RT A16WE E2GL 2004072900073 20040729 00073 2004 7 29 AUS20040424 4 20040525 G 3418 0861F1 SENSOR BOEING 737 737800* NM GE CFM56 CFM567B24 NE STALL WARNING SY FAULTY W O OTHER F J FLT CONT AFFECTED WARNING INDICATION CL CLIMB 1 AU S (AUS) LT ANGLE OF ATTACK (AOA) SENSOR FAULTY. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004072900074 20040729 00074 SO 2004 7 29 AUS20040425 1 20040523 G 3233 762554 ROD END PIPER PA31 PA31325 7103105 SO LYC O540 TIO540F2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL MLG ACTUATOR FAILED W O OTHER O OTHER LD LANDING 1 AU S (AUS) LT MAIN LANDING GEAR ACTUATOR ROD END FAILED. AIRCRAFT LANDED WITH LT MAIN LANDING GEAR FULLY RETRACTED. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004072900093 20040729 00093 NM 2004 7 29 AUS20040426 1 20040518 G 5610 WINDSHIELD BOEING 737 737376 NM GE CFM56 CFM563B1 13802 NE COCKPIT FAILED W O OTHER O OTHER CR CRUISE 1 AU S (AUS) FIRST OFFICER'S NR 1 WINDOW OUTER PANE SHATTERED ALONG WITH ARCING FROM THE WINDSCREEN. 2 L 7 2 4F 4 F RT A16WE E2GL 2004072900094 20040729 00094 NM 2004 7 29 AUS20040427 1 20040520 G 3260 PANEL BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU MLG INDICATOR FAULTY W O OTHER N FALSE WARNING NR NOT REPORTED 1 AU S (AUS) LANDING GEAR POSITION PANEL FAULTY. 2 L 7 2 4F 4 F RT A16WE E21EU 2004072900095 20040729 00095 NM 2004 7 29 AUS20040428 1 20040512 G 2121 FAN BOEING 747 747438 NM RROYCE RB211 RB211524G19 NE AIR DISTRIBUTION FAULTY W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S (AUS) SMOKE AND FUMES IN COCKPIT. SMOKE AND FUMES STOPPED WHEN UPPER FANS SWITCH OFF. CIRCUIT BREAKER TRIPPED. 2 L 7 4 4F 4 F RT A20WE E30NE 2004072900096 20040729 00096 EU 2004 7 29 AUS20040429 1 20040517 G 3230 HC321B0018000 LINK BAG BAE146 BAE146300A 1500267 EU MLG FRACTURED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) MAIN LANDING GEAR ASSISTOR JACK TRIANGULAR LINK FAILED AT JACK ATTACHMENT POINT. 2 H 7 4 4F RT A49EU 2004072900097 20040729 00097 NM 2004 7 29 AUS20040430 1 20040521 G 2421 AS323710 BOLT BOEING 737 737* NM GE CFM56 CFM567B24 NE AC GENERATOR MISSING W K NONE O OTHER IN INSP/MAINT 1 AU S AAAH003210 (AUS) INTEGRATED DRIVE GENERATOR (IDG) OIL/AIR COOLER BOLTS (5 OFF) MISSING AND REMAINING BOLTS (3 OFF) LOOSE. TWO BOLTS AND WASHERS WERE FOUND IN THE COWL. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004072900098 20040729 00098 NE 2004 7 29 AUS20040431 2 20040520 G 7261 3400140070 PIPE BOEING 737 737800* NM GE CFM56 CFM567B24 NE TURBINE ENGINE LOOSE W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S (AUS) ENGINE NR 4 AND NR 5 BEARING OIL SUPPLY LINE B NUT LOOSE (FINGERTIGHT). LOSS OF ENGINE OIL. PERSONNEL/MAINTENANCE ERROR. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004072900099 20040729 00099 NM 2004 7 29 AUS20040432 1 20040430 G 7830 3401659010 NIPPLE BOEING 737 7377Q8 1384418 NM GE CFM56 CFM567B24 NE THRUST REVERSER CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S (AUS) LT THRUST REVERSER OIL SCAVENGE LINE NIPPLE CRACKED. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004080400214 20040804 00214 NE 2004 8 4 AUS20040433 2 20040520 G 7261 3022376 SEAL BEECH 200 B200C 1152924 CE PWA PT6 PT6A42 52043 NE MCAULY 3G34C7 3GFR34C701 GL ENGINE WORN W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S (AUS) ENGINE ACCESSORY GEARBOX STARTER-GENERATOR DRIVE SHAFT SEAL WORN. LOSS OF ENGINE OIL. 1 L 7 2 4T 4 T A24CE E4EA 5 C P60GL 2004080400215 20040804 00215 CE 2004 8 4 AUS20040434 1 20040518 G 5320 07120591 SUPPORT BRACKET CESSNA 182 182S 2072701 CE LYC O540 IO540AB1A5 EA MCAULY 3D36C B3D36C431 GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) BATTERY SUPPORT BRACKETS CRACKED. 1 H 7 1 3O 3 O NT 3A13 1E4 5 C 2004080500013 20040805 00013 CE 2004 8 5 AUS20040435 1 20040330 G 5753 35115396 CLIP BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A42 52043 NE HARTZL HCB3T HCB3TN3 GL TE FLAPS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT OB FLAP IB TRACK RIVETS LOOSE IN AREA ADJACENT TO LOWER SKIN ATTACHMENT. FURTHER INSPECTION FOUND BUCKLING AND CRACKING OF THE OUTBOARD SHEAR CLIP. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2004080500014 20040805 00014 EU 2004 8 5 AUS20040436 1 20040401 G 3242 AHA1899 TORQUE TUBE BAG JETSTM JETSTM4112 EU BRAKE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) BRAKE ASSEMBLY TORQUE TUBE CONTAINED NUMEROUS CRACKS IN TENON SLOTS. FOUND USING FLUORESCENT MAGNETIC PARTICLE INS PECTION. CRACKS WERE FOUND UP TO APPROXIMATELY 6.35MM (0.25IN) IN LENGTH. BRAKE IS FROM A REGISTERED AIRCRAFT. BRAKE HAD BEEN REMOVED DUE TO RUBBING ON AXLE AND CONTACT WITH WHEEL HUB CAUSING DAMAGE. 1 L 7 2 4T RT A196 2004080500015 20040805 00015 NM 2004 8 5 AUS20040438 1 20040513 G 5310 65561001 DOOR FRAME BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 63697 (AUS) NR 1 CARGO DOOR FRAME CRACKED IN AREAS ADJACENT TO DOOR STOP NR 5 AND NR 6. FOUND DURING INSPECTION IAW AD/B727/1 65 AND MFG SB727-53A0219. 2 L 7 3 4F 4 F RT A3WE E2EA 2004080500016 20040805 00016 NM 2004 8 5 AUS20040439 1 20040526 G 3244 277A6000204 TIRE BOEING 737 737* NM GE CFM56 CFM567B24 NE MLG SEPARATED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NR 2 MAIN WHEEL TIRE TREAD SEPARATED AND TIRE DEFLATED. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004080500017 20040805 00017 SW 2004 8 5 AUS20040440 1 20040526 G 7120 206033201167 STIFFENER BELL 206 206L3 1182108 SW ALLSN 250C 250C30 03013 GL ENGINE MOUNT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 6394 (AUS) RT FORWARD ENGINE MOUNT STIFFENER CRACKED THROUGH. CRACK MIGRATED INTO LATERAL FRAME AT STN 155. 1 G 7 1 3U 3 U H2SW E1GL 2004080500018 20040805 00018 SO 2004 8 5 AUS20040441 1 20040521 G 3211 6792631 TRUNNION PIPER PA32 PA32R301 7103218 SO LYC O540 IO540K1G5 41532 EA HARTZL HCC3Y HCC3Y* GL RT MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT MAIN LANDING GEAR TRUNNION CRACKED. 1 L 7 1 3O 3 O A3SO 1E4 5 C P25EA 2004080500019 20040805 00019 NM 2004 8 5 AUS20040442 1 20040315 G 2913 6506806 PUMP BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL HYDRAULIC SYSTEM FAILED W O OTHER K J FLUID LOSS WARNING INDICATION DE DESCENT 1 AU S (AUS) LT ENGINE DRIVEN HYDRAULIC PUMP FAILED DUE TO LOSS OF HYDRAULIC FLUID. 2 L 7 2 4F 4 F RT A1NM E23EA 2004080500020 20040805 00020 NM 2004 8 5 AUS20040443 1 20040519 G 2751 98010903 INDICATOR BOEING 747 747338 NM RROYCE RB211 RB211524D419 54555 NE TE FLAPS FAULTY W O OTHER F J FLT CONT AFFECTED WARNING INDICATION CL CLIMB 1 AU S (AUS) LT OB TRAILING EDGE FLAP INDICATOR FAILED. 2 L 7 2 4F 4 F RT A20WE E12EU 2004080500021 20040805 00021 EU 2004 8 5 AUS20040444 1 20040520 G 2750 676801007 COMPUTER BAG BAE146 BAE146300A 1500267 EU LYC LF507 LF5071H 41580 NE TE FLAPS FAULTY W O OTHER F J FLT CONT AFFECTED WARNING INDICATION DE DESCENT 1 AU S (AUS) FLAP COMPUTER FAULTY. 2 H 7 4 4F 4 F RT A49EU E6NE 2004080500047 20040805 00047 GL 2004 8 5 AUS20040445 1 20040130 G 2510 SEAT BELT CIRRUS SR SR20 05628AJ GL CONT O360 IO360E 17025 SO HARTZL HCJ3Y PHCJ3YF1 GL COCKPIT FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) PILOTS SEAT BELT SHOULDER HARNESS DOES NOT FULLY RETRACT INTO INERTIA REEL. INVESTIGATION FOUND A STOP INSTALLED IN THE WEBBING IN AN AREA JUST BELOW JUNCTION. 1 L 7 1 3O 3 O NT A00009CH E1CE 5 C P36EA 2004080500048 20040805 00048 CE 2004 8 5 AUS20040446 1 20040526 G 5711 122210523 SPAR CESSNA 182 182F 2072714 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C* GL RT WING CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT WING MAIN SPAR ANGLE CONTAINED EXFOLIATION CORROSION IN AREA OF WING ATTACHMENT ANGLE. 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 2004080500049 20040805 00049 CE 2004 8 5 AUS20040447 1 20040517 G 3233 MS2877510 O-RING CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP NLG ACTUATOR DAMAGED W O OTHER K J FLUID LOSS WARNING INDICATION CL CLIMB 1 AU S (AUS) NOSE LANDING GEAR UPLOCK ACTUATOR O-RING DAMAGED. HYDRAULIC FLUID LEAKING FROM ACTUATOR BODY. 1 L 7 2 3T 4 T RT A28CE E4WE 2004080500050 20040805 00050 CE 2004 8 5 AUS20040448 1 20040521 G 3234 99102791 SELECTOR VALVE CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP MLG FAULTY W O OTHER O OTHER CL CLIMB 1 AU S (AUS) LANDING GEAR SELECTOR VALVE SOLENOID FAILED. 1 L 7 2 3T 4 T RT A28CE E4WE 2004080500051 20040805 00051 CE 2004 8 5 AUS20040449 1 20040524 G 8011 85104666 DRIVE ASSY LAMAR CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA MCAULY IC235 IC235LFA7570 EA STARTER SEIZED W O OTHER E VIBRATION/BUFFET NR NOT REPORTED 1 AU S 85104666 (AUS) STARTER MOTOR BENDIX DRIVE SEIZED INTERNALLY. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P12EA 2004080500052 20040805 00052 EU 2004 8 5 AUS20040450 1 20040527 G 3241 F7941116401 WIRE HARNESS FOKKER F27 F27MK50 EU PWA PWA120 PW125B NE ROTOL R352 R3526123F1 GL ANTISKID SYS BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S 32288 (AUS) LT IB WHEEL SPEED SENSOR WIRE BROKEN. RB IB TYRE BLOWNOUT. 2 H 7 2 4T 4 T RT A817 E20NE 6 C P16NG 2004080500053 20040805 00053 CE 2004 8 5 AUS20040452 1 20040519 G 2140 27D39 MOTOR BEECH 58 58 1152740 CE CONT O520 IO520* 17032 SO MCAULY 3AF32C 3AF32C512 GL BLOWER FAULTY W O OTHER B SMOKE/FUMES/ODORS/SPARKS DE DESCENT 1 AU S (AUS) CABIN HEATER BLOWER MOTOR FAULTY. MOTOR WAS VIBRATING AND PRODUCING SMOKE. 1 L 7 2 3O 3 O 3A16 E5CE 5 C P22EA 2004080500054 20040805 00054 NM 2004 8 5 AUS20040453 1 20040528 G 2710 BACC2C4C05138EG CONTROL CABLE BOEING 747 747438 NM RROYCE RB211 RB211524G19 NE AILERON WORN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) AILERON CABLE OUTER STRANDS BROKEN IN AREA LOCATED AT RT WING SPAR TRAILING EDGE AT WS 1110. SOME OUTER STRANDS W ERE ALSO BROKEN IN AN AREA LOCATED FURTHER OB AT APPROXIMATELY WS 1195. SUSPECT CAUSED BY CABLE WEARING ON FAIRLEADS AL ONG THE WING TRAILING EDGE. 2 L 7 4 4F 4 F RT A20WE E30NE 2004080500055 20040805 00055 NE 2004 8 5 AUS20040454 2 20040411 G 7200 3030700 ENGINE BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A42 52043 NE HARTZL HCD4N3 HCD4N3A GL RIGHT OVERHEATED W O OTHER M E J OVER TEMP VIBRATION/BUFFET WARNING INDICATION CR CRUISE 1 AU S (AUS) RT ENGINE OVERTEMPED ON START. ENGINE REMOVED. 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2004080500079 20040805 00079 CE 2004 8 5 AUS20040455 1 20040524 G 1430 NAS14740 BOLT CESSNA 206 U206G 2073356 CE CONT O520 IO520* 17032 SO MCAULY 3A32C D3A32C90 GL MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) UNDERCARRIAGE SADDLE BOLT CRACKED. 1 H 7 1 3O 3 O A4CE E5CE 5 C P21EA 2004101800186 20041018 00186 NM 2004 10 18 AUS20040456 1 20040412 G 2751 2061141 INDICATOR BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU TE FLAPS FAULTY W O OTHER F J FLT CONT AFFECTED WARNING INDICATION AP APPROACH 1 AU S (AUS) FLAP POSITION INDICATOR FAULTY. 2 L 7 2 4F 4 F RT A16WE E21EU 2004101800187 20041018 00187 2004 10 18 AUS20040457 4 20040330 G 2210 LIMITER BOEING 737 737376 NM CFMINT CFM56 CFM563B2 13802 EU AUTOPILOT SYSTEM FAULTY W O OTHER F FLT CONT AFFECTED CL CLIMB 1 AU S (AUS) AUTOPILOT TORQUE LIMITER FAULTY. 2 L 7 2 4F 4 F RT A16WE E21EU 2004101800188 20041018 00188 NM 2004 10 18 AUS20040458 1 20040525 G 2910 272T3100321 PIPE BOEING 767 767* NM RROYCE RB211 RB211524* NE HYDRAULIC SYSTEM WORN W O OTHER K J FLUID LOSS WARNING INDICATION CR CRUISE 1 AU S (AUS) LT HYDRAULIC SYSTEM PIPE WORN THROUGH BY BROKEN CLAMP LOCATED IN LT PYLON. LOSS OF HYDRAULIC FLUID. 2 L 7 2 4F 4 F RT A1NM E12EU 2004101800189 20041018 00189 NM 2004 10 18 AUS20040459 1 20040527 G 5210 60020019 BOTTLE BOEING 747 747438 NM RROYCE RB211 RB211524* NE PAX DOOR INOPERATIVE W K NONE O OTHER IN INSP/MAINT 1 AU S 7425 3742 (AUS) DOOR 4L EMERGENCY POWER SUPPLY (EPS) BOTTLE TRIGGER LOCKED BY FITMENT OF A TEMPORARY SAFETY BOLT IN THE TRIGGER ME CHANISM. THIS SAFETY BOLT WOULD HAVE PREVENTED FIRING OF THE BOTTLE TO OPEN THE DOOR IN AN EMERGENCY SITUATION. PERSONN EL/MAINTENANCE ERROR. 2 L 7 4 4F 4 F RT A20WE E12EU 2004101800190 20041018 00190 SO 2004 10 18 AUS20040460 1 20040601 G 5711 16010 SPAR PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA HARTZL HCE2Y HCE2YR2 GL WING CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT AND RT FORWARD AUXILIARY SPARS CRACKED AT IB LOWER RAD II LOCATED AT STN 27. CRACKS EXTEND FOR APPROXIMATELY 12 .7MM(0.5IN) OB OF THE END OF THE SPAR IN A HORIZONTAL PLANE. 1 L 7 2 3O 3 O 1A10 1E4 5 C P9EA 2004101800070 20041018 00070 NM 2004 10 18 AUS20040461 1 20040530 G 5220 DOOR BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL EMERGENCY EXITS STICKING W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT OVERWING EMERGENCY DOOR PREVENTED FROM COMPLETELY OPENING BY THE TARGET FOR THE LT SLIDE COMPARTMENT DOOR CLOSE D SENSOR (S218) CATCHING ON THE TAIL OF A SCREW NUT INSTALLED ON THE PACKBOARD. FURTHER INSPECTION REVEALED THAT THE LA TCH CONTROL ROD THE TARGET IS MOUNTED TO HAD BEEN TWISTED AT THE FIXED CLEVIS END ALLOWING THE TARGET TO DROP INTO THE P ATH OF THE SCREW INSTALLED ON THE PACKBOARD. 2 L 7 2 4F 4 F RT A1NM E23EA 2004101800071 20041018 00071 EA 2004 10 18 AUS20040462 2 20040530 G 7314 62E23186 PUMP PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2C 41532 EA HARTZL HCE3Y HCE3YR2 GL ENGINE FUEL LEAKING W O OTHER E K VIBRATION/BUFFET FLUID LOSS NR NOT REPORTED 1 AU S (AUS) RT ENGINE DRIVEN FUEL PUMP LEAKING EXCESSIVELY FROM PUMP BODY. A LARGE AMOUNT OF FUEL WAS SPRAYING ONTO THE TURBOC HARGER WITH A HIGH RISK OF ENGINE FIRE. THE PUMP WAS A NEW ITEM WITH NO SIGN OF DAMAGE TO THE PUMP AND ALL THE MFGS TAMP ER WIRES ARE IN PLACE. THERE IS NO SIGN OF LOOSENESS TO THE FOUR ALLEN KEY BOLTS AND THEY APPEAR TIGHT. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004101800072 20041018 00072 EU 2004 10 18 AUS20040463 1 20040531 G 3097 WIRE BAC 146 146100A 1500260 EU LYC ALF502 ALF502R5 41580 NE WINDSHIELD HEAT BURNED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 AU S (AUS) RT WINDSHIELD HEATING SYSTEM WIRING CABLE DAMAGED AND SHORTING TO EARTH IN AREA NEAR TERMINAL BLOCK. 2 H 7 4 4F 4 F RT A49EU E6NE 2004101800073 20041018 00073 NM 2004 10 18 AUS20040464 1 20040528 G 1420 DP1011 CONNECTOR BOEING 737 7378Q8 13844BX NM GE CFM56 CFM567B24 NE ENGINE EGT/TIT LOOSE W O OTHER E VIBRATION/BUFFET NR NOT REPORTED 1 AU S (AUS) NR 1 ENGINE EGT BOTTOM RT PROBE NOT CONNECTED. NO EVIDENCE OF LOCKWIRE. TOP RT PROBE LOOSE AND NOT LOCKWIRED. ELEC TRICAL CONNECTOR DP0911 LOOSE. PERSONNEL/MAINTENANCE ERROR. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004101800074 20041018 00074 NM 2004 10 18 AUS20040465 1 20040530 G 3242 26123121 BRAKE BOEING 737 737832 13844CF NM GE CFM56 CFM567B24 NE MLG FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 1679 (AUS) NR 3 BRAKE ASSEMBLY, BRAKE PADS SEPARATED AND JAMMED THE BRAKE ONTO THE WHEEL. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004101800075 20041018 00075 NM 2004 10 18 AUS20040466 1 20040531 G 2910 82920010363 LINE DHAV DHC8 DHC8202 2809007 NM PWA 120 PW123D 52152 NE HAMSTD 14SF 14SF23 NE HYDRAULIC SYS CRACKED W O OTHER K J FLUID LOSS WARNING INDICATION CL CLIMB 1 AU S (AUS) NR 2 HYDRAULIC SYSTEM, HYDRAULIC PIPE CRACKED INTERNALLY. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004101800102 20041018 00102 NM 2004 10 18 AUS20040467 1 20040529 G 2823 125334D1 VALVE BOEING 737 737724 13844BY NM GE CFM56 CFM567B24 NE FUEL SELECTOR FAILED W O OTHER E VIBRATION/BUFFET TX TAXI/GRND HDL 1 AU S (AUS) NR 1 ENGINE SPAR VALVE FAILED TO OPEN. INVESTIGATION COULD FIND NO FAULT WITH THE VALVE. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004101800114 20041018 00114 NM 2004 10 18 AUS20040468 1 20040601 G 2910 EM56203 VALVE BOEING 737 737724 13844BY NM GE CFM56 CFM567B24 NE HYDRAULIC SYSTEM DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NR 2 ENGINE HYDRAULIC SHUTOFF VALVE ELECTRICAL CONNECTOR D764 CROSS THREADED CAUSING DAMAGE TO CONNECTOR AND VALVE . FOUND DURING INSPECTION IAW SB 737-24A1148. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004101800115 20041018 00115 NM 2004 10 18 AUS20040469 1 20040601 G 7997 WIRE DHAV DHC8 DHC8202 2809007 NM PWA 120 PW123D 52152 NE HAMSTD 14SF 14SF23 NE OIL PRESS TRANS WORN W O OTHER E VIBRATION/BUFFET CL CLIMB 1 AU S (AUS) LT ENGINE OIL PRESSURE TRANSMITTER CONNECTOR WIRING HAD WORN INSULATION. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004101800116 20041018 00116 CE 2004 10 18 AUS20040470 1 20040531 G 3220 LANDING GEAR BEECH 76 76 1153005 CE LYC O360 IO360A1G6 41514 EA HARTZL HCM2Y HCM2YR GL NOSE COLLAPSED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) DURING INSPECTION OF NOSE LANDING GEAR FOR A NOSE LANDING GEAR FAULT, THE NLG COLLAPSED, TRAPPING THE AME BETWEEN THE NOSE CONE AND THE GROUND. DUE TO THE QUICK REACTION OF WORKMATES, THE AME WAS RELEASED FROM BENEATH THE AIRCRAFT AND ADMITTED TO HOSPITAL WITH MINOR INJURIES. THE REASON FOR THE NLG COLLAPSE IS STILL BEING INVESTIGATED. 1 L 7 2 3O 3 O A29CE 1E10 5 C P43GL 2004101800117 20041018 00117 WP 2004 10 18 AUS20040471 2 20040602 G 7230 31032523 BLADE SWRNGN SA227 SA227* SW GARRTT TPE331 TPE33112UHR WP MCAULY 4HFR34 4HFR34C652 NE COMPRESSOR BIRD STRIKE W C ABORTED TAKEOFF C E B F.O.D. VIBRATION/BUFFET SMOKE/FUMES/ODORS/SPARKS TO TAKEOFF 1 AU S (AUS) RT ENGINE FIRST STAGE COMPRESSOR BLADE BENT DUE TO BIRDSTRIKE. 2 L 7 2 4T 4 T RT A5SW E4WE 6 C 3PNE 2004101800118 20041018 00118 NM 2004 10 18 AUS20040472 1 20040530 G 3242 QF45085 SEAL BOEING 737 737800* NM GE CFM56 CFM567B24 NE BRAKE FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS LD LANDING 1 AU S QF45085 (AUS) LT MAIN LANDING GEAR NR 1 BRAKE PISTON SEAL PARTIALLY FAILED ALLOWING BRAKE FLUID TO LEAK ONTO BRAKE ROTORS. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004101800119 20041018 00119 EU 2004 10 18 AUS20040473 1 20040528 G 3320 BV033020205 SOCKET SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE ROTOL R375 R3754123F21 NE CABIN BURNED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S (AUS) WINDOW LIGHT LOCATED AT ROW 10 GAVE A BURNING SMELL. INVESTIGATION FOUND THE A BURNT FLUORESCENT LAMP HOLDER AND L AMP. CAUSE OF THE BURNING WAS AN INCORRECTLY INSTALLED LAMP WHICHCAUSED ARCING AT THE LAMP HOLDER. PERSONNEL/MAINTENANCE ERROR. 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P17NE 2004101800130 20041018 00130 CE 2004 10 18 AUS20040474 1 20040525 G 3010 10136458211 CIRCUIT BOARD BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA HARTZL HCB4M HCB4MP3 GL AIRFOIL ANTI-ICE FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) AIRFRAME DE-ICE SYSTEM PRINTED CIRCUIT BOARD (PCB) TIMER INOPERATIVE. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2004101800138 20041018 00138 SW 2004 10 18 AUS20040476 1 20040603 G 3230 55010021 DRAG BRACE SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP HARTZL HCB3T HCB3TN5 GL MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT IB LOWER MAIN LANDING GEAR DRAG BRACE CRACKED IN AREA ADJACENT TO GREASE FITTING. FOUND DURING INSPECTION IAW A D/SWSA226/89 AND SB226-32-068. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P15EA 2004101800139 20041018 00139 NM 2004 10 18 AUS20040477 1 20040525 G 7830 CF680C2 THRUST REVERSER BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL LT ENGINE FAULTY W O OTHER O OTHER LD LANDING 1 AU S (AUS) LT ENGINE THRUST REVERSER FAILED TO OPERATE ON SELECTION DURING LANDING. INVESTIGATION AND ENGINE GROUND RUN COULD NOT FAULT SYSTEM. SUSPECT CAUSED BY ICING. 2 L 7 2 4F 4 F RT A1NM E23EA 2004101800140 20041018 00140 NM 2004 10 18 AUS20040478 1 20040228 G 3840 45618380 THERMOSTAT BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL AIR SUPPLY FAILED W K NONE B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 AU S (AUS) POTABLE WATER COMPRESSOR OVERHEATING. INVESTIGATION FOUND THAT THE COMPRESSOR MOTOR HAD SEIZED DUE TO THE OVERHEAT THERMOSTAT (THERMAL PROTECTOR) PN 45618-380 FAILING IN A CLOSED POSITION CAUSING THE MOTOR TO CONTINUALLY OPERATE AND F INALLY SEIZE. 2 L 7 2 4F 4 F RT A1NM E23EA 2004101800141 20041018 00141 NM 2004 10 18 AUS20040479 1 20040523 G 3260 LIGHT BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU MLG FAULTY W O OTHER P NO WARNING INDICATION AP APPROACH 1 AU S (AUS) RT MAIN LANDING GEAR DOWN LIGHT FAILED TO ILLUMINATE ON GEAR SELECTION. INVESTIGATION FOUND A FAULTY LOCK MECHANIS M IN THE LAMP LENS CAP. 2 L 7 2 4F 4 F RT A16WE E21EU 2004101800143 20041018 00143 EU 2004 10 18 AUS20040480 1 20040602 G 2730 NB451803 CONTROL ROD BNORM BN2 BN2B20 1520302 EU LYC O540 IO540K1B5 41532 EA HARTZL HCC2Y HCC2YK2 GL ELEVATOR CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ELEVATOR CONTROL ROD CORRODED ON INTERNAL THREADS. FOUND DURING INSPECTION IAW SB 303 AND AD/BN2/082. 1 H 7 2 3O 3 O A17EU 1E4 5 C P920 2004101800144 20041018 00144 CE 2004 10 18 AUS20040481 1 20040520 G 3610 12945054V6001 MANIFOLD LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE7312 01518 WP PNEUMATIC CRACKED W O OTHER J WARNING INDICATION CL CLIMB 1 AU S (AUS) LT BLEED AIR SPLITTER DUCT CRACKED AND LEAKING FROM THE MATING FLANGE RADIUS. 2 L 7 2 4F 4 F RT T00008WI E6WE 2004101800145 20041018 00145 WP 2004 10 18 AUS20040482 2 20040518 G 7200 310338025 ENGINE BAG JETSTM JETSTM3201 1500217 EU GARRTT TPE331 TPE33112UHR WP MCAULY 4HFR34 4HFR34C653 NE LEFT OVERTEMP W O OTHER E VIBRATION/BUFFET CL CLIMB 1 AU S 3285 (AUS) LT ENGINE EGT ROSE TO APPROXIMATELY 720 DEGREES WITH A REDUCTION IN TORQUE AND FUEL FLOW. DUE TO THE EXCESSIVE EG T THE ENGINE WAS REMOVED FOR AN OVERTEMP INSPECTION. NO RESULTS TO DATE. 2 L 7 2 4T 4 T RT A56EU E4WE 6 C 3PNE 2004101800146 20041018 00146 NE 2004 10 18 AUS20040483 2 20040514 G 7200 CFM567B ENGINE BOEING 737 7377Q8 1384418 NM GE CFM56 CFM567B24 NE NR 2 BIRD STRIKE W O OTHER E C VIBRATION/BUFFET F.O.D. CL CLIMB 1 AU S 890451 (AUS) NR 2 ENGINE BIRDSTRIKE. INSPECTION FOUND EVIDENCE OF BIRD REMAINS IN BOOSTER. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004101800147 20041018 00147 NM 2004 10 18 AUS20040484 1 20040513 G 5753 FLAP TRACK BOEING 737 737* NM GE CFM56 CFM567B24 NE LT WING FOD W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) PASSENGER REPORTED RAG SEEN IN WING TRAILING EDGE. INVESTIGATION FOUND RAG LOCATED ON AREA OF LT WING REAR SPAR A BOVE NR 3 FLAP TRACK. THE RAG WAS NOT INTERFERING WITH ANY AIRCRAFT SYSTEM. FOD PERSONNEL/MAINTENANCE ERROR. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004101800148 20041018 00148 EU 2004 10 18 AUS20040485 1 20040510 G 2730 8500341403 REGULATOR FOKKER F27 F27MK500 4990629 EU RROYCE DART DART* NE ROTOL R4304 R1934304 EU ELEVATOR CONTROL STICKING W O OTHER F FLT CONT AFFECTED DE DESCENT 1 AU S 6132 (AUS) ELEVATOR CABLE TENSION REGULATOR STICKY IN OPERATION. 2 H 7 2 4T 4 T A817 6 C P899 2004101800149 20041018 00149 2004 10 18 AUS20040486 4 20040608 G 3416 40598501 LIGHT HONEYWELL DHAV DHC8 DHC8* NM ALTIMETER, BAROM FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 94057779 (AUS) ALTIMETER LAMP FAILED. FOUND DURING INSPECTION IAW AD/RAD/43. 2 H 7 2 4T RT A13NM 2004101800150 20041018 00150 NM 2004 10 18 AUS20040487 1 20040603 G 2701 BACB10BW21 BEARING BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU CONTROL COLUMN FAULTY W O OTHER F FLT CONT AFFECTED CR CRUISE 1 AU S (AUS) FIRST OFFICER'S CONTROL WHEEL BEARING NOTCHY. 2 L 7 2 4F 4 F RT A16WE E21EU 2004101800151 20041018 00151 NM 2004 10 18 AUS20040488 1 20040525 G 3610 8021704 VALVE BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL PNEUMATIC DIST FAULTY W C ABORTED TAKEOFF J WARNING INDICATION TO TAKEOFF 1 AU S 9612153 (AUS) RT ENGINE BLEED SYSTEM PRESSURE REDUCING VALVE (PRV) SUSPECT FAULTY. LIMITED INFORMATION PROVIDED. 2 L 7 2 4F 4 F RT A1NM E23EA 2004101800152 20041018 00152 NM 2004 10 18 AUS20040489 1 20040607 G 2430 285A18408 MODULE BOEING 737 737* NM GE CFM56 CFM567B24 NE DC GENERATING FAULTY W K NONE J WARNING INDICATION IN INSP/MAINT 1 AU S (AUS) ELECTRICAL METERS BATTERY AND GALLEY POWER MODULE FAULTY. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004101800153 20041018 00153 CE 2004 10 18 AUS20040490 1 20040529 G 5610 WINDSHIELD BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL COCKPIT CRACKED W O OTHER O OTHER CR CRUISE 1 AU S (AUS) PILOTS WINDSHIELD CRACKED ON INSIDE LAMINATE. OUTER LAMINATE WAS INTACT. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2004101800154 20041018 00154 SO 2004 10 18 AUS20040491 1 20040531 G 7922 53E22144A VALVE PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA HARTZL HCE3Y HCE3YR2 GL ENGINE OIL TEMP FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 824 (AUS) ENGINE OIL TEMPERATURE REGULATING VALVE (VERNATHERM) BREAKING UP. METAL CONTAMINATION OF ENGINE OIL SYSTEM. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004101800155 20041018 00155 CE 2004 10 18 AUS20040492 1 20040607 G 3231 4532103054003 SHAFT LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE7312 01518 WP MLG DOOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT MAIN LANDING GEAR IB DOOR GIMBAL ASSEMBLY SHAFT CRACKED FOR APPROXIMATELY 75 PERCENT OF CIRCUMFERENCE. 2 L 7 2 4F 4 F RT T00008WI E6WE 2004101800156 20041018 00156 NM 2004 10 18 AUS20040493 1 20040606 G 5610 5717623097 WINDOW BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU COCKPIT CRACKED W O OTHER O OTHER CR CRUISE 1 AU S (AUS) CAPTAIN'S NR 2 SLIDING WINDOW OUTER PANE CRACKED IN UPPER FORWARD CORNER. 2 L 7 2 4F 4 F RT A16WE E21EU 2004101800157 20041018 00157 NM 2004 10 18 AUS20040494 1 20040526 G 1430 BOLT BOEING 737 737376 NM CFMINT CFM56 CFM563B1US GL MLG SHEARED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT MAIN LANDING GEAR OB STABILIZING FITTING OB LOWER ATTACHMENT BOLT SHEARED ALONG THE SHANK IN AN AREA COINCIDING WITH THE WING REAR SPAR. 2 L 7 2 4F 4 F RT A16WE E2GL 2004101800158 20041018 00158 NM 2004 10 18 AUS20040495 1 20040604 G 3520 174080142 OXYGEN MASK BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL PASSENGER OXYGEN MISINSTALLED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) PASSENGER OXYGEN MASKS INCORRECTLY PACKED INTO PASSENGER SERVICE UNITS (PSU). OXYGEN MASK HOSES CAUGHT BETWEEN DO OR AND MASK HOUSING CAUSING HOSES TO BECOME KINKED AND THE DOORS TO BULGE WHEN CLOSED. UNITS AFFECTED WERE LOCATED AT 39 DEF , 37DEF,5JK, 1EF, 48DEF, 45DEF AND 40DEF. TOTAL NUMBER OF MASKS 14. PERSONNEL/MAINTENANCE ERROR. 2 L 7 2 4F 4 F RT A1NM E23EA 2004101800159 20041018 00159 EU 2004 10 18 AUS20040496 1 20040607 G 7120 60510021 TRUSS REIMS 406 F406 7535723 EU PWA PT6 PT6A112 52043 NE MCAULY 3G34C7 3GFR34C701 GL ENGINE MOUNT CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT ENGINE LOWER LT ATTACHMENT TRUSS CORRODED. 1 L 7 2 3T 3 T RT A54EU E4EA 5 C P60GL 2004101800160 20041018 00160 SW 2004 10 18 AUS20040497 1 20040610 G 2720 2672003 PEDAL SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP ROTOL R321 R321482F8 GL RUDDER CONTROL CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) PILOTS RT RUDDER PEDAL CRACKED. CRACK LENGTH 4MM (0.147IN). FOUND DURING INSPECTION IAW SB 227-27-049. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P61GL 2004101800161 20041018 00161 NM 2004 10 18 AUS20040498 1 20040606 G 2742 6355B000103 ACTUATOR BOEING 737 737* NM GE CFM56 CFM567B24 NE STAB TRIM FAULTY W K NONE F FLT CONT AFFECTED IN INSP/MAINT 1 AU S 1666 (AUS) HORIZONTAL STABILIZER TRIM ACTUATOR FAULTY. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004101800162 20041018 00162 SO 2004 10 18 AUS20040499 2 20040418 G 8520 630687P015 PISTON CESSNA 172 R172K 2072431 CE CONT O360 IO360K 17025 SO MCAULY 2A34C 2A34C203 GL ENGINE FAILED W O OTHER E VIBRATION/BUFFET CR CRUISE 1 AU S (AUS) PISTON FAILED. SUSPECT FAULTY INJECTOR. LIMITED INFORMATION PROVIDED. 1 H 7 1 3O 3 O 3A17 E1CE 5 C P3EA 2004101800163 20041018 00163 NM 2004 10 18 AUS20040500 1 20040606 G 2530 GENM2585015 OVEN BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU BUFFET/GALLEYS FAULTY W O OTHER B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 AU S 3609 90012615 (AUS) FORWARD GALLEY OVEN FAILED. FIRE EXTINGUISHED DISCHARGED INTO OVEN. 2 L 7 2 4F 4 F RT A16WE E21EU 2004101800164 20041018 00164 EU 2004 10 18 AUS20040501 1 20040610 G 5312 FIREWALL BAG BAE146 BAE146300A 1500267 EU FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) APU FIREWALL CRACKED AT 7 O'CLOCK POSITION. FOUND DURING INSPECTION IAW AD/BAE146/053. 2 H 7 4 4F RT A49EU 2004101800165 20041018 00165 EU 2004 10 18 AUS20040502 1 20040601 G 7603 SP126E WASHER LYC BNORM BN2 BN2A26 1520226 EU LYC O540 O540E4C5 41532 EA HARTZL HCC2Y HCC2YK2 GL POWER LEVER MISSING W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) THROTTLE QUADRANT FRICTION ADJUSTER WASHER MISSING. FOUND DURING INSPECTION IAW AD/BN2/69 AND SB 272. 1 H 7 2 3O 3 O A17EU E295 5 C P920 2004101800166 20041018 00166 NM 2004 10 18 AUS20040503 1 20040611 G 2913 66087 PUMP BOEING 737 7377Q8 1384418 NM GE CFM56 CFM567B24 NE HYDRAULIC SYS LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S (AUS) NR 2 ENGINE DRIVEN HYDRAULIC PUMP LEAKING. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004101800167 20041018 00167 NE 2004 10 18 AUS20040504 2 20040610 G 7260 3022376 SEAL BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A42 52043 NE HARTZL HCD4N3 HCD4N3A GL ENGINE LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S (AUS) ENGINE STARTER-GENERATOR OIL SEAL LEAKING. 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2004101800168 20041018 00168 CE 2004 10 18 AUS20040505 1 20040614 G 2710 05232182 CONTROL ROD CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA MCAULY IC235 IC235LFA7570 EA AILERON CONTROL BENT W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT AILERON PUSH-PULL ROD BENT. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P12EA 2004101800169 20041018 00169 NM 2004 10 18 AUS20040506 1 20040612 G 6210 A0162 BLADE ROBSIN R22 R22BETA 7640110 NM LYC O320 O320B2C 41508 EA MAIN ROTOR CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) MAIN ROTOR BLADE CORRODED ON BLADE TIP. 1 G 7 1 3O 3 O H10WE E274 2004101800170 20041018 00170 2004 10 18 AUS20040507 4 20040602 G 6122 A20028 BEARING CESSNA 404 404CESSNA 2075901 CE CONT O520 GTSIO520M 17032 SO MCAULY 3FF32 3FF32C501 GL PROP GOVERNOR FAILED W O OTHER E VIBRATION/BUFFET DE DESCENT 1 AU S 1727 (AUS) LT ENGINE PROPELLER GOVERNOR FAULTY. INVESTIGATION FOUND OIL PUMP GEAR PN A20107 WORN, PIVOT PIN PN A20026 EXTRE MELY WORN AND BEARING PN A20028 DESTROYED. THE HOUSING WAS GOUGED TO A DEPTH OF APPROXIMATELY 3.175MM (0.125IN) IN THE BEARING AREA AND THE PUMP WALL WERE BADLY SCORED. METAL CONTAMINATION OF ENGINE OIL SYSTEM. 1 L 7 2 3O 3 O A25CE E7CE 5 C P45GL 2004101800172 20041018 00172 SO 2004 10 18 AUS20040508 1 20040608 G 3232 OAS29243 ACTUATOR PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL MLG DOOR FAULTY W O OTHER J WARNING INDICATION CL CLIMB 1 AU S 2626 (AUS) LT MAIN LANDING GEAR DOOR HYDRAULIC RAM FAULTY. INVESTIGATION FOUND BRINNELLED LOCKING BALLS AND LOW SPRING PRESS URE ON LOCKPUCK. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004101800173 20041018 00173 EU 2004 10 18 AUS20040509 1 20040611 G 3610 3925308 VALVE FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE PNEUMATIC DISTRI FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 352 (AUS) LT BLEED AIR VALVE FAULTY. 2 L 7 2 4F 4 F RT E25NE 2004101800174 20041018 00174 NM 2004 10 18 AUS20040510 1 20040611 G 2597 WIRE HARNESS BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL PSU WORN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) PASSENGER SERVICE UNIT (PSU) LOOM WORN AND SPARKING. PSU LOCATED AT SEAT 44JK. 2 L 7 2 4F 4 F RT A1NM E23EA 2004101800175 20041018 00175 NE 2004 10 18 AUS20040511 2 20040607 G 7200 ARRIEL1S1 ENGINE SKRSKY S76 S76A 8143006 NE TMECA ARRIEL ARRIEL1S 60030 NE MAKING METAL W O OTHER E J VIBRATION/BUFFET WARNING INDICATION NR NOT REPORTED 1 AU S 654 (AUS) ENGINE CHIP DETECTORS AND OIL FILTER CONTAMINATED WITH METAL. ENGINE WAS REPLACED. 1 G 7 2 3U 3 U H1NE E19EU 2004101800176 20041018 00176 EU 2004 10 18 AUS20040512 1 20040615 G 5411 HC546J0032 RIB BAG BAE146 BAE146300A 1500267 EU LYC ALF502 ALF502R5 41580 NE NACELLE/PYLON CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NR 1, NR 3 AND NR 4 PYLONS HAD NR 4 RIB CRACKED IN THE LOWER FLANGE RADIUS. PYLON NR 1, CRACK LENGTH 22.86MM (0.9 IN) PYLON NR 3, CRACK LENGTH 12.7MM (0.5IN) PYLON NR 4, CRACK LENGTH 20.32 (0.8IN). 2 H 7 4 4F 4 F RT A49EU E6NE 2004101800177 20041018 00177 NM 2004 10 18 AUS20040513 1 20040611 G 3320 SOCKET DHAV DHC8 DHC8202 2809007 NM PWA 120 PW123D 52152 NE HAMSTD 14SF 14SF23 NE CABIN FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 AU S (AUS) FRONT RT CABIN FLOUROSCENT LAMP HOLDER ARCING AND SMOKING. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004101800179 20041018 00179 NM 2004 10 18 AUS20040514 1 20040614 G 3233 273A210102 ACTUATOR BOEING 737 7377Q8 1384418 NM GE CFM56 CFM567B24 NE MLG FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT MAIN LANDING GEAR ACTUATOR LOCKNUT LOOSE AND LOCKWIRE BROKEN. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004030400072 20040304 00072 EU 2004 3 4 B30R20040226 1 20040219 G 5310 DOOR FRAME SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE FUSELAGE CRACKED B B3OR K NONE O OTHER IN INSP/MAINT 1 SW 03 5204Y 1359 100 3101 9571 DURING 100 HOUR INSPECTION DISCOVERED CO-PILOT DOOR POST CRACKED 14 INCHES LONG STARTING 8 INCHES ABOVE CABIN FLOOR, EXC EEDING THE LIMITS IN REPAIR MANUAL. REPAIRED CRACK IAW MM. REQUESTED FROM MFG. 1 G 7 1 3U 3 U H9EU E19EU 2004091400202 20040914 00202 CE 2004 9 14 B3OR20040709 1 20040709 G 3240 1280509101 LINE CESSNA 210 T210N 2073456 CE CONT O550 IO550* SO MLG BRAKE CUT B B3OR O OTHER K J FLUID LOSS WARNING INDICATION TX TAXI/GRND HDL 1 SW 03 5515Y 21064233 289125R PILOTS ENTERED THE AC AND TAXIED DOWN THE TAXIWAY. AS BRAKES WERE BEING APPLIED, IT WAS NOTICED THAT RT BRAKE WAS NOT OP ERATING. AC EXITED TAXI WAY AT A LOW SPEED CAME TO A STOP IN ABOUT FOUR INCHES OF MUD ALONGSIDE OF TAXIWAY. THERE WAS NO DAMAGE TO AC OR PROP. PIC HAD SHUTDOWN ENG WHEN IT WAS REALIZED BRAKES WERE NOT WORKING. MECH FOUND BRAKE LINE COMING FROM AIRFRAME THAT PASSES THROUGH LANDING GEAR STRUT, HAD CONTACTED RT BRAKE DISC. BRAKE LINE TUBE BEING SOFTER METAL THAN BRAKE DISC WAS CUT AND CAUSED BRAKE FLUID TO LEAK OUT CAUSING NO BRAKE SITUATION ON RT SIDE. FUTHER INVESTIGATION SHOWED THAT LINE WAS POSSIBLY STEPPED ON PRIOR TO THE TAXI OPERATION, CAUSING IT TO COME IN CONTACT WITH BRAKE DISC. 1 H 7 1 3O 3 O 3A21 E3SO 2004091400201 20040914 00201 EU 2004 9 14 B3OR20040712 1 20040707 G 2150 900A4031 EVAPORATOR SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE AIR CONDITIONER CRACKED B B3OR O OTHER O OTHER NR NOT REPORTED 1 SW 03 5204X 3099 9570 PILOT WAS OPERATING AC AIR CONDTIONING SYSTEM AND HEARD A NOISE COMMING FROM THE FWD EVAPORATOR UNDER INSTRUMENT PANEL. UPON RETURN TO BASE, MECHANIC VERIFIED THAT THE NOISE WAS COMMING FROM THE FWD EVAPORATOR. THE EVAPORATOR WAS REMOVED AN D IT WAS FOUND TO HAVE CRACKS IN THE HOUSING NEAR THE BLOWER ASSEMBLIES. THE CRACKS CAUSED THE BLOWERS TO BE MISALIGNED AND THAT WAS THE SOURCE OF THE NOISE. THE UNIT WAS REPLACED AND THE SYSTEM SERVICED AND OPERATES NORMALLY. THIS OPERATOR HAS REPLACED FOUR (4) SUCH EVAPORATOR ASSEMBLIES IN THE PAST TWO (2) YEARS DUE TO CRACKS OF THIS TYPE. MAYBE THE MANUFA CTURER NEEDS TO LOOK INTO A BETTER HOUSING MATERIAL, THE HARD PLASTIC MATERIAL CURRENTLY USED IS NOT TOUGH ENOUGH. 1 G 7 1 3U 3 U H9EU E19EU 2004092000114 20040920 00114 CE 2004 9 20 B3OR20040719 1 20040719 G 7160 21500351 HINGE CESSNA 210 T210N 2073456 CE CONT O550 IO550N 17042 SO ALTERNATE AIR LOOSE B B3OR K NONE O OTHER IN INSP/MAINT 1 SW 03 5515Y 21064233 289125R ANNUAL INSP, ALTERNATE AIR SOURCE DOOR WAS LOOSE. MECHANIC FOUND DOOR SPRING P/N 1250728-1, HINGE PIN P/N MS20253P2-364 IN INDUCTION AIR BOX DUCTING. PIN AND SPRING WERE RE-ASSEMBLED WITH DOOR. WHEN PARTS WERE RE-ASSEMBLED, BOTH UPPER AND LOWER ENDS OF HINGE WERE CRIMPED. CRIMPING BOTH ENDS OF HINGE DOES NOT ALLOW PIN TO FALL OUT, OVER TIME, ALLOW SPRING TO COME LOOSE. ABOUT A YEAR AGO, ENGINE INGESTED SPRING AND CAUSED ENOUGH DAMAGE TO NR 5 CYLINDER AND NR 5 PISTON TO HAV E THEM BOTH REPLACED. MFG MM IS VAUGE ON HOW TO ASSEMBLE THESE PARTS. CRIMPING BOTH ENDS OF THE HINGE WOULD ENSURE THAT THESE PARTS WILL NOT COME LOOSE AND NOT GET INGESTED INTO THE ENGINE. 1 H 7 1 3O 3 O 3A21 E3SO 2004120600034 20041206 00034 CE 2004 12 6 B3OR20041029 1 20040922 G 5740 1011200131 ATTACH FITTING BEECH 200 A200 1152921 CE WING DAMAGED B B3OR K NONE O OTHER IN INSP/MAINT 1 SW 03 7247Y 13789 BC03 ON 22 SEPTEMBER 2004 A 5 YEAR WING BOLT INSPECTION WAS COMPLIED WITH ON A BEECHCRAFT A200 AIRCRAFT. THREE OF THE WING AT TACH FITTINGS WERE FOUND TO HAVE DAMAGE TO THE FLAT FACE PORTION OF THE FITTINGS, THE AREA WHERE THE WASHER RESTS ON THE FITTING. THE DAMAGE WAS SEVERE ENOUGH FOR THE AIRCRAFT MANF, RAYTHEON AIRCRAFT TO BE CONTACTED AND A REPAIR SCHEME TO R EPAIR THE DAMAGE WAS REQUESTED. THE AFFECTED FITTINGS WERE THE LT LOWER OUTBOARD AFT P/N: 35-115058-2, RT LOWER OUTBOARD AFT, P/N: 35-115058-3, AND THE RT LOWER INBOARD FWD FITTING WHICH INCORPORATES THE FWD CARRY THROUGH SPAR, P/N: 101-120 013-1. THE DAMAGE SEEMED TO BE CAUSED BY THE WASHER BEING INSTALLED BACKWARDS AT ONE POINT. 1 L 7 2 4T A24CE 2004030300202 20040303 00202 SO 2004 3 3 BHA03RS 2 20040223 G 8500 ENGINE CESSNA 340 340A 2076405 CE CONT O520 TSIO520NB 17040 SO MCAULY 3AF32C 3AF32C505 GL RIGHT DAMAGED E A UNSCHED LANDING F K FLT CONT AFFECTED FLUID LOSS CL CLIMB 1 NM 04 114BH 3094 1494 340A1230 503082 020379 DURING FLIGHT, RT ENGINE OIL PRESSURE GAGE INDICATED A SIGNIFICANT INCREASE IN PRESSURE. RT ENGINE DAMAGE OCCURRED. AIR CRAFT LANDED WITHOUT FURTHER INCIDENT. 1 L 7 2 3O 3 O 3A25 E8CE 5 C P22EA 2004050300153 20040503 00153 CE 2004 5 3 BHA04RS 1 20040408 G 5341 50110241 ATTACH FITTING CESSNA 414 414A 2075907 CE CONT O520 TSIO520* 17040 SO RT WING CORRODED B K NONE O OTHER IN INSP/MAINT 1 NM 04 414PG 3914 414A0811 IN COMPLYING WITH SUPPLEMENTAL INSPECTION 57-10-20, FOUND THE RT WING LOWER SPAR ATTACH FITTING HAD SIGNIFICANT CORROSIO N IN SOME OF THE FITTING MOUNTING HOLES. THE FITTING WAS REPLACED. NO FURTHERDEFECTS WERE NOTED. 1 L 7 2 3O 3 O A7CE E8CE 2004050700001 20040507 00001 SO 2004 5 7 BHA05RS 2 20040423 G 8530 TISN712BCA221 CYLINDER HEAD CESSNA 414 414A 2075907 CE CONT O520 TSIO520NB 17040 SO ENGINE SEPARATED B A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CL CLIMB 1 NM 04 414PG 204 414A0811 514461 DURING POWER REDUCTION FROM TAKE-OFF POWER TO CLIMB POWER, A (POP) WAS HEARD AND ONE OF THE ENGINES BEGAN RUNNING ROUGH. THERE WAS NO INSTRUMENT/GAGE INDICATION AS TO WHICH ENGINE. AIRCRAFT LANDED WITH OUT INCIDENT. POST FLIGHT EXAMINATION FOUND NR 1 ENGINE, NR 6 CYLINDER HEAD HAD SEPARATED. 1 L 7 2 3O 3 O A7CE E8CE 2004123000055 20041230 00055 SO 2004 12 30 BJ3R200400002 1 20040927 G 2410 3656624R ALTERNATOR PIPER PA32 PA32R300 7103213 SO LYC O540 IO540K1G5 41532 EA ENGINE DEFECTIVE B D RETURN TO BLOCK H ELECT. POWER LOSS-50 PC TX TAXI/GRND HDL 1 WP 03 75143 27 32R7680263 L1444048A PREVIOUSLY INSTALLED OVERHAULED ALTERNATOR FAILED AFTER APPROXIMATELY 27 HOURS OF OPERATION. THE ALTERNATOR WAS MANUFAC TURED BY KELLY AEROSPACE/ELECTROSYSTEMS. THERE WAS EXCESSIVE BINDING OF THE ALTERNATOR SHAFT AND PULLEY. IN ADDITION, TWO EACH OF THE COOLING FINS BROKE OFF THE ALTERNATOR. 1 L 7 1 3O 3 O A3SO 1E4 2005030800055 20050308 00055 EA 2005 3 8 BJ3R200400003 2 20041011 G 7314 62E22581 PUMP PIPER PA46 PA46350P 7104602 SO LYC O540 IO540* 41532 EA ENGINE FUEL DEFECTIVE B O OTHER R PARTIAL RPM/PWR LOSS DE DESCENT 1 WP 03 242RR 200 4636348 L1149261A PILOT REPORTED, WHEN TURNING ON ELECT FUEL BOOST PUMP TO PREPARE FOR DESCENT, ENG RAN VERY ROUGH AND WAS SIGNIFICANT POW ER LOSS. ENG WOULD NOT REMAIN RUNNING WITH FUEL BOOST PUMP ON. WHEN THE BOOST PUMP WAS TURNED OFF THE ENG OP WAS SATISF ACTORY. DURING SUBSEQUENT TAXI OPERATION, THE ENG WOULD DROP OVER 200 RPM WITH THE BOOST PUMP TURNED ON AND AT LOW RPM THE ENG WOULD SHUT DOWN. AFTER TALKING WITH LYCOMING TECH REPRESENTATIVES, IT WAS DETERMINED THAT THE ENG DRIVEN FUEL P UMP WAS PRESS SENSITIVE AND COULD NOT OPERATE WITH THE INCREASED FUEL PRESSURE THE ELECTRIC PUMP DELIVERED TO IT. AFTER REPLACING THE ENG DRIVEN FUEL PUMP, ENG OPERATION WAS SATISFACTORY WITH AND W/O THE ELECTRIC BOOST PUMP TURNED ON. 1 L 7 1 3O 3 O RT A25SO 1E4 2004030300200 20040303 00200 CE 2004 3 3 BROWN2004001 1 20040223 G 5410 PYLON LEAR 45 45LEAR 5170805 CE ENG PYLON VIBRATION C O OTHER E VIBRATION/BUFFET CR CRUISE 1 CE 03 042 AIRCRAFT CONTINUES TO EXPERIENCE A RUMBLE IN FLIGHT AT SPEEDS BETWEEN 430 AND 460 KTAS (NORMAL CRUISE SPEEDS). MFG HAS MADE NUMEROUS ATTEMPS TO CORRECT THE PROBLEM BUT THEY HAVE NOT BEEN SUCCESSFUL. THE RUMBLE CAN BE HEARD AND FELT IN THE COCKPIT AND CABIN. THE RUMBLE APPEARED TO HAVE COME FROM THE ENGINE PYLON AREAS. THE ENGINE PYLON AND RT GEAR DOOR LE ADING EDGE AREAS HAVE BEEN REWORKED IAW MFG ENGINEERING DISPOSITION. THE PROBLEM HAS NOT BEEN RECTIFIED AS TO DATE. 2 L 7 2 4F RT T00008WI 2005022200207 20050222 00207 NE 2005 2 22 C7GR861J 2 20040820 G 7310 419110003 MANIFOLD HONEYWELL LYC LTS101 LTS101750B1 41560 NE PT MODULE MISINSTALLED B K NONE O OTHER IN INSP/MAINT 1 SO 13 900 900 G94G001 LE48166BEF LTS101-750B-1 ENGINE, SN: LE-48166BEF WAS RECEIVED BY THIS REPAIR STATION (CRS NR C7GR861J) FOR ROUTINE MAINTENANCE. SI NCE WE HAD RECEIVED SOME NEW MANIFOLD ASSEMBLIES WITH IMPROPERLY TORQUED BOLTS (16 EA) THAT SECURE EIGHT COVERS ON THE I NJECTOR BLOCKS, DECIDED TO PERFORM A TORQUE CHECK ON THIS FUEL MANIFOLD (TSN = 900 HRS). BREAKAWAY TORQUES AS LOW AS 18 IN/LB WAS OBSERVED. THE PROPER TORQUE IS 40-45 IN/LB. THIS CONDITION HAS BEEN REPORTED TO HONEYWELL, PHOENIX FOR PROP ER INVESTIGATION AND RESOLUTION. 3 U E5NE10 2004031500113 20040315 00113 2004 3 15 CA040102002 4 20040102 G 3417 9B810202 ADC BOEING 737 737200 1384453 NM PWA JT8 JT8D17 52049 NE COCKPIT INTERMITTENT W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA (CAN) PRIOR TO DEPARTURE THE FLIGHT CREW A MACH AIRSPEED WARNING CLACKER INOPERATIVE ASSOCIATED WITH A FLAG ON THE MACH AIRSPEED INDICATOR. RECTIFICATION THE MACH AIRSPEED INDICATOR WAS REPLACED. HOWEVER THE SNAG RETURNED ON DECEMBER 29. T HE SYSTEM WAS PLACED ON MEL. THE MACH AIRSPEED INDICATOR WAS REPLACED AGAIN ON DECEMBER 31. HOWEVER THE FAULT RETURNED F OR A THIRD TIME ON JANUARY 2, 2004. 2 L 7 2 4F 4 F A16WE E2EA 2004031500122 20040315 00122 SO 2004 3 15 CA040103001 1 20040102 G 5540 4004009 TORQUE TUBE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL RUDDER CORRODED W K NONE F FLT CONT AFFECTED IN INSP/MAINT 1 CA (CAN) WHILE COMPLYING WITH AD 2003-24-07, FOUND SURFACE CORROSION OF RUDDER TORQUE TUBE (VISUAL INSPECTION OF RUDDER INT ERNAL STRUCTURE MFG SB NR 1105A. REMOVED TORQUE TUBE AND FOUND AREA TO BE INSPECTED IAW AD REPAIRABLE BUT FOUND THAT THE INTERNAL TORQUE TUBE CORROSION SEVERE AND METAL/OXIDE FALLING OFF TORQUE TUBE INTERNAL WALLS. (NOT MENTIONED BY AD). RU DDER ALUMINUM RIBS TO STEEL TORQUE TUBE CORROSION ALSO NOTED. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004031500132 20040315 00132 EA 2004 3 15 CA040104001 2 20040102 G 7320 252444076 FUEL CONTROL BEECH 100 100BEECH 1152916 CE PWA PT6 PT6A28 EA HARTZL HCD4N3 HCD4N3A GL LT ENGINE FAILED W O OTHER Y J ENGINE STOPPAGE WARNING INDICATION DE DESCENT 1 CA PCE52113 (CAN) LT ENGINE HAD TO BE SHUT DOWN IN FLIGHT AS FCU THROTTLE ARM WOULD NOT RETURN TO IDLE. DUE TO WEEKEND AND PARTS ON ORDER WE WILL BE REMOVING FCU NEXT WEEK. 1 L 7 2 3T 4 T A14CE E4EA 5 C STC 2004031500140 20040315 00140 2004 3 15 CA040104002 4 20040101 G 8300 FLANGE BOEING 727 727231 1384079 NM PWA JT8 JT8D15A 52051 NE ACCESSORY GEARBO CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 6674486K (CAN) SCHEDULED MAINTENANCE WAS CARRIED OUT TO REPLACE THE FCU/FUEL PUMP QUAD RING. THE RUN OUT TORQUE INSPECTION WAS CA RRIED OUT AND THE CLEARANCE FAILED. DISASSEMBLY OF THE AREA DETERMINED THAT THE QUAD RING NUT ATTACHMENT FLANGE WAS CRAC KED. THE UNSERVICEABLE GEARBOX WAS REMOVED AND A SERVICEABLE UNIT WAS INSTALLED. NO FURTHER PROBLEM WAS FOUND. 2 L 7 3 4F 4 F A3WE E2EA 2004031500141 20040315 00141 NM 2004 3 15 CA040105001 1 20040101 G 2435 51539008D GCU LUCAS DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE STARTER GEN FAILED W E ENGINE SHUTDOWN B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA 31251 31251 1163 (CAN) DURING NR 1 ENGINE START AFTER PUSHBACK SMOKE WAS NOTED COMING OUT OF THE GEN EXHAUST DUCT ON THE NR 1 NACELLE. T HE PILOT IMMEDIATELY SHUT ENGINE DOWN AND DECLARED AN EMERGENCY, REQUESTED ERS RESPONCE. PASSENGERS WERE DEPLANED AND PI LOT NOTED THAT GENERATOR WAS STILL SPOOLING AFTER EVERYTHING WAS SHUT DOWN, MAINTENANCE WAS SUMMONED TO AC AND MAIN BATT ERY WAS DISCONNECTED AND GENERATOR STOPPED. AC WAS BROUGHT BACK TO HANGAR AND STARTER GEN, GCU AND MAIN BATTERY WERE RE PLACED AND AIRCRAFT RETURNED TO SERVICE AFTER ALL FUNCTION CHECKS WERE CARRIED OUT. COMPONENTS WILL BE SENT OUT FOR REPA IR AND INVESTIGATION AS TO WHY THE GEN DIDN'T DISENGAGE AFTER START UP WHICH CAUSED THE INCIDENT. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004031500156 20040315 00156 EU 2004 3 15 CA040105008 1 20040103 G 3260 A23802105 SQUAT SWITCH AMD FALC20 FALCON20F5 2730105 EU GE CF700 CF7002D2 30010 NE NLG FROZEN W O OTHER N FALSE WARNING LD LANDING 1 CA (CAN) ON LANDING THE PIC COULD NOT ACTIVATE THE NORMAL BRAKES AND THE NOSE WHEEL STEERING. PIC USED NR 2 BRAKE SYSTEM AN D DIFFERENTIAL POWER TO CONTROL THE AC. SQUAT SWITCH WAS REMOVED, CLEANED AND RE-INSTALLED. NORMAL BRAKES AND NOSE WHEE L STEERING FUNCTION TESTED SERVICEABLE. AC RETURNED TO SERVICE. OPERATOR PLANS TO IMPLEMENT MONTHLY INSPECTION AND CLE ANING OF ALL LANDING GEAR SWITCHES OF MOISTURE. 2 L 7 2 4F 4 F RT A7EU E7EA 2004031500165 20040315 00165 NE 2004 3 15 CA040106002 2 20040102 G 7200 ENGINE CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE NR 2 MAKING METAL W A UNSCHED LANDING Y J ENGINE STOPPAGE WARNING INDICATION CR CRUISE 1 CA 872684 (CAN) CREW REPORTED APPROXIMATELY 30 MINUTES FROM DESTINATION, THAT NR 2 ENGINE OIL PRESSURE HAD DROPPED BELOW MINIMUM. CREW ELECTED TO PERFORM IN FLIGHT SHUT DOWN. CREW REQUESTED CFR AND LANDED WITHOUT INCIDENT. INSPECTION REVEALED NR 2 E NGINE 2 QTS LOW WITH NO SOURCE OF OIL LEAKS. AGB CHIP DETECTOR REVEALED SOME METAL DEBRIS. CHIP DETECTOR TROUBLESHOOTING KIT WAS INSTALLED AND SECOND INSPECTION OF THE CHIP DETECTOR REVEALED A SIGNIFICANT AMOUNT OF METAL. A BOROSCOPE INSPEC TION REVEALED THAT THE AXIS P GEAR WAS MISSING TEETH AND THAT THE AXIS B-B GEAR WAS HEAVILY WORN. LAB ANALYSIS OF THE RE MOVED DEBRIS CONFIRMED TO BE M50 MATERIAL. ENGINE WAS REPLACED. 2 L 7 2 4F 4 F RT A21EA E15NE 2004031500183 20040315 00183 EA 2004 3 15 CA040106008 1 20040106 G 2497 WIRE CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE E/E COMP. FAILED W K NONE B J SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION IN INSP/MAINT 1 CA (CAN) AFTER LANDING, CAUTION MSG ESS TRU 1 ON EICAS A PUFF OF ELECTRICAL ODOR WAS DETECTED AT GATE FOUND A1 CB POPPED WO ULD NOT RESET. DUE TO THIS SITUATION THREE WIRES WERE CHANGED ALSO TR1 REPLACED AND J12 CONNECTOR REPLACED. 2 L 7 2 4F 4 F RT A21EA E15NE 2004031500186 20040315 00186 EA 2004 3 15 CA040106011 1 20040104 G 2710 CONTROL CABLE CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE AILERON CONTAMINATED W D RETURN TO BLOCK O OTHER TX TAXI/GRND HDL 1 CA (CAN) WHILE TAXING DURING FLT CONTROL CHECK FOUND AILERONS NOT RETURNING TO NEUTRAL. AFTER INVESTIGATION FOUND WHEEL WEL L CONTAMINATED WITH DIRT AND MOISTURE. AREA CLEANED AND LUBRICATED. 2 L 7 2 4F 4 F RT A21EA E15NE 2004032500035 20040325 00035 GL 2004 3 25 CA040107008 1 20040107 G 7921 654585 OIL COOLER CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO HARTZL HCJ3Y PHCJ3YF1 GL ENGINE CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) OIL COOLER FOUND CRACKED ON OB FORWARD LOWER CORNER FLANGE WHERE THE BAFFLE IS ATTACHED. CRACK IS ABOUT 1 INCH LON G. THIS IS THE THIRD COOLER FOUND CRACKED ON THE TYPE OF INSTALLATION. 1 L 7 1 3O 3 O NT A00009CH E3SO 5 C P36EA 2004032500043 20040325 00043 EA 2004 3 25 CA040108003 1 20040107 G 2497 BMS1360T01C03G0 WIRE CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE ELECTRICAL INOPERATIVE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHILE RE-INSTALLING CIRCUIT BREAKER PANEL THAT WAS ROBBED TO SERVICE AN OTHER AIRCRAFT THE MECHANIC NOTICE THREE P OWER CABLES WERE SHAVING ALONG THE STRUCTURE OF THE PANEL. (STRAINS WERE SHOWING) THOSE THREE WIRES WERE REPLACED, FOL LOWING THIS FINDING, A CAMPAIN WILL BE LAUNCHED DUE TO FIRE POTENTIAL. 2 L 7 2 4F 4 F RT A21EA E15NE 2004032500046 20040325 00046 CE 2004 3 25 CA040108007 1 20040107 G 2820 VALVE CESSNA 560 560XL 2076702 CE PWA 545 PW545A NE FUEL CROSSFEED INOPERATIVE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING REFUELING, FBO LINE CREW FAILED TO CARRY OUT SINGLE POINT REFUELING PRE-CHECK. DURING FUELLING, ONLY LT TAN K WAS FILLED (RT REFUELING VALVE APPARENTLY FAILED IN THE CLOSED POSITION). BY THE TIME THE FLIGHT CREW NOTICED THE DIFF ICULTY A SIGNIFICANT FUEL IMBALANCE HAD BEEN CREATED, REQUIRING CROSSFEED FROM LT TO RT TANK. 2 L 7 2 4F 4 F RT A22CE E00059EN 2004032500049 20040325 00049 EA 2004 3 25 CA040109003 1 20040108 G 5270 600314703 ROLLER CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE STRIKER GUIDE MISALIGNED W K NONE N FALSE WARNING IN INSP/MAINT 1 CA (CAN) AFTER TAKE OFF, DOOR LATCH CAUTION. 30 SEC LATER, PASSENGER DOOR. PRESSURE OK AND DOOR INDICATION PIN INSIDE WERE IN THE GREEN. REPLACED FORWARD STRIKER GUIDE ROLLER IAW FMR. SEAL LUB AND VENT HOLE ALIGN. ALL LATCH PINS & HANDLE LUB. 2 L 7 2 4F 4 F RT A21EA E15NE 2004032500050 20040325 00050 NM 2004 3 25 CA040109004 1 20040109 G 2612 FIRE DETECTOR BOEING 727 72722C 138400F NM PWA JT8 JT8D7B 52053 NE ENGINE BAY MALFUNCTIONED W O OTHER N FALSE WARNING AP APPROACH 1 CA (CAN) ON APPROACH, THE ENGINE FIRE WARNING BELL SOUNDED CONTINUOUSLY, THERE WERE NO ENGINE WARNING LIGHTS ON. ON THE GR OUND MAINTENANCE INSPECTED ALL ENGINES NO FAULTS WERE FOUND. MAINTENANCE WAS UNABLE TO DUPLICATE PROBLEM AGAIN ON THE GR OUND. THE FIRE DETECTION DETECTOR UNIT P/N 65-24920-3 WAS REPLACED . REMOVED AND INSPECTED AND CLEANED PIN/SOCKETS AN AL L THREE ENGINE FIRE DETECTION POWER OPERATING UNITS P/N 1011B-1. THE SYSTEM WAS TESTED WITH NO FAULTS. THE AIRCRAFT WAS RETURNED TO SERVICE AND OPERATED WITHOUT ANY FURTHER PROBLEMS. 2 L 7 3 4F 4 F A3WE E2EA 2004032500062 20040325 00062 EU 2004 3 25 CA040109006 1 20040107 G 2913 716988 PUMP BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE HYDRAULIC SYS LEAKING W E A ENGINE SHUTDOWN UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA 23682 23682 LF05559AC (CAN) IN FLIGHT SHUT DOWN OF NR 2 ENGINE DUE TO LOSS OF OIL PRESSURE AND QUANTITY. MAINTENANCE FOUND EVIDENCE OF HYD FLU ID MIGRATION INTERNALLY FROM HYDRAULIC PUMP TO THE PUMP SHAFT. SUSPECT THAT HYD FLUID CAUSED DETERIORATION OF THE PUMP S HAFT SEAL (O-RING) TO THE POINT THAT IT CAUSED THE ENGINE OIL TO BE LOST. PUMP REPLACED. NR 2 ENGINE ALSO BEING REPLACE D. 2 H 7 4 4F 4 F A49EU E6NE 2004032500063 20040325 00063 NM 2004 3 25 CA040109007 1 20040109 G 5610 NP1579029 WINDOW DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE COCKPIT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ON PREFLIGHT INSPECTION , FLT ENGINEER DISCOVERED OUTER PLY OF PILOT SIDE WINDOW WITH MULTIPLE CRACKS EXTENDING AR OUND THE CIRCUMFERENCE OF WINDOW ORIGINATING FROM LOWER FWD CORNER. NO OBVIOUS IMPACT DAMAGE FOUND ON INSPECTION. NO M. E.L. RELIEF. MANUFACTURER ADVISED TO CHANGE WINDOW BEFORE FURTHER FLIGHT. OVERNIGHT TEMP: -13C 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004032500068 20040325 00068 EU 2004 3 25 CA040110001 1 20040109 G 2997 9740926112 RELAY PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL HYD SYSTEM FAILED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) AFTER TAKE OFF THE CREW SELECTED GEAR UP. THE HYDRAULIC CAWS LIGHT CAME ON AND THE GEAR WOULD NOT FULLY RETRACT. T HE GEAR WAS EXTENDED FULLY WITH THE HAND PUMP AND AN UNEVENTFUL LANDING CARRIED OUT. UPON INSPECTION BY MAINTENANCE, THE HYDRAULIC RELAY K601 WAS FOUND TO BE AT FAULT. THE RELAY WAS REPLACED, GEAR SWINGS CARRIED OUT AND THE AIRCRAFT RETURNE D TO SERVICE. THERE ARE SEVERAL OTHER INSTANCES INVOLVING FAILURE OF THESE RELAYS, WITH SIMILAR SNAG CIRCUMSTANCES. A SUGGESTION TO PLACE THESE COMPONENTS ON A HARD TIME INTERVAL IN LIEU OF, ON-CONDITION FOR OTHER OPERATORS WOULD BE BENEF ICIAL. WE ARE CURRENTLY RESEARCHING THE TIME BETWEEN FAILURE, AS THESE ARE NOT NORMALLY TIME TRACKED. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004032500069 20040325 00069 NM 2004 3 25 CA040112001 1 20040109 G 5610 80260008 WINDSHIELD BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU COCKPIT CRACKED W A UNSCHED LANDING O OTHER CR CRUISE 1 CA (CAN) DURING A FLIGHT THE RT COCKPIT WINDSHIELD CRACKED, ZERO VISIBILITY AND AN EMERGENCY LANDING WAS CARRIED OUT. MAINT ENANCE TECH'S CHANGED WINDOW AND A/C RETURNED TO SERVICE. A/C JUST CAME OUT OF 'C' CHECK, IS MODSUM 4Q5300002 COMPLETED, WHICH REMOVES BOTH WINDSHIELDS FOR RE-SEALING. BELIEVE THAT THE WINDOW WAS DAMAGED DURING THE REMOVAL PROCESS. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2004032500071 20040325 00071 NM 2004 3 25 CA040112003 1 20040109 G 3242 BRAKE PADS BOEING 727 727260 NM PWA JT8 JT8D17 52049 NE MLG DAMAGED W D RETURN TO BLOCK O OTHER TX TAXI/GRND HDL 1 CA (CAN) DURING TAXI, CREW REPORTED THAT THERE WAS SOME DRAGGING FELT WHEN THE BRAKES WERE APPLIED. THE AIRCRAFT RETURNED T O THE BLOCKS. A DETAILED INSPECTION WAS CARRIED OUT AND NR 4 BRAKE WAS FOUND UNSERVICEABLE. THE BRAKE PADS WERE DAMAGED AND BROKEN. A SERVICEABLE BRAKE WAS INSTALLED IAW MM 32-41-31 AND CHECKED SERVICEABLE. THERE WAS NO PROBLEM DURING SUB SEQUENT FLIGHT. 2 L 7 3 4F 4 F RT A3WE E2EA 2004032500090 20040325 00090 NE 2004 3 25 CA040112004 2 20040112 G 8500 ENGINE DOUG DC3 DC3C 3021457 WP PWA R1830 R183092 52020 NE HAMSTD 23E 23E50 NE RIGHT FAILED W E ENGINE SHUTDOWN J WARNING INDICATION CL CLIMB 1 CA (CAN) DURING CLIMB THE PILOT NOTICED THE RT ENGINE OIL TEMPERATURE WAS INCREASING SIGNIFICANTLY. THE ENGINE WAS SHUT DOW N AND FLIGHT CARRIED OUT WITHOUT INCIDENT. 2 L 7 2 4R 4 R A669 5E4 6 C P603 2004032500091 20040325 00091 SO 2004 3 25 CA040112005 1 20040111 G 3230 4204200 ARM PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL MLG BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AFTER TAKE-OFF, CREW SELECTED LANDING GEAR UP. RT MAIN LANDING GEAR STILL INDICATED DOWN AND LOCKED AFTER RETRACTI ON. CREWS SELECTED GEAR DOWN AND ALL GEAR INDICATED DOWN AND LOCKED. AIRCRAFT RETURNED TO BASE WITH NO FURTHER FAULTS NO TED BY CREW. VISUAL INSPECTION OF LANDING GEAR SYSTEM CARRIED OUT. FOUND RT MAIN LANDING GEAR RETRACTION ARM P/N 42042-0 0 BROKEN. THIS PART ORIGINAL CRACK LOCATION NOT POSSIBLE TO BE INSPECTED OR FOUND WITH OUT COMPLETE DISMANTLE OF RETRACT ION SYSTEM. RETRACTION ACTUATOR ROD END P/N 762-554 ALSO DAMAGED. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004032500092 20040325 00092 GL 2004 3 25 CA040112006 1 20040107 G 2752 SEAL DIAMON DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240B 17063 SO SNSNCH W69EK W69EK63 EA FLAP ACTUATOR LOOSE W O OTHER F FLT CONT AFFECTED AP APPROACH 1 CA (CAN) PILOT REPORTED FLAP STUCK IN LANDING POSITION, OVERSPED FLAPS 100 KTS FOR 5 MIN,FLAP INDICATOR U/S. UPON INSPECTI ON IT WAS FOUND THAT SPLINED RUBBER SEAL PUSHED OUT OF POSITION ON FLAP ACTUATOR ROD ASSY. SPLINED RUBBER SEAL INTERFERE D WITH FLAP POSITION SWITCHES. RE-INSTALLED SPLINED RUBBER SEAL WITH EPOXY AND ALLOWED TO CURE. FLAP SYSTEM FUNCTION TES TED, FLAP POSITION LIGHTS AND FLAPS SERVICEABLE. FLAPS INSPECTED FOR OVER SPEED DAMAGE NONE FOUND. AC RELEASED. IT APPE ARED THAT THE SPLINES WERE USED TO KEEP THE SEAL IN PLACED BUT AS THERE IS LITTLE LUBRICATION REQUIRED ON THE FLAP ACTUA TOR SHAFT, FRICTION OF THE SHAFT ON THE SEAL, PULLS THE SEAL OUT OF POSITION AND DRAGS IT ALONG INTO THE SWITCHES. 1 L 7 1 3O 3 O NT TA4CH E7SO 5 N TA4CH 2004032500093 20040325 00093 EU 2004 3 25 CA040113001 1 20040113 G 3234 210TS07Y01 SELECTOR AIRBUS A340 A340313 EU CFMINT CFM56 CFM565C4 13802 NE MLG MALFUNCTIONED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) SELECTED GEAR DOWN AND NOTHING HAPPENED FOR AT LEAST A MINUTE, THEN WIGGLED HANDLE THEN THE GEAR CAME DOWN. NOTE: AC SENT TO HANGAR FOR TROUBLE/SHOOTING. 2 L 7 4 4F 4 F RT A197 E37NE 2004032500094 20040325 00094 NM 2004 3 25 CA040113002 1 20040113 G 2824 MA20A10011 ACTUATOR BOEING 767 767209 1385127 NM PWA JT9 JT9D7R4D 52054 NE CROSSFEED VALVE FAILED W O OTHER J WARNING INDICATION CR CRUISE 1 CA (CAN) ON PRE-DESCENT CHECK WHEN FUEL CROSSFEED WAS CHECKED ON AND OFF, EICAS MESSAGE FUEL CROSSFEED AND VALVE LIGHT ON C ROSSFEED SWITCH REMAINED ILLUMINATED. ON GROUND RECYCLED CIRCUIT BREAKER NIL FIX. TAKEN OFF LINE FOR INVESTIGATION FLT CANCLED PART: ELECTRIC ACTUATOR REPLACED IAW AMM 28-22-12. 2 L 7 2 4F 4 F RT A1NM E3NE 2004032500096 20040325 00096 NM 2004 3 25 CA040113004 1 20040113 G 5610 141T480150 WINDSHIELD BOEING 767 767333 1385301 NM PWA 4060 PW4060 52119 NE COCKPIT FAILED W O OTHER O OTHER NR NOT REPORTED 1 CA 36170 (CAN) WHILE IN FLT ENROUTE FROM YYZ TO TLV, R1 WINDSHIELD OUTER PANE SHATTERED. FLT CONTINUED WITHOUT FURTHER INCIDENT. MTCE POOLED A WINDOW AND CHANGED. 2 L 7 2 4F 4 F RT A1NM E24NE 2004032500097 20040325 00097 EU 2004 3 25 CA040113005 1 20040113 G 3230 D31AAB4431 SAFETY VALVE AIRBUS A340 A340313 EU CFMINT CFM56 CFM565C4 13802 NE MLG INOPERATIVE W O OTHER J WARNING INDICATION AP APPROACH 1 CA (CAN) ON APPROACH, GEAR DID NOT EXTEND NORMALLY ON FIRST ATTEMPT, SECOND ATTEMPT HAD SAME RESULT. CREW ELECTED TO CARRY OUT GO AROUND. LANDING GEAR CONTROL LEVER REPLACED AND TESTED IAW MM 32-31-11-400, MLG ISOLATION SAFETY VALVE (85GA) REP LACED IAW MM 32-31-17. MLG. EXTENDED AND RETRACTED SEVERAL TIMES IAW MM 32-31-00-710-801, CHKD. SERV. REMOVE UNI 32-30-0 482C1024AC 001 FISOS: NINSTALLUNI 32-30-0482 FTN 1341Q9 AC 001REMOVE UNI 32-30-0513 FTN 5Y25Z5 AC FI SOS: N INSTALL UNI 32-30-0513FTN 55656R AC. 2 L 7 4 4F 4 F RT A197 E37NE 2004032500098 20040325 00098 SW 2004 3 25 CA040113006 1 20040107 G 6710 AN17415 BOLT BELL BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA DAMPER ARM SHEARED W A UNSCHED LANDING O OTHER CR CRUISE 1 CA (CAN) HELISKI OPERATION. PILOT REPORTED BAD VIBRATION IN TURNS AND CONTROLLABILITY CONCERNS, ALSO IN TURNS. RETURNED TO BASE IMMEDIATELY. SHEARED BOLT FOUND WHERE MAIN ROTOR HYDRAULIC DAMPER CONTROL ARM ATTACHES TO STABILIZER BAR CONTROL TU BE ROD END. BOLT WAS CORRODED WITH EVIDENCE OF BEING LOOSE. ALSO BLACK ON NUT AND WASHER. NO OTHER DAMAGE FOUND. ATTACHM ENT HARDWARE REPLACED WITH NEW AND AIRCRAFT RETURNED TO SERVICE. 1 G 7 1 4U 4 U H4SW E22EA 2004032500120 20040325 00120 NM 2004 3 25 CA040113007 1 20040111 G 5755 65982962 HINGE BOEING 727 72725C 138400H NM PWA JT8 JT8D7B 52053 NE SPOILER CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 61773 (CAN) DURING SERVICE CHECK, FOUR CRACKS WERE FOUND ON THE NR 7 GROUND SPOILER SUPPORT HINGE. HINGE REPLACED WITH NEW PA RT. ALL HINGES INSPECTED FOR CRACKS, NO FAULTS FOUND. 2 L 7 3 4F 4 F A3WE E2EA 2004032500126 20040325 00126 EU 2004 3 25 CA040113008 1 20040108 G 3310 2527 LAMP PIAGIO P180 P180 6960204 EU PWA PT6 PT6A66 52043 NE HARTZL HCE5N HCE5N3 GL MAP LIGHT INOPERATIVE W H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) DURING CRUISE, COCKPIT ROOF MOUNTED MAP LIGHT FAILED, C/B ACTIVATED, CREW NOTICED A SLIGHT ODOR. DURING TROUBLESHO OTING THE ROOF PANEL WAS REMOVED AND IT WAS DISCOVERED THAT THE LAMP TERMINAL HAD BEEN IN CONTACT WITH AIRFRAME STRUCTUR E CAUSING THE RUBBER PROTECTIVE BOOT ON THE TERMINALS TO WEAR THROUGH AND GROUND ELECTRICAL SUPPLY. IT WAS ESTABLISHED THAT DURING COMPLETION AT A THIRD PARTY COMPLETION CENTER SPACER RINGS UNDER THE LAMP COLLAR HAD BEEN OMITTED. FLEET RE VIEW FOUND THAT SISTER AIRCRAFT WAS IN SAME CONDITION, BUT AN OTHER HAD SPACERS INSTALLED. SPACERS OBTAINED AND INSTALLE D ON AFFECTED AIRCRAFT. 1 H 7 2 3O 4 T RT A59EU E26NE 5 C PZONE 2004032500127 20040325 00127 NM 2004 3 25 CA040113009 1 20040107 G 2910 82970009121 LINE DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE HYDRAULIC SYS LEAKING W O OTHER K J FLUID LOSS WARNING INDICATION AP APPROACH 1 CA (CAN) ON APPROACH, CREW REPORTED NR 2 HYDRAULIC SYSTEM WENT LOW. NR 2 ISO VALVE LIGHT AND OB ROLL SPOILER CAUTION LIGH TS CAME ON, WHEN MAIN LANDING GEAR SELECTED DOWN. AFTER LANDING DOWN DOORS STAYED OPEN AND FLUID LEAKING FROM LT WHEEL WELL. MAINTENANCE FOUND HYDRAULIC LINE FOR NR 2 SYSTEM MLG UP PRESSURE TO BE LEAKING FROM PIN HOLES. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004042900096 20040429 00096 EA 2004 4 29 CA040113010 2 20040108 G 7414 10400554 SEAL PIPER PA12 PA12 7101202 SO LYC O320 O320C1A 41508 EA SNSNCH 74DM M74DM EA MAGNETO WORN W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA BL6006441 (CAN) ENGINE OIL IN RT MAGNETO SEAL P/N 10-400554 LIP WORN FLAT. SLEEVE P/N 10-357078 APPEARS TO BE OF SINTERED IRON NO T STEEL AS SINTERED IRON AND SINTERED BRASS SLEEVES WERE OBSOLETED MANY YEARS AGO. FIVE NEW SLEEVES IN STOCK ALSO APPEAR TO BE SINTERED IRON. NOTE: SEAL IN LT HAND MAGNETO WAS NOT LEAKING BUT WAS WORN FLAT: DOES THE ENGINE OIL WEEP THRU T HE NEW SINTERED BUSHING SLEEVES? IS THERE TOO MUCH TENSION ON THE OIL SEAL GARTER SPRING CAUSING PREMATURE WEAR. OR I S THE SINTERED IRON THE CULPRIT CAUSING EARLY SEAL WEAR? 1 H 7 1 3O 3 O A780 E274 5 N P88614 2004032500137 20040325 00137 GL 2004 3 25 CA040114002 1 20040111 G 2752 SEAL DIAMON DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240B 17063 SO SNSNCH W69EK W69EK63 EA FLAP ACTUATOR LOOSE W O OTHER F FLT CONT AFFECTED AP APPROACH 1 CA (CAN) PILOT REPORTED FLAP STUCK IN LANDING POSITION, UPON INSPECTION IT WAS FOUND THAT THE SPLINED RUBBER SEAL PUSHED OU T OF POSITION ON FLAP ACTUATOR ROD ASSY. SPLINED RUBBER SEAL INTERFERED WITH FLAP POSITION MICRO SWITCHES. RE-INSTALLED SPLINED RUBBER SEAL WITH EPOXY AND ALLOWED TO CURE. FLAP SYSTEM FUNCTION TESTED, FLAP POSITION LIGHTS AND FLAPS SERVIC EABLE. IT APPEARED THAT THE SPLINES WERE USED TO KEEP THE SEAL IN PLACED BUT AS THERE IS LITTLE LUBRICATION REQUIRED ON THE FLAP ACTUATOR SHAFT, FRICTION OF THE SHAFT ON THE SEAL, PULLS THE SEAL OUT OF POSITION AND DRAGS IT ALONG WITH IT INTO THE SWITCHES. 1 L 7 1 3O 3 O NT TA4CH E7SO 5 N TA4CH 2004050300245 20040503 00245 GL 2004 5 3 CA040114003 2 20040105 G 7323 8575472 LOCK GEAR ALLSN 501D 501D13 03004 GL SSC DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) SPEED SENSITIVE CONTROL (SSC) RECEIVED FROM CHANNEL EXPRESS AS A TYPE-CERTIFICATED COMPONENT. STANDARD AERO LIMIT ED (SAL) ASSUMED OWNERSHIP OF SSC, AND PLACED UNIT INTO SAL REPAIRABLE STOCK. SSC RECENTLY REMOVED FROM SAL STOCK TO BE OVERHAULED AND INSTALLED ON A 501-D13 ENGINE. TECHNICIAN NOTED P/N 8575472, A NON TYPE-CERTIFICATED MILITARY COMPONENT , WAS EMBODIED IN THE SSC. 4 T E282 2004032500138 20040325 00138 CE 2004 3 25 CA040114004 1 20040107 G 7722 3031566 BUSS BAR BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL ENGINE UNSERVICEABLE W O OTHER P NO WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) PILOTS WERE CARRYING OUT AN ENGINE START ON THE RT ENGINE AND NOTICED THAT THERE WAS NO ITT INDICATION SO THE ENGI NE WAS SHUT DOWN. MAINTENANCE TROUBLESHOOTING DETERMINED THE ITT HARNESS WAS SERVICEABLE BUT THAT THE ENGINE INTERNAL B USSBAR HAD FAILED. THE ENGINE WAS SPLIT AT THE C FLANGE AND THE BUSS BAR WAS FOUND SEPARATED FROM THE TOP OF THE JUNCTIO N BLOCK. THE BUSS BAR P/N 3031566 WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2004032500139 20040325 00139 2004 3 25 CA040114005 4 20040112 G 2297 BACC47DJ1DJ2 PIN ROSEMOUNT BOEING 757 757* NM RROYCE RB211 RB211535E437 54555 NE RELAY MISMANUFACTURED W A UNSCHED LANDING W INADEQUATE Q C CL CLIMB 1 CA A44369 (CAN) UPON ROTATION, TAT PROBE EICAS MESSAGE FOLLOWED BY AUTO THROTTLE DISCONNECT, AND ASSOCIATED WARNINGS. AIR TURN BA CK. TAT PROBE REPLACED. GROUND TEST GOOD. DEFECT RECURRED ON NEXT TAKEOFF.K143 AND K203 AIR/GND RELAYS REPLACED. TESTED GOOD IAW MM 30-33-00-501. NO FAULTS ON RETURN FLIGHT TO YVR. REVIEW OF THE RECORDS SHOWED 4 REPORTS SINCE 4TH DECEMBE R 2003. DUE TO THE INTERMITTENT NATURE OF THIS DEFECT, AS A PRECAUTIONARY MEASURE WIRING CHECKS WERE PERFORMED ON RETUR N TO YVR. A POOR CRIMP AT THE BASE OF RELAY K203 PIN B2 WAS FOUND. PIN REPLACED. 2 L 7 2 4F 4 F RT A2NM E12EU 2004032900059 20040329 00059 NM 2004 3 29 CA040115001 1 20040110 G 3230 54C546349 SOLENOID VALVE DHAV DHC8 DHC8103 1386005 NM PWA PW121 PW121 52124 NE HAMSTD 14SF 14SF7 NE MLG FAILED W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CL CLIMB 1 CA (CAN) DURING TAKEOFF AND THE GEAR UP SELECTION THE AIRCRAFT EXPERIENCED A COMPLETE LOSS OF ALL FLUID FROM THE NR2 HYDRAU LIC SYSTEM. ALTERNATE LANDING GEAR EXTENSION PREFORMED AND AIRCRAFT RETURNED SAFELY TO BASE. FINDINGS, LT MLG SOLENOID SEQUENCE VALVE FAILED. SOLENOID SEPARATED FROM VALVE. TWO BOLTS OF FOUR, WHICH CONNECT SOLENOID HOUSING, HAD BROKEN. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004080400211 20040804 00211 WP 2004 8 4 CA040115002 2 20040113 G 7230 310166812 PLENUM SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA P54276 (CAN) FLIGHT CREW RECEIVED SPLIT SECOND FIRE WARNING INDICATION ON LT ENG. DUE TO BRIEF NATURE OF IND FLIGHT CREW MONITO RED GAUGES, DETERMINED FALSE INDICATION. SHORTLY AFTER ENG STARTED LOSING PWR UNTIL IT REACHED ABOUT 55 PERCENT TORQUE. UPON INSP, LT ENG PLENUM DRAIN FIT WAS FOUND CRACKED, PARTIALLY SEPARATED FROM ENG PLENUM IN REARWARD DIRECTION. ALLOWE D HOT COMBUST GASES INTO ENG COMPART. PLENUM DRAIN FITTING IS WELDED TO ENG PLENUM. INSP REVEALED MINOR FIRE DAMAGE TO ENG WIRING HARNESS, SURROUNDING AREA. REASON FOR CRACKED FITTING WAS DETERMINED TO BE DRAIN TUBE ATTACHED TO FITTING WA S INSTALLED IN SUCH WAY IT WAS PUTTING A REARWARD LOAD ON DRAIN FITTING, CAUSING IT TO CRACK AND BREAK AWAY FROM PLENUM. 2 L 7 2 4T 4 T RT A8SW E4WE 2004032900060 20040329 00060 NM 2004 3 29 CA040115003 1 20040112 G 4920 38007021 APU BOEING 737 73776N 13844CH NM CFMINT CFM567 CFM567B22 13802 NE APU BAY SMOKE W O OTHER B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA (CAN) ON ARRIVAL TO THE GATE, GROUND POWER WAS PLUGGED IN, SMOKE IN THE FLIGHT DECK AND CABIN WHEN APU BLEED AIR AND PNE UMATICS SELECTED 'ON'. CAPTAIN THEN SELECTED APU ELECTRICAL 'ON' AND F/O CONTACTED GROUND CONTROL TO REQUEST CFR. SMOKE CLEARED AND MAINTENANCE WAS CALLED TO AIRCRAFT. SUSPECT DE-ICE FLUID IN THE APU INLET AS A RESULT OF DE-ICING OUT OF YO W. APU MEL'D AND GROUND CHECKED SERVICEABLE. ON NEXT RUN, APU MEL CLEARED FOLLOWING FLIGHT MONITORING AND MAINTENANCE P ERFORMANCE RUNS. AIRCRAFT RETURNED TO SERVICE WITH NO FURTHER INCIDENTS TO REPORT. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004032900072 20040329 00072 2004 3 29 CA040115005 4 20040101 G 2562 G SWITCH DHAV DHC2 DHC2MK1 2800102 EA PWA R985 R985AN14B 52008 NE HAMSTD 2D 2D30 NE ELT FAILED W K NONE L NO TEST IN INSP/MAINT 1 CA 55130 (CAN) ELT HAS HAD A PREVIOUS HISTORY OF SELF ACTIVATIONS (1 PREVIOUS, ELT ACTIVATED WHILE THE AIRCRAFT WAS INACTIVE). E LT WAS RECERTIFIED AND ON INSTALLATION THE UNIT SELF ACTIVATED. REPAIR SHOP NOTED THAT THE G SWITCH ON THIS MODEL WAS V ERY SUSCEPTIBLE TO MOISTURE RELATED FAILURES. DUE TO AGE THERE ARE NO PARTS AVAILABLE FOR REPAIR, THE UNIT WILL BE SCRA PPED. 1 H 7 1 3R 3 R A806 5E1 5 C P206 2004032900102 20040329 00102 EU 2004 3 29 CA040116001 1 20040116 G 5270 WARNING SYSTEM AIRBUS 320 A320211 3930320 EU CFMINT CFM56 CFM565A1 NE CARGO DOOR INOPERATIVE W O OTHER N FALSE WARNING CL CLIMB 1 CA (CAN) IN CLIMB OUT OF 17T ECAM MSG DOOR AFT CARGO. PRESSURISATION NORMAL. MSG DISAPPEARED IN CRUISE 10 MIN. LATER. (SEE COMMENTS FOR TROUBLESHOOTING. FOR TROUBLESHOOTING, CARRY OUT TSM FAULT ISOLATION TASK NR 32-31-00-810-831 AND 32-31-00-8 10-833. SENSOR 34WV GAP WITHIN TOLERANCE. SENSOR 32WV RESISTANCE ONLY 11 OHMS BETWEEN PINS A AND B. (SHOULD BE 13) SEN SOR 32WV REPLACED IAW AMM 52-71-12. CHECKED SERVICEABLE. 2 L 7 2 4F 4 F RT A28NM E29NE 2004032900103 20040329 00103 EA 2004 3 29 CA040116003 1 20040116 G 2760 270007 PCU CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE SPOILERS INOPERATIVE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) REPEAT OF L1411710 UPON RT ENG START WITH HYD PUMPS IN AUTO RT FLT SPOILER HAS UNCOMMANDED DEPLOYMENT TO 50 DEG SL OWLY AND THEN RETRACTS TO ZERO . SPOILERS DO NOT OPERATE DURING THIS OCCURANCE REGARDLESS OF FLT SPOILER LEVER POSN. UNT IL RT SPOILER REACHES 0 DEG SECU'S INTERROGATED AND BOTH, NR 1 AND NR 2 FAULT LOG SHOWS CODE 82 (THROTTLE SWITCH). THROT TLE QUADRANT REPLACED IAW MM., TASK 76-10-00-720-801, CUTOUT, NO FAULTS. ACFT. SERVICEABLE. TH. QUADRANT REMOVED: FTN N R X21X8B INSTALLED: FTN NR JW4J0A. 2 L 7 2 4F 4 F RT A21EA E15NE 2004033000119 20040330 00119 NE 2004 3 30 CA040116004 2 20040113 G 7230 COMPRESSOR WHEEL LEAR 60 60LEAR 5170707 CE PWA 305 PW305A 52128 NE ENGINE FRACTURED W E ENGINE SHUTDOWN E VIBRATION/BUFFET TX TAXI/GRND HDL 1 CA (CAN) FOLLOWING UNEVENTFUL LANDING AND ROLL-OUT, CREW NOTED VIBRATION AND RISING ITT. ENGINE WAS SECURED. POST FLIGHT EX AMINATION SHOWED THAT ROTOR 1 OF THE HPC HAD .3333 OF ONE AIRFOIL MISSING. 2 L 7 2 4F 4 F RT A10CE E35NE 2004033000125 20040330 00125 NM 2004 3 30 CA040116005 1 20040104 G 2910 DSC3461 LINE DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE HYDRAULIC SYS RUPTURED W E ENGINE SHUTDOWN K J FLUID LOSS WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) AFTER ENGINE START NR 2 HYD CAUTION LIGHT ILLUMINATED, NR 2 QUANTITY NOTED TO BE DECREASING. A/C SHUT DOWN. LARGE HYDRAULIC LEAK FROM NR 2 ENGINE NOTED. FOUND PRESSURE LINE P/N DSC346-1 RUPTURED IN THE FLEXIBLE SECTION. LINE REPLAC ED. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004033000126 20040330 00126 CE 2004 3 30 CA040116006 1 20040116 G 3242 PIN CESSNA 180 180J 2072622 CE CONT O470 O470S 17026 SO MCAULY 2A34C 2A34C203 GL BRAKE LINKAGE WORN W K NONE O OTHER IN INSP/MAINT 1 CA 13232 (CAN) DURING GROUND HANDLING THE RT RUDDER PEDAL BRAKE ASSY SEEMED SLOPPY COMPARED TO THE LT UNIT. INVESTIGATION REVEAL ED THAT THE PIN THAT CONNECTS THE BRAKE PEDAL TO THE MASTER CYLINDER WAS ALMOST COMPLETELY WORN THROUGH, THIS IS A HOLLO W SHAFT PIN ASSY. WORN PARTS WERE REPLACED AND THE AIRCRAFT WAS RETURNED TO SERVICE. 1 H 7 1 3O 3 O 5A6 E273 5 C P3EA 2004033000127 20040330 00127 NE 2004 3 30 CA040117001 1 20040115 G 6320 WARNING LIGHT SKRSKY S61 S61N 8142104 NE GE CT58 CT581402 30011 NE GEARBOX OIL ILLUMINATED W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA 24309 (CAN) AT 5500 FT VFR ENROUTE TO THE PLATFORM, JUST NEARING THE COASTLINE, THE MASTER CAUTION AND INTERMEDIATE GEARBOX CH IP LIGHT ILLUMINATED. 2 G 7 2 4U 4 U 1H15 1E3 2004033000128 20040330 00128 EA 2004 3 30 CA040118001 1 20040107 G 3397 2LA006913 WIRE CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE FLOOD LIGHT BURNED W O OTHER A FLAME/FIRE AP APPROACH 1 CA (CAN) THE COPILOT REPORTED FWD FLOOD LIGHT WIRES CAUGHT FIRE. CAPTAIN REPORTED THAT FO PINCHED WIRE WITH FINGERS TO EXTI NGUISH FLAMES. AIRCRAFT LANDED WITHOUT FURTHER INCIDENT. THE FI FWD FLOOD LIGHT ASSEMBLY WAS REPLACED. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2004033000129 20040330 00129 EA 2004 3 30 CA040118002 1 20040113 G 5610 NP13932112 WINDSHIELD CNDAIR CL600 CL6002B19 1900309 EA COCKPIT CRACKED W A UNSCHED LANDING O OTHER CL CLIMB 1 CA (CAN) RT WINDSHIELD CRACKED OUTER PLY ON CLIMBOUT. REPLACED RIGHT WINDSHIELD IAW MM 56-00-00. THE WINDSHIELD IS POST S B. 2 L 7 2 4F RT A21EA 2004033000130 20040330 00130 CE 2004 3 30 CA040119001 1 20040115 G 3260 404EN16 SWITCH LEAR 35 35A 5170602 CE GARRTT TFE731 TFE73122B 01518 WP MLG FAULTY W A UNSCHED LANDING P NO WARNING INDICATION CL CLIMB 1 CA (CAN) AFTER TAKE-OFF PILOT SELECTED THE GEAR HANDLE TO THE UP POSITION. THE GEAR WOULD NOT RETRACT. AIRCRAFT RETURN TO MAINTENANCE BASE. MAINTENANCE TECH FOUND RT TRUNNION SWITCH AT FAULT. SWITCH REPLACED AND LANDING GEAR SYSTEM SWUNG. AIRCRAFT RETURN TO SERVICE. 2 L 7 2 4F 4 F A10CE E6WE 2004033000131 20040330 00131 CE 2004 3 30 CA040119002 1 20040116 G 2121 11438002811 BLOWER BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE AFT VENT BURNED W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 CA (CAN) DURING CLIMB, CREW NOTED AN ELECTRICAL ODOR AND TRACE OF SMOKE IN CABIN. AIRCRAFT RETURNED TO AIRPORT WITHOUT FUR THER INCIDENT. MAINT FOUND THE AFT VENT BLOWER HAD OVERHEATED DUE TO ONE OF THE BEARING RESISTING ROTATION. THE NORMAL TEMPERATURE FUSE THAT IS SUPPOSED TO BLOW, DISCONTINUING POWER TO THE UNIT DID NOT APPEAR TO OPEN PRIOR TO BOTH SPEED RE SISTORS BECOMING BADLY HEATED AND DISTORTED. THE RESISTORS AND TEMP FUSE ARE CONTAINED INSIDE A METAL CONTAINER MOUNTED ON THE SIDE OF THE BLOWER. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2004033000145 20040330 00145 NM 2004 3 30 CA040119003 1 20040117 G 3810 24E507009G03 WATER HEATER AIRBUS A319 A319114 3930350 NM CFMINT CFM56 CFM565A1 NE LAVATORY FAILED W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA (CAN) BURNING ELECTRICAL ODOR NOTICED IN LAVATORY D. WHEN ODOR BECAME STRONGER, FLIGHT DIVERTED, DECLARING AN EMERGENC Y, FOUND TO BE THE WATER HEATER AT FAULT HEATER DE-ACTIVATED, UNDER MEL. 2 L 7 2 4F 4 F RT A28NM E29NE 2004033000151 20040330 00151 NE 2004 3 30 CA040119004 2 20040112 G 7200 ENGINE CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE NR 2 FAILED W E A ENGINE SHUTDOWN UNSCHED LANDING E J VIBRATION/BUFFET WARNING INDICATION CR CRUISE 1 CA 807608 (CAN) AIRCRAFT HAS RECEIVED A REPORT WHICH WE FEEL IS A REPORTABLE EVENT. WHILE IN CRUISE, THE FLIGHT CREW FELT VIBRATI ON AND NR 2 ENGINE VIBRATION WAS FLUCTUATING BUT WAS WITHIN LIMITS. AFTER A FEW SECONDS, OIL PRESSURE DROPED TO ZERO. TH E CREW FOLLOWED THE QRH, AN EMERGENCY WAS DECLARED, NR 2 ENGINE WAS SHUT DOWN, AIRCRAFT DIVERTED AND LANDED WITHOUT FURT HER INCIDENT. ENGINE REMOVED AND REPLACED. AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT A21EA E15NE 2004033000152 20040330 00152 NM 2004 3 30 CA040120001 1 20040120 G 5610 141T480150 WINDSHIELD BOEING 767 767333 1385301 NM PWA 4060 PW4060 52119 NE COCKPIT BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHILE IN FLIGHT, R1 WINDSHIELD OUTER PANE SHATTERED. (FL370) R1 WINDOW REPLACED IAW AMM 56-11-01 REMOVED: UNI 56- 10-0174 MPN: 141T4801-50 INSTALLED: UNI 56-10-0174 MPN: 141T4801-50 2 L 7 2 4F 4 F RT A1NM E24NE 2004033000153 20040330 00153 WP 2004 3 30 CA040120002 1 20040119 G 6322 C1861 HUB ROBSIN ROBSIN R44 R44 7640120 WP LYC O540 O540F1B5 41532 EA CONING FLANGE GALLED W K NONE O OTHER IN INSP/MAINT 1 CA LOT102A (CAN) OTHER PART AFFECTED LOWER BEARING C181-3 S/N 1328 UPON REMOVING FAN ASSY FOR ACCESS TO A DEFECTIVE ACTUATOR C051-1 , DAMAGE (FRETTING AND GALLING) WAS DISCOVERED ON BOTH MATING FLANGE OF FAN HUB C186-1 (PART OF D174-2 ASSY) AND LOWER B EARING C181-3. NO PREVIOUS SIGN OF MOVEMENT WERE NOTED PRIOR TO DISMANTLING FAN ASSY. FAN WAS NEVER REMOVED AFTER IT LEF T FACTORY. FAN HAD BEEN BALANCED ONCE SINCE NEW. FAN HAS BEEN SPLIT APART FOR INVESTIGATION AND A LARGE AMOUNT OF METAL PARTICLES WERE DISCOVERED BETWEEN BACK PLATE AND FAN AND ALSO SOME EXTENSIVE CORROSION BETWEEN SHIM C178-2 FLANGES, HUB MATING SURFACE AND FAN ITSELF. PART REMOVED AND RETURNED FOR REPAIR AND FURTHER INVESTIGATION. 1 G 7 1 3O 3 O H11NM E295 2004071200199 20040712 00199 EU 2004 7 12 CA040120003 1 20040118 G 3246 300677 WHEEL PIAGIO P180 P180 6960204 EU PWA PT6 PT6A66 52043 NE HARTZL HCE5N HCE5N3 GL NLG DAMAGED W C ABORTED TAKEOFF O OTHER TO TAKEOFF 1 CA (CAN) THE AIRCRAFT ABORTED THE TAKE OFF DUE TO A FLAT NOSE TIRE. THE WHEEL ASSEMBLY WAS REPLACED AND THE AIRCRAFT RETUR NED TO SERVICE. THE WHEEL REMOVED WAS FOUND TO HAVE BEEN PUNCTURED BY THE TOW BAR. 1 H 7 2 3O 4 T RT A59EU E26NE 5 C PZONE 2004033000154 20040330 00154 NE 2004 3 30 CA040120004 3 20040120 G 6114 52590 THRUST WASHER CNDAIR CL215 CL2151A10 1900320 EA PWA R1340 AWASP 52016 NE HAMSTD 43E 43E60 NE PROPELLER GALLED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) PROPELLER REMOVED FOR AD 81-13-06R2, CF 83-16 CORROSION INSPECTION. EVIDENCE OF CORROSION WAS NOT FOUND BUT EXTENS IVE PITTING / GALLING WAS DISCOVERED ON A BEVELED THRUST WASHER P/N 52590 AND FLAT WASHER P/N 57525 AS IDENTIFIED IN HAM ILTON STANDARD BLADE OVERHAUL MANUAL NO. 130B, PAGE 424. PROPELLER TO BE SENT FOR REPAIR AND OVERHAUL ASSESSMENT. 2 H 7 2 4R 3 R RT A14EA ATC14 6 C P871 2004033000155 20040330 00155 NE 2004 3 30 CA040120005 2 20040120 G 7200 ENGINE BOEING 767 76735H 1385208 NM GE CF6 CF680C2B6F 30025 NE LEFT FLAMED OUT W O OTHER X J ENGINE FLAMEOUT WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) ON TAXI OUT LT ENGINE FLAMED OUT, WITH OIL ODOR IN THE CABIN. RETURNED TO GATE, AIRCRAFT CHANGED, ENGINE REPLACED IAW 71-00-02 CONF. 2 L 7 2 4F 4 F RT A1NM E13NE 2004033000156 20040330 00156 EU 2004 3 30 CA040120006 1 20040120 G 5610 NP1752321 WINDSHIELD AIRBUS A330 A330* EU RROYCE RB211 RB211TRENT77 NE COCKPIT BROKEN W A UNSCHED LANDING O OTHER CL CLIMB 1 CA 14463 (CAN) AFTER TAKE OFF, CLIMBING THROUGH 10000 FT, THE CAPTS SLIDING WINDOW SHATERED. CREW ELECTED TO RETURN TO CDG AND L ANDED APPROX 35000 KG OVER MLW. CAPTS SIDE WINDOW CHANGED IAW 56-12-11. PARTS: SLIDE WINDOW MPN NR NP175232-1 INSTALLED. OUTER STRUCTURAL PANE WAS SHATERED ON CAPTS SLIDING WINDOW (NO) DAMAGED REPORTED ON STRUCTURE. 2 L 7 2 4F 4 F RT A46NM E39NE 2004033000157 20040330 00157 CE 2004 3 30 CA040120007 1 20040118 G 2435 M230881320 BRUSHES LUCAS BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE STARTER GEN WORN W K NONE O OTHER IN INSP/MAINT 1 CA 98048 (CAN) DURING FLEET WIDE INSPECTION OF PREMATURE BRUSH WEAR. THIS UNIT FOUND TO HAVE EXCESSIVE WEAR. 149.4 SINCE TBO.618 HRS OF BRUSH WEAR REMAINING. TBO 1500 HRS. VENDOR IN CONTACT WITH BRUSH MANUFACTURER. OTHER OPERATORS FINDING SIMILAR SDR ALERT WOULD SPEED RECTIFICATION PROCESS. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2004033000158 20040330 00158 NM 2004 3 30 CA040120008 1 20040120 G 5511 65174392 RIB BOEING 727 727171C 1384057 NM PWA JT8 JT8D7A 52053 NE HORIZONTAL STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 46421 (CAN) DURING C CHECK,THE INSPECTION OF THE HORIZONTAL STABILIZER, REVEALED A CRACK ON THE ELEVATOR HINGE SUPPORT RIB ON THE RT SIDE AT STATION 136.5. 2 L 7 3 4F 4 F A3WE E2EA 2004033000168 20040330 00168 NM 2004 3 30 CA040120009 1 20040120 G 5510 6524189 BLOCK BOEING 727 727171C 1384057 NM PWA JT8 JT8D7A 52053 NE HORIZONTAL STAB WORN W K NONE O OTHER IN INSP/MAINT 1 CA 46421 (CAN) DURING C CHECK, ONE RUB BLOCK (P/N 69-31604-4) WAS FOUND LOOSE ON THE LOWER BEAM. AFTER REMOVAL OF THE BLOCK, IT W AS FOUND THAT THE LOWER BEAM WAS WORN OUT OF LIMIT AT THE PLACE WHERE THE RUB BLOCK WAS INSTALLED. THE LOWER BEAM HAS TO BE REPLACED. 2 L 7 3 4F 4 F A3WE E2EA 2004033000179 20040330 00179 NM 2004 3 30 CA040121001 1 20040119 G 7711 10607371 TRANSMITTER BOEING 727 727225 1384077 NM PWA JT8 JT8D15A 52051 NE ENGINE EPR FAILED W D RETURN TO BLOCK N FALSE WARNING TX TAXI/GRND HDL 1 CA (CAN) DURING TAXI, IT WAS OBSERVED THAT THE NR 1 ENGINE EPR HAD NO INDICATION. THE AIRCRAFT WAS RETURNED TO THE RAMP. AFTER SOME TROUBLESHOOTING, MEL 77-01-01 WAS RAISED. THIS IS A 3 FLIGHT DAY, A CAT, MEL. THE AIRCRAFT WAS DISPATCHED. ON RETURN TO HOME BASE, THE EPR TRANSMITTER WAS REPLACED AND CHECKED SERVICEABLE AND NO FURTHER PROBLEM DURING SUBSEQUEN T FLIGHT. 2 L 7 3 4F 4 F A3WE E2EA 2004092000061 20040920 00061 EU 2004 9 20 CA040121002 1 20040119 G 5620 WINDOW BAG JETSTM JETSTM3212 1500217 EU GARRTT TPE331 TPE33110UG 01514 WP ROTOL R333 R333482F12 GL CABIN CRACKED W O OTHER D INFLIGHT SEPARATION NR NOT REPORTED 1 CA (CAN) AC WAS IN LEVEL FLIGHT AT FL190. CABIN ALTITUDE WAS 5500 FT, NEAR MAX DIFFERENTIAL OF ABOUT 5.5 PSID. SLIGHT THU D WAS HEARD FROM PASSENGER COMPARTMENT. NO DECREASE IN PRESSURIZATION OR ANY OTHER WARNINGS. FLIGHT CONTINUED WITH NO P ROBLEMS. PASSENGER SEATED IN EMERGENCY EXIT SEAT REPORTED THAT HIS WINDOW HAD CRACKED IN MID FLIGHT. ON EXAMINATION BY MAINT, OUTER PANE OF TWO PANE CABIN WINDOW HAD CRACKED FROM TOP TO BOTTOM ON A DIAGONAL. CRACK APPEARS TO HAVE STARTED AT A CRAZE( 1.7 IN) IN CENTER OF OUTER PANE. PORTION OF WINDOW WITH CRAZE WAS THINNER THAN THE REST. TWO PANE CONCEPT WORKED PERFECTLY, WITH INNER PANE TAKING PRESSURIZATION LOAD W/O SIGNIFICANT PRESSURE LOSS. 2 L 7 2 4T 4 T RT BA15CAA E4WE 6 C P61GL 2004033000180 20040330 00180 CE 2004 3 30 CA040121003 1 20040119 G 2752 66000863 ACTUATOR LEAR 35 35LEAR 5170600 CE GARRTT TFE731 TFE73122B 01518 WP TE FLAP CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) DURING PRE-FLIGHT INSPECTION FLUID LOSS WAS NOTED. FLAP ACTUATOR WAS FOUND TO HAVE A CRACKED BODY. 2 L 7 2 4F 4 F A10CE E6WE 2004033000181 20040330 00181 CE 2004 3 30 CA040121004 1 20040104 G 5610 1013840252 WINDSHIELD BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA HARTZL HCB4M HCB4MP3 GL COCKPIT BROKEN W A UNSCHED LANDING O OTHER CR CRUISE 1 CA (CAN) WINDOW SHATTERED IN CRUISE, INSIDE AND OUT SIDE PANE. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2004033000182 20040330 00182 EU 2004 3 30 CA040121005 1 20040121 G 3246 32200022 BEARING AIRBUS A321 A321211 3930370 EU IAE V2530 V2530A5 NE NLG WHEEL FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) RT NOSE WHEEL SEPARATED FROM THE NLG SHOCK ABSORBER DURING TAXING IN, IT IS BELIEVED THAT THIS HAPPENED ON THE LAS T TURN TO THE GATE. THE AC HAS ACCUMULATED 4,747FH AND 1,813CY. A FAILURE OF THE NOSE LANDING GEAR WHEEL BEARING (TFU 32.41.12.006) IS SUSPECTED. 2 L 7 2 4F 4 F RT A28NM E40NE 2004033000183 20040330 00183 GL 2004 3 30 CA040122001 3 20040121 G 6114 D1657 CYLINDER PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL PROPELLER HUB DEFECTIVE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) PROPELLER CYLINDER FOUND DEFECTIVE. MANUFACTURE DEFECT IN THE C AREA MISSING MATERIAL. THIS HAS BEEN SEEN IN SEV ERAL OTHER CYLINDERS, MFG WAS CONTACTED ON ALL OF THE DEFECTIVE ASSEMBLIES. MFG INSPECTED AND ANALYZED THEM ALL AND HAS NOT PROVIDED ANY LIMITS FOR DAMAGES IN THE C AREA. ALL CYLINDERS HAVE BEEN WARRANTEED FOR REPLACEMENT. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004033000184 20040330 00184 CE 2004 3 30 CA040122002 1 20040121 G 2750 14601008 CONTROL CABLE CESSNA 337 T337G 2075726 CE CONT O360 TSIO360CB 17025 SO MCAULY 2AF34C D2AF34C303 GL TE FLAPS FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING INSPECTION IT WAS DICOVERED THAT THESE CABLES (2EA. 1 LT AND 1 RT) WERE FRAYED WHERE THE CABLE BENDS AROUND THE FLAP CABLE QUADRANT LOCATED IN THE WING TRAILING EDGE. 1 H 7 2 3O 3 O A6CE E9CE 5 C P5EA 2004033000185 20040330 00185 CE 2004 3 30 CA040122003 1 20040121 G 2750 14601007 CONTROL CABLE CESSNA 337 T337G 2075726 CE CONT O360 TSIO360CB 17025 SO MCAULY 2AF34C D2AF34C303 GL TE FLAPS FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING INSPECTION IT WAS DISCOVERED THAT THESE CABLES (2EA. 1 LEFT AND 1 RIGHT) WERE FRAYED WHERE THE CABLE BENDS AROUND THE FLAP CABLE QUADRANT LOCATED IN THE WING TRAILING EDGE. 1 H 7 2 3O 3 O A6CE E9CE 5 C P5EA 2004040200003 20040402 00003 CE 2004 4 2 CA040122004 1 20040108 G 5210 1295140791 BRACKET BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE PAX DOOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 12505 (CAN) DURING GROUND HANDLING, CREW ATTEMPTED TO OPEN DOOR FROM INSIDE AND THE MAIN HANDLE UPON APPLYING PRESSURE, RELEAS ED WITHOUT ACTUATING DOOR CAMS. MAINTENANCE FOUND THAT THE MAIN DOOR ACTUATION BRACKETHAD BROKEN INTO TWO PIECES. THE BR ACKET WAS REPLACED AND THE AIRCRAFT CONTINUED OPERATIONS. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2004042900097 20040429 00097 NM 2004 4 29 CA040122005 1 20040122 G 2997 W2900086 WIRE BOEING 767 767375 1385217 NM GE CF6 CF680C2B6F 30025 NE LT PYLON CHAFED W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA (CAN) FAULT: LT ENGINE HYD. ALT. CURRENT MOTOR DRIVEN PUMP (ACMP)POWER FEEDER WIRES FOUND CHAFFING AND ARCHING ON STRUT STRUCTURE. STRUC. DAMAGE WAS ALSO NOTED DUE TO ARCHING. 2 L 7 2 4F 4 F RT A1NM E13NE 2004042900098 20040429 00098 NM 2004 4 29 CA040122006 1 20040116 G 5630 WINDOW BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU AIRSTAIR DOOR CHAFED W F ACTIVATE FIRE EXT. B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA (CAN) DURING TAXI, A PASSENGER NOTICED A SMALL AMOUNT OF SMOKE / FIRE COMING UP FROM THE FLOOR NEXT TO THE MAIN CABIN DO OR AND POINTED IT OUT TO THE FLIGHT ATTENDANT WHO IMMEDIATELY NOTIFIED THE PILOTS. THE FIRE WAS APPROXIMATELY 1 INCH HIG H AND WAS LOCATED AT THE MAIN CABIN DOOR HINGE ARM WHERE THE MAIN CABIN DOOR LIGHT WIRES COME OUT OF A CONDUIT. THE PILO T GOT THE FIRE EXTINGUISHER FROM THE COCKPIT AND PUT OUT THE FIRE. THE PILOT THEN ORDER TO THE PASSENGERS TO EXIT OUT TH E REAR AIRSTAIR DOOR. THE CIRCUIT BREAKER FOR THE AIRSTAIR DOOR LIGHTS DID NOT TRIP. MFG IS INVESTIGATING THE EVENT. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2004042900100 20040429 00100 SW 2004 4 29 CA040123001 1 20040123 G 5744 250000281 WEB GULSTM 690TP 690 0141720 SW GARRTT TPE331 TPE3315251K NM HARTZL HCB3T HCB3TN5 GL LT IB HINGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ON AILERON INSPECTION, CRACK WAS FOUND UNDER LT IB HINGE. CRACK IS AROUND LOWER OB HINGE MOUNTING HOLE. ONE CRAC K OUT OF FIVE AC CHECKED. 1 H 7 2 3T 4 T 2A4 E2WE 6 C P15EA 2004042900102 20040429 00102 2004 4 29 CA040123003 4 20040114 G 3197 WIRE HARNESS PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL COCKPIT CHAFED W O OTHER O OTHER AP APPROACH 1 CA (CAN) DURING APPROACH FLIGHT ON MULTIPLE OCCASIONS THE PILOTS EHSI SCREEN WOULD POWER DOWN AND RESTART UNCOMMANDED. IN THE TROUBLESHOOTING PROCESS ALL REMOVABLE COMPONENTS WERE REPLACE WITH SERVICEABLE UNITS. A VISUAL INSPECTION OF THE A/ C WIRING BY THE AVIONICS SHOP REVEALED CHAFED WIRING UNDER THE PILOTS SEAT IN THE OUTFLOW VALVE COMPARTMENT. WIRING P/N REPAIRED 9C95A22, 9C94 A22, 9C3G20, 9C32A22, 3F14A22N,ITN5A24. CHAFE PROTECTION INSTALLED ON THIS BUNDLE TO PREVENT F UTURE SIMILAR HAPPENINGS. SYSTEM TESTED SERVICEABLE AND LOG ENTRIES MADE. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004031500028 20040315 00028 2004 3 15 CA040123004 4 20040114 G 3197 INSULATION PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL ELECTRICAL WIRE CHAFED W O OTHER H ELECT. POWER LOSS-50 PC AP APPROACH 1 CA (CAN) DURING APPROACH FLIGHT ON MULTIPLE OCCASIONS THE PILOTS EHSI FAILED ON APPROACH , POWERED DOWN AND RE POWERED UNCO MMANDED. ON EACH OCCASION THE SYSTEM TESTED NORMAL AFTER LANDING AND DID NOT REOCCUR FOR DAYS. EACH COMPONENT IN THIS S YSTEM WAS REPLACED WITH A SERVICEABLE UNIT WITH NO CHANGE. DURING INSP OF THE A/C WIRING CHAFED WIRING WAS DISCOVERED UN DER THE COPILOTS SEAT IN THE OUTFLOW VALVE COMPARTMENT. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004042900103 20040429 00103 2004 4 29 CA040123005 4 20040123 G 6122 4B2P8 GOVERNOR PROPELLER CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) UPON INSPECTION OF THE GOVERNOR, THE FOLLOWING WERE NOTED,1) 52142, DRIVE GEAR, CORROSION ON TEETH PN 50659, IDLER GEAR, CORRODED TEETH 50794, BEVEL GEAR, WORN 51866, PILOT VALVE, CORRODED 59818, R.V.PISTON, CORRODED 51742, BASE, C RACKED.THE ABOVE UNIT WAS ESTIMATED,FOR OVERHAUL, AND THE CUSTOMER ASKED US NOT TO PROCEED UNTIL ADVISED. 2004031500003 20040315 00003 EU 2004 3 15 CA040123006 1 20040105 G 2497 WIRE161 WIRE HARNESS BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE NR 1 GENERATOR CHAFED W O OTHER J WARNING INDICATION AP APPROACH 1 CA 37287 37287 (CAN) DURING APPROACH WHEN ATTEMPTING TO START APU , LOST AC BUSS 1 AND ESSAC , NR 1 GENERATOR WOULD NOT RE-SET, AIRCRAF T LANDED NORMALLY. MAINTENANCE INSPECTION FOUND CHAFING OF THE 'B' PHASE (YELLOW STRIPE) NR 1 ENGINE GENERATOR WIRING CH AFED TO GROUND AT THE LT TOP FWD COWL (WIRING BUNDLE CONTAINING FEEDER CABLE AND GEN CONTROL WIRING), ALSO FOUND CHAFIN G OF THE NR 1 GENERATOR 'RED STRIPE' WIRING AT PYLON COVER. NOTE: PREVIOUS SIMILAR EVENT ON THIS AIRCRAFT HAD BEEN BLAM ED ON CONTAMINATION OF THE CONNECTOR (1XB-7R), PROBLEMS WERE SEVERAL DAYS APART. 2 H 7 4 4F 4 F A49EU E6NE 2004071900054 20040719 00054 2004 7 19 CA040123007 4 20040123 G 6122 4030035 HOUSING WOODWARD GOVERNOR MISREPAIRED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 1046046U (CAN) OIL LEAK AT THE LOWER ECCENTRIC PLATE RETENTION SCREW WAS CAUSED BY IMPROPER HELI COIL INSTALLATIION. WHEN THE HE LI COIL WAS INSTALLED, THE HOLE WAS DRILLED TO DEEP, AND BROKE THROUGH INTO THE RESET AND AIR BLEED ROD BORE CAUSING A L EAK. THE ESTIMATE TO REPAIR THIS UNIT WAS GIVEN TO THE OWNER, AND WE WERE ADVISED NOT TO PROCEED WITH THE LEAK REPAIR ON THIS UNIT. 2004031500004 20040315 00004 SO 2004 3 15 CA040123008 1 20040120 G 1430 AN546 BOLT PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2B 41532 EA HARTZL HCE3Y HCE3YR2A GL MLG CORRODED W L ABORTED APPROACH J WARNING INDICATION AP APPROACH 1 CA (CAN) THE AIRCRAFT WAS ON APPROACH WHEN THE CREW COULD NOT GET A DOWN AND LOCKED (GREEN) INDICATION ON THE RT MAIN GEAR. THE AIRCRAFT FLEW LOCALLY AND AFTER SEVERAL ATTEMPTS FLEW TO ANOTHER AIRPORT FOR A TOWER FLYBY AND LANDING. UPON TOUCH DOWN, THE RT MAIN GEAR LIGHT ILLUMINATED. MAINTENANCE FOUND THE RT MAIN DOWN LOCK TO BE SLIGHTLY STIFF. SOME MOISTURE AND SLIGHT CORROSION WAS NOTED ON THE PIVOT BOLT FOR THE RT DOWNLOCK AND THE BOLT WAS REPLACED. BOTH MAIN DOWN LOCKS WE RE REMOVED, CLEANED, INSPECTED, AND RE-LUBRICATED. SUBSEQUENT GEAR SWINGS WERE NORMAL AND THE AIRCRAFT WAS RETURNED TO SERVICE. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004031500005 20040315 00005 NE 2004 3 15 CA040123009 2 20040119 G 7412 103815504C IGNITER BOX PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL ENGINE IGNITION INOPERATIVE W O OTHER J WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) THE PILOT MADE TWO ATTEMPTS TO START THE AIRCRAFT. THE ENGINE FAILED TO START AND THE PILOT NOTED THAT THE IGNITI ON LIGHT ON THE CAWS PANEL HAD NOT ILLUMINATED DURING EITHER ATTEMPT. THE CAWS PANEL LIGHTS WERE TESTED AND FOUND SERVI CEABLE. AFTER APPROX. 5 MINUTES A THIRD STARTING SEQUENCE WAS INITIATED AND SUCCESSFUL. THE AIRCRAFT RETURNED TO BASE W ITHOUT FURTHER INCIDENT. MAINTENANCE CARRIED STARTED THE AIRCRAFT WITH NO INDICATION OF ANY DEFECT. THE AIRCRAFT WAS S HUT DOWN, AND FURTHER INVESTIGATION REVEALED THAT THE IGNITION EXCITER BOX WAS NOT FIRING IAW THE ENGINE MFG REQUIREMENT S. A REPLACEMENT UNIT WAS INSTALLED, AND TESTED SERVICEABLE. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004031500020 20040315 00020 SO 2004 3 15 CA040125001 1 20040122 G 2913 1213HBG310A PUMP PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL HYD SYSTEM FAILED W K NONE L NO TEST IN INSP/MAINT 1 CA (CAN) THE FAILURE OF PUMP WAS FOUND BY PILOT AFTER FLIGHT HYDRAULIC PUMP CHECK- PUMP FAILED THE TEST. TIME EXCEEDED 11 S ECONDS. PUMP REMOVED, INSPECTED - NO DAMAGE FOUND FAILED INTERNALLY. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004031500021 20040315 00021 EA 2004 3 15 CA040126001 1 20040126 G 3234 750006000 SELECTOR VALVE CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE MLG DOOR INOPERATIVE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) GEAR DISAGREE ON UP SELECTION AFTER T/O. NOISE IN FLT DECK CONFORMING NOSE GEAR NOT RETRACTED (INDICATED RED HAT CHING ON EICAS CHECK- LIST CARRIED OUT GEAR INDICATED 3 GREEN AIRCRAFT RETURNED TO AIRPORT. DOOR SELECTOR VALVE REPLACED IAW AMM 32-22-15-400-801. A/C SERVICEABLE. 2 L 7 2 4F 4 F RT A21EA E15NE 2004031500022 20040315 00022 CE 2004 3 15 CA040126002 1 20040122 G 7160 1019100209 HINGE BEECH 200 B200 1152922 CE PWA PT6 PT6A42 52043 NE HARTZL HCB3T HCB3TN3 GL INLET VANE WORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) MAINTENANCE INSPECTION DISCOVERED LT ENGINE INLET VANE HINGE PIN WAS WORKING OUT OF THE HINGE AND CONTACTING THE I NNER COWL STRUCTURE. MFG ADVISES THE HINGE ENDS ARE CRIMPED TO PREVENT PIN MOVEMENT, HOWEVER ON THIS ASSY THE PIN APPE ARS TO HAVE WORN THROUGH THE CRIMP. HINGE ASSEMBLY REPLACED NEW. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2004031500023 20040315 00023 NM 2004 3 15 CA040126003 1 20040114 G 2910 AN81510D COUPLING DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE PRESS MANIFOLD CRACKED W O OTHER K J FLUID LOSS WARNING INDICATION DE DESCENT 1 CA (CAN) APPROXIMATELY 90 DME FROM LANDING AT THE TOP OF DESCENT THE CREW NOTICED THE NR 2 HYD CONTENTS DROPPING. AT APPRO X 12 DME THE NR 2 HYD CAUTION LIGHT ILLUMINATED. A PAN WAS CALLED AND QRH ACTIONS WERE CARRIED OUT. ENGINEERING INVEST IGATION REVEALED THAT THE NR 2 PRESSURE MANIFOLD INLET UNION HAD FRACTURED. THE UNION WAS REPLACED ALONG WITH THE HYD P UMP AND THE AIRCRAFT WAS RETURNED TO SERVICE. OPERATOR HAS BEEN INFORMED OF SYD 8-29-002, WHICH REPLACES THE ALUMINUM F ITTINGS WITH STAINLESS STEEL FITTINGS FOR THIS AREA. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004031500024 20040315 00024 EU 2004 3 15 CA040126004 1 20040126 G 3232 D3221401700062 UPLOCK AIRBUS 320 A320211 3930320 EU CFMINT CFM56 CFM565A1 NE NLG DOOR INOPERATIVE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) NOSE LDG DOOR WOULD NOT CLOSE AFTER T/O. RECYCLED 3 TIMES (NO SUCCESS) DOOR CLOSED NORMALLY WITH GEAR DOWN. NLG DOOR UPLOCK REPLACED IAW AMM32-31-21-400-001, CONSIDERED SERVICEABLE. 2 L 7 2 4F 4 F RT A28NM E29NE 2004031500029 20040315 00029 CE 2004 3 15 CA040126005 1 20040126 G 2571 10112011613 FLANGE BEECH B300 B300B350C CE PWA PT6 PT6A60A 52043 NE HARTZL HCB4M HCB4MP3 GL BATTERY COVER CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) INSPECTION REVEALED THE BATTERY COVER SUPPORT FLANGE (FWD) CRACKED WHERE IT ATTACHES TO THE VERTICAL SUPPORT ANGLE S. PART TO BE REPLACED NEW. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2004031500031 20040315 00031 EA 2004 3 15 CA040126006 1 20040126 G 2740 9960023 SWITCH CNDAIR CL600 CL6002D24 1390016 EA GE CF34 CF343A1 30015 NE STAB TRIM DIRTY W A UNSCHED LANDING F H FLT CONT AFFECTED ELECT. POWER LOSS-50 PC CL CLIMB 1 CA (CAN) WENT TO DISCONNECT STAB CHANNEL 1, LOST BOTH STAB TRIM CHANNELS AND MACH TRIM. TRIED TO ENGAGE EITHER STAB CHANNE L WITHOUT SUCCESS. ACTIONED QUICK RESPONSE PROCEDURE AND RETURNED TO AIRPORT USING FLAPS 20 IAW QRH. GREATER THAN NORM AL FORCE ELEVATOR FORCE WAS REQUIRED DURING APPROACH. LANDED WITHOUT FURTHER INCIDENT. THE STAB TRIM DISCONNECT SWITCH WAS CLEANED AND SYSTEM RETESTED SERVICEABLE IAW FUNCTIONAL TEST PROCEDURE P601R4500 PARA 5.6.20, THEN A/C WAS RETURNED T O FLIGHT WITHOUT ANY FURTHER OCCURENCES. 2 L 7 2 4F 4 F RT A21EA E15NE 2004031500032 20040315 00032 EU 2004 3 15 CA040126007 1 20040126 G 3251 Z4242170001 SPRING ZLIN 242 Z242L 9970204 EU LYC O360 AEIO360A1B6 41514 EA MUHBR MTV MTV3BC EU NLG STEERING BROKEN W D RETURN TO BLOCK O OTHER TX TAXI/GRND HDL 1 CA (CAN) DURING TAXI A STUDENT PILOT NOTICED THAT THE AIRCRAFT WOULD NOT STEER PROPERLY. MAINTENANCE NOTICED THAT THE RT ST EERING SPRING WAS BROKEN. THIS HAS BEEN AN ON GOING PROBLEM WITH STUDENTS WHEN THEY TRY TO STEER THE AIRCRAFT WITHOUT GE TTING THE AIRCRAFT ROLLING FIRST ADDING STRESS TO THE SPRINGS. 1 L 7 1 3O 3 O 0 A76EU 1E10 5 C USSR 2004031500033 20040315 00033 EA 2004 3 15 CA040126008 1 20040106 G 2720 272613 SWITCH CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE RUDDER TRIM FAILED W A UNSCHED LANDING F FLT CONT AFFECTED CR CRUISE 1 CA (CAN) 30 MINS OUT, FL260 RUDDER TRIM FAILED, INADVERTENT AND SUDDEN DISPLACEMENT TO HALFWAY TO FULL NOSE LT. DECLARED EM ERGENCY, UNEVENTFUL LANDING. RUDDER TRIM FAILED. REMOVED AND REPLACED RUDDER TRIM SWITCH. OPS CHECKS REQUIRED WHEN PANE L REINSTALLED IAW27-12-10, REMOVED AILERON/RUDDER TRIM CONTROL PANEL, REINSTALLED TRIM CONTROL PANEL AND TESTED IAW AMM 27-12-00, CHECKS OK. 2 L 7 2 4F 4 F RT A21EA E15NE 2004031500034 20040315 00034 NM 2004 3 15 CA040127001 1 20040121 G 2720 682015 SWITCH BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU RUDDER TRIM INOPERATIVE W A UNSCHED LANDING F FLT CONT AFFECTED CL CLIMB 1 CA (CAN) AFTER TAKE OFF, THE FLIGHT CREW REPORTED RUDDER TRIM INOPERATIVE. QRH PERFORMED. RETURNED TO DEPARTURE AIRPORT FO R LANDING WITHOUT FURTHER INCIDENT. MECHANIC RESET THE RUDDER TRIM CB THEN TESTED TRIM, NO MOVEMENT. RUDDER TRIM PANEL R EMOVED AND PANEL WAS (TAPPED) THEN RE-INSTALLED, THEN TRIM OPERATION WAS NORMAL. RUDDER TRIM SWITCH REPLACED AS PRECAUTI ON. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2004031500035 20040315 00035 EU 2004 3 15 CA040127002 1 20040126 G 3000 23053191 LEVER BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL ANTI ICE ACT CRACKED W O OTHER J WARNING INDICATION CR CRUISE 1 CA (CAN) PILOT REPORTED THAT THE INLET ANTI-ICE SYSTEM WAS UNSERVICEABLE. THE ANTI-ICE VALVE WOULD NOT TO CLOSE. THE CIRCUI T BREAKER FOR THE SYSTEM ALSO TRIPPED. UPON INSPECTION MAINTENANCE FOUND THAT THE ANTI-ICE LEVER WAS CRACKED AND ELONGAT ED WHERE IT ATTACHES TO THE ACTUATOR ALLOWING THE ANTI-ICE LEVER TO DISCONNECT FROM THE ACTUATOR. THE ACTUATOR WOULD RUN BUT NOT EXTEND OR RETRACT THE INLET ANTI-ICE VALVE. 1 G 7 2 3U 3 U H3EU E4CE 2004031500049 20040315 00049 EA 2004 3 15 CA040127006 1 20040127 G 2150 32156221 REGULATOR VALVE CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE LT & RT PACK INOPERATIVE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) LT AND RT PACK HI PRESS. MESSAGE ON T/O, CHECKLIST COMPLETED. LT PACK CAME BACK MOMENTARILY. BOTH PACKS U/S WITH H IGH PRESS. MSG. LT AND RT PRESSURE REGULATOR VALVES REPLACED, BOTH PACKS OPERATED AT T/O POWER, NO FAULT FOUND. CONS.SER V. 2 L 7 2 4F 4 F RT A21EA E15NE 2004031500050 20040315 00050 EA 2004 3 15 CA040127007 1 20040127 G 3250 STEERING SYS CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE NLG FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) LOST NOSEWHEEL STEERING ON LANDING CLT. TRIED NUMEROUS RESETS WITH NO SUCCESS. TUG ARRIVED AND TOWED TO GATE. OUT OF SERVICE FOR INVESTGATION. 2 L 7 2 4F 4 F RT A21EA E15NE 2004031500051 20040315 00051 EA 2004 3 15 CA040127008 1 20040127 G 2120 ODOR CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE CABIN DETECTED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) FLIGHT CREW NOTICED AN ACRID ODOR IN THE COCKPIT. AFTER NOTING THE ACRID ODOR THE FLIGHT CREW OBSERVED A CIRCUIT BREAKER THAT HAD POPPED. THE ODOR SEEMED TO CLEAR AND THEN REOCURRED ASSOCIATED WITH A SOUND. THE FLT CREW ELECTED TO DEC. MAINTENANCE INVESTIGATION UNDER WAY. 2 L 7 2 4F 4 F RT A21EA E15NE 2004031500053 20040315 00053 CE 2004 3 15 CA040127010 1 20040121 G 5610 10138402521 WINDSHIELD BEECH B300 B300B350C CE PWA PT6 PT6A60A 52043 NE HARTZL HCB4M HCB4MP3 GL COCKPIT CRACKED W B EMER. DESCENT H ELECT. POWER LOSS-50 PC CR CRUISE 1 CA (CAN) IN CRUISE 28,000 FT, OAT-32, WINDSHIELD HEAT ON. HEARD A BANG - PILOT'S WINDSHIELD CRACKED. DESCENDED TO 12,500 FT , REDUCED AIRSPEED AND CABIN PRESSURE DIFFERENTIAL TO 4.0, RETURNED TO BASE. LANDED AIRCRAFT FROM RT SEAT. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2004031500054 20040315 00054 NM 2004 3 15 CA040127011 1 20040127 G 3230 273T41202 GEAR BOEING 767 7673Y0 NM PWA 4060 PW4060 52119 NE NLG LOCK INOPERATIVE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHEN GEAR WAS LOWERED, NOSE DID NOT LOCK. CREW WAS ABLE TO EXTEND AND LOCK USING THE ALTERNATE METHOD, CONTINUING THE LANDING WITHOUT FURTHER INCIDENT. ACFT REMOVED FROM SERVICE FOR INVESTIGATION. 2 L 7 2 4F 4 F RT A1NM E24NE 2004031500058 20040315 00058 EA 2004 3 15 CA040127015 1 20040127 G 5270 WARNING LIGHT CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE PAX DOOR FALSE ACTIVATION W A UNSCHED LANDING N FALSE WARNING CL CLIMB 1 CA (CAN) AFTER DEPARTURE, CREW HAD DOOR WARNING INDICATION. CREW ELECTED TO RETURN, LANDED WITHOUT INCIDENT. OFF LINE FOR I NVESTIGATION. 2 L 7 2 4F 4 F RT A21EA E15NE 2004031500059 20040315 00059 EA 2004 3 15 CA040127016 1 20040127 G 2613 OVERHEAT SENSOR CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE LT ENGINE INOPERATIVE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) LT 14TH DUCT MESSAGE ON EICAS AT 500 AGL (84 PERCENT N1) SHORTLY AFTER T/O, DUCT SHOWED RED BETWEEN COWL A/I AND W ING A/I VALVES ON ANTI-ICE STATUS PAGE. CREW RETURNED, LANDED 700 KGS OVERWEIGHT. 2 L 7 2 4F 4 F RT A21EA E15NE 2004031500066 20040315 00066 SW 2004 3 15 CA040127017 1 20040105 G 6310 269A54021 NUT HUGHES 269 269C1 8059504 SW LYC O360 HO360C1A 41514 EA FREEWHEEL UNIT LOOSE W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) OIL LEAKING FROM FREEWHEEL WAS NOTED AT REFUELING STOP. NUT (WHICH IS ALSO SEAL RUNNER) WAS FOUND LOOSE. NUT WAS RETORQUED AND FLUSH OF FREEWHEEL PRODUCED NO DISCOLORATION OR PARTICLES. LEAK CHECK CARRIED OUT AND RETURNED TO SERVIC E. NOTE: THAT OIL ONLY LEAKED OUT AFTER SHUTDOWN (NO OIL SPRAY). THEREFORE, IN THIS INSTANCE, THE OIL WAS DYNAMICALLY HE LD IN, EVEN WITH THE LACK OF SEALING AT FRONT. 1 G 7 1 3O 3 O O 4H12 E286 2004031500067 20040315 00067 SO 2004 3 15 CA040127018 1 20040124 G 2820 465299 LINE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL FUEL SYSTEM LEAKING W O OTHER K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA (CAN) DURING START UP, PILOT NOTICED FUEL ODOR IN CABIN SHORTLY AFTER ENGINE START UP. MAINTENANCE WAS NOTIFIED AND AFTE R INSPECTION IT WAS NOTED A FINE MIST FROM RT FLEXIBLE FUEL PRESSURE LINE. HOSE WAS REPLACED WITH NO FURTHER PROBLEMS. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004031500068 20040315 00068 CE 2004 3 15 CA040127020 1 20040112 G 3340 055201913 RING CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160DTM GL LANDING LIGHT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) LANDING LIGHT ASSEMBLY MOUNTING RING (MADE OF ALUMINUM, RIVETED INTO COWLING NOSE BOWL) CRACKED THROUGH SEVERAL RI VET HOLES AND ANCHOR NUT HOLES. THESE RINGS ARE PRONE TO CRACKING, BUT THIS ONE HAS LASTED ONLY 20 MONTHS/1100 HOURS. MA TERIAL MAY BE TOO BRITTLE. OTHER FACTORS: FREQUENT LANDING LIGHT CHANGES, VIBRATION, POSSIBLE HEAT FROM LIGHTS, POSSIBLE OVER TIGHTENING OF SCREWS. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2004060900001 20040609 00001 NM 2004 6 9 CA040127021A 1 20040127 G 3320 LIGHT BOEING 767 767233 1385113 NM PWA JT9 JT9D7R4D 52054 NE CABIN ODOR W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA (CAN) READING LIGHTS 20DEF & 25DEF SPARKLING WITH ELECTRICAL ODR. POWER REMOVED ODOR DISAPATED. A/C REMOVED FROM SERVICE FOR INVESTIGATION. 2 L 7 2 4F 4 F RT A1NM E3NE 2004031500089 20040315 00089 SW 2004 3 15 CA040128001 1 20040128 G 6510 407340339107 BEARING RACE BELL 427 427 1182207 SW PWC PW207 PW207D NE T/R DRIVE MISMANUFACTURED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) IT WAS BROUGHT TO OUR ATTENTION THAT A BEARING WAS DELIVERED TO A CUSTOMER AND FOUND WITHOUT THE REQUIRED 4 (.062 DIA.) LUBE HOLES. THE 4 LUBE HOLES TO BE LOCATED IN THE LUBRICATION GROOVES. 1 G 7 1 3U 3 U R00001RC E42NE 2004031500090 20040315 00090 EU 2004 3 15 CA040128002 1 20040128 G 3510 89151114 OXYGEN BOTTLE AIRBUS A330 A330* EU RROYCE RB211 RB211TRENT77 NE COCKPIT FAILED W K NONE L NO TEST IN INSP/MAINT 1 CA (CAN) RAMP CHECK CREW O2 WAS 1200 PSIG AFTER 3.5 HOURS WE HEARD A RUSHING AIR NOISE WAS F/O O2 MASK THIS NOISE WAS STOP BY PUSHING TEST BUTTON O2 WAS DOWN TO 72 PSIG (MUST HAVE BEEN SLOWLY LEAKING ALONG THEN FAILED. CREW O2 BOTTLE AND REG. REPLACED. F/O MASK TESTED AND RESET OK. 2 L 7 2 4F 4 F RT A46NM E39NE 2004031500091 20040315 00091 NM 2004 3 15 CA040128003 1 20040123 G 3020 4100S02801 HEATER BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU AIR INTAKE BURNED W F ACTIVATE FIRE EXT. B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA (CAN) AFTER OUR AIRCRAFT ARRIVED ON THE PARKING POSITION OUR TECHNICIAN REPORTED SMOKE AND FLAMES COMING OUT OF THE LT E NGINE COWLINGS AND AIR INTAKE SECTION. THE FIRE WAS EXTINGUISHED AND THE CAUSE WAS FOUND TO BE THAT THE AIR INTAKE HEATE R CAUGHT FIRE. THE AIR INTAKE WHICH WAS THE CAUSE, WAS A PRE MOD UNIT PN 4100S028-01. RELATED REFERENCE, SYD 84-30-02, APPLIES ADDITIONAL SEALANT TO PREVENT FLUID INGRESS TO HEATER CORE. PN 4100S028-03, POST MODSUM 4-113435 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2004031500092 20040315 00092 NM 2004 3 15 CA040128004 1 20040127 G 7711 LINE BOEING 737 737201 1384454 NM PWA JT8 JT8D9A 52048 NE PT7 NR 1 ENGINE CHAFED W O OTHER O OTHER TX TAXI/GRND HDL 1 CA (CAN) NR 1 ENGINE EPR INDICATION ERRATIC. FOUND PT7 LINE CHAFED ON LT WING LEADING EDGE AT WBL 114.0. ELBOW AT END OF L INE CONNECTION FOUND CRACKED. BOTH CHAFED LINE AND ELBOW REPLACED. 2 L 7 2 4F 4 F A16WE E2EA 2004031500093 20040315 00093 EA 2004 3 15 CA040128005 2 20040109 G 7414 BEARING CONT 3200 PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL MAGNETO CONTAMINATED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA A0491056R (CAN) ON RETURN FLIGHT THE LT ENGINE STARTED TO RUN ROUGH. UPON LANDING THE PILOT DID A MAGNETO CHECK AND FOUND THAT THE MAGNETO DROP WAS EXCESSIVE. REMOVED MAGNETO WITH COVER OFF FOUND METAL IN BACK OF MAGNETO. INSTALLED OVERHAULED MAGNETO , GROUND RUN AIRCRAFT NO FAULTS FOUND. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004031500095 20040315 00095 NM 2004 3 15 CA040128007 1 20040126 G 3242 214664 BRAKE DISC DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE MLG BRAKE UNIT DEFORMED W K NONE O OTHER IN INSP/MAINT 1 CA 0092 (CAN) DURING REMOVAL OF THE BRAKE UNIT FROM THE AIRCRAFT, HALF OF THE BRAKE DISC DROPPED ONTO THE FLOOR. ONCE THE BRAKE UNIT WAS REMOVED FROM THE AIRCRAFT, THE REMAINING HALF OF THE DISC WAS RECOVERED FROM THE BRAKE UNIT. IT APPEARS TO BE S OME DEFORMITY OF THE DISC. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004031500098 20040315 00098 EU 2004 3 15 CA040129001 1 20040129 G 2120 ODOR AIRBUS 320 A320211 3930320 EU CFMINT CFM56 CFM565A1 NE COCKPIT DETECTED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) STRONG ELECTRICAL ODOR FOR 2 MIN DURING DESCENT. WENT AWAY AFTER SHUTTING THE VTRS OFF. CIRCUIT BREAKER WAS PULLED FOR THE REMAINING OF THE FLIGHT, DUE UNABLE TO REACH ANYBODY TO INVESTIGATE IN FLIGHT. 2 L 7 2 4F 4 F RT A28NM E29NE 2004031500106 20040315 00106 EA 2004 3 15 CA040129002 1 20040129 G 7110 ACCOUSTIC LINER CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE LT & RT ENGINE DAMAGED W C ABORTED TAKEOFF E VIBRATION/BUFFET TO TAKEOFF 1 CA (CAN) ON TAKEOFF, THRU 100KIAS N1 VIB. BOTH ENGINES 4.0 (RED),VIB. REDUCED AFTER APROX 5 MIN. FOUND ACCOUSTIC LINER DAMA GED. A/C REMOVED FROM SERVICE AND SENT TO HGR FOR REPAIR. (MORE INFO WILL FOLLOW). 2 L 7 2 4F 4 F RT A21EA E15NE 2004051000033 20040510 00033 EU 2004 5 10 CA040129004 1 20040127 G 2600 3473641 HEAD KIDDE BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE FIRE EXTINGUISH CONTAMINATED W K NONE O OTHER IN INSP/MAINT 1 CA 10152EL (CAN) THIS DUAL OUTLET CARGO BAY EXTINGUISHER WAS RECEIVED FOR OVERHAUL AFTER HAVING BEEN DISCHARGED THROUGH ONE OUTLET. UPON REMOVAL OF THE DISCHARGE HEAD FROM THE FIRED OUTLET, A SIGNIFICANT AMOUNT OF AN UNIDENTIFIED COARSLY CRYSTALLINE C ONTAMINANT WAS FOUND INSIDE THE DISCHARGE HEAD. THE MAJORITY OF THE CONTAMINANT WAS PACKED INTO THE UPPER PART OF THE DI SCHARGE HEAD, BETWEEN THE INSIDE SURFACES OF THE HEAD AND THE DEBRIS SCREEN. SOME OF THE CONTAMINANT HAD ALSO FALLEN INT O THE INTERIOR OF THE EXTINGUISHER THROUGH THE FIRED OUTLET.THE CONTAMINANT APPEARS TO BE CORROSIVE, BECAUSE SIGNIFICANT CORROSION WAS FOUND ON THE DISCHARGE HEAD RETAINING NUT, AND TO A LESSER DEGREE ON THE INSIDE SURFACES OF THE DISCHARGE 2 H 7 4 4F 4 F A49EU E6NE 2004031500108 20040315 00108 EU 2004 3 15 CA040129006 1 20040119 G 6320 350A38101891 BEAM SNIAS 350 AS350B1 8680811 EU TMECA ARRIEL ARRIEL1D1 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AIRCRAFT ON HELISKIING WHEN THIS OCCURRED. INSPECTED IAW AD96-156-071(B) R1 PART 1.1, EVERY 30 HOURS OR 150 CYCLES . THIS WAS BEING INSPECTED DUE TO THE CYCLES EVERY 2 OR 3 DAYS. THE CROSSBEAM WAS FOUND SMOKING IN THE REGION OF SUSPEC TED CRACK. THE AREA WAS CLEANED, INSPECTED AND FOUND TO BE SERVICEABLE. AFTER A NEXT DAY FLYING IT WAS INSPECTED AGAIN AND FOUND TO BE SMOKING AGAIN REMOVED FROM SERVICE TO BE NDT. SENT TO A NDT AMO AND CRACK WAS CONFIRMED. THE AD IS WOR KING. 1 G 7 1 3U 3 U H9EU E19EU 2004031500110 20040315 00110 SO 2004 3 15 CA040129008 1 20040122 G 3230 BRACKET PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL NLG BENT W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA 14630 (CAN) ON TAKE OFF WHEN GEARS SELECTED UP PILOT FOUND GEARS INTERMITTED INDICATION. NOSE GEAR WON'T STAY UP LOCKED. TROUB LESHOT SNAG FOUND TUBE ASSEMBLY, NOSE LANDING GEAR IDLER LINK PN: 41770-00, UNSERVICEABLE. UPLOCK HOOK HOLDING BRACKET I S BENT AND WORN, AS RESULT UPLOCK HOOK MISALIGNED WITH UPLOCK ROLLER, PREVENTING NOSE GEAR FROM LOCKING UP. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004031500114 20040315 00114 2004 3 15 CA040130001 4 20040125 G 3417 C17053AC03 ADC BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU COCKPIT INOPERATIVE W O OTHER J WARNING INDICATION LD LANDING 1 CA (CAN) DURING LANDING ROLL OUT IAS MISMATCH MESSAGE APPEARED, NR 1 IAS WAS 30 KTS HIGHER THAN NR 2 IAS. AFTER PARKING AT THE ARRIVAL GATE, NR 1 IAS INDICTED 38 KTS AND TAS WAS SCROLLING. NR 2 IAS STEADY AT 30 KTS (NORMAL). MAINTENANCE PU RGED NR 1 PITOT/STATIC LINES THEN RECONNECTED. NR 1 IAS CONTINUED TO FLUCTUATE AT 38 KTS FOR SEVERAL MINUTES THEN DROPP ED TO 30 KTS AND BECAME STEADY. NR 1 ADU REPLACED. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2004031500117 20040315 00117 NM 2004 3 15 CA040130002 1 20040106 G 2422 054021 RESISTOR DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE INVERTER FAILED W L ABORTED APPROACH J WARNING INDICATION AP APPROACH 1 CA 1882S8 (CAN) COMPONENT RESPONSIBLE FOR INVERTER FAILURE WAS THE RESISTOR (R324) P/N 054021 DESCRIPTION: ON APPROACH, PRIMARY IN VERTER, SECONDARY INVERTER, AND AUX INVERTER, L26AC BUS, AND R26AC BUS CAUTION LIGHTS ILLUMINATED. AFTER AUX INVERTER S WITCHED OFF, PRIMARY, SECONDARY AND BOTH 26AC BUS LIGHTS WENT OUT. CREW BROKE OFF APPROACH AND AC RETURNED. COULD NOT F AULT ON GROUND. PRIMARY INVERTER VOLTAGE INDICATING 107V AND REPLACED. AUX INVERTER REPLACED FOR T/S. ALL RELATED CON NECTOR PLUGS AND CIRCUIT BREAKERS INSPECTED SVC. INVERTERS SENT OUT TO VENDOR AND RETURNED WITH S/N 1882-S8 S WO CONFIRM ING FAULT, AND NAMING THE RESISTOR AS THE CULPRIT COMPONENT P/N 054021. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004031500118 20040315 00118 NE 2004 3 15 CA040130003 2 20040126 G 7200 3020159 RETAINER CESSNA 208 208B 2073701 CE PWA PT6 PT6A114A 52043 NE MCAULY 3AF34C 3GFR34C703 GL ENGINE COLLAPSED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THE HOT SECTION WAS GIVEN A SCHEDULED HOT SECTION INSPECTION. FOUR CT SHROUD SEGMENTS HAD SHIFTED SLIGHTLY. THE RE TAINING RING HAD COME OUT OF THE GROOVE. THIS PROBLEM HAS BEEN DOCUMENTED ON OTHER ENGINES. PWA HAS ISSUED P/N 3110741-0 2 RETAINING RING ON SB 13121 (60A, 61, 62, 65 SERIES) AND SB 3248 (41/42, 45 SERIES) TO PREVENT THE COLLAPSE OF THE RETA INING RING. THE LATTER SB HAS NOT BEEN ISSUED ON SMALLER ENGINE MODELS SUCH AS THE 114A ENGINE MODEL TO ALLOW THE MORE R OBUST RETAINING RING TO BE USED. 1 H 7 1 3T 3 T A37CE E4EA 5 C P60GL 2004042800030 20040428 00030 NM 2004 4 28 CA040130004 1 20040107 G 2422 048503 TRANSISTOR PHOENIX DH103024600C DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE INVERTER SHORTED W L ABORTED APPROACH J WARNING INDICATION AP APPROACH 1 CA 2218S8 (CAN) COMPONENT RESPONSIBLE FOR INVERTER FAILURE WAS DRIVER TRANSISTOR WHICH SHORTED. ON APPROACH MSTR CAUTION LIGHT I LLUMINATED GPWS, PRIM INV, SEC INV, AUX INV, L626AC AND/OR R26AC BUSES, BOTH TCAS S AND IVSI S FLAGGED, LASTED 1-2 MIN. AND THEN RETURNED TO NORMAL. MSTR CAUTION COULD NOT BE RESET, CONTINUOUSLY FLASHING. INITIATED MISSED APPROACH AND DIV ERTED. FOUND SECONDARY INV. OUTPUT VOLTAGE LOW. REPLACED SEC. INV. REPLACED 400 HZ 115V/26V TRANSFMR T1. REPLACED 400H Z CNTRL BOX. REPLACED PRIMARY INV. OPERATION TEST OF AC400 HZ SYSTEM SERVICEABLE IAW MM. INVERTERS SENT OUT TO VENDOR AND RETURNED TO JAZZ WITH WO CONFIRMING FAULT, AND NAMING THE DIVER TRANSISTOR AS THE CULPRIT COMPONENT. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004031500119 20040315 00119 NM 2004 3 15 CA040130005 1 20040116 G 5610 17180003 WINDOW DHAV DHC8 DHC8315 2809010 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE COCKPIT CRACKED W B EMER. DESCENT D INFLIGHT SEPARATION CR CRUISE 1 CA 14921 (CAN) SHORT WHILE AFTER TAKEOFF AT 13:54 AT 23000 FEET PILOT NOTICED COCKPIT PORT SIDE WINDOW SHOWING SIGNS OF DISCOLORA TION. WHEN PILOT NOTICED DISCOLORATION SIDE WINDOW HEAT WAS SELECTED ON. SHORTLY AFTER HEAT WAS SELECTED ON, OUTER PAN E CRACKED FOLLOWED NOT LONG AFTER BY A PARTIAL SEPARATION OF OUTER PANE. SEPARATION PORTION OF WINDOW PANE STRUCK THE L T IB WING LEADING EDGE AND LT HORIZONTAL STABILIZER CAUSING SOME MINOR DAMAGE TO DEICER BOOTS. FOLLOWING THIS, AC RETUR NED TO DORVAL. MAINTENANCE REPLACED THE PORT COCKPIT SIDE WINDOW AND AC WAS RETURNED BACK TO SERVICE. RECORDS INDICATE T HIS TO BE THE ORIGINAL WINDOW. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004031500120 20040315 00120 EU 2004 3 15 CA040130006 1 20040125 G 6230 11741904 SWASHPLATE BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE MAIN ROTOR WORN W O OTHER O OTHER CR CRUISE 1 CA (CAN) UPON RETURNING AFTER A TRIP THE PILOTS REPORTED A (HUMP) (VERTICAL VIBRATION) ON THE AIRCRAFT. A VISUAL INSPECTION WAS CARRIED OUT ON THE MAIN ROTOR HEAD, BLADES, PITCH LINKS, AND THE SWASHPLATE. CHECKING THE SWASHPLATE FOUND IT TO H AVE AN EXCESSIVE AMOUNT OF PLAY. 1 G 7 2 3U 3 U H13EU E5NE10 2004031500133 20040315 00133 CE 2004 3 15 CA040130007 1 20040106 G 2434 C6FF10555A HOUSING CESSNA 337 337G 2075730 CE CONT O360 IO360G 17025 SO MCAULY 2AF34C D2AF34C306 GL ALTERNATOR CRACKED W K NONE P NO WARNING INDICATION IN INSP/MAINT 1 CA 9041135 (CAN) ON INSPECTION OF ALTERNATOR HOUSING 2 RIBS WERE FOUND CRACKED COMPLETELY THROUGH. THERE HAVE BEEN TWO OTHER SIMILA R ALTERNATORS FOUND WITH CRACKED RIBS. 1 H 7 2 3O 3 O A6CE E1CE 5 C P5EA 2004031500135 20040315 00135 SO 2004 3 15 CA040130008 1 20040127 G 3220 67054003 TRUNNION PIPER PA28 PA28R200 7102811 SO LYC O360 IO360C1C 41514 EA HARTZL HCC2Y HCC2YK1 GL NLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) CRACK EMANATING FROM TOP OF WEB JUST RT OF CENTER STRUT HOUSING. NO REPORT OF HARD LANDING OR ABUSE. 1 L 7 1 3O 3 O 2A13 1E10 5 C P920 2004031500136 20040315 00136 SW 2004 3 15 CA040130009 1 20040130 G 5412 CAP BELL BELL 212 212 1181420 SW PWA PT6T PT6T3B 52045 NE MAIN BEAM CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) NOT UNUSUAL FOR THE OLDER STYLE BEAM CAP TO CRACK. THIS IS A REGION THAT IS PART OF OUR INSPECTION PROGRAM. THER E IS A MORE EXTENSIVE INSPECTION AFTER 10,000 HOURS. 1 G 7 1 4U 4 U H4SW E22EA 2004031500137 20040315 00137 EU 2004 3 15 CA040131001 1 20040130 G 2913 704A33690004 DRIVE BELT SNIAS 350 AS350BA 8680817 EU LYC LTS101 LTS101600A3 41560 NE HYDRAULIC PUMP BROKEN W A UNSCHED LANDING F FLT CONT AFFECTED CL CLIMB 1 CA (CAN) THE BELT BROKE 2 MINUTES AFTER TAKE-OFF. OAT WAS -15C. THE AIRCRAFT MADE A NORMAL HYDRAULIC-OFF LANDING. NO UNC OMMANDED CONTROL MOVEMENT OCCURRED AT THE TIME OF THE INCIDENT. 1 G 7 1 3U 3 U NC H9EU E5NE 2004031500138 20040315 00138 GL 2004 3 15 CA040202001 3 20040211 G 6110 LW13792 SEAL PIPER PA30 PA30 7103002 SO LYC O320 IO320B1A 41508 EA HARTZL HCE2Y HCE2YL2 GL PROPELLER BLOWN W E ENGINE SHUTDOWN K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA L175755A (CAN) PILOT NOTICED ENGINE SEEPING FROM LT ENGINE COWL, THEY WERE NEAR THE AIRPORT AND DECIDED TO SHUTDOWN LT ENGINE TO PREVENT ENGINE DAMAGE. IT WAS DETERMINED ON THE GROUND BY MAINTENANCE THAT THE LT PROP SEAL HAD BLOWN DUE TO A FROZEN BR EATHER. IT WAS DETERMINED THAT PROBLEM RESULTED FROM AN EXTREME DROP IN TEMPERATURE CAUSING ANY MOISTURE IN THE BREATHER FROM PREHEAT TO FREEZE. PROP SEAL WAS REPLACED AND TEST FLIGHT SUCCESSFUL. 1 L 7 2 3O 3 O A1EA 1E12 5 C P9EA 2004031500157 20040315 00157 NE 2004 3 15 CA040202003 2 20040102 G 7320 BELLCRANK DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE FUEL LEVER LACK OF LUBE W K NONE W E INADEQUATE Q C VIBRATION/BUFFET IN INSP/MAINT 1 CA (CAN) COULD NOT SHUT DOWN LT ENGINE WITH FUEL LEVER. HAD TO PULL FIRE HANDLE. ALSO RT ENGINE VERY DIFFICULT TO SHUT OFF. CABLE MECHANISM FOUND STIFF DUE TO VERY COLD WEATHER. FUSELAGE TO PYLON BELLCRANK LUBRICATED AND BOTH SYSTEMS SERVICEAB LE. 2 L 7 2 4F 4 F RT A6WE E9NE 2004031500158 20040315 00158 WP 2004 3 15 CA040202004 1 20040105 G 2133 39271411 OUTFLOW VALVE DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE CABIN PRESSURE FAULTY W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) UNABLE TO PRESSURIZE THE AIRCRAFT. AIRCRAFT LANDED. MAINTENANCE FOUND RT PRSO VALVE P/N 392714-1-1 S/N 2653 IN FAU LT. VALVE REPLACED. 2 L 7 2 4F 4 F RT A6WE E9NE 2004031500159 20040315 00159 WP 2004 3 15 CA040202005 1 20040109 G 2133 39245431 REGULATOR VALVE DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE CABIN PRESSURE FAILED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) COULD NOT PRESSURIZE THE AIRCRAFT. AIRCRAFT LANDED BACK, FOLLOWING INVESTIGATION, MAINTENANCE FOUND IN FAULT THE L T PILOT PRESSURE REGULATING VALVE P/N 392454-3-1 S/N 6549 AND LT PRESSURE REGULATOR VALVE P/N 392714-1-1 S/N 4522. BOTH VALVES REPLACED AND AIRCRAFT DISPATCHED SERVICEABLE. 2 L 7 2 4F 4 F RT A6WE E9NE 2004031500160 20040315 00160 WP 2004 3 15 CA040202006 1 20040115 G 2910 B-NUT DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE HYD LINE LOOSE W O OTHER K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA (CAN) UPON ARRIVAL AT GATE WHEN APU AIR SELECTED 'ON', CABIN AND COCKPIT FILLED WITH BLUE SMOKE. CAUSED BY THE INGESTION OF HYDRAULIC OIL IN THE APU AIR INTAKE. SOURCE OF FLUID CAME FROM RT WHEEL WELL. MAINTENANCE FOUND 2 (B) NUTS LOOSE ON ONE HYDRAULIC LINE NEAR RT HYDRAULIC RESERVOIR. NUTS TIGHTENED AND SYSTEM CHECKED SERVICEABLE. 2 L 7 2 4F 4 F RT A6WE E9NE 2004050700016 20040507 00016 WP 2004 5 7 CA040202007 1 20040116 G 2752 59370525001 ACTUATOR DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE RT FLAP LEAKING W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 CA (CAN) AFTER TAKEOFF, CABIN AND COCKPIT FILLED WITH BLUE SMOKE SMELLED LIKE SKYDROL. APU HAS INGESTED SKYDROL FROM LEAK R T WHEEL WELL. AIRCRAFT LANDED BACK. THE USE OF APU HAS BEEN CANCELLED IAW MEL. WATER SEPARATORS AND COALESER BAGS CLEANE D AND AIRCRAFT DISPATCHED SERVICEABLE. 2 L 7 2 4F 4 F RT A6WE E9NE 2004031500161 20040315 00161 NM 2004 3 15 CA040202010 1 20040202 G 7830 THRUST REVERSER BOEING 767 767233 1385113 NM PWA JT9 JT9D7R4D 52054 NE ENGINE INOPERATIVE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AFTER T/O CREW RECEIVED A FLAP WARNING AND T/O WARNING HORN. SIMILAR INCIDENT. THE FLIGHT RETURNED AND UPON LANDI NG, THE RT ENGINE QUIT. A/C REMOVED FROM SERVICE FOR INVESTIGATION. FLIGHT DATA RECORDER REMOVED FOR READOUT. CAPT CONTA CTED REGARDING ENGINE QUIT STATEMENT, THE ENGINE DID NOT QUIT, IT ROLLED BACK BELOW 60 KTS AFTER THRUST REVERSER STOWED NIL EGT, INCREASE NOTICED BY CREW. INCIDENT UNDER INVESTIGATION. 2 L 7 2 4F 4 F RT A1NM E3NE 2004031500162 20040315 00162 CE 2004 3 15 CA040202011 1 20040109 G 5260 10151417617 HANDLE BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE AIRSTAIR DOOR FAILED W O OTHER O OTHER TX TAXI/GRND HDL 1 CA 17475 (CAN) DURING TAKEOFF ROLL THE AIRSTAIR DOOR EXTERIOR HANDLE SEPARATED FROM THE DOOR. FURTHER INSPECTION FOUND IMPACT DAM AGE TO LT PROPELLER AND LT IB FLAP. APPROXIMATELY ONE INCH MISSING FROM TIP OF ONE PROPELLER BLADE AND DENT IN LOWER SKI N OF IB FLAP. HANDLE RECOVERED AND INSPECTED FOR CONDITION. RETAINER RING P/N MS16624-1075 MISSING ALLOWING HANDLE TO SE PARATE FROM DOOR. LSO FOUND PIN P/N MS9048-072 SHEARED. THIS PIN HOLDS SHAFT IN HANDLE. HANDLE ASSEMBLY REPLACED WITH NE W. PROPELLER ASSEMBLY REPLACED. SKIN REPAIR CARRIED OUT TO IB FLAP. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2004031500169 20040315 00169 CE 2004 3 15 CA040202012 1 20040113 G 5410 5012000886 SPAR RAYTHN BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA HARTZL HCD4N3 HCD4N3A GL NACELLE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA LJ1305 (CAN) NACELLE OB WEB TO SPAR ATTACHMENT CHANNEL CRACKED IN BEND RADIUS ON LOWER END OF CHANNEL. THIS CONDITION EXISTED I N THE SAME AREA ON BOTH NACELLES. CRACKS ARE COMMON IN THESE AREAS ON HIGH CYCLE AIRPLANES. LATER SN AIRCRAFT COME FROM THE FACTORY WITH DOUBLERS ALREADY INSTALLED IN THESE AREAS. 1 L 7 2 3T 4 T RT 3A20 E4EA 5 C STC 2004050700025 20040507 00025 NE 2004 5 7 CA040202013 2 20040106 G 7200 ENGINE PWA PT6 PT6A112 52043 NE ENGINE FAILED W O OTHER O OTHER NR NOT REPORTED 1 CA 12566 (CAN) ENGINE WAS INVOLVED IN A PROP STRIKE INCIDENT WHEN AIRPLANE PULLED OFF RUNWAY AND NLG STRUCK A STUMP, FORCE OF THI S IMPACT COLLAPSED THE LANDING GEAR AND BOTH PROPELLERS STRUCK THE GROUND. IT WAS CLEAR TO IDENTIFY THAT ENGINE HAD SUF FERED FROM A PROPELLER STRIKE. EXHAUST DUCT TWISTED CONDITION ALSO CAUSED POWER TURBINE DISK ASSEMBLY AND SEALS TO SEVER ELY RUB AGAINST THE PT SHROUD RING KNIFE-EDGES AND PTV RING INTERSTAGE BAFFEL, THIS IS ALSO REASON WHY PROPELLER SHAFT W AS NOT TURNING PRIOR TO DISASSEMBLY. DUCT OUTER SKIN SECTION MOVED OFF CENTER DURING IMPACT, WHICH CAUSED THESE COMPONEN TS TO RUB AND SEIZE. ENGINE WILL BE RESTORED TO A SERVICEABLE CONDITION THROUGH A COMPLETE OVERHAUL. 3 T E4EA 2004050700032 20040507 00032 NE 2004 5 7 CA040202014 2 20040106 G 7250 PT6A112 ENGINE PWA PT6 PT6A112 52043 NE FAILED W O OTHER O OTHER NR NOT REPORTED 1 CA 12519 (CAN) ENG WAS INVOLVED IN A PROP STRIKE INCIDENT, AC PULLED OFF THE RUNWAY AND NLG STRUCK A STUMP, FORCE OF THIS IMPACT COLLAPSED LANDING GEAR, BOTH PROPS STRUCK THE GROUND. IT WAS CLEAR TO IDENTIFY THAT ENG SUFFERED FROM PROP STRIKE. E XHAUST DUCT WAS SEVERELY TWISTED, DISTORTED AND ASSOCIATED IT WERE 2 BENT OIL TRANSFER TUBES. THIS TWISTED CONDITION OF EXHAUST DUCT ALSO CAUSED PT DISK ASSEMBLY, SEALS TO SEVERELY RUB AGAINST THE PT SHROUD RING KNIFE-EDGES AND THE PTV RING INTERSTAGE BAFFLE, PROP SHAFT WAS NOT TURNING PRIOR TO DISASSEMBLY. EXHAUST DUCT OUTER SKIN SEC MOVED OFF CENTER DURIN G IMPACT, WHICH CAUSED THESE COMPONENTS TO DISPLACE, RUB AND SEIZE. ENGINE WILL BE RESTORED TO A SERVICEABLE CONDITION. 3 T E4EA 2004031500171 20040315 00171 EU 2004 3 15 CA040202015 1 20040130 G 6320 332A32323300 TIE ROD UROCOP SNIAS AS332 AS332L 8680809 EU TMECA MAKILA MAKILA1A 60040 EU M/R GEARBOX SHEARED W K NONE O OTHER IN INSP/MAINT 1 CA M279 (CAN) ONE OF THE THREE BOLTS ATTACHING THE ENGINE TO THE MAIN GEARBOX WAS DISCOVERED SHEARED DURING A TURN AROUND CHECK. THE BOLT WAS SHEARED ABOUT MIDWAY IN THE THREADED PORTION OF THE BOLT. THE ENGINE WAS REMOVED AND AREA INSPECTED IAW WR ITTEN PROCEDURES. NO REASON FOR BOLT DAMAGE WAS DETERMINED. 2 G 7 2 4U 4 U H4EU E12NE 2004031500172 20040315 00172 EU 2004 3 15 CA040202016 1 20040202 G 3230 D172890 CONTROL CABLE BRAERO DH125 BAE125800A 1500285 EU GARRTT TFE731 TFE7315R 01518 WP MLG BINDING W K NONE P NO WARNING INDICATION IN INSP/MAINT 1 CA (CAN) UPON FUNCTIONAL TEST OF LANDING GEAR RETRACTION, THE SECONDARY MECHANICAL NOSE GEAR INDICATOR WAS NOT INDICATING P ROPER EXTENSION (PROTRUSION OF CABLE END). PROBLEM TRACED TO BINDING CABLE. EXAMINATION OF DEFECTIVE PART (REMOVAL OF CABLE FROM METAL JACKET BY CUTTING) REVEALED BULGE AT SWAGED END CAUSING CABLE TO BIND WITHIN ITS JACKET. THIS ASSY IS T O BE LUBRICATED (HAND PACKED) EVERY 48 MONTHS IAW MFG RECOMMENDATIONS. HOWEVER THE LIMITED TRAVEL OF THE CABLE WOULD PRE -EMPT ANY LUBRICANT FROM REACHING THE SWAGED WIRE PORTION ON THE E-CABLE. ONLY THE METAL ROD END WOULD RECEIVE THE LUBRI CANT. 2 L 7 2 4F 4 F RT A3EU E6WE 2004031500173 20040315 00173 NM 2004 3 15 CA040202017 1 20040106 G 2422 116250 CONNECTOR DH103024600C DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE LOAD EQUALIZER FAILED W L ABORTED APPROACH J WARNING INDICATION AP APPROACH 1 CA 1814S8 (CAN) COMPONENT RESPONSIBLE FOR INVERTER FAILURE IS SOLDER CONNECTION ON LOAD EQUALIZER SUBASSEMBLY P/N 116250. ON APPRO ACH, PRIMARY INVERTER, SECONDARY INVERTER, AND AUX INVERTER, L26AC BUS, AND R26AC BUS CAUTION LIGHTS ILLUMINATED. AFTER AUX INVERTER SWITCHED OFF, PRIMARY, SECONDARY AND BOTH 26AC BUS LIGHTS WENT OUT. CREW BROKE OFF APPROACH AND AC RETURNED . COULD NOT FAULT ON GROUND. PRIMARY INVERTER VOLTAGE INDICATING 107V AND REPLACED. AUX INVERTER REPLACED FOR T/S. ALL R ELATED CONNECTOR PLUGS AND CIRCUIT BREAKERS INSPECTED SVC. INVERTERS SENT TO VENDOR AND RETURNED WITH S/N 1814-S8 CONFI RMING FAULT, AND NAMING SOLDER CONNECTION ON LOAD EQUALIZER SUBASSEMBLY AS CULPRIT COMPONENT P/N 116250. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004031500174 20040315 00174 CE 2004 3 15 CA040203001 1 20040130 G 3260 1EN18 DOWNLOCK SWITCH LEAR 35 35LEAR 5170600 CE GARRTT TFE731 TFE73122B 01518 WP RT MLG FALSE INDICATION W O OTHER N FALSE WARNING AP APPROACH 1 CA (CAN) ON GEAR SELECT DOWN, INDICATED RT MAIN GEAR NOT DOWN AND LOCKED WITH 2 MAIN GEAR DOOR UNSAFE RED. LIGHT BULB TEST INDICATED THAT BULBS WERE OK. RECYCLED GEARS SELECTOR 3 TIMES WITH NO SUCCESS. HYDRAULIC PRESSURE WAS NORMAL. CONDUCTED EMERGENCY GEAR EXTENSION PROCEDURE BUT DID NOT OBTAIN NORMAL (DOWN AND LOCK) GREEN LIGHTS. TOWER CONFIRMED THAT THERE W AS NO LANDING LIGHT ON RT SIDE. EMERGENCY WAS DECLARED, LANDING WAS PERFORMED WITH NO FURTHER PROBLEMS, BESIDE (DOWN AN D LOCK) LIGHTS. RT DOWN AND LOCK SWITCH WAS REPLACED, GEAR SWINGS WERE C/O, AND THE SYSTEM WAS FOUND SERVICEABLE AND AIR CRAFT RELEASED TO SERVICE. 2 L 7 2 4F 4 F A10CE E6WE 2005011200002 20050112 00002 SW 2005 1 12 CA040203002 1 20040128 G 3233 ACTUATOR SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TFE33112UHR WP MCAULY 4HFR34 4HFR34C652 NE NLG BYPASSING W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA 20294 (CAN) ACFT RETURNED TO BASE. NLG NOT LOCKING UP, SWINGS CARRIED OUT, NO FAULTS FOUND. CARRIED OUT LOW PSI SWING TESTS, N O FAULTS FOUND. FOUND RT NLG TIRE FLAT. BOTH NLG TIRES REPLACED. INSP FOR DAMAGE, NO FAULTS FOUND, SWINGS CARRIED OUT, S YS PREFORMED PER MM. O/B STRIKERS ON LT & RT MLG AT WEAR LIMITS. RT MLG UPLOCK SWITCHES ADJUSTED. ALL 3 MLGS GREASED. SWINGS CARRIED OUT, SYS PREFORMED PER MM. NLG STILL NOT LOCKING UP. SWINGS CARRIED OUT AGAIN & LOW PSI TEST CARRIED OUT , APPLIED SIMULATED AIRFLOW ON NLG. MX ACHIEVED SNAG. MLG ACT LEAK CHK CARRIED OUT & RT NLG ACT FOUND BYPASSING HYD FLUI D. O/H'ED ACT INSTALLED. SWINGS CARRIED OUT WITH SIMULATED AIRFLOW LOAD, SYS FUNCTIONED AS PER MM. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C 3PNE 2004032500027 20040325 00027 SW 2004 3 25 CA040203003 1 20040202 G 2710 2771026001 CONTROL CHAIN SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP HARTZL HCE4N HCE4N3 NE AILERON WORN W O OTHER F FLT CONT AFFECTED DE DESCENT 1 CA (CAN) DURING DECENT THE FLIGHT CREW NOTICED THE AILERONS BINDING AND VERY DIFFICULT TO MOVE. UPON SLOWING DOWN THE AIRC RAFT THE AILERON CONTROL RETURNED TO NORMAL. INVESTIGATION BY MAINTENANCE REVEALED THAT THE 27-71026-001 CONTROL CHAIN WAS SEIZED AND ALMOST WORN THROUGH ON A COUPLE OF CHAIN LINK SEGMENTS. IT APPEARS AS THOUGH DURING HIGH SPEED FLIGHT TH E AIR LOAD ON THE AILERONS CAUSED HIGHER TENSION LOADS ON THE CONTROL CABLES PUTTING MORE FORCE ON THE CHAIN WHICH THEN BECAME VERY DIFFICULT TO MOVE. THE CHAINS (27-71026-001) AND SPROCKETS (26-71010-3) ON BOTH CONTROL COLUMN WHEELS WERE R EPLACED AND THE AIRCRAFT RELEASED FOR FLIGHT. 2 L 7 2 4T 4 T RT A8SW E4WE 5 C P10NE 2004032500028 20040325 00028 CE 2004 3 25 CA040203004 1 20040130 G 3230 MS24171D1 RELAY BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA HARTZL HCB4M HCB4MP3 GL MLG MOTOR FAILED W O OTHER O OTHER AP APPROACH 1 CA (CAN) LANDING GEAR FAILED TO EXTEND ON APPROACH. EMERGENCY EXTENSION WAS CARRIED OUT AND AIRCRAFT LANDED SAFELY. MAINTEN ANCE FOUND THAT THE LANDING GEAR MOTOR WAS NO LONGER RUNNING. THE LANDING GEAR RELAY WAS FOUND INTERNALLY DAMAGED WITH T HE CONTACTS STUCK IN THE CLOSED POSITION THUS PROVIDING CONTINUOUS POWER TO THE LANDING GEAR MOTOR. THIS CAUSED THE MOT OR TO FAIL. P/N OF RELAY MS24171D1 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2004050700044 20040507 00044 SW 2004 5 7 CA040203005 1 20040122 G 6320 3023724 TUBE BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA GEARBOX CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 10894 (CAN) DURING THE SCHEDULED INSPECTION CARRIED OUT THE BASE, THE AME NOTICED THAT THE TUBE P/N 3023724 WAS CRACKED BEHIND THE B-NUT AREA. THE CRACKED TUBE WAS REMOVED AND REPLACED. 1 G 7 1 4U 4 U H4SW E22EA 2004032500029 20040325 00029 CE 2004 3 25 CA040203006 1 20040108 G 5610 10138402518 WINDSHIELD BEECH 200 B200C 1152924 CE PWA PT6 PT6A42 52043 NE HARTZL HCD4N3 HCD4N3A GL COCKPIT BROKEN W B EMER. DESCENT H ELECT. POWER LOSS-50 PC CR CRUISE 1 CA (CAN) IN CRUISE RT WINDSHIELD HEAT ON, WINDOW SHATTERED, DESCENDED TO 12,000 FT, REDUCED AIR SPEED AND CABIN PRESSURE AN D RETURNED TO BASE. 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2004032500042 20040325 00042 EA 2004 3 25 CA040203007 1 20040122 G 2435 2007583 GROUND WIRE DHAV DHC3 DHC3 2800202 EA PWA PT6 PT6A34 52043 EA HARTZL HCB3T HCB3TN3 GL STARTER GEN FAILED W F ACTIVATE FIRE EXT. B A SMOKE/FUMES/ODORS/SPARKS FLAME/FIRE TX TAXI/GRND HDL 1 CA (CAN) ON STARTING THE ENGINE THERE WAS ARCING AND SPARKS COMING FROM THE STARTER GROUND ATTACHMENT LOCATED UNDERNEATH TH E COCKPIT. THE SPARKS CAME FROM THE GROUNDING ATTACHMENT BOLT ANCHOR NUT RIVET. RECOMMEND A BETTER GROUNDING LOCATION AND ATTACHMENT. 1 H 7 1 3R 4 T A815 E4EA 6 C P15EA 2005011200003 20050112 00003 CE 2005 1 12 CA040203008 1 20040122 G 5210 BOLT CESSNA 421 421B 2076014 CE CONT O520 GTSIO520H 17032 SO MCAULY 3AF34C 3AF34C92 GL PAX DOOR WRONG PART W O OTHER W INADEQUATE Q C NR NOT REPORTED 1 CA (CAN) BOLTS, BUSHINGS SEIZED ON MAIN DOOR TOP HALF. INCORRECT HARDWARE STACK-UP, IE INTERNAL WRENCHING BOLT HAD PLAIN W ASHER UNDER RADIUS OF HEAD. SEVERAL AIRCRAFT HAVE HAD THESE SAME PROBLEM OF SEIZED/CORRODED PARTS. CAUSED BY LACK OF LUB RICATION. MAIN DOOR BOLTS/BUSHING P/N MS20004-505111515-10 1 L 7 2 3O 3 O A7CE E7CE 5 C P22EA 2004032500054 20040325 00054 CE 2004 3 25 CA040203009 1 20040116 G 3220 5042013497A FORK CESSNA CESSNA 340 340A 2076405 CE CONT O520 TSIO520N 17040 SO MCAULY 3AF32C 3AF32C93 GL NLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) CRACK FOUND IN FORK CASTING ON LT SIDE OF TUBE BORE. DISASSEMBLY REVEALED FORK CRACKED COMPLETELY THROUGH LT SIDE OF BORE. 1 L 7 2 3O 3 O 3A25 E8CE 5 C P22EA 2004032500055 20040325 00055 CE 2004 3 25 CA040203010 1 20040126 G 5610 9031002P WINDSHIELD BEECH 100 A100 1152915 CE PWA PT6 PT6A28 EA HARTZL HCB4T HCB4TN3 GL COCKPIT CRACKED W B EMER. DESCENT O OTHER CR CRUISE 1 CA (CAN) DURING CRUISE, PILOT HEARD SMALL CRACK SOUND THOUGHT HE DROPPED SOMETHING, WHILE LOOKING AROUND, NOTICED RT WINDSH IELD CRACK DESCENDED AND CARRIED ON. LANDED WITHOUT INCIDENT. 1 L 7 2 3T 4 T A14CE E4EA 6 C P40EA 2004032500056 20040325 00056 NE 2004 3 25 CA040203011 2 20040127 G 7322 91620 SHAFT BELL 204 204B 1181404 SW LYC T53 T5313B 41549 NE FUEL CONTROL WORN W O OTHER P NO WARNING INDICATION NR NOT REPORTED 1 CA 2ADS1203 (CAN) UPON SUSPECTING A PROBLEM WITH FUEL CONTROL UNIT. REMOVED FCU FROM THE ENGINE TO INSPECT THE SPLINES IAW MFG SBT53 13-107. FOUND THE INTERNAL SPLINES KNIFE EDGED AND VERY CLOSE TO TOTAL FAILURE OF THE FCU. THIS WOULD HAVE LEAD TO THE F AILURE AND SHUTDOWN OF THE ENGINE. THESE PARTS HAD 434 HOURS SINCE THEY WERE REPLACED WITH SERVICEABLE UNITS. SHAFTS P/N 9162076081. 1 G 7 1 4U 4 U H1SW E17EA 2004041300024 20040413 00024 NM 2004 4 13 CA040203012 1 20040203 G 2910 272T3100351 LINE BOEING 767 767233 1385113 NM PWA JT9 JT9D7R4D 52054 NE HYDRAULIC SYS RUPTURED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) LT HYDRAULIC QTY LOST ON T/O ROLL NO HYD FLUID REMAINING ASSOCIATED SYSTEM AFFECTED. FOUND LT HYDRAULIC RETURN LIN E RUPTURED. LINE REPLACED, PRESS/CASE FILTERS REPLACED. LEAK AND FUNCTION CHECK SERVICEABLE. 2 L 7 2 4F 4 F RT A1NM E3NE 2004032500057 20040325 00057 GL 2004 3 25 CA040203013 1 20040123 G 7820 973670 MUFFLER DIAMON DA20 DA20A1 2990000 GL ROTAX 912 ROTAX912S3 EU HOFMAN HOV352 HOV352F NE ENGINE EXHAUST BROKEN W A UNSCHED LANDING O OTHER CL CLIMB 1 CA (CAN) TAILPIPE NEARLY SNAPPED OFF FROM MUFFLER, INTERNAL BAFFLES LOOSE AND OBSTRUCTING EXHAUST OUTLET PART, CAUSING THE BACK PRESSURE TO RISE AND FAILURE OF TAILPIPE HAS OCCURRED. ENGINE POWER WAS ROBBED AND FORCED THE BUILD-UP OF BACK PRES SURE TO EXIT THE HOLE IT HAS CREATED. CORRECTION ACTION IS TO SEND MUFFLER TO AN AMO WHOM MAY REPAIR MUFFLER AND COMPLE TE TAP TESTS TO MUFFLER TO VERIFY THE STATUS OF INTERNAL BAFFLES, AT EVERY INSPECTION. 1 L 7 1 3O 3 O NT TA4CH E00051EN 5 C TP5BO 2004032500058 20040325 00058 SW 2004 3 25 CA040203014 1 20040128 G 6320 206040030101 BEARING RACE BELL BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL M/R GEARBOX SPALLED W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA BKW1417 (CAN) BEARING SPALLED AND CAUSED A CAUTION LIGHT TO COME ON. 1 G 7 1 3U 3 U H2SW E4CE 2004032500059 20040325 00059 EU 2004 3 25 CA040203015 1 20040129 G 5347 STCSA9750 ADAPTER AIRBUS 310 A310304 3930339 EU SEAT TRACK MISMANUFACTURED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) THIS PROBLEM AFFECTS AIRCRAFT MODIFIED BY INSTALLATION OF AN EMS MODIFICATION IAW STC SA97-50 ONLY. SEAT TRACK ADA PTERS, PN 6372 HAVE BEEN DETERMINED TO BE UNDER STRENGTH BY DESIGN. DESIGN DOES NOT MEET THE CERTIFICATION BASIS OF THE AIRCRAFT. 2 L 7 2 4F RT A35EU 2004032500086 20040325 00086 CE 2004 3 25 CA040204005 1 20040121 G 2710 051010516 CONTROL CABLE CESSNA 180 180C 2072608 CE CONT O470 O470K 17026 SO MCAULY 2A34C 2A34C203 GL AILERON FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AILERON DIRECT CABLE LT AND RT FRAYED EACH IN 3 DIFFERENT PLACES AT PULLEYS, PULLEYS WERE NOT SEIZED, ROTATES FREE LY, ALSO FRAYED AILERON CARRY THROUGH CABLE P/N 0510105-113 AT PULLEY AREA. 1 H 7 1 3O 3 O 5A6 E273 5 C P3EA 2004032500088 20040325 00088 EU 2004 3 25 CA040204009 1 20040128 G 5210 5521012219 PIN PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL PAX DOOR HANDLE MISSING W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) PAX/CREW DOOR HANDLE LOCKING MECHANISM HARD TO OPERATE EXCEPT UPON ARRIVAL AT MAIN BASE. INSPECTING DOOR, FOUND P IN LOCK AND ITS SPRING FROM SAFETY LOCKING MECH TO BE MISSING. LOCKING MECH STOPS ACCIDENTAL OPERATION OF DOOR HANDLE IN SIDE AC. RELEASE LEVER IS INSTALLED ON INSIDE OF DOOR BELOW INNER HANDLE. CABLE CONNECTS IT TO A LOCKING PIN WHICH ENG AGES IN OUTER HANDLE IF PIN LOCK BREAKS OR IS FORCED OUT OF CRANK, COMPRESSION SPRING EJECTS ITSELF AND PIN LOCK AWAY FR OM AC AND THE DOOR CAN BE OPENED JUST BY ACTIVATING HANDLE. SUSPECT FORMATION OF ICE BETWEEN THE LOCKING PIN AND THE DO OR STRUCTURE TO RESTRAIN MOVEMENT OF PIN AND CAUSE A FAILURE OF LOCKING MECHANISM. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004032500089 20040325 00089 EU 2004 3 25 CA040204010 1 20040130 G 2435 23085024 BEARING LUCAS PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL STARTER GEN FAILED W O OTHER H ELECT. POWER LOSS-50 PC CR CRUISE 1 CA Y0253 (CAN) GEN NR 1 FAILED IN FLIGHT. UPON ARRIVAL, MAINTENANCE FOUND THE REAR BEARING OF THE STATER GENERATOR FAILED CAUSING THE COOLING FAN TO RUB ON THE CASE.CREATING VIBRATION. STARTER GENERATOR REPLACED. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004032500101 20040325 00101 NE 2004 3 25 CA040204011 2 20040111 G 7200 ENGINE DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE LEFT FAILED W A UNSCHED LANDING C F.O.D. CR CRUISE 1 CA (CAN) DURING CRUISE AT 31,000 FT, ENGINE SURGE FELT ON LT ENGINE (EPR REDUCED TO 1.67) WITH AN IMMEDIATE ODOR. SAME SURG E/ODOR WAS FELT A SECOND TIME APPROXIMATELY 45 MINUTES LATER. AIRCRAFT DIVERTED TO POP. MAINTENANCE FOUND FORWARD LAVATO RY LEAKING. LT ENGINE INSPECTED IAW MM 72-0-04 P.115 AND ENGINE RUN C/OUT TO 2-0 EPR AND NO FAULT FOUND. AIRCRAFT DISPAT CHED SERVICEABLE. 2 L 7 2 4F 4 F RT A6WE E9NE 2004032500102 20040325 00102 CE 2004 3 25 CA040204012 1 20040114 G 3260 1CH25 DOWNLOCK SWITCH BEECH 100 B100 1152919 CE GARRTT TPE331 TPE3316252B 01514 WP HARTZL HCB4T HCB4TN5 GL NLG FROZEN W O OTHER N FALSE WARNING AP APPROACH 1 CA (CAN) ON APPROACH THE PILOT SELECTED GEAR DOWN. THERE WAS NO NOSE GEAR INDICATION. AFTER CONFIRMING WITH THE TOWER THAT THE GEAR WAS DOWN, THE AIRCRAFT LANDED WITHOUT INCIDENT. THE DOWNLOCK SWITCH WAS FOUND DEFECTIVE AND SUBSEQUENTLY REPLAC ED. OAT WAS -25 TO -30 DEGREES CELSIUS. 1 L 7 2 4T 4 T A14CE E2WE 6 C P40EA 2004032500104 20040325 00104 EA 2004 3 25 CA040205001 1 20040129 G 3310 LIGHT CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE COCKPIT SHORTED W O OTHER B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 CA (CAN) SMOKE AND SPARKS WERE COMING FROM THE FIRST OFFICER FLOOD LIGHT. MAINTENANCE ACTION WAS TO REPLACED THE FLOOD LIGH T ASSEMBLY AND TO RETORQUE THE SIDE WINDOW. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2004032500105 20040325 00105 EA 2004 3 25 CA040205002 1 20040131 G 3310 2LA00691307 LIGHT CNDAIR CL600 CL6002C10 1390015 EA COCKPIT SHORTED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) FOS FLOOD LIGHT OVER LIGHTING CONTROL PANEL (UNDER RT WINDSHIELD/SIDE WINDOW POST) EMITTS A STRONG ELECTRICAL SMEL L AND THEN SHORTED OUT WITH ARCHING. AIRCRAFT CONTINUED ON AND LANDED WITHOUT FURTHER INCIDENT. MTCE FOUND THAT WATER W AS LEAKING INTO THE CABIN WHEN WATER SPRAY WAS CONCENTRATED ON THE UPPER AREA OF THE RT WINDSHIELD/SIDE WINDOW STRAP. TH E LIGHT ASSEMBLY WAS REPLACED. 2 L 7 2 4F RT A21EA 2004032500106 20040325 00106 EA 2004 3 25 CA040205003 1 20040126 G 5610 601R330333 WINDOW CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE COCKPIT CRACKED W A UNSCHED LANDING O OTHER CR CRUISE 1 CA 14843 (CAN) DURING CRUISE, FLIGHTDECK LT SIDE WINDOW CRACKED. FLIGHT WAS DIVERTED WHERE THE WINDOW WAS REPLACED. THE CRACKED W INDOW HAD BEEN FITTED SINCE THE A/C WAS NEW. THERE IS NO PRE OR POST SB FOR SIDE WINDOWS. 2 L 7 2 4F 4 F RT A21EA E15NE 2004032500154 20040325 00154 NE 2004 3 25 CA040205004 2 20040131 G 7200 ENGINE CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE NR 2 FAILED W O OTHER X J ENGINE FLAMEOUT WARNING INDICATION CL CLIMB 1 CA (CAN) AFTER TAKE OFF, 2000 ASL, NR 2 LOUD BANG FOLLOWED BY ENGINE STOPPAGE, MAYDAY DECLARED, ENGINE SECURED AND QRH DRIL LS ACTIONED. RADAR VECTORED SINGLE ENGINE APPROACH AND LANDING. FIRE SERVICE ESCORTED ON LANDING, PAX OFFLOADED ON STAND . THE ENGINE WAS REPLACED. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2004032500121 20040325 00121 CE 2004 3 25 CA040205005 1 20040202 G 8011 PM2401H DRIVE ASSY LAMAR CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA MCAULY 1A170 1A170E GL STARTER JAMMED W E ENGINE SHUTDOWN O OTHER TX TAXI/GRND HDL 1 CA 85017317 (CAN) STARTER DRIVE ONCE ENGAGED DID NOT RETRACT JAMMED OUTWARD. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P857 2004032500122 20040325 00122 EU 2004 3 25 CA040205006 1 20040203 G 7714 DISPLAY PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL EIS FAILED W A UNSCHED LANDING O OTHER CR CRUISE 1 CA (CAN) DURING CRUISE FLIGHT, THE UPPER PORTION OF THE ENGINE INDICATION SCREEN FAILED TQ, NG, & ITT. THE ALTERNATE SCREEN WAS SELECTED AND PERFORMED PROPERLY. THE EIS COMPUTER WAS REPLACED WITH A SERVICEABLE UNIT AND FUNCTION TREATED SERVICE ABLE. IT WAS NOTED A NORMAL ENGINE START COULD NOT BE ACCOMPLISHED AS THERE WAS NO ENGINE NG INFORMATION AVAILABLE TO T HE START COMPUTER TO SIGNAL IGNITION AND BOOST PUMPS. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004032500123 20040325 00123 NE 2004 3 25 CA040205007 2 20040122 G 7321 FUEL CONTROL CESSNA 560 560XL 2076702 CE PWA 545 PW545A NE LT ENGINE INOPERATIVE W D RETURN TO BLOCK X J ENGINE FLAMEOUT WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) WHILE TAXIING, LT ENG POWER LEVER WAS ADVANCED TO FACILITATE TURN. THRUST LEVER WAS ADVANCED, LT ENG SUFFERED A R OLL BACK AND FLAME-OUT. AC WAS TAXIED CLEAR OF RUNWAY, FAULT ANALYSIS RELIGHT ATTEMPTED WITH NO SUCCESS. RELIGHT WAS SU CCESSFUL. AC WAS THEN SHUT DOWN AND SURRENDERED TO MAINT FOR ACTION. EVENT FOLLOWED ACTION AND INSTALLATION OF SB 30253. FUEL LINE, ATTENUATOR ASSY AND FCU WERE REMOVED AND SENT TO MFG FOR ANALYSIS. DURING REMOVAL, A BLACK SUBSTANCE WAS DE TECTED. SUBSTANCE WAS SENT OFF FOR CHEMICAL ANALYSIS BY MFG. NR C 10420020 REGARDING SUBSTANCE. FUEL LINE, ATTENUATOR A SSY AND FCU WERE REPLACED, IAW SB 30253. AC WAS GROUND RUN AND TEST FLOWN SATISFACTORILY, RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT A22CE E00059EN 2004032500124 20040325 00124 NE 2004 3 25 CA040205008 2 20040122 G 7200 ENGINE CESSNA 560 560XL 2076702 CE PWA 545 PW545A NE LEFT FLAMED OUT W D RETURN TO BLOCK X J ENGINE FLAMEOUT WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) WHILE TAXIING AND TURNING ONTO THE RUNWAY, THE LT ENGINE POWER LEVER WAS ADVANCED TO FACILITATE THE TURN. AS THE T HRUST LEVER WAS ADVANCED, THE LT ENGINE SUFFERED A ROLL BACK AND FLAME-OUT. THE AIRCRAFT WAS TAXIED CLEAR OF THE RUNWAY AND A FAULT ANALYSIS RELIGHT ATTEMPTED WITH NO SUCCESS. THE AIRCRAFT WAS THEN TAXIED TO THE RAMP WHERE A FURTHER RELIGHT WAS ATTEMPTED. THE RELIGHT WAS SUCCESSFUL. THE AIRCRAFT WAS THEN SHUT DOWN AND SURRENDERED TO MAINTENANCE FOR ACTION. THE EVENT FOLLOWED ACTION AND INSTALLATION OF SERVICE BULLETIN 30253. 2 L 7 2 4F 4 F RT A22CE E00059EN 2004032500125 20040325 00125 SW 2004 3 25 CA040206002 1 20040128 G 2810 206288017 SIGHT GLASS BELL 206 206L 1181522 SW ALLSN 25OC 250C20R GL RANGE EXTENDER CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) SIGHT GLASS ON FORWARD SIDE OF RANGE EXTENDER WAS FOUND TO BE THE CAUSE OF A SLOW FUEL LEAK. WHEN THE AIRCRAFT WAS FULL OF FUEL AND KEPT IN THE HANGAR OVER NIGHT A SMALL POOL OF FUEL WAS NOTICED ON THE FLOOR. A CRACK RUNNING ACROSS FROM TWO SCREWS WAS FOUND. A NEW SIGHT GLASS HAS BEEN ORDERED AND WILL BE INSTALLED WHEN RECEIVED. UPON FURTHER INSPECT ION OF AIRCRAFT, ANOTHER WITH THE SAME RANGE EXTENDER WAS FOUND TO HAVE THE SAME CRACK IN THE SAME LOCATION. 1 G 7 1 3U 3 U H2SW E4CE 2004032500140 20040325 00140 SO 2004 3 25 CA040206003 1 20040204 G 2140 BLADE JANITROL B4050 PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL FAN CRACKED W O OTHER O OTHER CR CRUISE 1 CA (CAN) ONE OF FOUR BLADES SEPARATED FROM FAN AND MADE A SIGNIFICANT AMOUNT OF NOISE AND VIBRATION IN THE HEATER SUCH THAT THE PILOT SHUT THE HEATER DOWN IN FLT. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004032500141 20040325 00141 EU 2004 3 25 CA040206004 1 20040205 G 3110 9728132012 DISPLAY PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL CAWS FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) DURING CRUISE THE CREW NOTICED SOME OF THE CAWS LIGHTS OUT. THE TEST BUTTON WAS USED TO DETERMINE IF THE BULBS WE RE AT FAULT. ONCE PRESSED THE CAWS PANEL AND MASTER CAUTION/WARNING ILLUMINATED FOLLOWED A SERIES OF FLICKERING LIGHTS A ND A ODOR OF BURNED WIRES, THE PANEL THEN GOING BLACK. THE BREAKERS WERE PULLED, THE ODOR DISAPPEARED AND AIRCRAFT CONTI NUED FLIGHT TO ITS MAIN MAINTENANCE BASE. NO PASSENGERS WERE ON BOARD THE AIRCRAFT. THE CAWS DISPLAY AND CAWS COMPUTER W ERE BOTH REPLACED AND THE AIRCRAFT RETURNED TO SERVICE WITH NO FURTHER FAULTS. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004032500142 20040325 00142 EU 2004 3 25 CA040206005 1 20040202 G 2197 WIRE PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL HEATING SYSTEM BURNED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ONE POWER WIRE FOR THE FOOT HEATER HEAT CONTROL HAD FALLEN ON TO THE BRAKE LINE THAT RUNS ALONG THE FIREWALL JUST AHEAD OF THE RUDDER PEDALS. AS A RESULT ARCING OCCURED AND BURNED A HOLE IN THE LINE. THE .2500 INCH ALUMINUM BRAKE LIN E WAS REPLACED, SYSTEM BLED AND THE WIRE WAS REPLACED AND SECURED BETTER TO THE BUNDLE. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004032900051 20040329 00051 NE 2004 3 29 CA040208002 2 20040126 G 7320 FUEL CONTROL CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE RT ENGINE FAILED W O OTHER X J ENGINE FLAMEOUT WARNING INDICATION LD LANDING 1 CA (CAN) JUST AFTER TOUCHDOWN THE RT FADEC CAUTION MESSAGE CAME ON FOLLOWED BY THE RT ENG FLAMEOUT CAUTION MESSAGE. MAINTEN ANCE STARTED AND OPERATED THE ENGINE THROUGH SEVERAL CYCLES WITHOUT DUPLICATION OF THE FLAMEOUT CONDITION. MAINTENANCE R EPLACED THE RT FADEC AND FUEL MANAGEMENT UNIT, THEN OPERATED THE ENGINE THROUGH SEVERAL MORE CYCLES INCLUDING HIGH POWER AND REVERSE WITH NO FLAMEOUT OCCURANCE. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2004032900052 20040329 00052 EA 2004 3 29 CA040208003 1 20040125 G 4930 38004883 APU CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE APU BAY LEAKING W K NONE K J FLUID LOSS WARNING INDICATION IN INSP/MAINT 1 CA (CAN) FOR THE OVERNIGHT, THE FLIGHT CREW WERE ASKED TO LEAVE THE APU RUNNING TO PERMIT AIRCRAFT GROOMING. APPROXIMATELY ONE HOUR AFTER ARRIVAL, THE APU FIRE DETECTION SYSTEM PERFORMED AN AUTO SHUTDOWN AND APU FIRE BOTTLE WAS DEPLETED. GRO UND/AIRCRAFT PERSONNEL CONTACTED THE FIRE DEPARTMENT. THE APU WAS INSPECTED, AND EVIDENCE OF FUEL WAS OBSERVED, HOWEVER THE SOURCE OF THE APU FUEL LEAK COULD NOT BE ABSOLUTELY PIN-POINTED AND RESULTED IN THE APU'S REPLACEMENT. THE AIRCRAF T RETURNED TO SERVICE FOLLOWING THE APU REPLACEMENT. 2 L 7 2 4F 4 F RT A21EA E15NE 2004032900073 20040329 00073 CE 2004 3 29 CA040209001 1 20040205 G 2121 903840311 BLOWER BEECH 100 A100 1152915 CE PWA PT6 PT6A28 EA HARTZL HCD4N3 HCD4N3A GL AIR CONDITIONING SEIZED W H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) JUST AFTER LEVELING OUT PILOT NOTICED SMOKE IN THE COCKPIT/CABIN AREA. AIRCRAFT WENT TO 10000 FT, DEPRESSURIZED AN D ELECTRICAL POWER WAS REMOVED. POWER WAS RESTORED AND AIRCRAFT RETURNED TO BASE WITHOUT FURTHER INCIDENT. UPON INVESTI GATION IT WAS DETERMINED THAT THE VENTILATION BLOWER BEARING SEIZED AND CAUSED THE SMOKE. VENT BLOWER WAS REPLACED AND S YSTEM TESTED SERVICEABLE. 1 L 7 2 3T 4 T A14CE E4EA 5 C STC 2004032900095 20040329 00095 NM 2004 3 29 CA040209002 1 20040205 G 5610 57176249 WINDOW BOEING 727 727260 NM PWA JT8 JT8D17 52049 NE COCKPIT CRACKED W A UNSCHED LANDING O OTHER CL CLIMB 1 CA (CAN) DURING CLIMB, THE F/O OBSERVED THE R2 SLIDING WINDOW WAS CRACKED. THE DECISION WAS MADE TO RETURN TO BASE. THE AI RCRAFT LANDED WITHOUT INCIDENT. THE R2 WINDOW ASSY WAS REPLACED IAW MM 56-12-11 AND CHECKED SERVICEABLE. THE R2 WINDOW H EAT CONTROLLER AND TEMP SWITCH WERE CHANGED AS A PRECAUTION. FUNCTIONAL CHECK WAS CARRIED OUT SERVICEABLE IAW MM 30-41- 02. NO FURTHER PROBLEM DURING SUBSEQUENT FLIGHT. 2 L 7 3 4F 4 F RT A3WE E2EA 2004032900096 20040329 00096 NM 2004 3 29 CA040209003 1 20040205 G 3260 189915 TARGET BOEING 727 727225 1384077 NM PWA JT8 JT8D15A 52051 NE MLG MISINSTALLED W D RETURN TO BLOCK N FALSE WARNING TX TAXI/GRND HDL 1 CA (CAN) DURING TAXI, THE RT MLG UNSAFE LIGHT ILLUMINATED AND GREEN SAFETY LIGHT WAS OUT. MAINTENANCE INSTALLED LANDING GEA R PINS AND THE AIRCRAFT TAXIED BACK TO THE RAMP. DURING INSPECTION OF THE PROXIMITY LANDING GEAR SWITCHES, IT WAS OBSER VED THE TARGETS WERE INSTALLED IMPROPERLY. THE TARGETS WERE RE-INSTALLED CORRECTLY IAW MM 32-41-91 AND 32-04-121. FUNCT ION CHECKED SERVICEABLE IAW MM 32-61-91. NO FURTHER PROBLEM DURING SUBSEQUENT FLIGHT. 2 L 7 3 4F 4 F A3WE E2EA 2004032900097 20040329 00097 SO 2004 3 29 CA040209004 1 20040205 G 6120 2489410 CONTROL CABLE PIPER PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL PROP GOVERNOR BROKEN W O OTHER E VIBRATION/BUFFET TX TAXI/GRND HDL 1 CA (CAN) AT ENGINE WARMING UP PILOT FOUND ( WHEN TRYING CHECK OF PROP GOVERNOR WORK) LT PROP CONTROL LEVER WENT LOOSE, PROP DID NOT FOLLOW SETTING ANY MORE. INSPECTION REVEALED LT PROP GOVERNOR CABLE PN:24894-10 BROKEN AND SEPARATED CABLE END FITTING AT GOVERNOR SIDE. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004032900098 20040329 00098 WP 2004 3 29 CA040209005 1 20040208 G 6320 369D25100505 NOZZLE HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL M/R GEARBOX MISSING W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) UNIT INSTALLED IN A/C AFTER REPLACEMENT OF CRACKED CASE BY CUSTOMER US REPAIR FACILITY. AFTER INITIAL TEST RUNS IT WAS REPORTED TO HAVE VERY LOW OIL PRESSURE, AFTER NUMEROUS HOURS OF TROUBLESHOOTING (PRESSURE PUMP, SWITCH, GAUGE REPLA CEMENT AND WIRING CHECKS), THE UNIT WAS REMOVED FROM A/C FOR FURTHER INSPECTION. THE T/R O/P PINION WAS REMOVED TO EXPOS E A LARGE PART OF THE PRESSURE PROBLEM AS THE I/P OIL NOZZLES WERE MISSING. WE HAVE DOCUMENTED THIS ON DIGITALLY WITH PI CTURES.WE AWAIT FURTHER INSTRUCTION. 1 G 7 1 3U 3 U H3WE E4CE 2005011200004 20050112 00004 CE 2005 1 12 CA040209006 1 20040205 G 2497 P109A20 CONNECTOR LEAR 35 31A 5170531 CE GARRTT TFE731 TFE7312 01518 WP ELECTRICAL FAILED W K NONE H ELECT. POWER LOSS-50 PC IN INSP/MAINT 1 CA (CAN) DURING TROUBLESHOOTING FOR GROUND POWER SNAG, NOTICED THAT 5A CURRRENT LIMITER FOR HE GROUND POWER ENERGIZATION CI RCUIT WAS BLOWN. IT SHOULD BE NOTED THAT P109A20 WAS NOT PINNED TO X AT P309, AS WAS INDICATED BY THE WIRE DIAGRAMS FOR S/N 31-102. ACFT WIRED AS PER EFFECTIVITY 31-147 AND SUBSEQUENT, WITH P109A20 AT PIN J. 2 L 7 2 4F 4 F RT A10CE E6WE 2004032900099 20040329 00099 NM 2004 3 29 CA040209007 1 20040206 G 4900 23088002B STARTER GEN DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE APU BURNED W O OTHER B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 CA (CAN) APU FAILED TO START, TECHNICIANS FOUND STARTER / GENERATOR BURNED, THE ATTACHED WIRES AND CONNECTORS WERE ALSO FOU ND DAMAGED. OPERATOR ADVISED BY THEIR SPARES THAT THE STARTER GENERATOR, P/N 23088-002B SN Y0084 WAS REPAIRED BY THE VE NDOR ONCE ALREADY. THE GENERATOR WAS REPLACED YESTERDAY AND FAILED AFTER 2 FLIGHTS. THE APU WAS STARTED WITH BATTERY POW ER. DUTY CYCLE WAS OBSERVED. TIME SINCE REPAIR: 1.37 CYCLE SINCE REPAIR: 2. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004032900100 20040329 00100 EA 2004 3 29 CA040209008 1 20040202 G 2910 6607P953 PRESSURE SWITCH DHAV DHC6 DHC6 2802606 EA HYD SYSTEM OUT OF TOLERANCE W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) PRESSURE SWITCH HAS A CALIBRATION VARIANCE THAT FALLS OUTSIDE OF THE DRAWING SPECIFICATION. THE ACTUATION OF THE UNIT HAS A TIGHTER TOLERANCE FROM ACTUATION, THAN SPECIFIED. THE SWITCH IS DESIGNED TO DEACTUATE, ON DECREASING PRESSURE , AT A VALUE 150 TO 300 PSI BELOW THE ACTUATION POINT. (DEACTUATION IS LOWER THAN THE 150 PSI BENCH MARK. THIS, IN NO WA Y, HAS AFFECTED THE RELIABILITY OF THE UNIT.) THERE IS NO CONCERN OF UNITS FUNCTIONALITY OR QUALITY CHARACTERISTICS. IF THE TIGHTER TOLERANCE IS ACCEPTABLE/PREFERRED, CUSTOMERS MAY CONTINUE TO USE THEM. 1 H 7 2 3T RT A9EA 2004033000143 20040330 00143 GL 2004 3 30 CA040209009 2 20040209 G 7397 JG7039C2C33 WIRE HARNESS CVAC 340 340CVAC 242270A WP ALLSN 501D 501D13H 03004 GL FUEL QTY CHAFED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING WINTER MAINTENANCE INSPECTION, WIRES WERE FOUND RUBBING AGAINST EACH OTHER AT A FUEL QUANTITY TRANSMITTER P ROBE IN THE LT WING AT APPRX WS 253.0. ONE WIRE HAD CHAFED ENOUGH TO EXPOSED THE BARE WIRE. ALL OTHER AREAS IN BOTH W INGS WERE INSPECTED AT THE FUEL QUANTITY PROBES WITH NO OTHER DAMAGE NOTED. 2 L 7 2 4R 4 T 6A6 E282 2004033000146 20040330 00146 WP 2004 3 30 CA040209010 1 20040203 G 2540 WASTE TANK DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE LAVATORY LEAKING W O OTHER K FLUID LOSS DE DESCENT 1 CA (CAN) ON DESCENT, RT THROTTLE STUCK AT APPROXIMATELY 2 CM ABOVE IDLE POSITION. (UNABLE TO CONTROL POWER ON ENGINE) REGAI NED CONTROL OF THROTTLE AT 1000 FEET ABOVE GROUND. FUNCTIONED NORMAL FOR LANDING AND TAXI. MAINTENANCE FOUND ICE BUILD UPON RT ENGINE THROTTLE CABLE SYSTEM QUADRANT TO CROSS SHAFT. SYSTEM CLEANED AND CHECKED FREE FOR MOVEMENT. THE ICE BUIL D UP CAME FROM WATER LEAK FROM RT REAR LAVATORY. THE LAVATORY FAUCET WAS STUCK OPEN DURING FLIGHT AND OVERFILLED THE WA STE TANK. WATER OVERBOARD THE TANK ON THE TOILET FLOOR AND DRIPPED OVER THE ENGINE CONTROL. 2 L 7 2 4F 4 F RT A6WE E9NE 2004033000147 20040330 00147 EU 2004 3 30 CA040209011 1 20040209 G 3297 G21A24 WIRE PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL MLG INDICATOR BROKEN W O OTHER N FALSE WARNING TX TAXI/GRND HDL 1 CA (CAN) LT MLG GREEN INDICATION WAS INTERMITENTLY LOST. FAULT COULD BE DUPLICATED BY WIGGLING THE WIRES AT THE ACTUATOR P LUG. WIRE G21A24 FOUND BROKEN AT P055 CONNECTOR, REPAIRED, GROUND TESTS SATISFACTORY. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004033000148 20040330 00148 NE 2004 3 30 CA040209012 2 20040127 G 7321 85634 SHAFT BELL 204 204B 1181404 SW LYC T53 T5313B 41549 NE FUEL CONTROL WORN W K NONE O OTHER IN INSP/MAINT 1 CA 2ADS1203 (CAN) FUEL CONTROL RECEIVED FROM CUSTOMER FOR INSPECTION FOLLOWING PREVIOUS RECORDS ABOUT PUMP FAILURE (WSDR 20040128006 ). FUEL CONTROL HAS TSO- 3195.3 AND WAS OPERATING ON EXTENSION TIME DUE TO A GOOD PERFORMANCES. IT WAS REMOVED FROM A/C FOR INSPECTION IAW SB. T5317A-1-107 (CECO SB.73-39). INSPECTION FOUND WORN EXCESSIVELY, WORN MAIN DRIVE INTERNAL SPLIN ES, SECONDARY LARGE SPLINE AND PRIMARY PUMP GEAR EXTERNAL SPLINE. THIS IS THIRD CASE OF PUMP-MAIN DRIVE SHAFT FAILURE IN VESTIGATED. WE HAVE REPORTED THIS CASE TO MANUFACTURER AND WE ARE WAITING FOR FUTHER GUIDANCE. 1 G 7 1 4U 4 U H1SW E17EA 2004033000149 20040330 00149 EA 2004 3 30 CA040210001 1 20040209 G 3310 2LA00691307 LIGHT CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE COCKPIT INOPERATIVE W O OTHER B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA (CAN) THE FLIGHT CREW REPORTED, ON POWER UP, SMOKE COMING FROM THE RT SIDE OF COCKPIT. ADDITIONAL INFORMATION IS THAT T HE SMOKE WAS COMING FROM AROUND THE FO WINDSHIELD/WINDOW POST. MAINTENANCE DEFERED THE FLIGHT DECK FLOOD LIGHTS IAW MEL 33-11-01, AND RETURNED THE AIRCRAFT TO SERVICE. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2004070900005 20040709 00005 EA 2004 7 9 CA040210002 1 20040205 G 2613 601R3103914 CONTROL BOX CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE RT MLG WW MISSING W K NONE L NO TEST IN INSP/MAINT 1 CA (CAN) PRIOR FIRST FLIGHT OF DAY, PILOT NOTICED THAT GEAR BAY OVERHEAT TEST WAS INOPERATIVE. MECHANIC WENT TO INSPECT LOO PS IN WHEEL WELL AND DISCOVERED THAT RT WHEEL BIN WAS MISSING. AFTER INSP, NO DAMAGE WAS FOUND ON FASTENERS HOLES, HOWE VER SENSING LOOP AC CONNECTOR WAS TORN APART. CONNECTOR WAS REPAIRED, A NEW WHEEL BIN WAS INSTALLED AND AC RETURNED TO SERVICE. OPERATOR LAUNCHED A FLEET INSPECTION ON ALL THEIR AIRCRAFT TO INSPECT WHEEL BIN INSTALLATION, NOTHING ABNORMAL WAS FOUND EXCEPT SOME AC HAD A FEW FASTENERS MISSING. AN INTERNAL INVESTIGATION IS CURRENTLY ON GOING AT THIS OPERATOR T O TRY TO UNDERSTAND THIS OCCURRENCE. NOTE: THE P/N IN QUESTION 601R31039-146. 2 L 7 2 4F 4 F RT A21EA E15NE 2004033000150 20040330 00150 CE 2004 3 30 CA040210003 1 20040208 G 7120 265102215 RING CESSNA 208 208B 2073701 CE PWA PT6 PT6A114A 52043 NE MCAULY 3AF34C 3GFR34C703 GL ENGINE MOUNT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING ROUTINE MAINTENANCE THE ENGINE MOUNT RING (HORSE COLLAR) WAS FOUND CRACKED AT TWO OF THE FOUR CORNERS, INSI DE JOINT. DUE TO THIS BEING A KNOWN PROBLEM, AN ADDITIONAL TASK CARD TO CHECK FOR THIS CONDITION, INITIATED IN 1999, WAS ADDED TO OUR MAINTENANCE SCHEDULE EVERY 100 HOURS. AS A RESULT, WE HAVE DISCOVERED THE CONDITION ON 8 SEPARATE COLLARS. THE COLLAR WAS REPLACED AND THE AIRCRAFT RELEASED. 1 H 7 1 3T 3 T A37CE E4EA 5 C P60GL 2004050700027 20040507 00027 EA 2004 5 7 CA040210004 1 20040210 G 3220 LANDING GEAR CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE NOSE INOPERATIVE W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) UNABLE TO RETRACT NLG ON GEAR UP SELECTION. 2 L 7 2 4F 4 F RT A21EA E15NE 2004062100145 20040621 00145 CE 2004 6 21 CA040210005 1 20040210 G 5230 26012053 HINGE CESSNA CESSNA 208 208B 2073701 CE PWA PT6 PT6A114A 52043 NE MCAULY 3AF34C 3GFR34C703 GL CARGO POD DOOR TORN W O OTHER D INFLIGHT SEPARATION AP APPROACH 1 CA (CAN) ON SHORT FINAL THE PILOT HEARD A LOUD BANG AT THE BEGINNING OF THE FLARE. THE PILOT TAXIED THE AIRCRAFT TO THE CAR GO RAMP. AFTER THE PILOT GOT OUT OF THE COCKPIT HE NOTICED THAT THE FWD LOWER POD CARGO DOOR WAS MISSING. THE CARGO DOOR WAS FOUND ON TOP OF THE SNOW 50 FEET FORM THE THRESHOLD OF THE RUNWAY. THERE WAS NO DAMAGE TO THE AIRCRAFT OR THE DOOR. THE ONLY DAMAGE WAS THE TORN HINGE WHERE IT HAD SEPARATED FROM THE DOOR. THE DOOR LATCHING SYSTEM WAS FOUND TO BE OPERA TING NORMALLY WITH NO DAMAGE OR WEAR TO THE DOOR OR POD ASSY. SUSPECT THAT THE DOOR WAS NOT LATCHED CORRECTLY BEFORE DEP ARTURE. 1 H 7 1 3T 3 T A37CE E4EA 5 C P60GL 2004040200001 20040402 00001 EU 2004 4 2 CA040210006 1 20040206 G 7334 8346 PRESSURE SWITCH SAAB SF340 SF340A 7850100 EU GE CT7TP CT75A2 30030 NE ROTOL R389 R3894123F25 NE FUEL SYSTEM LEAKING W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA 367302 (CAN) DUE TO INTERNAL LEAKAGE OF DIFFERENTIAL PRESSURE SWITCH, A LOST OF FUEL WAS HAPPENING THRU THE OVERBOARD DRAIN WHI CH WAS CREATING A PRESSURE DROP IN FUEL PUMP SYSTEM, THE AUX PUMP WOULD THEN COME ON AND OFF THUS CREATING A SMALL FLUCT UATIONIN THE ENGINE PARAMETERS. AFTER INVESTIGATION AN IMPROVE SWITCH WAS MADE AVAILABLE THRU SB73-011 DUE TO IMPROVED R ELIABILITY. THE OLD PN 8346 CAN BE NOW IMPROVE BY USING PN 8346-001. 2 L 7 2 4T 4 T RT A52EU E8NE6 6 C P30NE 2004050700053 20040507 00053 CE 2004 5 7 CA040210008 1 20040206 G 3260 1003810061 DOWNLOCK SWITCH BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE MLG DEFECTIVE W O OTHER N FALSE WARNING AP APPROACH 1 CA 12293 (CAN) ON APPROACH TO HIGH LEVEL WHEN GEAR WAS EXTENDED THE GREEN NOSE GEAR DOWN LIGHT DID NOT ILLUMINATE. THE RED IN TR ANSIT LIGHT HAD EXTINGUISHED. AIRCRAFT LANDED UNEVENTFULLY AND WAS INSPECTED AND DEEMED SAFE FOR SPECIAL FLIGHT PERMIT WITH NO PAX. MAINTENACE FOUND THE NOSE GEAR DOWNLOCK SWITCH TO BE DEFECTIVE. IT WAS REPLACED AND GEAR SWINGS SHOWED NO FURTHER PROBLEMS. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2004050700054 20040507 00054 NE 2004 5 7 CA040211001 2 20040131 G 7322 2100140007 GEARBOX CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE RT THROTTLE INOPERATIVE W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) RT ENGINE WOULD NOT SHUTDOWN AT GATE WITH THRUST LEVER AT SHUT OFF POSITION. MAINTENANCE REPLACED THE RT THROTTLE CONTROL GEARBOX ASSY AND RT MAIN FUEL CONTROL UNIT. AIRCRAFT RETURNED TO SERVICE. PARTS REPLACED: THROTTLE CONT GEAR BOX ASSY, P/N: 2100140-007, S/N: 601, MAIN FUEL CONT, P/N: 6078T55P09, S/N: WYG85422, 2 L 7 2 4F 4 F RT A21EA E15NE 2004050700055 20040507 00055 EA 2004 5 7 CA040211002 1 20040203 G 5610 NP1393219 WINDOW CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE COCKPIT SIDE BROKEN W A UNSCHED LANDING O OTHER CR CRUISE 1 CA (CAN) CAPTAIN SIDE WINDOW SHATTERED IN CRUISE AT FL370. AN UNEVENTFUL LANDING FOLLOWED. THE SIDE WINDOW WAS REPLACED A ND THE AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2004050700056 20040507 00056 SO 2004 5 7 CA040211003 1 20040210 G 3245 0923440 TUBE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL RT MLG FAILED W O OTHER O OTHER LD LANDING 1 CA (CAN) ON LANDING , THE PILOT NOTICED A SLIGHT PULL TO THE RT. WHEN THE PILOT SLOWED THE AIRCRAFT, THE PULL GOT STRONGER FOLLOWED BY FLOPPING SOUND. THE PILOT STOPPED AND SHUT DOWN ON THE RUNWAY. ON INVESTIGATION OF THE TIRE AND TUBE, A S MALL .1250 INCH SLIT WAS FOUND IN THE TUBE. NOTHING SHARP WAS FOUND IN THE TIRE. SUSPECT THAT THE TUBE HAD A SLIGHT F OLD ON INSTALLATION AND COLD WEATHER OR RUBBING CREATED A HOLE. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004050700057 20040507 00057 WP 2004 5 7 CA040211004 1 20040210 G 6310 369F55101 DRIVE SHAFT HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL MAIN ROTOR CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING A SCHEDULED INSPECTION THE MAIN ROTOR DRIVESHAFT WAS REMOVED AND INSPECTED. THE DRIVE SPLINES SHOWED EVIDE NCE OF CORROSION UNDER THE COATING ON THE SPLINES. ALL SPLINES SHOWED BLACK FLAKES OF THE COATING COMING OFF AND YOU CO ULD SEE CORROSION UNDER THE COATING. 1 G 7 1 3U 3 U H3WE E4CE 2004050700058 20040507 00058 CE 2004 5 7 CA040211005 1 20040123 G 5610 101384025 WINDSHIELD BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA HARTZL HCB3T HCB3TN3 GL COCKPIT FAILED W A UNSCHED LANDING O OTHER CR CRUISE 1 CA (CAN) DEFECT REPORTED AS, RT OUTER WINDSHIELD SHATTERED IN FLIGHT. AIRCRAFT WAS ENROUTE AT FL250 WHEN THE WINDSHIELD S HATTERED WITH NO PRIOR INDICATIONS AND NO WINDSHIELD HEAT SELECTED, OAT WAS 41C. THE AIRCRAFT DIVERTED TO HOME BASE. UPON INSPECTION IT WAS DISCOVERED THAT THE INNER PANE HAD SHATTERED AND WINDSHIELD REPLACED WITH SUPERCEDED P/N 101-3840 25-24 IAW THE STRESS FREE INSTALLATION KIT INSTRUCTIONS. SCREWS TORQUED FOLLOWING SEALANT CURE TIME. 1 L 7 2 3T 4 T RT 3A20 E4EA 6 C P15EA 2004040200002 20040402 00002 EA 2004 4 2 CA040211006 1 20040205 G 7921 853877 OIL COOLER DHAV DHC6 DHC6300 2802606 EA PWA PT6 PT6A27 52043 EA ENGINE CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) AIRCRAFT RETURNED FROM FLIGHT WITH AN EXCESSIVE OIL LEAK ON THE LT ENGINE COWLS. INVESTIGATION DISCOVERED A CRACK IN THE OIL COOLER VERNATHERM INLET/OUTLET HOUSING. THE OIL COOLER WAS REPLACED WITH AZERO TIME UNIT AND CHECKED SERVICEA BLE.THE OIL COOLER HAD BEEN INSTALLED 77.2 HOURS EARLIER AS PART OF A 3000 HOUR BENCH TEST REQUIREMENT. 1 H 7 2 3T 4 T RT A9EA E4EA 2004031500002 20040315 00002 CE 2004 3 15 CA040211007 1 20040122 G 5610 10138402524 WINDSHIELD BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA HARTZL HCB3T HCB3TN3 GL COCKPIT CRACKED W A UNSCHED LANDING O OTHER CR CRUISE 1 CA (CAN) RT WINDSHIELD INNER LAYER CRACKED IN FLIGHT AT FLIGHT LEVEL 240. REPORTED OAT -45C. 1 L 7 2 3T 4 T RT 3A20 E4EA 6 C P15EA 2004031500011 20040315 00011 CE 2004 3 15 CA040211008 1 20040122 G 5610 10138402523 WINDSHIELD BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA HARTZL HCB3T HCB3TN3 GL COCKPIT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING SERVICING THE LT WINDSHIELD WAS FOUND CRACKED IN THE OUTER PLY. REPORTED OAT FOR THE PREVIOUS FLIGHT WAS -4 5C. 1 L 7 2 3T 4 T RT 3A20 E4EA 6 C P15EA 2004071200163 20040712 00163 SW 2004 7 12 CA040211009 1 20040209 G 1430 SCREW SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP MCAULY 4HFR34 4HFR34C652 NE GOVERNOR OUT OF ADJUST W C ABORTED TAKEOFF J WARNING INDICATION TO TAKEOFF 1 CA (CAN) RT ENGINE WOULD NOT MAKE TARGET TORQUE ON TAKE OFF AFTER 'MAX TORQUE' ADJUSTMENT. AIRCRAFT ABORTED TAKE OFF AND R ETURNED TO BLOCKS. MAINTENENACE FOUND GOVERNOR INTERFERENCE DUE TO INPROPER SCREW 'X' ADJUSTMENT. SCREW 'X' WAS ADJUST ED TO MANUFACTURERS SPECIFICATIONS AND AIRCRAFT RELEASED FOR TEST FLIGHT. AIRCRAFT WAS FOUND SEVICIBLE ON TEST FLIGHT A ND RELEASED TO SERVICE. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C 3PNE 2004031500012 20040315 00012 SW 2004 3 15 CA040211010 1 20040209 G 8012 REGULATOR SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP MCAULY 4HFR34 4HFR34C652 NE ENGINE INOPERATIVE W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA 27214 (CAN) CREW WERE ON A TRAINING FLIGHT AND WENT THROUGH A SIMULATED ENGINE FAILURE. ENGINE WOULD NOT RESTART AFTER 3 ATTEM PTS. AIRCRAFT RETURNED TO BASE. MAINTENANCE FOUND THE START PRESSURE REGULATOR TO BE AT FAULT. PART WAS REPLACED AND AI RCRAFT RETURNED TO SERVICE AFTER SUCCESSFUL ENGINE STARTS IAW MM. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C 3PNE 2004031500013 20040315 00013 EU 2004 3 15 CA040211011 1 20040114 G 6220 350A31190703 STARFLEX SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE MAIN ROTOR HEAD CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA M4517 (CAN) ON A ROUTINE AIRFRAME INSPECTION, A CRACK WAS NOTED ON THE TRAILING EDGE OF THE STAR ARM. AFTER COMPLETING THE R EPAIR TO THE AREA IAW THE SRM, IT WAS FOUND TO STILL BE A MUCH DEEPER FLAW. THE STAR WAS SENT TO MFG FOR FURTHER INVEST IGATION. A NEW STARFLEX WAS INSTALLED. 1 G 7 1 3U 3 U H9EU E19EU 2004031500014 20040315 00014 CE 2004 3 15 CA040212001 1 20040204 G 5210 051300735 POST CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160DTM GL CREW DOOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 10532 (CAN) DURING 200 HR INSPECTION, CRACK NOTED AT LOWER DOOR HINGE IN LT FRONT DOORPOST. VISIBLE THROUGH ACCESS HOLE ON IN SIDE OF POST. CRACK APPEARS TO HAVE INITIATED DUE TO FLEXING CAUSED BY HINGE PULLING ON POST WHEN DOOR CLOSES. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2004031500015 20040315 00015 CE 2004 3 15 CA040212002 1 20040130 G 2435 23078330 ARMATURE LUCAS BEECH 1900 1900D 1154162 CE COMMUTATOR FAILED W K NONE O OTHER IN INSP/MAINT 1 CA 97114 (CAN) ONE HALF OF ONE COMMUTATOR BAR MISSING (BROKEN OFF), TIPS OF FAN BLADES BROKEN OFF AND DAMAGED. THE EXACT SEQUENCE OF EVENTS CANNOT BE ACCURATELY DETERMINED, BUT IT APPEARS THAT THE PORTION OF THE COMMUTATOR BAR (NOT FOUND) BROKE OFF, DAMAGED THE NEAREST BRUSH AND WAS KICKED OUT INTO THE FAN, DAMAGING THE BLADES. BEARINGS SMOOTH, STATOR PASSED ALL CHEC KS. PREVIOUS SERVICE WAS A ROUTINE OVERHAUL AND CERTIFICATION OF ALL PARTS INSTALLED IS ON FILE. FAILURE IS UNRELATED T O WORKMANSHIP. DUE TO THE NATURE OF THIS FAILURE, A COMPLETE OVERHAUL IS NECESSARY. 2 L 7 2 4T RT A24CE 2004031500016 20040315 00016 EU 2004 3 15 CA040212004 1 20040203 G 6520 350A020005 GEARBOX SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE TAIL ROTOR MAKING METAL W K NONE J WARNING INDICATION IN INSP/MAINT 1 CA (CAN) T/R GEARBOX MAKING METAL. CHIPS DETECTED ON DETECTORS. REPLACED T/R GEARBOX. 1 G 7 1 3U 3 U NC H9EU E19EU 2004031500017 20040315 00017 CE 2004 3 15 CA040212005 1 20040206 G 5210 50430043619 CHANNEL BEECH BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCD4N3 HCD4N3A GL CABIN DOOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING INSPECTION OF THE DOOR HINGE FOR LOOSE RIVETS, A CRACK WAS DISCOVERED THAT PROPAGATED APPROXIMATELY .7500 T HE LENGTH OF THE DOOR CHANNEL. THE DOOR WAS REMOVED AND SENT TO AN APPROVED REPAIR STATION. 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2004031500018 20040315 00018 GL 2004 3 15 CA040213001 1 20040209 G 7810 2078000103 EXHAUST STACK BOMBDR DIAMON DA20 DA20A1 2990000 GL ROTAX 912 ROTAX912 55555 EU HOFMAN HOV352 HOV352F NE CYLINDER HEAD FRACTURED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THE LT REAR EXHAUST STACK WAS FOUND COMPLETELY BROKEN AND SEPARATED AT THE BEND NEAR THE CYLINDER. 1 L 7 1 3O 3 I NT TA4CH EXPE3I 5 C TP5BO 2004071200171 20040712 00171 CE 2004 7 12 CA040213002 1 20040212 G 2720 6233174200 TORQUE TUBE CESSNA CESSNA 650 650 2076802 CE GARRTT TPE731 TFE7313C WP RUDDER MISINSTALLED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) RECEIVED A RUDDER TORQUE TUBE NOT PROPERLY ASSEMBLED, FROM A MANUFACTURER. A RIB WAS NOT INSTALLED CORRECTLY DUR ING A MANUFACTURING PROCESS. 2 L 7 2 4F 4 F A9NM E6WE 2004031500030 20040315 00030 GL 2004 3 15 CA040213003 1 20040209 G 7810 2078000107 EXHAUST STACK BOMBDR DIAMON DA20 DA20A1 2990000 GL ROTAX 912 ROTAX912 55555 EU HOFMAN HOV352 HOV352F NE CYLINDER HEAD CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THE RT REAR EXHAUST STACK WAS FOUND CRACKED APPROX .5000 WAY AROUND THE CIRCUMFERENCE AT THE BEND NEAR THE CYLIND ER. THIS CRACK WAS IN A SIMILAR LOCATION AS THE ONE THAT LEAD TO THE COMPLETE FAILURE OF THE LT REAR EXHAUST STACK. 1 L 7 1 3O 3 I NT TA4CH EXPE3I 5 C TP5BO 2004031500038 20040315 00038 EA 2004 3 15 CA040213004 1 20040213 G 7830 MPN1267587 POWER UNIT CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE THRUST REVERSER INOPERATIVE W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) LT THRUST UNLOCKED IN CLIMB. QHR PARTIALLY CARRIED OUT LANDED (WOULD NOT STOW) FELT LIKE IT WAS NEVER DEPLOYED. AIRCRAFT CAME BACK FOR TROUBLESHOOTING AND REPAIR. 2 L 7 2 4F 4 F RT A21EA E15NE 2004031500039 20040315 00039 EU 2004 3 15 CA040213005 1 20040213 G 7830 THRUST REVERSER AIRBUS A319 A319112 3930323 EU CFMINT CFM565 CFM565B6 13802 NE ENGINE SMOKE W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA (CAN) AFTER LANDING AND EXITING THE RUNWAY, THE FLIGHT CREW WERE ADVISED BY THE FLIGHT ATTENDANT THAT THE CABIN HAD FILL ED WITH SMOKE. ATC CONTACTED AND EMERGENCY VEHICLE RESPONDED. THE SMOKE IN THE CABIN QUICKLY DISSIPATED AND ATC ADVIS ED. AFTER DISCUSSION WITH FLIGHT CREW SMOKE WAS INFACT INGESTED SMOKE FROM REVERSERS. THE CREW LEFT THE REVERSER WELL B ELOW 60KTS LIMIT. (NO FURTHER ACTION REQUIRED). 2 L 7 2 4F 4 F RT A28NM E37NE 2004031500040 20040315 00040 NE 2004 3 15 CA040213006 1 20040202 G 6210 6117020201067 SPAR SKRSKY SKRSKY S61 S61N 8142104 NE GE CT58 CT581402 30011 NE M/R BLADE CRACKED W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA 61M3314311 (CAN) MAIN ROTOR BLADE LEAK CHECKED AT BASE AND SPAR FOUND TO BE CRACKED. 2 G 7 2 4U 4 U 1H15 1E3 2004031500041 20040315 00041 EA 2004 3 15 CA040213007 1 20040210 G 2720 C2CF209 TORQUE TUBE DHAV DHC2 DHC2MK1 2800102 EA PWA R985 R985AN14B 52008 NE HAMSTD 2D 2D30 NE RUDDER PEDAL CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 12498 (CAN) RT RUDDER PEDAL TORQUE TUBE HAD AGGRESSIVE CORROSION BUILD UP ON THE EXTERIOR OF THE TORQUE TUBE IN THE VICINITY O F THE OIL COOLER. THIS IS A COMMON PROBLEM WITH FLOAT EQUIPPED AIRCRAFT OPERATING IN A SALT WATER ENVIRONMENT. 1 H 7 1 3R 3 R A806 5E1 5 C P206 2004031500042 20040315 00042 EA 2004 3 15 CA040213008 1 20040210 G 5552 C2T7A TORQUE TUBE DHAV DHC2 DHC2MK1 2800102 EA PWA R985 R985AN14B 52008 NE HAMSTD 2D 2D30 NE ELEVATOR WORN W K NONE O OTHER IN INSP/MAINT 1 CA 12498 (CAN) LOSS OF ELEVATOR CABLE TENSION REVEALED WORN ATTACH POINTS ON THE ELEVATOR TORQUE TUBE ASSEMBLY. 1 H 7 1 3R 3 R A806 5E1 5 C P206 2004031500043 20040315 00043 EA 2004 3 15 CA040213009 1 20040210 G 5552 C2TP11 HOUSING DHAV DHC2 DHC2MK1 2800102 EA PWA R985 R985AN14B 52008 NE HAMSTD 2D 2D30 NE ELEVATOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 12498 (CAN) LOSS OF ELEVATOR CABLE TENSION REVEALED WORN BEARINGS IN THE C2TP15A HOUSINGS (2), ON REMOVAL OF THE LT HOUSING FO R BEARING REPLACEMENT A CORROSION ASSISTED CRACK WAS NOTED. FAILURE OF THE BEARING HOUSING WAS NOT EASILY DETECTABLE UNT IL THE HOUSING ASSEMBLY WAS REMOVED FOR BEARING REPLACEMENT. 1 H 7 1 3R 3 R A806 5E1 5 C P206 2004031500044 20040315 00044 EA 2004 3 15 CA040213010 1 20040210 G 2731 C2T41 JACKSCREW DHAV DHC2 DHC2MK1 2800102 EA PWA R985 R985AN14B 52008 NE HAMSTD 2D 2D30 NE ELEVATOR TRIM CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 12498 (CAN) MINOR CORROSION NOTED ON THE EXTERNAL SURFACE OF THE TRIM DRUM (CABLE GROOVES EXFOLIATING NEAR THE CABLE INDEX PIN ) ON REMOVAL OF THE TRIM DRUM SCREW ASSEMBLY THE MIDDLE PORTION OF THE JACK SCREW PN NR C2T41 WAS FOUND TO BE SEVERELY C ORRODED IN THE MID PORTION OF THE ACME THREAD. THIS PART OF THE JACKSCREW IS NOT VISIBLE DURING ROUTINE MAINTENANCE, AN D REQUIRES THE JACK TO BE DISASSEMBLED TO VERIFY ITS CONDITION. 1 H 7 1 3R 3 R A806 5E1 5 C P206 2004031500045 20040315 00045 2004 3 15 CA040213011 4 20040210 G 2562 110324 ANTENNA ARTEX DHAV DHC2 DHC2MK1 2800102 EA PWA R985 R985AN14B 52008 NE HAMSTD 2D 2D30 NE ELT BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ELT ANTENNA FOUND BROKEN AT THE BASE OF THE ANTENNA MOUNTING FLANGE (EXTERNAL). 1 H 7 1 3R 3 R A806 5E1 5 C P206 2004031500046 20040315 00046 EA 2004 3 15 CA040215001 1 20040208 G 5610 NP13932110 WINDSHIELD CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE COCKPIT CRACKED W C ABORTED TAKEOFF O OTHER TO TAKEOFF 1 CA (CAN) TAKE OFF ABORTED AT APPROXIMATIVELY 80 KNOTS BECAUSE RT WINDSHIELD CRACKED. RT WINDSHIELD REPLACED. 2 L 7 2 4F 4 F RT A21EA E15NE 2004031500047 20040315 00047 NM 2004 3 15 CA040216001 1 20040216 G 2120 ODOR BOEING 767 76735H 1385208 NM GE CF6 CF680C2B6F 30025 NE COCKPIT DETECTED W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 CA (CAN) THE FLIGHT EXPERIENCED AN ACRID ODOR IN THE COCKPIT. AC DECLARED AN EMERGENCY LANDING AND CARRIED OUT THE QRH. AC SENT TO HANGAR FOR INVESTIGATION. 2 L 7 2 4F 4 F RT A1NM E13NE 2004031500048 20040315 00048 WP 2004 3 15 CA040216002 1 20040207 G 7933 56B17C SENSOR DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE OIL TEMP FAILED W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA (CAN) RT ENGINE OIL TEMP EXCEEDED 160 DEGREES DURING CRUISE. AIRCRAFT DIVERTED. OIL TEMP SENSOR REPLACED AND AIRCRAFT DISPATCHED SERVICEABLE. ON THE NEXT DAY FEB. 8, 2004, AIRCRAFT DEPARTED AND SAME PROBLEM CAME BACK DURING CLIMB. AIR CRAFT LANDED. THE OIL TEMP SENSOR WAS REPLACED WITH THE SYSTEM DISPLAY PANEL P/N 201EDP1-1 S/N AD660/072. AIRCRAFT DISP ATCHED SERVICEABLE. 2 L 7 2 4F 4 F RT A6WE E9NE 2004031500060 20040315 00060 CE 2004 3 15 CA040216003 1 20040114 G 2731 26616151 ACTUATOR CESSNA 208 208B 2073701 CE PWA PT6 PT6A114 52043 NE MCAULY 3AF34C 3GFR34C703 GL ELEVATOR TRIM FAILED W O OTHER F FLT CONT AFFECTED CR CRUISE 1 CA (CAN) DURING CRUISE FLIGHT WITH AUTOPILOT ENGAGED, PILOT NOTED THAT AIRCRAFT WAS NOT HOLDING ALTITUDE. PILOT DISENGAGED AUTOPILOT AND AIRCRAFT PITCHED NOSE UP. ELECTRIC ELEVATOR TRIM SELECTED BUT NO TRIM MOVEMENT. ATTEMPTED MANUAL TRIM BU T TRIM WHEEL WOULD NOT MOVE, SPRING BACK. PILOT MAINTAINED CONTROL OF AIRCRAFT WITH ELEVATOR AND LANDED WITHOUT INCIDEN T. INITIAL INSPECTION UNABLE TO MOVE ELEVATOR TRIM. AIRCRAFT HANGARED FOR SHORT PERIOD AND TRIM OPERATION OKAY. ELEVA TOR TRIM CABLE/CHAIN CIRCUIT INSPECTED, NO DEFECTS. LT AND RT TRIM ACTUATOR DISASSEMBLED AND FOUND MOISTURE. ACTUATORS I NSPECTED AND LUBRICATED IAW MFG INSTRUCTIONS. 1 H 7 1 3T 3 T A37CE E4EA 5 C P60GL 2004031500061 20040315 00061 NM 2004 3 15 CA040216004 1 20040121 G 2910 APT7510004000SG TRANSDUCER DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE HYD SYSTEM LEAKING W L ABORTED APPROACH K J FLUID LOSS WARNING INDICATION AP APPROACH 1 CA (CAN) DURING APPROACH TO AIRPORT THE HYDRAULIC ISOLATION VALVE LIGHT ILLUMINATED. THE CREW BROKE OFF THE APPROACH TO CHE CK LIGHT AND NOTED THE NR 1 HYDRAULIC CONTENTS LOW. AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE PERSONNEL DISCOVERED A LEAK FROM THE NR 1 HYDRAULIC STANDBY PUMP PRESSURE TRANSDUCER. NEW TRANSDUCER INSTALLED, HYDRAULIC FLUID REPLENISHED A ND LEAK CHECKED OKAY. CLOSE INSPECTION OF THE TRANSDUCER FOUND A CRACK IN THE BODY. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004031500062 20040315 00062 EA 2004 3 15 CA040216005 2 20040110 G 8520 78030 CONNECTING ROD CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA MCAULY 1A175 1A175ATM GL ENGINE WORN W K NONE O OTHER IN INSP/MAINT 1 CA L4427827A (CAN) ENGINE WAS CONTAMINATED. ABNORMAL WEAR WAS DETECTED ON FOUR CONNECTING RODS CAUSING METAL CONTAMINATION. DEMARCA TION WAS ALSO NOTED ON CRANKSHAFT. AFTER COMPLETING A THOROUGH INSP (MEASUREMENT OF INTERNAL BUSHINGS, A TORSION, PARALL ELISM, INSPECTION OF CONNECTING RODS, SIDE PLAY INSP OF CONNECTING RODS AND CRANKSHAFT), CONCLUDED THAT ALL MFG INSP REQ UIREMENTS WERE CARRIED OUT IN CONFORMITY WHEN IT WAS OVERHAULED. AC WAS IN OPERATION WITH 100 MINERAL OIL (SUMMER OIL) BECAUSE 80 MINERAL OIL (WINTER OIL) WAS NOT AVAILABLE. WE CONCLUDED THAT USE OF 100 MINERAL OIL IN VERY COLD STARTING C ONDITION CAUSED A LACK OF LUBRICATION IN THIS SPECIFIC AREA. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P857 2004031500063 20040315 00063 CE 2004 3 15 CA040216006 1 20040213 G 2510 05142132 LOCK CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA MCAULY 1C235 1C235LFA GL COCKPIT SEAT SHEARED W O OTHER O OTHER TX TAXI/GRND HDL 1 CA (CAN) DURING THE PRE-FLT PHASE, THE PILOT ATTEMPTED TO ADJUST THE LT SEAT WHEN THE SEAT BACK DROPPED BACK BEYOND ITS NOR MAL RANGE OF ADJUSTMENT. IT WAS DETERMINED THEN THAT THE SEAT WAS NOT IN A SAFE CONDITION TO USE AND THE CREW MADE AN E NTRY IN THE LOGBOOK THUS GROUNDING THE AIRCRAFT. CLOSER EXAMINATION OF THE SEAT ADJUSTING MECHANISM BY THE MAINTENANCE PERSONNEL REVEALED THAT THE AFT ROD ATTACHMENT FOR THE LOCK CYLINDER HAD SHEARED WHERE THE ROD IS SECURED INTO THE END C AP. THE CRIMP REMAINED INTACT WHERE AS THE SHEAR OCCURRED JUST FORWARD OF THE CRIMP. DIRECTLY CAUSING THE SEAT ADJUSTME NT MECHANISM TO FAIL. A NEW REPLACEMENT PART ORDERED FROM THE MFG. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P12EA 2004031500064 20040315 00064 NE 2004 3 15 CA040216007 2 20040205 G 7220 3036723 RETAINER PWA 120 PW123D 52152 NE ENG BREATHER MISSING W A UNSCHED LANDING K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 CA (CAN) ENGINE TSN 13318, TSO291, CSN 13305,AFTER TAKEOFF CONTROL TOWER NOTED FLUID LOSS/SMOKE FROM ENGINE AND INFORMED PI LOT. PILOT REDUCED POWER AND RETURNED TO DEPARTURE AIRPORT WHERE UNEVENTFUL LANDING WAS MADE. EXAMINATION OF THE ENGINE SHOWED BREATHER SHAFT PLUG AND RETAINING CIRCLIP TO BE MISSING. ENGINE REMOVED FOR TEARDOWN TO DETERMINE WHETHER CLIP FR ACTURED AND ENTERED AGB. OPERATOR IS CHECKING FLEET TO CONFIRM PRESENCE OF CIRCLIP AND PLUG IS PRESENT ON ALL ENGINES. S HOP HAS IMPLEMENTED DOUBLE WITNESS CHECK OF PLUG & CIRCLIP INSTALLATION. 4 T E20NE 2004041300029 20040413 00029 GL 2004 4 13 CA040216008 1 20040213 G 2510 VISOR BOMBDR BD700 BD7001A10 1390006 GL RROYCE BR700 BR700710A220 09500 NE COCKPIT SEPARATED W O OTHER Y J ENGINE STOPPAGE WARNING INDICATION CR CRUISE 1 CA (CAN) PILOT WAS MOVING HIS VISOR BACK FROM EXTREME RT SIDE OF VISOR RAIL TO LT, WHEN VISOR FELL OFF RAIL ONTO THROTTLE Q UADRANT. LT ENGINE RUN SWITCH ON QUADRANT WAS INADVERTENTLY MOVED TO OFF POSITION BY VISOR IMPACT AND ENGINE STARTED T O SHUT DOWN. PILOT DESCENDED TO FL410 TO KEEP SPEED UP, SELECTED ENGINE RUN SWITCH BACK TO RUN POSITION. SUCCESSFUL RE LIGHT OF ENGINE OCCURRED AND A/C WAS BROUGHT BACK TO FL450 AND TRIP CONTINUED WITHOUT FURTHER INCIDENT. MAINT CREW RAN ENGINES ON GROUND TO VERIFY THROTTLE QUADRANT AND ENGINE RUN SWITCHES FUNCTIONALITY OF ENGINE RUN SWITCH CONFIRMED. EN GINE GROUND RUNS PERFORMED BEFORE AIRCRAFT RETURNED TO SERVICE. NO FURTHER CONCERNS WERE IDENTIFIED. 2 L 7 2 4F 4 F RT T00003NY E00061EN 2004031500065 20040315 00065 CE 2004 3 15 CA040217001 1 20040217 G 7120 265102215 MOUNT CESSNA 208 208B 2073701 CE PWA PT6 PT6A114A 52043 NE MCAULY 3AF34C 3GFR34C703 GL ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING ROUTINE MAINTENANCE THE ENGINE MOUNT RING (HORSE COLLAR) WAS FOUND CRACKED AT TWO OF THE FOUR CORNERS, INSI DE JOINT. DUE TO THIS BEING A KNOWN PROBLEM, AN ADDITIONAL TASK CARD TO CHECK FOR THIS CONDITION, INITIATED IN 1999, WA S ADDED TO OUR MAINTENANCE SCHEDULE EVERY 100 HOURS. AS A RESULT, WE HAVE DISCOVERED THE CONDITION ON 9 SEPARATE COLLAR S. THE COLLAR WAS REPLACED AND THE AIRCRAFT RELEASED. 1 H 7 1 3T 3 T A37CE E4EA 5 C P60GL 2004031500069 20040315 00069 SW 2004 3 15 CA040217002 1 20040211 G 5210 44P14 HOSE SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP HARTZL HCB3T HCB3TN5 GL DOOR SEAL CRACKED W B EMER. DESCENT W INADEQUATE Q C CR CRUISE 1 CA (CAN) THE HOSE THAT SUPPLIES THE CABIN DOOR SEAL CRACKED, ALLOWING THE SEAL TO DEFLATE WHICH IN TURN ALLOWED THE CABIN OF THIS FREIGHTER TO DEPRESSURIZE AT 17000 FT. THE CREW DESCENDED TO A SAFE ALTITUDE AND COMPLETED THE FLIGHT. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P15EA 2004031500070 20040315 00070 CE 2004 3 15 CA040217003 1 20040217 G 3040 KRP3DH24 RELAY CESSNA 208 208B 2073701 CE PWA PT6 PT6A114A 52043 NE MCAULY 3AF34C 3GFR34C703 GL WINDSHIELD BURNED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING TROUBLESHOOTING OF THE WINDSHIELD HEAT AUTO FUNCTION, THE AUTO RELAY WAS FOUND TO BE INTERNALLY SHORTED AND HAD MELTED THE CLEAR CASE. THE RELAY WAS REPLACED AND THE AIRCRAFT RELEASED. 1 H 7 1 3T 3 T A37CE E4EA 5 C P60GL 2004031500071 20040315 00071 EA 2004 3 15 CA040217005 2 20040210 G 8520 LW13521 BEARING ROBSIN R44 R44 7640120 WP LYC O540 O540F1B5 41532 EA CONNECT ROD FAILED W D RETURN TO BLOCK O OTHER TX TAXI/GRND HDL 1 CA L2549440A (CAN) NR 5 CONNECTING ROD BEARING FAILED. BEARING FACE MATERIAL WAS BREAKING AWAY FROM BEARING. METAL CONTAMINATION WA S NOTED DURING PREFLIGHT CHECK. CONNECTING ROD BEARING HAD LOST APPROXIMATELY 15 PERCENT OF TOTAL SURFACE AREA. BOTH TH E CRANKSHAFT AND IDLER GEAR HAD RECEIVED SIGNIFICANT DAMAGE TO THEIR TEETH. BOTH GEARS HAD TO BE REMOVED FROM SERVICE. 1 G 7 1 3O 3 O H11NM E295 2004031500074 20040315 00074 NM 2004 3 15 CA040217008 1 20040213 G 2750 696670833 CONTROL CABLE BOEING 727 727225 1384077 NM PWA JT8 JT8D15A 52051 NE LT IB FLAP FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING SCHEDULED MAINTENANCE, IT WAS OBSERVED THAT THE LT IB FLAP ASSY WAS DROOPING. UPON FURTHER INVESTIGATION, T HE CABLE ASSY WAS FOUND FRAYED AND BROKEN. A NEW CABLE ASSY WAS INSTALLED IAW MM 27-51-5 AND FUNCTIONED SERVICEABLE IAW MM 27-51-0. NO FURTHER PROBLEM DURING SUBSEQUENT FLIGHT. 2 L 7 3 4F 4 F A3WE E2EA 2004031500078 20040315 00078 SW 2004 3 15 CA040217009 1 20040210 G 2497 206075559005 CONNECTOR BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL LEAD GRD CONNECT BURNED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) BURNED CABLE CONNECTORS AT FUSELAGE GROUND CONNECTION. LOOSE/CORRODED CONNECTION. CABLE ASSEMBLY REPLACED. THIS MA Y HAVE CONTRIBUTED TO EARLIER PROBLEMS WITH RCR /VOLT.REG. (CABLE K5B8N AND K5D8N) 1 G 7 1 3U 3 U H2SW E4CE 2004031500084 20040315 00084 EU 2004 3 15 CA040217012 1 20040216 G 2435 23085024 STARTER GEN PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL ENGINE INOPERATIVE W D RETURN TO BLOCK O OTHER TX TAXI/GRND HDL 1 CA (CAN) DURING AN ENGINE START THE PILOT NOTED THERE WAS AN ABNORMAL NOISE GENERATING FROM THE ENGINE. THE NOISE WAS NOTIC EABLE AROUND 10 PERCENT GG SPEED AND DISAPPEARED AFTER STABLE RPM WAS REACHED AT 17 PERCENT GG SPEED. THE STARTER GENERA TOR WAS REPLACED AND THE NOISE HAS NOT REOCCURRED. NO FURTHER ACTION REQUIRED. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004031500085 20040315 00085 WP 2004 3 15 CA040217013 2 20040211 G 7240 31016687 COMBUSTION LINER BAG JETSTM JETSTM3212 1500217 EU GARRTT TPE331 TPE33110UG 01514 WP MCAULY 4HFR34 4HFR34C652 NE LT ENGINE CRACKED W C ABORTED TAKEOFF O OTHER TO TAKEOFF 1 CA (CAN) THE LT ENGINE WOULD NOT PRODUCE RATED POWER, IN FACT IT ONLY WENT TO 80 PERCENT. THE CREW ABORTED THE TAKEOFF ROLL AND RETURNED TO THE HANGAR. ON INVESTIGATION, A CRACK WAS FOUND ON THE LOWER CENTER OF THE COMBUSTION CASE. THE CRACK GOES AROUND AN UNUSED PORT ON THE CASE. THIS APPEARS AT FIRST GLANCE TO BE VERY SIMILAR TO A PREVIOUS PROBLEM HAD WITH ANOTHER ENGINE OF THE SAME TYPE. ON THAT ONE IT TURNED OUT TO BE A FAILED SECOND STAGE COMPRESSOR IMPELLER THAT WAS CAUS ING DAMAGING VIBRATIONS. 2 L 7 2 4T 4 T RT BA15CAA E4WE 6 C 3PNE 2004031500086 20040315 00086 2004 3 15 CA040218001 4 20040212 G 2216 40002928511 SERVO PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL ELEVATOR TRIM INOPERATIVE W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) ELEVATOR TRIM SERVO WAS VERY NOISY REMOVED FOR REPAIR. LOANER INSTALLED. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004031500087 20040315 00087 2004 3 15 CA040218002 4 20040212 G 2216 40002928511 SERVO PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL ELEVATOR TRIM JAMMED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHEN TRIM WAS TESTED BY THE PILOT, THE TRIM SERVO JAMMED AND COULD NOT BE RELEASED. THE FLIGHT WAS CANCELLED. INST ALLED LOANER NEXT DAY AIRCRAFT SERVICEABLE. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004031500088 20040315 00088 EA 2004 3 15 CA040218003 2 20040212 G 8530 LW12966 CYLINDER PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL ENGINE DAMAGED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) OVERHAUL ENGINE WAS INSTALLED AT 7117.6. IN THE PROCESS OF DOING A 100 HOUR, FOUND NR 1 CYLINDER VERY LOW ON COMPR ESSION. REPLACED CYLINDER WITH OVERHAULED CYLINDER. CHECKED COMPRESSION AFTER INSTALLATION AND COMPRESSION WAS WHERE IT WAS SUPPOSED TO BE. GROUND RUN NO FAULTS FOUND. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004031500099 20040315 00099 EA 2004 3 15 CA040218004 2 20040212 G 8530 LW12966 CYLINDER PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL ENGINE INOPERATIVE W K NONE L NO TEST IN INSP/MAINT 1 CA (CAN) OVERHAUL ENGINE WAS INSTALLED AT 7117.6. IN THE PROCESS OF DOING A 100 HOUR FOUND NR 6 CYLINDER VERY LOW ON COMPRE SSION. REPLACED CYLINDER WITH OVERHAUL CYLINDER CHECKED COMPRESSION AFTER INSTALL, COMPRESSION WAS WHERE IT WAS SUPPOSED TO BE. GROUND RUN NO FAULTS FOUND. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004031500100 20040315 00100 EU 2004 3 15 CA040218005 1 20040218 G 7830 THRUST REVERSER AIRBUS A340 A340313 EU CFMINT CFM56 CFM565C4 13802 NE NR 1 ENGINE INOPERATIVE W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) SHORTLY AFTER T/O ROTATION ECAM ENG. NR 1 REV. UNLOCKED. NO BUFFET EXPERIENCED. JETTISONED FUEL AFTER ECAM AND RET URNED TO LAND, OVERWEIGHT 229,000, VERTICAL SPEED AT TOUCHDOWN ESTIMATED APPROX 300/FTM. THRUST REVERSER PLACED UNDER M EL 78-30-01. IAW REQUEST FROM MOC DFDR REMOVED FOR POSSIBLE INVESTIGATION. 2 L 7 4 4F 4 F RT A197 E37NE 2004031500101 20040315 00101 CE 2004 3 15 CA040218007 1 20040128 G 5610 5042006937 WINDSHIELD BEECH 100 100BEECH 1152916 CE PWA PT6 PT6A28 EA HARTZL HCD4N3 HCD4N3A GL COCKPIT CRACKED W O OTHER O OTHER CR CRUISE 1 CA (CAN) PILOTS FRONT WINDOW CRACKED ACROSS WINDOW ON OUTER PANE. 1 L 7 2 3T 4 T A14CE E4EA 5 C STC 2004031500102 20040315 00102 GL 2004 3 15 CA040219001 1 20040216 G 7810 2078000107 EXHAUST STACK DIAMON DA20 DA20A1 2990000 GL ROTAX 912 ROTAX912 55555 EU HOFMAN HOV352 HOV352F NE CYLINDER HEAD BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THE RT REAR EXHAUST STACK WAS FOUND TO BE COMPLETELY FRACTURED IN TWO AT THE BEND NEAR THE CYLINDER HEAD. THIS FAI LURE IS THE SECOND COMPLETE FRACTURE NOTED IN THE PAST WEEK. A THIRD EXHAUST STACK WAS FOUND CRACKED IN THE SAME LOCATIO N DURING THE PREVIOUS WEEK. 1 L 7 1 3O 3 I NT TA4CH EXPE3I 5 C TP5BO 2004031500103 20040315 00103 NE 2004 3 15 CA040219002 2 20040219 G 7200 ENGINE AIRBUS 320 A320211 3930320 EU CFMINT CFM56 CFM565A1 NE NR 1 STALLED W A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 CA (CAN) NR 1 ENGINE STALL IN CRUISE. DUE TO HISTORY MTC ADVISED RETURN FOR INVESTIGATION AND FURTHER T/S. DFDR PULLED. 2 L 7 2 4F 4 F RT A28NM E29NE 2004031500104 20040315 00104 NE 2004 3 15 CA040219003 2 20040218 G 7200 JT8D15A ENGINE BOEING 727 727225 1384077 NM PWA JT8 JT8D15A 52051 NE NR 1 FAILED W E A ENGINE SHUTDOWN UNSCHED LANDING E J VIBRATION/BUFFET WARNING INDICATION CR CRUISE 1 CA 685598 (CAN) UPON THE TRANSITIONING FROM CLIMB TO CRUISE, A LOUD BANG WAS HEARD AND SUBSEQUENT VIBRATION FELT THROUGHOUT THE AI RFRAME. ALL NR 1 ENGINE PARAMETERS IMMEDIATELY BEGAN TO DETERIORATE RAPIDLY. AT FL280, ENGINE FAILURE DRILL INITIATED A ND COMPLETED. ATC ADVISED OF ENGINE FAILURE. EMERGENCY DECLARED AND AIRCRAFT RETURNED. EMERGENCY CREW MET AIRCRAFT AN D AFTER INSPECTION OF ENGINE, AIRCRAFT WAS THEN TAXIED BACK TO RAMP AND SHUT DOWN. MORE TO FOLLOW AFTER INVESTIGATION. 2 L 7 3 4F 4 F A3WE E2EA 2004031500116 20040315 00116 EA 2004 3 15 CA040219005 1 20040129 G 2701 C3CF3915 CONTROL COLUMN DHAV DHC3 DHC3 2800202 EA PWA PT6 PT6A34 52043 EA HARTZL HCB3T HCB3TN3 GL COCKPIT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 14020 (CAN) CONTROL COLUMN FOUND CRACKED IN THREE LOCATIONS WHEN SB 3/39 CW. 1 H 7 1 3R 4 T A815 E4EA 6 C P15EA 2004031500126 20040315 00126 SO 2004 3 15 CA040219006 1 20040218 G 3213 4041304 AXLE PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2B 41532 EA HARTZL HCE3Y HCE3YR2A GL MLG BROKEN W C D ABORTED TAKEOFF RETURN TO BLOCK D INFLIGHT SEPARATION TX TAXI/GRND HDL 1 CA 16094 (CAN) PILOT WAS TAXIING OUT FOR TAKEOFF WHEN THE AXLE BROKE. VIBRATION AND NOISE WAS HEARD. TAXIED BACK AND DISCOVERED T HE MAIN WHEEL HAD TILTED OVER AND WAS RUBBING ON THE FORK ASSEMBLY. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004031500127 20040315 00127 EA 2004 3 15 CA040220001 2 20040219 G 8520 PISTON RING PIPER PA44 PA44180 7104402 SO LYC O360 O360* 41514 EA HARTZL HCC2Y HCC2YR2 GL ENGINE CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) CYLINDER NR 4 REMOVED DURING 100 HR INSPECTION DUE TO OIL CONTAMINATED SPARK PLUG. TOP COMPRESSION RING FOUND IN S EVERAL PIECES EMBEDDED INTO PISTON. ALL CYLINDERS REMOVED FROM BOTH ENGINES, 8 TOTAL AND 3 OTHER PISTONS FOUND WITH CRAC KED TOP COMPRESSION RINGS. NOTE THAT ALL OTHER CHECKS WHERE NORMAL, COMPRESSION TEST RESULTS ABOVE 70PSI. AFFECTED CYLI NDERS SENT TO OVERHAUL FACILITY FOR REPAIR/REPLACEMENT. 1 L 7 2 3O 3 O A19S0 E286 5 C P920 2004031500128 20040315 00128 2004 3 15 CA040220002 4 20040211 G 3416 24929412 ALTIMETER BEECH 99 99 1154002 CE PWA PT6 PT6A36 52043 NE HARTZL HCB3T HCB3TN3 GL COCKPIT FAILED W A UNSCHED LANDING P NO WARNING INDICATION CR CRUISE 1 CA 1535 (CAN) CAPTAIN'S ALTIMETER ERROR OF APPROXIMATELY 1,000 FEET CHECKED OK PRIOR TO DEPARTURE. NOT SURE WHEN FAILURE OCCURRE D, BUT NOTICED ERROR AT LEVEL CRUISE. MAINTENANCE CONFIRMED NO STATIC SYSTEM LEAKS. 1 L 7 2 3T 4 T A14CE E4EA 6 C P15EA 2004031500129 20040315 00129 CE 2004 3 15 CA040220003 1 20040211 G 3234 404EN16 SWITCH BEECH 99 99 1154002 CE PWA PT6 PT6A36 52043 NE HARTZL HCB3T HCB3TN3 GL MLG SELECTOR CONTAMINATED W A UNSCHED LANDING O OTHER AP APPROACH 1 CA (CAN) LANDING GEAR FAILED TO EXTEND WHEN SELECTED. APPROXIMATELY 1-5 MINUTES GEAR EXTENDING WITH NO ADDITIONAL CREW ACTI ONS. AIRCRAFT RETURNED TO MAINTENANCE BASE. AIRCRAFT EXPOSED TO -30 DEGREES COLD SOAK FOR APPROXIMATELY 3 HOURS. AIRCRAF T PREVIOUS OPERATED IN WARM CLIMATES FOR 20 YEARS. MAINTENANCE FOUND VERY DIRTY AND (GUMMED) SWITCHES IN LANDING GEAR CO NTROL HANDLE. FIRST EXPOSURE TO COLD CONDITIONS SINCE IMPORT. 1 L 7 2 3T 4 T A14CE E4EA 6 C P15EA 2004031500130 20040315 00130 WP 2004 3 15 CA040220004 1 20040216 G 2410 902241 WHEEL PRESTOLITE ROBSIN R44 R44 7640120 WP LYC O540 O540F1B5 41532 EA ALTERNATOR BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA F219612E (CAN) BROKEN ALTERNATOR FAN WHEEL. REPLACED WHEEL. 1 G 7 1 3O 3 O H11NM E295 2004031500131 20040315 00131 WP 2004 3 15 CA040220005 1 20040211 G 7711 LC80E1 TRANSMITTER DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE EPR FAILED W C ABORTED TAKEOFF N FALSE WARNING TO TAKEOFF 1 CA (CAN) TAKEOFF REJECTED DUE TO RT ENGINE EPR INDICATION INOPERATIVE. AIRCRAFT WAS DISPATCHED IAW MEL 77-1 FOR THE DAY. E PR TRANSMITTER REPLACED ON THE FOLLOWING DAY AND AIRCRAFT DISPATCHED SERVICEABLE. 2 L 7 2 4F 4 F RT A6WE E9NE 2004031500134 20040315 00134 CE 2004 3 15 CA040220006 1 20040213 G 2820 05001183 LINE CESSNA 172 172K 2072430 CE LYC O320 O320E2D 41508 EA MCAULY 1C172 1C172MTM GL FUEL SYSTEM CHAFED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) FUEL LINE WAS FOUND CHAFED DURING 200 HR INSPECTION. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2004031500148 20040315 00148 CE 2004 3 15 CA040220007 1 20040218 G 2133 47061 VALVE CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCB3T HCB3TN5 GL ENERGENCY PRESS FAILED W B G EMER. DESCENT O2 MASK DEPLOYED D J INFLIGHT SEPARATION WARNING INDICATION CL CLIMB 1 CA (CAN) DURING THE CLIMB THE AIRCRAFT EMERGENCY PRESSURIZATION VALVE OPENED WITH OUT BEING SELECTED. THE CREW DEPRESSURIZE D THE AIRCRAFT AND RETURNED TO BASE. THE EMERGENCY PRESSURIZATION VALVE WAS REPLACED AND THE AIRCRAFT SYSTEMS FUNCTION C HECKED SERVICABLE 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P15EA 2004031500149 20040315 00149 EA 2004 3 15 CA040220008 2 20040218 G 7510 909100999 HOSE BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA HARTZL HCB3T HCB3TN3 GL ANTI ICE SYSTEM CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) LT COWL ANTI ICE FLEX HOSE FOUND CRACKED DURING OPS 1 INSPECTION. 1 L 7 2 3T 4 T RT 3A20 E4EA 6 C P15EA 2004031500150 20040315 00150 EA 2004 3 15 CA040220009 2 20040202 G 7220 109910029121 DUCT BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA HARTZL HCB3T HCB3TN3 GL ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) LOWER FORWARD COWL AIR INLET DUCT CRACKED. REPAIR TO BE ACCOMPLISHED IAW MFG FIELD REPAIR PROCEDURE. 1 L 7 2 3T 4 T RT 3A20 E4EA 6 C P15EA 2004031500151 20040315 00151 CE 2004 3 15 CA040220010 1 20040202 G 5610 10138402523 WINDSCREEN BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA HARTZL HCB3T HCB3TN3 GL COCKPIT DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AIR CREW REPORTED THAT THE PILOTS WINDSCREEN WAS DISCOLOURED AT THE OB EDGES AND HAD A MILKY APPEARANCE. THE WINDS CREEN HAD PREVIOUSLY BEEN REPAIRED BY THE MFG. THE WINDSCREEN WAS REPLACED WITH A NEW UNIT AND THE DAMAGED UNIT WAS RETU RNED TO THE MFG FOR EVALUATION. 1 L 7 2 3T 4 T RT 3A20 E4EA 6 C P15EA 2004050300220 20040503 00220 GL 2004 5 3 CA040222001 1 20040220 G 2752 SEAL DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240B 17063 SO SNSNCH W69EK W69EK63 EA FLAP ACTUATOR LOOSE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) IT WAS FOUND THAT THE SPLINED RUBBER SEAL PUSHED OUT OF POSITION ON FLAP ACTUATOR ROD ASSY. ON THIS AIRCRAFT IT D ID NOT MAKE CONTACT WITH THE FLAP POSITION SWITCHES. THE COMPLETE ASSY WAS REMOVED AND SENT FOR INSPECTION. NEW ASSY IN STALLED. 1 L 7 1 3O 3 O NT TA4CH E7SO 5 N TA4CH 2004031500152 20040315 00152 EU 2004 3 15 CA040223001 1 20040221 G 2597 RDAV400111 WIRE AIRBUS 320 A320232 3930326 EU IAE V2527 V2527A5 NE VIDEO SYSTEM BURNED W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA (CAN) WHILE TROUBLE SHOOTING THE NON-DEPLOYMENT OF A VIDEO MONITOR IT WAS FOUND THAT THE JUNCTION BOX FOR THIS MONITOR H AD FAILED. THE UNIT SMELLED OF BURNED ELECTRICAL MATTER. THERE WHERE SIGNS OF ARCING SHOWING ON THE OUTSIDE CASE. THE AS SOCIATED MONITOR DID NOT WORK AND DID NOT WORK WITH ANOTHER JUNCTION BOX. BOTH THE MONITOR AND JUNCTION BOX WERE REPLACE D AND FUNCTIONED SERVICEABLE. THE JUNCTION BOX WILL BE INVESTIGATED. 2 L 7 2 4F 4 F RT A28NM E40NE 2004031500153 20040315 00153 NM 2004 3 15 CA040223002 1 20040217 G 5610 56100165 WINDOW BOEING 737 737201 1384454 NM PWA JT8 JT8D9A 52048 NE COCKPIT CRACKED W O OTHER O OTHER TX TAXI/GRND HDL 1 CA (CAN) UPON ARRIVAL AT GATE THE CREW NOTICED F/O NR 4 EYEBROW WINDOW CRACKED. SUSPECT INTERNAL O/HEAT WINDSHIELD SYSTEM C HECKED SERVICEABLE NR 4 EYEBROW WINDOW REPLACED AIRCRAFT RETURNED TO SERVICE 2 L 7 2 4F 4 F A16WE E2EA 2004031500154 20040315 00154 EU 2004 3 15 CA040223003 1 20040216 G 2910 10546641 MANIFOLD BOLKMS 117 BK117A1 5626010 EU HYD SYSTEM CORRODED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) UNIT SENT FROM THE USA FOR RECTIFICATION OF SEAL LEAKS. DURING DISSASEMBLY EXCESSIVE CORROSION WAS FOUND IN ONE OF THE VALVE MANIFOLD ATTACHMENT BOLT HOLES. BORE NOMINAL DIMENSION IS 6.4MM, BORE OVERSIZED TO 7.4MM AND CORROSION DAMAGE REMAINED. PART SCRAPED. BORE POSSIBLY DAMAGED DURING A PREVIOUS INSTALLATION OF THE BOLT. 1 G 7 2 3U H13EU 2004031500163 20040315 00163 CE 2004 3 15 CA040224001 1 20040218 G 7830 282D0007505 PRESSURE SWITCH EATON LEAR 60 60LEAR 5170707 CE PWA 305 PW305A 52128 NE HCU FALSE INDICATION W O OTHER L J NO TEST WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) WHILE TAXIING AIRCRAFT, FLIGHT CREW INCREASE ENGINE POWER. ONE THRUST REVERSER LIGHT STAYS ON. AFTER TROUBLESHOOT ING, MAINTENANCE REPLACED HYDRAULIC CONTROL UNIT. THE PRESSURE SWITCH INSIDE THE HCU GIVES A FALSE INDICATION. AIRCRAFT RETURN TO SERVICE. 2 L 7 2 4F 4 F RT A10CE E35NE 2004032500026 20040325 00026 EA 2004 3 25 CA040224002 2 20040216 G 7261 OIL SYSTEM PIPER PA31T PA31T 7103124 SO PWA PT6 PT6A28 EA HARTZL HCB3T HCB3TN3 GL RT ENGINE CONTAMINATED W O OTHER O OTHER LD LANDING 1 CA PCE51909 (CAN) PILOT REDUCED ENG POWER FOR LANDING AFTER FIRST FLIGHT OF DAY, RT ENGINE PRESSURE DECREASE WAS OBSERVED. TECH DIS COVERED LARGE QUANTITY OF CARBON IN ENGINE OIL FILTER. ENGINE WAS REMOVED AND SENT TO MFG FOR INVESTIGATION. ENGINE WA S DISSEMBLED AT THE (C FLANGE) FOR AN ITT PROBLEM. AFTER REASSEMBLY, ALL GROUND TESTS WERE PERFORMED AND AC WAS RETURNED TO SERVICE AND ENGINE OIL WAS ADDED. AN INTERNAL INVESTIGATION DETERMINED THAT CARBON DISCOVERED IN FILTER WAS MADE OF LITTLE BLACK STONES. FUNNEL THAT WAS USED TO ADD ENGINE OIL WAS LOCATED, INSPECTED AND CLEANED AND SAME LITTLE BLACK STO NES WERE DISCOVERED IN THE FUNNEL. WE WERE NOT ABLE TO DETERMINE THE ORIGIN OF THE LITTLE BLACK STONES. 1 L 7 2 3T 4 T A8EA E4EA 6 C P15EA 2004031500164 20040315 00164 CE 2004 3 15 CA040224003 1 20040216 G 3240 RIVET CLEVELAND BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA MCAULY 4HFR34 4HFR34C652 NE BRAKE PAD RIVETS SHEARED W K NONE O OTHER IN INSP/MAINT 1 CA 1544 (CAN) BRAKE ASSEMBLY S/N 1544 WAS FOUND WITH THE BRAKE PAD RIVETS SHEARED ALLOWING THE PADS TO BECOME DISLODGED, THIS IS THE SECOND TIME WE HAVE HAD WEAR PADS BEING DISLODGED FROM THE PRESSURE PLATE ASSEMBLY. THIS BRAKE ASSEMBLY WAS IN SER VICE FOR ONE YEAR SINCE NEW. NO TIMES AVAILABLE. 1 L 7 2 4T 4 T A24CE E4EA 6 C 3PNE 2004050300221 20040503 00221 EA 2004 5 3 CA040224004 2 20040217 G 7310 3011587 BEARING BEECH 100 100BEECH 1152916 CE PWA PT6 PT6A28 EA HARTZL HCD4N3 HCD4N3A GL FCU ROD END LOOSE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ON INSPECTION, THE ROD ENDS WERE FOUND TO BE BADLY WORN ON THE ROD FROM THE START CONTROL TO FUEL CONTROL UNIT. 1 L 7 2 3T 4 T A14CE E4EA 5 C STC 2004050300222 20040503 00222 NM 2004 5 3 CA040224005 1 20040224 G 3220 65462154 TORQUE LINK BOEING 737 7372T2 1384491 NM PWA JT8 JT8D17 52049 NE NLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 33572 (CAN) DURING THE SCHEDULED NOSE LANDING GEAR SEAL CHANGE AT THE C CHECK, A CRACK WAS DISCOVERED AT THE LOWER TORQUE LINK ATTACHMENT LUG. THE FINDING RESULTED IN THE TORQUE LINK BEING REPLACED. NOTE A FLEET CAMPAIGN HAS BEEN ISSUED TO VISU ALLY INSPECT ALL TORQUE LINKS ON FLEET. 2 L 7 2 4F 4 F RT A16WE E2EA 2004042700073 20040427 00073 EU 2004 4 27 CA040224006 1 20040220 G 3260 WARNING LIGHT PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL LT MLG ILLUMINATED W O OTHER N FALSE WARNING LD LANDING 1 CA (CAN) 3 GREEN ANNUNICATOR LIGHTS CAME AS WELL AS RED WARNING LIGHT ON LT MLG. AC DID FLY OVER TO CONFIRM LT MLG WAS DOW N. PILOT SELECTED 30 DEGREES OF FLAP TO SLOW AC DOWN. WHEN 30 DEGREES OF FLAP WAS REACHED, 3 RED WARNING LIGHTS FOR LT MLG CAME ON. AC LANDED WITHOUT INCIDENT. WHEN TAXING TO HANGAR, FLAPS WERE RETRACTED TO 15 DEGREES, 3 RED WARNING LIGHT S WENT OUT INDICATING LT MLG SYS WAS NORMAL. AC JACKED AND MLG CYCLED TO DUPLICATE PROBLEM. SYS OPERATED NORMAL. PINS OF CONNECTOR WERE SPRAYED WITH ELECTRICAL CONTACT CLEANER AND REINSTALLED ON TO ACTUATOR. OTHER WIRES IN SYS WERE INSPECTE D, LT MLG CYCLED SEVERAL TIMES AND NO DEFECTS FOUND. AC WAS RELEASED BACK TO SERVICE. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004031500170 20040315 00170 2004 3 15 CA040225001 4 20040213 G 3497 MS2536175 CIRCUIT BREAKER CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE EDU INOPERATIVE W O OTHER O OTHER TO TAKEOFF 1 CA (CAN) DURING TAKE OFF ROLL (LESS THAN 20 KTS), THE CAPT'S PFD, MFD, NR 2 EDU AND NR 1 RTU WENT BLANK THAN CAME BACK ON. REPLACED 75 AMP. DC ESS FEED, CIRCUIT BREAKER IN LT DCPC. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2004031500175 20040315 00175 EA 2004 3 15 CA040225002 1 20040218 G 3340 2LA00691307 LIGHT CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE COCKPIT INOPERATIVE W O OTHER B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 CA (CAN) FLOODLIGHT CAUSED SMOKE IN THE FLT DECK. CB POPPED AND WHEN FLOOD LIGHT WAS TURNED OFF IT QUIT SMOKING. FLOOD LI GHT ASSEMBLY WAS REPLACED. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2004031500176 20040315 00176 EA 2004 3 15 CA040225003 1 20040220 G 5610 NP1393226 WINDOW CNDAIR CL600 CL6002B19 1900309 EA COCKPIT CRACKED W O OTHER O OTHER CR CRUISE 1 CA (CAN) DURING CRUISE THE FIRST OFFICER'S SIDE WINDOW HAD A PLY CRACK. THE SIDE WINDOW WAS THE OLDER CONFIGURATION. THE WI NDOW WAS REPLACED IAW AMM. 2 L 7 2 4F RT A21EA 2004050300224 20040503 00224 NE 2004 5 3 CA040225004 2 20040225 G 7200 ENGINE AIRBUS 320 A320211 3930320 EU CFMINT CFM56 CFM565A1 NE NR 1 STALLED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) REPEAT NR 1 ENG STALL. (MORE INFO WILL FOLLOW) 2 L 7 2 4F 4 F RT A28NM E29NE 2004031500177 20040315 00177 CE 2004 3 15 CA040225005 1 20040121 G 2710 051010513 CONTROL CABLE CESSNA 180 180C 2072608 CE CONT O470 O470K 17026 SO MCAULY 2A34C 2A34C203 GL AILERON FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) CABLE FRAYED AT PULLEY AREA. WING ROOT PULLEY WAS NOT SEIZED. 1 H 7 1 3O 3 O 5A6 E273 5 C P3EA 2004031500180 20040315 00180 EA 2004 3 15 CA040225008 1 20040223 G 5247 70821271 BRACKET CNDAIR CL600 CL6002C10 1390015 EA APU DOOR LOOSE W O OTHER J WARNING INDICATION LD LANDING 1 CA (CAN) APU SHUT DOWN BY ITSELF UPON LANDING AT APROX. 100 KTS. INVESTIGATION REVEALED THAT 2 BOLTS MS9556-45 SECURING APU INLET DOOR ARM TO CLAMP WERE NOT TORQUED PROPERLY AND INLET DOOR SHAFT SLIPPED AND CLOSED DOOR UPON FINAL LANDING DUE T O VIBRATION. APU SHUT DOWN WAS IMMINENT. ATTEMPT TO RESTART DURING TAXI WAS UNSUCCESSFUL. IN 2 PREVIOUS FLIGHT, APU SHUT DOWN OCCURRED AT 41000 FT AT 4.5 HRS. DOOR RIGGING WAS ADJUSTED BUT REAL CAUSE NOT YET DISCOVERED AT THAT POINT. 2 BOL TS WERE RETORQUED AND FUNCTIONAL CHECK CARRIED OUT AND FOUND SERVICEABLE. 2 L 7 2 4F RT A21EA 2005011200005 20050112 00005 EA 2005 1 12 CA040225010 1 20040224 G 5220 CC670380011 ESCAPE HATCH CNDAIR CL600 CL6002C10 1390015 EA COCKPIT UNLOCKED W O OTHER D INFLIGHT SEPARATION LD LANDING 1 CA (CAN) IMMEDIATELY FOLLOWING FINAL LANDING WHILE DECELERATING THROUGH 70 KTS & DEPRESSURIZING AIRCRAFT, COCKPIT ESCAPE HA TCH FELL OPEN INSIDE THE COCKPIT. INVESTIGATION REVEALED THAT NEITHER THE PILOT OR THE ACA HAD CONFIRM ALIGNMENT OF LOCK PINS WITH GREEN BANDS BEFORE INTENDED FLIGHT BUT THE HANDLE WAS STOWED. COMPLETE MANUFACTURING FUNCTIONAL CHECK WERE CA RRIED OUT ON THEESCAPE HATCH AND WAS FOUND SERVICEABLE. SUSPECT DOOR NOT PROPERLY LOCKED (POSIT IVELY) AND VIBRATIONS AN D MULTIPLE LANDINGS WAS SUFFICIENT TO COMPLETELY UNLOCK THE PINS AND OPEN THE DOOR. THE HATCH COULDN'T BE OPEN WHILE PRE SSURIZED. ISOLATED CASE. PILOT CHECK LIST WILL BE REVISED TO SHOW DOOR CLOSED AND LOCKED IN LIEUOF CLOSED AND LATCHED. 2 L 7 2 4F RT A21EA 2004032500036 20040325 00036 CE 2004 3 25 CA040225011 1 20040224 G 2750 14601008 CONTROL CABLE CESSNA 337 337A 2075704 CE CONT O360 IO360C 17025 SO MCAULY 2AF34C D2AF34C59 GL TE FLAPS FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) FLAP CABLES REMOVED FOR INSPECTION DUE TO SERVICE DIFFICULTY ALERT AL-2003-05. LT AND RT OUTBOARD FLAP CABLES FOUN D TO BE FREYED AT THE INBOARD BELLCRANK, APPROXIMATELY 1 INCH FROM THE SWAGGED TERMINAL. BOTH CABLES ARE ORIGINAL CESSNA FLAP CABLES AND WERE REPLACED WITH NEW CESSNA FLAP CABLES. ALSO, THE RT, INBOARD FLAP CABLE WAS FREYED AT THE INBOARD B ELLCRANK, APPROXIMATELY 1 INCH FROM THE SWAGGED TERMINAL. 1 H 7 2 3O 3 O A6CE E1CE 5 C P5EA 2004050300230 20040503 00230 NM 2004 5 3 CA040225012 1 20040225 G 2710 550030017 ACTUATOR BOEING 767 767375 1385217 NM GE CF6 CF680C2B6F 30025 NE RT AILERON STUCK W K NONE O OTHER IN INSP/MAINT 1 CA 66125 (CAN) EICAS MESAGE AILERON LOCKOUT, FOUND RT AILERON LOCK OUT ACTUATOR STUCK IN THE EXTEND POSITION, ACTUATOR REPLACED. 2 L 7 2 4F 4 F RT A1NM E13NE 2004050300232 20040503 00232 SW 2004 5 3 CA040225013 1 20040218 G 2140 BEARING BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL HEATER FAILED W H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) DURING FLIGHT PILOT COULD SMELL SOMETHING ABNORMAL, HE LOOKED AT CB PANEL AND NOTICED HELICRAFT HEATER CB SWITCH H AD TRIPPED. HE THEN TURNED OFF BLEED AIR TO PREVENT HEAT DAMAGE, ONCE BLOWER WAS REMOVED IT WAS DETERMINED THAT THE BEAR INGS HAD FAILED. 1 G 7 1 3U 3 U H2SW E4CE 2004032500037 20040325 00037 CE 2004 3 25 CA040225014 1 20040224 G 2750 14601007 CONTROL CABLE CESSNA 337 337A 2075704 CE CONT O360 IO360C 17025 SO MCAULY 2AF34C D2AF34C59 GL TE FLAPS FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) FLAP CABLES REMOVED FOR INSPECTION, REFERENCE SD ALERT AL-2003-05 IB FLAP CABLE, RT SIDE, PART NR 1460100-7 FRAYED APPROX 50 PERCENT AT IB BELLCRANK. 1 INCH FROM SWAGGED TERMINAL. ALSO BOTH OB CABLES PN 1460100-8 FRAYED AT IB BELLCRAN K, APPROX. 1 INCH FROM SWAGGED TERMINAL. ALL CABLES ARE ORIGINAL FLAP CABLES AND HAVE BEEN REPLACED WITH NEW FLAP CABLES SUPPLIED BY MFG. 1 H 7 2 3O 3 O A6CE E1CE 5 C P5EA 2005011200006 20050112 00006 GL 2005 1 12 CA040225015 3 20040218 G 6114 A251352 BOLT CESSNA 150 150M 2071830 CE CONT O200 O200A 17020 SO MCAULY 1A102 1A102OCM GL PROPELLER BROKEN W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) PROPELLER BOLTS WERE BEING INSTALLED AND TORQUED TO THE SPECIFIED VALUE OF 25 - 30 POUNDS FOOT. AS THE TORQUE WAS REACHING APPROXIMATELY 27 FOOT POUNDS, THE BOLT BROKE. THE BREAK WAS WHERE THE THREADS MEET THE GRIP. A SECOND BOLT WAS TORQUED AND IT BROKE AT APPROXIMATELY THE SAME TORQUE VALUE AND AT THE SAME LOCATION. 1 H 7 1 3O 3 O 3A19 E252 5 N P918 2005011200007 20050112 00007 CE 2005 1 12 CA040225016 1 20040219 G 3397 LIGHT BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE PAX CABIN MISWIRED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) A 1900 D LANDED AT A MX BASE WITH 3 ELECTRICAL SNAGS. CABIN LIGHTS WOULD INTERMITTENTLY CHANGE FROM PARTIAL TO FUL L. ON LANDING, GROUND FINE SELENOIDS WERE CHANGING FROM FLT MODE TO GROUND MODE AND STEERING DISCONNECT ACTUATOR CYCLED FROM GROUND TO FLT MODES NUMEROUS TIMES. IN DEPTH INVEST REVEALED THAT WIRING OF CABIN & READING LIGHTS WAS NOT IN ACCOR DANCE WITH WIRING MANUAL. IT APPEARS FROM MANUFACTURE, THE POSITIVE LEAD WAS NOT ALWAYS INSTALLED ON HOT SIDE OF BULBS. GENERAL FEELING IS THAT THE ELECTRICAL BUSS WAS BEING BACKFED 28VDC. THE LIGHTING SYSTEM WAS REWIRED IAW THE WIRING MANU AL AND ALL THREE SYSTEMS FUNCTIONED NORMALLY. A FLEET WIDE INSPECTION AND RECTIFICATION OF THE WIRING IS IN PROGRESS. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2005011200008 20050112 00008 EU 2005 1 12 CA040225017 1 20040224 G 2750 5757117701600 SENSOR AIRBUS A340 A340313 EU CFMINT CFM56 CFM565C4 13802 NE TE FLAPS MALFUNCTIONED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) AFTER TAKE OFF ABOUT 100 FOOT ABOVE GROUND LEVEL FLAPS LOCK ECAM MESSAGES, TRIED RESET , NIL FIX, RETURN TO GATE. RESET OF THE COMPUTER SLAT FLAP COMPUTERS ON GROUND FIXED THE PROBLEM BUT SAME THING HAPPENNED ON THE SECOND ATTEMPT. AI RCRAFT UNDER INVESTIGATION 2 L 7 4 4F 4 F RT A197 E37NE 2004050300240 20040503 00240 EA 2004 5 3 CA040226001 1 20040221 G 2497 VOLT REGULATOR DHAV DHC6 DHC6300 2802606 EA PWA PT6 PT6A27 52043 EA HARTZL HCB3T HCB3TN3 GL ELECTRICAL FAILED W A UNSCHED LANDING B G H SMOKE/FUMES/ODORS/SPARKS MULTIPLE FAILURE ELECT. POWER LOSS-50 PC CR CRUISE 1 CA (CAN) AFTER DEPARTURE, THE AIRCRAFT SUFFERED A COMPLETE ELECTRICAL FAILURE. THE CREW NOTICED A BURNING ODOR. THE AIRCRAF T RETURNED WITHOUT FURTHER INCIDENT. UPON INVESTIGATION IT SEEMS LIKE A VOLTAGE SURGE OCCURRED, BOTH GPS ACU'S, BOTH COM M'S, RCR, DME, NR 1 NAV, NR 1 VOLTAGE REGULATOR ARE ALL UNSERVICEABLE AFTER THE EVENT. 1 H 7 2 3T 4 T RT A9EA E4EA 6 C P15EA 2004032500038 20040325 00038 EU 2004 3 25 CA040226002 1 20040217 G 6410 10531980 BLADE UROCOP BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20 03013 GL TAIL ROTOR PEELING W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) TAIL ROTOR BLADES RECEIVED FROM MFG WITH THE PAINT REFINISHED AFTER REPAIR OR INSPECTION ARE PEELING OR SHREDDING TO THE BLADE BODY SURFACE BELOW. THIS IS OCCURRING USUALLY WITHIN THE FIRST 100 HOURS OF OPERATION. THE NEW REFINISHED PAINT SURFACE IS THICK ENOUGH TO PROTRUDE CONSIDERABLY ABOVE THE LEADING EDGE ABRASION STRIP CAUSING THE PAINT TO PEEL BACK ON THE SURFACE OF THE BLADE, CAUSING IMBALANCE, AND BLADE SURFACE TO BE SUSCEPTIBLE TO MOISTURE. THE PAINT REFINISH ING PROCESS APPEARS TO BE TOO THICK WITH NO TRANSITION POINT TO THE LEADING EDGE ABRASION STRIP. THIS IS AN ON GOING PRO BLEM INVOLVING NUMEROUS TAIL ROTOR BLADE SETS FOR THE PAST 18 MONTHS. 1 G 7 2 3U 3 U H3EU E4CE 2004032500039 20040325 00039 EA 2004 3 25 CA040226003 1 20040224 G 2421 721428 IDG CNDAIR CL600 CL600* EA LYC ALF502 ALF502* 41580 EA LT ENGINE LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) OIL NOTED LEAKING FROM LT ENGINE DRAIN MAST. INTEGRATED DRIVE GENERATOR REMOVED AND ACCESSORY DRIVE GARLOCK SEAL AND IDG SHAFT O-RING REPLACED. LEAK RETURNED AT DRAIN MAST TWO DAYS LATER. IDG WAS REMOVED AND INSPECTED. THE LEAK WA S DETERMINED TO ORIGINATE FROM THE INTEGRATED DRIVE GENERATOR CARBON SEAL. THIS IS AN ABNORMAL OCCURRENCE. IDG REPLACED WITH SERVICEABLE UNIT. 2 L 7 2 4F 4 F RT A21EA E6NE 2004032500040 20040325 00040 EA 2004 3 25 CA040226004 2 20040224 G 7322 G20102 FLOAT VALVE CNDAIR CL600 CL600* EA LYC ALF502 ALF502* 41580 EA CARBURETOR CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING GROUND RUN MAINTENANCE NOTED A RUMBLE FROM THE RT ENGINE AT HI IDLE AND BELOW. THE ECOLOGY TANK FLOAT VALV E WAS REMOVED AND THE FLOAT WAS FOUND TO BE CORRODED AND DETERIORATED PREVENTING PROPER VALVE OPERATION. THE VALVE WAS H ELD OPEN ALLOWING AIR TO BE DRAWN INTO THE INLET SIDE OF THE ENGINE DRIVEN FUEL PUMP CAUSING THE PUMP TO CAVITATE. ABOVE HIGH IDLE THE EJECTOR VALVE CLOSES THE SUCTION LINE PREVENTING FURTHER CAVITATION AND STOPPING THE RUMBLE. A NEW FLOAT VALVE WAS INSTALLED AND A SUBSEQUENT GROUND RUN CONFIRMED THE REPAIR. 2 L 7 2 4F 4 F RT A21EA E6NE 2004050300242 20040503 00242 WP 2004 5 3 CA040226006 2 20040224 G 7200 TPE33110UA ENGINE SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP HARTZL HCE4N HCE4N3 NE RIGHT MAKING METAL W E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA 22198 P54043 (CAN) ONCE AT LEVEL FLIGHT THE RT ENGINE OIL PRESSURE WAS NOTICE TO BE AT THE LOWER END OF THE GREEN ARC 70 PSI, THE OIL PRESSURE WAS MONITORED UNTIL IT DROPPED TO 65 PSI AND THE CREW ELECTED TO RETURN. THE PRESSURE REMAINED STABLE AT 65 PS I, UNTIL TOUCHDOWN WHERE THE OIL PRESSURE DROPPED TO ZERO. THE ENGINE WAS SECURED AND THE LANDING COMPLETED WITHOUT FURT HER INCIDENT. A SUBSEQUENT INSPECTION REVEALED EXCESSIVE METAL IN THE OIL FILTER, THE LT ENGINE WAS REMOVED FOR REPAIR. FOLLOWUP INFORMATION WILL BE ADDED ONCE TEAR DOWN AND ANALYSIS IS COMPLETE. 2 L 7 2 4T 4 T RT A8SW E4WE 5 C P10NE 2004050300243 20040503 00243 WP 2004 5 3 CA040227001 2 20040224 G 7200 TPE33110UA ENGINE SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP HARTZL HCE4N HCE4N3 NE RIGHT MAKING METAL W E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA 22198 P54043 (CAN) ONCE AT LEVEL FLIGHT THE RT ENGINE OIL PRESSURE WAS NOTICE TO BE AT THE LOWER END OF THE GREEN ARC 70 PSI, THE OIL PRESSURE WAS MONITORED UNTIL IT DROPPED TO 65 PSI AND THE CREW ELECTED TO RETURN. THE PRESSURE REMAINED STABLE AT 65 PS I, UNTIL TOUCHDOWN WHERE THE OIL PRESSURE DROPPED TO ZERO. THE ENGINE WAS SECURED AND THE LANDING COMPLETED WITHOUT FURT HER INCIDENT. A SUBSEQUENT INSPECTION REVEALED EXCESSIVE METAL IN THE OIL FILTER, THE LT ENGINE WAS REMOVED FOR REPAIR. FOLLOWUP INFORMATION WILL BE ADDED ONCE TEAR DOWN AND ANALYSIS IS COMPLETE. 2 L 7 2 4T 4 T RT A8SW E4WE 5 C P10NE 2005011200009 20050112 00009 SW 2005 1 12 CA040227002 1 20040226 G 2140 1898221 HEAT EXCHANGER SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP AIR CON SYS CONTAMINATED W A UNSCHED LANDING W B INADEQUATE Q C SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) ACFT LEVELED OFF IN CRUISE, FLT CREW NOTICED A FOUL ODOUR. FUMES BECAME QUITE STRONG & FLT CREW CALLED MX & RETURN ED TO BASE. ENROUTE, SEVERAL PAX WERE SUPPLIED O2 DUE TO ODOUR. UPON INSP OF ACFT & MX RECORDS FROM PREVIOUS NIGHT, AIR TO AIR HEAT EXCHANGER ASSY FOR RT WING AIR CON SYS FOUND REPLACED. UPON REMOVAL OF EXCHANGER, ODOUR FOUND TO BE COMING F ROM HEAT EXCHANGER ITSELF. ODOUR ASSOCIATED WITH CHEMICALS USED IN REPAIR PROCESS OF EXCHANGER. REPAIR FACILITY CONTACTE D ABOUT CHEMICALS & PROCEDURES USED FOR REPAIR OF HEAT EXCHANGERS & NORMAL PROCESS TO FLUSH EXCHANGER. IT APPEARS AS THO UGH ISOPROPYL FLUSH & OVEN DRYING PROCESS WERE MISSED ON ALL 4 HEAT EXCHANGERS. 2 L 7 2 4T 4 T RT A8SW E4WE 2004050300248 20040503 00248 NE 2004 5 3 CA040227003 2 20040206 G 7322 PD12H4 CARBURETOR DOUG DC3 DC3C 3021457 WP PWA R1830 R183092 52020 NE HAMSTD 23E 23E50 NE ENGINE OUT OF ADJUST W K NONE O OTHER IN INSP/MAINT 1 CA CP356035 (CAN) AIRCRAFT LANDED AND THROTTLES RETURNED TO IDLE, THE NR 2 ENGINE LOADED UP AS IF IT WAS EXCESSIVELY RICH AND THE EN GINE STOPPED. IT WAS IN TAXI PHASE SO THE AIRCRAFT ROLLED TO PARKING POSITION. MAINTENANCE FOUND THAT THE IDLE MIXTURE W AS EXCESSIVELY RICH AND WOULD NOT RESPOND TO ADJUSTMENT CARBURETOR WAS REPLACED AND THE AIRCRAFT RELEASE FOR RETURN TO S ERVICE. CARBURETOR WITH ONLY 3.8 HOURS TSO, WAS SENT FOR WARRANTY AND REPORT OF DEFECT. 2 L 7 2 4R 4 R A669 5E4 6 C P603 2004050300251 20040503 00251 CE 2004 5 3 CA040228001 1 20040227 G 2720 AN2311 CLEVIS BOLT CESSNA 206 206CESSNA 2073302 CE CONT O520 IO520F 17032 SO MCAULY 2A34C D2A34C58 GL RUDDER BELCRANK WORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) RUDDER CABLE CLEVIS BOLTS INSPECTED DURING ROUTINE INSPECTION FOUND TO BE WORN APPROX. 30 PERCENT THROUGH THE BOLT . NEW CLEVIS BOLTS PART NUMBER AN23-11 INSTALLED. 1 H 7 1 3O 3 O A4CE E5CE 5 C P3EA 2004050300252 20040503 00252 SO 2004 5 3 CA040301001 1 20040219 G 2497 W23X1A1G20 CIRCUIT BREAKER PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL BURNED W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 CA (CAN) CIRCUIT BREAKER SENT FOR EVALUATION. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004050300264 20040503 00264 EU 2004 5 3 CA040301003 1 20040224 G 2420 5243212137 DRIVE SHAFT PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL GENERATOR SHEARED W O OTHER H ELECT. POWER LOSS-50 PC CR CRUISE 1 CA (CAN) ON RETURN FLIGHT, THE FLIGHT CREW HAD A GEN 2 FAILURE SO DECREASED ELECTRICAL LOAD AND CONTINUED TO MAINTENANCE BA SE. MAINTENANCE REMOVED THE GEN 2 AND INSPECTED IT FOR ANY FAULTS. A REPLACEMENT GENERATOR WAS BEING INSTALLED WHEN IT WAS NOTICED THAT THE DRIVE PULLEY WAS LOOSE AND DID NOT SEEM TO BE CONNECTED TO THE ENGINE. THE HOUSING WAS REMOVED AND THE DRIVE SHAFT WAS FOUND TO BE SHEARED, NO OTHER DAMAGE WAS NOTICED. A NEW SHAFT, BEARINGS AND GASKET WERE INSTALLED. SYSTEM WAS GROUND TESTED SERVICEABLE. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004050300270 20040503 00270 NM 2004 5 3 CA040301004 1 20040215 G 2150 7786832 HEAT EXCHANGER DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE CABIN AIR CRACKED W O OTHER O OTHER CR CRUISE 1 CA 15073 (CAN) PILOT REPORTED UNABLE TO CONTROL CABIN ALTITUDE AT LOWER POWER SETTINGS. AFTER ARRIVAL MAINTENANCE FOUND FORWARD HEAT EXCHANGE CRACKED/SPLIT OPEN. UNIT REPLACED AND AIRCRAFT RETURNED TO SERVICE. NOTE: THIS HEAT EXCHANGER HAD BEEN RE PAIRED FOR (CRACK ALONG INSIDE WELD OF PRIMARY INLET HEADER) IN MAY OF 2002. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004050300275 20040503 00275 EU 2004 5 3 CA040301005 1 20040216 G 5302 350A2310534451 SUPPORT SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE TAIL BOOM CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) A CRACK WAS DISCOVERED IN MAY ON THE NR 5 HANGER BEARING SUPPORT. THIS PART WAS REPLACED IN THE FIELD USING ALL TH E APPROPIATE TOOLING. SOMETIME LATER THE PILOT COMPLAINED OF A HIGH FREQ VIBRATION. THE SHAFT WAS REBALANCED TO .2 IPS. AGAIN ABOUT 20 HOURS LATER THE PILOT COMPLAINED OF A HIGH FREQ, AGAIN IT WAS DETERMINED THE SHAFT WAS OUT OF BALANACE. FURTHER INVESTIGATION DETERMINED THE HANGER SUPPORT WAS AGAIN CRACKED. 1 G 7 1 3U 3 U H9EU E19EU 2004050300276 20040503 00276 CE 2004 5 3 CA040301006 1 20040225 G 7810 17540071 TUBE CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160CTM GL EXHAUST CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) HAIRLINE CRACK IN TUBING, AROUND APPROXIMATELY .25 OF THE CIRCUMFERENCE, IMMEDIATELY BELOW WELDED FLANGE. CRACK WA S ON IB SIDE OF FLANGE AND NOT READILY VISIBLE. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2004050300277 20040503 00277 EA 2004 5 3 CA040301007 2 20040229 G 7210 3021467 BEARING PWA BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA REUX GEARBOX DISINTEGRATED W A UNSCHED LANDING J WARNING INDICATION AP APPROACH 1 CA (CAN) VISUAL INSPECTION REVEALED BEARING RETAINING FAILURE. APRROXIMATELY ONE QUARTER OF RETAINER MISSING. WILL SEND TO PWC FOR EXAMINATION. 1 G 7 1 4U 4 U H4SW E22EA 2004050300278 20040503 00278 NE 2004 5 3 CA040302001 3 20040223 G 6114 73030SOCN817388 SEAL HAMSTD DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE BLADE LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA 20030512 (CAN) EXCESSIVE OIL LEAK FROM RT PROP, NR 3 BLADE. BLADES NR 1, 3, 4 REMOVED, BLADE SEALS AND SPRING ASSEMBLIES INSPECT ED. ON INSP ONE SEAL WAS FOUND TO BE BADLY SPLIT WITH A DISTORTED SPRING. OTHER 2 BLADE SEALS SPRING ASSEMBLIES WERE BRO KEN AND SHOWING SIGNS OF DISTORTION. ALL 3 BLADE SEAL AND SPRING ASSEMBLIES WERE REPLACED WITH NEW. LEAK CHECK CARRIED OUT, NIL LEAKS. NR 2 BLADE SEAL AND SPRING ASSEMBLY PREVIOUSLY REPLACED DUE TO OIL LEAK, SPRING WAS FOUND TO BE BROKEN DURING REPLACEMENT. LT PROP INSPECTED AS PRECAUTIONARY MEASURE, NR 1, 4 BLADES CHECKED SERVICEABLE, NR 2, 3 BLADE SEALS FOUND TO BE DAMAGED DUE TO INCORRECT SPRINGS FITTED. NEW SEALS AND SPRING ASSEMBLIES FITTED, NO DEFECTS. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004050400002 20040504 00002 EA 2004 5 4 CA040302002 2 20040221 G 7230 BLADE DHAV DHC7 DHC7102 2802708 EA PWA PT6 PT6A50 52043 EA HAMSTD 24PF 24PF305 GL COMPRESSOR SEPARATED W E A ENGINE SHUTDOWN UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) ON 2ND FLIGHT OF THE DAY, A SUDDEN PARTIAL POWER LOSS OCCURRED ON NR 1 ENGINE, A STRONG SMELL ACCOMPANIED THE POWE R LOSS. ENGINE NR 1 WAS SUBSEQUENTLY SHUT DOWN. THE AIRCRAFT COMPLETED AN UNEVENTFUL UNSCHEDULED LANDING. UPON SUBSEQU ENT INSPECTION IT WAS FOUND THAT ENGINE SUFFERED SEVERE DAMAGE TO THE COMPRESSOR SECTION RESULTING FROM THE LOSS OF A BL ADE FORM THE FIRST STAGE COMPRESSOR. THE BLADE WAS FOUND STUCK IN THE INLET SCREEN AND ALL THE FIRST STAGE BLADES SUFFE RED SEVERE DAMAGE. THE ENGINE WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 2 H 7 4 4T 4 T A20EA E4EA 6 C P1NE 2004050400003 20040504 00003 WP 2004 5 4 CA040302003 1 20040131 G 2435 150SG117Q STARTER GEN HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL ENGINE BURNED W B EMER. DESCENT H A D ELECT. POWER LOSS-50 PC FLAME/FIRE INFLIGHT SEPARATION CR CRUISE 1 CA (CAN) WHILE IN FLIGHT PILOT NOTICED NR BEGIN TO DROP. HE INITIATED AN AUTOROTATION, HEARD A LOUD BANG, AND THE RPM CAME BACK UP. UPON LANDING FLAMES AND SMOKE WERE NOTICED IN THE ENGINE BAY. PILOT EXTINGUISHED FIRE AND DETERMINED IT WAS THE STARTER GENERATOR. IT APPPEARS THE BEARINGS SEIZED WHICH WAS BRINGING DOWN THE ENGINE RPM UNTIL THE SG SHAFT SHEARED. 1 G 7 1 3U 3 U H3WE E4CE 2004050400006 20040504 00006 2004 5 4 CA040302004 4 20040214 G 5301 143232 CABLE 143232 HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL HOOK END FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) PILOT HAD UNCOMMANDED LOAD RELEASE. INVESTIGATION DETERMINED THAT A FRAYED MANUAL RELEASE CABLE HAD CAUSED THIS PR OBLEM. IT WAS BADLY FRAYED WHERE THE CABLE WENT INTO THE CARGO HOOK. 1 G 7 1 3U 3 U H3WE E4CE 2004050400007 20040504 00007 2004 5 4 CA040302005 4 20040225 G 5301 143232 CABLE 143232 HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL HOOK END FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) PILOT HAD UNCOMMANDED LOAD RELEASE. INVESTIGATION REVEALED THAT THE MANUAL RELEASE CABLE HAD FRAYED WHERE THE CABL E GOES INTO THE CARGO HOOK. THIS CAUSED THE HOOK TO RELEASE. THIS IS A ONBOARD SYSTEMS KEEPERLESS HOOK. 1 G 7 1 3U 3 U H3WE E4CE 2004050400008 20040504 00008 SW 2004 5 4 CA040302006 1 20040224 G 2822 2C271 PUMP BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL FUEL BOOST DESTROYED W E F ENGINE SHUTDOWN ACTIVATE FIRE EXT. A FLAME/FIRE NR NOT REPORTED 1 CA (CAN) DURING GROUND RUN FOR MAINTENANCE ACTIVITY STROBING OF TAIL ROTOR ASSEMBLY AN EXPLOSING AND SUBSEQUENT FIRE OCCURR ED IN THE FUEL CELL ASSEMBLY AND AFT PASSENGER COMPARTMEN. AIRCRAFT WAS ON ITS FOURTH START OF THE DAY FOR TAIL ROTOR B ALANCING CHECK, FIRE EXTINGUISHED. AIRCRAFT SUFFERED SERIOUS STRUCTUREAL DAMAGE. MINOR GROUND MAINTENANCE PERSONNEL INJ URY. 1 G 7 1 3U 3 U H2SW E4CE 2004050400009 20040504 00009 EA 2004 5 4 CA040302007 1 20040221 G 3897 4E32644 DRAIN MAST CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE WATER SYS SHORTED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) FWD GALLEY WATER SYSTEM PUMP WAS NOT OPERATING. TROUBLESHOOTING REVEALED THAT A WIRE BEHIND THE GALLEY WAS AT FAUL T, NO COMMAND WAS BEING SENT TO THE PUMP. MAINT REMOVED THE GALLEY AND FOUNDTHE WIRING FROM THE PORTABLE WATER SYSTEM C ONTROLLER TO BE DAMAGED FROM OVERHEATING, SPECIFICALLY WIRES GBG7044W-22 & GBG7044B-22 TO THE DRAIN HEATERS FROM A177P3 PINS 20 AND 21. THIS OVERHEATING HAD ALSO AFFECTED ADJACENT WIRES OVER A CONSIDERABLE LENGTH, REQUIRING REPLACEMENT OF E NTIRE WIRING BUNDLE FROM THE PWS CONTROLLER, HARNESS PN SH670-59071-001. THIS HARNESS INCLUDES THE WIRING FROM PLUGS A17 7P1, A177P2, A177P3 AND A177P4. A SHORT WAS FOUND IN THE HEATING CIRCUIT OF DRAIN MAST ASSY HR02 (P/N 4E3264-4 ) 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2004050400011 20040504 00011 WP 2004 5 4 CA040303001 2 20040302 G 7230 3072163 BLADE GARRTT LEAR 35 35A 5170602 CE GARRTT TFE731 TFE73122B 01518 WP FAN ROTOR DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA 970322900732 (CAN) A MECHANIC WAS CARRYING OUT A SERVICE CHECK AND HE NOTICED FOD IN THE RT ENGINE INTAKE. UPON INSPECTION OF THE IN TAKE, FOUND A PIECE OF BLADE RUB STRIP MISSING, REAR ACOUSTIC LINER DAMAGE AND TWO DAMAGED FAN BY PASS STATOR BLADES. ON E FAN BLADE DAMPENER WAS ALSO MISSING. ENGINE REPLACED. 2 L 7 2 4F 4 F A10CE E6WE 2004050400012 20040504 00012 CE 2004 5 4 CA040303002 1 20040226 G 2435 PLUG PWA LEAR 60 60LEAR 5170707 CE PWA 305 PW305A 52128 NE GEAR SHAFT DISLODGED W E A ENGINE SHUTDOWN UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CL CLIMB 1 CA (CAN) EN-ROUTE, THE CREW OBSERVED A LOSS OF OIL PRESSURE. THE ENGINE WAS SECURED AND AN UNEVENTFUL LANDING WAS MADE. EXA MINATION OF THE ENGINE REVEALED THAT A PLUG IN THE STARTER GEAR SHAFT ASSEMBLY WAS DISLODGED, SUCH THAT PRESSURE OIL COU LD ESCAPE THE ENGINE. FURTHER EXAMINATION SHOWED THAT THE PLUG HAD NOT BEEN ADEQUATELY SWAGED INTO THE BORE OF THE GEAR SHAFT. OTHER OPERATORS WHO HAVE GEAR SHAFTS FROM THE SAME PROCESS BATCH OF GEAR SHAFTS HAVE BEEN ADVISED AND THEIR GEAR SHAFTS ARE BEING RE-INSPECTED TO CONFIRM ADEQUATE SWAGING OF THE PLUG. 2 L 7 2 4F 4 F RT A10CE E35NE 2004050400013 20040504 00013 CE 2004 5 4 CA040303003 1 20040221 G 3010 571531025 TUBE CESSNA 441 441 2076020 CE GARRTT TPE331 TPE33110 01514 WP BLEED AIR CRACKED W O OTHER J WARNING INDICATION CR CRUISE 1 CA 10921 10921 (CAN) DURING FLIGHT THE CREW NOTICE AN INTERMITENT WING O/H WARNING. MAINTENANCE WAS CONTACTED AND THE AIRCRAFT INSPECTE D. INSPECTION REVEALED A CRACK IN BLEED AIR TUBE PN 5715310-25. THE TUBE WAS REPLACE. THERE WAS NO RESULTING DAMAGE FROM THE BLEED AIR LEAK. 1 L 7 2 3T 4 T RT A28CE E4WE 2004050400014 20040504 00014 CE 2004 5 4 CA040303004 1 20040302 G 5310 GUSSET BEECH 100 B100 1152919 CE GARRTT TPE331 TPE3316252B 01514 WP HARTZL HCB4T HCB4TN5 GL WINDOW POST UNBONDED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHILE REMOVING A BROKEN CO-PILOT WINDSHIELD IT WAS NOTED CHAFFING ON THE WINDSHEILD FRAME. INTERIOR TRIM THAT IS ATTACHED TO THE CENTER PILLAR HAD BECOME UNATTACHED AND FALLEN DOWN INTO CONTACT WITH THE WINDSHEILD PILLAR GUSSET. MF G WAS IMMEDIATELY CONTACTED AND A REPAIR SCHEME FORWARDED TO ALLOW THE AIRCRAFT TO RETURN TO SERVICE. 1 L 7 2 4T 4 T A14CE E2WE 6 C P40EA 2004050400015 20040504 00015 NM 2004 5 4 CA040303005 1 20040302 G 3242 BRAKE BOEING 757 75728A 1384976 NM RROYCE RB211 RB211535E437 54555 NE MLG CONTAMINATED W K NONE B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA (CAN) NR 5 BRAKE SMOKING ON ARRIVAL. A/C HAS JUST RETURNED FROM PAINT, IT IS SUSPECTED THAT EXCESS FLUID HAD COLLECTED O N THE SURROUNDING AREA OF NR 5 BRAKE. BRAKE AND WHEEL AREA THOROUGHLY CLEANED. 2 L 7 2 4F 4 F RT A2NM E12EU 2004050400016 20040504 00016 EU 2004 5 4 CA040304001 1 20040227 G 2910 PILOT VALVE SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE FORE, AFT SERVO SEIZED W O OTHER F FLT CONT AFFECTED NR NOT REPORTED 1 CA DE013 (CAN) IN ORDER TO COMPLY WITH AIRWORHTINESS DIRECTIVE CF-2003-002R1, THE FLIGHT CONTROL RODS WERE DISCONNECTED AND THE P ILOT VALVE WAS FOUND TO BE SEIZED ON THE FORE AND AFT SERVO. 1 G 7 1 3U 3 U NC H9EU E19EU 2005011200010 20050112 00010 NM 2005 1 12 CA040304002 1 20040301 G 3244 DSC475 TIRE DHAV DHC8 DHC8101 2809002 NM PWA PW121 PW121 52124 NE HAMSTD 14SF 14SF7 NE MLG FAILED W O OTHER O OTHER DE DESCENT 1 CA (CAN) ACFT DECLARED EMERGENCY DURING DECENT INTO BASE & LANDED WITHOUT INCIDENT. IT APPEARS RT O/B TIRE BLEW WHILE IN WH EEL WELL & CAUSED EXTENSIVE DAMAGE TO AFT NACELLE & WHEEL WELL AREA, & CAUSED FINGERNAIL TO DEPART A/C IN FLT. DAMAGE C AUSED LOSS OF NR 2 HYD SYS DUE TO DAMAGED LINES IN THE AFT NACELLE AREA. WHILE IN CRUISE FLT APPROX 35 MILES SOUTH OF IT 'S NEXT BASE WHEN INCIDENT OCCURRED. ACFT LANDED SAFELY HOWEVER DUE TO NR 2 HYD SYS FAILURE CREW ELECTED TO STOP A/C ON RUNWAY & DEPLANED PAX. TIRE WAS RE-CAPPED. THIS WAS TIRE'S FIRST RE-CAP & HAD 603 CYCLES ON IT WHEN IT BLEW. TIRE HAD APPROX 1200-1300 TOTAL CYCLES ON IT SINCE NEW. THE ISSUE IS UNDER INVESTIGATION BY THE NTSB. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004050400017 20040504 00017 EU 2004 5 4 CA040304003 1 20040225 G 6730 704A34635019 O-RING DUNLOP SNIAS 350 AS350BA 8680817 EU LYC LTS101 LTS101600A3 41560 NE CHECK VALVE FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) HAD A HARD OVER CYCLIC PROBLEM WITH AN ENGINE, THE AIRCRAFT WAS EQUIPPED WITH MFG SERVOS. HAD THIS PROBLEM AT 30 D EGREES C TO -15 DEGREES C (OUTSIDE TEMPERATURE), NO DIFFERENCE. BOLT LATERAL SERVOS WAS DUE FOR OVERHAUL, SEND SERVOS FO R OVERHAUL AND REINSTALLED THESE SERVOS AFTER OVERHAUL, NOTHING CHANGED. REPLACED THE VALVE FILTER BLOCK AND NOTHING CHA NGE. REPLACED THE LT INPUT CHECK VALVE AT THE SERVO AND HAD A GAIN OF 60 PERCENT. REPLACED THE RT INPUT CHECK VALVE AT T HE SERVO AND HAD A GAIN OF 100 PERCENT, NO MORE FEED BACK. FOUND THE O-RING INSIDE OF THE CHECK VALVE (FLAT). 1 G 7 1 3U 3 U NC H9EU E5NE 2004050400018 20040504 00018 EU 2004 5 4 CA040304004 1 20040225 G 2913 704A33690004 BELT AEROSP SNIAS 350 AS350BA 8680817 EU LYC LTS101 LTS101600A3 41560 NE HYD PUMP UNBONDED W B A EMER. DESCENT UNSCHED LANDING F Z FLT CONT AFFECTED SIGNIFICANT FAILURE REPORT CR CRUISE 1 CA (CAN) WHILE IN FLIGHT THE PILOT EXPERIENCE A LOST OF HYDRAULIC POWER AND EMERGENCY LANDED ON A NEAR BY LEAKE WITH NO DAM AGE TO AIRCRAFT. AFTER INSPECTION THE HYDRAULIC BELT HAS BEEN FOUND SECTIONED AT THE GLUED JOINT. 1 G 7 1 3U 3 U NC H9EU E5NE 2004050700021 20040507 00021 NE 2004 5 7 CA040304005 2 20040303 G 7321 4147T70P02 FCU CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE ENGINE MALFUNCTIONED W A UNSCHED LANDING E J VIBRATION/BUFFET WARNING INDICATION CL CLIMB 1 CA GEE950069 (CAN) DURING TEST FLIGHT PROCEDURES, AFTER DOING RELIGHT OF LT ENGINE, THERE WAS NO THROTTLE REPONSE ON THE LT ENGINE. THE CREW DECLARED AN EMERGENCY AND CARRIED OUT A SINGLE ENGINE LANDING WITHOUT FURTHER INCIDENT. UPON RETURN, ALL ENGIN E RIGGING WAS VERIFIED ( STATIC AND DYNAMIC ) WITHOUT ANY FINDINGS. EVERYTHING WAS NORMAL. THEN, A/C WAS TAKEN OUT TO RUN ENGINE AND PROBLEM WAS CONFIRMED, THEN FAULT ISOLATION LED TO THE FUEL CONTROL UNIT SINCE MOTIVE FLOW WAS PRESENT. THE FUEL CONTROL UNIT WAS REPLACED AND A/C RAN SERVICEABLE. IT HAS SINCE RETURNED TO FLIGHT WITHOUT FURTHER OCCURENCES. 2 L 7 2 4F 4 F RT A21EA E15NE 2004050700022 20040507 00022 CE 2004 5 7 CA040304007 1 20040303 G 7602 5038901027 CONTROL CABLE BEECH 95 95B55 1152729 CE CONT O470 IO470L 17026 SO HARTZL HCC2Y BHCC2YF2 GL MIXTURE CONTROL BROKEN W O OTHER E VIBRATION/BUFFET CR CRUISE 1 CA (CAN) DURING CRUISE FLIGHT THE PILOT NOTICED THAT THE RT MIXTURE WAS NOT RESPONDING TO CONTROL MOVEMENT. THE AIRCRAFT RE TURNED TO BASE UNEVENTFULLY AND UPON MAINTENANCE INSPECTION FOUND THE ENGINE SIDE OF THE CABLE HAD BROKEN AT THE ROD END WHERE THE CABLE SHEATH WAS SWAGED ONTO THE CABLE. THE CABLE IS BEING REPLACED. THE TOTAL TIME ON THIS CABLE ASSY WAS 4. 6 TSN. 1 L 7 2 3O 3 O RT 3A16 3E1 5 C P920 2004050700023 20040507 00023 NM 2004 5 7 CA040304008 1 20040227 G 6120 3034384 LINE DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE P3 SENSE OUT OF POSITION W O OTHER E VIBRATION/BUFFET NR NOT REPORTED 1 CA (CAN) THE SHOP ENGINEER WAS TAKING STOCK OF ENGINE WHEN HE NOTICED THAT THE PCU CONTROL ROD (CONDITION) P/N 87620097-023 ,POWER PLANT BUILD IPC REF 71-00-02 FIG 10ITEM 2 WAS CONTACTING THE P3 AIR PRESSURE SENSING LINE P/N 3034384 (PW) IPC 72 -01-30 FIG 1 ITEM 10 BEFORE CONTACTING THE HMU STOP AT MAX SETTING.THIS OCCURS WHEN THE HMU IS REPLACED AND THE T FITTIN G P/N MS9196-04 IS NOT POSITIONED PROPERLY AND OVERLOOKED WHEN RIGGING IS DONE.THE OFFENDING PART IPC REF 72-01-40 FIG 1 ITEM 120 WAS REPOSITIONED SO A GAP BETWEEN THE SENSE LINE AND THE CONTROL ROD WAS SUFFICIENT FOR FULL AND NORMAL MOVEME NT OF THE HMU CONTROL ROD. THE MECHANISM WAS FUNCTIONED WITH NO REOCCURRENCE OF THE PROBLEM ON THE ENGINE IN QUESTION. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004050700024 20040507 00024 NE 2004 5 7 CA040304009 3 20040304 G 6114 69494R124 SEAL HAMSTD LKHEED 382 382G 526414U SO ALLSN 501D 501D22A 03006 GL HAMSTD 54H 54H60117 NE PUMP HOUSING DISLODGED W E A ENGINE SHUTDOWN UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CL CLIMB 1 CA 233452 (CAN) DEPARTING ,THE CREW OBSERVED A LOW PROPELLER FLUID INDICATION ON NR 2. THE ENGINE WAS SHUTDOWN AND THE AIRCRAFT RE TURNED TO POINT OF DEPARTURE. MAINTENANCE FOUND THE PACKING FOR THE PRESSURE SUMP FILLER PORT DISLODGED. PACKING REPOSIT IONED, FLUID LEVEL SERVICED, AIRCRAFT GROUND CHECKED SERVICEABLE. 2 H 7 4 4T 4 T A1SO E282 6 C P906 2004050700026 20040507 00026 EU 2004 5 7 CA040304011 1 20040303 G 2910 69596 MAXARET BAG JETSTM JETSTM3212 1500217 EU GARRTT TPE331 TPE33110UG 01514 WP ROTOL R333 R333482F12 GL HYD SYSTEM BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AFTER A FLIGHT THE AIRCRAFT WAS BEING PULLED INTO THE HANGAR. AN AME WAS WALKING PAST THE AIRCRAFT AND NOTICED TH E LT ANTI-SKID COVER WAS MISSING THE THREE RIVETS ON THE CASE. ON REMOVAL OF THE COVER THE COMPOSITE BLOCKS DESIGNED TO HOLD THE DRIVE PORTION OF THE MAXARET AND THE DRIVING HEAD WERE FOUND BROKEN. THE MAXARET APPEARS TO HAVE SEIZED CAUSI NG THE DAMAGE. THIS UNIT HAS NO LIFE OR OVERHAUL LIMITS. THE ONLY SCHEDULED INSPECTION OF THE UNIT IS WHEN IT IS INSTA LLED. 2 L 7 2 4T 4 T RT BA15CAA E4WE 6 C P61GL 2004050700034 20040507 00034 WP 2004 5 7 CA040305001 1 20040304 G 5240 HOOK CVAC 340 340CVAC 242270A WP ALLSN 501D 501D13D 03004 GL SERVICE DOOR DISENGAGED W A UNSCHED LANDING D INFLIGHT SEPARATION CL CLIMB 1 CA (CAN) ON CLIMB OUT, CREW EXPERIENCED CABIN DEPRESSURIZATION AND ILLUMINATION OF (REAR SERVICE DOOR UNLOCKED) LIGHT. UPON RETURN TO THE RAMP, MAINTENANCE PERSONEL DISCOVERED ONE OF THE FOUR HOOKS THAT HOLD THE DOOR CLOSED WAS NOT PROPERLY EN GAGED IN IT'S YOKE. AFTER INSPECTING THE DOOR AND CYCLING SEVERAL TIMES, THE DOOR WAS CLOSED AND THE A/C WAS PRESSURIZED ON THE GROUND. THE AIRCRAFT WAS THEN RETURNED TO SERVICE. 2 L 7 2 4R 4 T 6A6 E282 2004050700035 20040507 00035 NM 2004 5 7 CA040305002 1 20040304 G 3260 PROXIMITY SENSOR DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE NLG DISCONNECTED W O OTHER N FALSE WARNING CL CLIMB 1 CA (CAN) AFTER TAKEOFF, CREW SELECTED LANDING GEAR UP, AFTER SELECTION OF LANDING GEAR UP THE CREW HAD AN UNSAFE NOSE GEAR INDICATION, AND PROCEEDED TO SELECT LANDING GEAR DOWN WHEN SELECTION DOWN WAS COMPLETED THE NOSE GEAR INDICATION REMAINE D NOSE UNSAFE, BUT ALTERNATE NOSE DOWN AND SAFE WAS GREEN (POSITIVE DOWN) CREW DECLARED EMERGENCY LANDING, LANDED SAFELY . MAINTENANCE FOUND BROKEN WIRE AT NOSE LANDING GEAR DRAG STRUT PROXIMITY SENSOR, WIRES WERE REPAIRED, GEAR SWING CARRI ED OUT AND AIRCRAFT RETURNED TO SERVICE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004050700037 20040507 00037 EA 2004 5 7 CA040305004 1 20040304 G 3310 RV4NBYSD502A RHEOSTAT BOMBDR DHAV DHC8 DHC8311 1386006 EA PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE CAPT DIMMER BURNED W H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA 28503 (CAN) DURING PRE-FLIGHT CHECKS ON THE RAMP, THERE WAS A BURNING ODOR IN THE COCKPIT AND SMOKE WAS OBSERVED COMING OFF TH E CAPTAIN'S SIDE OVERHEAD CEILING PANEL IN THE COCKPIT. AIRCRAFT POWER WAS SHUT DOWN. MAINTENANCE INVESTIGATION REVEALE D A BURNED RHEOSTAT ON THE DIMMER CONTROL FOR THE CAPTAIN'S OVERHEAD LIGHT. THE PANEL ASSY WAS REPLACED WITH NO FURTHER FAULTS. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004050700038 20040507 00038 NM 2004 5 7 CA040305005 1 20040303 G 5755 85711503001 BRACKET AEROSP DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE ROLL SPOILER UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 CA 36304 095 (CAN) ROLL SPOILER MOUNTING BRACKET P/N 85710559-001. THE AIRCRAFT WAS IN THE PAINT SHOP BEING PREPPED FOR PAINT AND THE CLEANERS THAT WERE CLEANING THE AREA IN AND AROUND THE RT OB ROLL SPOILER ACTUATOR ON THE REAR SPAR NOTICED A LARGE CRA CK IN THE MOUNTING BRACKET. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004062100120 20040621 00120 EA 2004 6 21 CA040306002 1 20040304 G 2170 COALESCER BAG CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE CABIN AIR CONTAMINATED W O OTHER B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA (CAN) DURING TAXI, ELECTRICAL TYPE ODOR, WITH CLEAR/GREY SMOKE COMING FROM F/O SIDE PANEL AREA. SMOKE CONTINUED ACROSS TOWARDS CAPTAIN'S SIDE. CREW WAITED 10-15 SECONDS, SMOKE DID NOT CLEAR. AIRCRAFT DID A EMERGENCY EVACUATION ABOUT 200 Y ARDS FROM INTENDED GATE POSITION DUE TO SMOKE IN THE COCKPIT. AIRCRAFT WAS POWERED DOWN AND DEPLANED. SMOKE AND ODOR T HEN DISSIPATED. MAINTENANCE RAN APU, UPON BLEED SELECTION, OIL BURNING ODOR NOTED. APU OIL LEVEL WAS FOUND .5000 QUART OVERSERVICED. REMOVED AND REPLACED BOTH COALESCER BAGS. RAN BOTH PACKS FOR LONG TIME. NO FURTHER DEFECTS NOTED. AI RCRAFT RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT A21EA E15NE 2004050700045 20040507 00045 NE 2004 5 7 CA040306003 2 20040227 G 7320 FADEC CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE COCKPIT LIGHTNING STRIKE W O OTHER X J ENGINE FLAMEOUT WARNING INDICATION AP APPROACH 1 CA (CAN) DURING APPROACH, WITH FLAPS 20, GEAR UP, WING AND COWL ANTI-ICE ON, CONTINUOUS IGNITION ON AC HIT BY A SEVERE LIGH TNING STRIKE. WITHIN 10 SECONDS, ENGINE 2 FLAMED OUT WITH N1 AROUND 20 PERCENT. AROUND 10 SECONDS AFTER, FADEC AUTO RE LIGHT SUCCESSFULLY CARRIED OUT. WITHIN THAT TIME FRAME MESSAGES RT ENG DEGRADED, RT ENG BLEED AND STALL FAIL APPEARED. QRH APPLIED, ALL ENGINES PARAMETERS NORMAL. AC LANDED WITHOUT FURTHER INCIDENT. ON GROUND, LIGHTNING STRIKE CONFIRMED WITH SEVERAL IMPACT ON FUSELAGE. ENGINE RUNS SUCCESSFULLY CARRIED OUT TO CONFIRM GOOD OPERATION OF ENGINE AND FADEC.R FADEC AND DFDR. REMOVED FROM AC FOR ANALYSIS. STRUCTURAL DAMAGES REPAIRED AND AC RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2004050700047 20040507 00047 CE 2004 5 7 CA040308001 1 20040218 G 1430 A251352 BOLT CESSNA 150 150M 2071830 CE CONT O200 O200A 17020 SO MCAULY 1A102 1A102OCM GL PROPELLER BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING INSTALLATION OF THE PROPELLER, WHEN TIGHTENING THE BOLTS TO THE SPECIFIC TORQUE OF 25-30 POUNDS FOOT. ONE OF THE BOLTS BROKE AT APPROXIMATELY 27 POUNDS FOOT. THE BOLT BROKE AT THE BASE OF THE THREADS NEAR THE START OF THE GRI P. A SECOND BOLT WAS TIGHTENED USING A DIFFERENT TORQUE WRENCH AND IT ALSO BROKE AT THE BASE OF THE THREADS AND AT APPRO XIMATELY THE SAME TORQUE VALUE. THE TORQUE WRENCHES HAD BEEN CERTIFIED APPROXIMATELY ONE WEEK PRIOR. THE PROPELLER AND BOLTS HAD BEEN OVERHAULED AT A PROPELLER OVERHAUL SHOP AND WERE BEING REINSTALLED ON THE AIRCRAFT. 1 H 7 1 3O 3 O 3A19 E252 5 N P918 2004050700048 20040507 00048 EU 2004 5 7 CA040308002 1 20040224 G 2913 704A33690008 BELT SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE HYDRAULIC PUMP STRETCHED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHILE INSPECTING THE HYDRAULIC DRIVE BELT IAW 63.00.00.601 PARA 4 FOR PROPER TENSION IT WAS FOUND TO BE LOOSE. AT TEMPTS WERE MADE TO TENSION THE BELT IAW 63.00.00.401 PARA 4.2.3. WE WERE UNABLE TO GET THE REQUIRED TENSION DUE TO NO MORE MOTION OF THE TENSIONING BRACKET. MET 63.00.00.601 PARA 4.1 STATES THAT IF YOU CANT ACHIEVE REQUIRED TENSION REPL ACE THE BELT WHICH OCCURRED. THIS IS THE LATEST BELT PT NR 704A33690008 POLY V 597K4 WHICH HAS A PUBLISHED LIFE IAW M SR OF 1500 HOURS. THIS BELT FAILED INSPECTION AT 371. HOURS. DISCUSSIONS WITH MFG INDICATED THAT A LOWER TIGHTENING TEN SION IS IN THE WORKS SO THE BELT WOULD NOT BE RUNNING AS TIGHT. 1 G 7 1 3U 3 U H9EU E19EU 2004050700049 20040507 00049 GL 2004 5 7 CA040308003 1 20040301 G 2752 SEAL DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240B 17063 SO SNSNCH W69EK W69EK63 EA FLAP ACTUATOR LOOSE W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) DURING A 50 HR INSPECTION, IT WAS FOUND THAT THE SPLINED SEAL PUSHED OUT OF POSITION ON FLAP ACTUATOR ROD ASSY. O N THIS AIRCRAFT IT DID NOT MAKE CONTACT WITH THE FLAP POSITION SWITCHES. THE COMPLETE ASSY HAD BEEN REPLACED ONLY 26.3 HRS PREVIOUSLY DUE TO AN UNRELATED PROBLEM. MFG SUGGESTED WE CLEAN THE AREA WITH ALCOHOL AND RE-GLUE THE SEAL USING LOC TITE 409 ADHESIVE. THIS HAS BEEN CARRIED OUT AND AIRCRAFT RETURNED TO SERVICE. 1 L 7 1 3O 3 O NT TA4CH E7SO 5 N TA4CH 2004050700050 20040507 00050 EA 2004 5 7 CA040308005 1 20040308 G 5297 840534 SWITCH CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE SERVICE DOOR INOPERATIVE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) SERVICE DOOR EXTERIOR HANDLE WAS OUT AFTER LANDING WITH NO CAUTION OR INDICATIONS. SWITCH REPLACED. DOOR RIGGED IA W AMM. 2 L 7 2 4F 4 F RT A21EA E15NE 2004070900007 20040709 00007 2004 7 9 CA040308006 4 20040308 G 3425 COMPUTER CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE FLT DIR MALFUNCTIONED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) FAULT:FD AND ALL RAW DATA FAILURE X3 DURING FINAL APPROACH. FOUND EVIDENCE OF DIRT INSIDE IAPS CARD CAGE, CLEANED, 'SERV.' 2 L 7 2 4F 4 F RT A21EA E15NE 2004050700051 20040507 00051 CE 2004 5 7 CA040308007 1 20040302 G 3230 GEARBOX BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA MCAULY 4HFR34 4HFR34C652 NE MLG INOPERATIVE W O OTHER O OTHER CL CLIMB 1 CA 405880 (CAN) DURING FLIGHT THE LANDING GEAR TOOK LONGER THAN NORMAL TO RETRACT. COULD NOT DUPLICATE THE PROBLEM IN THE HANGAR E VEN WHEN SWINGING THE GEAR WITH EXTRA LOADS. SUSPECTED THAT THE CLUTCH WAS SLIPPING DURING RETRACTION WITH THE INCREASE D LOADS DURING FLIGHT. THE LANDING GEAR GEARBOX WAS REPLACED AND THE AIRCRAFT WAS RETURNED TO SERVICE WITH OUT FURTHER I NCIDENT. 1 L 7 2 4T 4 T A24CE E4EA 6 C 3PNE 2004050700040 20040507 00040 SO 2004 5 7 CA040308008 1 20040303 G 5540 4004009 TORQUE TUBE PIPER PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL RUDDER ASSY CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 20210 315435 (CAN) DURING INSPECTION IAW AD 2003-24-07 RUDDER FOUND TORQUE TUBE CORRODED. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004040500001 20040405 00001 EA 2004 4 5 CA040308009 1 20040304 G 3310 82510189S103 RHEOSTAT DHAV DHC8 DHC8311 1386006 EA PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE COCKPIT LIGHT FAILED W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA 28497 28497 (CAN) DURING MAINT WHEEL REPLACEMENT ON RAMP , FLIGHT CREW (ONLY PERSONNEL ONBOARD) NOTICED SMOKE IN THE COCKPIT (NO FIR E) . MAINTENANCE INSPECTION FOUND OVERHEAD READING LIGHT RHEOSTAT WAS SOURCE OF SMOKE. COCKPIT OVERHEAD PANEL ASSEMBLY WITH RHEOSTAT REPLACED. AIRCRAFT RETURNED TO SERVICE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004040500002 20040405 00002 SO 2004 4 5 CA040308010 1 20040221 G 2731 4420000 TRIM SYSTEM PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2B 41532 EA HARTZL HCE3Y HCE3YR2A GL ELEVATOR TRIM LACK OF LUBE W A UNSCHED LANDING F FLT CONT AFFECTED CL CLIMB 1 CA (CAN) PILOT REPORTED ELEVATOR TRIM JAMMED FULL FORWARD AND COULD NOT TRIM NOSE UP. ELEVATOR TRIM JACK FOUND NOT LUBRICA TED. SHAFT LUBRICATED, SYSTEM FUNCTIONS NORMAL. FORWARD TRIM JACK SPOOL CHECKED OK. SPOOLING AROUND ELECTRIC ACTUATOR CKECKED OK. CABLE TENSION CHECKED OK. AFT TRIM TAB ACTUATOR FREE PLAY CHECKED WITHIN LIMITS IN MM. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004040500003 20040405 00003 CE 2004 4 5 CA040309001 1 20040303 G 7603 1143890503 CONTROL CABLE BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA HARTZL HCB4M HCB4MP3 GL POWER LEVER SEVERED W E D ENGINE SHUTDOWN RETURN TO BLOCK W E INADEQUATE Q C VIBRATION/BUFFET TX TAXI/GRND HDL 1 CA (CAN) AFTER LANDING AND SUBSEQUENT TAXI THE RT ENGINE SPOOLED UP AND DID NOT RESPOND TO POWER LEVER MOVEMENT. THE ENGINE WAS SHUT DOWN AND THE AIRCRAFT COMPLETED TAXI TO THE TERMINAL ON THE LT ENGINE. MAINTENANCE INVESTIGATED AND DISCOVERED THAT THE POWER LEVER CABLE HAD BEEN SEVERED BY THE PULLEY OF THE VAPOR CYCLE AIR CONDITIONING SYSTEM. THE CABLE HAD BEE N ROUTED TOO CLOSE TO THE PULLEY DURING AN ENGINE REMOVAL AND REINSTALLATION 64 HOURS PRIOR TO THE INCIDENT. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2004040500004 20040405 00004 EA 2004 4 5 CA040309002 1 20040304 G 6320 61352095012 COVER SKRSKY CARSON S61 S61LSKRSKY EA GE CT58 CT581401 30011 NE M/R GEARBOX CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 26356 A14994 (CAN) CRACK ON LOWER LT LEG OF MAIN GEARBOX REAR COVER DISCOVERED ON DAILY INSPECTION. 2 G 7 2 4U 4 U H8EA 1E3 2004040500005 20040405 00005 NE 2004 4 5 CA040309003 1 20040307 G 6320 FILTER SKRSKY 613520600046 SKRSKY S61 S61N 8142104 NE GE CT58 CT581401 30011 NE M/R GEARBOX INOPERATIVE W A UNSCHED LANDING J WARNING INDICATION HO HOVERING 1 CA 18054 A141027 (CAN) MAIN GEAR BOX OIL PRESSURE DROPPED IN FLIGHT. AIRCRAFT RETURNED TO LANDING AREA AND SHUT DOWN. EXAMINATION OF MGB COARSE SCREEN FILTER REVEALED RESIN COATING FROM INSIDE OF MGB HAD FLAKED OFF. MGB REPLACED. 2 G 7 2 4U 4 U 1H15 1E3 2004040500006 20040405 00006 NM 2004 4 5 CA040309004 1 20040225 G 2742 6355B000103 MOTOR BOEING 737 73776N 13844CH NM CFMINT CFM567 CFM567B22 13802 NE STAB TRIM JAMMED W H DEACTIVATE SYST/CIRCUITS F J FLT CONT AFFECTED WARNING INDICATION CR CRUISE 1 CA (CAN) 2 HRS INTO FLT (STAB OUT OF TRIM) LIGHT ILLUMIN. NON-NORMAL CKLIST WAS COMPLETED, ELEC TRIM REMAINED INOP,TRIM C HANGES ACCOMPLISHED MANUALLY. MAINT CTRL WAS CONSULTED AND CB 6B AND 610 WERE PULLED AND RESET. (STAB OUT OF TRIM) LIGHT CONTINUED INTERMITTENT, PILOTS CONTINUED MANUALLY INPUT REQUIRED TRIM CHANGES. STAB BECAME COMPLETELY JAMMED NON-NORMAL CKLIST WAS COMPLETED. STAB REMAINED JAMMED FOLLOWING COMPLETION OF CKLIST, MAINT CTRL REQUESTED THAT CB 6B AND 610 BE PULLED AND LT OUT. MAN CTRL OF STAB WAS RESTORED AND A NON-NORMAL LANDING WAS COMPLETED, WITHOUT FURTHER INCIDENT. UPDAT E: MAR.09/04 - MFG HAS REQUESTED FLIGHT DATA RECORDED READOUT FROM SUBJECT FLIGHT AND RELATED TROUBLESHOOTING RESULTS. 2 L 7 2 4F 4 F RT A16WE E00055EN 2005011200011 20050112 00011 EA 2005 1 12 CA040309005 1 20040309 G 2520 C3FF183 LOCK PIN DHAV DHC3 DHC3 2800202 EA PWA PT6 PT6A34 52043 EA SEAT WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) INCORRECT PART DISCOVERED DURING SEAT INSPECTION THE PROPER SEAT LOCK PIN HAD BEEN REPLACED BY A GROUND DOWN A/N B OLT 1 H 7 1 3R 4 T A815 E4EA 2004040500007 20040405 00007 NM 2004 4 5 CA040310001 1 20040306 G 4997 CONNECTOR GARRTT GTCP8511 BOEING 737 7372H4 138448C NM PWA JT8 JT8D9A 52048 NE APU BURNED W A E UNSCHED LANDING ENGINE SHUTDOWN J WARNING INDICATION CR CRUISE 1 CA P34583 (CAN) INDICATION OF APU FIRE AT 35,000 FT. AFTER DISCHARGING BOTTLE AND SHUTTING DOWN APU, RED WARNING LIGHT EXTINGUISHE D. CREW DIVERTED AND AC LANDED W/O INCIDENT. MAINT INSP FOR FIRE DAMAGE IAW SRM 51-4-10. FIRE CONTAINED BETWEEN BLKHD S TA.1156 AND APU EXHAUST BAFFLE. NO EVIDENCE OF BURNED PRIMER OR DISCOLORED METAL. APU EGT AND TAIL PIPE FIRE DETECTION WIRING HARNESS FOUND BURNED, TAIL PIPE FIRE. APU TUB REMOVED AND INSP, NO LEAKS AND NO INDICATION OF FIRE DAMAGE. MAINT SUSPECT CAUSED OFFIRE AT EGT CONNECTORS TO WIRE HARNESS, FOUND BURNED. POSSIBLE SHORT OCCURRED, DAMAGED WIRING HARNESS ES REPLACED AND APU FIRE DETECTION SYSTEM TESTED SERVICEABLE. APU FIRE BOTTLE REPLACED. AC RETURNED TO SERVICE. 2 L 7 2 4F 4 F A16WE E2EA 2004040500008 20040405 00008 EU 2004 4 5 CA040310002 1 20040308 G 2510 EQMFG200002901 SEAT BELT SNIAS 350 AS350B3 8680954 EU TMECA ARRIEL ARRIEL2B NE COCKPIT INOPERATIVE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) SHOULDER HARNESS INERTIA REEL ON COPILOT'S SEAT WOULD NOT RETRACT AFTER FULL EXTENSION. THE PN SPECIFIED IN 9B AP PLIES TO THE 4 POINT HARNESS ON ENERGY ABSORBING STYLE OF SEAT. 1 G 7 1 3U 3 U H9EU E00054EN 2004040500009 20040405 00009 SO 2004 4 5 CA040310003 1 20040226 G 2435 MHB4016B STARTER GEN PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL LT ENGINE FAILED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) AIRCRAFT WAS AT AIRPORT. AFTER STARTING THE RT ENGINE, THE PILOT WENT TO START THE LT ENGINE, THE ENGINE WOULD NO T TURN OVER, FOUND THAT THE STARTER WAS TURNING OVER BUT THE BENDIX WOULD NOT TURN. CHANGED LT STARTER ENGINE STARTED. NO FAULTS FOUND. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004040500010 20040405 00010 SW 2004 4 5 CA040310004 1 20040225 G 5313 206031314123 LONGERON BELL 206 206L1 1182107 SW ALLSN 250C 250C30P 03013 GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING SCHEDULED MAINTENANCE THE ENGINEER DETECTED THE ENGINE MOUNT TO BE LOOSE. FURTHER INVESTIGATION INDICATED A CRACKED LONGERON WITH THE ENGINE MOUNT IS ATTACHED. 1 G 7 1 3U 3 U H2SW E1GL 2004040500011 20040405 00011 EA 2004 4 5 CA040310005 2 20040108 G 8520 CAMSHAFT PIPER PA44 PA44180 7104402 SO LYC O360 O360E1A6 41514 EA HARTZL HCC2Y HCC2YR2 GL ENGINE WORN W O OTHER J WARNING INDICATION CR CRUISE 1 CA L52772T (CAN) CAMSHAFT LOBES AND LIFTERS WEARING PREMATURALLY. 1 L 7 2 3O 3 O A19S0 E286 5 C P920 2004072900075 20040729 00075 2004 7 29 CA040310007 4 20040308 G 2561 BATTERY LIFEJACKET LIGHT LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) SEALED BATTERIES ARE INTEGRAL PART OF SURVIVOR LIGHT IN AVIATION LIFEJACKET. LIFEJACKET AND LIGHT IS USED AS PART OF HELICOPTER PASSENGER TRANSPORTATION SUIT SYSTEM APPROVED TO CAN/CGSBS-65.17-99. SEVERAL BATTERIES IN THIS LOT NUMBE R HAVE BEEN LEAKING AND SOME HAVE BEEN DIM OR FAILED TO FUNCTION WHEN TESTED. STORAGE LIFE IS STATED AS 60 MONTHS. HAVE NOT YET CONFIRMED THE NATURE OF THE LEAKING SUBSTANCE. WE ARE REMOVING ALL OF THE LIGHTS OF THIS BATCH DESIGNATION FRO M SERVICE. APPROXIMATELY 100 LIGHTS IN TOTAL. BATTERY ONLY 16 MONTH. 2004040500013 20040405 00013 CE 2004 4 5 CA040310008 1 20040218 G 1430 A251352 BOLT MCAULY CESSNA 150 150M 2071830 CE CONT O200 O200A 17020 SO MCAULY 1A102 1A102OCM GL PROPELLER SHEARED W K NONE O OTHER IN INSP/MAINT 1 CA K19086 (CAN) UPON APPLICATION OF 27 FT/LBS TO 2 OF THE MOUNTING BOLTS AT THE THREADS FAILED. BOLTS FORWARDED TO COMPANY FOR E VALUATION. 1 H 7 1 3O 3 O 3A19 E252 5 N P918 2004040500014 20040405 00014 SO 2004 4 5 CA040310009 1 20040310 G 3230 WTC345 POWERPACK PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2C 41532 EA HARTZL HCE3Y HCE3YR2A GL HYD SYSTEM FAILED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) WHEN THE PILOT SELECTED GEAR UP, ONE OF THE GEARS WAS NOT RETRACTING AND THE TRANSITION LIGHT REMAINED ILLUMINATED . AFTER SEVERAL ATTEMPTS THE GEAR RETRACTED AND EVERYTHING WAS NORMAL. THE POWER PACK WAS REPLACED. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004040500015 20040405 00015 NM 2004 4 5 CA040310010 1 20040309 G 5610 NP15790213 WINDOW DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE COCKPIT BROKEN W O OTHER O OTHER CL CLIMB 1 CA (CAN) AFTER TAKEOFF THROUGH 6000 FT. THE OUTER PANE OF THE CAPTAIN'S SIDE WINDOW SHATTERED. THERE WAS NO NOTICEABLE CHAN GE IN PRESSURIZATION. THE CAPTAIN DEPRESSURIZED THE AIRCRAFT AND THE FLIGHT RETURNED WITHOUT FURTHER INCIDENT. DETERMINE D TO BE OUTER PLY (NON-STRUCTURAL).WINDOW SPEED TAPED AND DETERMINED TO BE SAFE FOR FERRY. A/C FERRIED FOR REPAIRS. LOG PAGE 343040 AND 343041 EXPLAIN THE DEFECT AS DESCRIBED ABOVE, AND DESCRIBE THE RECTIFICATION DETAILS TO BE AS FOLLOWS: LT SIDE WINDOW REPLACED, AND TEMP CONTROLLER REPLACED. LT SIDE WINDOW P/N NP157902-13, S/N 00213H4459 TEMP CONTROLLER P/N SYLZ50970, S/N 724C REASON FOR FAILURE NOT YET DETERMINED. TEAR DOWN REPORTS TO FOLLOW. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004040500016 20040405 00016 CE 2004 4 5 CA040311001 1 20040310 G 3260 JE6 SWITCH CESSNA 310 310L 2074230 CE CONT O470 IO470VO 17026 SO HARTZL HCJ3Y PHCJ3YF2 GL MLG BROKEN W O OTHER O OTHER AP APPROACH 1 CA (CAN) UPON APPROACH THE LANDING GEAR WAS SELECTED DOWN WITH NO GREEN LIGHT DOWN AND LOCKED INDICATION ON THE RT GEAR. T HE GEAR WAS CYCLED, THE MANUAL EXTENSION WAS PERFORMED ALL WITH THE SAME RESULT. THE AIRCRAFT LANDED UNEVENTFULLY AND U PON INVESTIGATION THE MICRO SWITCH ACTUATOR TAB WAS FOUND BROKEN AT THE ATTACHING BRACKET. THE ACUATOR WAS REPLACED AND THE GEAR WAS SWUNG NUMEROUS TIMES SERVICEABLE. 1 L 7 2 3O 3 O 3A10 3E1 5 C P36EA 2004040500017 20040405 00017 NM 2004 4 5 CA040311002 1 20040208 G 6120 697073002 PITCH CONTROL BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU NR 1 PROP INOPERATIVE W O OTHER E VIBRATION/BUFFET NR NOT REPORTED 1 CA (CAN) AIRCRAFT EXPERIENCED NR 1 PROPELLER TO FEATHER PITCH JUST AFTER TAKEOFF POWER WAS SET ON. PIREP RATING POWER SET, NR 1 ENG TORQUE INDICATION IN TURNED RED AND PROPELLER RPM DECREASED TO 200RPM. CONDITION LEVER MOVED TO START/FEATHER THEN BACK TO MAX BUT NO HELP. TAKE OFF REJECTED. NR 1 PROP REMAINED FEATHERED DURING TAXI TO GATE. PP FAULTS CHECKED, NO FAULTS. EMU DOWNLOAD, NO PP EXCEEDENCE RECORDED. ENGINE RUN-UP CHECKS, COULD NOT DUPLICATE. CLEANED FADEC, PEC AND PCU CONNECTORS. REPLACED NR 1 PCU FOR TROUBLESHOOTING. AIRCRAFT RTS. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2004041300008 20040413 00008 GL 2004 4 13 CA040311003 2 20040210 G 7261 6896451 TRANSFER TUBE ALLSN 250C 250C30P 03013 GL OIL SYSTEM MISMANUFACTURED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) FERRULE UNDER B NUT OF SCAVENGE OIL LINE FROM NR 8 BEARING WAS WRONGLY MANUFACTURED, CAUSING PENDING FRACTURE OF F LANGE. HAS CAUSED 360 DEGREE LINE AROUND THE BASE OF THE FLANGE. TUBE REPLACED, A/C RETURNED TO SERVICE. OIL LOSS AT T HIS LOCATION WOULD HAVE CAUSED OIL STARVATION TO NR 8 BEARING RESULTING IN ENGINE FAILURE. 3 U E1GL 2004040500018 20040405 00018 WP 2004 4 5 CA040311004 1 20040307 G 2910 7936907615 LINE DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE HYD SYSTEM CRACKED W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA (CAN) ON DEPARTURE LT HYD PRESSURE LIGHT ILLUMINATED IN FLIGHT WITH HYD PRESS. READING ZERO. AIRCRAFT LANDED. MAINTENAN CE FOUND LT EDP INOPERATIVE. LT EDP SWAPPED WITH RT EDP AND AIRCRAFT DISPATCHED IAW MEL 29-5.EDP P/N AS666411-L-5666 S /N MX134145-4M. THE LT HYDRAULIC QTY LOW LIGHT ILLUMINATED IN FLIGHT WITH QTY INDICATION OF 3 QTS WITH SYSTEM PRESSURIZE D. FOLLOWING INVESTIGATION BY MAINTENANCE, FOUND LT PIPE ASSY-FUSELAGE SECTION HYD SYSTEM PRESSURE P/N 7936907-615 CRAC KED AT FLARE. 2 L 7 2 4F 4 F RT A6WE E9NE 2004040500019 20040405 00019 EU 2004 4 5 CA040311005 1 20040310 G 2822 9868411404 PUMP PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL FUEL BOOST INOPERATIVE W K NONE J WARNING INDICATION CR CRUISE 1 CA (CAN) WHILE IN CRUISE FLIGHT THE PILOT NOTED A 2 LED DIFFERENCE BETWEEN LT AND RT FUEL INDICATORS. A FEW MINUTES LATER T HE RT BOOST PUMP LT INDICATOR CAME ON. THE LT REMAIN ON FOR THE DURATION OF THE FLIGHT AND THE FUEL IMBALANCE REMAINED. ON THE GROUND THE FUEL BOOST PUMPS WERE TESTED MANUALLY. THE RT BOOST PUMP INDICATED NORMALLY BUT NO SOUND OF THE PUMP RUNNING WAS NOTED. THE FUEL PUMP WAS REPLACED AND THE SYSTEM TESTED SERVICEABLE. NO FURTHER ACTION WAS REQUIRED. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004040500020 20040405 00020 GL 2004 4 5 CA040311006 2 20040302 G 8550 23038229 SEPARATOR AROFAL OH58 OH58C 1181580 SW ALLSN 250C T63A720 03002 GL OIL/AIR SHEARED W K NONE O OTHER IN INSP/MAINT 1 CA AE405314 (CAN) ON DISASSEMBLY OF THE GEARBOX ASSEMBLY, THE AIR OIL SEPARATOR GEAR SHAFT WAS FOUND SHEARED AT THE JUNCTION OF GEAR AND SHAFT. THE ENGINE WAS SENT TO THE SHOP FOR METAL CONTAMINATION. THE AIRCRAFT HAD PREVIOUSLY BEEN INVOLVED IN A WIR E STRIKE. THE ENGINE RAN FOR 5 MINUTES AFTER THE STRIKE BUT BOTH CHIP DETECTORS HAD A LOT OF METAL. 1 G 7 1 3U 3 U NC H22NM E4CE 2004040500021 20040405 00021 EU 2004 4 5 CA040311007 1 20040311 G 3340 0320713406 LIGHT PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL EXTERIOR FAILED W K NONE L NO TEST IN INSP/MAINT 1 CA (CAN) NAVIGATION LIGHT ASSEMBLY (TAIL) APPEARS TO HAVE PROBLEMS WITH THE TOP BULB BURNING OUT. THERE HAS BEEN 8 BULBS P/ N 972.87.87.184 REPLACED WITHIN 7 DAYS. THE COMPLETE ASSEMBLY HAS BEEN REPLACED ALONG WITH A ELECTRONIC SWITCH UNIT. THE SAME RESULTS. THE BULBS THEMSELVES ARE EXTREMELY HOT WITHIN A SORT TIME OF OPERATION.(SECONDS) THIS NAV LIGHT ASSEMBLY IS PART OF A KIT P/N 500.50.12.276 DUAL NAV LIGHT SYSTEM. MFG S/B 33-009 WAS USED FOR THE INSTALLATION OF THIS PRODUCT. IN SHORT, THE LIGHT IS UNRELIABLE. ON GOING TRIALS ARE CONTINUING TO FIND A SOLUTION. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004040500022 20040405 00022 NE 2004 4 5 CA040311008 2 20040308 G 7230 3040933 DISK PWA PT6 PT6A67B 52043 NE COMPRESSOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ENGINE WAS STRIPPED AS PART OF ROUTINE SCHEDULED OVERHAUL. VISUAL EXAMINATION OF HPC DISK 3 SHOWS CRACK IN RIM OF DISK. FURTHER INVESTIGATION IS UNDERWAY. 4 T E26NE 2004040500023 20040405 00023 WP 2004 4 5 CA040311009 1 20040310 G 3220 STRUT DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE NLG DEFLATED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) DURING CLIMB OUT, L/G SELECTED UP, NOSE GEAR UNSAFE LIGHT ON WITH ASSOCIATED BUFFERING & NOISE. AIRCRAFT LANDED. M AINTENANCE FOUND NOSE OLEO DEFLATED. NOSE STRUT SERVICED, GEAR RETRACTION CARRIED OUT AND AIRCRAFT DISPATCHED SERVICEABL E. 2 L 7 2 4F 4 F RT A6WE E9NE 2004040500024 20040405 00024 EA 2004 4 5 CA040311010 2 20040309 G 8520 LW16812 LIFTER PIPER PA44 PA44180 7104402 SO LYC O360 O360E1A6 41514 EA HARTZL HCC3Y HCC3YR2 NE LT ENGINE SPALLED W K NONE O OTHER IN INSP/MAINT 1 CA L44377T (CAN) DURING A ROUTINE INSPECTION, METAL CONTAMINATION WAS DETECTED IN THE FULL FLOW OIL FILTER CARTRIDGE ELEMENT. THE L IFTER ASSEMBLIES WERE REMOVED NEXT TO DETERMINE THEIR CONDITION. THIS HAS BEEN A RECURRING PROBLEM ON THIS MODEL ENGINE. THE SURFACE OF THE LIFTERS HAD EVIDENCE OF SPALLING AND SURFACE CHIPS. THE ENGINE WAS SUBSEQUENTLY REMOVED FROM THE AIR CRAFT FOR INSPECTION BY THE OVERHAUL SHOP. A S IMILAR INSPECTION WAS CARRIED OUT ON THE RIGHT ENGINE, HOWEVER THERE WAS NO EVIDENCE OF DAMAGE DUE TO THE CONDITION DESCRIBED ABOVE. 1 L 7 2 3O 3 O A19S0 E286 5 C P25EA 2004040500025 20040405 00025 CE 2004 4 5 CA040311011 1 20040227 G 5210 50430043619 CHANNEL BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCD4N3 HCD4N3A GL DOOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING INSPECTION A CRACK WAS DISCOVERED ALONG THE TRAILING EDGE OF THE CABIN DOOR CHANNEL P/N 50430043619. THE CR ACK PROPAGATED APPROXIMATELY 6 IN, JUST ABOVE THE DOOR HINGE. THE DOOR WAS REMOVED AND SENT TO AN APPROVED OVERHAUL SHOP , REPAIRED AND REINSTALLED. AIRCRAFT RETURNED TO SERVICE. 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2004040500026 20040405 00026 EA 2004 4 5 CA040312002 2 20040309 G 8530 CONNECTING ROD PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL ENGINE CRACKED W E A ENGINE SHUTDOWN UNSCHED LANDING E B VIBRATION/BUFFET SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA L230368A (CAN) DURING CRUSE, THE CREW HEARD NOISES COMING FROM THE NR 2 ENGINE, SHORTLY AFTER THERE WAS A LOUD BANG AND VIBRATION . THE CREW NOTICED OIL AND SMOKE COMING FROM THE ENGINE COWL, THE PROP WAS FEATHERED AND ENGINE STOWED. THE OIL HIT THE TURBOCHARGER AND IGNITED CAUSING FIRE TO FLOW ALONG THE LOWER WING AND CAUSED DAMAGE TO THE LOWER SKIN AND GEAR DOOR. TH E LOWER FLAP SKIN ALSO SHOWED SIGNS OF HEAT DAMAGE. THE A/C LANDED WITH NO FURTHER PROBLEMS. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004040500027 20040405 00027 SO 2004 4 5 CA040312003 2 20040312 G 8530 C8512F CYLINDER HEAD CESSNA 120 120 2071402 CE CONT C85 C8512F 17008 SO MCAULY 1B90 1B90CM GL ENGINE MISALIGNED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) ENGINE WAS SENT TO ENGINE SHOP FOR PROP STRIKE INSPECTION. UPON REINSTALLATION OF NR 1 CYLINDER, IT WAS DISCOVERE D THAT THE BARREL AND HEAD WERE MISALIGNED BY APPROX. 5 DEGREES (UNIT WAS REPLACED). ENGINE SHOP ADVISES THIS IS A DEFE CT OCCURING DURING ORIGINAL ASSEMBLY AT THE FACTORY AND FURTHER ADVISE THAT THIS IS THE SECOND ONE THEY HAVE FOUND. 1 H 7 1 3O 3 O A768 E233 5 N P842 2004040500028 20040405 00028 NM 2004 4 5 CA040312004 1 20040311 G 3230 ACCESSORY UNIT BOEING 727 727225 1384077 NM PWA JT8 JT8D15A 52051 NE MLG FAULTY W L ABORTED APPROACH N FALSE WARNING LD LANDING 1 CA (CAN) DURING APPROACH AND LANDING GEAR HANDLE EXTENDED, IT WAS OBSERVED THAT THERE WAS AN UNSAFE LT LANDING GEAR LIGHT. IT WAS DECIDED THAT A MISSED APPROACH WOULD BE CARRIED OUT AND GO AROUND. EMERGENCY PROCEDURES WERE CARRIED OUT. TOWE R WAS NOTIFIED OF THE PROBLEM AND EMERGENCY EQUIPMENT WAS MADE READY. IT WAS CONFIRMED THE GEAR WAS DOWN AND LOCKED AND THE LANDING WAS PERFORMED WITHOUT INCIDENT. MTCE INSPECTED THE AIRCRAFT AND THE LANDING GEAR ACCESSORY UNIT WAS SWAPPED WITH ANOTHER AIRCRAFT FOR TROUBLESHOOTING. IT WAS CONFIRMED THAT THE L/G ACCESSORY UNIT WAS AT FAULT AND A SERVICEABLE UNIT WAS INSTALLED, ADJUSTED AND FUNCTIONED SERVICEABLE IAW MM 32-09-121. NO FAULT DURING SUBSEQUENT FLIGHT. 2 L 7 3 4F 4 F A3WE E2EA 2004040500029 20040405 00029 GL 2004 4 5 CA040315001 2 20040309 G 7210 6850209 GEARBOX LKHEED 382 382G 526414U SO ALLSN 501D 501D22A 03006 GL HAMSTD 54H 54H60117 NE NR 2 REDUCTION CONTAMINATED W E ENGINE SHUTDOWN J WARNING INDICATION CL CLIMB 1 CA (CAN) AT TOP OF CLIMB ENROUTE, NR 2 RGB CHIP LIGHT OBSERVED. THE INDICATION WOULD NOT CLEAR, NR 2 ENGINE WAS SHUT DOWN. MAINTENANCE FOUND BOTH RGB CHIP PLUGS BRIDGED. NR 2 ENGINE WAS REPLACED FOR CONVENIENCE AND THE AIRCRAFT RETURNED TO S ERVICE. 2 H 7 4 4T 4 T A1SO E282 6 C P906 2004040600001 20040406 00001 NM 2004 4 6 CA040315002 1 20040313 G 8011 97907021 START VALVE BOEING 727 727243 138408D NM PWA JT8 JT8D9A 52048 NE NR 1 ENGINE CRACKED W K NONE O OTHER TX TAXI/GRND HDL 1 CA (CAN) DURING DEPARTURE CREW WAS UNABLE TO START NR 1 ENGINE. MAINTENANCE CALLED TO PERFORM A MANUAL START. FOUND THE B OTTOM OF THE START VALVE CRACKED AT THE ADJUSTMENT SCREW. VALVE REPLACED AND A/C DEPARTED. 2 L 7 3 4F 4 F RT A3WE E2EA 2004040600002 20040406 00002 SO 2004 4 6 CA040315003 1 20040310 G 3245 650X10600X6 TUBE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL NLG FLAT W O OTHER O OTHER TX TAXI/GRND HDL 1 CA (CAN) A/C DEPARTED WITH 10KT WINDS AND BLOWING SNOW. A/C MADE ROUTINE TAKE OFF AND FLIGHT. AFTER LANDING, DURING TAXI ON RUNWAY, PILOT NOTICED A/C WAS PULLING TO ONE SIDE. PILOT TAXIED OFF RUNWAY AND PARKED. HE THEN VISUALLY INSPECTED LT MA IN TIRE AND SAW IT WAS FLAT. MAINT WAS DISPATCHED. MAINT REPLACED MAIN WHEEL AND INSTALLED NEW TUBE IN NOSE WHEEL. UPON INSP MAIN ASSY HAD A SHEARED VALVE STEM AND NOSE TUBE HAD A PIN HOLE IN IT. CAUSE OF SHEARED VALVE STEM IS BELIEVED T O HAVE BEEN FROZEN BRAKES. CAUSE OF PIN HOLE IN THE NOSE TUBE IS BELIEVED TO HAVE BEEN THE CHANGE IN TEMPERATURE BETWEE N AREA OF DEPARTURE AND AREA OF ARRIVAL CAUSING WHEEL PRESSURE TO HAVE GONE DOWN AND TUBE GETTING PINCHED. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004040600003 20040406 00003 CE 2004 4 6 CA040315004 1 20040311 G 2510 05130391 LIGHTER CESSNA 172 172N 2072434 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160CTM GL COCKPIT SHORTED W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) SMOKE/ FUMES DETECTED IN COCKPIT DURING CRUISE FLT. CREW SURVEYED ELECTRICAL SYSTEM CONTROLS AND FOUND CIGAR LIGH TER TO BE HOT. REMOVED LIGHTER FROM DASH AND RETURNED TO BASE WITH NO FURTHER COMPLICATIONS. INSPECTION REVEALED COILS O F LIGHTER SHORTED CAUSING FUMES. MAINTENANCE DISCONNECTED POWER WIRE TO LIGHTER ASSEMBLY IAW AD 78-08-03. NOTE: THIS AD DOES NOT APPLY TO THIS A/C SN BUT CERTAINLY WAS AFFECTED IN THIS INSTANCE, SHIPS AFFECTED BY THIS SN SHOULD BE REVISITE D BY THE AD ISSUER. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2004041300011 20040413 00011 CE 2004 4 13 CA040315008 1 20040302 G 2823 1013890253 SHUTOFF VALVE BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA HARTZL HCB3T HCB3TN3 GL FUEL SYSTEM FAILED W O OTHER L NO TEST TX TAXI/GRND HDL 1 CA (CAN) DURING PRESTART CHECKS FLIGHT CREW COULD NOT EXTINGUISH (LOW FUEL PRESSURE) WARNING LIGHT. FLIGHT CANCELLED. INSPE CTION FOUND RT FUEL SHUT OFF VALVE HAD FAILED IN THE CLOSED POSITION. VALVE HAD BEEN RECENTLY OVERHAULED. 1 L 7 2 3T 4 T RT 3A20 E4EA 6 C P15EA 2004041300012 20040413 00012 EU 2004 4 13 CA040315009 1 20040306 G 5330 SKIN BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 36314 (CAN) A PILOT IN THE PROCESS OF DOING HIS DAILY INSPECTION OF THE AIRCRAFT NOTICED A CRACK (2.5 INCHES) IN THE LT FORWAR D FUSELAGE SKIN JUST BELOW A LAP JOINT BETWEEN FRAMES 10 AND 11 NEAR THE WATER LINE. THE AIRCRAFT WAS REMOVED FOR SERVIC E, A SECTION OF SKIN IN THE AFFECTED AREA WAS REMOVED AND SENT FOR ANALYSIS, THE BREAK OCCURRED ON AN INSIDE RADIUS OF T HE SKIN THAT WAS CHEMICALLY MILLED. OUR SHEET METAL PEOPLE EXAMINED THE SPECIMEN THAT WAS REMOVED AND THEY FELT THAT TH E RADIUS OF THE CONTOUR WAS A BIT SHARP WHERE THE CRACK OCCURRED. THE AIRCRAFT WAS TEMPORARILY REPAIRED IAW BARA/AVR/66 81/04-DC INSTRUCTIONS FROM THE MANUFACTURER WITH A PERMANENT REPAIR DUE AT THE NEXT C-CHECK. 2 H 7 4 4F 4 F A49EU E6NE 2004041300013 20040413 00013 NM 2004 4 13 CA040315010 1 20040308 G 3250 65727628 COLLAR BOEING 727 727233 138408A NM PWA JT8 JT8D15 52051 NE NLG STEERING WORN W C ABORTED TAKEOFF J WARNING INDICATION TO TAKEOFF 1 CA 12000 (CAN) THE TAKE-OFF WAS REJECTED AT 70KTS DUE TO NLG SHIMMEY. BOTH NLG WHEELS REPLACED AND STEERING COLLAR ADJUSTMENT CHE CKED. AIRCRAFT WAS RETURNED TO SERVICE. 2 L 7 3 4F 4 F RT A3WE E2EA 2004041300014 20040413 00014 CE 2004 4 13 CA040315011 1 20040308 G 7712 3012347 VALVE BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3A NE TORQUEMETER ERODED W O OTHER O OTHER DE DESCENT 1 CA PS0164 (CAN) FLIGHT CREW REPORTED OCCASIONAL PROBLEMS WITH TORQUE INDICATION DURING POWER REDUCTIONS. TORQUE INDICATION WOULD H ANG UP AT VARIOUS HIGH SETTINGS DESPITE POWER REDUCTIONS TO IDLE. FROM A PREVIOUS CASE OF THIS ON ANOTHER AIRCRAFT, THE POWER REDUCTION CASE WAS SPLIT WITH AN EXPECTATION THAT THE TORQUEMETER VALVE WAS PREMATURELY WORN, AND IT WAS. A PREV IOUS SUBMISSION UNDER AGL-0120 REFLECTS EXACTLY THE SAME PROBLEM, PRESENTATION AND FIX. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2004041300015 20040413 00015 EU 2004 4 13 CA040315012 1 20040314 G 6730 AC67246 SERVO VALVE SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE COLLECTIVE UNSERVICEABLE W C ABORTED TAKEOFF F FLT CONT AFFECTED TO TAKEOFF 1 CA (CAN) PILOT REPORTED THAT WHEN HE TRIED TO PULL THE COLLECTIVE UP, IT FELT VERY HEAVY. IT WAS NOTED DURING TROUBLESHO OTING THAT THE SPOOL VALVE WAS VERY DIFFICULT TO MOVE AND THEN IT WOULD ONLY MOVE A SMALL AMOUNT. A SERVICEABLE SERVO W AS INSTALLED AND CONTROLS CHECKED OUT NORMAL. 1 G 7 1 3U 3 U H9EU E19EU 2005042700315 20050427 00315 2005 4 27 CA040315013 1 20040316 G 2435 03601018 BEARING ARMATURE IMPROPER PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 15154 (CAN) LUCAS USES BARDEN BEARINGS WITH THE LUCAS LOGO AND PART NUMBER STAMPED ON. BEARINGS REMOVED MADE BY SKF. LUCAS NEV ER USED SKF BEARINGS. 2004041300016 20040413 00016 SO 2004 4 13 CA040315014 2 20040312 G 8530 538684 BUSHING CIRRUS SR SR20 05628AJ GL CONT O360 IO360ES SO HARTZL HCJ2Y BHCJ2YF1 GL ENGINE BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA 357431 (CAN) DURING OIL CHANGE, NOTED A .5000 LONG X .1250 INCH WIDE ROUND PIECE OF WHAT APPEARS TO BE BUSHING MATERIAL STUCK O N THE OIL DRAIN PLUG S MAGNET. FOUND THE NR 5 CYLINDER CONNECTING ROD S PISTON PIN BUSHING HAD A MISSING PIECE WHICH MA TCHES THE PIECE FOUND ON THE OIL SUMP DRAIN PLUG. 1 L 7 1 3O 3 O NT A00009CH E1CE 5 C P37EA 2004071900053 20040719 00053 CE 2004 7 19 CA040316001 1 20040301 G 2621 WIRE BEECH B300 B300B350C CE PWA PT6 PT6A60A 52043 NE HARTZL HCB4M HCB4MP3 GL SQUIB MISWIRED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) WHEN THE ENGINEER WAS TASKED TO PERFORM A SCHEDULED SQUIB REPLACEMENT IAW THE MAINTENANCE SCHEDULE, HE FOUND THAT THE SQUIB WIRING WAS INCORRECTLY WIRED. SOLUTION: THE ENGINEER RE-WIRED THE SQUIB CORRECTLY. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2004072100064 20040721 00064 EA 2004 7 21 CA040316002 1 20040223 G 3150 8220179013 CONTROL UNIT CNDAIR CL604 CL604 1900301 EA GE CF34 CF343B1 NE DISPLAY FAILED W E A ENGINE SHUTDOWN UNSCHED LANDING N FALSE WARNING CR CRUISE 1 CA (CAN) BLEED AIR OVERHEAT CONDITION (LT HAND) DOWNSTREAM OF ENG BLEED AIR SHUT OFF VALVE. WARNING WAS INTERMITTENT, BUT REMAINED ON. FOLLOWING AFM PROCEDURES, LT ENG WAS SHUT DOWN IN FLIGHT WHEN WARNING PERSISTED AFTER AFFECTED BLEED VALVE WAS CLOSED. AC WAS DIVERTED DEFECT WAS TROUBLESHOT. AFTER SWAPPING BLEED LEAK CONTROL UNITS, DEFECT APPEARED TO BE REC TIFIED. DEFECT REOCCURRED WHILE AC POWER RED UP IN HANGAR. REVEALED THAT SOURCE OF FALSE INDICATION ORIGINATED IN NR 1 DISPLAY CONTROL UNIT (DCU). INVESTIGATION DID NOT REVEAL PREVIOUS EXAMPLES OF THIS TYPE OF FAILURE. DCU IS DESCRIBED AS A COMPLEX COMPUTER THAT MONITORS VARIOUS SYS AND DISPLAYS FAILURES, FAULTS TO FLIGHT CREW. DCU WAS REPLACE. 2 L 7 2 4F 4 F RT A21EA E15NE 2004072100065 20040721 00065 CE 2004 7 21 CA040316003 1 20040311 G 3260 MS243313 SWITCH CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE MLG OVERHEATED W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA (CAN) AC WAS SITTING ON RAMP WITH GROUND POWER ATTACHED TO AC, AC MASTER SWITCH ON. SMOKE ORIGINATING FROM LOWER SIDE O F IB SECTION OF RT WING. CREW WAS NOTIFIED, AC WAS POWERED DOWN ELECTRICALLY, GPU REMOVED. SMOKE STOPPED WITH POWER OFF, VERIFIED TO BE COMING FROM RT WHEEL WELL. CAUSE OF SMOKE WAS QUICKLY ISOLATED TO LANDING LIGHT SAFETY SWITCH IN RT M AIN GEAR WELL. THIS PLUNGER TYPE SWITCH IS ACTIVATED BY GEAR DOOR, UPON RETRACTION, REMOVES POWER SOURCE TO LANDING LIGH T AS BACK UP TO COCKPIT SWITCH. NORMALLY POWER IS ALWAYS APPLIED THROUGH THIS SWITCH. FAULT WAS ISOLATED TO SWITCH ONLY , WITH NO ASSOCIATED HEAT DISTRESS TO AC OR TO WIRING. AC ELECTRICAL SYS WAS VERIFIED SERVICEABLE, SWITCH REPLACED. 1 L 7 2 4F 4 F A22CE E1NE 2004041300017 20040413 00017 EU 2004 4 13 CA040316004 1 20040218 G 2435 03600923 BEARING LUCAS PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL STARTER GEN WORN W O OTHER J WARNING INDICATION TX TAXI/GRND HDL 1 CA 98103 (CAN) OPERATOR HEARD GRINDING NOISE DURING ENGINE START. NOISE WAS LOUDEST AT 10 PERCENT NG. ABORTED START AND INVESTI GATED. FOUND RADIAL PLAY AT FAN END OF ARMATURE. REPLACED STARTER GEN. SENT FAILED UNIT FOR REPAIRS. FOUND THE ADE B EARING HAD RADIAL PLAY, MEASURED .0045 INCH. INSPECTED FOR CORRECT ASSY AT PREV OVERHAUL, FOUND OK(BRG PART NR TOWARD A RMATURE). REMOVED BEARING. IT RATTLES, IS LOOSE, HAS CONSIDERABLE PLAY BOTH RADIALLY AND AXIALLY. IF LEFT IN SERVICE, THIS WOULD HAVE FAILED AND DESTROYED THE STARTER-GEN WITHIN AFEW HOURS. BEARINGS WERE REPLACED AND UNIT OVERHAULED. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004041300018 20040413 00018 NM 2004 4 13 CA040316006 1 20040305 G 2897 W5200100718 WIRE BOEING 757 75728A 1384976 NM RROYCE RB211 RB211535E437 54555 NE PYLON CHAFED W O OTHER J WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) RT SPAR FUEL SHUTOFF VALVE CB C1062 ACTIVATED DURING SHUTDOWN AFTER FLIGHT. CB WOULD NOT RESET, AND SPAR VALVE DIS AGREEMENT LIGHT ALSO ILLUMINATED. TROUBLESHOOTING REVEALED WIRE HAD CHAFING DAMAGE AT BULKHEAD LOCATED AT STATION PP ST N 208.40 VISIBLE BEHIND PANEL 313N5018. WIRE WAS REPAIRED IAW SWPM20-30-12. GIVEN THE PROBLEM IS IN THE FLAMMABLE ARE A OF THE NACELLES, IT IS SUGGESTED THAT THE COMPLETE WIRE BUNDLE CONTAINING WIRE W5200-1007-18 BE INSPECTED REPAIRED AN D PROTECTED AS REQUIRED BETWEEN CONNECTION POINTS AT D92292J AT BRACKET AN2285 TO THE VALVE CONNECTOR D2022 AT STN PP ST N 265.60AFTSN 7524:36 AFCSN 2509 2 L 7 2 4F 4 F RT A2NM E12EU 2004050600009 20040506 00009 2004 5 6 CA040316007 4 20040304 G 2310 064101700 COUPLER DHAV DHC7 DHC7102 2802708 EA PWA PT6 PT6A50 52043 EA HAMSTD 24PF 24PF305 GL HF AMPLIFIER BURNED W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA P2193 (CAN) HF SYS FAILED, SMOKE AND BURN SMELL CAME FROM HF PWR AMP/COUPLER. UNIT WAS REMOVED AND SENT FOR INSP. FOUND THAT HARDWARE ATTACHING COVER ON CONNECTOR J9524 TO FACEPLATE OF UNIT HAD CONTACTED PRINTED CIRCUIT BD AND SHORTED +28 VDC S UPPLY TO GROUND. ELEC TRACE MELTED AND OPENED CIRCUIT TO UNIT. PC BOARD WAS REPAIRED, TRACE REPLACED. UPON TESTING IT WAS FOUND THAT COUPLER WOULD NOT TUNE AT ALL. TROUBLESHOOTING DISCLOSED, VSWR SENSOR WAS NOT OPERATING PROPERLY. IT WAS DISCOVERED CNTRL BOARD HAD AN OBSOLETE MICROPROCESSOR. MOST OF BOARDS ARE OBSLETE. WIRING ON AC FOR HF SYS WAS TESTED IA W WIRING MANUAL AND NO FAULT WAS FOUND. REPLACEMENT HF PWR AMP/COUPLER WAS INSTALLED, SYSTEM TESTED, OK. 2 H 7 4 4T 4 T A20EA E4EA 6 C P1NE 2004041300019 20040413 00019 NM 2004 4 13 CA040316008 1 20040305 G 3010 85720014005 BOOT DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE LT LE DEICE DELAMINATED W C ABORTED TAKEOFF N FALSE WARNING TO TAKEOFF 1 CA 36874 36874 (CAN) CREW REJECTED TAKE-OFF AT ROTATION DUE TO STICK PUSHER SHAKE. AIRCRAFT WAS AT MORE THAN 80 KNOTS AT TIME OF REJEC TION. FLIGHT RETURNED TO GATE. BOTH STALL SYSTEMS CHECKED SERVICEABLE ON THE GROUND. FOUND THAT THE LT LE DEICE BOOT DE LAMINATING CAUSING THE STALL/STICK SHAKER TO ACTIVATE. THE LEADING EDGE WAS REPLACED AND THE AIRCRAFT BROUGHT BACK TO SE RVICE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004041300020 20040413 00020 NM 2004 4 13 CA040316009 1 20040229 G 2750 M390166105L RELAY DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE TE FLAP CONTROL FAILED W O OTHER F J FLT CONT AFFECTED WARNING INDICATION AP APPROACH 1 CA (CAN) ON APPROACH FLAPS FAILED TO LOWER WHEN SELECTED. AIRCRAFT DID A GO AROUND AND THE PERFORMED AN UNEVENTFUL FLAPLESS LANDING. MAINTENANCE NOTED THAT FLAP POWER CAUTION LIGHT NOT OPERATING WHEN FLAP LEVER SELECTED. TROUBLESHOOTING DISCOV ERED RELAYS AT 2752-K2 AND 2752-K3 HAD FAILED. RELAYS REPLACED AND FLAPS FUNCTION CHECKED SERVICEABLE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004041600030 20040416 00030 2004 4 16 CA040316010 4 20040316 G 6122 13101053612033 SOLENOID WOODWARD GOVERNOR UNSECURE W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 1826703 (CAN) UPON RECEIVING INSPECTION OF EXCHANGE GOVERNOR FROM HONEYWELL IT WAS NOTED THAT THE RESET SOLENOID P/N 1310-105 WA S LOOSE AND IMPROPERLY LOCKED. ALSO THE 3612-033 PICK UP PLUG WAS FOUND TO BE MISSING LOCKWIRE. THE RESET SOLENOID WAS T HEN TIGHTENED UP AND PROPERLY LOCKED AND THE PICK UP PLUG WAS LOCKED. 2004041600031 20040416 00031 2004 4 16 CA040316011 4 20040316 G 6122 46200161310105 ADAPTER WOODWARD UNFEATHERING UNSECURE W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 920265 (CAN) UPON RECEIVING AN EXCHANGE GOVERNOR FROM MFG. IT WAS NOTED THAT THE 4620-016 UNFEATHERING ADAPTER PLATE WAS MISSIN G LOCKWIRE AND THE RESET SOLENOID 1310-105 WAS FOUND TO BE LOOSE AND POORLY LOCKED. THE UNFEATHERING PLATE WAS THEN LOCK ED AND THE SOLENOID WAS TIGHTENED AND LOCKED PROPERLY. 2004071900079 20040719 00079 EA 2004 7 19 CA040317001 1 20040222 G 5270 840534 PROXIMITY SWITCH CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE PAX DOOR MALFUNCTIONED W A UNSCHED LANDING N FALSE WARNING CL CLIMB 1 CA (CAN) ON CLIMB OUT AT APPROX FL290, (PAX DR OUT HNDL) CAUTION MESSAGE ILLUMINATED. CREW COMPLIED WITH QRH, INCLUDING VI SUALLY VERIFYING ALL 8 ALIGNMENT INDICATORS CONFIRMED DOOR LOCKED AND OUTER HANDLE STOWED. CAS MESSAGE PERSISTED. LAND ING WAS UNEVENTFUL AND NO EMERGENCY WAS DECLARED. REPLACED PROXIMITY SWITCH PS2MB. PASSED OPS TEST, AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT A21EA E15NE 2004080400216 20040804 00216 EU 2004 8 4 CA040317002 1 20040310 G 3242 16402201 BRAKE DISC BNORM BN2 BN2B27 7080227 EU LYC O540 O540E4C5 41532 EA HARTZL HCC2Y HCC2YK2 GL MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DISC FAILED AROUND FLANGE. PART 6 OF SB 7071 ASK PILOTS TO LOOK AT WHEELS DISC ON PRE-FLIGHT INSPECTION, AT THE S TAGE OF THE CRACK NOW IT WOULD HAVE BEEN NEXT TO IMPOSSIBLE TO SEE THE CRACK WITHOUT CLEANING THE DISC. 1 H 7 2 3O 3 O A17EU E295 5 C P920 2004042800029 20040428 00029 EA 2004 4 28 CA040317003 2 20040309 G 7200 ENGINE PWA PT6 PT6A27 52043 EA FAILED W K NONE O OTHER IN INSP/MAINT 1 CA 11359 (CAN) ENG WAS REMOVED FROM WING, NOTED HIGHER THAN NORMAL OIL TEMP, OIL DISCOLORATION. UPON REMOVAL, EXH DUCT WAS MISSI NG SECT OF INNER DUCT EXPOSING PT SHAFT HSG TO EXH GASES. IT WAS FOUND THAT REAR SECTION OF EXH DUCT INNER SKI JUMP S ECTION, EXTENDING FWD FROM NR 3 BRG END ABOUT 5 INCHES HAD DISAPPEARED. SAME SECTION OF INSULATION BLANKET HAD ALSO DIS APPEARED. IMPACT MARKS IN ONE EXH PORT AREA, NO SIGNIFICANT DAMAGE TO PT DISK, BLADES INDICATING THAT EXH DUCT SKIN HA D FRACTURED INTO A LARGE NR OF SMALL PIECES. THERE WERE A NR OF CRACKS EMANATING FROM SURFACE CORROSION PITS IN AREAS A WAY FROM FRACTURE EDGES THAT EXTENDED ACROSS DUCT WALL. MATERIAL DEGRADATION WAS PRIMARY CAUSE, FAILURE OF THIS DUCT. 4 T E4EA 2004041300021 20040413 00021 CE 2004 4 13 CA040317004 1 20040311 G 5520 115610010125 SPLINE BEECH 100 B100 1152919 CE GARRTT TPE331 TPE3316252B 01514 WP HARTZL HCB4T HCB4TN5 GL ELEVATOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ON INSPECTION FOUND THREE VISUAL CRACKS IN OB SECTION OF THE ELEVATOR TRAILING EDGE SPLINE, AS DESCRIBED IN OTHER SDR'S /SERVICE DIFFICULTY ADVISORY. 1 L 7 2 4T 4 T A14CE E2WE 6 C P40EA 2004041300022 20040413 00022 EA 2004 4 13 CA040318001 2 20040309 G 7250 3032151 RING BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA ENGINE VANE BURNED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING ROUTINE HOT END BORESCOPE INSPECTION, HOT END DISTRESS WAS NOTED. POWER SECTION REMOVED FROM AIRCRAFT, HOT END REMOVED. COMBUSTION CHAMBER CRACKED (MANY) ON NR 2 LOUVERED COOLING RING. SMALL DUCT BURNED/WARPED IN TWO AREAS (V ANES). VANE RING ASSEMBLY, SEVERE BURNING ON 1 VANE AT TRAILING EDGE APPROXIMATELY .5 SQUARE INCH MISSING. ADJACENT VA NE TRAILING EDGE CRACKED. VANE RIM BURNED AND CRACKED (3032151). HOUSING ASSEMBLY, CT SHROUD, ONE SEGMENT 3018503 WARPE D INWARD CAUSING CT BLADE CONTACT. BLADE LEADING EDGE AT TIP ROUNDED. DISK/BLADE ASSEMBLY, CONTACT WITH WARPED BLADE S HROUD SEGMENT. 1 G 7 1 4U 4 U H4SW E22EA 2004041300023 20040413 00023 SW 2004 4 13 CA040318003 1 20040309 G 6510 2120406883 COUPLING BELL BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA DRIVESHAFT CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA A20218 (CAN) DRIVESHAFT UNDERGOING SCHEDULED 600 HR/12 MONTH INSPECTION/LUBRICATION. COUPLING HAS EXCESSIVE CORROSION. PART R EPLACED. COUPLING P/N 212-040-688-3. 1 G 7 1 4U 4 U H4SW E22EA 2004041300025 20040413 00025 SW 2004 4 13 CA040318004 1 20040311 G 6420 AN5161A GREASE FITTING BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL TAIL ROTOR CLOGGED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING 50 HOUR LUBRICATION INTERVAL. FITTINGS WOULD NOT PASS GREASE. FITTING REPLACED. 1 G 7 1 3U 3 U H2SW E4CE 2004041300026 20040413 00026 WP 2004 4 13 CA040318005 1 20040315 G 5610 5887275505 WINDSHIELD DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE COCKPIT CRACKED W A UNSCHED LANDING O OTHER CR CRUISE 1 CA (CAN) CENTER WINDSHIELD CRACKED IN FLIGHT AND SPARK, CREW DECIDED TO TURNBACK. THE CENTER WINDSHIELD WAS REPLACED IAW TH E MM 56-10-01. THE WINDSHIELD ANTI-ICE AND ANTI-FOG SYSTEM WAS CHECKED SERVICEABLE IAW THE AMM. 2 L 7 2 4F 4 F RT A6WE E9NE 2004050300163 20040503 00163 CE 2004 5 3 CA040318006 1 20040304 G 5330 1304300515 SKIN BEECH B300 B300B350C CE PWA PT6 PT6A60A 52043 NE HARTZL HCB4M HCB4MP3 GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING INSP, SEVERAL LOOSE RIVETS IN FWD AREA OF PRESSURE VESSEL, 2 RIVET HEADS SHEARED OFF AT FS 201.775. AFTER REMOVING ELEC PANEL AND DUCTS UNDER CABIN FLOOR, CRACKS WERE DETECTED IN RADIUS OF RIB WHERE IT ATTACHES TO STINGER 16, 15L. STRIPPED PAINT OFF BELLY FROM FS 158 TO 201 TO FACILITATE CLOSER INSP 2 CRACKS WERE VISUALLY DETECTED IN SKIN AROUN D RIVET HOLES FOR STRINGERS 16. HAD EDDY CURRENT TESTING ON ENTIRE AREA WITH CRACKS FOUND AND NOTED IN BELLY SKIN AT FS 179.525 AT 1ST RIVET LT OF C/L , 1ST RIVET RT OF CENTER LINE AND 8TH RIVET RT OF CENTER LINE. EDDY CURRENT TESTING WAS CARRIED OUT ON RIB WITH CRACKS NOTED IN RADIUS ON OB SIDE OF STRINGER 15 LT AND BOTH SIDES OF STRINGER 16 (C/L). 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2004080500022 20040805 00022 EA 2004 8 5 CA040318007 1 20040318 G 7830 THRUST REVERSER CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE RIGHT MALFUNCTIONED W O OTHER J WARNING INDICATION NR NOT REPORTED 1 CA (CAN) EICAS MSG R REV. UNLOCKED DISPLAYED DURING FINAL APPROACH. ENG POWER WAS AT IDLE. NOTICED AC ROLL AND YAW. EMERG ENCY STOW SELECTED AND A/P DISCONNECTED. RT REVERSER NOT SELECTED ON LANDING ROLL. REVERSER DEACTIVATED AND AC DXD UND ER MEL. VERBAL COMMENT FROM THE CREW WAS THAT THEY FELT THE REVERSER HAD UNLOCKED/PARTIALLY DEPLOYED FLT RECORDER PULLED FOR FURTHER EVALUATION. 2 L 7 2 4F 4 F RT A21EA E15NE 2004080500023 20040805 00023 NE 2004 8 5 CA040318009 2 20040317 G 7200 ENGINE CNDAIR CL600 CL6002D24 1390016 EA GE CF34 CF343B1 NE RIGHT FAILED W A UNSCHED LANDING E VIBRATION/BUFFET NR NOT REPORTED 1 CA GEE950064 (CAN) WHILE CARRYING OUT RELIGHT TESTS, RT ENGINE DID NOT RELIGHT VIA WINDMILL OR ATS.EMERGENCY WAS DECLARED AND SUCCESS FULL SINGLE ENGINE APPROACH WAS COMPLETED WITHOUT FURTHER INCIDENT. RT ENGINE WAS REPLACED AND AC FLOWN SINCE WITHOUT F URTHER INCIDENTS. 2 L 7 2 4F 4 F RT A21EA E15NE 2004041300027 20040413 00027 EU 2004 4 13 CA040319001 1 20040312 G 2731 Z4244120000 CONTROL CABLE ZLIN 242 Z242L 9970204 EU LYC O360 AEIO360A1B6 41514 EA MUHBR MTV MTV9* EU ELEVATOR TRIM FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING A 100 HOUR INSPECTION, IT WAS NOTICED THAT THE AFT TRIM CABLE HAD A BROKEN STRAND FORWARD OF THE RT PULLEY NEAR THE TRIM DRUM. THROUGH EXPERIENCE IT WAS FOUND THAT CONDITION WOULD LEAD TO A TOTAL FAILURE OF THE CABLE IN THE NE AR FUTURE. THE CABLE WOULD FRAY SO MUCH THAT IT WOULD BIND UP IN THE DRUM ASSEMBLY RENDERING THE ELEVATOR TRIM SYSTEM I NOPERABLE. THIS SYSTEM IS CLOSELY INSPECTED EVERY 100 HOUR INSPECTION DUE TO SIMILAR FAILURES OF THIS CABLE. 1 L 7 1 3O 3 O 0 A76EU 1E10 5 C P24NE 2004041300028 20040413 00028 CE 2004 4 13 CA040319002 1 20040309 G 3020 1099100491 ANTI-ICE SYSTEM BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA HARTZL HCB3T HCB3TN3 GL RT ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AIR INTAKE ANTI-ICE LIP WAS FOUND CRACKED AT THE WELDED ATTACH JOINTS AT BASE OF EXHAUST INLET/OUTLET TUBES. 1 L 7 2 3T 4 T RT 3A20 E4EA 6 C P15EA 2005042700316 20050427 00316 EU 2005 4 27 CA040319003 1 20040304 G 2820 VALVE AIRBUS 320 A320231 3930325 EU IAE V2500 V2500A1 NE FUEL SYSTEM MALFUNCTIONED W O OTHER K J FLUID LOSS WARNING INDICATION NR NOT REPORTED 1 CA (CAN) CREW REPORTED SEVERAL INCIDENTS OF UNEXPLAINED FUEL LOSS FROM RT FUEL SYS RESULTING IN INCONSISTENT FUEL IMBALANCE S ON VARIOUS OCCASIONS. NO VISIBLE SIGNS OF FUEL SYS LEAKAGES WITHIN ACRFT NOR ON GROUND. FUEL QTYS CLOSELY MONITORED B Y CREW WHILE TROUBLE SHOOTING PERFORMED. AIR RELEASE VALVE, & SUCTION VALVE BOTH REPLACED DURING TROUBLESHOOTING THIS C ORRECTED DISCREPANCY. BOTH VALVES HAVE BEEN SENT OUT FOR BENCH CHK, & RESULTS WILL BE SUBMITTED WHEN THE SHOP REPORTS A RE RETURNED TO IDENTIFY THE CULPRIT(S). 2 L 7 2 4F 4 F RT A28NM E311NE 2004080500024 20040805 00024 CE 2004 8 5 CA040319005 1 20040312 G 2820 652635537 LINE CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE FUEL TANK CHAFED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING THE INSP PROCESS OF SB550-28-14, WING FUEL BOOST PUMP WIRING INSPECTION, IT WAS NOTED THAT BOOST PUMP WIRIN G WAS RUBBING ON MAIN EJECTOR TO CHECK VALVE ALUMINUM FUEL LINE P/N 6526355-37, CAUSING CHAFFING WEAR THROUGH FUEL LINE. THE WEAR WAS APPROX 75 PERCENT OF WALL THICKNESS ON LT FUEL TANK LINE AND 45 PERCENT ON RT FUEL TANK LINE. THERE WAS NO NOTICABLE WEAR THROUGH WIRING OUTTER INSULATION AROUND AREA IN CONTACT WITH LINE. BOTH LT AND RT FUEL LINES WERE REPLAC ED WITH NEW. SB KIT INCLUDES INSTALLATION OF NEW CLAMPS AND STAND OFFS TO HOLD THE BOOST PUMP WIRING AWAY FROM ALL STR UCTURE AND FUEL LINES AS WELL AS RE-ROUTE WIRE UNDER RATHER THAN OVER THE FUEL LINE NOTED. 1 L 7 2 4F 4 F A22CE E1NE 2004041300030 20040413 00030 NM 2004 4 13 CA040319006 1 20040317 G 2421 700842A CSD BOEING 727 727225 1384077 NM PWA JT8 JT8D15A 52051 NE AC GENERATOR FAILED W C ABORTED TAKEOFF H ELECT. POWER LOSS-50 PC TO TAKEOFF 1 CA (CAN) DURING TAKEOFF, IT WAS OBSERVED THAT ELECTRICAL POWER WAS LOST WITH NR 3 GENERATOR. A REJECTED TAKE-OFF WAS CARRIE D OUT AND AIRCRAFT RETURNED TO THE GATE WITHOUT INCIDENT. NR 3 ENGINE CONSTANT SPEED DRIVE WAS DISCONNECTED AND SYSTEM W AS DEFERRED IAW MEL 24-01. NO FURTHER INCIDENT DURING SUBSEQUENT FLIGHT. 2 L 7 3 4F 4 F A3WE E2EA 2005011200012 20050112 00012 EA 2005 1 12 CA040321001 1 20040317 G 5610 STRAP CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE WINDSHIELD LOOSE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DE-ICE FLUID AND WATER APPEARS TO BE LEAKING AROUND THE FOS MAP LIGHT. FOUND FLUID LEAKING FROM THE RT I STRAP FAS TENERS BETWEEN THE FOS WINDOW AND WINDSHIELD. I STRAP WAS RE-SEALED AND RE-TORQUE. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2005011200013 20050112 00013 EA 2005 1 12 CA040321002 1 20040118 G 5610 NP13932111 WINDSHIELD CNDAIR CL600 CL6002B19 1900309 EA COCKPIT FAILED W O OTHER O OTHER CR CRUISE 1 CA (CAN) THE CAPTAIN WINDSHIELD HAD SHATTERED IN CRUISE. THE WINDSHSIEL IS THE NEW CONFIGURATION. THE WINDSHIELD WAS REMOVE D AND REPLACED. 2 L 7 2 4F RT A21EA 2005011200014 20050112 00014 EA 2005 1 12 CA040321003 1 20040113 G 5610 NP1393225 WINDOW CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF341A NE COCKPIT FAILED W A UNSCHED LANDING O OTHER CR CRUISE 1 CA (CAN) THE LEFT SIDE WINDOW HAD SHATTERED. AN EMERGENCY DESCENT WAS TAKEN.THE REMAINDER OF THE FLIGHT, APPROACH AND LAND ING WERE UNEVENTFUL. THE WINDOW WAS REPLACED. THE WINDOW IS OLDER VERSION. 2 L 7 2 4F 4 F RT A21EA E15NE 2005011200015 20050112 00015 CE 2005 1 12 CA040322001 1 20040224 G 2912 99122813 FILTER HOUSING CESSNA 560 560XL 2076702 CE PWA 545 PW545A NE ANTI SKID PUMP BROKEN W D RETURN TO BLOCK K W FLUID LOSS INADEQUATE Q C TX TAXI/GRND HDL 1 CA (CAN) DURING TAXI PRIOR TO TAKE-OFF EXPERIENCED A BRAKE ANTI-SKID PUMP FILTER BOWL FAILURE WITH A HYDRAULIC FLUID LOSS. THIS EVENT OCCURRED BEFORE ON NOV. 19, 2002 (1725.6 HRS TTSN AND 1534 TCSN), ON BOTH TIMES A CRACK WAS FOUND ON FILTER B OWL THREADS.THE FIRST FAILURE WAS REPORTED TO CESSNA AND THE DEFECTIVE PART WAS SENT FOR INVESTIGATION AND THE FILTER BO WL CRACKED WAS DUE TO A MACHINING DEFECT DURING MANUFACTURE. SEVERAL FILTER BOWLS WERE OFFSET DURING MACHINING, WHICH CA USED A THIN WALL AT THE THREADS AND COULD CRACK.A SECOND SCR REPORT WILL BE SENT TO CESSNA. WE ARE EVALUATING THE NEED T O REPLACE THE HOUSING ON A REGULAR BASIS TO PREVENT RE-OCCURRENCE, UNTIL CESSNA PROVIDE A FIX. 2 L 7 2 4F 4 F RT A22CE E00059EN 2004041600032 20040416 00032 NM 2004 4 16 CA040322002 1 20040319 G 5210 693741810 ROLLER CAM BOEING 727 727227 1384078 NM PWA JT8 JT8D9A 52048 NE PAX DOOR SHEARED W A UNSCHED LANDING D INFLIGHT SEPARATION CL CLIMB 1 CA (CAN) ON CLIMB OUT, CREW HEARD A LOUD BANG AND FELT A CORRESPONDING PRESSURE BUMP. UPON RETURNING TO THE APRON, IT WAS D ISCOVERED THAT THE AFT UPPER GUIDE ROLLER ON THE MAIN ENTRANCE DOOR HAD SHEARED OFF. AFTER INSPECTING THE DOOR, THE CREW ELECTED TO CONTINUE THE FLIGHT UNPRESSURIZED. THE A/C RETURNED TO A MAINTENANCE FACILITY WHERE THE DOOR WAS REPLACED. 2 L 7 3 4F 4 F A3WE E2EA 2004080500056 20040805 00056 WP 2004 8 5 CA040322003 2 20040312 G 7200 ENGINE SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP MCAULY 4HFR34 4HFR34C652 NE LEFT FLUCTUATES W A UNSCHED LANDING N FALSE WARNING CL CLIMB 1 CA 15839 P44720C (CAN) AIRCRAFT TOOK OFF AND THEN PILOT RETURNED WHEN HE NOTICED THAT THE LT ENGINE EGT WAS FLUCTUATING. RUNUPS WERE CAR RIED OUT BY MAINTENANCE AND CONFIRMED THAT WHEN THE SHORT HARNESS WIRING WAS WIGGLED THE INDICATION WOULD FLUCTUATE. CO NTACTS WERE CLEANED AND WIRING SECURED. NO OTHER FLUCTUATIONS HAVE BEEN NOTICED SINCE . 2 L 7 2 4T 4 T RT A8SW E4WE 6 C 3PNE 2004080500057 20040805 00057 EA 2004 8 5 CA040322004 1 20040322 G 2913 848847 PUMP CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE HYD SYS CONTAMINATED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) FAULT:AFTER TAKE-OFF MASTER WARNING AND GEAR DISAGREE MSG ON EICAS. ACTION: FOUND METAL CONTAMINATION IN HYD. SYS T. NR 3, IN RETURN PRESS, CASE DRAIN FILTERS. ALL FILTERS REPLACED AND SYSTEMS FLUSHED IAW AMM 29-10-00-617-803. HYD PUMPS 3A, B REPL'D. NOSE GEAR STRUT SERVICED AND G/SWING C/OUT IAW AMM 32-20-00. ACFTSERV. 2 L 7 2 4F 4 F RT A21EA E15NE 2004080500058 20040805 00058 SO 2004 8 5 CA040322005 2 20040310 G 7414 103493504 MAGNETO CESSNA 182 182Q 2072732 CE CONT O470 O470U 17026 SO MCAULY 2A34C C2A34C204 GL ENGINE FAILED W D RETURN TO BLOCK R J PARTIAL RPM/PWR LOSS WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) THE LT MAGNETO FAILED OPERATIONAL MAGNETO CHECK DURING PRE FLIGHT RUN-UP. AT TIMES THE RPM WAS NOTED TO HAVE DROPP ED BY 200. DURING SUBSEQUENT TROUBLESHOOTING IT WAS NOTED THAT THE MAGNETO DROP WAS WELL WITHIN LIMITS AT 50 RPM BUT WOU LD LATER DROP TO A TOTAL OF 200 RPM. EVERY 3 SECONDS THE RPM DROP WOULD CHANGE FROM 50/ 200 RPM. THE SAME CONDITION EXIS TED AT HIGH POWER SETTINGS AS WELL. WITH BOTH MAGNETOS OPERATING AT HIGH POWER A SLIGHT RPM CYCLING COULD BE DETECTED. T WO LOWER SPARK PLUGS WERE REPLACED DUE TO CARBON FOULING. THE MAGNETO WAS REMOVED AND INSPECTED AND FOUND CONTAMINATED W ITH ENGINE OIL DUE TO A FAILED SHAFT SEAL. UNIT WAS REPLACED AND THE AIRCRAFT GROUND CHECKED SERVICEABLE. 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 2005011200016 20050112 00016 EA 2005 1 12 CA040322006 1 20040311 G 4920 3846068 PLENUM CNDAIR CL600 CL600* EA LYC ALF502 ALF502* 41580 EA APU FRACTURED W K NONE O OTHER IN INSP/MAINT 1 CA P110 (CAN) WHEN APU STARTED IT WOULD NOT ACCELERATE PAST 40 PERCENT. INVESTIGATION FOUND A LARGE BREACH OF PLENUM ASSY. NATUR E OF FRACTURES APPEARS TO BE FATIGUE RELATED DUE TO VIBRATION. APU REMOVED AND FURTHER INVESTIGATION REVEALED A COMPLETE LY DETACHED PIECE BROKEN BRACKET RESTING IN THE COMPRESSOR INLET DUCT. PIECE WAS IDENTIFIED AS A BROKEN FLANGE FROM THE INSIDE OF THE INLET DUCT. INSPECTION OF THE COMPRESSOR ROTOR SHOWED SIGNIFICANT DAMAGE FROM CONTACT WITH THE BRACKET. EL BOW TUBE ASSEMBLY P/N 3846007-1 ATTACHED TOTHE INLET PLENUM WAS ALSO FOUND TO BE LOOSE AND WORN FROM VIBRATION. WHEN THI SAPU WAS INSTALLED IT WAS REPORTED TO HAVE A HIGH PITCH WHINE. THE CAUSE WAS NOT DETECTIBLE. IT OPERATED NORMALLY UNTIL 2 L 7 2 4F 4 F RT A21EA E6NE 2004041600033 20040416 00033 SO 2004 4 16 CA040322007 2 20040311 G 8530 631397 CYLINDER HEAD CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO HARTZL HCJ3Y PHCJ3YF1 GL ENGINE SEPARATED W O OTHER E D B VIBRATION/BUFFET INFLIGHT SEPARATION SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA 195786R (CAN) IN FLIGHT SEPARATION OF CYL NR 3 HEAD. 1 H 7 1 3O 3 O A4CE E5CE 5 C P36EA 2004041600034 20040416 00034 NM 2004 4 16 CA040322008 1 20040322 G 2520 25606801 SEAT BACK BOEING 767 767233 1385113 NM PWA JT9 JT9D7R4D 52054 NE CABIN BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHILE IN THE AIR, SEATBACK 17K BROKE AT HINGE CAUSING PAX WHO WAS SITTING IN SEAT TO HURT THEIR BACK. YYZ MTCE TO REPAIR DURING O/NIGHT.STUD PIVOT PIN REPLACED. 2 L 7 2 4F 4 F RT A1NM E3NE 2004041600035 20040416 00035 WP 2004 4 16 CA040323001 1 20040318 G 4900 CSD DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE APU OVERSERVICED W A UNSCHED LANDING W M J INADEQUATE Q C OVER TEMP WARNING INDICATION CR CRUISE 1 CA (CAN) DURING CRUISE FROM FLL, LT CSD OIL TEMP WENT HIGH. GENERATOR SWITCHED OFF. AIRCRAFT LANDED BACK TO FLL DUE TO APU NOT START. MAINTENANCE FOUND LT CSD OIL OVERFILLED. CSD RESERVICED IAW MM AND AIRCRAFT DISPATCHED SERVICEABLE. 2 L 7 2 4F 4 F RT A6WE E9NE 2004080500059 20040805 00059 EU 2004 8 5 CA040323002 1 20040318 G 2923 9603001153 PUMP PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL HYD SYSTEM CRACKED W O OTHER E K VIBRATION/BUFFET FLUID LOSS LD LANDING 1 CA (CAN) AIRCRAFT WAS ON DECENT. WHEN GEAR DOWN WAS SELECTED DOWN GRINDING NOISES WERE HEARD IN THE CABIN AND THE NOSE DOWN AND LOCKED LIGHT WAS NOT ILLUMINATED. EMERGENCY PROCEDURES WERE USED TO GET THE NOSE DOWN LOCKED LIGHT AND THE A/C WAS LANDED WITHOUT FURTHER INCIDENT. HYDRAULIC FLUID WSA NOTICED LEAKING IN THE POWER PACK AREA. THE A/C WAS FERRIED. ON CHA NGING THE POWER PACK A CRACK WAS DISCOVERED ON THE PUMP BODY ON THE OPPOSITE END FROM THE MOTOR. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005011200017 20050112 00017 SW 2005 1 12 CA040323003 1 20040323 G 3211 71470209L TUBE BBAVIA 8 8GCBC 1220803 SW LYC O360 O360C2E 41514 EA MCAULY 1A200 1A200* GL FUSELAGE BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AS INSTRUCTED BY THE NATIONAL DEFENSE SPECIAL INSPECTION, THE VERTICAL TUBE, ON THE LT SIDE OF THE A/C JUST ABOVE THE LANDING GEAR TUBE STRUCTURE, WAS FOUND BROKEN JUST ABOVE THE WELD. 1 H 7 1 3O 3 O A21CE E286 5 N P874 2005011200018 20050112 00018 WP 2005 1 12 CA040323005 2 20040313 G 7200 ENGINE SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP MCAULY 4HFR34 4HFR34C652 NE RIGHT MALFUNCTIONED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA 15475 (CAN) RT ENGINE EXPERIENCED RPM FLUCTUATIONS AND SRL LIGHT ANNUCIATOR LIGHT FLICKERING. AIRCRAFT RETURNED TO BASE. PIN B ON INLET TEMP WIRING REPAIRED. AIRCRAFT RETURNED TO SERVICE 2 L 7 2 4T 4 T RT A8SW E4WE 6 C 3PNE 2005011200019 20050112 00019 CE 2005 1 12 CA040323006 1 20040318 G 2760 ROLL PIN CESSNA 750 750 2076810 CE ALLSN AE3007 AE3007C GL SPOILER MIXER DAMAGED W O OTHER F FLT CONT AFFECTED IN INSP/MAINT 1 CA (CAN) DURING MX, FOUND 1 ROLL PIN LOOSE AND ONE ROLL PIN MISSING ON THE LT OUTPUT SECTOR OF THE ROLL SPOILER MIXER UNIT. - STILL HAD ISSUES WITH RIGGING AND REMOVED AND OPENED UP THE SPOILER MIXER UNIT. FOUND ANOTHER ROLL PIN MISSING AND ON E LOOSE ON THE L/H OUTPUT SECTOR (INSIDE THE UNIT) - CLOSER INSPECTION OF THE ROLL PINS SHOWED THEY HAD BEEN TAPERED DUR ING INSTALLATION - WE HAD PREVIOUSLY COMPLIED WITH SB750-27-38 WHICH CALLS OUT FOR A ONE TIME INSPECTION OF SPOILER MIXE R UNIT FOR LOOSE OR MISSING ROLL PINS (DOES NOT REQR AN INSPECTION OF PINS INSTALLED WITHIN THE UNIT)- REV 1 OF THEBULLE TIN STATES NO REWORK REQR ON AIRCRAFT THAT HAVE PREVIOUSLY COMPLIED WITH THE ORIGIANL ISSUE.- THE ROLL SPOILER MIXER UNI 2 L 7 2 4J 4 F RT T00007WI TE6CH 2005011200020 20050112 00020 CE 2005 1 12 CA040323007 1 20040322 G 3230 PDLM60 CIRCUIT BREAKER BEECH 100 B100 1152919 CE GARRTT TPE331 TPE3316252B 01514 WP HARTZL HCB4T HCB4TN5 GL HYD PUMP TRIPPED W O OTHER J WARNING INDICATION CL CLIMB 1 CA (CAN) THE 60 AMP BREAKER THAT PROTECTS THE HYDRAULIC LANDING GEAR PUMP MOTOR CIRCUIT TRIPPED WHEN THE GEAR WAS RETRACTED AFTER TAKE OFF. THE CREW ELECTED TO BLOW THE GEAR DOWN AND RETURNED TO BASE WITHOUT FURTHER INCIDENT. HYDRAULIC SYSTE M ON THIS AIRCRAFT ORIGINALLY HAD A 120 AMP BREAKER IN THIS CIRCUIT BUT IT WAS CHANGED TO 60 AMPS TO COMPLY WITH AD 95-1 3-03. THIS AD WAS INTENDED FOR MECHANICAL RETRACTION SYSTEM. THE HYDRAULIC SYSTEM HAS A 100 AMP MOTOR WHICH RUNS LONGER THAN THE MECHANICAL SYSTEM AND IS PRONE TO NUISANCE TRIPS OF THE 60 AMP BREAKER. THE AD SHOULD BE NOTED AS NOT APPLYING TO HYDRAULIC SYSTEMS WHICH SHUTS OFF BY VIRTUE OF A HYDRAULIC PRESSURE SWITCH. 1 L 7 2 4T 4 T A14CE E2WE 6 C P40EA 2005011200021 20050112 00021 CE 2005 1 12 CA040324001 1 20040324 G 3233 MS28775328 O-RING LEAR LEAR 35 35LEAR 5170600 CE GARRTT TFE731 TFE73122B 01518 WP MLG ACTUATOR SEPARATED W B EMER. DESCENT K FLUID LOSS DE DESCENT 1 CA KL0055 (CAN) RT MAIN GEAR DOWN AND LOCK LIGHT WON'T COME ON. FLIGHT CREW EXTENDED THE GEAR WITH THE BLOW DOWN SYSTEM. MAINTENAN CE CREW FOUND A HYDRAULIC (O-RING) SEAL SEPERATED IN TWO INSIDE THE RT MAIN LANDING GEAR SIDE BRACE ACTUATOR ASSY. ACTUA TOR ASSY REPAIRED. 2 L 7 2 4F 4 F A10CE E6WE 2005011200022 20050112 00022 CE 2005 1 12 CA040324002 1 20040315 G 2432 BATTERY BEECH 200 B200 1152922 CE PWA PT6 PT6A42 52043 NE MASTER DISCHARGED W A UNSCHED LANDING H ELECT. POWER LOSS-50 PC CL CLIMB 1 CA (CAN) PILOT REPORTED COMPLETE ELECTRICAL FAILURE AND LANDED WITH GEAR MANUALLY EXTENDED. INSPECTION FOUND STARTER SWITCH ES IN THE 'ON' POSITION AND BATTERY DOWN TO 12VOLTS, NO OTHER INDICATION OF FAULT WAS FOUND. I FEEL THAT WITH THE SWITCH ES IN THE 'ON' POSITION, THE GENERATORS WERE NOT CHARGING THE BATTERY, AND THE BATTERY EVENTUALLY EXHAUSTED ITSELF TO TH E POINT WHERE IT COULD NO LONGER POWER THE SYSTEMS. 1 L 7 2 4T 4 T A24CE E4EA 2005011300012 20050113 00012 EU 2005 1 13 CA040324003 1 20040307 G 6720 350A33020004 BELLCRANK AEROSP AS355 AS355F1 8680810 EU ALLSN 250C 250C20F 03013 GL TAIL ROTOR DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) TAIL ROTOR BELLCRANK FOUND WITH WEAR DAMAGE ON INSIDE YOKE AREA AT THE ATTACHMENT BOLT WITH THE TAIL ROTOR PITCH C HANGE SPIDER. THE WEAR CORRESPONDS TO THE BEARING SURFACE OF BALL END P/N 350A33-2150-01. IT IS SUSPECTED THAT THE ATTAC HMENT BOLT WAS NOT TORQUED TO SPECIFICATIONS AND CAUSED MOVEMENT AND WEAR. 1 G 7 2 3U 3 U H11EU E4CE 2005011300013 20050113 00013 EU 2005 1 13 CA040324004 1 20040307 G 6220 350A37122823 RING AEROSP AS355 AS355F1 8680810 EU ALLSN 250C 250C20F 03013 GL MAIN ROTOR WORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ALL 3 DROOP RING YOKES WERE FOUND WITH WEAR DAMAGE ON OUTSIDE DIAMETER. THIS WEAR CORRESPONDS WITH WEAR FOUND ON T HE DROOP RING CONTACT FITTINGS P/N 350A31-1852- 20 ON EACH STAR ARM. SUSPECT THAT THE YOKES WERE AT ONE TIME INSTALLED UNDER EACH STAR ARM AND CONTACTED THE DROOP FITTINGS. BOTH PARTS WERE INSPECTED FOR DEFORMATION AND CRACKING. NO FURTH ER DEFECTS FOUND. THE AS355 MAINTENANCE WORK CARD 62.20.00.401 PARA 3 SIMPLY STATES' POSITION YOKES 120 DEG. APART'. H OWEVER WORK CARD 62.20.16.401 PARA 3 STATES 'POSITION EACH YOKE BETWEEN 2 ARMS OF THE ROTOR HUB'. THE MANUFACTURER HAS BEEN CONTACTED TO MODIFY THE STATEMENT IN WORK CARD 62.20.00.401. 1 G 7 2 3U 3 U H11EU E4CE 2005011300014 20050113 00014 GL 2005 1 13 CA040324005 2 20040324 G 7323 2522125 LEVER ALLSN 250C 250C20B 03013 GL FUEL CONTROL MISINSTALLED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THE CAM LEVER WAS INSTALLED INCORRECTLY. THE LEVER CAN BE INSTALLED POINTING EITHER UP OR DOWN (THE ORIENTATION O F THE LEVER ON THE PT6 IS OPPOSITE TO THAT OF ROLLS ROYCE). THE CALIBRATION PROCESS DONE DURING THE OVERHAUL IS UNAFFEC TED BY THE ORIENTATION. THE INCORRECT ORIENTATION WAS NOT NOTICED UNTIL THE PART WAS BEING INSTALLED BY A CUSTOMER WHO WAS UNABLE TO CONNECT THE AIRFRAME CONTROL TO THE UNIT. UNITS WERE RECALLED AND ONE OTHER GOVERNOR WAS FOUND TO HAVE IT S LEVER INCORRECTLY INSTALLED. CHANGES HAVE BEEN MADE TO THE COMPANY'S INTERNAL OVERHAUL PROCESS DOCUMENTATION TO ENSUR E THE LEVER IS CORRECTLY INSTALLED, AS THE OEM OVERHAUL MANUAL COULD BE MORE DESCRIPTIVE ABOUT THE ORIENTATION. 3 U E4CE 2005011300015 20050113 00015 EU 2005 1 13 CA040324007 1 20040302 G 7830 32726023 ROD END AIRBUS 310 A310300 3930305 EU GE CF6 CF680C2A5 NE JACKSCREW ACT SHEARED W K NONE O OTHER IN INSP/MAINT 1 CA GRTE1062 (CAN) DURING ROUTINE INSPECTION, NR 1 ENGINETHRUST REVERSER RT TRANSLATING COWL LOWER JACKSCREW ACTUATOR ROD END FOUND S HEARED IN THREADPORTION OF ROD END. JACKSCREW ACTUATOR ASSEMBLY REPLACED AND SYSTEM VERIFIED SERVICEABLE. 2 L 7 2 4F 4 F RT A35EU E13NE 2005011300016 20050113 00016 EU 2005 1 13 CA040324008 1 20040320 G 2750 132002260 SWITCH AIRBUS 310 A310300 3930305 EU GE CF6 CF680C2A5 NE TE FLAPS BROKEN W O OTHER F FLT CONT AFFECTED TX TAXI/GRND HDL 1 CA (CAN) AIRCRAFT ARRIVED WITH FLAP UNABLE TO RETRACT PAST THE INTERMEDIATE POSITION OF +-5 DEGREES.UPON INVESTIGATION FOUN D THE LEFT HAND OUTBOARD VANE JAM DETECTOR UNIT SWITCH SHEARED AND INTERNALLY JAMMED AND BUFFER CRUSHED. THE BRACKET/SWI TCH ASSEMBLY WAS REPLACED AND SYSTEM VERIFIED SERVICEABLE. FAILURE IS UNDER INVESTIGATION TO DETERMINE IF FATIGUE OR WEA THER ( ICE ) WOULD BE THE CAUSE. 2 L 7 2 4F 4 F RT A35EU E13NE 2005011300017 20050113 00017 EU 2005 1 13 CA040324009 1 20040324 G 7830 32726023 ROD END AIRBUS 310 A310300 3930305 EU GE CF6 CF680C2A5 NE JACKSCREW ACT SHEARED W K NONE O OTHER IN INSP/MAINT 1 CA AEX22761C (CAN) DURING TROUBLE SHOOTING A DEFECT ON NR 2 ENGINE REVERSER, LT LOWER SLEEVE NOT STOWING PROPERLY, FOUND THE LOWER JA CKSCREW ACTUATORROD END BROKEN. ACTUATOR ASSEMBLY REPLACED AND SYSTEM VERIFIED SERVICEABLE. THIS IS THE SECOND EVENT WIT H THE SAME FAILURE WITHIN 3 WEEKS. THE FAILURES ARE UNDER INVESTIGATION BY THEENGINEERING GROUP. 2 L 7 2 4F 4 F RT A35EU E13NE 2005011300018 20050113 00018 EA 2005 1 13 CA040324010 1 20040320 G 3010 GG670800121 CONTROLLER CNDAIR CL600 CL6002C10 1390015 EA ANTI ICE LEAK WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) ANTI-ICE LEAK CONTROLLER HAS BEEN REPLACED FOLLOWING A FLIGHT SNAG CONCERNING A CAUTION MESSAGE. A NEW AILC WAS S UPPLIED AND REPLACED ON THE AIRCRAFT. THIS NEW AILC HAD A DIFFERENT PART NUMBER USED ON MODEL CL-600-2D24 BUT WAS INSTAL LED ON AIRCRAFT CL-600-2C10. THE BOX IS SIMILAR BUT IS NOT APPROVED ON THIS LAST MODEL. AIRCRAFT WAS RELEASED FOR PRODUC TION FLIGHT IN AN IFR PREVALING WEATHER. NO FAULT WERE FOUND AND THE AIRCRAFT COMPLETED THE FLIGHT WITHOUT A PROBLEM.IT COULD HAVE HAD AN HAZARDOUS ENDING (WE DIDN'T KNOW). THE AILC WAS THEN REMOV ED AND REPLACED BY A GOOD PN, THE AIRCRAFT RE-TESTED AND THEN FOUND SERVICEABLE. 2 L 7 2 4F RT A21EA 2005011300019 20050113 00019 CE 2005 1 13 CA040324011 1 20040324 G 2730 187504 BELLCRANK BEECH 18 3NM 1151044 CE PWA R985 R985AN14B 52008 NE ELEVATOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) A CRACK WAS DISCOVERED IN THE ELEVATOR BELLCRANK AT THE POINT WHERE IT ATTACHES TO THE CONTROL COLUMN ASSY. THE CR ACK ORIGINATES AT ONE OF THEHOLES FOR TAPER PINS WHICH ATTACH THE ARM TO THE SHAFT OF THE BELLCRANK. AD 77-19-07 CALLS F OR PERIODIC INSPECTION OF THIS PART FOR CRACKS. THE BELLCRANK ASSY WAS REPLACED. 1 L 7 2 3R 3 R A765 5E1 2004080600021 20040806 00021 NM 2004 8 6 CA040325002 1 20040325 G 2782 269002916 ACTUATOR BOEING 727 72722C 138400F NM PWA JT8 JT8D7B 52053 NE LE FLAP LEAKING W L ABORTED APPROACH K J FLUID LOSS WARNING INDICATION AP APPROACH 1 CA (CAN) ON APPROACH INTO CYVR SELECTED FLAPS 2, AMBER IN-TRANSIT LIGHT STAYED ON. NR 7 SLAT DID NOT EXTEND. HYDRAULIC SYST EM (A) LOW PRESSURE LIGHTS ILLUMINATED AND HYDRAULIC (A) SYSTEM QUANTITY INDICATED ZERO QUANTITY. AIRCRAFT WAS VECTORED AND CREW PERFORMED HYDRAULIC LOSS CHECK LIST AND ONE SLAT INOP. LANDING CHECK LIST. AFTER CHECK LISTS COMPLETED AN EMERG ENCY WAS DECLARED AND THE AIRCRAFT LANDED AND WAS TOWED TO THE RAMP. NR 7 SLAT ACTUATOR END CAP THREADS FAILED CAUSING A LEAK AND LOSS OF HYDRAULIC FLUID. 2 L 7 3 4F 4 F A3WE E2EA 2004042100018 20040421 00018 EA 2004 4 21 CA040325003 2 20040322 G 7314 69159 ADAPTER PIPER PA31 PA31300 7103104 SO LYC O540 TIO540A2C 41532 EA HARTZL HCE3Y HCE3YR2A GL ACC CASE BROKEN W E ENGINE SHUTDOWN K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA (CAN) OIL LOSS WAS NOTED BY PILOTS AS THE OIL PRESSURE DROPPED. INFLIGHT SHUTDOWN WAS INITIATED. ON LANDING, MAINTENANCE DISCOVERED THAT THE ENGINE DRIVEN FUEL PUMP DRIVE ADAPTER HAD BROKEN AND CAUSED THE LOSS OF OIL FROM THE ACCESSORY CASE . ALSO NOTED WAS THAT THE EDFP IDLER GEAR HAD BROKEN GEAR TEETH. P/N OF THE IDLER GEAR IS LW-10324. ENGINE HAS BEEN REMO VED AND SENT FOR REPAIR OR OVERHAUL. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004080600022 20040806 00022 EU 2004 8 6 CA040325004 1 20040322 G 2913 704A33690004 DRIVE ASSY SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE HYD PUMP BROKEN W A UNSCHED LANDING F FLT CONT AFFECTED NR NOT REPORTED 1 CA (CAN) DURING A HOVER FLIGHT HYDRAULIC WARNING LIGHT CAME ON. THE PILOT STABILIZED THE A/C AND RETURNED TO CAMP IN MANUAL CONTROL MODE. UPON INSPECTION, AME DISCOVERED BROKEN HYDRAULIC PUMP PULLEY DRIVE BELT. BELT REPLACED, A/C RETURNED TO SERVICE. 1 G 7 1 3U 3 U H9EU E19EU 2004080600023 20040806 00023 WP 2004 8 6 CA040325005 1 20040325 G 5230 DOOR CVAC 340 340CVAC 242270A WP ALLSN 501D 501D13D 03004 GL CARGO LEAKING W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) ON CLIMB OUT, CREW EXPERIENCED A LOSS OF CABIN PRESSURE AND A CORRESPONDING DOOR WARNING LIGHT. THE CREW RETURNED TO DEPARTURE, CYCLED THE C1 DOOR, AND RE-DEPARTED WITHOUT FURTHER INCIDENT. 2 L 7 2 4R 4 T 6A6 E282 2004042100019 20040421 00019 GL 2004 4 21 CA040326001 3 20040323 G 6114 PROPELLER PIPER J3 J3L65 7100546 SO CONT A65 A658F 17003 SO MCAULY 1B90 1B90CM GL CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) CUSTOMER REQUESTED REPITCH ONLY. ADVISED CUSTOMER TO OVERHAUL DUE TO VISUAL CORROSION ON PROP CORROSION REMOVED IA W MANUAL 730720. 1 H 7 1 3O 3 O A698 E205 5 N P842 2004080600024 20040806 00024 NE 2004 8 6 CA040326002 2 20040319 G 7230 BLADE DHAV DHC8 DHC8311 1386006 EA PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE IMPELLER BENT W C ABORTED TAKEOFF D INFLIGHT SEPARATION TO TAKEOFF 1 CA (CAN) ON TAKE OFF, CREW HEARD A STRANGE WHINING SOUND. SOUND IDENTIFIED AS FROM NR 1 ENGINE. TAKE OFF REJECTED AT 30 KT S. MAINTENANCE FOUND BENT BLADE ON LOW PRESSURE COMPRESSOR IMPELLER. ENGINE REPLACED. CREW ON PREVIOUS FLIGHT HAD REP ORTED A BIRD STRIKE. AIRCRAFT HAD BEEN INSPECTED BY MAINTENANCE WITH NO APPARENT DAMAGE FOUND. ENGINE S/N TSN:23746 HR S, TSO:10578 HRS,CYCLES:34323. HOURS AND CYCLES ON IMPELLER BLADE TO BE DETERMINED. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004080600025 20040806 00025 EA 2004 8 6 CA040326003 1 20040322 G 7603 GEARBOX AERO CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE THROTTLE CONTROL BINDING W O OTHER E VIBRATION/BUFFET NR NOT REPORTED 1 CA 10352 10352 245 (CAN) PILOT REPORTED THROTTLE ACTION STIFF. MAINTENANCE TROUBLESHOT PROBLEM TO NR 1 ENGINE THROTTLE CONTROL GEARBOX BIND ING. NR 1 THROTTLE CONTROL GEARBOX REPLACED. IT IS NOTED THAT AD CF-2004-01, HAS BEEN ISSUED AGAINST GEARBOX P/N 21001 40-007, ALTHOUGH IN THIS CASE IT WAS A PILOT REPORTED DEFECT AND NOT AS A RESULT OF AN INSPECTION IAW THE AD. 2 L 7 2 4F 4 F RT A21EA E15NE 2004080600026 20040806 00026 CE 2004 8 6 CA040326004 1 20040322 G 3230 CONTROL VALVE CESSNA 500 550 2076604 CE MLG MALFUNCTIONED W O OTHER J WARNING INDICATION AP APPROACH 1 CA (CAN) AIRCRAFT DEPARTED, ON THE FIRST GEAR DOWN SELECTION THE LT MAIN GEAR DOWN LOCK INDICATION DID NOT ILLUMINATE. AN EMERGENCY EXTENSION PROCEDURE WAS PERFORMED WITH NO LT MAIN GEAR SAFE LIGHT VISIBLE. ON SHORT FINAL THE GEAR CIRCUIT BRE AKERS WERE RESET TO DETERMINE GEAR SAFE CONDITION AND THREE GREEN WERE OBSERVED INITIALLY AND THEN THE LT GEAR SAFE LIGH T EXTINGUISHED. GEAR CIRCUIT BREAKERS WERE LEFT IN TO ENSURE POSITIVE HYDRAULIC SYSTEM DOWN PRESSURE TO THE GEAR. THE A IRCRAFT LANDED SAFELY AND RETURNED TO BASE. MAINTENANCE DETERMINED THAT THE MAIN LANDING GEAR CONTROL VALVE HAD MALFUNCT IONED AND REPLACED THE UNIT. THE GEAR RETRACTION SYSTEM WAS FUNCTION CHECKED AND THE AIRCRAFT RETURNED TO SERVICE. 1 L 7 2 4F A22CE 2004080600027 20040806 00027 2004 8 6 CA040326005 4 20040325 G 2565 7A1510110 SLIDE AIRBUS 330 A330342 EU RROYCE RB211 RB211TRENT77 NE CABIN LEAKING W K NONE O OTHER IN INSP/MAINT 1 CA 13305 (CAN) FOLLOWING A SLIDE RAFT DEPLOYMENT TEST, FOUND SLIDE RAFT DEFLATING AT SLOW RATE BY A PIN HOLE. PIN HOLE LOCATE ON FORWARD TUBULAR SECTION AT APPROXIMATELY 4 FEET FROM GROUND. DEFECT IS UNDER INVESTIGATION WITH ENGINEERING AND VENDOR . 1 L 7 2 4F 4 F RT A46NM E39NE 2004080600049 20040806 00049 SO 2004 8 6 CA040326006 1 20040323 G 7120 8401002 MOUNT PIPER PA46 PA46310P 7104605 SO CONT O550 TSIO550C SO HARTZL HCC2Y BHCC2YF1 GL ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ENGINE MOUNT CRACKED AT AREA DESCRIBED IN MFG SB NR 1103 REV.B NOTE: THIS SHOULD BE NOTIFIED TO ALL OWNERS BY AN A IRWORTHINESS DIRECTIVE. 1 L 7 1 3O 3 O RT A25SO E5SO 5 C P920 2004080600055 20040806 00055 2004 8 6 CA040329001 4 20040327 G 2350 G2412 SELECTOR PANEL BOEING 727 727223 1384074 NM PWA JT8 JT8D15A 52051 NE VHF COMMS FAILED W O OTHER O OTHER DE DESCENT 1 CA (CAN) DURING DESCENT, COMMUNICATIONS WERE LOST. AN EMERGENCY WAS DECLARED AND THE AIRCRAFT LANDED WITHOUT INCIDENT. TH E FIRST OFFICER'S AUDIO SELECTOR PANEL WAS SUSPECT. A HOT MIKE SITUATION WAS APPARENT IN VHF 1 AND VHF 2. THE AUDIO SE LECTOR PANEL WAS REPLACED IAW MM 23-20-00 AND CHECKED SERVICEABLE. NO FURTHER INCIDENT DURING SUBSEQUENT FLIGHT. 2 L 7 3 4F 4 F A3WE E2EA 2004080600056 20040806 00056 CE 2004 8 6 CA040329002 1 20040318 G 5511 115620010325 RIB BEECH BEECH 100 A100 1152915 CE PWA PT6 PT6A28 EA HARTZL HCB3T HCB3TN3 GL HORIZONTAL STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 18824 B247 (CAN) ON INSPECTION OF THE HORIZONTAL STABILIZER THE UPPER SKIN WAS FOUND TO BE OIL CANNING. UPON FURTHER INSPECTION IT WAS FOUND THAT 6 RIBS WERE CRACKED INTERNALLY (PN 115-620010-325, 115-620010-210, 115-620010-355, 115-620010-255, 115-6 20010-215, 115-620010-209). WE BELIEVE THIS DAMAGE WAS FROM PEOPLE WALKING ON THE STABILIZER. 1 L 7 2 3T 4 T A14CE E4EA 6 C P15EA 2004080600057 20040806 00057 CE 2004 8 6 CA040329003 1 20040302 G 2420 1101912R GENERATOR CESSNA 180 180F 2072614 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C203 GL ENGINE LOOSE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) GENERATOR WAS FOUND TO BE LOOSE AND SLOPPY. UPON REMOVAL IT WAS DISCOVERED THAT FRONT LUG HOLE HAD BEEN PREVIOUSL Y DRILLED AND BUSHED. BOTH GEN MOUNTING LUG HOLES WERE SEVERELY WORN AND ELONGATED, BOLTS WORN, AND BUSHING WORN WITHIN .1250 INCH OF SIDE OF LUG. GEN MOUNT BRACKET (P/N539579) HOLES ALSO ELONGATED. REPAIR REQUIRED NEW GENERATOR AND NEW M OUNT BRACKET. OWNER CLAIMS NO KNOWLEDGE OF PREVIOUSLY UNAPPROVED INSTALLATION OF BUSHING IN GENERATOR. UNAPPROVED REPAI R CAUSED DAMAGE TO MOUNT BRACKET. OWNERS SHOULD BE WARNED AGAINST INSTALLING BUSHINGS AT GEN ATTACH POINTS. 1 H 7 1 3O 3 O 5A6 E273 5 C P3EA 2004080600058 20040806 00058 2004 8 6 CA040329004 4 20040316 G 6122 210385 GOVERNOR BEECH 65 A65 1152803 CE LYC O480 IGSO480A1E6 41529 EA HARTZL HCB3Z HCB3Z202 GL PROPELLER RUPTURED W E A ENGINE SHUTDOWN UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA (CAN) THE OIL LEAK WAS TRACED TO THE PROP GOVERNOR AND ONLY SHOWED UP AT APPROXIMATELY 2500 RPM. A PIECE OF GASKET .125 0 INCH WIDE WAS FOUND MISSING FROM THE GASKET WHICH CAUSED A LEAK OF AN ESTIMATED 1 QUART OF OIL EVERY 2 MINUTES. NO AP PARENT REASON COULD BE FOUND FOR THE DEFECT. THE GASKET WAS DESTORYED IN THE PROCESS OF REMOVAL. AS IT WAS STUCK, THE M ATING SURFACES HAD NO DEFECTS AND HOLD DOWN NUTS WERE TIGHT. NEW GASKET INSTALLED AND GROUND RUNS CARRIED OUT WITH NO L EAKS. 1 L 7 2 3O 3 O 3A20 E284 5 C P907 2005011300021 20050113 00021 NM 2005 1 13 CA040329005 1 20040321 G 2910 82950010161 TUBE DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE FLT SPOILER LEAKING W O OTHER K FLUID LOSS CR CRUISE 1 CA (CAN) HYDRAULIC SYSTEM FAILURE (NR 1 ISO VALVE AND ROLL SPOILER INBOARD HYDRAULIC CAUTION LIGHTS) HYDRAULIC TUBE FOR LT INBOARD FLIGHT SPOILER ACTUATOR (UNLOAD) FOUND WITH PINHOLES. TUBE REPLACED, FUNCTION AND LEAK CHECKS COMPLETED. NR 1 HYDRAULIC EDP WAS NOT RUN DRY (APPROX. 1 LITER IN RESERVOIR ON ARRIVAL). NR 1 HYDRAULIC FILTER BYPASS INDICATORS OK. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005011300022 20050113 00022 NE 2005 1 13 CA040330001 3 20040326 G 6197 WIRE DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE PROP FEATHER CHAFED W A UNSCHED LANDING E VIBRATION/BUFFET CL CLIMB 1 CA (CAN) AN OPERATOR CARRIED OUT AN UNSCHEDULED LANDING DUE TO UNCOMMANDED NR 2 PROPELLER FEATHER DURING CLIMB, AND SUBSEQU ENT OVERTORQUE OF THE NR 2 ENGINE. THEY FOUND THE CAUSE OF THIS PROBLEM WAS: CHAFING OF SEVERAL WIRES (HYDRAULIC SYSTEM, PROPELLER AUTOFEATHER SYSTEM, AND GALLEY ELECTRICAL POWER) ON A BRACKET IN THE RT WINGROOT CAUSED A 'MIXTURE' OF 28VDC AND 115VAC IN THESE SYSTEM, AND SUBSEQUENT MALFUNCTION OF THE NR 2 PROP AUTOFEATHER SYSTEM. THE AFFECTED BRACKET IN THE RT REAR WINGROOT HAS P/N 85350711-001. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005011300023 20050113 00023 NM 2005 1 13 CA040330002 1 20040329 G 5620 56B2251733 WINDOW BOEING 747 747433 NM PWA 4056 PW4056 NE ROW 31 CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AIRCRAFT TOTAL TIME 49,175HRS,7715 CYCLES ITEM NOT A TRACKED ITEM.IN FLIGHT, PASSENGER WINDOW AT ROW 31 CRACKED,IT WAS THE OUTER PANE, WITH NO DEPRESSURISATION WINDOW REPLACED. 2 L 7 4 4F 4 F RT A20WE E24NE 2005011300024 20050113 00024 GL 2005 1 13 CA040330003 2 20040327 G 7260 2062301 COMPUTER CVAC 340 340CVAC 242270A WP ALLSN 501D 501D13 03004 GL ENGINE DRIVE MALFUNCTIONED W B H EMER. DESCENT DEACTIVATE SYST/CIRCUITS W J INADEQUATE Q C WARNING INDICATION CR CRUISE 1 CA (CAN) ON A CARGO FLIGHT FROM CINCINATI TO MONTRIAL NR 2 ENGINE WAS SHUTDOWN. AIRCRAFT WAS DIVERTED TO TRENTON ONTARIO B ECAUSE COCKPIT CREW WERE UNABLE TO CONFIRM THAT THE EDC WAS ACTUALLY DISCONNECTED AFTER SELECTING DISCONNECT, DUE TO LOW OIL PRESSURE. THE NORMAL WAY ON PASSENGER AIRCRAFT IS AIR FLOW REDUCTION IN COCKPITT AFTER EDC DISCONNECTED. ON CARGO A IRCRAFT THERE IS NO REDUCTION OF AIR FLOW DUE TO DUCTING MODIFICATION. MAINTENANCE WAS DISPATCHED TO CONFIRM EDC DISCONN ECTED AND RELEASE AIRCRAFT IAW MEL PROCEDURE. AIRCRAFT RETURN TO MONTRIALWHERE EDC WAS REPLACED AND AIRCRAFT RETURN TO S ERVICE. 2 L 7 2 4R 4 T 6A6 E282 2005011300025 20050113 00025 NE 2005 1 13 CA040330004 2 20040322 G 7250 TURBINE BLADES PWA PW121 PW121 52124 NE ENGINE FAILED W K NONE O OTHER IN INSP/MAINT 1 CA 11575 121337 (CAN) ENGINE SUSTAINED AN LPT BLADE FAILURE DUE TO CREEP OF THE LP BLADES. DEBRIS FROM FAILURE OF THE LPT BLADES RESULTE D IN EXTENSIVE DOWNSTREAM DAMAGE TO THE PT SECTION. RESIDUAL VIBRATIONS RESULTING FROM THE LPT BLADE FAILURE CAUSED A N UMBER OF TUBES IN THE REAR PORTION OF ENGINE TO FRACTURE. 1 OF TUBES WHICH FRACTURED WAS NR 6&7 BEARING OIL PRESSURE SUP PLY TRANSFER TUBE. FRACTURE OF THIS TUBE RESULTED IN OVRBOARD OIL LEAK & REPORTED LOW OIL PRESSURE INDICATIONS. INFLT SH UTDOWN HAD OCCURRED DUE TO A LOW OIL PRESSURE IND. THESE BLADES WERE INSTALLED NEW DURING 2000 OVERHAUL & HAVE ACCUMULAT ED 5049.1 HOURS & 6022 CYCLES OF OPERATION SINCE. TURBOMACHINE RESTORED TO SERVICE. RGB MODULE WAS BORESCOPE INSPECTED. 4 T E20NE 2005011300026 20050113 00026 CE 2005 1 13 CA040330005 1 20040323 G 3230 NA WIRE BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL SWITCH LOOSE W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) AFTER TAKE OFF THE CREW SELECTED THE LANDING GEAR UP. THE LANDING GEAR DID NOT MOVE AND STAYED EXTENDED. THE CREW PUT THE GEAR HANDLE BACK DOWN AND RETURNED TO THE HANGER. AIRCRAFT PUT ON JACKS AND GEAR RETRACTION TRIED AGAIN WITH NO MOVEMENT OF THE GEAR. AFTER INSPECTION IT WAS FOUND THAT 1 WIRE HAD COME DISCONNECTED FROM THE EMERGENCY EXTENTION CLUTC H MICRO SWITH (SCREW CAME OUT). WIRE REINSTALLED WITH LOCKTITE ON THE SCREW. GEAR FUNCTION CHECKED OK. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2005011300027 20050113 00027 SO 2005 1 13 CA040330006 1 20040330 G 3620 441CC7 DRIVE SHAFT PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA PNEUMATIC PUMP SHEARED W K NONE J WARNING INDICATION IN INSP/MAINT 1 CA (CAN) PNEUMATIC MALFUNCTION LIGHT WAS ON UNTIL 2000 RPM. TROUBLESHOT SNAG AND FOUND THE DRIVE SHAFT OF PUMP SHEARED. 1 L 7 2 3O 3 O A20SO E14EA 2005011300028 20050113 00028 SW 2005 1 13 CA040331001 1 20040323 G 5510 407023801123 DOUBLER 407023801109 BELL 407 407 1182206 SW ALLSN 250C 250C47B GL HORIZONTAL STAB DELAMINATED W K NONE O OTHER IN INSP/MAINT 1 CA BP588 (CAN) HORIZONTAL STAB. WAS FOUND WITH AN EDGE DELAMINATION BETWEEN THE STAB TOP SKIN AND THE -123 DOUBLER AT 1.85. 1 G 7 1 3U 3 U O H2SW E1GL 2005011300029 20050113 00029 NM 2005 1 13 CA040331002 1 20040319 G 2910 82970009387 LINE DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE HYD SYS LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) DURING WALK AROUND BEFORE DEPARTURE PILOT NOTED SUBSTANTIAL HYDRAULIC LEAK FROM NR 2 NACELLE. MAINTENANCE FOUND N R 1 SYSTEM LIFT DUMP PRESSURE LINE WITH A PIN HOLE LEAK. LINE REPLACED LEAK AND FUNCTION CHECK CARRIED OUT, AND AIRCRAFT RETURNEDTO SERVICE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005011300030 20050113 00030 SO 2005 1 13 CA040331003 1 20040326 G 3220 NAS464P427 BOLT PIPER PIPER PA44 PA44180 7104402 SO LYC O360 O360D1A 41514 EA HARTZL HCC3Y HCC3YR2 NE SHAFT SHEARED W O OTHER O OTHER LD LANDING 1 CA (CAN) THE AIRCRAFT WAS ON A ROUTINE TRAINING FLT & HAD JUST LANDED WHEN THE NLG SUDDENLY COLLAPSED DURING LANDING ROLL. ONCE ACFT WAS CLEARED TO BE MOVED FROM RUNWAY, IT WAS TOWED TO RAMP AREA WHERE MX PERSONNEL WERE ABLE TO INVESTIGATE FAI LURE. EXAMINATION OF THE NLG SYS BY AN AME REVEALED THAT THE DRAG LINK PIVOT BOLT HAD SHEARED & SUBSEQUENTLY BACKED OUT OF POSITION CAUSING DRAG LINK MECH TO FAIL. FAILURE OF DRAG LINK MECH IN TURN CAUSED THE NLG TO COLLAPSE. AT THE TIME OF THE INVESTIGATION THE AME DETERMINED THAT THE BOLT HAD SHEARED ABOUT HALF WAY ALONG THE SHAFT AND THAT THE END WITH THE NUT ATTACHED HAD FALLEN FROM THE AIRCRAFT AND THE REMAINING HALF HAD BACKED OUT ENOUGH TO ALLOW THE LINKAGE TO SEPARATE 1 L 7 2 3O 3 O A19S0 E286 5 C P25EA 2005011300031 20050113 00031 EA 2005 1 13 CA040331005 2 20040330 G 8530 PUSHROD TUBE GRUMAN TS2 TS2ACALFORST 3951102 WP WRIGHT R1820 982C9HE2 67020 EA HAMSTD 43D 43D51 NE NR 5 CYLINDER BROKEN W E ENGINE SHUTDOWN J WARNING INDICATION CR CRUISE 1 CA BL516303 (CAN) DURING A TRAINING FLIGHT THE CREW OBSERVED THE RT ENGINE LOW OIL PRESSURE LIGHT HAD ILLUMINATED. THE CREW THEN CHE CKED THE OIL PRESSURE GAUGE AND NOTED A DROP IN OIL PRESSURE. THE ENGINE WAS SHUT DOWNAND THE PROPELLER WAS FEATHERED. T HE AIRCRAFT RETURNED TO BASE. UPON INVESTIGATION MAINTENANCE NOTED THAT THE PUSH ROD TUBES FOR CYLINDER NR 5 WERE BENT A ND BROKEN. THE MAIN OIL SCREEN WAS REMOVED FOR INSPECTION AND FOUND CONTAMINATED. THE ENGINE IS BEING REMOVED AND WILL B EREPLACED WITH A SERVICEABLE QCU AND THE AIRCRAFT WILL BE RETURNED TO SERVICE. 2 H 7 2 4R 4 R A25WE E259 6 C P8879 2005011300032 20050113 00032 EU 2005 1 13 CA040331006 1 20040315 G 7120 001269004 ISOLATOR BARRYCTRLS PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL ENGINE MOUNT MISREPAIRED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 864894910 (CAN) DURING A SCHEDULED ENGINE CHANGE NEW ENGINE MOUNT ASSEMBLIES WERE BEING INSTALLED. THREE OUT OF FIVE NEW ENGINE MO UNT FORWARD VIBRATION ISLOATORS HAD A BUSHING DIAMETER TOO SMALL TO ALLOW INSERTING THE NEW ENGINE MOUNT BOLTS. EVEN THE OLD ENGINE MOUNT BOLTS COULD NOT BE INSTERED THROUGH THE NEW VIBRATION ISOLATORS. THEDIAMETER OF THE FORWARD ISOLATOR C OMPARED TO THE REAR ISOLATOR WAS .010 SMALLER. THE ENGINE MOUNT BOLTS FIT THROUGH THE REAR ISOLATORS. SUSPECTING THE NEW ENGINE MOUNTS WERE SUBSTANDARD, THEY WERE RETURNED TO STORES WITH UNSERVICEABLE TAGS. NEW ENGINE MOUNTS WERE ORDERED & INSTALLED WITH NO DIFFICULTIES. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005011300033 20050113 00033 NM 2005 1 13 CA040401001 1 20040401 G 2760 HINGE DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE FLT SPOILER BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING INSPECTION , AN ENGINEER NOTICED THE INBOARD HINGE OF THE RT OTBD FLT SPOILER HAS BEEN BROKEN. THE SPOILER PANEL WAS REPLACED .TOTAL TIME ON A/C IS 41510.48 AND TOTAL CYCLES ARE 52560 THE PANEL S/N IS F1-038 PLEASE VIEW ATTACH ED FILES FOR PART CONDITION REFER TO ILLUSTRATED PARTS CATALOG FOR DHC-8-100SECTION 57-53-00 FIG 10 FOR ILLUSTRATED DRAW ING 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005011300034 20050113 00034 SO 2005 1 13 CA040401002 1 20040330 G 3220 NAS464P427 BOLT PIPER PA44 PA44180 7104402 SO LYC O360 O360E1A6 41514 EA HARTZL HCC2Y HCC2YR2 GL NLG DRAG LINK BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING REGULAR MAINTENANCE, IT WAS DECIDED TO INSPECT THE CONDITION OF THE CENTRE BOLT OF THE DRAG LINK ASSY AS A RESULT OF THE FAILURE OF THIS BOLT ON THE OTHER COMPANY OPERATED AIRCRAFT. THIS BOLT WAS FOUND IN PLACE, BUT WHEN THE NU T WAS ROTATED IT WAS FOUND THAT THE BOLT WAS BROKEN IN TWO. 1 L 7 2 3O 3 O A19S0 E286 5 C P920 2005011300035 20050113 00035 NE 2005 1 13 CA040401003 2 20040313 G 7320 230305204 CONTROLLER BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE 2NDARY OVERSPEED FAILED W A UNSCHED LANDING Y J ENGINE STOPPAGE WARNING INDICATION CR CRUISE 1 CA 10119 10119 LFO5482AC (CAN) ACFT WAS IN CRUISE WHEN CREW REPORTED THAT THE NR 3 ENGINE LOST POWER & SPOOLED DOWN BY ITSELF, SEVERAL ASSOCIATED MWS CAUTION LIGHTS ILLUMINATED. ACFT LANDED SAFELY AT ITS INTENDED DESTINATION. ACFT FERRIED HOME ON THREE ENGINES. MX FOUND THE NR 3 ENGINE SECONDARY OVERSPEED CONTROLLER AT FAULT. ACFT RUN WITH NO FURTHER OCCURRENCE OF DIFFICULTY. ACFT S CHEDULED IN FOR ITS HEAVY CHECK & HONEYWELL THEN REQUESTED THAT WE RING OUT THE ENTIRE OVERSPEED ELECTRICAL SYSTEM ON TH AT & ALL OTHER ENGINES CONFIRMING THE FUNCTION & SERVICEABILITY OF THE OVERSPEED SYS. NO FAULTS HAVE BEEN FOUND TO DATE. OVERSPEED CONTROLLER THAT INITIALLY CAUSED PROBLEM HAS BEEN SENT TO HONEYWELL FOR ANALYSIS. 2 H 7 4 4F 4 F A49EU E6NE 2005011300036 20050113 00036 CE 2005 1 13 CA040401004 1 20040329 G 5544 05310187 ATTACH BRACKET CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA RUDDER CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 14384 (CAN) RUDDER UPPER ATTACHED BRACKET WAS FOUND CRACKED. 1 H 7 1 3O 3 O NT 3A12 E274 2005011300037 20050113 00037 CE 2005 1 13 CA040401005 1 20040329 G 5510 07321014 REINFORCEMENT CESSNA 180 180A 2072604 CE CONT O470 O470K 17026 SO MCAULY 2A34C 2A34C50 GL HORIZONTAL STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) REPAIRED HORIZONTAL STABILIZER. AFT ATTACHMENT POINT REINFORCEMENT BRACKET PN 07321014 REPLACED WITH NEW. ADJACE NT RIVETS REPLACED. TAIL REASSEMBLED. INDEPENDENT CONTROL CHECK CARRIED OUT. 1 H 7 1 3O 3 O 5A6 E273 5 C P3EA 2004062100121 20040621 00121 EU 2004 6 21 CA040401006 1 20040326 G 2742 1291110002 ACTUATOR PILATS PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL PITCH TRIM FAILED W K NONE L NO TEST IN INSP/MAINT 1 CA 218 (CAN) AUTO-PILOT TEST FAILED. ALTERNATE TRIM WAS SELECTED AND TESTED AND FOUND TO BE INTERMITTENT. PITCH TRIM ACTUATOR WAS REPLACED. NO FURTHER ACTION REQUIRED. PITCHTRIM FAILED TO MAKE OVERHAUL LIFE. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004062100138 20040621 00138 EU 2004 6 21 CA040401007 1 20040329 G 6410 355A12005004 BLADE SNIAS 350 AS350B3 8680954 EU TMECA ARRIEL ARRIEL2B NE TAIL ROTOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 8296 (CAN) DURING DAILY INSPECTION AND DAILY COMPLIANCE WITH AD 2001-640-089(A), A CHORDWISE CRACK WAS DETECTED APPROXIMATEL Y 3 INCHES IB OF THE BLADE-TIP. 1 G 7 1 3U 3 U H9EU E00054EN 2004062100139 20040621 00139 NM 2004 6 21 CA040401008 1 20040401 G 3246 LM522546 BEARING BENDIX BOEING 727 727233 138408A NM PWA JT8 JT8D15 52051 NE WHEEL CONTAMINATED W O OTHER D INFLIGHT SEPARATION LD LANDING 1 CA (CAN) WHILE LANDING THE FLIGHT CREW NOTICED A SHIMMY IN THE LANDING GEAR. BELIEVING THAT THEY HAD BLOWN A TIRE, THEY ST OPPED ON A TAXIWAY AND CONTACTED MAINTENANCE. MAINTENANCE DROVE TO THE AIRCRAFT AND INSPECTED THE LANDING GEAR. FINDING NO OBVIOUS FAULTS, MAINTENANCE HAD THE CREW TAXI THE AIRCRAFT TO THE RAMP. AFTER A THOROUGH INSPECTION OF THE LANDING GE AR, BRAKES AND TORQUE LINKS THE NR 1 AND NR 4 MAIN WHEEL BEARINGS WERE FOUND WITH WATER CONTAMINATION. BOTH WHEEL ASSEMB LIES WERE REPLACED. NR 2 AND NR 3 MAIN WHEEL ASSEMBLIES WERE INSPECTED AND FOUND TO BE SERVICEABLE. AIRCRAFT WAS DECLAR ED SERVICEABLE AND NO OTHER FAULTS WERE FOUND. (ALSO: US NR 2004042300081) 2 L 7 3 4F 4 F RT A3WE E2EA 2004062100140 20040621 00140 EA 2004 6 21 CA040401009 2 20040329 G 8530 CYLINDER PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL NR 2 CONTAMINATED W A UNSCHED LANDING C F.O.D. CL CLIMB 1 CA (CAN) SMALL PIECE OF RUBBER FOUND FLOATING IN AIR SIDE OF NR 2 CYLINDER INJECTOR. THE PIECE APPEARED TO BE VERY DRY AND HARD O-RING MATERIAL, MOST LIKELY FROM THE BANJO FITTING SEALS. NO OTHER FAULTS FOUND ON OTHER BANJO FITTINGS. REMOVAL OF CONTAMINATION AND NEW SPARK PLUGS FOR THIS CYLINDER RETURNED THE AIRCRAFT TO NORMAL OPERATION. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004062100141 20040621 00141 EA 2004 6 21 CA040402001 1 20040402 G 5210 601R31974112 BRACKET CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE PAX DOOR FRACTURED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AIRSTAIR DOOR FREE FELL TO THE GROUND DUE TO THE FAILURE OF BOTH FWD/AFT (BOTH) SWIEL BRACKETS THAT HOLD THE CABLE S TO THE FUSELAGE. IN THIS CASE THE DOOR WAS OPENED FROM INSIDE THE A/C AND NO HARM OR DAMAGE WAS DONE TO PERSONNEL OR E QUIPMENT , BUT THERE EXIST A HIGH POSSIBILITY OF PERSONAL INJURY IF THE DOOR WAS TO BE OPENED FROM OUTSIDE. TOTAL DOOR C YCLES ARE UNKNOWN . 2 L 7 2 4F 4 F RT A21EA E15NE 2004062100142 20040621 00142 CE 2004 6 21 CA040402002 1 20040401 G 2133 D26D6412 OUTFLOW VALVE LEAR 35 35A 5170602 CE GARRTT TFE731 TFE73122B 01518 WP CABIN PRESSURE FAILED W B G EMER. DESCENT O2 MASK DEPLOYED W J INADEQUATE Q C WARNING INDICATION CR CRUISE 1 CA (CAN) AIRCRAFT AT A CRUISE ALTITUDE CABIN DEPRESSURIZED. O2 SYSTEM ACTIVATED AUTOMATICLY. EMERGENCY DESCENT DECLARED. 2 L 7 2 4F 4 F A10CE E6WE 2004062100143 20040621 00143 EU 2004 6 21 CA040402003 1 20040325 G 5280 25N2612 DOOR ISRAEL 1125 ASTRASPX 4500205 EU GARRTT TFE731 TFE73140 29001 NE MLG MISRIGGED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ON VISUAL INSPECTION AND NDT INSPECTION A CRACK OF 1 INCH WAS FOUND IN THE LT MLG OB DOOR SKIN AREA. IT WAS SUSPEC TED THAT AT SOME TIME THE DOOR WAS RIGGED IMPROPERLY, DRAG LINK ADJUSTED TOO SHORT AND STRESSES THE AREA. 2 L 7 2 4F 4 F RT A16NM E1NM 2004070900006 20040709 00006 NE 2004 7 9 CA040402004 2 20040325 G 7230 3020159 RETAINING RING PWA PWA PT6 PT6A114A 52043 NE HOT SECTION COLLAPSED W K NONE O OTHER IN INSP/MAINT 1 CA A0012M8Y (CAN) THE HOT SECTION WAS GIVEN AN UNSCHEDULED HOT SECTION INSPECTION DUE TO PERFORMANCE SHIFT. A FEW CT SHROUD SEGMENT S HAD SHIFTED SLIGHTLY AND WERE RUBBED. THE RETAINING RING HAD COME OUT OF HTE GROOVE. THIS PROBLEM HAS BEEN DOCUMENTED ON OTHER ENGINES. MFG HAS ISSUED P/N 3110741-02 RETAINING RING ON SB 13121 (60A, 61, 62, 65 SERIES) AND SB 3248 (41/42 , 45 SERIES) TO PREVENT THE COLLAPSE OF THE RETAINING RING. THE LATTER SB HAS NOT BEEN ISSUED ON SMALLER ENGINE MODELS S UCH AS THE -114A ENGINE MODEL TO ALLOW THE MORE ROBUST RETAINING RING TO BE USED. 3 T E4EA 2004062100146 20040621 00146 NE 2004 6 21 CA040402005 2 20040325 G 7250 3020159 RETAINING RING PWA PT6 PT6A114A 52043 NE ENGINE COLLAPSED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THE HOT SECTION WAS GIVEN A SCHEDULED HOT SECTION INSPECTION. A FEW CT SHROUD SEGMENTS HAD SHIFTED SLIGHTLY AND W ERE RUBBED. THE RETAINING RING HAD NO END GAP AND WAS STARTING TO COME OUT OF THE GROOVE. THIS PROBLEM HAS BEEN DOCUME NTED ON OTHER ENGINES. PWA HAS ISSUED P/N 3110741-02 RETAINING RING ON SB 13121 (60A, 61, 62, 65 SERIES) AND SB 3248 (4 1/42, 45 SERIES) TO PREVENT THE COLLAPSE OF THE RETAINING RING. THE LATTER SB HAS NOT BEEN ISSUED ON SMALLER ENGINE MOD ELS SUCH AS THE 114A ENGINE MODEL TO ALLOW THE MORE ROBUST RETAINING RING TO BE USED. 3 T E4EA 2004062100154 20040621 00154 NM 2004 6 21 CA040402006 1 20040401 G 1497 WIRE HARNESS BOEING 727 727260 NM PWA JT8 JT8D17 52049 NE AC PACK BAY INOPERATIVE W E ENGINE SHUTDOWN S B AFFECT SYSTEMS SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA (CAN) DURING START UP, IT WAS OBSERVED THAT AC PACK WATER SEPARATOR CB POPPED FOLLOWED BY A PACK TRIP. A BURNING ODRO W AS SENSED. ENGINES WERE SHUTDOWN. MAINTENANCE BEGAN INSPECTION AND COCKPIT LIGHTING BEGAN TO FLICKER. COCKPIT WAS FIL LING WITH SMOKE. NR 10 AND NR 11 MAIN DECK CARGO SMOKE DETECTOR LIGHTS ILLUMINATED. APU WAS SHUT DOWN AND BATTERY POWE R TURNED OFF. TROUBLESHOOTING WAS CARRIED OUT AND A WIRE BUNDLE IN THE PACK AREA WAS INSPECTED. A WIRE WAS FOUND TO BE HOT CAUSING THE UNSERVICEABILITY. ONCE ALL THE PAPERWORK HAS BEEN FORWARDED, WILL UPDATE THIS SDR. 2 L 7 3 4F 4 F RT A3WE E2EA 2004062100155 20040621 00155 NE 2004 6 21 CA040402007 2 20040401 G 8550 215P6311018 LINE CNDAIR CL215 CL2151A10 1900320 EA PWA R2800 CA3 52026 NE HAMSTD 43E 43E60 NE ENGINE OIL LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) AN OIL LEAK WAS DISCOVERED BY MAINT IN THE OB SIDE OF NACELLE. AFTER CLEANING AREA, OIL WAS OBSERVED RUNNING DOWN OIL RETURN LINE (COOLER TO TANK)FROM AN AREA WHERE A WIRE BUNDLE WAS LAYING AGAINST LINE. A WIRE HAD BEEN CHAFED THROUGH AND BARE WIRE WAS ARCING AGAINST OIL TUBE CAUSING A PIN HOLE IN TUBE. WIRE WAS POWER WIRE FOR THE HYD FIREWALL SHUT OFF VALVE. ARCING ALSO DAMAGED WIRE FOR OIL SHUT OFF VALVE. REMAINING AC IN FLEET WERE INSPECTED, ONE ADDITIONAL AIRCRAFT H AD WIRE BUNDLE UP AGAINST THE OIL RETURN TUBE. DEFECT WAS RECTIFIED. DAMAGED TUBE WILL BE REPLACED WITH A SERVICEABLE UN IT AND AC WILL BE RETURNED TO SERVICE. 2 H 7 2 4R 4 R RT A14EA E231 6 C P871 2004062100156 20040621 00156 EA 2004 6 21 CA040403001 1 20040331 G 2910 AE2464218E01 HYDRAULIC LINE CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE LT WHEEL WELL PUNCTURED W D RETURN TO BLOCK K J FLUID LOSS WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) ON TAXI OFF THE RUNWAY HYD 2 LOW PRESSURE CAUTION POSTED ON EICAS. PRESSURE SHOWED BETWEEN 100-300 PSI. MAINTENA NCE FOUND THE RT IB GROUND SPOILER EXTENSION FLEX LINE P/N AE2464218E0164 IN THE GEAR WELL RUPTURED. THE LINE WAS FOUND TO BE CHAFFING ON THE WING BOX STRUCTURE UNDER THE COVER ASSEMBLY P/N 600-31594-15. 2 L 7 2 4F 4 F RT A21EA E15NE 2004070900085 20040709 00085 NE 2004 7 9 CA040403002 2 20040328 G 7200 412T03G02 ENGINE CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE RIGHT MALFUNCTIONED W C ABORTED TAKEOFF J WARNING INDICATION TO TAKEOFF 1 CA (CAN) ON MARCH 28TH, PILOT REPORTS (AFTER A 5-6 MIN TAXI, THRUST LEVERS ADVANCED FOR T/O BUT PRIOR TO BRAKES RELEASE, RT ENGINE FLAMEOUT MSG. ITT ON RH ENGINE 1012 DEGREES C. ENGINE STARTED TO RELIGHT BY ITSELFT (FADEC RELIGHT) BUT CREW S HUT OFF THE FUEL PRIOR TO FADEC RELIGHT.WORK PERFORMED PRIOR TO RELEASE TO SERVICE INCLUDE: EXTERNAL INSPECTION OF ENG INE, VG, BORESCOPE HPT, COMBUSTION SECTION, POWER ASSURANCE RUNS, FADEC, MDC AND FDR DOWNLOADS SENT TO ASA ENGINEERING , ON MAR 31ST, PROBLEM RE-OCCURED. THE ENGINE WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2004070900086 20040709 00086 EU 2004 7 9 CA040405001 1 20040328 G 2797 WIRE AIRBUS 310 A310300 3930305 EU GE CF6 CF680C2A5 NE FLAP COMPUTER MALFUNCTIONED W A UNSCHED LANDING F FLT CONT AFFECTED CL CLIMB 1 CA (CAN) FLAP JAM OCCURRED AFTER TAKE OFF. AIRCRAFT RETURNED TO THE STATION FOR RECTIFICATION. FLAP SFCC COMPUTER WAS RESET BY MAINTENANCE. FLAP SYSTEM WAS INSPECTED AND OPERATED SEVERAL TIMES WITH NO FAULT FOUND. AIRCRAFT WAS DISPATCH WITH NO FURTHER PROBLEM. AIRCRAFT WAS ROUTED TO THE MAIN BASE FOR FURTHER INVESTIGATION. DURING INSPECTION, FOUND WIRING DAMAGE D AT REAR SPAR CONNECTOR 37 NVA. WIRING REPAIRED AND COMPLETE WIRING INSPECTION WAS CARRIED OUT. EO RAISED TO CARRY OUT A FLEET INSPECTION ON REAR SPAR WIRING AND MAINTENANCE PROGRAM PERIODIC INSPECTION WILL BE IMPLEMENTED BASE ON RESULT O F THE INSPECTION EO. 2 L 7 2 4F 4 F RT A35EU E13NE 2005011300038 20050113 00038 WP 2005 1 13 CA040405002 2 20040405 G 7250 31080661 NUT GARRTT TPE331 TPE33110UA 01514 WP TURBINE SHAFT MISMANUFACTURED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) UPON ATTEMPTING TO INSTALL THE REAR TURBINE SHAFT NUT ONTO TURBINE SHAFT IT WAS FOUND THAT THE NUT WOULD ONLY THRE AD HALFWAY DOWN & THEN THREADS WOULD START TO PILE UP AND BIND. WITH THE TURBINESHAFT IN AN UNSTRETCHED CONDITION, NUT W OULD WORK FINE & WOULD THREAD ON FREELY BY FINGERS. ONCE THE SHAFT IS STRETCHED UPON INSTALLATION, NUT WOULD NOT THREAD ON COMPLETL Y. TO ELIMINATE THE POSSIBILITY OF THE SHAFT BEING A PROBLEM, A DIFFERENT BATCH OF NUTS WERE CHECKED WITH NO PROBLEMS BEING INSTALLED ON THE STRETCHED SHAFT. 20 NUTS HAVE BEEN REMOVED FROM COMPANY STORES DUE TO THE FACT THEY ARE FROM THE SA ME HONEYWELL LOT NUMBER AS THE DEFECTIVE NUTS. THE LOT NR OF THE DEFECTIVE NUTS IS 0311024140. 4 T E4WE 2004070900088 20040709 00088 EU 2004 7 9 CA040405004 1 20040316 G 2821 O-RING BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL CONNECTOR LEAKING W O OTHER K FLUID LOSS NR NOT REPORTED 1 CA (CAN) FUEL WAS OBSERVED LEAKING FROM THE CONNECTOR ON TOP OF THE FUEL FILTER ASSEMBLY. REMOVAL OF THE CONNECTOR PLUG REV EALED FUEL CONTAMINATION INSIDE THE PLUG. THE O-RING LOCATED INSIDE THE CONNECTOR HOUSING WAS DAMAGED CAUSING LEAKAGE. 1 G 7 2 3U 3 U H3EU E4CE 2004070900098 20040709 00098 EU 2004 7 9 CA040405005 1 20040330 G 2550 145202 RELEASE CABLE BREEZE BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL CARGO HOOK ASSY FAILED W K NONE O OTHER IN INSP/MAINT 1 CA 181 (CAN) WHILE SLINGING OPERATIONS WERE BEING CONDUCTED, THE LOAD WAS INADVERTENTLY RELEASED DUE TO FAILURE OF THE RELEASE CABLE ASSEMBLY SWAGING AT THE LOWER END. 1 G 7 2 3U 3 U H3EU E4CE 2004070900101 20040709 00101 EA 2004 7 9 CA040405006 2 20040330 G 7510 9091010017 HOSE BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA HARTZL HCB3T HCB3TN3 GL ANTI-ICE SYS CRACKED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) DURING PHASE 3 INSPECTION THE RT ENGINE IB INLET ANTI-ICE TUBE WAS FOUND CRACKED. UNIT REPLACED WITH NEW. 1 L 7 2 3T 4 T RT 3A20 E4EA 6 C P15EA 2004070900102 20040709 00102 CE 2004 7 9 CA040405007 1 20040330 G 7110 109910029117 COWLING BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA HARTZL HCB3T HCB3TN3 GL LT ENGINE CRACKED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) DURING PHASE 3 INSPECTION THE LT ENGINE LOWER AFT COWL WAS FOUND CRACKED A LONG A SEAM WELD. UNIT WAS REPAIRED IAW COMPANY PROCEDURE ASSY 681-71-10-0093. 1 L 7 2 3T 4 T RT 3A20 E4EA 6 C P15EA 2005011300039 20050113 00039 NE 2005 1 13 CA040405008 2 20040403 G 8500 ENGINE DOUG DC4 C54A 3021512 WP PWA R2000 R20007M2 52023 NE NR 3 MALFUNCTIONED W E ENGINE SHUTDOWN W INADEQUATE Q C CR CRUISE 1 CA P103067 (CAN) DURING CRUISE, THE CREW NOTICED THAT THE NR 3 ENGING WAS STARTING TO OVERSPEED. THE ENGINE WAS SHUTDOWN, PROPELLER FEATHERED, AND THE FLT RESUMED WITHOUTANY FURTHER ACTION. 2 L 7 4 4R 4 R A762 5E5 2004100500017 20041005 00017 EU 2004 10 5 CA040405AAA 1 20040402 G 3610 F212529300000 DUCT AIRBUS 330 A330342 EU RROYCE RB211 RB211TRENT77 NE AIR CON RUPTURED W O OTHER D INFLIGHT SEPARATION CR CRUISE 1 CA (CAN) FLIGHT CREW REPORTED A RUMBLE NOISE HEARD FROM COCKPIT AND CABIN CONTINUOUSLY WITH BLEED AIR / AIR CONDITIONING. U NABLE TO ISOLATE WITH AIR CONDITIONING PACKS. DURING INVESTIGATION, MAINTENANCE FOUND THE GROUND AIR CONDITIONING DUCT ( COMPOSITE ) RUPTURED AT THE AIR CONDITIONING PLENUM. DUCTING ASSEMBLY REPLACED.AT THIS TIME WE RE UNABLE TO DETERMINE I F DUCT WAS DAMAGE DURING PREVIOUS INSTALLATIONOR COMPOSITE MATERIAL FAILURE. DUCTING WILL BE SENT TO AIRBUS FOR EVALUATI ON. 1 L 7 2 4F 4 F RT A46NM E39NE 2004070900103 20040709 00103 NE 2004 7 9 CA040406001 2 20040402 G 7200 ENGINE CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE LEFT VIBRATION W E A ENGINE SHUTDOWN UNSCHED LANDING E M J VIBRATION/BUFFET OVER TEMP WARNING INDICATION CR CRUISE 1 CA 807418 (CAN) MFG HAS RECEIVED A REPORT WHICH WE FEEL IS A REPORTABLE EVENT. LT ENG OIL PRESS WARNING MESSAGE POSTED WITH LT EN GINE OIL QUANTITY DECREASING. LT ENGINE VIBS INCREASED UP TO 3.5 MILS. ENGINE SHUT DOWN IAW QRH. FLIGHT DIVERTED. CARBO N SEAL NR 7 (P/N AS1895-7-150) REPLACED. CHIP DETECTOR VERIFIED OK. COMPRESSOR AND TURBINE BOROSCOPED - NO FINDING. ENGI NE RUN PERFORMED, FOR 20 SECONDS, NORMAL, THEN ENGINE VIB FROM 0.4 TO 2.8 MILS. OIL LOST THROUGHT JET PIPE. ENGINE REPL ACED. 2 L 7 2 4F 4 F RT A21EA E15NE 2004070900104 20040709 00104 EA 2004 7 9 CA040406003 2 20040403 G 7314 SEAL PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL EDP LEAKING W O OTHER K FLUID LOSS NR NOT REPORTED 1 CA 807418 (CAN) DURING A ROUTINE ENGINE INSPECTION THE NR 1 ENGINE COWL WAS REMOVED TO FACILITATE THE INSPECTION ON THE ENGINE. WHEN THE COWL WAS REMOVED IT WAS NOTED THERE WAS A LARGE BLUE STAIN ON THE BOTTOM OF THE COWL, JUST BELOW THE ENGINE DRI VEN FUEL PUMP. THIS FUEL PUMP IS OF THE NEW STYLE INSTALLED TO ELIMINATE THE REPETITIVE INSPECTION ON AD 2003-14-03. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004071200175 20040712 00175 EU 2004 7 12 CA040406004 1 20040406 G 3020 9787315301 ACTUATOR PILATS PC12 PC12 7090550 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL FAILED W O OTHER O OTHER CR CRUISE 1 CA (CAN) PILOT REPORTED A CLACKING NOISE IN FLIGHT COMING FROM THE INSTRUMENT PANEL. DURING TROUBLESHOOTING THE INTERNAL BY PASS DOOR WAS FOUND INOP. IN THE CLOSED POSITION. FURTHER INVESTIGATION REVEALED AN INTERNAL FAILURE AS THE STOP BUTTON THAT ACTUATES THE INTERNAL LIMIT MICRO SWITCH HAD FALLEN OUT OF PLACE. THUS ALLOWING THE ACTUATOR TO GO BEYOND THE ALL OWABLE LIMITS. THE ACTUATOR HAD COMPLETELY UNSCREWED ITSELF FROM THE LINEAR PORTION AND UNDER LOAD WOULD HAVE CONTINUED TO OPERATE AND CAUSE A THUMPING SOUND UNTIL THE MOTOR FAILED. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004071200183 20040712 00183 EU 2004 7 12 CA040406005 1 20040405 G 7820 L24266710000 BAFFLE ZLIN 242 Z242L 9970204 EU LYC O360 AEIO360A1B6 41514 EA MUFFLER BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DUE TO PREVIOUS DISCOVERIES OF BROKEN INTERNAL BAFFLES INSIDE THE NR 1 EXHAUST SILENCER ON OTHER AIRCRAFT IN OUR F LEET, AN INTERNAL INSPECTION HAS BEEN CALLED UP EVERY 100 HOURS TO COINCIDE WITH A 100 HR INSPECTION. THIS PARTICULAR BA FFLE WAS FOUND BROKEN DURING A WALK AROUND BY A STUDENT.I T WAS NOTICED THAT A PIECE OF METAL WAS HANGING OUT THE NR 2 E XHAUST SILENCER EXIT. THERE HAS BEEN OTHER SDR'S SUBMITTED ON THIS SUBJECT. 1 L 7 1 3O 3 O 0 A76EU 1E10 2004071200184 20040712 00184 SO 2004 7 12 CA040406006 2 20040329 G 7314 5367001 PUMP DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240B 17063 SO SNSNCH W69EK W69EK63 EA FUEL SYSTEM INOPERATIVE W O OTHER Y J ENGINE STOPPAGE WARNING INDICATION LD LANDING 1 CA (CAN) AIRCRAFT HAD JUST BEEN RETURNED TO SERVICE AFTER A LONG PERIOD OF STORAGE (ABOUT18 MOTHS). THE AIRCRAFT FLEW 11.7 AFTER RETURNING FROM STORAGE BEFORE THE FUEL PUMP FAILED. 1 L 7 1 3O 3 O NT TA4CH E7SO 5 N TA4CH 2004071200185 20040712 00185 NE 2004 7 12 CA040407001 2 20040406 G 7261 ENGINE BOEING 767 767333 1385301 NM GE CF6 CF680C2B6F 30025 NE LEFT LEAKING W E A ENGINE SHUTDOWN UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA (CAN) LT ENGINE SHUTDOWN, OIL IND LOW, FOUND OIL IN TAIL PIPES. REPORT TO FOLLOW. 2 L 7 2 4F 4 F RT A1NM E13NE 2004071200186 20040712 00186 SW 2004 7 12 CA040407008 1 20040403 G 2435 303001383 BRUSHES BELL 206 206L4 1182110 SW ALLSN 250C 250C30P 03013 GL STARTER GEN WORN W K NONE O OTHER IN INSP/MAINT 1 CA 5759 (CAN) ON INSPECTION OF THE START/GEN BRUSHES IT WAS DISCOVERED THAT THE REAR BRUSHES WERE SLIGHTLY SHORTER (MORE WORN) T HAN THE FORWARD BRUSHES. REPLACED BRUSHES AND INSPECTED AGAIN AFTER 100 HOURS. FOUND THE AFT BRUSHES WITH A MUCH HIGHE R DEGREE OF WEAR IN RELATION TO LAST INSPECTION ALSO ONE OF THE BRUSH WIRES HAD COME OFF THE BRUSH, CHANGED START/GEN. 1 G 7 1 3U 3 U NC H2SW E1GL 2004071200187 20040712 00187 EU 2004 7 12 CA040407009 1 20040407 G 2910 105456611 HOUSING BOLKMS 105 BO105LSA3 5626020 EU ACTUATOR CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA 31007 (CAN) DURING TESTING THE ACTUATOR SHOWED HIGH INTERNAL LEAKAGE. AFTER INVESTIGATION IT WAS DISCOVERED THAT THE HOUSING WAS CRACKED INTERNALLY. THE CRACK IS IN THE SERVO VALVE AXIS OF THE HOUSING AND APPEARS TO ORIGINATE FROM A DRILLED PAS SAGE. THIS ASSEMBLY RECEIVED FROM AN AIRCRAFT IN THE USA. 1 G 7 2 3U H3AU 2004120700164 20041207 00164 SW 2004 12 7 CA040407010 1 20040407 G 3110 6390016901 PIVOT ASSY BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA INDICATOR MOUNT DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ADJUSTABLE PIVOT HAD MOST OF THE ADJUSTMENT SLOT BROKEN AWAY. PREVIOUS REPAIRER HAD 'FIXED' THE PROBLEM BY FLOODI NG THE AREA WITH EPOXY TO STOP THE PIVOT FROM ROTATING. THE RETAINING SCREW HAD INSUFFICIENT MATERIAL TO HOLD THE PIVOT AS DESIGNED. 1 G 7 1 4U 4 U H4SW E22EA 2005022300125 20050223 00125 2005 2 23 CA040407011 4 20040407 G 3420 TAPE BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA GYROS IMPROPER PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) ADHESIVE BACKED LEAD TAPE HAD BEEN USED TO BALANCE THE PITCH ERECTION VANES. IAW MANUFACTURER'S SERVICE ADVISORY NR 75, DATED JANUARY 25, 1985, LEAD TAPE SHOULD NOT BE USED TO BALANCE AIM GYROS AS IT CAN FALL OFF AND CAUSE THE GYRO T O BECOME INOPERATIVE. 1 G 7 1 4U 4 U H4SW E22EA 2004071900016 20040719 00016 NE 2004 7 19 CA040407013 3 20040221 G 6111 C792 BEARING HARTZL HCE4A3I BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE PROP BLADE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA KX44 (CAN) PROPELLER WAS REMOVED FROM THE AIRCRAFT TO REPAIR DAMAGE TO THE ERROSION SHIELD INSTALLED ON NR 1 BLADE. UPON SPLI TTING THE HUB 2 OB BLADE BEARINGS WERE FOUND TO BE CRACKED. ALL 4 BLADE BEARINGS HAVE BEEN REPLACED BY NEW D7745 BEARIN GS IAW MM NR 143A AND S/B 61-258 . 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2004071900017 20040719 00017 NE 2004 7 19 CA040407014 3 20040401 G 6111 C0792 THRUST BEARING HARTZL HCE4A3I BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE PROPELLER CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA HJ799 (CAN) PROPELLER WAS REMOVED FROM AIRCRAFT DUE TO EXCESSIVE GREASE LEAKAGE AND BLADE END PLAY. UPON SPLITTING THE HUB IT WAS FOUND THAT 2 BLADE THRUST BEARINGS HAD CRACKED. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2004071900018 20040719 00018 NE 2004 7 19 CA040408001 2 20040326 G 7320 EEC BOMBDR BD700 BD7001A10 1390006 GL RROYCE BR700 BR700710A220 09500 NE RT ENGINE MALFUNCTIONED W A UNSCHED LANDING Y J ENGINE STOPPAGE WARNING INDICATION CR CRUISE 1 CA 970146 (CAN) OPERATOR REPORTED A RECENT IN-FLIGHT OCCURRENCE WHERE, AFTER APPROXIMATELY 2 HOURS INTO THE FLIGHT, AT 41,000 FT, THE RT ENGINE SHUTDOWN AND AN AMBER FADEC FAIL. 2 L 7 2 4F 4 F RT T00003NY E00061EN 2004071900019 20040719 00019 EA 2004 7 19 CA040408002 1 20040403 G 7830 22850741115 SWITCH CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE THRUST REVERSER FAILED W O OTHER J WARNING INDICATION NR NOT REPORTED 1 CA (CAN) THRUST REVERSER UNLOCK LIGHT AND REVERSER ICON ON NR 1 GAUGE CAME ON IN FLIGHT AT FLIGHT LEVEL 210QRH CARRIED OUT, LIGHT REMAIN ON FOR THE REST OF THE FLIGHT. 2 L 7 2 4F 4 F RT A21EA E15NE 2004071900020 20040719 00020 NE 2004 7 19 CA040408004 2 20040407 G 7532 BLEED VALVE AIRBUS A319 A319114 3930350 NM CFMINT CFM56 CFM565A1 NE NR 2 ENGINE MALFUNCTIONED W B EMER. DESCENT E J VIBRATION/BUFFET WARNING INDICATION CR CRUISE 1 CA (CAN) DURING CRUISE AT FLIGHT LEVEL 390 NO ENGINE BLEED FAULT , BLEED SHUT OFF, 10 MINUTES LATER NR 2 ENGINE BLEED FAULT . LOSS OF PRESSURIZATION EMERGENCY DESCENT TO 8000 FT, ABLE TO RESET BLEEDS AND CLIMB BACK TO FLIGHT LEVEL 160 NO FAU LT FOUND, FDR SENT FOR READ OUT. 2 L 7 2 4F 4 F RT A28NM E29NE 2004071900021 20040719 00021 GL 2004 7 19 CA040408005 1 20040402 G 5714 5867001 PUMP DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240B 17063 SO SNSNCH W69EK W69EK63 EA ENG FUEL FAILED W O OTHER J WARNING INDICATION LD LANDING 1 CA (CAN) INCONSISTENCIES IN FUEL PRESSURE, FUEL PRESSURE WAS CHECKED AND FOUND THAT THE LOW SIDE OF THE ELECTRIC FUEL PUMP WAS NEAR NIL. HIGH SIDE WAS 5.5. THE FUEL PUMP FAILURE IS BELIEVED TO BE CAUSED BY THE AIRCRAFT BEING OUT OF SERVICE FOR LONG PERIOD OF TIME 15-16 MONTHS. FUEL TANK WAS HALF FULL DURING THIS TIME. THE FUEL SYSTEM PRESSURE HAD BEEN CHECKED ON ENGINE INSTALLATION AND WAS FOUND TO BE WELL WITHIN LIMITS. 1 L 7 1 3O 3 O NT TA4CH E7SO 5 N TA4CH 2004071900022 20040719 00022 SO 2004 7 19 CA040408007 1 20040408 G 3230 6716800 SPRING PIPER PA44 PA44180 7104402 SO LYC O360 O360A1H 41514 EA HARTZL HCC2Y HCC2YR2 GL NLG BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING A LANDING GEAR INSPECTION THE NOSE LANDING GEAR INNER ASSIST SPRING WAS FOUND BROKEN AT THE UPPER HOOK. TH ERE WAS NO INDICATION OF ANY LANDING GEAR MALFUNCTION IN THE FLIGHT PREVIOUS TO THE INSPECTION. THE LANDING GEAR INSPEC TION WAS PART OF AN EVENT NR 2 INSPECTION ON THE AIRCRAFT. A SIMILAR FAILURE OF THIS SPRING HAPPENED ON ANOTHER AC IN O UR FLEET. IT WAS NOTICED BY A PILOT WHEN THE GEAR WAS SELECTED DOWN THE NOSE TOOK APPROX 2 MINUTES TO EXTEND. (THERE W AS AN SDR SUBMITTED ON THIS NR 20021121004 )THIS SPRING GETS A CLOSE LOOK EVERY 50 HOURS AT EACH EVENT ON THE AIRCRAFT. 1 L 7 2 3O 3 O A19S0 E286 5 C P920 2004071900026 20040719 00026 SO 2004 7 19 CA040408008 2 20040404 G 7414 GEAR BENDIX CESSNA 185 A185F 2072821 CE CONT O550 IO550D 17042 SO MCAULY D3A34 D3A34C403 GL DISTRIBUTER DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA E5663 (CAN) DURING A RUN-UP FOR A 50 HOUR INSPECTION THE AME NOTED THAT THE LT MAG WAS TOTALLY DEAD. UPON INSPECTION IT SHOWE D THAT 2 TEETH ON THE DRIVE GEAR FOR THE DISTRIBUTOR WERE TOTALLY MISSING. THESE TEETH BEING MISSING WOULD NOT ALLOW TH E DISTRIBUTOR ON THE MAG TO FUNCTION CORRECTLY. THE OLD MAGNETO HAD 47.4 SINCE 500 HOUR INSPECTION AND 93.9 SINCE OVERH AUL. THE MAGNETO WAS REPLACED AND THE ENGINE WAS GROUND RUN AND LEAK CHECKED, ENGINE FOUND TO BE WORKING AS IT SHOULD WI TH THE NEW MAG. 1 H 7 1 3O 3 O 3A24 E3SO 5 C P47GL 2004071900045 20040719 00045 GL 2004 7 19 CA040408009 2 20040430 G 7210 6850209 GEARBOX LKHEED 382 382G 526414U SO ALLSN 501D 501D22A 03006 GL HAMSTD 54H 54H60117 NE NR 2 CONTAMINATED W E ENGINE SHUTDOWN J WARNING INDICATION CR CRUISE 1 CA (CAN) ENROUTE, THE A/C HAD A NR 2 RGB CHIP LIGHT INDICATION. THE ENGINE WAS SHUT DOWN AND FLIGHT CONTINUED. THE A/C WA S 3 ENGINE FERRIED, FOR RGB CHANGE OUT. THE RGB WAS REPLACED AND THE A/C RETURNED TO SERVICE. 2 H 7 4 4T 4 T A1SO E282 6 C P906 2004071900046 20040719 00046 NM 2004 7 19 CA040408010 1 20040407 G 2760 WARNING LIGHT BOEING 727 7272H3 138368N NM PWA JT8 JT8D9A 52048 NE CONFIGURATION FALSE ACTIVATION W C ABORTED TAKEOFF N FALSE WARNING TO TAKEOFF 1 CA (CAN) THE CREW OBSERVED AN AURAL CONFIGURATION WARNING ON TAKE OFF WHEN THE GEAR WAS SELECTED UP AND FLAP 15. THE A/C R ETURNED TO BLOCKS WHERE IT WAS DETERMINED THAT THE SPEED BRAKE WARNING SWITCH WAS OUT OF ADJUSTMENT. THE SWITCH WAS ADJ USTED AND THE TOW CS CHECKED SERVICEABLE IAW MM31-26-25 AND THE A/C WAS RETURNED TO SERVICE. 2 L 7 3 4F 4 F RT A3WE E2EA 2004071900047 20040719 00047 GL 2004 7 19 CA040408012 1 20040401 G 2780 5910461 TORQUE TUBE BOMBDR BD700 BD7001A10 1390006 GL RROYCE BR700 BR700710A220 09500 NE RT SLAT DISCONNECTED W O OTHER F FLT CONT AFFECTED AP APPROACH 1 CA (CAN) ON APPROACH THE CREW SELECTED SLATS TO GO OUT AND GOT A FAIL MESSAGE ON EICAS. POST LANDING INSPECTION REVEALED TH AT THE LT SLAT PARTIALLY DEPLOYED AND THE RT SLAT WAS STOWED. MAINTENANCE CREW FOUND THE RT TORQUE TUBE DISCONNECTED FR OM THE SLAT POWER DRIVE UNIT. THE COUPLING BOLT NOT ENGAGE THROUGH THE PDU SHAFT. NO DAMAGE WAS FOUND ON THE SYSTEM AND SURROUNDING STRUCTURE. BOLT RE-INSTALL IAW MM AND AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT T00003NY E00061EN 2004071900048 20040719 00048 EA 2004 7 19 CA040408013 2 20040408 G 8550 L24276000600 TEE FITTING ZLIN 242 Z242L 9970204 EU LYC O360 AEIO360A1B6 41514 EA PICK UP TUBE SEPARATED W K NONE J WARNING INDICATION IN INSP/MAINT 1 CA (CAN) DURING AN ENGINE REMOVAL THE OIL DRAIN TEE FITTING WAS FOUND TO HAVE THE PICK UP TUBE LOOSE IN THE TEE FITTING. T HIS PROBLEM WAS PREVIOUSLY REPORTED IN AN SDR. A MANDATORY SB WAS ISSUED FROM THE MANUFACTURER (MSBZ242L/42A) AND THE F ITTINGS WERE REPAIRED AND TESTED IAW THE SB. THIS FITTING WILL BE REPAIRED IAW THE SB AND THEN TESTED IAW THE SB. IF TH IS FITTING HAD SEPARATED THE RESULT WOULD HAVE BEEN A RESTRICTION IN THE OIL SYSTEM WITH LOW OIL PRESSURE IN THE ENGINE. 1 L 7 1 3O 3 O 0 A76EU 1E10 2004071900049 20040719 00049 EU 2004 7 19 CA040408014 1 20040402 G 2913 704A33690004 BELT SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE HYD PUMP BROKEN W A UNSCHED LANDING F FLT CONT AFFECTED CR CRUISE 1 CA (CAN) HYDRAULIC PUMP PULLEY BROKE DURING FLIGHT. UNSCHEDULED LANDING CARRIED OUT WITHOUT INCIDENT. BELT REPLACED, AIRC ARFT RETURNED TO SERVICE. 1 G 7 1 3U 3 U NC H9EU E19EU 2004071900050 20040719 00050 SW 2004 7 19 CA040409001 1 20040407 G 3230 915019000 TUBE MOONEY MOONEY M20 M20C 5870208 SW LYC O360 O360A1D 41514 EA HARTZL HCC2Y HCC2YR1 GL MLG DOWNLOCK BENT W O OTHER O OTHER LD LANDING 1 CA (CAN) RT MAIN GEAR COLLAPSED ON LANDING ROLL OUT. INITIAL FINDING MAIN GEAR ACTUATING TUBE INSIDE BELLY IS BENT. IT IS UNKNOWN IF THIS TUBE WAS BENT BEFORE OR AS RESULT OF GEAR COLLAPSE. FURTHER INFORMATION WILL FOLLOW AS MORE DETAIL INS PECTION/DISASSEMBLY IS REQUIRED FOR ROOT CAUSE. 1 L 7 1 3O 3 O 2A3 E286 5 C P920 2004071900051 20040719 00051 NM 2004 7 19 CA040409002 1 20040404 G 2751 SWITCH BOEING 727 72725C 138400H NM PWA JT8 JT8D7B 52053 NE TE FLAPS MALFUNCTIONED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) ON CLIMB OUT NR 5 KREUGER FLAP INTRANSIT LIGHT ILLUMINATED. A/C RETURNED ANC. SWITCH REPLACED AND OVERWEIGHT LAND ING INSPECTION C/W. 2 L 7 3 4F 4 F A3WE E2EA 2004071900052 20040719 00052 EA 2004 7 19 CA040410001 1 20040401 G 6300 234D33003 DRIVE ASSY BOEING 234 234 1385049 EA LYC AL5512 AL5512 41581 NE MAIN ROTOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING INSPECTION IAW AD 2004-06-51 A CRACK WAS DETECTED IN THE UPPER EXTENSION 37 INCHES FROM THE TOP. SHAFT WAS REMOVED FROM SERVICE AND RETURNED TO MFG FOR INSPECTION. MFG IS CONDUCTING INSPECTIONS OF ALL IN-SERVICE SHAFTS AND SP ARES TO ELIMINATE ANY SHAFT FROM THE SYSTEM THAT HAS ARC BURNS. 2 G 7 2 4U 4 U H9EA E4NE 2005022300126 20050223 00126 NM 2005 2 23 CA040412001 1 20040406 G 3411 PITOT LINE ROSEMOUNT BOEING 737 737200 1384453 NM PITOT TUBE ASSY LEAKING W K NONE O OTHER IN INSP/MAINT 1 CA 151720 (CAN) B737-200 PITOT TUBE ASSEMBLY FAILED BENCH CHECK WITH A PITOT LEAK IN EXCESS OF 200 KTS/MIN. THE LEAK WAS DETERMIN ED TO BE ORIGINATING WHERE THE PITOT TUBE AIRFRAME ATTACHMENT CONNECTS TO THE BASE OF THE PITOT TUBE ASSEMBLY. THE COMP ONENT WAS A USED PART ACQUIRED FROM A DISTRIBUTOR, QWEST AIR PARTS INC, IN MEMPHIS TN. THE PITOT TUBE HAD BEEN BENCH CH ECKED SERVICEABLE BY CROSS-CHECK AVIATION, FAA REPAIR STATION XK8R253Y LOCATED IN RENO, NEVADA. 2 L 7 2 4F A16WE 2005022300127 20050223 00127 NM 2005 2 23 CA040412002 1 20040406 G 3411 PITOT LINE ROSEMOUNT BOEING 737 737200 1384453 NM PITOT TUBE ASSY LEAKING W K NONE O OTHER IN INSP/MAINT 1 CA 156586 (CAN) B737-200 PITOT TUBE ASSEMBLY FAILED BENCH CHECK WITH A PITOT LEAK IN EXCESS OF 350 KTS/MIN. THE LEAK WAS DETERMIN ED TO BE ORIGINATING WHERE THE PITOT TUBE AIRFRAME ATTACHMENT CONNECTS TO THE BASE OF THE PITOT TUBE ASSEMBLY. THE COMP ONENT WAS A USED PART ACQUIRED FROM A DISTRIBUTOR, QWEST AIR PARTS INC, IN MEMPHIS TN. THE PITOT TUBE HAD BEEN BENCH CH ECKED SERVICEABLE BY CROSS-CHECK AVIATION, FAA REPAIR STATION NR XK8R253Y LOCATED IN RENO, NEVADA. 2 L 7 2 4F A16WE 2005022300128 20050223 00128 NM 2005 2 23 CA040412003 1 20040408 G 3411 PITOT LINE ROSEMOUNT BOEING 737 737200 1384453 NM PITOT TUBE ASSY LEAKING W O OTHER O OTHER NR NOT REPORTED 1 CA 165698 (CAN) B737-200 PITOT TUBE ASSEMBLY FAILED BENCH CHECK WITH A PITOT LEAK IN EXCESS OF 350 KTS/MIN. THE LEAK WAS DETERMIN ED TO BE ORIGINATING WHERE THE PITOT TUBE AIRFRAME ATTACHMENT CONNECTS TO THE BASE OF THE PITOT TUBE ASSEMBLY. THE COMP ONENT WAS A USED PART ACQUIRED FROM A DISTRIBUTOR, QWEST AIR PARTS INC, IN MEMPHIS TN. THE PITOT TUBE HAD BEEN BENCH CH ECKED SERVICEABLE BY CROSS-CHECK AVIATION, FAA REPAIR STATION NR XK8R253Y LOCATED IN RENO, NEVADA. 2 L 7 2 4F A16WE 2004072100071 20040721 00071 CE 2004 7 21 CA040412004 1 20040221 G 3010 571531025 TUBE CESSNA 441 441 2076020 CE GARRTT TPE331 TPE33110 01514 WP BLEED AIR CRACKED W O OTHER J WARNING INDICATION CR CRUISE 1 CA 10921 10921 (CAN) DURING FLIGHT THE CREW NOTICE AN INTERMITENT WING O/H WARNING. MAINTENANCE WAS CONTACTED AND THE AIRCRAFT INSPECTE D. INSPECTION REVEALED A CRACK IN BLEED AIR TUBE PN 5715310-25. THE TUBE WAS REPLACE. THERE WAS NO RESULTING DAMAGE FROM THE BLEED AIR LEAK. 1 L 7 2 3T 4 T RT A28CE E4WE 2005022300129 20050223 00129 NM 2005 2 23 CA040412005 1 20040408 G 3411 PITOT LINE ROSEMOUNT BOEING 737 737200 1384453 NM PITOT TUBE ASSY LEAKING W O OTHER O OTHER NR NOT REPORTED 1 CA 147844 (CAN) B737-200 PITOT TUBE ASSEMBLY FAILED BENCH CHECK WITH A PITOT LEAK IN EXCESS OF 10 KTS/MIN. THE LEAK WAS DETERMINE D TO BE ORIGINATING WHERE THE PITOT TUBE AIRFRAME ATTACHMENT CONNECTS TO THE BASE OF THE PITOT TUBE ASSEMBLY. THE COMPO NENT WAS A USED PART ACQUIRED FROM A DISTRIBUTOR, QWEST AIR PARTS INC, IN MEMPHIS TN. THE PITOT TUBE HAD BEEN BENCH CHEC KED SERVICEABLE BY CROSS-CHECK AVIATION, FAA REPAIR STATION # XK8R253Y LOCATED IN RENO, NEVADA.REF SDRS20040412001, 2004 041202, AND 2004041203. 2 L 7 2 4F A16WE 2005022300130 20050223 00130 NE 2005 2 23 CA040412006 2 20040412 G 7200 ENGINE AIRBUS 320 A320211 3930320 EU CFMINT CFM56 CFM565A1 NE NR 1 BIRD INGESTION W C ABORTED TAKEOFF C F.O.D. TO TAKEOFF 1 CA (CAN) FAULT: HIT 2 GEESE ON T/O HIGH SPEED REJECTED RETURNED TO GATE. FOUND EVIDENCE OF BIRD INGESTION AT NR 1 ENG. S EVERAL DAMAGED BLADES, A/C ROUTED TO HANGAR FOR ENGINE BOROSCOPE. 2 L 7 2 4F 4 F RT A28NM E29NE 2004080500081 20040805 00081 NM 2004 8 5 CA040412007 1 20040412 G 3250 STEERING SYS AIRBUS A319 A319114 3930350 NM CFMINT CFM56 CFM565A1 NE NLG MALFUNCTIONED W O OTHER J WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) ON APPROACH AFTER PUTTING THE LANDING GEAR DOWN, THERE WAS AN ECAM MSG REF. TO NOSE WHEEL STEERING FAULT. AC CARR IED OUT A MISSED APPROACH AND WENT THROUGH THE QRH. TOWER CALLED OUT THE EMERGENCY EQUIPMENT FOR THE LANDING. AC LANDED ON 24L, AFTER LANDING, THE AC WAS ABLE TO TAXI TO THE RAMP. (AC REMOVED FROM SERVICE FOR N/W STEERING INVEST.) 2 L 7 2 4F 4 F RT A28NM E29NE 2004080500082 20040805 00082 NE 2004 8 5 CA040412008 2 20040410 G 8550 GASKET DOUG DC4 C54 3021506 WP PWA R2000 R20007M2 52023 NE ENGINE OIL LINE LEAKING W E ENGINE SHUTDOWN K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA (CAN) DURING CRUISE THE CREW NOTICED AN OIL LEAK ON THE NR 2 ENGINE. THE ENGINE WAS SHUT DOWN AND PROPELLER FEATHERED. O N INSPECTION IT WAS NOTICED THAT THE OIL PRESSURE LINE GASKET HAD BLOWN OUT. THE GASKET WAS REPLACED AND THE AIRCRAFT RE TURNED TO SERVICE. 2 L 7 4 4R 4 R A762 5E5 2004080500083 20040805 00083 2004 8 5 CA040412009 4 20040407 G 6122 R20007M2 GOVERNOR DOUG DC4 C54ADC 3021510 WP PWA R2000 R20007M2 52023 NE HAMSTD 23E 23E50 NE PROPELLER OUT OF RIG W C ABORTED TAKEOFF W INADEQUATE Q C TO TAKEOFF 1 CA (CAN) DURING TAKE-OFF THE NR 3 ENGINE ENCOUNTERED AN OVERSPEED. THE AIRCRAFT RETURNED TO THE HANGER. IT WAS FOUND THAT THE PROP GOVENOR WAS OUT OF RIG. IT WAS RE-RIGGED AND THE AIRCRAFT WAS RETURNED TO SERVICE. 2 L 7 4 4R 4 R A762 5E5 6 C P603 2004080500084 20040805 00084 2004 8 5 CA040412010 4 20040320 G 2310 14379 ANTENNA CESSNA 560 560XL 2076702 CE PWA 545 PW545A NE TENSIONER BROKEN W O OTHER D INFLIGHT SEPARATION DE DESCENT 1 CA (CAN) PILOTS REPORTED VIBRATION IN FLOORBOARDS 240 TO 260 KIAS AT ARRIVAL. DURING INSPECTION NOTICED THE HF ANTENNA BROK EN OFF AT THE TENSIONER UNIT ON FIN, THE COPPER WIRE BROKEN. THIS OCCURRED AT 2638.1 HRES AND 2308 CYCLES. THIS WIRE ANT ENNA WAS REPLACED DEC 11/ 01 FOR EXACTILY THE SAME PROBLEM AT 1055.2 HRES AND 946 CYCLES. THIS CAUSED ONLY MINOR SCRATCH ES ON THE TAILCONE. OUR MAIN CONCERN IS THE POSSIBILY OF THIS WIRE INTERFERING WITH THE FLIGHT CONTROLS. WE ARE EVALUAT ING THE NEED TO REPLACE THE WIRE ANTENNA ON A REGULAR BASIS (EVERY 500 HOURS) TO PREVENT RE-OCCURRENCE. 2 L 7 2 4F 4 F RT A22CE E00059EN 2004080500093 20040805 00093 CE 2004 8 5 CA040412011 1 20040409 G 2750 1013800001 SHAFT BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE TE FLAP CONTROL BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA 18075 (CAN) DURING THE REPLACEMENT OF A FLAP ACTUATOR AND DURING TESTING, THE NR 4 FLAP PANEL CEASED TO MOVE. IT WAS FOUND TH AT THE FLAP FLEXIBLE SHAFT HAD INTERNALLY CORRODED AND FAILED. THIS ISSUE WAS FOUND ONCE PRIOR UNDER SDR NR 20030825014 BUT WITHOUT THE EVIDENCE OF CLAMP INTERFERENCE. WATER HAS ONCE AGAIN FOUND ITS WAY INAND STAYED IN THE LOW POINT OF THE CABLE. THE CABLE WAS REPLACED AND THE SYSTEM CHECKED OK. MFG HAS ONCE AGAIN BEEN NOTIFIED OF THIS CONDITION. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2004080500094 20040805 00094 CE 2004 8 5 CA040412012 1 20040409 G 3246 114800893 BEARING BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE MLG WHEEL FAILED W A UNSCHED LANDING O OTHER CL CLIMB 1 CA (CAN) DURING TAKEOFF, THE CREW WAS NOTIFIED THAT NR 3 WHEEL HAD SEPARATED FROM THE AIRCRAFT. THE BEARING HAD FAILED WHIC H ALLOWED THE WHEEL ASSY TO PASS OVER THE RETENTION NUT AND SEPARATE. DUE TO PAST ISSUES WITH BEARING FAILURES, A GREAS E ANALYSIS HAS BEEN CONDUCTED SINCE MARCH 19, 2004 DUE TO ON GOING ISSUES WITH AEROSHELL 22 AND 5 WHEEL BEARING GREASE. OUR TEST INDICATED THAT A SWITCH TO MOBIL SHC100 IS IN ORDER AND THE FLEET WILL BE SWITCHED OVER EXPEDIOUSLY. 2 L 7 2 4T 4 T RT A24CE E26NE 2004080500095 20040805 00095 NM 2004 8 5 CA040412013 1 20040409 G 3246 26010452 WHEEL BOEING 737 737201 1384454 NM PWA JT8 JT8D9A 52048 NE NLG BROKEN W D RETURN TO BLOCK O OTHER TX TAXI/GRND HDL 1 CA (CAN) DURING AIRCRAFT LOW SPEED TAXI TO RUNWAY, THE INBOARD WHEEL HALF OF THE RT NOSEWHEEL ASSEMBLY SEVERED AND TIRE DEF LATED. FUSELAGE AND NLG AREA INSPECTED FOR DAMAGE. NO FAULTS FOUND. BOTH NOSE LANDING GEAR WHEEL ASSEMBLIES REPLACED IAW MM. 2 L 7 2 4F 4 F A16WE E2EA 2005022300131 20050223 00131 CE 2005 2 23 CA040412014 1 20040407 G 7120 LUG LYC HELIO H295 H295 4300802 CE LYC O480 GO480G1D6 41527 EA HARTZL HCB3Z HCB3Z201 GL CRANKCASE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) HARD LANDING OCCURRED AND A HARD LANDING INSPECTION WAS CARRIED OUT ON THE ENTIRE A/C. NO OTHER DEFECTS WERE FOUN D OTHER THAN THE CRACKED LUG MOUNT. AN ENGINE CHANGE WAS DONE. ENGINE MODEL G0-480-G1D6 S/N L-394-37 WAS INSTALLED. 1 H 7 1 3O 3 O 1A8 E275 5 C P907 2004100500018 20041005 00018 NE 2004 10 5 CA040412BBB 2 20040412 G 7261 3371535030 LINE AIRBUS 320 A320211 3930320 EU CFMINT CFM56 CFM565A1 NE ENGINE OIL LEAKING W E ENGINE SHUTDOWN O OTHER CR CRUISE 1 CA (CAN) AFTER T/O FROM YYJ NO.1 OIL QUANTITY FELL TO 2.5 QT. REDUCED TO IDLE THRUST,QUANTITY ROSE TO 4.0 AND THEN STARTED TO FELL AGAIN. SHUT ENGINE DOWN AT 10,000 FT ON APP TO YVR. ACTION: FOUND OIL LINE FITTING LOOSE. OIL LINE LOCATED IN BE TWEEN GEAR BOX AND REAR BEARING. FITTING RE-TIGHTENED,ENG. IDLE RUN CARRIED OUT FOR 5 MINS NIL LEACKS FOUND, CONSIDERED SERVICEABLE. 2 L 7 2 4F 4 F RT A28NM E29NE 2004080500096 20040805 00096 EA 2004 8 5 CA040413001 1 20040404 G 2520 SPRING CNDAIR CL604 CL604 1900301 EA GE CF34 CF34* NE SEAT BELTBUCKLE MISSING W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) PASSENGER SEATBELT BUCKLE WAS FOUND TO HAVE NO SPRING TENSION IN THE LOCK POSITION. THE DRIVE SCREW PIN HAD BACKE D OFF .0312 WHICH ALLOWED TENSION TO RELEASE. BELT ASSEMBLY IS SAFTEY PRODUCTS. THE BUCKLE IS STAMPED. THIS IS A MID COAST STC INTERIOR INSTALLATION. ITEM P/N BL/6-3800BOB54TSA REV. A 2 L 7 2 4F 4 F RT A21EA E15NE 2004080500097 20040805 00097 EA 2004 8 5 CA040413002 1 20040407 G 2424 720846B VOLT REGULATOR SUNDSTRANDAI CNDAIR CL600 CL600* EA LYC ALF502 ALF502R 41580 NE GCU FAILED W B A EMER. DESCENT UNSCHED LANDING H J ELECT. POWER LOSS-50 PC WARNING INDICATION CL CLIMB 1 CA 580 (CAN) IN FLIGHT LOSS OF NR 2 AC BUSS SERVICES CAUSED BY NR 2 GENERATOR DROPPING OFF LINE. RESET ATTEMPTS FAILED. DUE TO AN AD IN EFFECT ON THE REMAINING GENERATOR, A LANDING AT THE NEAREST AIRPORT WAS CARRIED OUT. DURING FAULT ISOLATION I T WAS FOUND THAT THE GENERATOR WAS DISPLAYING AN OVER VOLTAGE CONDITION ON THE VOLTAGE CHECK. THE NR 2 GCU WAS SWAPPED W ITH NR 1 AND THE OVER VOLTAGE CONDITION TRANSFERRED TO THE NR 1 SYSTEM. AS THE VOLTAGE REGULATOR SECTION OF THE GCU IS BELIEVED TO BE AT FAULT, SERVICEABLE GCU WAS INSTALLED AND NORMAL SYSTEM OPERATION WAS RESTORED. 2 L 7 2 4F 4 F RT A21EA E6NE 2004080500098 20040805 00098 EU 2004 8 5 CA040413003 1 20040407 G 5246 A52475147012 ACCESS DOOR AIRBUS 310 A310300 3930305 EU GE CF6 CF680C2A5 NE LAV SERVICING MISSING W K NONE D INFLIGHT SEPARATION IN INSP/MAINT 1 CA (CAN) THE AIRCRAFT ARRIVED AT THE STATION WITH THE MID LAVATORY SERVICING ACCESS DOOR MISSING. THE AIRCRAFT WAS DISPATC HED UNDER CDL AND A NEW DOOR WAS INSTALLED AT THE MAIN BASE. THE LAVATORY SYSTEM WAS CHECKED SERVICEABLE (NO LEAK). SU SPECT PANEL NOT PROPERLY LATCHED AT THE PREVIOUS STATION. 2 L 7 2 4F 4 F RT A35EU E13NE 2004080500101 20040805 00101 SW 2004 8 5 CA040413006 1 20040325 G 6410 406016100119 BLADE BELL 407 407 1182206 SW ALLSN 250C 250C47B GL TAIL ROTOR CONTAMINATED W C ABORTED TAKEOFF O OTHER TO TAKEOFF 1 CA (CAN) ONE TAILROTOR BLADE FOUND TO HAVE ABSORBED WATER, THROWING THE TAIL ROTOR OUT OF BALANCE AND CREATING EXCESSIVE VI BRATIONS. 1 G 7 1 3U 3 U O H2SW E1GL 2004080500102 20040805 00102 EA 2004 8 5 CA040413007 1 20040301 G 5755 2651001011 ACTUATOR DHAV DHC7 DHC7* EA SPOILERS DISLODGED W O OTHER K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA 15131 15131 (CAN) DURING CRUISE FLIGHT LT ROLL SPOILER ACTUATOR BROKE OFF ITS MOUNTS. NR 2 HYDRAULIC SYSTEM WAS LOST DUE TO A HYDR AULIC LEAK FROM THE ACTUATOR. AIRCRAFT LANDED SAFELY. PROBLEM WAS FOUND TO BE A PRE MOD ROLL SPOILER ACTUATOR WHICH THE OPERATOR HAD NOT UPDATED TO THE IMPROVED. 2 H 7 4 4T RT A20EA 2004080500103 20040805 00103 2004 8 5 CA040413008 4 20040407 G 3460 4043912902 CDU AIRBUS 310 A310300 3930305 EU COCKPIT SMOKE W H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA 49995 49995 (CAN) DURING TAXIING TO THE GATE, AIRCRAFT EXPERIENCED SMOKE IN THE FLIGHT DECK CAUSED BY NR 2 FMS CDU. NR 2 CDU WAS CO NFIRMED FAULTY AFTER MAINTENANCE INVESTIGATION AND THE AIRCRAFT WAS DISPATCHED UNDER MEL. CDU WAS REPLACED ON RETURN FL IGHT AND ROUTED TO VENDOR FOR INVESTIGATION. TSSV: 1861 HRS. 2 L 7 2 4F RT A35EU 2004080500104 20040805 00104 NM 2004 8 5 CA040413009 1 20040410 G 3220 658005113 DRAG BRACE BOEING 737 737201 1384454 NM PWA JT8 JT8D9A 52048 NE NLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 58478 (CAN) NOSE GEAR UPPER DRAG BRACE HAS A CRACK APPROXIMATELY .2500 INCHES IN LENGTH AND .1250 INCHES IN DEPTH, NEAR LT GE AR DOOR ATTACHMENT POINT. UPPER DRAG BRACE REPLACED. 2 L 7 2 4F 4 F A16WE E2EA 2004080500105 20040805 00105 NM 2004 8 5 CA040413010 1 20040409 G 3220 658005113 DRAG BRACE BOEING 737 737201 1384454 NM PWA JT8 JT8D9A 52048 NE NLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 57213 (CAN) NOSE GEAR UPPER DRAG BRACE HAS A CRACK APPROXIMATELY .2500 INCHES IN LENGTH AND .1250 INCHES IN DEPTH, NEAR LT GEA R DOOR ATTACHMENT POINT. UPPER DRAG BRACE REPLACED. TIMES 57213:23 CYCLES 53614. 2 L 7 2 4F 4 F A16WE E2EA 2004080500106 20040805 00106 NE 2004 8 5 CA040413011 2 20040409 G 7310 2C68 PUMP CESSNA 208 208B 2073701 CE PWA PT6 PT6A114A 52043 NE MCAULY 3AF34C 3GFR34C703 GL FUEL BOOST FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING ROUTINE INSPECTION ALUMINUM PARTICLES WERE FOUND IN THE AIRFRAME FUEL FILTER DOWNSTREAM OF THE FUEL BOOST P UMP. RUNNING THE BOOST PUMP SHOWED THAT WHILE IT MAINTAINED OPERATING PRESSURE AN INTERMITTENT GRINDING NOISE COULD BE HEARD. DISSASEMBLY OF THE PUMP SECTION OF THE ASSEMBLY SHOWED THE TWO PIECE IMPELLER ASSEMBLY HAD BECOME DISBONDED. 1 H 7 1 3T 3 T A37CE E4EA 5 C P60GL 2004080500107 20040805 00107 SO 2004 8 5 CA040413012 1 20040412 G 3710 SEAL PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA VACUUM PUMP LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) AT 400 HRS SPECIAL INSPECTION FOUND OIL LEAK ON RT ENGINE, OUT OF VACUUM PUMP SHAFT. REMOVED PUMP FOUND DRIVE SHA FT SEAL LEAKING PN: 06A19956. AFTER THE SEAL REMOVAL DURING VISUAL INSPECTION FOUND RUBBER PART OF THE SEAL SCUFFED IN S OME PLACES CAUSING THE LEAKAGE. 1 L 7 2 3O 3 O A20SO E14EA 2004080600001 20040806 00001 EA 2004 8 6 CA040413013 1 20040408 G 2435 230481490 FAN LUCAS DHAV DHC6 DHC6300 2802606 EA PWA PT6 PT6A27 52043 EA HARTZL HCB3T HCB3TN3 GL STARTER GEN BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA 4835 (CAN) DURING INSTALLATION OF FAN PN 230481490 AT OVERHAUL, THE CENTER PART OF THE FAN BROKE AWAY FROM THE FAN BODY AND B LADES. THE CAST ALUMINUM FAN WAS BEING ATTACHED TO THE SHAFT, ARMATURE AND BEARING ASSY WHEN IT BROKE CIRCUMFERENTIALLY BEFORE REACHING TARGET TORQUE ON THE SHAFT NUT OF 110 INCH-LBS. THE BREAK APPEARS TO BE A CLEAN BREAK, IE THERE IS NO S IGN OF A PRE-EXISTING CRACK. PART WAS REPLACED BY AN ALTERNATE P/N 23048-1240. BROKEN FAN HAS BEEN QUARANTINED. 1 H 7 2 3T 4 T RT A9EA E4EA 6 C P15EA 2004080600002 20040806 00002 NE 2004 8 6 CA040414001 2 20040401 G 7230 3020159 RETAINING RING CESSNA 208 208B 2073701 CE PWA PT6 PT6A114A 52043 NE MCAULY 3AF34C 3GFR34C703 GL COMPRESS SHROUD COLLAPSED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THE HOT SECTION WAS DISMANTLED FOR A SCHEDULED CT DISK REPLACEMENT. CT SHROUD SEGMENTS HAD SHIFTED AXIALLY. THE RETAINING RING HAD COME OUT OF THE GROOVE. THIS PROBLEM HAS BEEN DOCUMENTED ON OTHER ENGINES. MFG HAS ISSUED P/N 31107 41-02 RETAINING RING ON SB 13121 (60A, 61, 62, 65 SERIES) AND SB 3248 (41/42, 45 SERIES) TO PREVENT THE COLLAPSE OF THE RETAINING RING. THE LATTER SB HAS NOT BEEN ISSUED ON SMALLER ENGINE MODELS SUCH AS THE 114A ENGINE MODEL TO ALLOW THE M ORE ROBUST RETAINING RING TO BE USED. 1 H 7 1 3T 3 T A37CE E4EA 5 C P60GL 2004080600003 20040806 00003 SO 2004 8 6 CA040414002 1 20040414 G 5730 4065910 SKIN PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL RT WING CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 15452 (CAN) CRACKING OF RT WING LEADING EDGE SKIN AT STA 160.50 AND 174.50 FROM RIVETS 1 RIVET FORWARD OF STRINGER AHEAD OF TH E SPAR. REVIEW OF AIRCRAFT RECORDS DID NOT SHOW ANY RECENT HISTORY OF HARD LANDINGS. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004080600004 20040806 00004 EA 2004 8 6 CA040414003 1 20040309 G 2750 664901 SOLENOID DHAV DHC7 DHC7* EA FLAP DUMP MALFUNCTIONED W O OTHER F FLT CONT AFFECTED CR CRUISE 1 CA 18724 (CAN) SCREWS ON THE SECOND STAGE FLAP DUMP SOLENOID VALVE BROKE AND CAUSED THE TRAILING FLAPS TO MALFUNCTION. NO FLUID WAS LOST. PART WAS REPLACED AND AIRCRAFT RETURNED TO SERVICE. PART SENT TO MFG FOR INVESTIGATION. 2 H 7 4 4T RT A20EA 2004080600005 20040806 00005 EU 2004 8 6 CA040414004 1 20040406 G 3246 13889 BEARING BNORM BN2 BN2 1520202 EU LYC O540 O540E4C5 41532 EA HARTZL HCC2Y HCC2YK2 GL MLG WHEEL DESTROYED W F ACTIVATE FIRE EXT. B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA (CAN) NR 4 WHEEL OUTER AND INNER BEARINGS FAILED. THE BRAKE CALIPER SLIPPED FROM THE TORQUE PLATE AND THE BRAKE HYDRAULI C HOSE BROKE. THE CAPTAIN USED THE AIRCRAFT FIRE EXTINGUISHER TO EXTINGUISH THE SMOKE AT THE WHEEL. SHE SAYS NO FIRE WAS SEEN. THE AXLE WAS FOUND DAMAGED DUE TO THE FAILED WHEEL BEARINGS. 1 H 7 2 3O 3 O A17EU E295 5 C P920 2004080600007 20040806 00007 NM 2004 8 6 CA040415001 1 20040327 G 2740 6355C000101 MOTOR BOEING 737 737* NM CFMINT CFM567 CFM567B22 13802 NE STAB TRIM FAILED W O OTHER F J FLT CONT AFFECTED WARNING INDICATION CR CRUISE 1 CA (CAN) FLIGHT CREW REPORTS WHILE AT LEVEL AT FLIGHT 39,000 FT, (AUTOPILOT DISENGAGED, MASTER CAUTION FLIGHT CONTROL ILLUM INATED, SPEED TRIM FAIL LIGHT ILLUMINATED, NO ELECTRIC TRIM, NO AUTOPILOT) FOLLOWING IN-FLIGHT TROUBLESHOOTING/NON NORMA L CHECKLISTS, AC LANDED W/O INCIDENT. MAINT REPLACED ELECTRIC STABILIZER TRIM MOTOR IAW MM AND TESTED SYSTEM IAW MM. NO FAULTS FOUND. AC RETURNED TO SERVICE WITH NO FURTHER PROBLEMS TO REPORT. THIS UNIT IS A NEW MFG (C) MODEL WHICH VENDOR H AS COMPLETELY OVERHAULED BECAUSE OF PROBLEMS WITH THEIR (B) MODEL. THIS WAS FIRST SUCH STAB TRIM PROBLEM WITH NEW (C) MO DEL AND IS CURRENTLY BEING INVESTIGATED BY MFG. RELIABILITY DEPT IS CURRENTLY WAITING FOR FINAL STRIP REPORT FROM MFG. 2 L 7 2 4F 4 F RT A16WE E00055EN 2004080600008 20040806 00008 SO 2004 8 6 CA040415002 2 20040404 G 8530 VALVE GUIDE CONT CESSNA 172 172 2072402 CE CONT O300 O300A 17022 SO MCAULY 1A170 1A170* GL CYLINDER WORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) CYLINDER NR 3, 4 AND 5, EXCESSIVE OIL CONSUMPTION AND LOW COMPRESSION. ENGINE WAS RETURNED TO OVERHAUL FACILITY W HERE IT WAS DISCOVERED THAT 3 OF 6 CYLINDERS HAD EXCESSIVE PLAY IN THE EXHAUST VALVE GUIDES WHICH CAUSED THE VALVE TO BE COME COKED AND STICK IN THE GUIDE. CYLINDERS MFG. S/N: NR 3, 31109,NR 4, 31215, AND NR 5, 31213. 1 H 7 1 3O 3 O NT 3A12 E253 5 N P857 2004080600009 20040806 00009 CE 2004 8 6 CA040415003 1 20040325 G 1430 AN2312 CLEVIS BOLT CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160DTM GL ELEVATOR MISINSTALLED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) INCORRECT INSTALLATION OF UPPER ELEVATOR CABLE TO ELEVATOR BELLCRANK. AFTER A RECENT PAINT JOB WHERE THE ELEVATOR HAD BEEN REMOVED, THE UPPER BOLT WAS INSTALLED INCORRECTLY. THE AIRCRAFT SERVICE MANUAL MAKES (SPECIAL NOTE) THAT THE UP PER CABLE MUST BE ATTACHED WITH BOLT HEAD ON RT, THIS SUPPLIES PROPER CLEARANCE BETWEEN BOTH HEAD AND ADJACENT STRUCTURE WITH THE BOLT INSTALLATION REVERSED. THE NUT (AN310-3) INTERFERED WITH ADJACENT BULKHEAD, THIS LIMITED UP ELEVATOR TRAV EL THE POSSIBILITY ALSO EXISTED THAT THE ELEVATORS COULD HAVE JAMMED IN THE FULL UP POSITION. THE AIRCRAFT HAD PREVIOUSL Y FLOWN A TRAINING FLIGHT DOING INTENTIONAL STALLS AND SPINS. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2004080600019 20040806 00019 EU 2004 8 6 CA040415004 1 20040408 G 2730 298G3096 BELLCRANK BRAERO 748 HS7482A 4231001 EU RROYCE DART DART5342 EU ROTOL R4304 R2124304 EU ELEVATOR CONTROL CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ON PREFLIGHT INSPECTION, WHEN CHECKING ELEVATOR PLAY, EXCESSIVE MOVEMENT REVEALED THE ELEVATOR CONTROL BELLCRANK P RIMARY ATTACH LUG WAS CRACKED THROUGH AND ROD END WAS BEING RETAINED BY OVERSIZED SECONDARY LUG RESULTING IN A DECREASE OF TRAVEL ON STARBOARD ELEVATOR AND SUBSTANTIALLY INCREASED FREE PLAY. THE ELEVATOR ACTUATOR ROD WAS RETAINED BY THE RES TRICTING BRACKET, INTRODUCED BY MANDATORY MODIFICATION 2449/SB27-33. THERE IS NO REPORT OF THE AIRCRAFT RECENTLY EXPERIE NCING ANY GUST LOADS TO THE ELEVATORS. 2 L 7 2 3T 4 T A24EU A196 6 C P899 2004080600036 20040806 00036 NM 2004 8 6 CA040415005 1 20040405 G 3210 6524480412 ATTACH FITTING BOEING 727 727227 1384078 NM PWA JT8 JT8D9A 52048 NE MLG UPLOCK CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING ROUTINE MAINTENANCE BY VISUAL INSPECTION OF THE RT LANDING GEAR UPLOCK ATTACH FITTING, A SUSPECTED CRACK WA S DETECTED AT THE UPLOCK ATTACH LUG. FITTING WAS REMOVED FROM AIRCRAFT AND SUBMITTED FOR NDT. NDT INSPECTION BY EDDY CURRENT CARRIED OUT AND CONFIRMED THAT THE LUG WAS CRACKED TO APPROXIMATELY 50 PERCENT OF MATERIAL. FITTING REPLACED ON AIRCRAFT. 2 L 7 3 4F 4 F A3WE E2EA 2005022300132 20050223 00132 EA 2005 2 23 CA040415006 2 20040402 G 7200 ENGINE PWA PT6 PT6A28 EA DAMAGED W O OTHER Y J ENGINE STOPPAGE WARNING INDICATION TO TAKEOFF 1 CA 15516 50870 ENG REMOVED AFTER A/C DRIFTED TO LT SIDE OF RWY & HIT A 4 FT SNOWBANK. NLG COLLAPSED & ENG HIT BANK AT MAX PWR. EXHAUST DUCT & GG CASE HAD OUTER SKIN BUCKLING. 2ND STAGE REDUCTION PLANET GEAR CARRIER BENT, PT RUB DAMAGE ON BLADE TIPS. COMP BLADES, STATORS & IMPELLER RUB DAMAGE. PT DISK DISPLACED, COMPRESSOR RUB DAMAGE GG CASE. RGB OIL PRESS XFER TUBE BENT & CONNECTING ELBOW BROKEN. IN TEST CELL, DURING TEST FOUND ENG PERFORMANCE ACCEPTABLE, BUT A LOUD RUB NOISE HEARD ON RUNDO WN, TRACED TO WORN SPLINES ON RGB HOUSING. CHANGED HOUSING. REMOVED FROM CELL TO INVEST 2ND STAGE GEARING, FOUND REAR FA CE OF 2ND STAGE CARRIER DISTORTED. CARRIER CHANGED, ENG TESTED. NO ADVERSE NOISES ON SHUTDOWN, ENG DECLARED SERVICEABLE. 4 T E4EA 2004080600037 20040806 00037 WP 2004 8 6 CA040415007 2 20040413 G 7250 310117017 PINION GEAR SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP ENGINE BROKEN W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) AFTER TAKEOFF, FLIGHT CREW HAD CHIP DETECTOR LIGHT ILLUMINATE ON RT ENG. CREW REDUCED POWER AND IMMEDIATELY RETUR NED TO LAND. MAINT WAS SENT TO INSPECT CHIP DETECTOR, DISCOVERED SEVERAL CHUNKS OF FERROUS METAL ON CHIP DETECTOR PLUG. OIL FILTER WAS REMOVED AND INSPECTED, FOUND TO CONTAIN AN ABNORMAL AMOUNT OF METAL. UPON ROTATING PROP, A GRINDING/RATTL ING NOISE WAS OBSERVED COMING FROM GEAR CASE. ENG WAS REPLACED AND UNSERVICEABLE ENG TORN DOWN. INITIAL FINDINGS WERE T HAT HIGH SPEED PINION GEAR HAD SHED A GEAR TOOTH WHICH WAS WHAT WAS FOUND ON CHIP DETECTOR. NO FURTHER REASON FOR PINIO N GEAR FAILURE HAS BEEN DISCOVERED. MORE INFORMATION WILL FOLLOW IF ANY CAUSE OR CONTRIBUTING FACTORS CAN BE DETERMINED. 2 L 7 2 4T 4 T RT A8SW E4WE 2004080600038 20040806 00038 NM 2004 8 6 CA040415008 1 20040328 G 3242 58570 VALVE DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE PARK BRAKE SLOW W O OTHER A FLAME/FIRE TX TAXI/GRND HDL 1 CA 37510 37510 (CAN) ON TAXI TO HANGER, BRAKES OVERHEATED CAUSING FIRE ON NR 3 AND NR 4 MAIN WHEEL ASSEMBLIES AND NR 1 AND NR 2 BRAKE A SSEMBLIES TO GLOW RED HOT. ALL FOUR MAIN WHEEL AND BRAKE ASSEMBLIES REPLACED. RT MAIN LANDING GEAR SHOCK STRUT REPLACED . OTHER ITEMS, BRAKE LINES, FIRE EXTINGUISHERS, ETC REPLACED AS REQUIRED. EXTENSIVE TROUBLESHOOTING COMPLETED AND FAULT TRACED TO PARKING BRAKE VALVE SLOW TO RELEASE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004080600039 20040806 00039 SO 2004 8 6 CA040416001 1 20040408 G 3230 4032700 TRUNNION PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL MLG CRACKED W O OTHER K FLUID LOSS LD LANDING 1 CA 13080 (CAN) ON LANDING, THE AIRCRAFT SLOWLY SETTLED WITH THE LT WING LOW ON LANDING ROLL. THE PILOT STOPPED AND SHUT DOWN THE ENGINES. THE PILOT CALLED MAINTENANCE AND MAINTENANCE INSPECTED THE AIRCRAFT ON THE RUNWAY. THE AME NOTICED A LOT OF HYD RAULIC FLUID ON THE GEAR LEG AND FOUND THE CRACK IN THE HOUSING. THE AIRCRAFT WAS TOWED TO THE HANGER. THE HOUSING WAS R EPLACED WITH A NEW UNIT AND THE AIRCRAFT WAS RETURNED TO SERVICE. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004080600040 20040806 00040 SO 2004 8 6 CA040416002 1 20040416 G 8100 LW18302 SUPPORT PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA HARTZL HCE3Y HCE3YR2A GL TURBOCHARGER CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) TURBOCHARGER SUPPORT MOUNT FOUND CRACKED ON LOWER LT TUBE. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004080600041 20040806 00041 NE 2004 8 6 CA040416003 2 20040416 G 8530 153072 CYLINDER HEAD DOUG DC4 C54A 3021512 WP PWA R2000 R20007M2 52023 NE HAMSTD 23E 23E50 NE ENGINE SEPARATED W E A ENGINE SHUTDOWN UNSCHED LANDING E VIBRATION/BUFFET CR CRUISE 1 CA (CAN) DURING CRUISE, THE CREW NOTICE A SLIGHT VIBRATION TO THE NR 1 ENGINE, THEY ALSO NOTICED AN OIL LEAK. THE ENGINE WA S SHUT DOWN AND PROPELLER FEATHERED. DURING INSPECTION IT WAS NOTICED THAT THE NR 9 CYLINDER HEAD WAS SEPARATING FROM T HE BARREL, THE ENGINE WILL BE REPLACED FOR COMPANY CONVIENCE. 2 L 7 4 4R 4 R A762 5E5 6 C P603 2004080600042 20040806 00042 EA 2004 8 6 CA040417001 1 20040413 G 5510 600220591008 FAIRING CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE HORIZONTAL STAB LIGHTNING STRIKE W O OTHER O OTHER DE DESCENT 1 CA (CAN) FLYING THRU SHOWERS AT 10000 FT , ON ARRIVAL, LARGE FLASH WAS OBSERVED. NO AIRCRAFT SYSTEM AFFECTED. AFTER LANDI NG, 2 BLACK MARKS WERE FOUND ON THE LOWER RT HORIZONTAL STABILIZER. REPAIR EO 670-55-12-153 ALONG WITH NON DESTRUCTIVE TEST (NDT) CARRIED OUT AND AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT A21EA E15NE 2004080600043 20040806 00043 EA 2004 8 6 CA040417002 1 20040414 G 3230 69210 SEQUENCE VALVE DHAV DHC8 DHC8311 1386006 EA PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE MLG INOPERATIVE W O OTHER J WARNING INDICATION AP APPROACH 1 CA 28730 (CAN) ON APPROACH , THE CREW SELECTED GEAR DOWN, NOSE GEAR WOULD NOT COME DOWN, AMBER AND RED CATION AND WARNING LIGHTS ON AND LOUD GRINDING NOISE IN NOSE WHEEL AREA WAS HEARD, THE CREW CARRIED OUT AN ALTERNATE GEAR SELECTION (THE ABOVE IS EXTRACTS FROM PILOT'S REPORT ) SEVERAL GEAR SWINGS COMPLETED AND WAS UNABLE TO DUPLICATE THE SNAG. SEQUENCE VALVE REPLAC ED FOR TROUBLE SHOOTING. SEVERAL MORE GEAR SWINGS COMPLETED WITH NO FAULT FOUND. SEQUENCE VALVE WAS SENT FOR TEAR DOWN R EPORT, WILL UPDATE AS REPORT BECOME AVIALABLE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004080600067 20040806 00067 GL 2004 8 6 CA040419001 2 20040416 G 7230 23050833 COMPRESSOR BELL 206 206L 1181522 SW ALLSN 25OC 250C20R GL ENGINE DAMAGED W A UNSCHED LANDING Y ENGINE STOPPAGE CL CLIMB 1 CA (CAN) ENGINE FAIL AT APPROX 150 FT. AGL ON CLIMB OUT, PILOT HEARD LOUD BANG ENGINE QUIT. PRELIMINARY INSPECTION SHOWS C OMPLETE COMPRESSOR FAILURE. 1 G 7 1 3U 3 U H2SW E4CE 2004080600068 20040806 00068 NM 2004 8 6 CA040419002 1 20040413 G 7830 BACC2A3A00764CG CONTROL CABLE BOEING 737 7372Q9 138448M NM PWA JT8 JT8D9A 52048 NE THRUST REVERSER CHAFED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING C-CHECK, THE LT ENGINE THRUST LEVER CONTROL CABLE (T1A) WAS FOUND TO BE CHAFED AND HAD BROKEN CABLE STRANDS . DURING INSTALLATION OF NEW CABLE, IT WAS FOUND THAT THE T1A CABLE HAD BEEN ROUTED UNDER THE CABLE GUARD INSTEAD OF OV ER, CONTRIBUTING TO THE ABOVE MENTIONED DAMAGE TO THE THRUST LEVER CONTROL CABLE. TIMES 60322.07 CYCLES 56643. 2 L 7 2 4F 4 F A16WE E2EA 2005022300133 20050223 00133 SO 2005 2 23 CA040419003 1 20040415 G 2421 BRUSH BLOCK PRESTOLITE PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2C 41532 EA HARTZL HCE3Y HCE3YR2A GL ALTERNATOR SHORTED W A UNSCHED LANDING H J ELECT. POWER LOSS-50 PC WARNING INDICATION CR CRUISE 1 CA AFTER DEPART, LOW VOLT IND & SELECTED AUX VOLTAGE REG WITH NO IMPROVEMENT. SEVERAL SELECTIONS WERE MADE BETWEEN MAIN & A UX REG WITH NO IMPROVEMENT. A/C RETURNED TO AIRPORT FOR A LANDING. INVEST REVEALED A SHORT-CIRCUITED BRUSHBLOCK IN RT AL TERNATOR R, WHICH DESTROYED BOTH MAIN & AUX REGULATORS, WHICH PREVENTED FUNCTIONAL LT ALTERNATOR FROM FUNCTIONING. SHORT ED BRUSHBLOCK IN THE RT ALTERNATOR REPLACED WITH A FUNCTIONAL BRUSHBLOCK & BOTH REG`S REPLACED WITH NEW UNITS. ENG`S WER E GROUND RUN & VOLT REGULATORS CHECKED AT 28.5 VOLTS, A/C RETURNED TO SERV. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004080600069 20040806 00069 NE 2004 8 6 CA040419004 2 20040417 G 7200 ENGINE DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE LEFT FAILED W E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA (CAN) DEPARTING, WHILE CRUISING AT 31 000 FT, LOUD BANG COMING FROM LT ENGINE WITH DECREASING EPR , INCREASING EGT UP TO 575 C. DID NOT HAVE A RE-LIGHT WITH IGNITER ON INCREASING POWER WAS NOT RESPONDING, SO WE TREATED THAT AS A SEVERE D AMAGE OR SEPARATION AND THE ENGINE WAS SHUT DOWN. AIRCRAFT WAS DIVERTED. 2 L 7 2 4F 4 F RT A6WE E9NE 2004080600070 20040806 00070 EU 2004 8 6 CA040420001 1 20040415 G 6321 10541227 STRUCTURE BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL ROTOR BRAKE BOX DAMAGED W O OTHER F FLT CONT AFFECTED NR NOT REPORTED 1 CA (CAN) THE COLLECTIVE FRICTION ASSEMBLY WAS REPORTED FEELING LOOSE. LOOSENESS WAS TRACED TO THE BRAKE BOX, WHICH WAS MOUN TED WITH 6MM BOLTS IN 10MM HOLES. 1 G 7 2 3U 3 U H3EU E4CE 2004080600071 20040806 00071 EU 2004 8 6 CA040420002 1 20040329 G 2913 704A33690004 BELT SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE HYDRAULIC PUMP CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHILE DOING BULLETIN ON HYDRAULIC SYSTEM IT WAS NOTICED THAT THE BELT WAS CRACKED. 1 G 7 1 3U 3 U NC H9EU E19EU 2004080600072 20040806 00072 SW 2004 8 6 CA040420004 1 20040401 G 5320 206032307 ANGLE BELL 206 206L3 1182108 SW ALLSN 250C 250C30P 03013 GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) A CRACK WAS FOUND IN A 1200 HR INSPECTION. THE PART WAS REPLACED AND TB 206L-87-139 WAS C/W TO STOP MORE DAMAGE 1 G 7 1 3U 3 U H2SW E1GL 2004080600073 20040806 00073 GL 2004 8 6 CA040420005 2 20040413 G 7250 23033195 TURBINE BELL 206 206L3 1182108 SW ALLSN 250C 250C30P 03013 GL 1ST STAGE NOZZLE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHEN INSTALLING A NEW SMOKELESS LINER A CRACK WAS WAS FOUND IN FIRST NOZZLE. TURBINE WAS REPAIRED AT AN ENGINE SHO P 1 G 7 1 3U 3 U H2SW E1GL 2005022300134 20050223 00134 EA 2005 2 23 CA040420007 1 20040415 G 2820 MS29513326 O-RING CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE FUEL COUPLING LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) DURING ROUTINE WALK AROUND , MAINTENANCE DISCOVERED FUEL LEAK AROUND RT WING DRYBAY DRAIN. DRY BAY PANELS WERE RE MOVED AND DRY BAY FOUND TO HAVE SMALL AMOUNT OF FUEL PRESENT. THE COUPLING THAT ATTACHES THE AIR SCOOP TO THE FUEL TANK VENTLINES ON THE RT WING WAS FOUND TO BE LEAKING INTO THE DRY BAY. COUPLING PACKINGS WERE REPLACED AND LEAK CHECK WAS COMPLETED WITH NO LEAKS FOUND. AIRCRAFT WAS RETURNED TO SERVICE. AIRCRAFT HOURS WERE 11178:51 AIRCRAFT CYCLES WERE 910 7 2 L 7 2 4F 4 F RT A21EA E15NE 2005022300135 20050223 00135 NE 2005 2 23 CA040421001 2 20040419 G 8500 ENGINE DOUG DC3 DC3C 3021457 WP PWA R1830 R183092 52020 NE HAMSTD 23E 23E50 NE NR 1 VIBRATION W C ABORTED TAKEOFF E VIBRATION/BUFFET TO TAKEOFF 1 CA CP353136 (CAN) DURING TAKEOFF, THE CREW NOTICED THE NR 1 ENGINE HAD A NOTICEABLE VIBRATION, THE TAKEOFF WAS ABORTED. THE ENGINE WILL BE REMOVED AND SENT FOR EVALUATION UNDER WARRANTY. 2 L 7 2 4R 4 R A669 5E4 6 C P603 2005022300136 20050223 00136 EU 2005 2 23 CA040421002 1 20040418 G 3040 TERMINAL PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL CB PANEL BURNED W K NONE J WARNING INDICATION IN INSP/MAINT 1 CA (CAN) THE AIRCRAFT WAS HAVING PROBLEMS WITH THE WINDSCREEN DE-ICE SYSTEM. THE MAIN POWER INPUT LEAD TO THE GENERATOR 2 BUSS WAS FOUND BURNED AND CORRODED. A NEW TERMINAL WAS INSTALLED AND THE SYSTEM FUNCTIONED NORMALLY. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005022300137 20050223 00137 2005 2 23 CA040421003 4 20040420 G 3422 CARD CESSNA CESSNA 208 208 2073702 CE PWA PT6 PT6A114A 52043 NE MCAULY 3AF34C 3GFR34C703 GL DIRECTIONAL GYRO BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA T41571E (CAN) THE CO-PILOT'S DIRECTIONAL GYRO WAS RECENTLY REPLACED WITH THE ABOVE MENTIONED OVERHAULED INSTRUMENT. UPON COMPLA INT FROM PILOT, THE INSTRUMENT WAS HARD TO SET, A FUNCTIONAL TEST WAS COMPLETED. IT WAS FOUND THAT PUSHING THE KNOB IN AND TURNING IT DID NOT ROTATE THE CARD WITH EASE. FOUND THAT IT TOOK ABNORMALLY GREAT AMOUNT OF INWARD PRESSURE WHILE T URNING THE KNOB TO GET ANY MOVEMENT OF THE CARD ESPECIALLY IN THE CLOCKWISE ROTATION. THE INSTRUMENT HAS ONLY 37.6 HOUR S AND 34 CYCLES SINCE OVERHAUL. 1 H 7 1 3T 3 T NT A37CE E4EA 5 C P60GL 2005022300138 20050223 00138 CE 2005 2 23 CA040421004 1 20040421 G 7111 07520144 PAN CESSNA 185 A185F 2072821 CE CONT O550 IO550D 17042 SO MCAULY D3A34 D3A34C401 GL COWL FLAP CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING RIGHT COWL FLAP HINGE REPLACEMENT, FOUND COWL FLAP PAN ASSEMBLY HAS SEVERE CORROSION UNDER HINGE HALF. THI S AREA IS ONLY VISIBLE AFTER REMOVING THE HINGE. 1 H 7 1 3O 3 O 3A24 E3SO 5 C P47GL 2005022300139 20050223 00139 NM 2005 2 23 CA040422001 1 20040420 G 2910 82920010229 LINE DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE HYDRAULIC SYS LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) FLIGHT CREW REPORTED NR 1 AND NR 2 HYDRAULIC QUANTITIES AT MINIMUM LEVELS. MAINTENANCE FOUND PERMASWAGE FITTING O N NR 2 LANDING GEAR DOWN LINE IN CENTER FUSELAGE LEAKING. NEW SECTION OF HYDRAULIC LINE WAS INSTALLED AND SWAGGED IAW A MM 20-06-13. LEAK CHECKS AND GEAR SWINGS WERE PERFORMED AND CHECKED SERVICEABLE. AIRCRAFT HOURS 36612:46 AIRCRAFT CYCL ES 37042. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005022300140 20050223 00140 CE 2005 2 23 CA040422002 1 20040421 G 7722 30739501 THERMOCOUPLE LEAR 35 35A 5170602 CE GARRTT TFE731 TFE73122B 01518 WP RT ENGINE SHORTED W O OTHER O OTHER CL CLIMB 1 CA (CAN) IN CLIMB AND CRUISE ALTITUDE THE FLIGHT CREW NOTICED A FLUCTUATION OF THE ITT ON THE RT ENGINE INDICATOR (ITT). T ROUBLESHOOTING WAS DONE BY MAINTENANCE PERSONNEL AND THEY FOUND THE RT ITT HARNESS WAS TOUCHING THE OUTER CASE OF THE EX HAUST SHROUD (POOR ROUTING). THE HARNESS SHEILD WAS SHORTED. 2 L 7 2 4F 4 F A10CE E6WE 2005022300141 20050223 00141 CE 2005 2 23 CA040422003 1 20040422 G 7120 045100336 MOUNT CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 11850 (CAN) AT INSPECTION THE ENGINE MOUNT WHICH ALSO HAS PROVISION FOR MOUNTING THE NOSE LANDING GEAR WAS FOUND DAMAGED. TWO TUBES WERE CRACKED, THREE OTHERS WERE SLIGHTLY BENT. ALL EVIDENCE POINTS TO A UNREPORTED HARD LANDING. AIRCRAFT HAS B EEN THOROUGHLY INSPECTED FOR FURTHER DAMAGE. NONE FOUND. 1 H 7 1 3O 3 O NT 3A19 E223 5 N P50GL 2005022300142 20050223 00142 SW 2005 2 23 CA040422004 1 20040418 G 6710 2050010461 GRIP BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA CYCLIC STICK BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING ROUTINE GREASING AND SERVICING OF MAIN ROTOR COMPONENTS AME ATTEMPTED TO MOVE THE PILOT'S CYCLIC STICK. AS THE MOVEMENT WAS ATTEMPTED, THE GRIP BROKE INTO TWO PIECES. THE FRACTURE OCCURRED BETWEEN THE FORCE TRIM RELEASE SWITC H AND CARGO RELEASE SWITCH. NEW GRIP WAS REWIRED AND INSTALLED. A/C RETURNED TO SERVICE. 1 G 7 1 4U 4 U H4SW E22EA 2005022300143 20050223 00143 NM 2005 2 23 CA040422005 1 20040211 G 3233 46455109 ACTUATOR BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA LT MLG LEAKING W O OTHER K FLUID LOSS AP APPROACH 1 CA (CAN) AFTER GEAR DOWN SELECTION, NR 2 HYD ISO VALVE' CAUTION CAME ON AND DURING THE WHOLE APPROACH TO LANDING, 'OUTBOARD ROLL SPOILER CAUTION LIGHT' CAME ON INTERMITTENTLY. THIS WAS DUE TO, LOW QUANTITY IN NR 2 HYD SYSTEM. MADE A GO AROUN D, AND KEPT GEAR DOWN WITH FLAPS 5. PERFORMED SYSTEM FAILURE CHECKLISTS AND DECIDED TO COMPLETE ALTERNATE GEAR EXTENSIO N PROCEDURE AS WELL. A NORMAL LANDING COMPLETED. INVESTIGATION/ACTION, EXTENSION HOSE FOR LT MAIN LANDING GEAR EXTENSI ON/RETRACTION ACTUATOR FOUND LEAKING. EXTENSION HOSE REPLACED ACCORDING AMM 32-31-11. 2 H 7 2 4T 4 T RT A13NM E00062EN 2005022300144 20050223 00144 NM 2005 2 23 CA040422006 1 20040217 G 3297 WIRE BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA NLG PROX SENSOR SHORTED W O OTHER N FALSE WARNING CL CLIMB 1 CA GEAR OUT INDICATION AFTER TAKEOFF, NOSE GEAR DOWN, NOSE GEAR UNSAFE AND GEAR IN TRANSIT LIGHT REMAINED ON. DURING DESCE NT, THE LIGHTS WENT OUT AND ON FOUR TIMES. INVESTIGATION/ACTION, THE PROXIMITY SENSOR ELECTRONIC UNIT INTERROGATED FOR FAULTS, PSEU FAULT NR 1. THE NOSE GEAR DOWN SENSOR WIRING WERE FOUND SHORTED. SENSOR REPLACED ACCORDING AMM 32-61-06. 2 H 7 2 4T 4 T RT A13NM E00062EN 2005022300145 20050223 00145 CE 2005 2 23 CA040422007 1 20040421 G 2140 2062071 RECEPTACLE BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCD4N3 HCD4N3A GL CABIN BURNED W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA (CAN) WHEN THE CABIN CENTER HEADLINER WAS REMOVED DURING ROUTINE MX, RADIANT HEAT RECEPTACLES/SOCKETS WERE FOUND CHARRED AND MELTED WITH THE WIRE CONNECTERS INSIDE THE SOCKET LOOSE AND BURNT, PROBABLY FROM THE AMOUNT OF CURRENT BEING DRAWN THROUGH THE WIRES WHEN RADIANT HEAT WAS ON FOR LONG PERIODS OF TIME OVER THE YEARS OF OPERATION. RECEPTACLES, SOCKETS, A ND CONNECTERS WERE REPLACED NEW ON BOTH THE FRONT AND BACK OF THE CABIN CENTER HEADLINER, AND FUNCTION TESTED SERVICEABL E. ALL OTHER KA 200 S OPERATED BY THE COMPANY WERE INSPECTED AND FOUND TO HAVE SIMILAR DAMAGE, TO SOME DEGREE ON THE RAD IANT HEAT CONNECTERS. ALL PARTS WERE REPLACED NEW AND SYSTEMS CHECKED SERVICEABLE. 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2005022300146 20050223 00146 SO 2005 2 23 CA040423001 1 20040413 G 7603 AN37 BOLT PIPER PA28 PA28140 7102802 SO LYC O320 O320E3D 41508 EA SNSNCH 74D 74DM EA POWER LEVER FAILED W O OTHER E VIBRATION/BUFFET CR CRUISE 1 CA THE PILOT WAS UNABLE TO CHANGE PWR SETTINGS IN FLT AS THE THROTTLE DID NOT RESPOND FROM MOVEMENTS IN THE PWR LVR. THE A/ C IMMEDIATELY RETURNED FOR AN UNEVENTFUL LANDING WITH THE RPM SET AT 2300. INSPECTION OF A/C FOUND THAT THROTTLE CNTRL WAS DISCONNECTED FROM CARBURETOR THROTTLE ARM. THE ATTACHING HARDWARE WAS MISSING AND NOT RECOVERED DUE TO OPEN NATURE O F LOWER COWING. THE SPHERICAL ROD END ASSY WAS FOUND STIFF AND COULD NOT BE ROTATED BY NORMAL HAND PRESSURE. IT IS SUSPE CTED THAT BOLT HAD FRACTURED DUE TO FATIGUE OVER TIME AS THIS BOLT IS ON CONDITION ITEM AND THE AGE IS UNKNOWN. ALSO THE STIFF ROD END BEARING MAY HAVE AFFECTED THE FAILURE OF THE BOLT. 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 2005022300148 20050223 00148 CE 2005 2 23 CA040423003 1 20040423 G 3230 12416432 SPRING CESSNA 210 210L 2073448 CE CONT O520 IO520L 17032 SO MCAULY 3A32C D3A32C88 GL MLG DOWNLOCK SEIZED W O OTHER O OTHER NR NOT REPORTED 1 CA DOWNLOCK SPRING ASSY SLIDING ACTION WAS RESTRICTED BY ACCUMULATION OF DIRT AND DEBRIS. DOWNLOCK WAS UNABLE TO FULLY ENGA GE RESULTING IN AN 'UNSAFE' GEAR IND. INSPECT REVEALED WET LUBRICATION ATTRACTED DEBRIS AND DIRT IN THE SPRING ASSY CON CENTRIC SLEEVE AND SPRING. CESSNA INSPECTION MANUAL SECTION 2 IS VAGUE REGARDING LUBRICATION TYPE AND APPLICABILITY AND STATES IN PART - 'AND ANY OTHER FRICTION POINT OBVIOUSLY REQUIRING LUBRICATION'. CONFUSION MAY ARISE IN THIS EXAMPLE. SUBMITTER RECOMMENDS A DRY LUBRICATION IN THIS AREA, AND INCREASED AWARENESS IN INDIVIDUAL INSPECTION PROGRAMS FOR A/C OPERATING IN 'OFF AIRPORT' LOCATIONS, GRAVEL AND DUSTY STRIPS. SUBMITTER'S A/C IS MODIFIED BY STC SA 5737SW NO DOOR KIT 1 H 7 1 3O 3 O 3A21 E5CE 5 C P21EA 2005022300149 20050223 00149 SO 2005 2 23 CA040423004 2 20040423 G 8530 653446 CYLINDER CESSNA 210 210L 2073448 CE CONT O520 IO520L 17032 SO HARTZL HCJ3Y PHCJ3YF1 GL ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 293039R CYLINDER CRACKED THROUGH 75 PERCENT OF CIRCUMFERENCE AT CYLINDER CROWN FROM A POINT BEYOND THE UPPER SPARK PLUG HOLE, AR OUND THE EXHAUST VALVE, AND TERMINATING AT A POINT BEYOND THE LOWER SPARK PLUG HOLE (BUT NOT TRANSECTING THE HOLE). 1 H 7 1 3O 3 O 3A21 E5CE 5 C P36EA 2005022300150 20050223 00150 SW 2005 2 23 CA040423005 1 20040423 G 5710 2734023008 SPAR SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE3311U 01514 WP MCAULY 4HFR34 4HFR34C652 NE AILERON CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 19156 DURING REPLACEMENT OF A BRACKET ON THE RT AILERON, A CRACK APPOXIMATELY .075 INCH WAS DISCOVERED UNDER THE BRACKET AT ON E OF THE ATTACH POINT BOLT HOLES ON THE SPAR LEADING EDGE. THE CRACK WAS REPAIRED IN ACCORDANCE WITH APPROVED DATA AND THE FAIRCHILD SRM. 2 L 7 2 4T 3 T RT A8SW E3WE 6 C 3PNE 2004062100122 20040621 00122 2004 6 21 CA040423006 4 20040422 G 3418 1013646283 SWITCH BEECH 200 B200 1152922 CE PWA PT6 PT6A42 52043 NE HARTZL HCE4N HCE4N3 NE STALL WARNING SHORTED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) PILOT REPORTED THAT THE STALL HEAT APPEARED TO BE ON (HIGH) MODE ON THE GROUND WHEN A WALK-AROUND WAS CONDUCTED. MAINTENANCE CONFIRMED BY RESEARCHING WIRING DIAGRAM AND SYSTEM OPERATION. TROUBLESHOT AND FOUND LT MAIN GEAR SAFETY SWI TCH P/N 101-364628-3 HAD HIGH RESISTANCE THROUGH THE CONTACTS ON SWITCH WHEN AIRCRAFT WAS ON GROUND. THE SWITCH WAS GIVI NG FALSE INFORMATION TO STALL HEAT PANEL MAK ING IT THINK THE AIRCRAFT WAS IN FLIGHT AND GIVING MAXIMUM VOLTAGE FOR MAXI MUM HEAT. SWITCH WAS REPLACED AND OPERATION FOUND NORMAL. 1 L 7 2 4T 4 T A24CE E4EA 5 C P10NE 2004062100131 20040621 00131 2004 6 21 CA040423007 4 20040416 G 3418 600591541 POTENTIOMETER CONRAC CNDAIR CL601 CL6012A12 1900303 EA GE CF34 CF341A NE AOA TRANSDUCER INTERMITTENT W A UNSCHED LANDING N FALSE WARNING CL CLIMB 1 CA 247028 (CAN) DURING TAKEOFF ROTATION, THE STICK SHAKER ACTIVATED ON THE LOW LEVEL, THE STALL PROTECT SYSTEM (SPS) WARBLER SOUN DED, THE SPS FAIL LIGHTS WENT TO A FLASH CYCLE AND THE STALL PUSH LIGHTS ACTIVATED. THE LT SPS NEEDLE WAS SWINGING BACK AND FORTH INTO THE STALL RANGE OVER AN APPROXIMATELY A 60-DEGREE ARC. MEANWHILE THE RT INDICATOR WAS INDICATING A NORMA L AND STEADY FLIGHT REGIME. WHILE AIRCRAFT WAS RETURNING FOR LANDING THE WARNING CONTINUED WITH OCCASIONAL PAUSES UNTIL TOUCHDOWN. TROUBLESHOOTING INDICATED FLUCTUATING RESISTANCE VALUES AT THE INDICATOR WITH NO MOVEMENT OF THE VANE. THE V ANE ASSEMBLY WAS REPLACED AND THE LATERAL ACCELEROMETERS ADJUSTED WITHIN LIMITS. THE AIRCRAFT WAS RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT A21AE E15NE 2004062100132 20040621 00132 EU 2004 6 21 CA040423008 1 20040420 G 2197 WIRE AEROSP ATR42 ATR42300 8680920 EU PWA 120 PW120 NE HAMSTD 14SF 14SF5 NE COOLING FAN SHORTED W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA (CAN) DURING AN INSPECTION, A PERFORATION WAS DETECTED AT A CARGO NET RECEPTACLE. THE SOURCE WAS DETERMINED TO ELECTRICA L ARCING. THE SUPPLY CABLE FOR THE NR 2 COOLING FAN HAD SHORTED AGAINST THE NET FITTING HOUSING DUE TO CHAFING. THIS EQU IPMENT IS PART OF STC SA 02-122 THE REMAINING AIRCRAFT INCORPORATING THIS STC HAVE BEEN REVIEWED WITH NO ANOMALIES. 2 H 7 2 4T 4 T RT A53EU E20NE 6 C P7NE 2004062100133 20040621 00133 NM 2004 6 21 CA040423009 1 20040421 G 3242 26010425 QUICK DISCONNECT HONEYWELL BOEING 737 7372Q8 138448K NM PWA JT8 JT8D15 52051 NE BRAKE SYSTEM LEAKING W O OTHER K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS LD LANDING 1 CA BC1009 (CAN) AC LANDED, ON ROLL-OUT, WAS OBSERVED TO HAVE SMOKE ISSUING FROM UNDERSIDE OF AC. TOWER ADVISED CREW AND CALLED OUT AFF. RT MAIN GEAR WAS FULLY ENGULFED IN HEAVY SMOKE. SMOKE WAS BROUGHT UNDER CONTROL AND AC PASSENGERS AND CREW EVACUAT ED ONTO RUNWAY. MAINT REPORTED THAT A/C HAD A NR 3 BRAKE HYD LINE LEAK, WHICH CREATED A LOT OF SMOKE ON CONTACT WITH BR AKES. AC HAS APPROXIMATELY 55,500 HOURS AND 49,000 CYCLES. BRAKE LINE WAS REPAIRED AND A/C FERRIED TO BASE FOR FURTHER MAINTENANCE. MAINTENANCE INVESTIGATION ONGOING. AIRCRAFT REMAINS OUT OF SERVICE. BRAKE ASSEMBLY WILL BE SENT TO MFG FO R ANALYSIS, TEARDOWN REPORT AND DETAILS OF INVESTIGATION REQUESTED. WILL FOLLOW UP SDR PENDING VENDOR RESULTS. 2 L 7 2 4F 4 F RT A16WE E2EA 2004062100134 20040621 00134 2004 6 21 CA040423010 4 20040421 G 2297 WIRE CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA MCAULY 1C235 1C235LFA GL AUTOPILOT SYS CHAFED W D RETURN TO BLOCK J WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) PILOT REPORTED THAT FLIGHT CONTROLS WERE (STIFF AND VERY HARD TO MOVE). DURING RUN-UP PRIOR TO DEPARTURE. PILOT ELECTED TO RETURN TO BASE. AMO FOUND THAT WIRE HARNESS BEHIND RADIO PANEL WAS CHAFING ON THROTTLE MOUNT CAUSING SHORT T O GROUND. THIS CAUSED THE AUTOPILOT SERVO TO ENGAGE UNCOMMANDED. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P12EA 2004062100135 20040621 00135 EA 2004 6 21 CA040423011 1 20040421 G 1430 RIVET CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE FUSELAGE BURNED W O OTHER O OTHER AP APPROACH 1 CA (CAN) UPON DESCENT AIRCRAFT WAS STRUCK BY LIGHTNING ON LT SIDE OF NOSE. AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE COMPLETED LIGHTNING STRIKE INSPECTION IAW AMM 05-51-05. INSPECTION OF AIRCRAFT STRUCTURE FOUND 25 RIVETS BURNED ALONG THE LENGTH OF THE LT FUSELAGE. RIVETS WERE REPLACED WITH FASTENERS IAW MFG REO:601R-53-00-114. INSPECTION OF AIRCRAFT SYSTEMS REVEALED NO DAMAGE. AIRCRAFT WAS RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT A21EA E15NE 2004062100136 20040621 00136 EA 2004 6 21 CA040425001 1 20040423 G 5311 601360012930 FRAME CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 10579 (CAN) DURING COMPLETION OF AD CF-2003-12/A DVI OF AFT FUSELAGE AND REINFORCING ANGLE AT FS640 ON BOTH LT AND RT SIDES BE TWEEN STRINGERS 9 AND 12 IAW PART A OF MFG SB601-53-061, RT SIDE REINFORCEMENTS PLATE WAS FOUND CRACKED APPROX .8750 IN CH LONG AND CORRESPONDING CRACK WAS FOUND ON THE FRAME AT THE UPPER CORNER OF THE ENGINE SUPPORT BEAM APPROX. .6875 INCH LONG. IAW SB601R-53-061 WORK PROGRESSED TO PART B STEP E ITEM NR 4. EDDY CURRENT HAS BEEN PERFORMED WITH NO CRACKS FOU ND ON SKIN DOUBLER. WORK IS CONTINUING IAW SB AND WILL BE REPORTED AS SOON AS MORE INFORMATION BECOMES AVAILABLE . 2 L 7 2 4F 4 F RT A21EA E15NE 2004062100137 20040621 00137 SW 2004 6 21 CA040426001 1 20040424 G 5210 SEAL SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE3311U 01514 WP MCAULY 4HFR34 4HFR34C652 NE CABIN DOOR PINCHED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) AIRCRAFT DEPARTED AND RETURNED DUE TO NO PRESSURIZATION. MAINTENANCE FOUND THE FABRIC DOOR SILL COVER HAD BECOME PINCHED IN THE CABIN DOOR SEAL. FABRIC COVER REMOVED AND AIRCRAFT CHECKED SERVICIBLE FOR PRESSURIZATION. 2 L 7 2 4T 3 T RT A8SW E3WE 6 C 3PNE 2004062100147 20040621 00147 CE 2004 6 21 CA040426003 1 20040330 G 5610 1014301835 WINDOW BEECH 200 B200 1152922 CE PWA PT6 PT6A42 52043 NE HARTZL HCD4N3 HCD4N3A GL COCKPIT WARPED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING A ROUTINE DAILY INSPECTION IT WAS NOTED THE RT AFT CABIN WINDOW HAD A INWARD CONCAVE APPEARANCE ACROSS THE CENTER FROM TOP TO BOTTOM. UPON REMOVAL WITH THE USE OF A STRAIGHT EDGE IT WAS WARPED ACROSS THIS AREA. NO FURTHER DEFEC TS IN THE FORM OF CRACKING OR CRAZING WERE NOTED. INTEGRITY OF WINDOW PANE APPEARED NORMAL. THE WINDOW AND SEAL WEAR REP LACED WITH NEW IAW B200 MM. NO FURTHER DEFECTS HAVE BEEN NOTED. 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2004062100148 20040621 00148 EA 2004 6 21 CA040426004 2 20040421 G 7314 RG9080J4AM PUMP PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2C 41532 EA HARTZL HCE3Y HCE3YR2A GL FUEL SYSTEM INOPERATIVE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) PUMP WAS RECENTLY MODIFIED/OVERHAULED. IT WAS DISCOVERED THAT ENGINE DRIVEN FUEL PUMP OUTPUT PRESSURE DROPPED RIG HT OFF AT IDLE POWER BUT WAS FINE AT HIGH POWER SETTINGS. ENGINE DID NOT GIVE ANY INDICATION OF PUMP PRESSURE DIFFICULTI ES, ROUGH RUNNING, QUITTING,ETC. PUMP WAS REMOVED AND REPLACED WITH A SERVICEABLE UNIT. SUSPECTED INTERNAL RELIEF VAL VE AT FAULT. PUMP IS PRESENTLY AT COMPONENT SHOP. TEARDOWN REPORT RECEIVED FROM AND FINDINGS WERE AS FOLLOWS: RELIEF VALVE POPPET SEATING AREA UNEVENLY WORN AND NICKED CAUSING POOR SEATING ON RELIEF VALVE HSG. LOCK RING. ADJUSTMENT SCR EW CAME OFF AND WAS LODGED BETWEEN SPRING AND SPRING SEAT. DRIVE SEAL NUT LOCK SCREW WRONG. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004062100149 20040621 00149 EU 2004 6 21 CA040426005 1 20040327 G 3244 266F432 TIRE AMD FALCON FALCON20 2730103 EU GE CF700 CF7002D2 30010 NE MLG DAMAGED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) ON TAKEOFF THE CREW WAS UNABLE TO RETRACT THE LANDING GEAR. AFTER LANDING AN INSPECTION REVEALED THE NR 2 TIRE TRE AD CAP HAD PEELED OFF AND BROKEN THE LT SQUAT SWITCH, WHICH PREVENTED RETRACTION OF THE LANDING GEAR. THE SQUAT SWITCH, DANGLING BY ITS ELECTRICAL CORD DAMAGED THE FLAP. MAINTENANCE WAS DISPATCHED TO ASSESS AND REPAIR THE DAMAGE. THE WIRIN G WAS INSPECTED AND NO VISIBLE DAMAGE FOUND. THE SQUAT SWITCH AND WHEEL ASSEMBLY WERE REPLACED. THE AIRCRAFT WAS JACKED , THE SQUAT SWITCH (1791) WAS ADJUSTED AND THE GEAR SWING. THE LT IB FLAP WAS REPLACED, RIGGED AND FUNCTION TESTED. AIRC RAFT WAS RETURNED FOR FLIGHT. 2 L 7 2 4F 4 F RT A7EU E7EA 2004062100150 20040621 00150 EA 2004 6 21 CA040426006 2 20040317 G 8520 SL75060 BOLT LYC O540 TIO540* 41532 EA CONNECTING ROD FAILED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) DURING ASSEMBLY OF ENGINE, A NEW SUPERIOR CONNECTING ROD BOLT, P/N SL75060 AND LOT NR 574065 WAS BEING USED. FOUN D THAT THIS BOLTS MACHINING WAS INADEQUATE AND ALREADY WITHIN THE STRETCH LIMITS OF 2.255 - 2.256 INCHES WITHOUT A LOAD ON BOLT. 3 O E14EA 2004062100151 20040621 00151 CE 2004 6 21 CA040426007 1 20040402 G 2497 WIRE CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA MCAULY 1C160 1C160CTM GL ALTERNATOR BURNED W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) WHILE IN CRUISE FLIGHT, THE ALTERNATOR FIELD CIRCUIT BREAKER POPPED. THE PILOT PUSHED IN THE BREAKER SEVERAL TIMES UNTIL THE BREAKER STAYED IN. SMOKE THEN APPEARED AND THE PILOT LANDED SAFELY. THE MAIN POWER WIRE AT THE BACK OF THE AL TERNATOR WAS FOUND WORN. THE WIRE SHORTED OUT AGAINST THE ALTERNATOR CASE. THE FIELD BREAKER GOT SO HOT THAT IT STAYED C ONTACTED. THE WIRES FROM THE BREAKER TO THE MASTER SWITCH TO THE VOLTAGE REGULATOR WERE FOUND BURNED. THE WIRES WERE REP LACED AS REQUIRED. THE 5 AMP ALTERNATOR FIELD CB, MASTER SWITCH, ALTERNATOR BRUSHES, AND VOLTAGE REGULATOR WERE ALL REPL ACED. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2004070900084 20040709 00084 SO 2004 7 9 CA040426008 1 20040426 G 3231 RELEASE PIN PIPER PA24 PA24260 7102406 SO LYC O540 IO540D4A5 41532 EA HARTZL HCC3Y HCC3YR GL NLG DOOR WORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ON ANNUAL INSPECTION, WAS UNABLE TO RELEASE DOOR FOR EMERGENCY GEAR EXTENSION. PIN WAS FOUND WORN, AND RETURNED TO MFG FOR REPAIR. PIN REINSTALLED AND PROBLEM REPEATED, INVESTIGATION REVEALED NOSE DOOR SYSTEM WAS RIGGED TOO TIGHT. REP EATED CALLS TO MANUFACTURER WERE MADE FOR ASSISTANCE OR INSTRUCTIONS. NO REPAIR OR MAINTENANCE MANUAL EXISTS. 'WE JUST U SE A SHUT ON THE WALL AND RIG IT UNTI L WE'RE HAPPY'. I WAS TOLD FINALLY WAS GIVEN VERBAL INSTRUCTIONS AND WAS ABLE TO RIG THE SYSTEM AND TEST EMERGENCY GEAR EXTENSION SUCCESSFULLY. TWO PROBLEMS: WORN PIN MAKING GEAR EXTENSION IMPOSSIBL E. NO MANUAL OR TECHNICAL SUPPORT FROM MANUFACTURER. 1 L 7 1 3O 3 O 1A15 1E4 5 C P25EA 2004062100152 20040621 00152 EU 2004 6 21 CA040426009 1 20040425 G 4920 APU BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE APU BAY FAILED W E O ENGINE SHUTDOWN OTHER A Y J FLAME/FIRE ENGINE STOPPAGE WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) DURING START OF NR 4 ENGINE, THE APU GENERATOR WENT OFF LINE CAUSING AN ABORTED START. ON SECOND ATTEMPT FLAMES C AME OUT OF THE EXHAUST. THE CREW WAS REPORTED OF THIS INCIDENT AND A/C WAS RETURNED TO GATE FOR INSPECTION BY MAINTENAN CE. FOLLOWING THE INSPECTION, THE APU WAS DEFERRED IAW MEL 49-00-1 AND GROUND RUN OF ENGINE C/O BY MAINTENANCE. A/C WA S RELEASED FOR SERVICE AND ON THE EVENING OF THIS INCIDENT FURTHER INSPECTION CARRIED OUT BY MEANS OF BOROSCOPE WITH NO DAMAGE FOUND. THE RAMP CREW CALLED THE FIRE DEPT AS PRECAUTIONARY MEASURE. 2 H 7 4 4F 4 F A49EU E6NE 2004070900099 20040709 00099 NM 2004 7 9 CA040427001 1 20040426 G 2420 GENERATOR DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE DC SYSTEM LIGHTNING STRIKE W O OTHER H J ELECT. POWER LOSS-50 PC WARNING INDICATION AP APPROACH 1 CA (CAN) ON APPROACH, AIRCRAFT WAS STRUCK BY LIGHTENING . BOTH DC GENERATORS WENT OFF LINE AND RESET IAW QUICK REFERENCE HA ND BOOK (QRH) . LIGHTENING ENTERED AT NOSE GEAR DOOR AND EXITED AT TAIL CONE AND THE TAIL SKID . LIGHTENING STRIKE INSP ECTION CARRIED OUT BY MAINTENANCE IAW MM 5-50-31 AND THE FOLLOWING COMPONENTS FOUND DAMAGED AND REPLACED 1)- RADOME P/N 4426X-2-10 S/N 0159 2)- STROBE LAMP ASSY. P/N 01-0770417-003- STATIC WICK. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004071200164 20040712 00164 NE 2004 7 12 CA040427002 2 20040416 G 7230 BLADE CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE COMPRESSOR DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA 10423 (CAN) DURING BOROSCOPE INSPECTION, DAMAGE FOUND ON COMPRESSOR BLADES . MAUFACTURER WAS ADVISED AND GE ADVISED ENGINE REP LACEMENT. ENGINE REPLACED IAW MM PROCEDURE. 2 L 7 2 4F 4 F RT A21EA E15NE 2004071200165 20040712 00165 EA 2004 7 12 CA040427003 1 20040424 G 3230 5323300 PRIORITY VALVE CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE NLG FAILED W A UNSCHED LANDING M J OVER TEMP WARNING INDICATION CL CLIMB 1 CA (CAN) AFTER TAKE OFF CREW SELECTED GEAR UP AND RECEIVED A (GEAR UP DISAGREE) MESSAGE WITH AMBER CAUTION MESSAGE ON THE R T MAIN GEAR INDICATOR. AFTER LANDING THE CREW RECEIVED HYD PUMP 3B (HIGH TEMP) MESSAGE . A/C WAS RETURNED TO DEPARTURE AIRPORT. MAINTENANCE PERSONNEL REPLACED THE 3B HYD PUMP AND THE NOSE LANDING GEAR PRIORITY VALVE AND HYD FILTER AND CAR RIED OUT SEVERAL GEAR RETRACTIONS AND FOUND IT SERVICEABLE A/C HOURS WERE 8810 AND 6799 CYCLES. 2 L 7 2 4F 4 F RT A21EA E15NE 2004071200166 20040712 00166 NM 2004 7 12 CA040427004 1 20040422 G 5610 141T480150 WINDSHIELD BOEING 767 767* NM GE CF6 CF680C2B6F 30025 NE COCKPIT FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING CRUISE, FIRST OFFICER WINDSHIELD NON STRUCTURAL OUTER PANE SHATTERED. WINDSHIELD TOTAL TIME 9,854 HRS. AIR CRAFT TOTAL TIME 50,585 HRS. 2 L 7 2 4F 4 F RT A1NM E13NE 2004071200167 20040712 00167 EA 2004 7 12 CA040427006 2 20040415 G 7421 REM37BY SPARK PLUG CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL ENGINE FAILED W O OTHER E VIBRATION/BUFFET TX TAXI/GRND HDL 1 CA (CAN) DURING RUN UP ABNORMAL DROP. RT MAGNETO PROBLEM TRACED TO DEFECTIVE SPARK PLUG. 1 H 7 1 3O 3 O NT 3A19 E223 5 N P50GL 2004071200168 20040712 00168 EU 2004 7 12 CA040427007 1 20040415 G 3097 WIRE AIRBUS 310 A310304 3930339 EU GE CF6 CF680C2* GL WINDSHIELD HEAT DAMAGED W O OTHER O OTHER CR CRUISE 1 CA (CAN) FLIGHT CREW REPORTED LT SIDE WINDSHIELD HEAT C/B POPPING. WINDSHIELD HEAT REGULATOR REPLACED. FURTHER INVESTIGAT ION REVEALED AN OPEN WIRE BETWEEN PIN J AND GROUND. FOUND THE ELECTRICAL RETRACTABLE CORD DAMAGE BELOW THE SLIDING WIND OW. CORD ASSEMBLY WAS REPLACED. THE MAINTENANCE PROGRAM WAS REVISED TO CARRY INSPECTION OF THE RETRACTABLE CORD ON REGUL AR BASIS. 2 L 7 2 4F 4 F RT A35EU E23EA 2004071200177 20040712 00177 EA 2004 7 12 CA040427008 2 20040407 G 7421 REM37BY SPARK PLUG CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL ENGINE CONTAMINATED W A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 CA (CAN) DURING TAKEOFF, PILOT NOTICED ROUGH RUNNING ENGINE AND POWER LOSS. THREE OF THE FOUR LOWER SPARK PLUGS WHERE LEAD CONTAMINATED. NR 2 SPARK PLUG ELECTRODES WERE (WELDED) OVER WITH LEAD. 1 H 7 1 3O 3 O NT 3A19 E223 5 N P50GL 2004071200188 20040712 00188 WP 2004 7 12 CA040427009 1 20040425 G 2910 S305201 COUPLING LKHEED 1011 1011385114 WP RROYCE RB211 RB21122B NE HYD SYSTEM CRACKED W O OTHER K J FLUID LOSS WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) DURING TAXI TO THE GATE, THE HYD SYS STARTED TO DECREASE RAPIDLY. QRH WAS PERFORMED BY THE CREW. HYDRAULIC LEAK WA S FOUND AT NR 3 PYLON REAR SPAR AREA. FOUND CONNECTION WING O-FLEX COUPLING CRACKED ON SYSTEM D SUCTION LINE FOR EDP. NO OBVIOUS DAMAGE WAS FOUND ON TUBE AND FLANGE, AND COUPLING WAS REPLACED. SUSPECT THE COUPLING WAS DAMAGE BY VIBRATION SINCE THE TUBE CLAMP AND HARDWARE WERE FOUND NOT PROPERLY SECURE. CLAMP AND HARDWARE REPOSITIONED AND SECURED CORRECTL Y. 2 L 7 3 4F 4 F A23WE E12EU 2004071200189 20040712 00189 GL 2004 7 12 CA040427010 1 20040406 G 1430 SCREW PARKERHANFIN BOMBDR BD700 BD7001A10 1390006 GL RROYCE BR700 BR700710A110 NE PITCH TRIM ACT GALLED W K NONE O OTHER IN INSP/MAINT 1 CA 0021 (CAN) DURING INCORPORATION OF SERVICE BULLETIN THE SERVICE CENTER TECHNICIAN FOUND GALLING ON THE ACME SCREW AND A SMALL PIECE OF THE SCREW THREAD WAS MISSING. THE PITCH TRIM ACTUATOR WAS REMOVED FROM THE AIRCRAFT AND SHIPPED TO THE VENDOR FOR INVESTIGATION. NEW UNIT INSTALLED AND AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT T00003NY E00057EN 2004071200190 20040712 00190 CE 2004 7 12 CA040427011 1 20040112 G 3260 SWITCH BEECH 17 D17S 1150538 CE PWA R985 R985AN1 52008 NE LT MLG OUT OF ADJUST W O OTHER N FALSE WARNING AP APPROACH 1 CA (CAN) LT MAIN LDG GEAR (DOWN) SWITCH OUT OF ADJUSTMENT CAUSING (NOT LOCKED DOWN) INDICATION. SWITCH READJUSTED, GEAR S WINGS COMPLETED WITH ALL OPERATIONS AND INDICATIONS NORMAL. 1 Q 7 1 3R 3 R A649 5E1 2004071200191 20040712 00191 EA 2004 7 12 CA040427012 2 20040426 G 7200 ENGINE DHAV DHC6 DHC6300 2802606 EA PWA PT6 PT6A27 52043 EA HARTZL HCB3T HCB3TN3 GL RIGHT FAILED W A UNSCHED LANDING X J ENGINE FLAMEOUT WARNING INDICATION CR CRUISE 1 CA 50326 (CAN) IN CRUISE FLIGHT THE PILOT HEARD A BANG AND THE RT ENGINE STOPPED TURNING. THE PROP WAS FEATHERED AND THE AIRCRAF T LANDED WITHOUT INCIDENT. AFTER LANDING, THE PROPELLER COULD NOT BE TURNED BY HAND. 1 H 7 2 3T 4 T RT A9EA E4EA 6 C P15EA 2004071200192 20040712 00192 SW 2004 7 12 CA040427013 1 20040312 G 6320 269A510351 SHAFT HUGHES 269 269C1 8059504 SW LYC O360 HO360C1A 41514 EA M/R GEARBOX BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA 50603 (CAN) BEARING SIZE DUE TO LACK OF LUBRICATION. DUE TO INCORRECT INSTALLATION AT REPAIR. 1 G 7 1 3O 3 O O 4H12 E286 2004071200193 20040712 00193 GL 2004 7 12 CA040427014 2 20040414 G 7261 9A1424 COUPLING BELL 206 206L 1181522 SW ALLSN 250C 250C20R2 GL OIL PUMP WORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) UPON INSPECTION, SPLINE/COUPLING P/N 9A1424 WAS FOUND WORN. REMOVED OIL PUMP AND TACH GENERATOR AND MATING COUPLI NG P/N 9A1424 FOR INSPECTION AND REPAIR. REPLAC ED WITH NEW GLOBE TACH GEN P/N 22A650 S/N 6209 AND OHC OIL PUMP P/N 206 -140-190-005 S/N SPF82 AS REPLACEMENT OF SPLINE REQUIRES REPLACEMENT OF ALL MATING SURFACES. 1 G 7 1 3U 3 U H2SW E4CE 2004071200194 20040712 00194 SW 2004 7 12 CA040427015 1 20040416 G 7120 206032303014 MOUNT BELL 206 206L 1181522 SW ALLSN 25OC 250C20R GL RT ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) CLIP AND FITTING AT RT ENGINE MOUNT LOCATION HAS CRACK DAMAGE. REMOVED CLIP P/N 206-032-303-014 AND FITTING P/N 20 6-031-337-004 AND REPLACED WITH NEW CLIP P/N 206-032-303-230S AND NEW FITTING P/N 206-033-670-104S. RT ENGINE PAN UPPER LONGERON FOUND TO HAVE INTER GRANULAR CORROSION. REMOVED AND ARE PLACED WITH NEW LONGERON P/N 206-031-314-125S. REPAIRS CARRIED OUT AMO 100/94 UNDER WORK ORDER NR 24122. APRIL 16, 2004. 1 G 7 1 3U 3 U H2SW E4CE 2004071200195 20040712 00195 SO 2004 7 12 CA040427016 1 20040424 G 2400 688219 MASTER SWITCH PIPER PA42 PA42720 7104212 SO PWA PT6 PT6A61 52043 EA HARTZL HCB3T HCB3TN3 GL COCKPIT WORN W O OTHER H ELECT. POWER LOSS-50 PC AP APPROACH 1 CA (CAN) NEARING FINAL APPROACH THE PILOT NOTICED HE HAD LOST PRIMARY AVIONICS POWER AND THE STANDBY POWER SUPPLY HAD ENGAG ED TO PROVIDE BASIC POWER. AN UNEVENTFUL LANDING WAS CARRIED OUT. MAINTENANCE DETERMINED THE AVIONICS MASTER SWITCH (PUS H TO ENGAGE, PUSH AGAIN TO DISENGAGE) HAD DISENGAGED TO THE (OFF) POSITION BY ITSELF. THE INTERNAL LATCHING MECHANISM IS NOT VISIBLE FOR INSPECTION AND THE SWITCH IS IN THE PROCESS OF BEING REPLACED. 1 L 7 2 4T 4 T A23SO E4EA 6 C P15EA 2004071200203 20040712 00203 GL 2004 7 12 CA040427017 1 20040420 G 3242 201095001 TRANSDUCER BOMBDR BD700 BD7001A10 1390006 GL BRAKE PEDAL MALFUNCTIONED W O OTHER O OTHER TX TAXI/GRND HDL 1 CA 615159 (CAN) AFTER LANDING, DURING ROLL OUT AND TAXI, THE PILOT REPORTED THAT HIS LT BRAKE PEDAL WAS GRINDING AND WOULD NOT SPR ING BACK UNLESS HE TAPPED IT AND QUICKLY RELEASED THE PEDAL. ALSO, THE AIRCRAFT PULLED SLIGHTLY TO THE LT WHILE THE PE DAL WAS STUCK. THE LT BRAKE PEDAL TRANSDUCER (LVDT) WAS REPLACED AND TESTED IAW AIRCRAFT MM. THE AIRCRAFT WAS RETUNED I N SERVICE WITH NO FURTHER EVENT. 2 L 7 2 4F RT T00003NY 2004071200210 20040712 00210 CE 2004 7 12 CA040427018 1 20040427 G 5510 053200199 RIB CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA MCAULY 1A170 1A170E GL HORIZONTAL STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING INSPECTION OF HORIZONTAL STABILIZER ATTACH BOLT HOLES INSPECTION IAW MFG SB04-55-01, FOUND RT AFTER ATTACHM ENT HOLE ON THE RIB HAS TWO .0937 INCH LONG CRACKS. THE CRACKS ARE HIDDEN UNDER THE MOUNTING WASHER. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P857 2004071200211 20040712 00211 SW 2004 7 12 CA040428001 1 20040427 G 5410 212060822001 ACCESS DOOR BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA COWL CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING THE DAILY INSPECTION THE COWL INSPECTION DOOR HINGE WAS FOUND LOOSE ALLOWING THE DOOR TO HANG DOWN. UPON RE MOVAL OF THE COWLING IT WAS FOUND THAT THE ATTACH FLANGE FOR THE COWL ACCESS DOOR HINGE WAS CRACKED ACROSS 75 PERCENT OF THE FLANGE LENGTH. THE DOOR WAS REMOVED AND THE FLANGE REPAIRED. IF THE CRACK HAD EVENTUALLY CROSSED THE FLANGE THE D OOR COULD HAVE FALLEN UPON THE MAIN DRIVESHAFT SHAFT, WHICH ROTATES AT 6600 RPM DURING FLIGHT. THERE WAS POTENTIAL FOR SERIOUS DAMAGE. 1 G 7 1 4U 4 U H4SW E22EA 2004072900076 20040729 00076 EA 2004 7 29 CA040428002 1 20040427 G 5750 6001038841 FAIRING CNDAIR CL600 CL6002D24 1390016 EA GE CF34 CF343B1 NE WX RADAR LIGHTNING STRIKE W L ABORTED APPROACH O OTHER AP APPROACH 1 CA (CAN) LIGHTNING STIKE ON APPROACH INTO AIRPORT. LIGHTNING ENTERED LT SIDE OF WEATHER RADAR. NO OBVIOUS EFFECT TO AIRCRA FT SYSTEM 2 L 7 2 4F 4 F RT A21EA E15NE 2004071300001 20040713 00001 CE 2004 7 13 CA040428003 1 20040419 G 7810 FA572618R EXHAUST STACK BEECH 200 B200 1152922 CE PWA PT6 PT6A42 52043 NE HARTZL HCD4N3 HCD4N3A GL LT ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING ROUTINE INSPECTION A CRACK WAS NOTED AT THE LIP HEAT WELD TO THE FORWARD SECTION OF THE EXHAUST STACK. EXH AUST UNIT WAS ORDERED AND INSTALLED WITHOUT ANY INCIDENT. 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2004071300002 20040713 00002 2004 7 13 CA040428004 4 20040419 G 2562 AK450 ELT BELL 206 206L 1181522 SW ALLSN 250C 250C20R2 GL CABIN FAILED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) UPON ANNUAL RE-INSPECTION FOR RE-CERTIFICATION PURPOSES, AVIOINICS SHOP REPORTED ELT S/N 353494 FAILS TEST PROBABL Y DUE TO A BAD CRYSTAL. UPON BEING ADVISED THAT A COMPANY DOES NOT SUPPLY PARTS, OPERATOR PURCHASED AND INSTALLED A NEW ELT ONTHE AIRCRAFT. 1 G 7 1 3U 3 U H2SW E4CE 2004071900015 20040719 00015 EA 2004 7 19 CA040428005 2 20040415 G 7421 REM37BY SPARK PLUG CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL ENGINE FAILED W O OTHER E VIBRATION/BUFFET TX TAXI/GRND HDL 1 CA (CAN) DURING RUN UP, ABNORMAL DROP IN RT MAGNETO NOTED. PROBLEM TRACED TO FAULTY SPARK PLUG. TIME IN SERVICE 1 HOUR. 1 H 7 1 3O 3 O NT 3A19 E223 5 N P50GL 2004120600072 20041206 00072 CE 2004 12 6 CA040428006 1 20040428 G 2710 AILERON BEECH 100 A100 1152915 CE PWA PT6 PT6A28 EA WINGS OUT OF RIG W O OTHER F FLT CONT AFFECTED CR CRUISE 1 CA DURING TROUBLESHOOTING OF A PILOT REPORTED SNAG, THE CONTROL COLUMN IS BANKED SLIGHTLY TO THE LEFT IN ORDER FOR THE AIRC RAFT TO FLIGHT STRAIGHT AND LEVEL, CHECKED THE AILERON RIGGING AND FOUND THAT IF THE PROCEDURES FROM THE MM ARE FOLLOWED THE AIRCRAFT WILL BE INCORRECTLY RIGGED AND THE RESULTS WOULD BE THE SAME AS THE REPORTED SNAG. THE PROBLEM IS THAT RA YTHEON HAS ISSUED A MANDATORY SERVICE BULLETIN (SB 27-3459) DELETING WITH THE GUST LOCK INSPECTION/REPLACEMENT. IN THIS SB WE ARE REQUIRED TO COMPLY WITH SERVICE INSTRUCTION NO 0887-155. THIS SI REQUIRES THE REPOSITION THE LOCK PIN HOLE IN THE FLIGHT CONTROL COLUMN RESULTING WITH THE COLUMN BANKED 15 DEGREES WHEN THE PIN IS INSTALLED. 1 L 7 2 3T 4 T A14CE E4EA 2004071900039 20040719 00039 GL 2004 7 19 CA040428007 2 20040428 G 7250 TURBINE BELL 206 206L 1181522 SW ALLSN 25OC 250C20R GL ENGINE FAILED W A UNSCHED LANDING X T J ENGINE FLAMEOUT ENGINE CASE PENETRATION WARNING INDICATION CR CRUISE 1 CA CAE295208 (CAN) THIS MORNING THE PILOT WAS IN CRUISE WHEN A LOUD BANG OCCURRED AND THE TOT INCREASED. WITH NO ENGINE, THE PILOT AUTOROTATED TO A CLEAR SPOT TO THE GROUND. NO DAMAGE TO AIRCRAFT. THE ENGINE HAD FAILED. A VISUAL OF THE TURBINE SECT ION SHOWS SUBSTANTIAL DAMAGE. AT THIS TIME UNKNOWN SOURCE OF WHAT CAUSED THIS DAMAGE. 1 G 7 1 3U 3 U H2SW E4CE 2004071900040 20040719 00040 GL 2004 7 19 CA040429001 3 20040427 G 6140 WIRE GULSTM 690TP 690A 0141722 SW GARRTT TPE331 TPE3315251K NM HARTZL HCB3T HCB3TN5 GL BETA SWITCH FAILED W E A ENGINE SHUTDOWN UNSCHED LANDING N FALSE WARNING CR CRUISE 1 CA (CAN) DURING CRUISE, THE RT ENGINE BETA LIGHT ILLUMINATED. ALL PROPELLER AND ENGINE PERFORMANCE WAS NORMAL. THE FLIGHT C REW SHUT DOWN THE AFFECTED ENGINE AND FEATHERED THE PROPELLER AS A PRECAUTION. THE AIRCRAFT RETURNED TO THE AIRPORT. UP ON INVESTIGATION, MAINTENANCE DISCOVERED THE FAULT WAS WITH THE BETA LIGHT SWITCH WIRE. THE WIRE WAS REPAIRED AND THE SY STEM FUNCTION CHECKED SERVICEABLE AND THE AIRCRAFT WAS RETURNED TO SERVICE. 1 H 7 2 3T 4 T 2A4 E2WE 6 C P15EA 2004071900041 20040719 00041 EA 2004 7 19 CA040429002 1 20040429 G 5210 2R595730011 CABLE CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE PAX DOOR DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) BROKEN STRANDS ON MAIN ENTRANCE DOOR ASSIST CABLE AT THE POINT WHERE THE CABLE STARTS TO OVERLAP ITSELF ON THE DO OR ACTUATOR SERVO DRUM FOR THR FIRST TIME. CABLE REPLACED. IPC REFERENCE : CRJIPC MANUAL CHAPTER 52-11-08, FIGURE 1A , ITEM 45. NOTE: THE CABLE HAD BEEN REPLACED ON PREVIOUS AIRCRAFTS THAT HAS COME THROUGH C-CHECK INSPECTIONS. THE DAMAGE TO THIS CABLE HAS BEEN IN THE SAME AREA EVERYTIME. 2 L 7 2 4F 4 F RT A21EA E15NE 2004071900042 20040719 00042 WP 2004 7 19 CA040429003 1 20040427 G 3260 833703 PROXIMITY SENSOR DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE RT MLG OUT OF TOLERANCE W O OTHER N FALSE WARNING DE DESCENT 1 CA (CAN) RT MAIN LANDING GEAR LIGHT (RED) WAS ILLUMINATED WHEN GEAR SELECTED DOWN. VISUAL CHECK CONFIRMED GEAR DOWN AND LOC KED. MAINTENANCE FOUND DOWN LOCK PROX SENSOR OUT OF TOLERANCE. PROX SENSOR REPLACED AND TESTED SERVICEABLE. 2 L 7 2 4F 4 F RT A6WE E9NE 2004071900043 20040719 00043 NE 2004 7 19 CA040429004 2 20040428 G 7261 STRAINER DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE RT ENGINE OIL CLOGGED W E ENGINE SHUTDOWN J WARNING INDICATION CR CRUISE 1 CA (CAN) RT ENGINE OIL STRAINER CLOG LIGHT ILLUMINATED IN FLIGHT. PRECAUTIONARY ENGINE SHUTDOWN IN FLIGHT. RT ENGINE OIL STRAINER FOUND WITH CARBON PARTICLES, FILTER CLEANED AND REINSTALLED. ENGINE RUN-UP CARRIED OUT AND ENGINE RELEASE SERVI CEABLE. 2 L 7 2 4F 4 F RT A6WE E9NE 2004071900044 20040719 00044 EA 2004 7 19 CA040429005 2 20040407 G 8550 75528 FILTER ADAPTER CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA ENGINE OIL MALFUNCTIONED W O OTHER M J OVER TEMP WARNING INDICATION CR CRUISE 1 CA (CAN) IN CRUISE THE OIL TEMPERATURE CLIMB INTO THE RED ZONE. THE THERMOSTATIC VALVE WAS REPLACED AND A TEST FLIGHT WAS C ARRIED OUT WITH THE ENGINE STILL OVERHEATING. WE REPLACED THE OIL FILTER ADAPTER P/N 75528 AND THE OIL SCREEN HOUSING P/ N 69510 AND EVERYTHING RETURNED TO NORMAL. 1 H 7 1 3O 3 O NT 3A12 E274 2004071900062 20040719 00062 GL 2004 7 19 CA040429006 3 20040429 G 6110 1C160DTM755 PROPELLER CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160CTM GL CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) PROPELLER WAS RECIEVED FOR 5 YR. CORROSION IAW CAR 625, APPENDIX C, PARAGRAPH 5. PROPELLER SPACER WAS VERY DIFFICU LT TO REMOVE. UPON VISUAL INSPECTION OF SPACER DOWEL HOLES IT WAS FOUND THAT THEY WERE CORRODED BEYOND REPAIR RENDERING THE PROPELLER UNSERVICEABLE. THIS PROPELLER HAD BEEN PREVIOUSLY INSPECTED ON JULY 10/96 MAKING IT 3 YEARS OVER DUE FOR S ERVICE. IF THE MAINTENANCE SCHEDULE SET OUT IN THE CARS HAD BEEN FOLLOWED, THIS PROPELLER MAY HAVE BEEN REPAIRED AND RE TURNED TO SERVICE. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2004071900088 20040719 00088 CE 2004 7 19 CA040429007 1 20040408 G 2916 231707510 RESERVOIR LEAR 35 35LEAR 5170600 CE GARRTT TFE731 TFE73122B 01518 WP HYD SYSTEM CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) DURING INSPECTION, FLUID LEAK WAS FOUND AROUND FILLER AREA. EDDY CURRENT INSPECTION CONFIRMED A 1INCH CRACK IN THE WELD AT FILLER NECK. CRACK WAS WELD REPAIRED IAW MFG INSTRUCTIONS, PENETRANT INSPECTED AND RESERVOIR PROOF PRESSURE TES TED D TO 30 PSI. 2 L 7 2 4F 4 F A10CE E6WE 2004071900089 20040719 00089 CE 2004 7 19 CA040429008 1 20040415 G 3244 0283353 TIRE BEECH 100 B100 1152919 CE GARRTT TPE331 TPE3316252B 01514 WP HARTZL HCB4T HCB4TN5 GL MLG CHAFED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) MECHANIC NOTICED THAT TIRE SIDEWALL HAD RUBBED AGAINST BRAKE HOUSING, CREATING A GROOVE IN THE RUBBER. THERE WAS S TATIC CLEARANCE BUT WHEN THE TIRE FLEXED ON LANDING IT COULD RUB AGAINST THE BRAKE HOUSING. CLEVELAND WHEELS AND BRAKES HAD BEEN INSTALLED IN AUGUST OF 1996 IAW STC SA646GL, OVERSIZE TIRES INSTALLED IAW CAT STC SA00185LA IN JANUARY OF 1997. THERE HAD BEEN NO PROBLEMS NOTED UNTIL RECENTLY. ALL CORRECT PARTS WERE IN PLACE. OTHER THREE TIRES WERE ALSO RUBBING, SOME WORSE THAN OTHERS. A SECOND COMPANY B100 ALSO HAD THE PROBLEM. REVERTED TO ORIGINAL SMALLER TIRES TO ALLEVIATE THE PROBLEM. MFG MAY HAVE CHANGED PROFILE OF TIRE AND THIS HAS CREATED PROBLEM BUT CANNOT CONFIRM THIS. 1 L 7 2 4T 4 T A14CE E2WE 6 C P40EA 2004071900090 20040719 00090 EU 2004 7 19 CA040429009 1 20040427 G 5230 HINGE BRAERO 748 HS7482A 4231001 EU RROYCE DART DART5342 EU ROTOL R4304 R2124304 EU CARGO DOOR BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) UPON OPENING FORWARD BAGGAGE DOOR TO UNLOAD BAGS THE UPPER FORWARD DOOR HINGE BROKE AWAY FROM THE FUSELAGE. THE A/ C WAS THEN SHUTDOWN AND OFFLOADED. SCREWS ATTACHING HINGE TO FUSELAGE BROKE. SCREW PN 6DSS4910 HINGE (UPPER) PN 2D12172H INGE (LOWER) PN 2D13024PIN PN 4D11535 CORRECT SCREWS WERE INSTALLED. 2 L 7 2 3T 4 T A24EU A196 6 C P899 2004072100066 20040721 00066 GL 2004 7 21 CA040429010 3 20040429 G 6114 HUB CESSNA 170 170A 2072304 CE CONT O300 O300A 17022 SO MCAULY 1C172 1C172EM GL PROPELLER CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 76822 (CAN) UPON INSPECTION SEVERE CORROSION IN HUB CAVITY AND IN MOUNTING BORE. DIMENSIONS AT MINIMUM BEFORE REWORK. PROPELLE R IS UNSERVICEABLE. 1 H 7 1 3O 3 O A799 E253 5 N P910 2004072100067 20040721 00067 NM 2004 7 21 CA040430001 1 20040426 G 5711 13017R RIB UNIVAR 415 415CD 0420304 NM CONT C85 C8512F 17008 SO MCAULY 1B90 1B90CM GL CENTER WING CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING INSPECTION TO COMPLY WITH AD 2003-21-01 SEVERE CORROSION FOUND ON FORWARD END OF RIB, AFT OF REAR SPAR, IN THE RT CENTER SECTION, BETWEEN THE FUSELAGE AND WING. THE CORROSION WAS NOT READILY NOTICEABLE UNTIL INSTALLATION OF INS PECTION PANELS SK 80-2 IAW SB 31 REV 1. THIS ALLOWED ACCESS TO THIS AREA WHICH OTHERWISE IS HARD TO SEE, EVEN THOUGH THE WINGS WERE REMOVED TO COMPLY WITH THE INSPECTION REQUIREMENTS OF 2003-21-01. 1 L 7 1 3O 3 O A718 E233 5 N P842 2004072100068 20040721 00068 WP 2004 7 21 CA040430002 2 20040425 G 7314 30607591 PUMP ISRAEL 1125 ASTRASPX 4500205 EU GARRTT TFE731 TFE7314R 01518 WP FUEL SYSTEM FAILED W O OTHER J WARNING INDICATION NR NOT REPORTED 1 CA (CAN) RT ENGINE FUEL FILTER BY-PASS LIGHT FLICKERING AT TAKE-OFF CLIMB POWER SETTINGS. AIRCRAFT RETURN TO MAINTENANCE BA SE, MAINTENANCE TECHNICIAN FOUND FUEL FILTER CONTAMINATED BY A LOTS OF FINE GREY SEDIMENT. IT WAS DETERMINED THAT THE EN GINE DRIVEN MOTIVE FLOW PUMP WAS DEFECTIVE. THE PUMP WAS REPLACED AS WELL AS THE FUEL FILTER, FUEL CONTROL UNIT, FLOW DI VIDER AND FUEL MANIFOLD NOZZLES. AIRCARFT RETURN TO SERVICE. 2 L 7 2 4F 4 F RT A16NM E6WE 2004072100069 20040721 00069 EA 2004 7 21 CA040430003 3 20040430 G 6114 HUB PIPER PA28 PA28140 7102802 SO LYC O320 O320E2A 41508 EA SNSNCH 74DM M74DM EA PROPELLER CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) PROPELLER RECEIVED FOR 5 YR. CORROSION INSPECTION IAW CAR 625, APPENDIX C, PARA. 5. UPON VISUAL INSPECTION OF THE HUB, CORROSION WAS FOUND IN ONE OF THE PROP BOLT HOLES. THE MANUFACTURER HAS BEEN CONTACTED TO SUPPLY MINIMUM SPEC'S FO R THIS AREA. NOT ENOUGH MATERIAL REMAINS TO REMOVE CORROSION DAMAGE. PROPELLER IS UNSERVICEABLE. 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 2004072100070 20040721 00070 SO 2004 7 21 CA040430004 1 20040426 G 2420 2642997 ALTERNATOR PIPER PA28 PA28140 7102802 SO LYC O320 O320E2A 41508 EA SNSNCH 74DM M74DM EA ENGINE FAILED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) AFTER OVERHAUL WAS CONDUCTED, BEARINGS REF X-4130 AND X-4612 WERE NON-APPROVED PARTS. 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 2004080500061 20040805 00061 EU 2004 8 5 CA040430005 1 20040417 G 3246 AHA1483 WHEEL BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE MLG BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ENGINEERS RETURNING TO HANGAR FROM LINE, CAME UPON A PIECE OF DEBRIS ON APRON TO HANGAR. THEY RETRIEVED THE OBJECT AND FOUND THAT IT WAS A 10-INCH SECTION OF A WHEEL BEAD FLANGE. AC HAD BEEN OUT FOR ENGINE RUNS AFTER AN ENGINE CHANGE AND WAS IN THE HANGAR, IT WAS CHECKED AND FOUND TO HAVE A SECTION OF THE NR 2 MAIN WHEEL P/N AHA1489 OB FLANGE MISSING. THE OUTER WHEEL HALF P/N AHA1483 IS FOUND IN THE MFG CMM IPL 32-42-59 FIG NR 1 ITEM NR 160. THIS WHEEL WAS ON BUILD 17 AND HAD BEEN NDT AT THAT TIME WITH NO DEFECTS NOTED AT THE TIME. THE WHEEL WAS REPLACED AND THE WHEEL HALF HAS BEEN SEN T TO MFG FOR ANAYLSIS. WE WILL FOLLOW-UP ON THE INCIDENT ONCE WE HEAR BACK FROM THE MANUFACTURER WITH THEIR FINDINGS. 2 H 7 4 4F 4 F A49EU E6NE 2004080500062 20040805 00062 2004 8 5 CA040430006 4 20040427 G 6122 321475 SOLENOID WOODWARD CNDAIR CL215 CL2151A10 1900320 EA PWA R2800 CA3 52026 NE HAMSTD 43E 43E60 NE PROP GOVERNOR FAILED W O OTHER F FLT CONT AFFECTED CR CRUISE 1 CA 121286 (CAN) DURING A TEST FLIGHT THE RT ENGINE WAS SHUT DOWN AND THE PROP FEATHERED AS PART OF THE TEST FLIGHT PROCEDURE. THE FLIGHT CREW WAS UNABLE TO UNFEATHER THE PROPELLER. THE AIRCRAFT RETURNED TO THE AIRPORT AND LANDED SAFELY. UPON INVESTIG ATION BY MAINTENANCE THE FEATHERING SOLENOID ON THE PROP GOVERNOR WAS FOUND TOBE AT FAULT. THE SOLENOID WAS REPLACED AND THE SYSTEM FUNCTION CHECKED SERVICEABLE. 2 H 7 2 4R 4 R RT A14EA E231 6 C P871 2004080500063 20040805 00063 CE 2004 8 5 CA040503001 1 20040429 G 2823 1013890253 SHUTOFF VALVE BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA HARTZL HCB3T HCB3TN3 GL FUEL SYSTEM FAILED W O OTHER L NO TEST NR NOT REPORTED 1 CA (CAN) DURING PILOTS PREFLIGHT CHECK THE RT FUEL SHUTOFF VALVE FAILED. THE VALVE WAS REPLACED. TSO 75.4 HOURS 1 L 7 2 3T 4 T RT 3A20 E4EA 6 C P15EA 2004080500064 20040805 00064 CE 2004 8 5 CA040503002 1 20040408 G 3233 508202085 ACTUATOR BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCD4N3 HCD4N3A GL MLG FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING TROUBLESHOOTING OF A LANDING GEAR PROBLEM WE NOTICED THAT THE NUT ASSEMBLY IN THE NOSE GEAR ACTUATOR COULD MOVE A SMALL AMOUNT FROM SIDE TO SIDE PLAY IN THE HOUSING. THE ACTUATOR WAS REMOVED AND WE NOTICED THAT THE MECHANISM WA S A LITTLE ROUGH WHEN TURNED BY HAND. THE ACTUATOR WAS RETURNED TO THE OVERHAUL SHOP FOR FURTHER INVESTIGATION. THE OVER HAUL SHOP HAS RESPONDED: UNIT FAILED THE END PLAY TEST AND SCREW/NUT ASSEMBLY SEEMED TO HAVE SOME SIDE TO SIDE PLAY. DIS ASSEMBLED, INSPECTED, NDT, ECT FOUND: SCREW ASSEMBLY / NUT ASSEMBLY OUT-OF-LIMITS. HOUSING HAS DEEP CORROSION PITTING IN BOLT HOLE BOSS .THIS ACTUATOR WAS OVERHAULED IN APRIL 2003 AND ONLY HAD 819 CYCLES SINCE THEN. 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2004080500065 20040805 00065 EU 2004 8 5 CA040503003 1 20040415 G 6210 355A11003000 BLADE SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE MAIN ROTOR DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) BLADE RETURNED FOR EVALUATION. AT STA 760 MM, AT ROOT END, AN AREA OF SKIN (150 MM LONG BY 2 MM WIDE) WAS MISSING FROM THE ROOT MATING FACE. THIS APPEARS TO BE A MANUFACTURING DEFECT AND HAS BEEN RETURNED TO THE MANUFACTURER FOR EVAL UATION/REPAIR. 1 G 7 1 3U 3 U NC H9EU E19EU 2005011300007 20050113 00007 CE 2005 1 13 CA040503005 1 20040315 G 3246 95440263 WHEEL LEAR 35 35LEAR 5170600 CE GARRTT TFE731 TFE73122B 01518 WP MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ON ROUTINE TIRE CHANGE, NDT INSPECTION REVEALED A CRACK IN THE FLANGE OF THE WHEEL HALF. WHEEL HALF REMOVED FROM SERVICE. 2 L 7 2 4F 4 F A10CE E6WE 2005011300008 20050113 00008 NM 2005 1 13 CA040503006 1 20040430 G 3242 BACB30MT9T15 PIN BOEING 737 737201 1384454 NM PWA JT8 JT8D9A 52048 NE BRAKE ASSY SHEARED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING C-CHECK NR 4 BRAKE ASSEMBLY LOCATOR PIN FOUND SHEARED. PIN REPLACED. AREA CHECKED AND NO OTHER FAULTS FO UND. TIMES 58561:01CYCLES 54866. 2 L 7 2 4F 4 F A16WE E2EA 2005011300009 20050113 00009 EU 2005 1 13 CA040503007 1 20040430 G 5270 SWITCH BRAERO 748 HS7482A 4231001 EU RROYCE DART DART5342 EU ROTOL R4304 R2124304 EU MAIN DOOR FAULTY W A UNSCHED LANDING N FALSE WARNING CL CLIMB 1 CA (CAN) THE CREW OBSERVED A DOOR WARNING INDICATION AFTER T/O. THE AIRCRAFT RETURNED TO POINT OF DEPARTURE WITHOUT FURTHE R INCIDENT. MAINTENACE DETERMINED THE CREW/FREIGHT DOOR WARNING SWITCH TO BE AT FAULT. THE MICROSWITCH AND PLUNGER WER E REPLACED, AIRCRAFT TEST FLOWN AND RETURNED TO SERVICE. 2 L 7 2 3T 4 T A24EU A196 6 C P899 2005011300010 20050113 00010 SW 2005 1 13 CA040503010 1 20040530 G 2910 2781032081 LINE SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP MCAULY 4HFR34 4HFR34C652 NE HYDRAULIC SYS BURST W A UNSCHED LANDING K B J FLUID LOSS SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CL CLIMB 1 CA (CAN) AIRCRAFT DEPARTED AIRPORT AND SHORTLY AFTER BOTH HYDRAULIC ANNUNCIATOR LIGHTS CAME ON INDICATING LOW HYDRAULIC PRE SSURE. AIRCRAFT RETURNED TO ALTERNATE AIRPORT DUE TO WEATHER AT ORIGINAL AIRPORT AND LANDED WITHOUT INCIDENT. INVESTIG ATION FOUND THAT THE HYDRAULIC LINE HAD BURST UNDER THE PILOTS FLOOR PANEL. LINE REPLACED ALONG WITH BOTH HYDRAULIC PUM PS DUE TO CAVITATION REQUIREMENTS. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C 3PNE 2005011300011 20050113 00011 NE 2005 1 13 CA040503011 2 20040430 G 7320 8062549 GOVERNOR BOEING 757 75728A 1384976 NM RROYCE RB211 RB211535E437 54555 NE FUEL FLOW INOPERATIVE W D RETURN TO BLOCK J WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) LT ENG VALVE LIGHT ILLUMINATED AND EICAS MSG L ENG FUEL VAL DISPLAYED WITH FUEL CONDITION SWITCH IN RUN. NO FUEL FLOW INDICATED. LT ENG FFG REPLACED C/O IAW AMM 73-21-01. TEST 1, 2, 9 AND 10 CARRIED OUT SATIFACTORY. 2 L 7 2 4F 4 F RT A2NM E12EU 2005012400036 20050124 00036 CE 2005 1 24 CA040503012 1 20040428 G 5523 TAB CESSNA 207 207 2073602 CE CONT O520 IO520F 17032 SO MCAULY D3A34 D3A34C404 GL ELEVATOR CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHILE PERFORMING CAP INSPECTION, EXAMINATION OF ELEVATOR T/E AND TRIM TAB FOR CORROSION, DELAMINATION OF FOAM STRU CTURE, IT WAS DISCOVERED THAT ASSEMBLIES HAD NO FOAM INSIDE. PROPER SKINS WERE THEN ORDERED. UPON THEIR DELIVERY, THEY W ERE ALSO FOUND NOT TO HAVE ANY FOAM INSIDE THEM. NO INFO WAS AVAILABLE. ALL SIGNS POINTED TO BOGUS PARTS, WE CALLED MFG TECH AND WERE TOLD TO CALL DEALER BECAUSE THEY KNEW NOTHING ABOUT SUBJECT. DEALER WAS ABLE TO FIND OUT (AFTER SEVERAL CALLS) THIS IS A RESULT OF PRODUCT IMPROVEMENT THAT MFG CAME OUT WITH. IT IS NOT MENTIONED IN ANY MANUAL OR INSPECTION CRITERIA THAT THERE CAN BE NON-FOAM FILLED ASSEMBLIES INSTALLED. 1 H 7 1 3O 3 O A16CE E5CE 5 C P47GL 2005012400037 20050124 00037 NE 2005 1 24 CA040503013 2 20040429 G 8530 VALVE PWA CURTIS C46 C46DCURTIS 2622704 SO PWA R2800 R280051M1 52026 NE HAMSTD 23E 23E50 NE INOPERATIVE W A UNSCHED LANDING E D VIBRATION/BUFFET INFLIGHT SEPARATION CL CLIMB 1 CA (CAN) DURING CLIMB, RT ENGINE STARTED TO BACKFIRE, THE CREW LANDED AND RETURNED TO HANGER WITHOUT INCIDENT. 2 L 7 2 4R 4 R 3A2 5E8 6 C P603 2005012400038 20050124 00038 EU 2005 1 24 CA040504001 1 20040430 G 6720 332A27233006 ADJUSTER SNIAS AS332 AS332L 8680809 EU TMECA MAKILA MAKILA1A 60040 EU PEDAL CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AIRCRAFT REPORTED PEDAL ADJUSTER JAMMED, AFTER INSPECTION THE SUPPORT WAS FOUND TO BE CRACKED. AIRCRAFT IS IN NOR WAY FOR A G-CHECK INSPECTION AND WAS ALSO CHECKED FOR THIS PROBLEM , AND WAS FOUND TO ALSO HAVE A CRACK IN THE SAME AREA . FLEET INSPECTION OF THE AIRCRAFT AT BASE RESULTED IN NO DEFECTS FOUND. 2 G 7 2 4U 4 U H4EU E12NE 2005012400047 20050124 00047 CE 2005 1 24 CA040504002 1 20040504 G 2916 55171001 RESERVOIR CESSNA 501 501 2076603 CE PWA JD15 JT15D1A NE BRAKE LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) HYDRAULIC BRAKE RESERVOIR LEAKING. CRACK WELDED AND RETURNED TO SERVICE. 1 L 7 2 4F 4 F A27CE E25EA 2005020100031 20050201 00031 CE 2005 2 1 CA040504004 1 20040429 G 5520 11552405813 SUPPORT BRACKET BEECH 100 100BEECH 1152916 CE PWA PT6 PT6A28 EA HARTZL HCB3T HCB3TN3 GL ELEV BELLCRANK CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING AIRCRAFT INSPECTION, IT WAS NOTED THE AFT RT ELEVATOR BELLCRANK SUPPORT BRACKET P/N 115-524058-13 WAS CRACK ED. THE CRACK EXTENDED APPROX. 1.5 INCHES VERTICALLY AROUND THE BELLCRANK PIVOT BOLT ATTACHMENT. 1 L 7 2 3T 4 T A14CE E4EA 6 C P15EA 2005020100032 20050201 00032 NM 2005 2 1 CA040504005 1 20040503 G 2781 756158 SENSOR DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE TORQUE FAILED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA 34832 (CAN) ON CLIMB OUT THE FLAP DRIVE CAUTION LIGHT ILLUMINATED CONTINUOUSLY, AND WOULD NOT EXTINGUISH. TROUBLE SHOOTING BY MAINTENANCE SUSPECTED A INTERNAL SWITCH FAILURE OF THE TORQUE SENSOR. A TEAR DOWN REPORT FOR FURTHER DETAILS OF THE REAS ON FOR FAILURE SO SOON AFTER LAST REPAIR HAS BEEN REQUESTED. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004080600050 20040806 00050 EU 2004 8 6 CA040504006 1 20040428 G 3397 LJILO38 WIRE SNIAS 350 AS350B3 8680954 EU TMECA ARRIEL ARRIEL2B NE NAVIGATION LIGHT SEVERED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ROUTINE TROUBLESHOOTING FOR INOPERATIVE NAV LIGHT STARBOARD, DISCOVERED POSITIVE WIRE WAS SEVERED FROM CRIMPED PIN BY SLIGHTLY TUGGING ON WIRES FROM THE BACKSHELL. SINCE NO ACCESS AVAILABLE TO REMOVE BROKEN OFF PIN OUT OF LAMP ASSEMB LY, A NEW ASSEMBLY HAD TO BE INSTALLED. 1 G 7 1 3U 3 U H9EU E00054EN 2005022400010 20050224 00010 EU 2005 2 24 CA040505001 1 20040501 G 3246 AHA1481 WHEEL BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 10960 A/C IN HEAVY MX IN YHZ AND HAD JUST BEEN TAKEN OFF THE JACKS WHEN ENGINEERS NOTED THAT NR 3 MAIN WHEEL WAS FLAT. THE WH EEL WAS REPLACED ALONG WITH ITS MATE AS PER COMPANY POLICY, THE WHEEL WAS ROUTED TO WHEEL/BRAKE SHOP AND WENT THROUGH A BUILD (22) INSPECTION. NDT FOUND THE INNER WHEEL HALF HAD CRACK EMANATING FROM ONE OF THE THREE-FUSE PLUGHOLE.THE INNER WHEEL HALF P/N AHA1481 IS FOUND IN THE DUNLOP CMM IPL 32-42-59 FIG 1 ITEM 280.THIS WHEEL WAS ON BUILD 21 AND HAD BEEN ND T AT THAT TIME WITH NO DEFECTS NOTED AT THE TIME. THIS MATTER HAS BEEN BROUGHT TO THE ATTN OF THE MANUF AND WE HAVE ASKE D WHAT HAS BEEN THE OCCURRENCE ON THIS TYPE OF FAILURE AND HAVE ASKED WHETHER OR NOT THEY WOULD LIKE TO SEE THE COMPONEN 2 H 7 4 4F 4 F A49EU E6NE 2004080600051 20040806 00051 CE 2004 8 6 CA040505002 1 20040428 G 3080 1013800153 HOSE BEECH 200 B200 1152922 CE PWA PT6 PT6A42 52043 NE BRAKE DEICE RUPTURED W H DEACTIVATE SYST/CIRCUITS J WARNING INDICATION CR CRUISE 1 CA (CAN) BRAKE DEICE HOSE RUPTURED AND CAUSED BLEED AIR FAILURE SYSTEM TO ACTIVATE LIGHT. HOSE WAS REMOVED AND LINE CAPPED , WARNING SYSTEM REPAIRED IAW MFG MM. CH 21 BRAKE HOSE ORDERED AND SYSTEM PLACARDED AND MADE INOPERATIVE. 1 L 7 2 4T 4 T A24CE E4EA 2004080600052 20040806 00052 CE 2004 8 6 CA040505003 1 20040427 G 5753 SKIN CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160CTM GL LT TE FLAP CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) SMALL CRACK WAS FOUND AT TRAILING EDGE OF THE LT FLAP. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2004080600053 20040806 00053 NE 2004 8 6 CA040505004 2 20040430 G 7250 3020159 RETAINING RING PWA PT6 PT6A114A 52043 NE TURBINE SHROUD COLLAPSED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THE HOT SECTION WAS GIVEN A SCHEDULED BORESCOPE INSPECTION. CT SHROUD SEGMENTS HAD SHIFTED AXIALLY. DISMANTLE SH OWED THE RETAINING RING TO HAVE DISTORTED AND BECOME DISLOCATED. THIS PROBLEM HAS BEEN DOCUMENTED ON OTHER ENGINES. MF G HAS ISSUED P/N 3110741-02 RETAINING RING ON SB 13121 (60A, 61, 62, 65 SERIES) AND SB 3248 (41/42, 45 SERIES) TO PREVEN T THE COLLAPSE OF THE RETAINING RING. THE LATTER SB HAS NOT BEEN ISSUED ON SMALLER ENGINE MODELS SUCH AS THE 114A ENGIN E MODEL TO ALLOW THE MORE ROBUST RETAINING RING TO BE USED. 3 T E4EA 2004080600054 20040806 00054 NM 2004 8 6 CA040505005 1 20040503 G 3230 BACH8B04NN214T HOSE BOEING 737 737201 1384454 NM PWA JT8 JT8D9A 52048 NE NLG FAILED W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CL CLIMB 1 CA (CAN) ON DEPARTURE THE NOSE GEAR FAILED TO RETRACT WHEN THE LANDING GEAR SELECTOR WAS MOVED TO THE UP POSITION. RETURNE D TO BLOCKS. HOSE REPLACED WITH LOANER HOSE. 2 L 7 2 4F 4 F A16WE E2EA 2005022400012 20050224 00012 CE 2005 2 24 CA040506002 1 20040419 G 3246 3665710 BAR EDOAIREXXXXX CESSNA 180 180H 2072618 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C201 GL FLOATS CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA DURING A ROUTINE, CHANGE OVER FROM SKIS TO FLOATS, IT WAS DISCOVERED THAT THE FORWARD SPREADER BAR ASSEMBLY PART NUMBER 36657-10 WAS BADLY CORRODED AND CRACKED. THE SPREADER BAR ASSEMBLY WAS REMOVED FROM EDO 249-2870 FLOATS. NEW PART NUMB ER 26-32096 INSTALLED IN ACCORDANCE WITH STC SA00066SE AND INSTALLATION GUIDE FORAEROCET 26-32096 SPREADER BAR REPLACEME NT DOCUMENTA-10013. 1 H 7 1 3O 3 O 5A6 E273 5 C P3EA 2005022400013 20050224 00013 CE 2005 2 24 CA040506003 1 20040206 G 3221 04425061 TORQUE LINK CESSNA 172 172K 2072430 CE LYC O320 O320E2D 41508 EA MCAULY 1A175 1A175ATM GL NLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 17425 (CAN) DURING INSPECTION, IT WAS DISCOVERED THE UPPER TORQUE LINK PART NUMBER 0442506-1WAS CRACKED. NEW PART WAS INSTALL ED. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P857 2004101800108 20041018 00108 CE 2004 10 18 CA040506004 1 20040504 G 3242 10500900 RIVET CLEVELAND 30162 BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCD4N3 HCD4N3A GL BRAKE PAD BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA 1606 (CAN) DURING INSPECTION IT WAS NOTICED THAT ONE OF THE RIVETS THAT RETAIN THE BRAKE PAD ON TO THE BRAKE ASSEMBLY WAS BRO KEN, THE BRAKE ASSEMBLY WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. THIS IS THE THIRD OCCURRENCE IN THE LAST FEW MONTHS, (SDR 20030925005 AND 20040224003) ALL HAPPENED ON NEW BRAKE ASSEMBLIES SUPPLIED BY THE SAME MANUFACTURER. SUSPE CT THAT THEY MAY HAVE A BAD BATCH OF RIVETS, AS A PRECAUTION WILL BE REPLACING THE RIVETS IN THE REMAINING BRAKE ASSEMB LIES WITH S/N ABOVE 1500. 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2005022400014 20050224 00014 EU 2005 2 24 CA040506006 1 20040501 G 3260 222D232M88051 SQUAT SWITCH DORNER DO228 DO228202 2992030 EU NLG INTERMITTENT W A UNSCHED LANDING N FALSE WARNING CL CLIMB 1 CA I AIRCRAFT DEPARTED AND LANDING GEAR WOULD NOT RETRACT. NOSE WEIGHT SWITCH TESTED AND FOUND TO BE INTERMITTENT. PART CHA NGED OUR WITH SERVICABLE UNIT 2 H 7 2 4T RT A16EU 2005022400015 20050224 00015 NE 2005 2 24 CA040506007 1 20040412 G 5300 PD6154407003 BUSHING SKRSKY S61 S61N 8142104 NE GE CT58 CT581401 30011 NE PYLON FAILED W K NONE O OTHER IN INSP/MAINT 1 CA ON INSTALLATION OF THE BUSHING, WHILE IT WAS BEING PRESSED INTO THE LUG OF THE PYLON, THE TOP OF THE BUSHING SHEARED OF THE BODY. MARKS ON THE BUSHING SHOW A TWISTING ACTION AS THE BUSHING WAS BEING INSTALLED. AN INDEPENDENT COMPANY, DID AN INSPECTION (REPORT ON FILE) ON THE FAILED PART AND COULD NOT FIND ANY MATERIAL OR MANUFACTURING DEFECTS AND FELT THAT THE FAILURE WAS 'IT IS PROBABLE THAT THE SUBJECT BUSHING FAILED AS A RESULT OF SOME ANOMALY IN THE INSTALLATION PROCEDU RE' THIS IS THE FIRST FAILURE AF ANY KIND SINCE WE STARTED MANUFACTURING THESE BUSHINGS. 2 G 7 2 4U 4 U 1H15 1E3 2005022400016 20050224 00016 2005 2 24 CA040507001 4 20040329 G 2215 6225027101 ACTUATOR CNDAIR CL600 CL6002B19 1900309 EA LYC O360 O360A1A 41514 EA PITCH CONTROL FAILED W O OTHER F FLT CONT AFFECTED AP APPROACH 1 CA CAPT REPORTED THE PITCH CONTROL STICKING ( HARD POINT FEELING ) AFTER AP DISCONNECTION. CPT HAD TO PULL THE CONTROL COL UMN TO RECOVER THE FLIGHT CONTROL. PITCH SERVO ACTUATOR WAS REPLACED. 2 L 7 2 4F 3 O RT A21EA E286 2005022400017 20050224 00017 2005 2 24 CA040507002 4 20040423 G 2215 8220260001 SERVO CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE ELEVATOR FAILED W O OTHER F FLT CONT AFFECTED CR CRUISE 1 CA 254 DURING CRUISE FLIGHT, AP TRIM IS RWD POSTED ON AND OFF EVERY FEW SECONDS. AUTO-PILOT DISCONNECTED. NOTICED THAT AILERON IS EXTREMELY HARD TO MOVE ALMOST BLOCKED. IN DESCENT WITHOUT AUTO-PILOT, WE NOTICED THAT THE ELEVATOR ALSO COULD NOT B E MOVED (FL310-300 / SAT -50 C). AROUND FL290 AND AFTER APPLYING STRONG INPUT, THE AILERON CAME FREE WITH A JERK. AROU ND FL130 (TAT 0C), ELEVATOR FREE AGAIN. APPROACH AND LANDING NORMAL. AILERON AND ELEVATOR SERVO MOUNT CHANGED. OPERAT IONAL TESTS ON A/P SERVOS SUCCESSFULLY PERFORMED. AILERON SERVO CYCLE 18126/ HOURS 23075 ELEVATOR SERVO CYCLE 19592/ HO URS 24455. 2 L 7 2 4F 4 F RT A21EA E15NE 2005022400018 20050224 00018 EA 2005 2 24 CA040507003 1 20040430 G 3040 HEATER CNDAIR CL600 CL6002B19 1900309 EA WINDSHIELD SMOKE W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA DURING CRUISE, SMOKE FROM LEFT WINDOW HEATER. WHEN LT WINDSHIELD HEAT WAS TURNEDOFF, SMOKE STOP. DIVERTED FLIGHT. FOU ND LOOSE SCREW AND DAMAGED TERMINAL LUG ON LEFT WINDSHIELD HEAT ELEMENT. LUG REPLACED AND SCREW TIGHTENED. 2 L 7 2 4F RT A21EA 2005022400019 20050224 00019 SW 2005 2 24 CA040507004 1 20040506 G 2910 TUBE FRCHLD SA227 SA227DC 3377521 SW GARRTT TPE331 TPE33112UHR WP MCAULY 4HFR34 4HFR34C652 NE HYD SYSTEM CHAFED W O OTHER K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA AT FL 200 RT HYDRAULIC PRESSURE ANNUNCIATION WENT FROM INTERMITTENT TO CONTINUOUS. ON LANDING FLAPS AND GEAR SELECTION RESULTED IN FURTHER LOSS OF HYDRAULIC PRESSURE AND THE LT HYDRAULIC ANNUNCIATOR ILLUMINATED AND FLAPS WERE SLOW TO EXTEN D. AUXILLIARY GEAR EXTENSION PROCEDURE WAS RUN AND THE GEAR LOCKED DOWN. POST FLIGHT INSPECTION REVEALED HYDRAULIC OIL ON THE UNDER SIDE OF THE AIRCRAFT. MAINTENANCE DISCOVERED A CHAFFED HOLE IN A HYDRAULIC SUPPLY LINE IN THE RT WING LEA DING EDGE INBOARD OF THE NACELLE WHICH THEY REPLACED. THE LEADING EDGE AREA IS CROWDED WITH MANY METAL LINES THAT CAN C HAFE EACH OTHER. 2 L 7 2 4T 4 T RT A18SW E4WE 6 C 3PNE 2005022400020 20050224 00020 NM 2005 2 24 CA040510001 1 20040509 G 5542 85540001003 SKIN DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE RUDDER CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA DURING ROUTINE MAINTENANCE WALKAROUND INSPECTION, A CRACK WAS DISCOVERED ON THE UPPER RT SKIN OF THE FORE RUDDER. REPAI R IS CURRENTLY BEING ACCOMPLISHED IAW BOMBARDIER RD8-55-335. MORE INFORMATION WILL BE ADDED AS IT BECOMES AVAILABLE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005022400021 20050224 00021 EA 2005 2 24 CA040510002 1 20040503 G 5341 21531036212 FRAME CNDAIR CL215 CL2151A10 1900320 EA WING TO BODY CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA WHILE PERFORMING AD CF-1997-07R2 A CRACK WAS DISCOVERED BY EDDY CURRENT ABOUT ONE AND A HALF INCHES LONG ON THE OUTBOARD RT REAR WING TO FUSELAGE FRAME ANGLE. THE CRACK BECAME VISUALLY APPARENT AFTER BEING DETECTED BY NDT. THE CRACK START ED AT THE TOP OF FRAME P/N 215-31036-212 AND EXTENDED PASS THE FIRST HIGH LOCK AND ON TOWARDS THE SECOND. THE AD WAS PE RFORMED AT AIRFRAME TIME 1984.2 AND TOTAL WATER DROPS 6843 WHICH IS PRIOR TO THE COMPLIANCE REQUIREMENTS OF AD CF-1997-0 7R. 2 H 7 2 4R RT A14EA 2005022400022 20050224 00022 EA 2005 2 24 CA040510003 1 20040503 G 2720 215903812 CONTROL CABLE CNDAIR CL215 CL2151A10 1900320 EA PWA R2800 R2800* 52026 NE RUDDER CONTROL CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA DURING A STRUCTURAL REPAIR TO THE RT REAR WING-TO-FUSELAGE FRAME ANGLE A PANEL AT WS 60.80, ADJACENT TO REAR SPAR, HAD T O BE DRILLED OFF TO FACILITATE THE REPAIR. IT WAS AT THIS TIME CORROSION WAS DISCOVERED ON THE RUDDER/AILERON INTERCONN ECT CABLE P/N 215-90381-2 WHICH LIES DIRECTLY UNDER THIS PANEL. THE CORROSION WAS REMOVED AND UPON A CLOSER INSPECTION SEVERAL BROKEN STRANDS WERE NOTICED. THE MM WAS CONSULTED AND IT WAS DETERMINED THAT THE CABLE WAS BEYOND LIMITS. THE CABLE WAS REMOVED AND REPLACED WITH A SERVICEABLE UNIT AND THE WING PANEL WAS SEALED WITH AN APPROVED SEALANT. ITS WORT H NOTING THAT THE DAMAGE WOULD BE IMPOSSIBLE TO SPOT HAD IT NOT BEEN FOR THE REMOVAL OF THE RIVETED PANEL. THIS IS AN AR 2 H 7 2 4R 4 R RT A14EA 5E8 2005022400024 20050224 00024 NE 2005 2 24 CA040510004 2 20040507 G 7310 MS905820 RING BOEING 737 737217 1384464 NM PWA JT8 JT8D17 52049 NE FUEL FLOW TRANS DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA HAVE HAD SEVERAL OCCURRENCES OF FUEL LEAKS FROM THE JT8D FUEL FLOW TRANSMITTERS. THE LEAKS ARE EVIDENT AT VERY HIGH POWE R SETTINGS. A FLEET CAMPAIGN HAS BEEN COMPLETED WHICH CHECKED ALL ENGINES FOR LEAKS AND RECTIFIED DEFECTS. AN EXTENSIVE INVESTIGATION IS BEING CONDUCTED BY OUR MAINTENANCE PROVIDER AND PRELIMINARY RESULTS SHOW THE CAUSE TO BE DEFECTIVE TEF LON BACK-UP RINGS MS9058-20. ALL STOCK OF THE SUSPECT PART HAS BEEN INSPECTED AND ANY DEFECTIVE BACK-UP RINGS FOUND HAV E BEEN QUARANTINED. OUR MAINTENANCE PROVIDER HAS CONTACTED THEIR SUPPLIER OF THE PART WITH THE FINDING. ADDITIONALLY T HEY ARE CHECKING FOR OTHER APPLICATIONS FOR THE PART WITHIN THEIR VARIOUS FLEETS. A FULL REPORT WILL BE ISSUED AND I WI 2 L 7 2 4F 4 F A16WE E2EA 2005022400025 20050224 00025 EA 2005 2 24 CA040510005 1 20040506 G 5511 C2TP57 SPAR DHAV DHC2 DHC2* 2800108 EA PWA R985 R985AN14B 52008 NE HAMSTD 2D 2D30 NE HORIZONTAL STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 15271 THE TAILPLANE WAS BEING INSPECTED IAW CF 91-42 ADDITIONAL CRACK WAS DISCOVERED LEADING FROM A PREVOUSLEY CRACK THAT HAD BEEN STOP DRILLED. 1 H 7 1 3R 3 R A806 5E1 5 C P206 2005020100033 20050201 00033 CE 2005 2 1 CA040510006 1 20040506 G 5520 11561001S1 FITTING BEECH 100 A100 1152915 CE PWA PT6 PT6A28 EA MCAULY 4HFR34 4HFR34C652 NE ELEVATOR TORQUE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING A PHASE INSPECTION THE TAIL CONE WAS BEING REINSTALLED WHEN A CRACK WAS NOTICED ON THE LT TORQUE TUBE. THE CRACK EXTENDS FROM THE TAPER PIN HOLE TO THE EDGE OF THE FITTING. THESE FITTINGS ARE NDT EVERY 1000 HRS AND THIS TUBE WAS DONE AT 142.5 HRS. 1 L 7 2 3T 4 T A14CE E4EA 6 C 3PNE 2004062100123 20040621 00123 CE 2004 6 21 CA040510007 1 20040506 G 5310 50430043867 DOOR FRAME BEECH 100 A100 1152915 CE PWA PT6 PT6A28 EA MCAULY 4HFR34 4HFR34C652 NE PAX DOOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING A PHASE INSPECTION A CRACK WAS FOUND ON THE CABIN DOOR FRAME, WHICH EXTENDED FROM THE CUT-OUT FOR THE UPPER FWD BAYONETTE TO THE BAYONETTE SUPPORT BRACKET SCREW HOLE. 1 L 7 2 3T 4 T A14CE E4EA 6 C 3PNE 2004062100125 20040621 00125 EA 2004 6 21 CA040511001 1 20040509 G 3411 DRAIN CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE PITOT TUBE CONTAMINATED W C ABORTED TAKEOFF P NO WARNING INDICATION TO TAKEOFF 1 CA (CAN) ON TAKE-OFF ROLL , THE PILOT NOTICED THAT STANDBY ALTIMETER-AIR SPEED INDICATOR NOT SHOWING ANY AIRSPEED THUS REJE CTING TAKEOFF. MAINTENANCE REPLACED THE INSTRUMENT AND NOTED THERE WAS EXCESSIVE AMOUNT OF MOISTURE DRAINED FROM THE PI TOT DRAIN PLUG . 2 L 7 2 4F 4 F RT A21EA E15NE 2004062100126 20040621 00126 CE 2004 6 21 CA040511002 1 20040510 G 3211 05411212 SUPPORT BRACKET CESSNA 172 172K 2072430 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160CTM GL MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) RT MAIN LANDING GEAR OB SUPPORT BRACKET CRACKED AT U BOLT FORWARD HOLE. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2004062100127 20040621 00127 NE 2004 6 21 CA040511003 2 20040422 G 8530 399359 CASTING PWA DHAV DHC3 DHC3 2800202 EA PWA R1340 S3H1G 52016 NE HAMSTD 23D 23D40 NE VALVE GUIDE CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA PCCP2272 (CAN) THE ALUMINUM CASTING IN WHICH THE VALVE GUIDE SLIDES HAD DISINTEGRATED DUE TO CORROSION INSIDE THE EXHAUST PORT. I T WAS PROBABLY A POOR QUALITY PART THAT WAS INSTALLED DURING THE LAST OVERHAUL. 1 H 7 1 3R 3 R A815 E142 6 C P719 2004062100128 20040621 00128 WP 2004 6 21 CA040511004 1 20040509 G 2781 WARNING LIGHT DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE LE SLAT ILLUMINATED W O OTHER F J FLT CONT AFFECTED WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) DURING TAXING, DISAGREE AMBER LIGHT REMAINED ILLUMINATED WHEN SLATS RETRACT SELECTED. AIRCRAFT WAS FERRIED. DUR ING CLIMB OUT, SLAT DISAGREE LIGHT EXTINGUISHED APROX 13000 FT WHILE SLAT RETRACTED. AT YUL, MAINTENANCE DID FUNCTIONAL CHECK IAW MM AND NO FAULT FOUND. AIRCRAFT RELEASED SERVICEABLE. 2 L 7 2 4F 4 F RT A6WE E9NE 2004062100129 20040621 00129 NE 2004 6 21 CA040511005 2 20040302 G 7230 ENGINE CNDAIR CL604 CL604 1900301 EA GE CF34 CF343B1 NE LEFT FOD W A UNSCHED LANDING C B J F.O.D. SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CL CLIMB 1 CA UNJ73540 (CAN) AFTER TAKEOFF THE CREW REPORTED SMOKE IN THE CABIN. AN EMEREGENCY WAS DECLARED AND THE AIRCRAFT RETURNED TO BASE A ND MADE AN UNEVENTFUL LANDING. BOROSCOPE INSPECTION REVEALED FOD (FOD TYPE WAS NOT IDENTIFIED) FROM 1ST TO 7TH STAGE CO MPRESSOR OF LT ENGINE. ENGINE WAS REMOVED. COMPRESSOR DAMAGE WAS REPAIRED, ALSO REPLACED 9 BLADES OF 1ST STAGE HPT AN D BOTH IGNITERS. ENGINE RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT A21EA E15NE 2004062100130 20040621 00130 EA 2004 6 21 CA040511007 2 20040510 G 7414 1068291013 MAGNETO PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL LT ENGINE MALFUNCTIONED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ON LT ENGINE RUN UP, MAGNETO TEST FOUND RPM DROP BY 400 RPM. DURING TROUBLESHOOTING FOUND FAULTY MAGNETO, REPAIRE D ON MAY 3/ 2002, 460.1 HRS IN SERVICE SINCE REPAIR. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004062100153 20040621 00153 CE 2004 6 21 CA040512001 1 20040330 G 2710 051010516 CONTROL CABLE CESSNA 180 180C 2072608 CE CONT O470 O470K 17026 SO MCAULY 2A34C 2A34C203 GL AILERON FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) CABLE FRAYED AT PULLEY, PULLEY NOT SEIZED. 1 H 7 1 3O 3 O 5A6 E273 5 C P3EA 2004070900089 20040709 00089 CE 2004 7 9 CA040512002 1 20040503 G 2710 051010513 CONTROL CABLE CESSNA 185 A185F 2072821 CE CONT O520 IO520D 17032 SO MCAULY 2A34C D2A34C58 GL AILERONS FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) FRAYED AT PULLEY WING ROOT, PULLEY NOT SEIZED. 1 H 7 1 3O 3 O 3A24 E5CE 5 C P3EA 2004070900090 20040709 00090 CE 2004 7 9 CA040512003 1 20040503 G 2710 051010516 CONTROL CABLE CESSNA 185 A185F 2072821 CE CONT O520 IO520D 17032 SO MCAULY 2A34C D2A34C58 GL AILERON FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) FRAYED AT WING ROOT PULLEY. 1 H 7 1 3O 3 O 3A24 E5CE 5 C P3EA 2004070900091 20040709 00091 SW 2004 7 9 CA040512004 1 20040512 G 6710 206001342001 CYCLIC STICK BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL COCKPIT CRACKED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) DURING ROUTINE INSPECTION CYCLIC TUBE P/N 206-001-342-001 WAS FOUND CRACKED AT THE UPPER BOLT HOLE ON THE PILOTS S IDE SLOT ATTACHMENT. THIS TUBE HAD ACCUMULATED408.7 HOURS SINCE ITS LAST INSPECTION MAY 20, 2003. THIS INSPECTION IS A 1 200 HOUR REQUIREMENT IAW MFG BHT-206-A/B SERIES MAINTENANCE MANUAL. WE HAVE RETAINED A COMPANY REQUIREMENT TO ALSO INSPE CT THIS PART ANNUALLY. A SECOND CYCLIC TUBE P/N 206-001-342-001 REMOVED FROM AN AIRCRAFT ON OVERHAUL WAS ALSO FOUND CRAC KED IN THE SAME AREA. THIS PART HAD ACCUMULATED 298 HOURS SINCE ITS LAST INSPECTION. ASSB 206-85-29 AND BHT-206 A/B-SER IES M/M BOTH REFERENCE THE INSPECTION REQUIREMENTS. 1 G 7 1 3U 3 U H2SW E4CE 2004070900092 20040709 00092 SW 2004 7 9 CA040512005 1 20040507 G 5711 1108111 SPAR BBAVIA 7 7GCBC 1220601 SW LYC O320 O320A2D 41508 EA SNSNCH 74D 74DM EA WING CHAFED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ON METAL-SPAR WINGS RETROFITTED TO THIS AC THE AFT SPARS HAVE THREE FOOT STIFFENERS RIVETED TO THEM AT AFT STRUT A TTACH POINT. CLEARANCE BETWEEN FABRIC AND STIFFENER IS MINIMAL, AND INSPECTION HOLE COVER CLIPS CAN CONTACT STIFFENER AN D CHAFE GROOVES INTO IT AS FABRIC DRUMS OR FLEXES IN FLIGHT, DEPENDING ON LOCATION OF INSPECTION HOLE AND ORIENTATION OF THE COVER. TURBULENCE OFF STRUTS CREATES CONSIDERABLE FABRIC MOVEMENT IN THIS AREA. ON THIS PARTICULAR AC THE STIFFENE RS WERE DAMAGED ENOUGH TO REQUIRE REPLACEMENT. RECOMMEND USING A TWO-CLIP COVER AT THIS HOLE, RATHER THAN FOUR-CLIP TYP E, AND ORIENTING CLIPS TO AVOID INTERFERENCE WITH SPAR. INDEXING AND LABELING OF COVER AND WING MIGHT BE ADVISABLE. 1 H 7 1 3O 3 O NC A759 E274 5 N P88614 2004070900093 20040709 00093 EU 2004 7 9 CA040512006 1 20040510 G 2997 12TW13 SWITCH SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE COLLECTIVE FAILED W C ABORTED TAKEOFF P NO WARNING INDICATION TO TAKEOFF 1 CA (CAN) AFTER START UP PILOT TESTED THE HYD SYSTEM IAW FLIGHT MANUAL AND HAD HYD FAIL LIGHT BUT NO HORN. FLIGHT WAS ABORT ED. THE HYD CUTOFF SWITCH ON THE PILOTS COLLECTIVE WAS FOUND TO BE U/S.SWITCH CHANGED A/C RETURNED TO SERVICE. 1 G 7 1 3U 3 U NC H9EU E19EU 2004070900094 20040709 00094 CE 2004 7 9 CA040512007 1 20040404 G 1430 NAS130436 BOLT CESSNA CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE BELLCRANK WORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING SERVICEABILITY CHECK, THE AME FOUND THE ELEVATOR SYSTEM SEEMED LOOSE. HE ALSO FOUND THAT HE COULD MOVE BOTH ELEVATORS IN THE OPPOSITE DIRECTION SLIGHTLY. FURTHER TROUBLESHOOTING REVEALED THAT THE UPPER CONTROL TUBE TO BELL CRA NK BOLT WAS INSUFFICIENTLY TORQUED AND THE BOLT WAS WORN. THE BELL CRANK WAS ALSO WORN .003 ON ONE SIDE OF THE MOUNT HO LE AND .007 ON THE OTHER. THERE IS NO ALLOWABLE WEAR TOLERANCE GIVEN FOR THIS PART. AN AIRCRAFT SERVICES CAMPAIGN NOTI CE WAS ISSUED TO INSPECT THE REST OF THE FLEET. 1 L 7 2 4F 4 F A22CE E1NE 2005050300200 20050503 00200 EU 2005 5 3 CA040513001 1 20040513 G 2700 UNKNOWN AIRBUS 320 A320211 3930320 EU CFMINT CFM56 CFM565A1 NE UNKNOWN W O OTHER F FLT CONT AFFECTED NR NOT REPORTED 1 CA (CAN) DURING A FULL THRUST TAKEOFF AT APPROX 100 KNTS IAS, ACFT SNAPPED TO THE LT REQUIRED ABRUPT RT RUDDER. AGAIN AT APPROX 130 KNTS IAS, ACFT VEERED LT THOUGH LESS ABRUPT. ALL OTHER INDICATIONS NORMAL AND FLIGHT CONTINUED ON TO DESTINAT ION. AC TO BE REMOVED FROM SERVICE ON ARRIVAL FOR MTCE INVEST. FLT DATA RECORDER TO BE REMOVED, BLUE TAGGED AND SENT TO PLAY BACK CENTER. (FLT REC. TO BE QUARANTEENED IN UNTIL ADVISED.) 2 L 7 2 4F 4 F RT A28NM E29NE 2004070900095 20040709 00095 NM 2004 7 9 CA040513002 1 20040510 G 3246 314802 WHEEL DHAV DHC8 DHC8101 2809002 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE LT MLG SEPARATED W A UNSCHED LANDING D INFLIGHT SEPARATION CL CLIMB 1 CA (CAN) AN OPERATOR EXPERIENCED AN IN-FLIGHT MAIN WHEEL SEPARATION ON TAKE-OFF. A REQUEST WAS MADE FOR EMERGENCY PERSONNE L AND EQUIPMENT TO BE ON STANDBY. AFTER A NORMAL EXTENSION OF THE LANDING GEAR VISUAL INSPECTION CONFIRMED THAT LT INNE R MAIN WHEEL WAS MISSING. A/C MADE AN UNSCHEDULED LANDING. MAIN WHEEL BEARING FAILURE FOUND TO BE THE CAUSE. INVESTIG ATION ON-GOING. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004070900096 20040709 00096 2004 7 9 CA040513003 4 20040513 G 3417 4040800906 COMPUTER BOEING 767 767375 1385217 NM GE CF6 CF680C2B6 30025 NE RT ADC FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AFTER T/O EICAS MSGS (RUDDER RATIO,AILERON LOCKOUT) ALTIMETER, AIRSPEED, IVSI OUTSIDE LIMITS BETWEEN CAPT AND F/O, AUTO PILOTS WOULD NOT ENGAGE. NOTE: MOC REQUESTED F/O ALT ADC BE SELECTED, FAULT CLEARED. FLT CREW ELECTED TO RTN TO YVR. RT ADC FAULT BULB SHOWS AFTER TEST. ADC REPLACED AND FUNCTION CHECK SERVICE. 2 L 7 2 4F 4 F RT A1NM E13NE 2006061200427 20060612 00427 2006 6 12 CA040513004 4 20040512 G 2565 D31041147 SLIDE BOEING 757 757236 1384971 NM RROYCE RB211 RB211535E437 54555 NE CABIN MISINSTALLED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA ADDITIONAL PARTS P/N D30854 S/N 0278 AND P/N 61571 S/N 0175, DURING OVERHAUL INSPECTION BY AIR CRUISERS ALL 3 SLIDES WER E FOUND IMPROPERLY PACKED WITH IMPROPER RESTAINTS. THIS COULD HAVE A SERIOUS PROBLEM IF UNITS WERE DEPLOYED. 2 L 7 2 4F 4 F RT A2NM E12EU 2004070900097 20040709 00097 NM 2004 7 9 CA040513005 1 20040512 G 5330 SKIN BOEING 737 737201 1384454 NM PWA JT8 JT8D9A 52048 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 61271 (CAN) DURING ROUTINE CHECK A 2.5 INCH (TWO AND A HALF INCH) CRACK WAS FOUND ON THE OUTER FUSELAGE SKIN AT FS 943 AND 945 .5 STRINGER 24R. CRACK REPAIRED IAW SRM 53-30-3 FIG 48 DETAIL 9 PAGE 284. TIMES 61271:42 CYCLES 59436. 2 L 7 2 4F 4 F A16WE E2EA 2004070900100 20040709 00100 NM 2004 7 9 CA040513006 1 20040508 G 2750 FLAP TRACK BOEING 727 72744C 1384100 NM PWA JT8 JT8D7B 52053 NE FLAP SYSTEM CONTAMINATED W A UNSCHED LANDING F FLT CONT AFFECTED CL CLIMB 1 CA (CAN) DEPARTING, THE CREW OBSERVED A DIAGEEMENT BETWEEN IB AND OB FLAP POSITION. THE AIRCRAFT CONTINUED TO YFB BYPASSING YSR. MAINTENANCE IN YFB FOUND SIGNIFICANT CONTAMINATION DUE TO POOR RUNWAY CONDITION AT YRB (SLUSH AND MUD) AND SUSPECT FLAP SYSTEM FOULED BY THIS CONTAMINATION. THE AIRCRAFT WAS CLEANED AND CHECKED SERVICEABLE, DEPARTURE FOR YOW WAS UNEVE NTFUL. 2 L 7 3 4F 4 F A3WE E2EA 2004080400213 20040804 00213 CE 2004 8 4 CA040513008 1 20040512 G 7603 901187263 SPRING BEECH 99 99 1154002 CE PWA PT6 PT6A20 52043 EA HARTZL HCB3T HCB3TN3 GL POWER CONTROL DAMAGED W E A ENGINE SHUTDOWN UNSCHED LANDING E VIBRATION/BUFFET CL CLIMB 1 CA (CAN) ON TAKE OFF ROLL, PWR SET TO 1290 FT LBS. AFTER ROTATION NOTICED TORQUE INCREASING ON RT ENG. FO ATTEMPTED TO RE DUCE PWR BUT PWR LEVER WOULD NOT MOVE. TORQUE INCREASED TO APPROX 1500 FT LBS FOR ABOUT 90 SECONDS. AFTER REACHING SAF E ALTITUDE RT ENG SHUTDOWN AND AC LANDED SAFELY. ON INSPECT ENG CNTRLS, PWR CNTRL SPRING LINK FOUND TO BE CATCHING ON C NTRL LEVER MNTG BRKT. LINK IS AT BASE OF ROD END THAT ATTACHES AIRFRAME PWR CABLE TO INPUT ARM ON CAM CLUSTER. ACTION OF LINK ON CNTRL LEVER BRACKET WOULD BE TO PULL PWR LEVER TOWARDS HIGHER PWR SETTING, ULTIMATELY JAM THERE. THIS LINK S HOULD HAVE BEEN MOUNTED 10-15 DEGREES FURTHER IN THE COUNTER CLOCKWISE DIRECTION ON THE POWER CABLE. 1 L 7 2 3T 3 T A14CE E4EA 6 C P15EA 2004071200178 20040712 00178 EA 2004 7 12 CA040514001 1 20040513 G 2150 SHAFT CNDAIR CL604 CL604 1900301 EA GE CF34 CF343B1 NE A/C PACK SHEARED W O OTHER O OTHER TX TAXI/GRND HDL 1 CA (CAN) AFTER ENGINE START CREW WAS UNABLE TO OBTAIN COLD AIR-CONDITIONED AIR OUT OF THE LT AIR CONDITIONING PACK. ENGINES WERE SHUTDOWN AND MAINTENANCE WAS NOTIFIED OF THE SNAG. MAINTENANCE DISCOVERED THAT THE LOW LIMIT VALVE, BUTTERFLY VAL VE WAS NO LONGER ATTACHED TO ITS SHAFT. THE BUTTERFLY VALVE WAS LOCATED IN THE DUCT JUST BELOW THE AIR-COOLING TURBINE. THE AIR-COOLING TURBINE WAS ALSO REPLACED AS A PRECAUTION DUE TO SUSPECTED FOD DAMAGE. A NEW LOW LIMIT VALVE AND AIR-COO LING TURBINE WERE INSTALLED AND THE AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT A21EA E15NE 2004071200179 20040712 00179 SO 2004 7 12 CA040514002 1 20040510 G 2731 110321004 BRACKET EMB 110 EMB110* SO PWA PT6 PT6A34 52043 EA HARTZL HCB3T HCB3TN3 GL ELEVATOR TAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING AIRCRAFT DI BY MAINTENANCE THE ELEVATOR TRIM TAB WAS FOUND TO HAVE EXCESSIVE PLAY. INVESTIGATION REVEALED T HE ATTACH BRACKET FOR THE TRIM TAB ACTUATOR WAS CRACKED AND THE ACTUATOR BRACKET WAS MOVING WITH THE ACTUATOR ALLOWING T HE EXCESSIVE PLAY IN THE ELEVATOR TRIM TAB. 1 L 7 2 4T 4 T RT A21SO E4EA 6 C P15EA 2004071200180 20040712 00180 NM 2004 7 12 CA040514003 1 20040511 G 2760 CONTROL CABLE BOMBDR DHC8 DHC8402 1390042 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU SPOILER WORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) PLEASE TAKE NOTE THAT FOLLOWING MFG Q400 AOM NR 122 MANY AILERON AND SPOILER CONTROL CABLES WERE FOUND WORN TO OR CLOSE TO LIMIT ON OUR A/C WITH ONLY 2038HRS AND 2858 CYCLES SINCE MFG. SIMILAR FINDING WERE FOUND ON OUR OTHER Q400 S/N 4004 (1610 HRS AND 2100 CYCLES). THE MAJOR DIFFERENCE BETWEEN THE 2 A/C WAS THAT 4003 CABLES FOUND DIRTY BUT TENSION OK AND 4004 TENSION LOWER THAN SPECIFIED IN THE AMM BUT CABLES WERE CLEAN. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2004071200204 20040712 00204 NE 2004 7 12 CA040514004 2 20040430 G 7323 8210161C GOVERNOR DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE OVERSPEED MALFUNCTIONED W E ENGINE SHUTDOWN E VIBRATION/BUFFET AP APPROACH 1 CA 28638 (CAN) DURING APPROACH AT 8000 FT, NR 2 ENGINE UNCOMMANDED FEATHER . ENGINE SHUT DOWN. NORMAL LANDING. MAINTENANCE REPLA CED PROP TRANSFER TUBE , PCU AND FCU, WITHOUT CORRECTING PROBLEM. OVERSPEED GOVERNOR AND OVERSPEED GOV HYD PUMP REPLACE D, GROUND RUNS SUCCESSFUL. AIRCRAFT RETURNED TO SERVICE. OVERSPEED GOV AND OVERSPEED GOV HYD PUMP SENT TO VENDOR FOR IN VESTIGATION/REPAIR. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004071200206 20040712 00206 EA 2004 7 12 CA040515001 1 20040505 G 2721 272613 TRIM SWITCH CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE RUDDER FAILED W A UNSCHED LANDING F FLT CONT AFFECTED CL CLIMB 1 CA (CAN) RUDDER TRIM GOES FULL RT WITHOUT INPUT COMMAND. WITH NOSE LT SELECTED, TRIM MOVES FURTHER RT. AIRCRAFT RETURNED AND LANDED WITHOUT FURTHER INCIDENT. REMOVED AND REPLACED RUDDER TRIM PANEL AND OPS CHECKED. NO FURTHER DEFECTS NOTED. 2 L 7 2 4F 4 F RT A21EA E15NE 2004071200207 20040712 00207 EA 2004 7 12 CA040515002 1 20040510 G 3213 17064103 FITTING CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE MLG CRACKED W O OTHER O OTHER NR NOT REPORTED 1 CA 20873 (CAN) LT MAIN FITTING WAS FOUND CRACKED DURING INSPECTION IAW SB601R-32-079E. THE MAIN FITTING HAD BEEN INSPECTED BY EDD Y CURRENT ON 22-APR-04 WITH NO FINDINGS (20599 TFH, 16653 TFC). NO EVIDENCE WAS FOUND OF INCORRECT SHOCK STRUT SERVICIN G OR STRUCTURAL DAMAGE. BOTH MLG ASSYS WILL BE REPLACED AND SENT TO MFG FOR INVESTIGATION. THE A/C HAS NO HISTORY OF H EAVY LANDINGS OR REJECTED TAKEOFFS. 2 L 7 2 4F 4 F RT A21EA E15NE 2005020100133 20050201 00133 EU 2005 2 1 CA040517001 1 20040510 G 6520 350A33100021 PINION GEAR AEROSP SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE T/R GEARBOX WORN W K NONE O OTHER IN INSP/MAINT 1 CA M2519 (CAN) GEAR BOX ASSY HAD OIL SAMPLES TAKEN AFTER OVERHAUL FOR 1160.O HRS AND ALL OIL SAMPLES TAKEN WHERE NORMAL , AFTER I NTERM REPAIR TO INPUT HOUSING ALL OIL SAMPLES TAKEN SHOWED SIGNS OF WEAR DUE TO ABNORMAL WEAR FOR 188.9 HOURS. 1 G 7 1 3U 3 U H9EU E19EU 2004071200208 20040712 00208 2004 7 12 CA040517002 4 20040511 G 2210 62701160 CONTROL CABLE PIPER PA44 PA44180 7104402 SO LYC O360 O360A1H 41514 EA HARTZL HCC2Y HCC2YR2 GL AT TRIM SERVO FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHILE REMOVING AN ELECTIC TRIM SERVO FOR THE STABILATOR SYSTEM, IT WAS NOTICED THAT THE FORWARD STABILATOR TRIM CA BLE WAS FRAYED AT THE AREA THAT IT WAS WOUND AROUND THE ELECTIC TRIM SERVO PULLEY. THE CABLE WAS REPLACED WITH A NEW ON E. THIS AREA SHOULD BE INSPECTED CLOSELY AT THE TWO PULLEYS ON THE SERVO. IT IS DIFFICULT TO SEE ANY DEFECT ON THE CABLE UNLESS THE TRIM IS RUN COMPLETELY IN BOTH DIRECTIONS. 1 L 7 2 3O 3 O A19S0 E286 5 C P920 2004071200209 20040712 00209 CE 2004 7 12 CA040517003 1 20040515 G 5340 501200742 FITTING BEECH 99 99 1154002 CE PWA PT6 PT6A28 EA HARTZL HCB3T HCB3TN3 GL MAIN SPAR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 23069 (CAN) DURING A ROUTINE DETAILED INSPECTION, MAINTENANCE DISCOVERED A CRACK IN THE LT UPPER FORWARD WING FITTING OF THE WING CENTER SECTION. NDT, USING LPI AND EDDY CURRENT CONFIRMED THIS AS A CRACK. THIS AIRCRAFT HAS FLOWN 513.9 SINCE LAS T NDT IAW MFG SIRM. AIRCRAFT GROUNDED AND MANUFACTURER NOTIFIED. 1 L 7 2 3T 4 T A14CE E4EA 6 C P15EA 2004071900027 20040719 00027 CE 2004 7 19 CA040518001 1 20040203 G 7920 655601110 MANIFOLD CESSNA 500 560CESSNA 2076750 CE PWA 530 PW535A NE ENGINE OIL LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) OIL MANIFOLD FLARE FITTING MADE VERY POORLY, VERY ROUGH/SCRAPPED SURFACE ON FLARE MATING SURFACE, ALLOWING FITTIN G TO WEEP OIL. REPLACEMENT PART WAS NOT MUCH BETTER BUT NO OIL LEAKS. 2 L 7 2 4F 4 F RT A22CE E00053EN 2004071900033 20040719 00033 EA 2004 7 19 CA040518002 2 20040518 G 7414 MAGNETO LYC O540 O540E4C5 41532 EA ENGINE FAILED W K NONE L NO TEST IN INSP/MAINT 1 CA (CAN) DUE TO ROUGH RUNNING ENGINE. MAG WAS DETERMINED TO BE FAULTY, WAS REPLACED. A/C WAS TEST FLOWN, ENGINE RAN VERY ROUGH. INSP OF ENG AND REPLACED MAG NOTED INTERNAL MAG GEAR WAS DAMAGED WITH MISSING TEETH. NOTED METAL IN OIL SCREEN . ENG WAS REMOVED AND SHIPPED FOR INSPECTION AND REPAIR. ENGINE WAS DISMANTLED AND CRANKSHAFT GEAR WAS DAMAGED WITH TE ETH BROKEN OFF. OTHER INTERNAL DAMAGE INCLUDED A DAMAGED IDLER GEAR, OIL PUMP DRIVE, AND TACH SHAFT. EXACT CAUSE OF FA ILURE IS U/K BUT IT IS SUSPECTED THAT WHEN A/C WAS FIRST SERVICED, MAG WAS REPLACED THAT INTERNAL TIMING 10 PENNY NAIL W AS LEFT INSTALLED AND THUS CAUSED LOCKING UP OF MAG GEARS. WHEN ENGINE WAS STARTED MAG AND CRANK GEARS WERE BROKEN OFF. 3 O E295 2004071900034 20040719 00034 EA 2004 7 19 CA040518003 2 20040515 G 7220 SCDEETS41446 HOSE BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA HARTZL HCB4M HCB4MP3 GL BREATHER KINKED W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 CA (CAN) AFTER TAKE OFF, CABIN BEGAN TO FILL WITH FUMES AND OIL VAPOR. CREW TURNED OFF ENGINE BLEED AIR AND RETURNED TO AIR PORT. MAINTENANCE FOUND NR 1 ENGINE BREATHER HOSE HAD BEEN KINKED AND PINCHED CAUSING THE ACCESSORY CASE TO PRESSURIZE A ND FORCE OIL TO PASS THE ENGINE LABYRINTH AND GARLOCK SEALS AND ENTER THE COMPRESSOR. SOME OF THIS OIL ENTERED THE CABIN THROUGH THE AIRCRAFT BLEED AIR SYSTEM CREATING FUMES AND VISIBLE OIL VAPOR. ENGINE BREATHER HOSE WAS INSPECTED AND REPO SITIONED. SEVERAL SUCCESSFUL GROUND RUNS WERE CARRIED OUT AND AIRCRAFT WAS RETURNED TO SERVICE. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2004071900035 20040719 00035 EA 2004 7 19 CA040518004 2 20040518 G 8550 DIPSTICK LYC O360 IO360A2B 41514 EA ENGINE LEAKING W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION NR NOT REPORTED 1 CA (CAN) INFLIGHT ENGINE STOPPAGE WAS DUE TO OIL STARVATION. IT IS SUSPECTED THAT THE OIL DIP STICK WAS REPLACED BUT NOT S CREWED DOWN THUS PERMITTING OIL TO ESCAPE VIA THE OIL FILL TUBE. IT WAS NOTED THAT THE FRONT OF THE ENGINE WAS DRY WHIL E THE AFT PART WAS COATED. 3 O 1E10 2004071900036 20040719 00036 CE 2004 7 19 CA040518005 1 20040506 G 2810 2500010071 LINE CESSNA CESSNA 303 T303 2073820 CE CONT O520 TSIO520AE 17040 SO MCAULY 3AF32C 3AF32C506 GL FUEL CROSSFEED RESTRICTED W O OTHER J WARNING INDICATION CR CRUISE 1 CA T30300265 (CAN) DURING CRUISE FLIGHT, PILOT SELECTED CROSSFEED FOR RT ENGINE. SHORTLY AFTERWARDS, THE RT ENGINE LOST POWER/FUEL F LOW. SELECTOR WAS RETURNED TO NORMAL, AND ENGINE CONTINUED TO RUN NORMALLY. MAINTENANCE DISCOVERED UPON INSPECTION THA T THERE WERE 2 LONG STRINGS, AND NUMEROUS BITS OF PRC SEALANT THAT CAME OUT OF THE LINE WHEN BLOWN OUT WITH COMPRESSED A IR. MOST LIKELY SOURCE OF CONTAMINATION WAS WHEN FUEL TANK MAINTENANCE WAS CARRIED OUT, AND NOT ALL REMOVED SEALANT WAS CLEANED OUT OF TANK. AIRCRAFT THOROUGHLY GROUND RUN AND RELEASED. NO FURTHER OCCURRENCE. 1 L 7 2 3O 3 O A34CE E8CE 5 C P57GL 2004071900037 20040719 00037 CE 2004 7 19 CA040518006 1 20040506 G 7714 C668022101 NEEDLE CESSNA 303 T303 2073820 CE CONT O520 TSIO520AE 17040 SO MCAULY 3AF32C 3AF32C506 GL TACHOMETER STUCK W O OTHER P NO WARNING INDICATION DE DESCENT 1 CA (CAN) PILOT REPORTED THAT LT TACH NEEDLE WAS STUCK AT 2400 RPM. INDICATOR REPLACED AND TESTED SERVICEABLE WITH NEW GAUG E. INTERNAL PROBLEM WITH GAUGE, SENT TO REPAIR FACILITY. 1 L 7 2 3O 3 O A34CE E8CE 5 C P57GL 2004071900038 20040719 00038 CE 2004 7 19 CA040518007 1 20040517 G 3020 11891003415 HOSE BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA HARTZL HCB4M HCB4MP3 GL STACK TO COWL CRACKED W E A ENGINE SHUTDOWN UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 CA (CAN) AFTER TAKE OFF CREW OBSERVED SPARKS AND GLOW FROM RT ENGINE COWL. CREW SHUTDOWN RT ENGINE AND RETURNED TO AIRPORT. MAINTENANCE FOUND THE FLEXIBLE HOSE FROM THE EXHAUST STACK TO THE LIP HEATER HAD CRACKED AND SEPERATED FROM THE COWLIN G. THIS ALLOWED THE EXHAUST THAT WAS INTENDED FOR THE INTAKE HEATER TO ENTER THE FORWARD COWLING. COWLING WAS REPLACED WITH SERVICEABLE UNIT AND FLEXIBLE HOSE WAS REPLACED ON COWL THAT WAS REMOVED. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2004071900063 20040719 00063 CE 2004 7 19 CA040518008 1 20040508 G 2910 623372 SELECTOR VALVE BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA HARTZL HCB4M HCB4MP3 GL HYD POWER INTERMITTENT W O OTHER J WARNING INDICATION AP APPROACH 1 CA (CAN) DURING APPROACH THE CREW NOTICED THAT THE LANDING GEAR WAS LOUDER THAN USUAL ANDSLOWER TO EXTEND. MAINTENANCE FOUN D THE POWER PACK SELECTOR VALVE TO BE INTERMI TTENT AND THE POWER PACK TO BE NOISY. WITH THE AIRCRAFT ON JACKS THERE WER E TIMES WHEN THE GEAR WOULD FAIL TO EXTEND WHEN SELECTED AND HAD TO BE MANUALLY EXTENDED. POWER PACK ASSY INCLUDING THE SELECTOR VALVE WAS REPLACED AND THE LANDING GEAR TESTED SERVICEABLE. AIRCRAFT WAS PLACED BACK INTO SERVICE ON MAY 13TH. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2004071900064 20040719 00064 CE 2004 7 19 CA040518009 1 20040326 G 3020 1173T423 SWITCH CESSNA 500 560CESSNA 2076750 CE PWA 530 PW535A NE UNDERTEMP OUT OF LIMITS W O OTHER O OTHER TX TAXI/GRND HDL 1 CA (CAN) LT ENGINE ANTI-ICE LIGHT SLOW TO EXTINGUISH. LT UNDERTEMP SWITCH GOES OFF AT 340 DEGREES F, SHOULD GO OFF AT 300+ /-7 DEGREES F. NEW SWITCH INSTALLED AND OPERATION CHECKED SATISFACTORY. 2 L 7 2 4F 4 F RT A22CE E00053EN 2004071900065 20040719 00065 CE 2004 7 19 CA040518010 1 20040326 G 2110 DRIVE ASSY CESSNA 500 560CESSNA 2076750 CE PWA 530 PW535A NE COMPRESSOR LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA 1862 (CAN) AIR CONDITIONER COMPRESSOR DRIVE PULLEY SHAFT OIL SEAL LEAKING OIL. AIR COMPRESSOR REPLACED. 2 L 7 2 4F 4 F RT A22CE E00053EN 2004071900066 20040719 00066 SW 2004 7 19 CA040518011 1 20040511 G 6410 2060016201131 BLADE BELL 206 206B 1181511 SW TAIL ROTOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) CHORDWISE CRACK, APPROX 2.8 INCHES LONG, OBSERVED TO START AT LEADING EDGE RUNNING TOWARDS TRAILING EDGE. LOCATED 0.5 INCHES AWAY FROM THE OB TIP OF DOUBLER. ONLY ONE SIDE OF THE TAIL ROTOR BLADE IS CRACKED. 1 G 7 1 3U H2SW 2004071900067 20040719 00067 2004 7 19 CA040518012 4 20040507 G 3457 AVSAT100 ANTENNA BRAERO 748 HS7482A 4231001 EU RROYCE DART DART5342 EU ROTOL R4304 R2124304 EU GPS OUT OF POSITION W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING ROUTINE SERVICING MAINTENANCE OBSERVED THAT THE GPS ANTENNA ON THE CROWN OF THE AIRCRAFT STA 108F-126F BETW EEN STR O AND 2L TO BE OUT OF POSITION. INSPECTION FOUND FATIGUE CRACKING ALONG BOTH SIDES AND THE FRONT EDGE WAS BEGINN ING TO LIFT AWAY. THE AIRCRAFT WAS REPAIRED AND RETURNED TO SERVICE. BOTH DOUBLER AND AIRCRAFT SKIN SUFFERED FATIGUE FAI LURE. 2 L 7 2 3T 4 T A24EU A196 6 C P899 2004071900068 20040719 00068 CE 2004 7 19 CA040519001 1 20040401 G 7830 183238001 SOLENOID CESSNA 500 560CESSNA 2076750 CE PWA 530 PW535A NE THRUST REVERSER WEAK W O OTHER E VIBRATION/BUFFET LD LANDING 1 CA (CAN) SECONDARY THROTTLE RT UNABLE TO ADVANCE PAST FLIGHT IDLE AFTER RT THRUST REVERSER DEPLOYED DUE TO WEAK INTERLOCK S OLENOID. SOLENOID ASSEMBLY 183238-001 REPLACED. OPERATION OF RT AND LT SECONDARY THROTTLE INTERLOCKS CHECK SATISFACTOR Y. 2 L 7 2 4F 4 F RT A22CE E00053EN 2004071900069 20040719 00069 NE 2004 7 19 CA040519002 2 20040419 G 7530 655551117 TUBE CESSNA 500 560CESSNA 2076750 CE PWA 530 PW535A NE BLEED AIR WORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) TUBE CHAFED INSIDE SUPPORTING CLAMP P/N S2894-24 TUBE 6555511-17 AND CLAMP (REVISED P/N 471-24) REPLACED LT AND RT ENGINE. THIS WAS FOUND DURING PERFORMANCE OF SB 560-71-05 WHICH WAS TO INSPECT TUBE AND INSTALL REVISED CLAMP. 2 L 7 2 4F 4 F RT A22CE E00053EN 2004071900070 20040719 00070 EA 2004 7 19 CA040519003 1 20040504 G 3244 95X1612 TIRE FRCHLD F27 F27F 3373008 EA RROYCE DART DART5297E 54507 EU ROTOL R4304 R1934304 EU MLG SEPARATED W O OTHER D INFLIGHT SEPARATION LD LANDING 1 CA (CAN) UPON LANDING, THE LT IB TIRE RE-TREAD SEPARATED FROM THE TIRE. 2 H 7 2 4T 4 T 7A1 E297 6 C P899 2004071900074 20040719 00074 CE 2004 7 19 CA040519004 1 20040512 G 2720 5052432627 RUDDER PEDAL BEECH 200 B200 1152922 CE PWA PT6 PT6A42 52043 NE HARTZL HCD4N3 HCD4N3A GL COCKPIT WORN W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) RUDDER PEDAL ATTACH POINT BROKEN AT BUSHING ATTACH. 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2004071900081 20040719 00081 NE 2004 7 19 CA040519005 1 20040506 G 7931 636716 PUMP SKRSKY S64 S64E 8142604 NE PWA JFTD12 JFTD12A4A 52047 NE ENGINE OIL FAILED W E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION HO HOVERING 1 CA 672516 (CAN) THE FLIGHT CREW WAS ALERTED BY THE ILLUMINATION OF THE ENGINE OIL PRESSURE WARNING LIGHT FOR NR 1 ENGINE. A CHECK OF THE CORRESPONDING OIL PRESSURE INDICATOR RELIEVED ZERO PSI. THE CREW IMMEDIATELY SHUT DOWN THE SUBJECT ENGINE, RETU RNED TO THE SERVICE LANDING AND MADE A SINGLE ENGINE LANDING. A SUBSEQUENT INSPECTION OF THE ENGINE FOR LOW OIL LEVEL, CLOGGED FILTER, MALFUNCTIONING OIL PRESSURE REGULATOR, PRESSURE SWITCH, TRANSMITTER AND INDICATOR REVEALED NO FAULT WITH ANY. IT WAS CONCLUDED THAT THE FAULT HAD TO BE WITH THE ENGINE OIL PUMP. CONSEQUENTLY THE ENGINE WAS REMOVED AND RETU RNED FOR REPAIR. 2 G 7 2 4U 4 U H4EA E15EA 2004071900082 20040719 00082 SO 2004 7 19 CA040519006 1 20040518 G 3040 BOOT PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL DE-ICE SYS FAILED W A UNSCHED LANDING O OTHER CL CLIMB 1 CA (CAN) DURING CLIMB OUT, THE LT PROP LOST A DE-ICE BOOT. THE PILOT HEARD IT AND RETURNED TO THE AIRPORT. THE REMAINING 2 DE-ICE BOOTS WERE REMOVED AND THE PROP WAS INSPECTED TO BE SERVICEABLE. THE PROP DE-ICE CIRCUIT BREAKER WAS PULLED AND THE COCKPIT PLACARDED (NOT TO BE OPERATED IN KNOWN ICING). 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004071900083 20040719 00083 SO 2004 7 19 CA040519007 1 20040510 G 6120 2489407 CABLE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL PROPELLER BROKEN W A UNSCHED LANDING F FLT CONT AFFECTED CL CLIMB 1 CA (CAN) THE PROPELLER CABLE WORE WHERE IT ATTACHES TO THE SUPPORT CONNECTED TO THE STARTER JUST BELOW THE GOVERNOR. THIS A REA OF THE ASSEMBLY CANNOT BE VISUALLY INSPECTED. THE CREW NOTICED ON TAKING OFF, THE LOSS OF PROP PITCH CONTROL, REDUCE D MANIFOLD PRESSURE, COMPLETED PROP OVERSPEED CHECK AND MADE AN UNEVENTFUL LANDING BACK AT LA RONGE. THE PROP CABLE WAS REPLACED AND THE AIRCRAFT WAS GROUND RUN, RIGGED TO SPEC, AND RETURNED TO SERVICE. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004071900084 20040719 00084 2004 7 19 CA040519008 4 20040519 G 2562 MN1300 BATTERY ACK CESSNA 185 A185F 2072821 CE CONT O520 IO520D 17032 SO MCAULY 2AF34C D2AF34C* GL ELT LEAKING W K NONE H K ELECT. POWER LOSS-50 PC FLUID LOSS IN INSP/MAINT 1 CA 045329 (CAN) DURING ANNUAL PERFORMANCE TEST IT WAS NOTICED THAT DURACELL MN1300 BATTERIES DATED MAR 2010 WERE LEAKING WHAT APPE ARED TO BE BATTERY ACID. WHEN THE VOLTAGE OF THE BATTERIES WAS CHECKED IT WAS FOUND THAT THE AFFECTED BATTERIES WERE BEL OW TWO VOLTS. ELT BATTERY CASE WAS CLEANED AND FULL SET OF NEW BATTERIES WERE INSTALLED. ELT WAS FUNCTIONAL TESTED AND F OUND TO BE MEET MANUFACTURERS SPECIFICATIONS. 1 H 7 1 3O 3 O 3A24 E5CE 5 C P5EA 2004071900085 20040719 00085 EA 2004 7 19 CA040519009 2 20040312 G 8530 LW12597 CYLINDER PIPER PA28 PA28140 7102802 SO LYC O320 O320E2A 41508 EA SNSNCH 74DM M74DM EA ENGINE BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) BROKEN RINGS IN CYLINDER NR 4. FOUND AT ANNUAL INSPECTION. COMPRESSION TEST AND METAL IN OIL FILTER. 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 2004071900086 20040719 00086 NE 2004 7 19 CA040519010 2 20040513 G 7261 AS3209114 O-RING BEECH B300 B300B350C CE PWA PT6 PT6A60A 52043 NE HARTZL HCB4M HCB4MP3 GL RGB TRNS OIL TUB PINCHED W C E ABORTED TAKEOFF ENGINE SHUTDOWN K J FLUID LOSS WARNING INDICATION TO TAKEOFF 1 CA PCEPK0205 (CAN) RT ENGINE SHUTDOWN DUE TO OIL PRESSURE, LIGHT ON AND OIL PRESSURE BETWEEN 60 AND 60 PSI. AFTER INVESTIGATION FOUND ONE O-RING LEAKING ON RT ENGINE REDUCTION GEARBOX OIL TRANSFER TUBE, REPLACED O-RING P/N AS3209-114. AFTER DISCUSSION W ITH PILOTS, DID NOT EXCEED TRANSIENT LIMITS IAW MFG MM 3034342 REV.26 CHAP 71-00-00 TABLE 503, OIL LEVEL ADJUSTED, LOST OF 5 QTS OF OIL. ENGINE INSPECTED IAW MFG MM 3034342 REV.26 CHAP 72-00-00 INSP.Q. RUN-UP CARRIED OUT, OIL FILTER CHECK ED FOR CONTAMINATION. FOUND SERVICEABLE. NOTE: CHIP DETECTOR TO BE CHECK DAILY FOR ONE WEEK, MIN25 HOURS. (IAW EMM 72-00 -00 P640 Q(2)(B), OIL FILTER TO BE CHECK BETWEEN 25-65 HOURS. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2004071900087 20040719 00087 NM 2004 7 19 CA040519011 1 20040519 G 5314 KEELBEAM BOEING 727 727227 1384078 NM PWA JT8 JT8D9A 52048 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHILE TROUBLESHOOTING APU SNAG, MAINT DISCOVERED A CRACK IN THE KEELBEAM WEB (STA 870 LOAD CONTROL VALVE AREA) THE DAMAGE IS BEING REPAIRED IAW SRM 53-10-9.CRACK LENGTH APPROX 3.5 INCHES. 2 L 7 3 4F 4 F A3WE E2EA 2004080500085 20040805 00085 WP 2004 8 5 CA040519012 1 20040508 G 6120 VALVE DOUG A26 A26BSHIELDS 3020504 WP PWA R2800 R280079 52026 NE HAMSTD 23E 23E50 NE PROPELLER LEAKING W E ENGINE SHUTDOWN K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA NK140140 (CAN) ON A TRAINING FLIGHT THE RT ENGINE WAS SHUT DOWN. DURING THE RESTART, THE RT PROP BEGAN TO OVERSPEED. THE CREW A CCOMPLISHED THE OVERSPEED PROCEDURE AND RETURNED TO BASE WITHOUT INCIDENT. MAINTENANCE FOUND IN TROUBLESHOOTING THE DIS TRIBUTOR VALVE HAD OIL LEAK. 2 M 7 2 4R 4 R L34 5E8 6 C P603 2004080500086 20040805 00086 CE 2004 8 5 CA040519013 1 20040515 G 5341 501200735 FITTING BEECH 100 100BEECH 1152916 CE PWA PT6 PT6A28 EA FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 16063 (CAN) DURING THE ROUTINE COMPLETION OF CF1981-35 SITES NR 1 AND NR 2, A SMALL CRACK WAS DISCOVERED ON THE LOWER RT, IB B ATHTUB FITTING. THE CRACK APPEARED TO START ON THE FEATHERED EDGE AT THE CENTER OF THE RADIUS AND PROPOGATE TOWARD THE M ATING SURFACE OF THE FITTING FOR A DISTANCE OF APPROXIMATELY 0.164 INCH. MFG WAS CONSULTED AND A REPAIR WAS GENERATED T HROUGH THEIR REPAIR DESIGN OFFICE. IT CONSISTED OF BLENDING OUT THE CRACK TO THE SPECIFIED DIMENSIONS, PERFORMING FPI TO ENSURE ALL THE CRACK WAS REMOVED AND SURFACE TREATING THE ALUMINUM TO PREVENT CORROSION. THE WING BOLT WAS REINSTALLED IAW SIRM AND THE AIRCRAFT RELEASED FOR SERVICE. 1 L 7 2 3T 4 T A14CE E4EA 2004080500087 20040805 00087 NM 2004 8 5 CA040519014 1 20040518 G 2761 65449617 ACTUATOR BOEING 737 737217 1384464 NM PWA JT8 JT8D17 52049 NE SPOILER FAILED W O OTHER K FLUID LOSS LD LANDING 1 CA (CAN) DURING TAXI TO GATE LOSS OF NOSE WHEEL STEERING OCCURRED WITH TOTAL LOSS OF HYDRAULIC A PRESSURE AND QUANTITY AT Z ERO. MAINTENANCE FOUND THE NR 8 GROUND SPOILER ACTUATOR TO BE THE CAUSE. THE ACTUATOR BODY HAD STRUCTURAL FAILURE CAUSI NG FLUID LOSS. ACTUATOR REPLACED AND AIRCRAFT RETURNED TO SERVICE. ACTUATOR ROUTED TO OUR MAINTENANCE PROVIDER'S SHOP WITH REQUEST FOR FULL REPORT. WILL ADD FURTHER DETAILS OF THE FAILURE WHEN AVAILABLE. 2 L 7 2 4F 4 F A16WE E2EA 2004080500088 20040805 00088 EU 2004 8 5 CA040520001 2 20040511 G 7200 ENGINE BRAERO 748 HS7482A 4231001 EU RROYCE DART DART5342 EU ROTOL R4304 R2124304 EU RIGHT SEIZED W A UNSCHED LANDING X J ENGINE FLAMEOUT WARNING INDICATION CL CLIMB 1 CA 16375 (CAN) THE AIRCRAFT WAS CLIMBING EN-ROUTE WHEN THE FLIGHT CREW OBSERVED THE RT ENGINE OIL PRESSURE RISING ABOVE LIMITS. T HE ENGINE CEASED OPERATING AND THE PROPELLER FEATHERED BEFORE THE CREW COULD ACTION THE ENGINE SHUTDOWN CHECKLIST. SHUT DOWN AND CLEANUP CHECKLISTS WERE CARRIED OUT AND THE FLIGHT DIVERTED BACK TO MAIN BASE. THE FLIGHT CREW DECLARED AN EME RGENCY AND LANDED AT LAKE WITHOUT FURTHER INCIDENT. COMPANY MAINTENANCE FOUND THE ENGINE WAS SEIZED. THE ENGINE AND PRO P WERE REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. THE ENGINE WILL BE SHIPPED OUT TO A FACILITY FOR INSPECTION AS SO ON AS PRACTICAL. 2 L 7 2 3T 4 T A24EU A196 6 C P899 2004080500089 20040805 00089 NM 2004 8 5 CA040520002 1 20040515 G 2760 BACC2A3A01262GG CONTROL CABLE BOEING 727 72744C 1384100 NM PWA JT8 JT8D7B 52053 NE SPOILERS BROKEN W O OTHER F FLT CONT AFFECTED CR CRUISE 1 CA (CAN) MAINTENANCE FOUND THE WSB2 CABLE BROKEN WHEN INVESTIGATING A REPORT OF SPOILER FLOAT. THE CABLE WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 2 L 7 3 4F 4 F A3WE E2EA 2004080500090 20040805 00090 CE 2004 8 5 CA040520003 1 20040520 G 8011 640174 RETAINING RING CESSNA 150 150M 2071830 CE CONT O200 O200A 17020 SO MCAULY 1A102 1A102OCM GL STARTER GEAR DISLODGED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) STARTER GEAR RETAINING RING (P/N 6401740) DISENGAGED FROM THE STARTER SHAFT AND LODGED IN THE STARTER GEAR NEEDLE BEARING (P/N 639788). THE NEEDLE BEARING FAILED WITH THE BEARING NEEDLES ENTERING THE ENGINE REAR CASE AND OIL SYSTEM. THE NEEDLES IN THE OIL SYSTEM DAMAGED THE FOLLOWING PARTS: OIL PUMP GEARS (2) P/N'S 3562 AND 21343 REAR CASE(1) P/N 640 174STARTER DRIVE AND CLUTCH (1) P/N 641500. 1 H 7 1 3O 3 O 3A19 E252 5 N P918 2004080500091 20040805 00091 SO 2004 8 5 CA040520004 1 20040520 G 5312 50090XX BULKHEAD PIPER PA31T PA31T 7103124 SO PWA PT6 PT6A28 EA HARTZL HCB3T HCB3TN3 GL BEHIND FIREWALL CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 17794 (CAN) MAINTENANCE INSPECTION REVEALED CRACKING IN THE LONGITUDINAL BULKHEADS (BOTH) BEHIND EACH ENGINE. THESE BULKHEADS RUN THE LENGTH OF THE NACELLE, FROM THE FIREWALL TO THE TRAILING EDGE OF THE NACELLE. THE CRACKS ARE PRESENT WHERE THE BULKHEADS NARROW TO ACCOMODATE THE FRONT WALL OF THE NACELLE FUEL TANK AND THE CUTOUTS FOR PLUMBING AND AIR DUCTS. PRES ENTLY PURSUING A REPAIR DESIGN CERTIFICATE TO ADDRESS THIS PROBLEM. 1 L 7 2 3T 4 T A8EA E4EA 6 C P15EA 2004080500092 20040805 00092 NM 2004 8 5 CA040521001 1 20040519 G 3233 656021123 MODULE BOEING 727 727243 138408D NM PWA JT8 JT8D15 52051 NE MLG ACTUATOR FAILED W J A DUMP FUEL UNSCHED LANDING N FALSE WARNING CL CLIMB 1 CA (CAN) ON CLIMB OUT, CREW NOTICED NOSE (GEAR UNSAFE) LIGHT DID NOT EXTINGUISH. AFTER DUMPING FUEL, CREW RETURNED TO MAINT ENANCE FACILLITY WHERE THE LANDING GEAR ACCY UNIT WAS REPLACED AND GEAR SWINGS PERFORMED. A/C RETURNED TO SERVICE. 2 L 7 3 4F 4 F RT A3WE E2EA 2004071900071 20040719 00071 2004 7 19 CA040521003 4 20040520 G 3418 C771075 TRANSDUCER BAG JETSTM JETSTM3212 1500217 EU GARRTT TPE331 TPE33110UG 01514 WP MCAULY 4HFR34 4HFR34C652 NE RT WING LIFT MALFUNCTIONED W D RETURN TO BLOCK F FLT CONT AFFECTED TX TAXI/GRND HDL 1 CA (CAN) CREW REPORTED THAT ON TAXI FOR TAKE-OFF FOR THE SECOND FLIGHT OF THE MORNING THAT THE RT STALL SYSTEM WAS ACTUATED ON GROUND WITH STALL IDENT LIGHT RT ON AND CONTINUOUS STICK SHAKER IN FLIGHT CONTROL SYSTEM. UNABLE TO CANCEL. AIRCRA FT RETURNED TO BLOCKS. 2 L 7 2 4T 4 T RT BA15CAA E4WE 6 C 3PNE 2005022400027 20050224 00027 EU 2005 2 24 CA040521004 1 20040517 G 2160 959902012 CONTROL VALVE PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL CABIN TEMP MALFUNCTIONED W H DEACTIVATE SYST/CIRCUITS J WARNING INDICATION CR CRUISE 1 CA (CAN) THE PILOT REPORTED THAT THE 'OVERTEMP' LIGHT ON THE CAWS PANEL CAME ON DURING FLIGHT. WHEN THE TEMPERATURE CONTROL WAS TURNED DOWN, THERE WAS NO CHANGE IN THE CABIN TEMP OR THE INDICATION ON THE CAWS PANEL. THE PILOT SELECTED THE ECS SWITCH TO MANUAL, WHICH AGAIN FAILED TO EXTINGUISH THE CAWS INDICATION. THE AIRCRAFT RETURNED TO BASE AND MAINTENANCE FO UND THAT THE TEMPERATURE CONTROL VALVE WAS SEIZED IN THE FULL HOT POSITION. A NEW VALVE WAS INSTALLED ALONG WITH A SERVI CEABLE TEMPERATURE SENSOR. THE AIRCRAFT ECS SYSTEM WAS GROUND TESTED AND RETURNED TO SERVICE. THE AIRCRAFT MANUFACTURER HAS NO OVERHAUL SCHEDULE FOR THE TEMPERATURE CONTROL VALVE. THIS IS THE SECOND FAILURE WE HAVE HAD OCCUR WHERE THE VALVE 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005022400028 20050224 00028 EU 2005 2 24 CA040521005 1 20040515 G 7700 WARNING LIGHT SNIAS 350 AS350B3 8680954 EU TMECA ARRIEL ARRIEL2B NE ENGINE ILLUMINATED W B A EMER. DESCENT UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA MAY 15TH THE PILOT IN COMMAND NOTED A RED GOV WARNING LIGHT AT 700 FEET ABOVE GROUND. HE ELECTED TO LAND ON A SAND BAR AND NOTED IN THE DESCENT THE MAIN ROTOR RPM EXCEEDED THE MAX LIMIT. A LANDING WAS CARRIED OUT WITH NO INJURIES TO PERSO NS. THE HELICOPTER WAS TRANSPORTED TO AIR SERVICES FACILITY. THE CAUSE OF THE OVER SPEED IS UNDER INVESTIGATION AT THI S TIME WITH NO RESULTS AS OF YET. 1 G 7 1 3U 3 U H9EU E00054EN 2005030800002 20050308 00002 NE 2005 3 8 CA040521006 2 20040520 G 7414 11052 COUPLER BENDIX DHAV DHC3 DHC3 2800202 EA PWA R1340 S3H1G 52016 NE HAMSTD 23D 23D40 NE RT MAGNETO CRACKED W A UNSCHED LANDING E VIBRATION/BUFFET CR CRUISE 1 CA 452008 ENGINE STARTED TO RUN ROUGH AT CRUISE SETTINGS AND ABOVE. ENGINE BACKFIRE VIOLENTLY WHEN RIGHT MAG SELECTED . RUBBER D ISK COUPLER BETWEEN MAG AND MAG DRIVE FOUND TO BE SEVERLY CRACKED AT EACH COG ON THE DISK, CAUSING THE MAG TO BECOME OUT OF TIME AT RPM GREATER THAN 1750. BELOW 1750 RPM ENGINE OPERATED NORMAL. THE MAD AND MAG COUPLER WERE REPLACED AND AI RCRAFT RELEASED FOR RETURN TO SERVICE. 1 H 7 1 3R 3 R A815 E142 6 C P719 2005030800003 20050308 00003 CE 2005 3 8 CA040521007 1 20040203 G 5610 1013840252 WINDSHIELD BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL COCKPIT FAILED W B A EMER. DESCENT UNSCHED LANDING O OTHER CR CRUISE 1 CA PILOTS WINDSHIELD INNER PANE SHATTERED WHILE IN FLIGHT 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2005030800004 20050308 00004 NM 2005 3 8 CA040521008 1 20040521 G 3231 141085 SEQUENCE VALVE BOEING 727 727243 138408D NM PWA JT8 JT8D15 52051 NE RT MLG DOOR CRACKED W O OTHER K FLUID LOSS CL CLIMB 1 CA AFTER T/O AND GEAR RETRACTION, CREW NOTICED HYDRAULIC QUANTITY LOW. CREW MONITORED HYDRAULIC LEVEL FOR DURATION OF FLIG HT WITH NO CHANGE. UPON GEAR EXTENSION, HYDRAULIC QUANTITY DROPPED FURTHER, REQUIRING THE A/C TO BE TOWED TO RAMP FROM THE ACTIVE TAXIWAY. MAINTENANCE DISCOVERED THE RT MLG DOOR SEQUENCE VALVE HAD CRACKED. THE VALVE WAS REPLACED. 2 L 7 3 4F 4 F RT A3WE E2EA 2005030800005 20050308 00005 SW 2005 3 8 CA040525001 1 20040521 G 2750 19023 CONTROL CABLE BBAVIA 8 8GCBC 1220803 SW LYC O360 O360C2A 41514 EA MCAULY 1A200 1A200* GL TE FLAPS FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA STAINLESS STEEL CABLES, LT AND RT, FRAYED AT WING ROOT PULLEY. FLAP DOWN POSITION. 1 H 7 1 3O 3 O A21CE E286 5 N P874 2005030800006 20050308 00006 SW 2005 3 8 CA040525002 1 20040521 G 2750 19023 CONTROL CABLE BBAVIA 8 8GCBC 1220803 SW LYC O360 O360C2E 41514 EA MCAULY 1A200 1A200* GL TE FLAPS FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA STAINLESS STEEL CABLES, LT AND RT, FLAP CONTROL AT WING ROOT PULLEYS FRAYED. 1 H 7 1 3O 3 O A21CE E286 5 N P874 2005030800007 20050308 00007 NE 2005 3 8 CA040525003 2 20040521 G 7314 SPE31342 DIAPHRAGM DHAV DHC2 DHC2* 2800108 EA PWA R985 R985AN14B 52008 NE HAMSTD 23D 23D30 NE FUEL PUMP CRACKED W O OTHER O OTHER NR NOT REPORTED 1 CA PILOT REPORTED FUEL PRESSURE INDICATOR DROPPED INTERMITTENTLY DURING ALL PHASES OF OPERATION. AIRCRAFT WAS RETURNED TO MAINTENANCE BASE. FUEL FOUND TO BE LEAKING FROM WOBBLE PUMP. WOBBLE PUMP DIAPHRAGM FOUND TO BE CRACKED. DIAPHRAGM RE PLACED, ENGINE GROUND RUN SATISFACTORY. AIRCRAFT RETURNED TO SERVICE. 1 H 7 1 3R 3 R A806 5E1 6 C P719 2004080600028 20040806 00028 GL 2004 8 6 CA040525004 3 20040525 G 6114 45C33173472 SEAL HARTZL HCB3TN3 HARTZL HCB3T HCB3TN3 GL PISTON CUT W K NONE O OTHER IN INSP/MAINT 1 CA BUA20747 (CAN) PROPELLER WAS SENT IN FOR AN OIL LEAK, AND UPON DISASSEMBLY INNER SURFACE OF THE PISTON SEAL WAS FOUND TO BE CUT. THE SEAL WAS REPLACED PROPELLER TESTED FOR LEAKS, AND THE PROPELLER WAS RETURNED TO THE CUSTOMER. 6 C P15EA 2005030800008 20050308 00008 CE 2005 3 8 CA040525005 1 20040525 G 2560 SHOULDER BELT CESSNA 185 A185F 2072821 CE CONT O520 IO520D 17032 SO MCAULY D3A34 D3A34C401 GL COCKPIT INADEQUATE W K NONE O OTHER IN INSP/MAINT 1 CA IT WAS NOTED DURING INSPECTION, THAT THE REAR SEAT SHOULDER HARNESSES WERE NOT INCOMPLIANCE WITH AIRWORTHINESS DIRECTIVE 86-26-04. THIS DIRECTIVE IS SERIAL NUMBER SPECIFIC AND SHOULD NOT APPLY TO THIS AIRCRAFT. IT APPEARS THAT THESE HARNE SSES WERE RECYCLED BY BELT MAKERS INC AND INSTALLED IN THIS AIRCRAFT WHEN THE INTERIOR WAS REDONE IN 2003. 1 H 7 1 3O 3 O 3A24 E5CE 5 C P47GL 2004080600029 20040806 00029 EA 2004 8 6 CA040526001 1 20040524 G 3230 858601 PSEU DHAV DHC8 DHC8311 1386006 EA PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE MLG FAILED W O OTHER N FALSE WARNING AP APPROACH 1 CA 17727 (CAN) FLIGHT CREW REPORTED UPON SELECTION OF GEAR DOWN, INITIALLY THREE GREEN INDICATED, SHORTLY AFTER, A FLICKERING OF THE NOSE GEAR DOOR (AMBER) AND UNSAFE (RED) AND HORN SOUNDED, THEN CLEARED. ON TAXI IN SNAG RE-OCCURRED AND GREEN GEAR SAFE LIGHT NOW U/S. ALTERNATE VERIFICATION LIGHTS INDICATED GEAR SAFE. MAINTENANCE FOUND CARD FAULT ON PSEU. REPLACED AND TESTED UNIT AND COMPLETED GEAR SWINGS WITH NO FAULTS FOUND. AIRCRAFT WAS RETURNED TO SERVICE. SNAG RE-OCCURRED FO UR FLIGHTLEGS LATER WITH INDICATION OF GEAR UNSAFE ON TAXI. AIRCRAFT IS CURRENTLY IN HANGAR BEING INVESTIGATED. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004080600030 20040806 00030 WP 2004 8 6 CA040526002 1 20040522 G 2410 696233B CSD DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE LT GENERATOR FAILED W C ABORTED TAKEOFF J WARNING INDICATION TO TAKEOFF 1 CA (CAN) COMPLETE POWER INTERRUPTION ON TAKE OFF ROLL COMPLETED INTERRUPTION DURING 1 TO 3 SEC. WAS CAUSED BY RELAY DURING POWER TRANSFER. AIRCRAFT CAME BACK TO THE GATE. MAINTENANCE FOUND LT GENERATOR FREQUENCY TO LOW. AIRCRAFT WAS DISPATC HED AS IAW MEL 24-1. THE LT GENERATOR WAS REPLACED THE DAY AFTER. 2 L 7 2 4F 4 F RT A6WE E9NE 2004080600031 20040806 00031 WP 2004 8 6 CA040526003 1 20040522 G 2410 696233B CSD DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE RIGHT OVERHEATED W A UNSCHED LANDING H J ELECT. POWER LOSS-50 PC WARNING INDICATION CR CRUISE 1 CA (CAN) RT CSD OIL TEMPERATURE HIGH DURING CRUISE. CSD DISCONNECTED AND AIRCRAFT DIVERTED. BECAUSE THE LT GENERATOR WAS INOPERATIVE (ACFT DISPATCHED IAW MEL 24-1). RT CSD , GENERATOR AND CSD OIL COOLER WERE REPLACED AND AIRCRAFT DISPATCHED SERVICEABLE. 2 L 7 2 4F 4 F RT A6WE E9NE 2004080600032 20040806 00032 SW 2004 8 6 CA040526004 1 20040520 G 6320 406040056107 CASE BELL BELL 206 206L4 1182110 SW ALLSN 250C 250C30 03013 GL M/R GEARBOX CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA A302 (CAN) A DOZEN STUD HOLES FOUND DEEPLY CORRODED AND NEEDED SPECIAL REPAIR IAW MFG INSTRUCTIONS. THE CORROSION IS CAUSED BY DISSIMILAR METALS AND MOISTURE. MFG CANNOT SOLVE THE PROBLEM DEFINITELY BUT SUGGEST METHODS TO SLOW IT DOWN AND DIMI NISH DAMAGE TO CASE. 1 G 7 1 3U 3 U NC H2SW E1GL 2004080600033 20040806 00033 NM 2004 8 6 CA040526005 1 20040317 G 3260 401020101 PROXIMITY SWITCH BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R320 CR3204123F1 GL NLG MALFUNCTIONED W A UNSCHED LANDING N FALSE WARNING CL CLIMB 1 CA (CAN) AFTER GEAR UP SELECTION, GEAR CAME UP AND LOCKED BUT NOSE GEAR DOOR LIGHT REMAINED ON. WHEN GEAR WAS SELECTED DOW N, THE NOSE GEAR DOOR CAUTION LIGHT REMAINED ON. (GEAR DOWN AND LOCKED). UNSCHEDULED LANDING COMPLETED. NOSE GEAR DOOR CLOSED PROXIMITY SENSOR REPLACED IAW AMM 32-61-00. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P5NE 2004080600034 20040806 00034 NM 2004 8 6 CA040526006 1 20040412 G 3297 WIRE BFGOODRICH BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R320 CR3204123F1 GL SHORTED W A UNSCHED LANDING N FALSE WARNING CL CLIMB 1 CA (CAN) AFTER DEPARTURE GEAR WOULD NOT RETRACT WHEN GEAR UP WAS SELECTED. GEAR WAS RECYCLED BUT WOULD STILL NOT COME UP. THE ONLY INDICATIONS WERE THREE GREEN AND THREE RED LIGHTS. NO CAUTION OR AURAL WARNINGS. THE FLIGHT WAS RETURNED TO BA SE. INVESTIGATION/ACTION, NOSE WHEEL CENTERING SENSOR WIRING FOUND SHORTED. SENSOR REPLACED IAW AMM 32-61-00. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P5NE 2004080600035 20040806 00035 CE 2004 8 6 CA040526007 1 20040519 G 3230 MOTOR BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL MLG FAILED W O OTHER J WARNING INDICATION LD LANDING 1 CA (CAN) ON APPROACH, CREW SELECTED LANDING TO EXTEND. LANDING GEAR WOULD NOT EXTEND. GEAR HANDLE CYCLED. STILL NO GEAR EXT ENSION. CREW CARRIED OUT LANDING GEAR EMERGENCY EXTENSION. NO FURTHER FAULTS. MAINTENANCE FOUND LANDING GEAR ELECTRIC MOTOR PREMATURELY FAILED. REPLACE ELECTRIC MOTOR . NO FURTHER FAULTS. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2005030800009 20050308 00009 CE 2005 3 8 CA040526008 1 20040511 G 2121 C4140070101 FAN CESSNA 206 U206G 2073356 CE CONT O550 IO550F 17042 SO MCAULY D3A34 D3A34C402 GL E/E BAY FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 CA SHORTLY AFTER TAKEOFF SMOKE WAS OBSERVED IN THE COCKPIT AND EMERGENCY WAS DECLARED AND THE AIRCRAFT RETURNED FOR LANDING . AT THIS TIME THE AIRSPEED WAS READING EXTREMELY LOW. INVESTIGATION REVEALED THE STROBE/AVIONICS COOLING FAN CIRCUIT BREAKER OPEN. THE FAN ASSY EXHIBITED A STRONG BURNED ODOR AND THE PITOT LINE FOR THE LAKE AND AIR GEAR ADVISORY WAS FOU ND MELTED WHERE ROUTED IN CLOSE PROXIMITY TO THE FAN MOTOR. THE PITOT LINE WAS REPAIRED AND RE-ROUTED AND A NEW BLOWER ASSY INSTALLED. 1 H 7 1 3O 3 O A4CE E3SO 5 C P47GL 2005030800010 20050308 00010 EU 2005 3 8 CA040526009 1 20040525 G 2750 9742001902 RELAY PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL TE FLAPS FAILED W O OTHER O OTHER TX TAXI/GRND HDL 1 CA AFTER LANDING PILOTS TRIED TO RETRACT THE FLAPS BUT COULD NOT GET THEM TO MOVE. AIRCRAFT WAS INSPECTED AND FLAP UP RELA Y WAS FOUND TO HAVE FAILED, P/N 974.20.01.902. RELAY WAS REPLACED AND FLAP SYSTEM TESTED. AIRCRAFT RETURNED TO FLIGHT LINE. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005030800011 20050308 00011 EU 2005 3 8 CA040527001 1 20040512 G 6240 50071550020 TRANSDUCER SNIAS 350 AS350B3 8680954 EU TMECA ARRIEL ARRIEL2B NE M/R GEARBOX SHORTED W K NONE O OTHER IN INSP/MAINT 1 CA AFTER MAIN ROTOR GEAR BOX REPLACEMENT GROUND RUN WAS ACCOMPLISHED, HOWEVER NO INDICATION WAS PRESENT. DISCOVERED AFTER CONTINUITY CHECKS THAT THE TRANSDUCER WAS OPEN CIRCUIT. REPLACED PART INDICATION NORMAL 1 G 7 1 3U 3 U H9EU E00054EN 2005030800012 20050308 00012 EA 2005 3 8 CA040527002 1 20040520 G 2730 C2CF815A CONTROL CABLE DHAV DHC2 DHC2* 2800108 EA PWA R985 R985AN14B 52008 NE LT ELEVATOR FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA DURING SCHEDULED INSPECTION, THE LT ELEVATOR CONTROL CABLE WAS FOUND TO BE FRAYED AT THE FWD PULLEY LOCATED UNDER THE BA TTERY BOX. NO EVIDENCE OF BATTERY ACID FOUND IN LOCATION. THE CABLE WAS REPLACED AND AIRCRAFT RETURNED TO SERVICE. 1 H 7 1 3R 3 R A806 5E1 2005030800013 20050308 00013 NM 2005 3 8 CA040527003 1 20040523 G 2400 ELECTRICAL SYS BOEING 737 737201 1384454 NM PWA JT8 JT8D9A 52048 NE ALL UNKNOWN W C ABORTED TAKEOFF H ELECT. POWER LOSS-50 PC TO TAKEOFF 1 CA ON THE ROLL IN CYXY, ALL ELECTRICS WERE LOST. ALL ELECTRICS RESTORED BY THEMSELVES AFTER APPROX 30 SECONDS THEN FAILED AGAIN SHORTLY AFTER. 2 L 7 2 4F 4 F A16WE E2EA 2005030800014 20050308 00014 NE 2005 3 8 CA040527004 1 20040506 G 2140 DUCT SKRSKY S64 S64E 8142604 NE PWA JFTD12 JFTD12A4A 52047 NE CABIN HEAT FAILED W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS HO HOVERING 1 CA A/C WAS INVOLVED IN HELICOPTER LOGGING OPERATIONS IN THE AREA OF POWER RIVER BRITISH COLUMBIA. DURING THE FIRST LOGGING CYCLE OF THE DAY THE FLIGHT CREW NOTICED WHAT APPEARED TO BE SMOKE IN THE COCKPIT. AN IMMEDIATE A CHECK OF ALL SYSTEMS AND CIRCUIT BREAKERS REVEALED NO DISCREPANCIES. THE FLIGHT CREW ELECTED TO RETURN TO THE SERVICE LANDING FOR FURTHER I NVESTIGATION BY THE MX CREW. A SUBSEQUENT INSPECTION AND GROUND RUN OF ALL A/C SYSTEMS RESULTED IN NO FAULT FOUND. IT WAS CONCLUDED THAT SINCE THE AIRCRAFT WAS FRESH OUT OF HEAVY MX AND IT WAS THE FIRST COOL MORNING THAT REQUIRED CABIN HE AT THAT BRAND NEW DUCTING FROM THE BLEED AIR HEATER WAS THE CAUSE. THE A/C WAS RETURNED TO SERVICE WITH NO FURTHER RELA 2 G 7 2 4U 4 U H4EA E15EA 2005030800015 20050308 00015 CE 2005 3 8 CA040527005 1 20040518 G 7603 6676101000013 CONTROL MODULE LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE7312 01518 WP THROTTLE STIFF W O OTHER O OTHER NR NOT REPORTED 1 CA RT POWER LEVER 'PIGGYBACK' LEVER VERY STIFF, DIFFICULT TO MOVE TO STOW POSITION. THROTTLE CONTROL MODULE REPLACED. 2 L 7 2 4F 4 F RT T00008WI E6WE 2005030800016 20050308 00016 CE 2005 3 8 CA040527006 1 20040430 G 2450 700GC02Y07 CONTROL PANEL LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE731* 01518 WP POWER DIST FAILED W K NONE H J ELECT. POWER LOSS-50 PC WARNING INDICATION IN INSP/MAINT 1 CA RT GENERATOR WILL DROP OFF LINE AFTER OPPOSITE ENGINE START. RT AFT POWER DISTRIBUTION PANEL REPLACER WITH NEW UNIT. 2 L 7 2 4F 4 F RT T00008WI E6WE 2005030800017 20050308 00017 SO 2005 3 8 CA040527007 1 20040524 G 2432 ALU8421R POST ELECTROSYS PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA ALTERNATOR BROKEN W A UNSCHED LANDING H ELECT. POWER LOSS-50 PC CR CRUISE 1 CA 9040609 PILOT RETURNED TO BASE FOR ELECTRICAL AND AVIONICS DIFFICULTIES. ON RETURN, AIRCRAFT BATTERY DEPLETED CAUSING MULTIPLE ELECTRICAL AND AVIONICS PROBLEMS. PILOTS INITIATED PRECAUTIONARY MANUAL GEAR EXTENSION DUE TO LACK OF POSITIVE GEAR EXT END INDICATION AT NO TIME DID EITHER ALTERNATOR FAIL LIGHT ILLUMINATE. UPON INSPECTION, FOUND RT ALTERNATOR BATTERY POS T BROKEN AND SHORTING ON STARTER CASE INSTALLED BELOW ALTERNATOR. 1 L 7 2 3O 3 O A20SO E14EA 2005030800018 20050308 00018 2005 3 8 CA040527008 4 20040520 G 6113 09520046 BULKHEAD CESSNA 180 180H 2072618 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C50 GL SPINNER CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA BACK PLATE CRACKS FOUND RADIATING FROM RIVET HOLES. AT MANUFACTURING THE TALL SIDE OF RIVET AREAS NOT DEBURED PROPERLY. HOLES MAY HAVE BEEN PUNCH PRESSED AND SMALL AMOUNTS OF EXCESS MATERIAL REMAINED. 1 H 7 1 3O 3 O 5A6 E273 5 C P3EA 2005030800019 20050308 00019 EU 2005 3 8 CA040527009 1 20040522 G 2910 T2C5000605500 LINE BRAERO 748 HS7482A 4231001 EU RROYCE DART DART5342 EU HYD SYSTEM CHAFED W O OTHER K J FLUID LOSS WARNING INDICATION AP APPROACH 1 CA ON APPROACH, THE CREW OBSERVED LOW FLOW INDICATION ON BOTH SYSTEMS AND 1700 PSI. LANDING WAS CARRIED OUT WITHOUT INCIDE NT. MAINTENANCE FOUND THE SUPPLY LINE FROM THE HP FILTER TO THE GEARBOX DRIP TRAY IN THE RIGHT HAND NACELLE CHAFED THRO UGH. THE LINE WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 3T 4 T A24EU A196 2005030800020 20050308 00020 SW 2005 3 8 CA040527010 1 20040526 G 7697 C1006 WIRE SWRNGN SA227 SA227AC 8780603 SW MCAULY 4HFR34 4HFR34C652 NE POWER LEVER SWIT BROKEN W C ABORTED TAKEOFF J WARNING INDICATION TO TAKEOFF 1 CA ON TAKEOFF THE CREW ABORTED DUE TO AN AMBER 'NOSE STEER FAIL' LIGHT WAS 'ON'. SYSTEM WAS TROUBLESHOT AND A BROKEN WIRE WAS FOUND ON THE LT POWER LEVER ENABLE NOSE WHEEL STEERING SWITCH. THE WIRE WAS REPAIRED AND THE SYSTEM TESTED SERVICIB LE. AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4T RT A8SW 6 C 3PNE 2005030800021 20050308 00021 EU 2005 3 8 CA040527011 1 20040526 G 5210 RMRE04UCBBFF ROD END BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE PAX DOOR FAILED W K NONE O OTHER IN INSP/MAINT 1 CA 39734 39734 ON ARRIVAL, CREW UNABLE TO OPEN MAIN FWD LEFT HAND CABIN DOOR. PASSENGERS DEPLANED USING REAR PASSENGER DOOR. DOOR MEL 'D AND AIRCRAFT OPERATED TO MAINTENANCE BASE. MAINTENANCE INSPECTION FOUND DOOR OPERATING MECHANISM DISCONNECTED FROM O PERATING HANDLE DUE TO FAILED CONNECTING ROD ROD END. ROD END P/N RMRE04UCBBFF REPLACED AND DOOR FUNCTION TESTED. AIRC RAFT RETURNED TO SERVICE. (PART IS CLASSIFIED AS AN EXPENDABLE IN THE MAINTENANCE TRACKING SYSTEM AND DEFINITIVE PART T IME NOT AVAILABLE, TIMES PROVIDED ARE AIRCRAFT TIMES, PART BELIEVED TO BE ORIGINAL EQUIPMENT). 2 H 7 4 4F 4 F A49EU E6NE 2005030800022 20050308 00022 NM 2005 3 8 CA040527012 1 20040526 G 3260 LANDING GEAR DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE UNKNOWN W A UNSCHED LANDING N FALSE WARNING CL CLIMB 1 CA ON TAKEOFF, CREW REPORTED WEIGHT ON WHEELS CAUTION LIGHT ILLUMINATED ON TAKEOFF AND STAYED ON FOR ABOUT 20 MINUTES. CRE W DECIDED TO RETURN TO TORONTO. THE LIGHT HAD GONE OFF BY THEN. IN TORONTO THE MAINTENANCE ENGINEERS INSPECTED THE AIR CRAFT RELEVANT SYSTEMS INCLUDING ALL THE WOW SWITCHES/SENSORS, ELECTRICAL CONNECTORS AND THE PSEU(PROXIMATY SWITCH ELECT RONIC UNIT) AND SEVERAL GEAR SWINGS CARRIED OUT AND THEY COULD NOT DUPLICATE THE FAULT OR ACCERTAIN THE CAUSE OF THIS WA RNING. THE AIRCRAFT WAS RETURNED TO SERVICE . 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005030800023 20050308 00023 2005 3 8 CA040528001 4 20040527 G 3442 6229302003 TRANSMITTER CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE WX RADAR SYS FAILED W A UNSCHED LANDING O OTHER CL CLIMB 1 CA DURING FLIGHT, UPON SELECTION OF WEATHER RADAR, THE BLUE 'RADAR FAULT' AND AMBER 'RADAR CONTROL FAULT' MESSAGES APPEARED ON THE MFD DISPLAY, CREW CYCLED ON AND OFF WITH NO SUCCESS, CREW DETERMINED TO RETURN AIRCRAFT WHERE MAINTENANCE ENGINE ERS UPON TESTING THE SYSTEM REPLACED WEATHER RADAR RECEIVER TRANSMITTER AND ANTENNA (ALL ONE UNIT) AND RETURNED AIRCRAFT TO SERVICE. TIME ON UNIT UNKNOWN TIME ON AIRCRAFT IS 10227.58 2 L 7 2 4F 4 F RT A21EA E15NE 2005030800024 20050308 00024 EA 2005 3 8 CA040528002 1 20040524 G 5610 NP13932112 WINDSHIELD CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE COCKPIT CRACKED W O OTHER O OTHER DE DESCENT 1 CA FLIGHT EN ROUTE WHILE DESCENDING OUT OF 25,000 FT, FIRST OFFICER'S WINDSHIELD CRACKED. WINDSHIELD REPLACED. AIRCRAFT R ETURNED TO SERVICE. 2 L 7 2 4F 4 F RT A21EA E15NE 2005030800025 20050308 00025 EU 2005 3 8 CA040528003 1 20040516 G 3240 80197035099 LINE PIAGIO PIAGIO P180 P180 6960204 EU PWA PT6 PT6A66 52043 NE BRAKE SYSTEM DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA THE BRAKE LINE WAS FOUND WITH MECHANICAL DAMAGE DURING THE 600 HOUR INSPECTION. DAMAGE TO THE LINE WAS ON THE UNDER SID E AND COULD ONLY BE SEEN WITH A MIRROR. THE LINE IS LOCATED OVER A FLIGHT CONTROL CABLE WITH ABOUT 3 INCHES OF CLEARANC E. THE MARKS ON THE LINE ARE 90 DEGREES TO THE MOVEMENT OF THE FLIGHT CONTROL SO THE DAMAGE COULD NOT HAVE BEEN CAUSED B Y THE CABLE. THERE WAS NO SIGN OF DEBRIS UNDER THE LINE TO INDICATE DAMAGE. 1 H 7 2 3O 4 T RT A59EU E26NE 2005030800027 20050308 00027 NM 2005 3 8 CA040528005 1 20040517 G 2910 6590737329 LINE BOEING 737 737210C 1384459 NM PWA JT8 JT8D9A 52048 NE HYD SYSTEM BURST W A UNSCHED LANDING K FLUID LOSS CR CRUISE 1 CA ON GO-AROUND WHEN GEAR SELECTED UP. RT MAIN GEAR FAILED TO RETRACT AND LOSS OF SYSTEM 'A' HYDRAULIC FLUID. AIRCRAFT DI VERTED TO CYFB, DECLARED EMERGENCY. GEAR UP LINE P/N 65-90737-329 REPLACED, HYDRAULIC SYSTEM SERVICED, FUNCTION CHECK C ARRIED OUT. AIRCRAFT SERVICEABLE. NO OTHER PROBLEMS OR ACTIONS. 2 L 7 2 4F 4 F A16WE E2EA 2005030800028 20050308 00028 EA 2005 3 8 CA040528006 2 20040509 G 8550 204418156 ADAPTER CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA OIL FILTER FAILED W A UNSCHED LANDING K M J FLUID LOSS OVER TEMP WARNING INDICATION CR CRUISE 1 CA IN FLIGHT THE ENGINE OIL TEMPERATURE INDICATION WAS IN THE RED. UPON AIRCRAFT RETURN, THE THERMOSTATIC VALVE P/N SL E196 00 AND THE OIL FILTER ADAPTER 204418-156WAS REPLACED. RUN UP CARRIED OUT. TEMPERATURE INDICATION WITHIN LIMITS, P/N 69 510. 1 H 7 1 3O 3 O NT 3A12 E274 2005030800029 20050308 00029 SO 2005 3 8 CA040528007 1 20040515 G 3242 MS28775132 O-RING PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2C 41532 EA HARTZL HCE3Y HCE3YR2 GL BRAKE SYSTEM CUT W O OTHER K FLUID LOSS LD LANDING 1 CA UPON LANDING, THE LEFT BRAKE DID NOT WORK. TWO O-RINGS IN THE BRAKE ASSEMBLY WERE DISCOVERED TWISTED AND CUT WHICH CAUS ED A LARGE BRAKE FLUID LEAK. THE O-RINGS WERE REPLACED, THE SYSTEM WAS BLED AND TESTED. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2005030800030 20050308 00030 SO 2005 3 8 CA040528008 2 20040511 G 7314 6462125 PUMP CESSNA 310 310R 2074245 CE CONT O520 IO520M 17032 SO MCAULY 3AF32C 3AF32C87 GL ENGINE FUEL LEAKING W O OTHER K J FLUID LOSS WARNING INDICATION NR NOT REPORTED 1 CA 12698770C DURING AIRCRAFT 100 HOURS INSPECTION, THE TECHNICIAN DISCOVERED A BLUE COLORED TRACE OF FUEL ORIGINATING FROM THE FUEL P UMP LOW-METERED ADJUSTMENT SCREW. PRESSURIZED THE FUEL SYSTEM AND NOTICED MORE FUEL LEAKING FROM THE ADJUSTMENT SCREW O F THE FUEL PUMP. THE TECHNICIAN REPLACED THE FUEL PUMP MECHANISM AND RE-PRESSURIZED THE FUEL SYSTEM, NO LEAKS FOUND. 1 L 7 2 3O 3 O 3A10 E5CE 5 C P22EA 2005030800031 20050308 00031 CE 2005 3 8 CA040528009 1 20040525 G 2910 10404900 FITTING BEECH 100 100BEECH 1152916 CE PWA PT6 PT6A28 EA HYD SYSTEM CRACKED W D RETURN TO BLOCK K FLUID LOSS TX TAXI/GRND HDL 1 CA AIRCRAFT HAD NO BRAKES AFTER LANDING ON A GRAVEL AIR STRIP. HYDRAULIC FLUID WAS SEEN LEAKING OUT OF THE BRAKE ASSY. EN GINEER WAS FLOWN OUT AND FOUND THE HYDRAULIC FITTING HAD BEEN HIT WITH A ROCK AND WAS BENT AND CRACKED. FITTING WAS REP LACED AND BRAKE SERVICED. 1 L 7 2 3T 4 T A14CE E4EA 2005030800032 20050308 00032 NM 2005 3 8 CA040531001 1 20040528 G 2782 ACTUATOR BOEING 727 727225 1384077 NM PWA JT8 JT8D15A 52051 NE LT SLATS DAMAGED W O OTHER F FLT CONT AFFECTED NR NOT REPORTED 1 CA DURING A SCHEDULED ROUTINE MAINTENANCE CHECK IT WAS OBSERVED THAT THE LEFT HAND OUTBOARD SLAT ACTUATOR WAS DAMAGED. THE CORNER OF THE SLAT WAS GROUNDED OFF EXPOSING A SECONDARY STRUCTURAL EXTRUSION. THE AIRCRAFT WAS GROUNDED A SUSPECTED A WING TIP STRIKE ON LANDING. TSB WAS NOTIFIED AND WITH COMPANY QUALITY ASSURANCE AN INVESTIGATION IS IN PROGRESS. 2 L 7 3 4F 4 F A3WE E2EA 2005030800033 20050308 00033 EU 2005 3 8 CA040531002 1 20040529 G 7722 WIRE HARNESS BRAERO 748 HS7482B 1500248 EU RROYCE DART DART5342 EU ROTOL R4304 R2124304 EU NR 1 ENG TGT CHAFED W A UNSCHED LANDING N FALSE WARNING CL CLIMB 1 CA AFTER DEPARTING, THE CREW OBSERVED ABNORMALLY LOW TGT VALUE ON NR 1 ENGINE. THE AIRCRAFT RETURNED TO POINT OF DEPARTURE . MAINTENANCE FOUND CHAFED WIRING AT THE TGT JUNCTION BOX, THE EXTERNAL CALIBRATION TEST CONNECTOR ASSY WAS REMOVED AND THE AIRCRAFT RETURNED TO SERVICE AFTER OVERWEIGHT LANDING INSPECTION. 2 L 7 2 3T 4 T A24EU A196 6 C P899 2005030800034 20050308 00034 NE 2005 3 8 CA040531003 2 20040527 G 7230 3400010260 FAN BLADE BOEING 737 7377CG 13844FA NM CFMINT CFM567 CFM567B22 13802 NE ENGINE BIRD INGESTION W C ABORTED TAKEOFF C E F.O.D. VIBRATION/BUFFET TO TAKEOFF 1 CA 890811 AIRCRAFT STRUCK ONE, POSSIBLY TWO SEAGULLS ON TAKEOFF, IMMEDIATE VIBRATION FELT. TAKEOFF ABANDONED AND AIRCRAFT RETURNE D TO GATE. MAINTENANCE CONDUCTED 'BIRD STRIKE INSPECTION' PER MM 05-51-18, DAMAGES FOUND AT NR 1 ENGINE FAN BLADES NR 1 1, 12, 13. FURTHER INSPECTION REVEALED BLADES 11 AND 12 DAMAGED BEYOND LIMITS, BLADES 11 AND 12 REPLACED IAW MM72-21-02, MATCHING BLADES ALSO REPLACED (23 AND 24). BLADES PLATFORMS BETWEEN FAN BLADE 11 AND 12, AND 12 AND 13 REPLACED IAW MM 72-21-02. BORESCOPE OF NR 1 ENGINE COMPLETED, NO FAULTS FOUND. ENGINE RUNS COMPLETED, SYSTEM CHECKS SERVICEABLE. AIR CRAFT RETURNED TO SERVICE WITH NO FURTHER INCIDENTS TO REPORT. 2 L 7 2 4F 4 F RT A16WE E00055EN 2005030800035 20050308 00035 NM 2005 3 8 CA040531004 1 20040526 G 3260 864202 DOWNLOCK SENSOR DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE MLG DAMAGED W O OTHER N FALSE WARNING AP APPROACH 1 CA 41196 41196 DURING APPROACH WHEN LANDING GEAR SELECTED DOWN , LEFT MAIN GEAR UNSAFE INDICATION. ALTERNATE GEAR INDICATION CONFIRMED AS THREE GREEN, ALTERNATE EXTENSION PROCEDURE USED. AIRCRAFT LANDED NORMALLY. MAINTENANCE INSPECTION FOUND LT MAIN G EAR SIDESTAY SENSOR DAMAGED. SENSOR REPLACED. GEAR SWINGS CARRIED OUT. AIRCRAFT RETURNED TO SERVICE. (PART IS CONSIDER ED AN EXPENDABLE AND TIMES ON PART ARE NOT TRACKED. TIMES PROVIDED ARE AIRCRAFT TOTAL TIMES.) 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005030800037 20050308 00037 NE 2005 3 8 CA040531006 2 20040515 G 7200 ENGINE CNDAIR CL604 CL604 1900301 EA GE CF34 CF343B1 NE RIGHT BIRD INGESTION W O OTHER C F.O.D. CL CLIMB 1 CA SHORTLY AFTER TAKEOFF A BIRD STRIKE OCCURRED ON THE RIGHT ENGINE. CREW CONTINUED CLIMB-OUT AND REDUCED POWER TO IDLE. F LIGHT CONTINUED AND MADE AN UNEVENTFUL LANDING. POST FLIGHT INSPECTION REVEALED SEVERAL FAN BLADES DAMAGED BEYOND LIMI TS AND DAMAGE TO THE ABRAIDABLE MATERIAL OF THE FAN STATOR CASING. THE AFFECTED ENGINE WAS REPLACED WITH LOANER AND SEN T FOR REPAIR TO LOCAL SERVICE CENTER. NO INFORMATION ON EXTENT OF REPAIRS AVAILABLE. 2 L 7 2 4F 4 F RT A21EA E15NE 2005030800038 20050308 00038 NE 2005 3 8 CA040531007 2 20040515 G 7200 ENGINE CNDAIR CL604 CL604 1900301 EA GE CF34 CF343B1 NE RIGHT BIRD INGESTION W O OTHER C F.O.D. CL CLIMB 1 CA SHORTLY AFTER TAKEOFF, A BIRD STRIKE OCCURRED ON THE RIGHT ENGINE. CREW CONTINUED CLIMB-OUT AND REDUCED POWER TO IDLE. FLIGHT CONTINUED TO AND MADE AN UNEVENTFUL LANDING. POST FLIGHT INSPECTION REVEALED SEVERAL FAN BLADES DAMAGED BEYOND LIMIT AND DAMAGE TO THE ABRAIDABLE MATERIAL OF THE FAN STATOR CASING. THE AFFECTED ENGINE WAS REPLACED WITH LOANER AND SENT FOR REPAIR TO LOCAL SERVICE CENTER’S INFORMATION ON EXTENT OF REPAIRS AVAILABLE. 2 L 7 2 4F 4 F RT A21EA E15NE 2005030800039 20050308 00039 SW 2005 3 8 CA040601001 1 20040528 G 6720 407001732117 BELLCRANK BELL 407 407 1182206 SW TAIL ROTOR DAMAGED W O OTHER O OTHER NR NOT REPORTED 1 CA BELLCRANK FOUND WITH HOLES (.2495 - .2505 DIA.) OVERSIZE AND OVAL RANGING FROM .253 TO .275. (3 PLACES). 1 G 7 1 3U O H2SW 2005030800040 20050308 00040 SW 2005 3 8 CA040601002 1 20040527 G 6720 407001732125 BELLCRANK BELL 427 427 1182207 SW TAIL ROTOR DAMAGED W O OTHER O OTHER NR NOT REPORTED 1 CA BELLCRANK FOUND WITH HOLES (.2495 - .2505 DIA.) OVERSIZE AND OVAL RANGING FROM .253 TO .275. (2 PLACES). 1 G 7 1 3U R00001RC 2005030800041 20050308 00041 2005 3 8 CA040601003 4 20040530 G 3418 COMPUTER DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE STALL WARNING MALFUNCTIONED W A UNSCHED LANDING N FALSE WARNING CR CRUISE 1 CA DURING FLIGHT FROM YUL TO CYO, ACFT DIVERTED TO FLL DUE TO NR 2 STALL INDICATION FAIL ILLUMINATED. FOLLOWING TROUBLE SH OOTING, MX FOUND NO SIGNAL BETWEEN HORIZONTAL STAB POSITION SENSOR NR 2 AND STALL WARNING COMPUTER NR 2 CONNECTOR CLEANE D ON STAB SENSOR AND STALL WARNING COMPUTER. AIRCRAFT DISPATCHED SERVICEABLE. 2 L 7 2 4F 4 F RT A6WE E9NE 2005030800042 20050308 00042 EA 2005 3 8 CA040601004 2 20040520 G 8520 GEAR LYC PIPER PA23 PA23250 7102308 SO LYC O540 TIO540C1A 41532 EA CRANKSHAFT BROKEN W B A EMER. DESCENT UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 CA L363861A RIGHT ENGINE STOP DURING FLIGHT. FOUND SPRING PIN OF CRANKSHAFT GEAR BROKEN. WHEN THE CRANKSHAFT WAS REMOVED, THE CHAN KSHAFT BOLT SHEARED AND BROKE EASILY. THIS BOLT IS SUBJECT TO AD 2002-23-06AND AD 2004-04-25C. THE NEW BOLT KIT WAS REP LACED (MARCH 18, 2003 - REFER TO PURCHASE ORDER 11618) 343.4 HOURS BEFORE THE ENGINE STOP INCIDENT. THE NEW BOLT KIT P# N 05K19987 WERE SUPPLIED BY AVIALLON PURCHASE ORDER 11600 (01/22/2003) 1 L 7 2 3O 3 O 1A10 E14EA 2005030800043 20050308 00043 WP 2005 3 8 CA040601005 1 20040530 G 2741 ACTUATOR DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE STAB TRIM FAILED W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA 1919 DURING CRUISE FROM YYZ, THE PRIMARY STAB TRIM CB POPPED OUT. AIRCRAFT LANDED BACK TO YYZ. MAINTENANCE FOUND THE PRIMA RY TRIM ACTUATOR IN FAULT. ACTUATOR WAS REPLACED AND AIRCRAFT DISPATCHED SERVICEABLE. 2 L 7 2 4F 4 F RT A6WE E9NE 2005030800044 20050308 00044 NM 2005 3 8 CA040601006 1 20040531 G 3297 WIRE DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE INHIBIT SWITCH LOOSE W O OTHER O OTHER AP APPROACH 1 CA 38595 ON APPROACH , WHEN CREW SELECTED GEAR DOWN AND GOT 3 RED GEAR LIGHTS. REVERTED TO ALTERNATE GEAR EXTENSION AND GOT 3 GR EEN LIGHTS. MAINTENANCE FOUND LOOSE WIRING CONNECTION TO THE GEAR INHIBIT SWITCH. PROBABLY WORKED ITSELF LOOSE OVER TI ME WITH VIBRATION. SWITCH REPLACED AND WIRING SECURED. GEAR SWINGS CARRIED OUT AND SYSTEM FOUND SERVICEABLE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005030800045 20050308 00045 WP 2005 3 8 CA040601007 1 20040530 G 4900 696233B CSD DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE APU FAILED W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA DURING CRUISE FROM VRA TO YYZ, RT CSD OUTLET TEMPERATURE INCREASED. CSD HAS BEEN DISCONNECTED. FEW TIME LATER, APU OIL TEMP WHEN HIGH AND APU HAS BEEN SHUT DOWN. AIRCRAFT LANDED AT YYZ AS SCHEDULED. MAINTENANCE IN YYZ DID DEFER THE RT C SD AS PER MEL 24-1. APU OIL RESERVICED AND TESTED/CHECKED SERVICEABLE. AIRCRAFT DISPATCHED SERVICEABLE WITH RT CSD UND ER MEL. DURING CLIMB AFTER DEPARTURE FROM YYZ, APU OIL TEMP WHEN HIGH. AIRCRAFT LANDED BACK TO YYZ. RT CSD WAS REPLAC ED AND APU RECTIFICATION DEFERRED AS PER MEL 49-1. AIRCRAFT DISPATCHED AS PER MEL 49-1. TEMPERATURE BULB SENSOR REPLAC ED AS PRECAUTIONARY MEASURE. 2 L 7 2 4F 4 F RT A6WE E9NE 2005030800046 20050308 00046 CE 2005 3 8 CA040601008 1 20040328 G 1430 AN17642 BOLT CESSNA 441 441 2076020 CE GARRTT TPE331 TPE33110 01514 WP NLG BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA GROUND HANDLING PERSONAL ATTEMPTED TO TOW THE AIRCRAFT INTO THE HANGAR FOR A MAINTENANCE FUNCTION. THE TOW BAR BECAME D ETATCHED FOLLOWING HOOK UP. THERE WAS NO DAMAGE TO THE AIRCRAFT OTHER THAN THE BROKEN LOWER TORQUE LINK BOLT ON THE NOS E GEAR. 1 L 7 2 3T 4 T RT A28CE E4WE 2005030800047 20050308 00047 WP 2005 3 8 CA040601009 1 20040527 G 6210 369D21100523 BLADE HUGHES 369 369D 4470706 WP MAIN ROTOR UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 CA UPON INSPECTION, A LINE WAS NOTICED EXTENDING CHORDWISE FROM THE LOWER ROOT FITTING. AFTER REMOVING THE PAINT, THE DOUL BER HAD ABOUT A 2.5 INCH CRACK THAT EXTENDED BOTH FOR AND AFT OF THE LOWER ROOT FITTING OF THE M/R BLADE. THE BLADE WAS REMOVED FORM SERVICE AND DISASSEMBLED. THE CRACK HAD GONE THRU THE MAIN SKIN OF THE BLADE AND THE DOUBLER. THE CRACK DID NOT GO THRU THE SPAR OF THE BLADE. 1 G 7 1 3U H3WE 2005030800048 20050308 00048 EU 2005 3 8 CA040601010 1 20040531 G 2932 9738114304 PRESSURE SWITCH PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL HYD SYSTEM LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA HYD PRESSURE SWITCH WAS FOUND TO HAVE A SLIGHT SEEPAGE OF HYDRAULIC FLUID AT THE SWITCH BODY SEAM. SWITCH REPLACED WITH NEW, GROUND CHECKS SATISFACTORY. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005030800049 20050308 00049 2005 3 8 CA040601011 4 20040531 G 2211 ANNUNCIATOR PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL AUTOPILOT INOPERATIVE W K NONE L NO TEST IN INSP/MAINT 1 CA 'FD' ANNUNCIATOR LIGHT INOP. FLIGHT DIRECTOR COMMAND BARS FUNCTION OK. UNIT REPAIRED AT LOCAL AVIONICS FACILITY, REINS TALLED. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005030800050 20050308 00050 EU 2005 3 8 CA040601012 1 20040531 G 3030 HEATER PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL PITOT TUBE INOPERATIVE W O OTHER J WARNING INDICATION CR CRUISE 1 CA P-S 2 FAIL INDICATION. NR 2 PITOT HEAT FOUND INOP. PITOT TUBE ASSY REPLACED WITH NEW. AIRCRAFT TTAF 3710.72576 CYC. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005030800051 20050308 00051 2005 3 8 CA040601013 4 20040601 G 2562 MN1300 BATTERY ACK BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL ELT LEAKING W O OTHER H ELECT. POWER LOSS-50 PC NR NOT REPORTED 1 CA 039274 DURING ANNUAL PERFORMANCE TEST, IT WAS NOTICED THAT DURACELL MN1300 BATTERIES DATED MAR 2010 WERE LEAKING WHAT APPEARED TO BE BATTERY ACID. BATTERY VOLTAGE WAS LOW. ELT BATTERY CASE WAS CLEANED AND A FULL SET OF NEW BATTERIES WERE INSTALL ED. ELT WAS PERFORMANCE TESTED AS PER CAR 571 APPENDIX G AND FOUND TO BE OK. 1 G 7 1 3U 3 U H2SW E4CE 2004072900002 20040729 00002 EU 2004 7 29 CA040601014 1 20040530 G 7697 MS3476W1419S CONNECTOR BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE NR 4 ENGINE SHORTED W E ENGINE SHUTDOWN J WARNING INDICATION AP APPROACH 1 CA LF05649AC (CAN) UNCOMMANDED IN-FLIGHT SHUTDOWN OF NR 4 ENG. DURING FINAL APPROACH. CONNECTOR IDENT (P52) ON BACK-UP OVERSPEED CO NTROLLER FOUND TO BE SHORTED INTERNALLY. VOLTAGE LEAKING ACROSS VARIOUS PINS ON PLUG ALSO OUT TO OVERSPEED FUEL BYPASS/ SHUT-OFF VALVE. THIS IS WHAT ACTIVATED FUEL BYPASS VALVE, CAUSING ENG TO SHUTDOWN. REPLACING (P52) CONNECTOR (P/N MS34 76W14-19S) WILL ALSO REPLACE SECONDARY/BACK-UP CONTROLLER AS PRECAUTIONARY MEASURE (TO HAVE IT BENCH CHECKED TO ENSURE THERE WAS NO INTERNAL DAMAGE CAUSED BY STRAY VOLTAGE). ONCE SYS IS RE-ASSEMBLED, WILL CARRY OUT FURTHER CHECKS TESTING. GROUND RUNS, CARRIED OUT FUNCTIONING OVERSPEED ON PARTICULAR ENG WITH NO FAULTS AND SYS WAS GROUND CHECKED SERVICEABLE. 2 H 7 4 4F 4 F A49EU E6NE 2004072900003 20040729 00003 GL 2004 7 29 CA040602001 2 20040602 G 7250 BLADE ALLSN EMB 135 EMB135ER 3260203 SO ALLSN AE300 AE3007A GL TURBINE ROTOR FAILED W B A EMER. DESCENT UNSCHED LANDING Y J ENGINE STOPPAGE WARNING INDICATION CL CLIMB 1 CA 311526 (CAN) AC YAW AND LOUD BANG IN CLIMB AT 21,000 FT. ENGINE SHUTDOWN UNCOMMANDED. EMERGENCY DECLARED AND AC DIVERTED. ON GROUND INSP FOUND THAT N1 WOULD NOT ROTATE. DISASSEMBLY OF ENG AT RRC SHOWED SEVERE TURBINE DAMAGE. SULPHIDATION, PR OBABLY CAUSED THE DETERIORATION OF THE HPT 1 AND 2 NGVS. A SECTION OF THE HPT 2 NGV BROKE AND WENT INTO THE HPT 2BLADES WHICH CAUSED A BLADE FAILURE. ALL THE HPT 2 BLADES BROKE AT THE ROOT AND CAUSED THE FOD DAMAGE TO THE LPT MODULE. THI S SITUATION CAUSED THE IFSD. WHEN WE RECEIVED THE ENGINE, THE HPT MODULE WOU LD NOT TURN AND THE LPT MODULE WAS VERY DI FFICULT TO ROTATE. MFG IS EVALUATING IF THE ENGINE WILL BE REBUILT DUE TO THE EXTENSIVE TURBINE DAMAGE. 2 L 7 2 4F 4 F RT T00011AT TE6CH 2004072900004 20040729 00004 2004 7 29 CA040602002 4 20040602 G 8300 23056789 BEVEL GEAR EMB 145 EMB145XR 3260214 SO ALLSN AE300 AE3007A GL ACCESSORY G/B FAILED W B A EMER. DESCENT UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 CA 312274 (CAN) FLIGHT LOST POWER NOTICED SHORTLY AFTER TAKE OFF. NR 2 INDICATION WENT TO ZERO. THE CREW REPORTED THE NR 1 ENGINE SHUT DOWN IN FLIGHT. THE SHUT DOWN WAS UNCOMMANDED. THE AIRCRAFT RETURNED AND LANDED WITHOUT FURTHER INCIDENT. DISASSE MBLY OF THE ENGINE AT RRC REVEALED THAT NR 6 BEARING BEVEL DRIVING GEAR SYSTEM THAT DRIVE MODULE 05 ACCESSORY GEARBOX HA S FAILED. BEVEL GEAR HAS BROKEN IN PIECES. SUSPECT BEVEL DRIVE SHAFT DRIVING GEARBOX IS CAUSING THE FAILURE. SHAFT RE TURNED TO INDY FOR INVESTIGATION. 2 L 7 2 4F 4 F RT TE6CH 2004072900005 20040729 00005 2004 7 29 CA040602003 4 20040602 G 8300 23056789 SHAFT EMB 145 EMB145 3260210 SO ALLSN AE300 AE3007A GL BEVEL GEAR FAILED W A UNSCHED LANDING Y J ENGINE STOPPAGE WARNING INDICATION CL CLIMB 1 CA 13130 310066 (CAN) IN CLIMB AT 8000 FT A LOUD BANG WAS HEARD AND UNCOMMANDED ENGINE SHUTDOWN AND AIR RETURN AND UNEVENTFUL LANDING OC CURRED. DISASSEMBLY OF THE ENGINE AT RRC REVEALED THAT NR 6 BEARING BEVEL DRIVING GEAR SYSTEM THAT DRIVE MODULE 05 ACCE SSORY GEARBOX HAS FAILED. BEVEL GEAR HAS BROKEN IN PIECES AND HOLED THE FRONT FRAME, THE FRONT FRAME IS SCRAP. SUSPEC T BEVEL DRIVE SHAFT DRIVING GEARBOX IS CAUSING THE FAILURE. SHAFT RETURNED TO INDY FOR INVESTIGATION. 2ND CASE FOR RRC OF SAME OCCURANCE REFER TO SDR 20040602002. 2 L 7 2 4F 4 F RT T00011AT TE6CH 2004072900006 20040729 00006 EA 2004 7 29 CA040602004 1 20040602 G 2150 9795804 VALVE CNDAIR CL604 CL604 1900301 EA GE CF34 CF343B1 NE CABIN AIR GOUGED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) THE LOW LIMIT VALVE WAS OBSERVED TO STICK IN AN OPEN POSITION AND WOULD NOT MODULATE. AFTER REMOVAL OF THE VALVE T HE BUTTERFLY WAS FOUND TO BE SCRAPING AGAINST THE BODY OF THE VALVE.ANOTHER VALVE WITHTHIS CONDITION HAD PREVIOUSLY BEEN FOUND TO SHEAR THE BUTTERFLY SHAFT COMPLETLY. REF. SDR 2004051401. 2 L 7 2 4F 4 F RT A21EA E15NE 2004072900007 20040729 00007 EA 2004 7 29 CA040602005 1 20040602 G 4920 TURBINE CNDAIR CL604 CL604 1900301 EA GE CF34 CF343B1 NE APU SEIZED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) DURING INITIAL START AN UNUSUAL NOISE WAS HEARD FROM THE APU. THE UNIT WAS RUN FOR APPROXIMATELY ONE HOUR WITH NO ABNORMAL INDICATIONS. UPON FURTHER INVESTIGATION OF THE NOISE IT WAS DISCOVERED THAT IT WAS NOT POSSIBLE TO ROTATE THE T URBINE WHEEL BY HAND. A PARTIAL TURBINE SEIZURE WAS IDENTIFIED. THE APU WAS REMOVED AND SENT FOR REPAIR. 2 L 7 2 4F 4 F RT A21EA E15NE 2004072900038 20040729 00038 GL 2004 7 29 CA040602006 2 20040602 G 7530 MS955608 BOLT EMB 145 EMB145XR 3260214 SO ALLSN AE300 AE3007A GL MANIFOLD LOOSE W A UNSCHED LANDING Y J ENGINE STOPPAGE WARNING INDICATION CL CLIMB 1 CA 312265 (CAN) COMMANDED IFSD AND AIR RETURN. CREW REPORTED EMERGENCY WHEN ITT EXCEEDED 950C. UNEVENTFUL AIR RETURN. DISASSEMBLY OF ENGINE AT RRC SHOWED THAT OUTER MANIFOLD SERVICE ATTACHMENT BOLTS LOOSEN. BLEED AIR LEAKAGE CAUSED THERMAL DAMAGE TO THE SURROUNDING COMPOSITE STRUCTURE OF THE OUTER BYPASS DUCT. REDUCE COOLING AIR TO THE TURBINE HAS INCREASE THE ITT. S ERVICE BULLETIN 75-025 INTRODUCE A MODIFIED RETAINING BOLT WHICH INCLUDE A LOCKING WIRE HOLE TO PREVENT BOLT TO LOOSEN A ND SB 75-026 INTRODUCE A SAFETY WIRE. REAR BYPASS DUCT REPLACED AN SB INCORPORATED. BOTH SB ARE OPTIONAL CATEGORY. 2 L 7 2 4F 4 F RT TE6CH 2004072900039 20040729 00039 EU 2004 7 29 CA040602007 1 20040619 G 5610 NP1653114 WINDSHIELD AIRBUS 320 A320211 3930320 EU CFMINT CFM56 CFM565A1 NE COCKPIT FAILED W O OTHER O OTHER CR CRUISE 1 CA (CAN) WINDSHIELD OUTER PANE SHATTERED ONLY, AIR TURNBACK WINDSHIELD REPLACED WINDSHIELD HAD 21,599 HRS. 2 L 7 2 4F 4 F RT A28NM E29NE 2004072900040 20040729 00040 EA 2004 7 29 CA040602008 1 20040602 G 3222 200811218 FITTING CNDAIR CL600 CL600* EA LYC ALF502 ALF502* 41580 EA NLG AXLE CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA DRG10899R (CAN) 5 YEAR DETAILED INSPECTION REVEALED CORROSION PITTING BEYOND MANUFACTURER'S LIMITS, INTERNAL, BETWEEN NLG SLIDING TUBE (P/N 200811707)AND AXLE FITTING. NEW PART INSTALLED. THE AXLE FITTING WAS PREVIOUSLY REPLACED IN JUNE 1999 DURING THE 10 YEAR RESTORATION OF THE GEAR AT 2503 CSN. 2 L 7 2 4F 4 F RT A21EA E6NE 2004072900042 20040729 00042 NE 2004 7 29 CA040603001 2 20040601 G 7323 230305204 GOVERNOR BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE OVERSPEED FAILED W K NONE L NO TEST IN INSP/MAINT 1 CA 29131 17720 (CAN) DURING PILOT OPERATIONAL CHECK, NR 4 ENGINE DID NOT SHUT DOWN WITH THE OVERSPEED STOP. NR 4 ENGINE OVERSPEED CONT ROLLER REPLACED AND NR 4 ENGINE OVERSPEED TEST CARRIED OUT IAW AMM 71-00-00 BLOCK 501. TEST COMPLETED AS SERVICEABLE AN D AIRCRAFT WAS RETURNED TO SERVICE. 2 H 7 4 4F 4 F A49EU E6NE 2004072900043 20040729 00043 EU 2004 7 29 CA040603002 1 20040602 G 7120 332A32323300 BOLT SNIAS AS332 AS332L 8680809 EU TMECA MAKILA MAKILA1A 60040 EU ENGINE MOUNT FRACTURED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AFTER LAST FLIGHT, DAILY INSPECTION WAS BEING CARRIED OUT ON THE AIRCRAFT, WHEN THE NR 1 ENG LT UPPER TIE BOLT WA S FOUND TO BE FRACTURED. THE OTHER TWO TIE BOLTS WERE REMOVED AND INSPECTED AND FOUND TO BE SERVICEABLE. THIS TIE BOLT ATTACHES THE ENGINE TO THE G/B P/N 332A32-1007-03P. 2 G 7 2 4U 4 U H4EU E12NE 2004080400208 20040804 00208 NE 2004 8 4 CA040603003 2 20040520 G 7320 586982 DUMP VALVE SKRSKY S64 S64E 8142604 NE PWA JFTD12 JFTD12A4A 52047 NE ENGINE FUEL MALFUNCTIONED W E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION DE DESCENT 1 CA 1638341 (CAN) PILOT BEGAN DESCENT, HEARD (WHOOSH) SOUND TYPICAL OF SOFT STALLING ENG. FOLLOWED BY N1 UNDERSPEED AUDIO, INDICATO R LIGHT WARNING. FLT CREW VERIFIED NR 1 ENG AS BEING AT FAULT. COPILOT SHUTDOWN ENG, BEGAN TO MOTOR TO DECREASE T5 TEMP WHILE PILOT RELEASED LOAD. WITH T5 TEMP STABILIZED ENG WAS SECURED, AC RETURNED TO ITS SERVICE LANDING, MADE AN UNEVENTF UL SINGLE ENG LANDING. COMPLETE VISUAL INSP OF ENG WAS CARRIED OUT BY MAINT CREW WHICH REVEALED NOTHING ABNORMAL. FUEL P RESS AND DUMP (P&D) VALVE, ENG FUEL FILTER WERE REPLACED AS IS MAINT PROCEDURE AFTER AN ENG SOFT STALL. LIMITS HAVE NOT BEEN EXCEEDED. ENG FCU WAS ALSO REPLACED. FOLLOWING ENG GROUND RUN AND TEST, AC WAS RETURNED TO SERVICE. 2 G 7 2 4U 4 U H4EA E15EA 2004072900044 20040729 00044 2004 7 29 CA040603004 4 20040603 G 2210 40E228410693 AILERON CNDAIR CL601 CL6012A12 1900303 EA GE CF34 CF341A NE AUTO PILOT MISMANUFACTURED W K NONE L NO TEST IN INSP/MAINT 1 CA (CAN) WHILE INVESTIGATING A SNAG, DISCOVERED AN AILERON A/P QUADRANT ASSEMBLY P/N 40E22-84-1069-1 WHICH DID NOT MEET TH E MANUFACTURER'S DRAWING IN THE INSTALLATION OF THE NR 1 COLLINS A/P SERVO, LOCATED IN THE LT MLG WHEEL WELL. FOR THE D ISABLING OF THE NR1 A/P SYSTEM, PENDING THE MANUFACTURING OF A NEW QUADRANT BY A PRECISION MACHINE SHOP. 2 L 7 2 4F 4 F RT A21AE E15NE 2004072900077 20040729 00077 NE 2004 7 29 CA040603005 2 20040602 G 7397 EO266QF16 WIRE AIRBUS 310 A310304 3930339 EU GE CF6 CF680C2A5 NE FUEL PUMP CHAFED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AIRCRAFT ARRIVED WITH THE RT OUTER TANK FUEL PUMP NR 1 LOW PRESSURE LIGHT ON. FOLLOWING TROUBLE SHOOTING, THE WIR E FOR NR 1 RT OUTER PUMP WAS FOUND SHORTED IN THE CONDUIT AT REAR SPAR WS 915.0. WIRE WAS REPLACED. MFG WAS ADVISED OF THIS PROBLEM. A CAMPAIGN HAS BEEN INITIATED TO INSPECT REAR SPAR WIRING ON ALL OF THESE MODELS. 2 L 7 2 4F 4 F RT A35EU E13NE 2004072900078 20040729 00078 NM 2004 7 29 CA040603006 1 20040603 G 3242 260881211 BRAKE BOEING 767 7673Y0 NM PWA 4060 PW4060 52119 NE MLG DISINTEGRATED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) NR 5 AFT BRAKE DISINTEGRATED ON T/O. NR 5 BRAKE ASSY REPLACED IAW J/C 6-232A, NR 5 WHEEL ASSY REPLACED IAW J/C 6-232B. 2 L 7 2 4F 4 F RT A1NM E24NE 2004072900079 20040729 00079 GL 2004 7 29 CA040603007 2 20040602 G 7250 TURBINE BELL 206 206L 1181522 SW ALLSN 250C 250C20R2 GL ENGINE LOCKED W K NONE O OTHER IN INSP/MAINT 1 CA CAE834565 (CAN) TURBINE HAD AN N2 LOCK UP. SUSPECT UNKNOWN AT THIS TIME. TURBINE SENT TO OVERHAUL SHOP FOR ASSESSMENT. 1 G 7 1 3U 3 U H2SW E4CE 2004072900080 20040729 00080 WP 2004 7 29 CA040604001 1 20040601 G 7160 INLET GUIDE VANE DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE NR 2 ENGINE OUT OF LIMITS W K NONE O OTHER IN INSP/MAINT 1 CA P728047 (CAN) CRACK FOUND ON ONE ENGINE INLET GUIDE VANE APROX 3.5 IN LONG (OUT OF LIMITS IAW MM 72-00-00). AIRCRAFT WAS FERRIE D, IAW FLIGHT PERMIT AUTHORIZATION AND THE MANUFACTURER APPROVAL, ENGINE NR 2 HAS BEEN REPLACED. 2 L 7 2 4F 4 F RT A6WE E9NE 2004080400212 20040804 00212 EA 2004 8 4 CA040604002 2 20040519 G 8520 75089LW11775 PISTON PIPER PA44 PA44180 7104402 SO LYC O360 O360A1H 41514 EA HARTZL HCC2Y HCC2YR2 GL ENGINE BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING NR 1 INSP, A SIG AMOUNT OF NON-FERROUS METAL WAS FOUND IN OIL FILTER ELEMENT. OIL SUCTION SCREEN WAS PULLE D AND WAS FOUND TO BE FULL OF NON-FERROUS METAL. CYL NR 1 WAS PULLED AND FWD PISTON PIN PLUG WAS FOUND TO BE WORN COMPL ETELY ALLOWING PISTON PIN TO MIGRATE FWD TO POINT AFT PISTON PIN PLUG WAS ONLY PART LEFT IN AFT PISTON BOSS BETWEEN CONN ECT ROD AND PISTON. AFT PISTON BOSS HAD 1 INCH PIECE BROKEN OUT OF IT. NR 3 CYL WAS REMOVED, WAS FOUND THAT FORWARD P ISTON PIN PLUG WAS STARTING TO WEAR ABOUT .0625 OF AN INCH. HEAT AND TIME, ALUMINUM PLUG WORE AGAINST STEEL CYLINDER AN D ONCE WEAR STARTED, IT WORE RAPIDLY. NO IND OF OIL PRESS OR POWER LOSS ON PREVIOUS FLIGHT OR DURING RUN UP FOR INSP. 1 L 7 2 3O 3 O A19S0 E286 5 C P920 2004072900081 20040729 00081 2004 7 29 CA040604003 4 20040603 G 8300 3022376 SEAL PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL EPA CAN DAMAGED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) AIRCRAFT HAD JUST LANDED AND SHUT DOWN AT IT'S DESTINATION AIRPORT. THE PILOT DISEMBARKED THE AIRCRAFT AND NOTICED A LARGE STREAK OF OIL DOWN THE LT SIDE OF THE FUSELAGE. MAINTENANCE INVESTIGATED THE INCIDENT AND FOUND ANOTHER LARGE O IL STREAK DOWN THE BELLY OF THE AIRCRAFT. IN ADDITION TO THE TWO OIL STREAKS THE EPA CAN WAS COMPLETELY FULL. THE START ER-GENERATOR WAS REMOVED, AND MAINTENANCE FOUND THE OIL SEAL WAS SLIGHTLY DAMAGED. A NEW SEAL WAS INSTALLED AND THE AIR CRAFT GROUND RUN WITH NO FURTHER DEFECTS NOTED. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004072900082 20040729 00082 SW 2004 7 29 CA040604004 1 20040602 G 2435 PW203PPC7FS500 BEARING LUCAS BELL 407 407 1182206 SW ALLSN 250C 250C47B GL STARTER GEN ROUGH W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 98278 (CAN) STARTER-GEN, UNDERGOING IMPORT INSPECTION. BEARINGS WERE FOUND TO BE ROUGH AND NOISY WHEN SPUN. REMOVED BEARINGS , FOUND THEM TO BE SUP. ARE MARKED PW203PP C7 FS50000. IAW DATAPLATE, THEY SHOULD BE P/N 03-6009-23 (MOD B). THE SOUR CE OF THE LAST OVERHAUL IN MAY 2002 IS KNOWN. 1 G 7 1 3U 3 U O H2SW E1GL 2004080400217 20040804 00217 CE 2004 8 4 CA040604006 1 20040526 G 5554 05310186 HINGE BRACKET CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160DTM GL RUDDER CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 18000 (CAN) DURING ROUTINE INSPECTION OF RUDDER THE BRACKET IN QUESTION WAS FOUND TO HAVE TWO CRACKS BESIDE THE THRUST SURFACE . DUE TO THE HIGH HOURS OF THIS ASSEMBLY THE THRUST SURFACE WAS FOUND TO HAVE WORN TO HALF OF ITS ORIGINAL THICKNESS. REPAIR TO THE RUDDER ASSEMBLY WAS ACCOMPLISHED BY REPLACEMENT OF ALL SIX HINGE BRACKETS. SUBSEQUENT INSPECTIION OF SIMI LAR AIRCRAFT WITH SIMILAR TIME WERE FOUND TO HAVE SAME WEAR PATTERN BUT NO CRACKS PRESENT. FIVE MORE ASSEMBLIES HAD HIN GE BRACKET REPLACEMENT DUE TO EXCESSIVE WEAR. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2004080400218 20040804 00218 NE 2004 8 4 CA040604007 2 20040524 G 7200 430110209 MODULATOR SNIAS 350 AS350D 8680803 EU LYC LTS101 LTS101600A2 41560 NE AIRFLOW FAILED W A UNSCHED LANDING D INFLIGHT SEPARATION AP APPROACH 1 CA (CAN) PILOT HEARD AND FELT LOUD POPPING NOISE FROM ENGINE ACCOMPANIED WITH LOSS OF POWER. AIRCRAFT LANDED SUCCESSFULLY. FLOW FENCE PROBLEM SUSPECTED. AIRFLOW MODULATOR REPLACED, AIRCRAFT TEST FLOWN OK. 1 G 7 1 3U 3 U H9EU E5NE 2004080400219 20040804 00219 CE 2004 8 4 CA040604008 1 20040525 G 5344 DOOR FRAME CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160CTM GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) INSPECTION LOWER DOOR POST IAW SB 97-1 AND FOUND CRACK AT CORNER IAW SB. BOTH RT AND LT DOOR POSTS. REPAIRED WITH MFG REPAIR KIT. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2004080500001 20040805 00001 CE 2004 8 5 CA040604009 1 20040602 G 7500 ADAPTER BEECH 100 A100 1152915 CE PWA PT6 PT6A28 EA HARTZL HCB4T HCB4TN3 GL P2.5 BLEED SYS CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING A ROUTINE HOT SECTION INSPECTION MAINTENANCE FOUND THE P2.5 BLEED ADAPTER (LOCATED AT APPROXIMATELY 1 O'CLO CK ON THE GAS GENERATOR CASE) WITH OBVIOUS CRACKS. THE RETAINING LUGS WERE BOTH CRACKED AND ONE OF THE ADAPTER WELDING JOINTS WAS CRACKED ON A LENGTH OF APPROXIMATELY 1.5 INCHES. THE ENGINE WAS SENT OUT FOR REPAIR AND HAS SINCE BEEN REINST ALLED AND PUT BACK INTO SERVICE. 1 L 7 2 3T 4 T A14CE E4EA 6 C P40EA 2004080500002 20040805 00002 CE 2004 8 5 CA040604010 1 20040527 G 3710 SHAFT AIRBORNE CESSNA 402 402C 207590R CE CONT O520 TSIO520VB 17040 SO MCAULY 3AF32C 3AF32C* GL VACUUM PUMP SHEARED W O OTHER O OTHER TX TAXI/GRND HDL 1 CA 1AE48 (CAN) VACUUM PUMP SHEAR SHAFT BROKE ON START. 1 L 7 2 3O 3 O A7CE E8CE 5 C P22EA 2004080500003 20040805 00003 CE 2004 8 5 CA040604011 1 20040527 G 3710 SHAFT AIRBORNE CESSNA 402 402C 207590R CE CONT O520 TSIO520VB 17040 SO MCAULY 3AF32C 3AF32C* GL VACUUM PUMP BROKEN W O OTHER O OTHER TX TAXI/GRND HDL 1 CA 104361 (CAN) VACUUM PUMP SHEAR SHAFT, BROKE AFTER INSTALLED. REPLACED PUMP BY OTHER SOURCE. 1 L 7 2 3O 3 O A7CE E8CE 5 C P22EA 2004080500025 20040805 00025 WP 2004 8 5 CA040604013 2 20040529 G 7210 31025613 PLANETARY GEAR SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP MCAULY 4HFR34 4HFR34C652 NE GEARBOX FLAKING W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA P44205C (CAN) INSTALLED PLANETARY GEAR BRG INTO ENG, DURING ROUTINE ENG CAM INSP. 16.4 HOURS LATER, ACCOMPLISHED 1ST SOAP SAMPLE IAW MFG EMM. MAJOR SILVER PARTICLES FOUND IN OIL, MFG RECOMMENDED RESAMPLE. BOTH AGAIN HAD SILVER PARTICLES IN OIL. MFG RECOMMENDED TO INSPECT THIS ENG IMMEDIATELY, ENG WAS REMOVED AND REPLACED, ENG TEARDOWN INSP IN ORDER TO DETERMINE CAUS E FOR METAL IN OIL, DUE TO MAJOR SILVER. ENG HAD 101.7 HRS SINCE CAM AND 129 CYC WHEN IT WAS REMOVED. DURING INSP IT WAS FOUND THAT TWO PLANETARY GEARS O/H HAD LARGE AMOUNTS OF SILVER MISSING, FLAKING OFF BRG CAGE SURFACES. OTHER TWO PLANET ARY GEAR BRGS INSTALLED HAD MINOR AMOUNT OF SILVER WORN OFF WHICH WAS SMALL IN COMPARISON ABOVE MENTIONED BEARINGS. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C 3PNE 2004080500027 20040805 00027 NM 2004 8 5 CA040604014 2 20040603 G 7321 8953804 VALVE GULSTM 690TP 690 0141720 SW GARRTT TPE331 TPE3315251K NM HARTZL HCB3T HCB3TN5 GL HP LIMITER FLUCTUATES W E ENGINE SHUTDOWN J WARNING INDICATION CL CLIMB 1 CA P06034 (CAN) DURING CLIMB OUT THROUGH 5000 FEET, ENGINE POWER BEGAN TO FLUCTUATE. ENGINE WAS SHUTDOWN AND SECURED. AIRCRAFT LA NDED WITHOUT INCIDENT. INVESTIGATION FOUND THAT THE HORSE POWER LIMITER BYPASS VALVE WAS LEAKING INTERNALLY. BYPASS VAL VE WAS REPLACED. 1 H 7 2 3T 4 T 2A4 E2WE 6 C P15EA 2004080500028 20040805 00028 SW 2004 8 5 CA040604015 1 20040604 G 6720 206010795105 PIN BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL T/R PITCH DISLODGED W B EMER. DESCENT F FLT CONT AFFECTED CR CRUISE 1 CA (CAN) PIN P/N 100-035-187.5-30.5 WAS INSTALLED CORRECTLY. HOWEVER AN ADDITIONAL PIN WAS FOUND FLOATING INSIDE THE SHAFT. THE LAST MAINTENANCE PERFORMED IN THAT AREA WAS 27 JUNE 2003. APPROX 666.1 HOURS. PIN WAS REMOVED AND THE REST OF TH E ASSEMBLY WAS INSPECTED FOR DAMAGE. AIRCRAFT RETURNED TO SERVICE AFTER ACCEPTABLE TEST FLIGHT. 1 G 7 1 3U 3 U H2SW E4CE 2004080500029 20040805 00029 EA 2004 8 5 CA040604016 1 20040511 G 3244 H29X901516 TIRE CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE MLG SEPARATED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) THE NR 2 MLG TIRE HAD SEPARATED THAT INCURRED DAMAGE TO THE IB FLAP SURFACE, FLAP STUB FAIRING AND 3 FAN BLADES.. 2 L 7 2 4F 4 F RT A21EA E15NE 2004080500030 20040805 00030 CE 2004 8 5 CA040607001 1 20040604 G 3260 20700291 WIRE CESSNA 177 177RG 2073709 CE LYC O360 IO360A1B6 41514 EA MCAULY 2D34C B2D34C207 GL NLG DOWNLOCK SW BROKEN W O OTHER N FALSE WARNING AP APPROACH 1 CA (CAN) PILOT EXPERIENCED NO GEAR DOWN AND LOCK INDICATION LIGHT AFTER GEAR HAD COMPLETED CYCLE. AFTER AN UN-EVENTFUL LAN DING AND INSPECTION, FOUND NOSE GEAR DOWNLOCK SWITCH WIRE WAS BROKEN AT BASE OF SWITCH. 1 H 7 1 3O 3 O A20CE 1E10 5 C P7EA 2004080500031 20040805 00031 NE 2004 8 5 CA040607002 2 20040604 G 8530 NUT DOUG B26 B26C 3200524 WP PWA R2800 CA18 52026 NE HAMSTD 23E 23E50 NE PUSHROD TUBE LOOSE W E ENGINE SHUTDOWN K FLUID LOSS CR CRUISE 1 CA (CAN) PILOT NOTICED OIL LEAK AND DID A PRECAUTIONARY ENGINE SHUT DOWN. HE DID A ONE ENGINE OUT LANDING PROCEDURE AT AIRP ORT WITHOUT INCIDENT. MAINTENANCE FOUND NR 17 CYLINDER PUSHROD TUBE NUT LOOSE. THE SEAL WAS REPLACED AND THE NUT TORQU ED. THE ENGINE WAS GROUND RUN WITH NO EVIDENCE OF AN OIL LEAK. 2 M 7 2 4R 4 R L34 E231 6 C P603 2004080500032 20040805 00032 CE 2004 8 5 CA040607003 1 20040302 G 3230 LANDING GEAR BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA MCAULY 4HFR34 4HFR34C652 NE MALFUNCTIONED W O OTHER J WARNING INDICATION CL CLIMB 1 CA (CAN) DURING FLIGHT, THE LANDING GEAR TOOK LONGER THAN NORMAL TO RETRACT. COULD NOT DUPLICATE THE PROBLEM IN THE HANGAR EVEN WHEN SWINGING THE GEAR. 1 L 7 2 4T 4 T A24CE E4EA 6 C 3PNE 2006061200430 20060612 00430 EU 2006 6 12 CA040608001 1 20040606 G 2434 5243212161 DRIVE SHAFT PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL NR 2 GENERATOR SHEARED W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA 4797 ON RETURN, PILOT NOTED GEN 2 FAILURE IN CRUISE AND CONT`D ON TO COMPLETE FLT. NR 1 GEN AUTO COVERS FOR NR 2 GEN WHEN A FAILURE OCCURS. INVESTIGATION BY MX REVEALED SHEARED DRIVE SHAFT FOR NR 2 GEN. SHAFT BROKE AT PROPER SHEAR POSITION WI TH NO DAMAGE TO ANY OTHER COMPONENT. CAUSE IS UNCLEAR, BUT THERE IS SOME SCORING ON DRIVESHAFT AT FWD BEARING INNER RAC E POSITION. BEARING APPEARS IN GOOD COND W/NO BINDING OR ROUGH SPOTS. GEN 2 ALSO APPEARS IN GOOD MECH CONDITION W/NO B EARING DISTRESS OR DRAG ON ALT SHAFT. IT IS SUSPECTED THAT CYCLE LIFE COULD HAVE POSSIBLE AFFECTED SHAFT LIFE AS LOADS ARE CLOSE TO 100 AMPS AFTER STARTUP TO RECHARGE BATTERIES. ALIGNMENT OF SHAFT LOOKS GOOD, NO GREAT AMT OF SPLINE WEAR A 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004080500067 20040805 00067 CE 2004 8 5 CA040608002 1 20040603 G 2730 1156100103 TORQUE TUBE BEECH 100 A100 1152915 CE PWA PT6 PT6A28 EA MCAULY 4HFR34 4HFR34C652 NE ELEVATOR OUT OF LIMITS W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING THE INSTALLATION OF A NEW ELEVATOR TORQUE TUBE, IT WAS NOTICED THAT ONE OF THE TAPERED PINS WAS INSTALLED B EYOND THE MANUFACTURES LIMITS. THE MM 27-30-00 PAGE 202 A, STATES IN PART THE SMALL END OF THE TAPER PIN BODY SHOULD EX TEND .000 TO 0.060 INCH BEYOND THE SURFACE OF THE SUPPORT. IF THE DIMENSIONS ARE NOT MET, NEW PARTS WILL BE REQUIRED. T HE SMALL END ON THE SUBJECT TUBES EXTENDED 0.125 INCHES BEYOND THE SURFACE. A SECOND TORQUE TUBE FROM OUR STOCK WAS ALSO FOUND IN THE SAME CONDITION. BOTH TUBES WERE NEW, SUPPLIED BY THE AIRCRAFT MFG. A THIRD TUBE FROM THE SAME BATCH WAS REMOVED FROM OUR STOCK. MFG WAS CONTACTED AND THEY WILL BE INVESTIGATING THE MATTER FURTHER. 1 L 7 2 3T 4 T A14CE E4EA 6 C 3PNE 2004080500068 20040805 00068 EU 2004 8 5 CA040609008 1 20040607 G 7334 8G12561 PRESSURE SWITCH AMD FALC50 FALCON900 2700160 EU GARRTT TFE731 TFE7315BR WP FUEL SYSTEM MALFUNCTIONED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) DURING WALK AROUND AFTER COMPLETION OF A FLIGHT, NOTICED FUEL LEAKING OUT OF BOTTOM OF NR 1 ENGINE COWLING. FOUND NR 1 FUEL PRESSURE SWITCH LEAKING OUT OF VENT HOLE. SWITCH WAS REPLACED WITH A NEW UNIT AND TESTED OK. 2 L 7 3 4F 4 F RT A46EU E6WE 2004080500069 20040805 00069 CE 2004 8 5 CA040609009 1 20040609 G 1420 M817141120D CONNECTOR BEECH B300 B300B350C CE PWA PT6 PT6A60A 52043 NE HARTZL HCB4M HCB4MP3 GL FUEL PROBE CORRODED W K NONE P NO WARNING INDICATION IN INSP/MAINT 1 CA (CAN) LT WING AUX FUEL TANK INDICATION ALWAYS INDICATING (0). WHEN TESTING SYSTEM LT QUANTITY CAUTION LIGHT WON'T COME ON. DURING TROUBLESHOOTING, FOUND A LOT WATER TRAPPED UNDER THE ACCESS PANEL AND THE WIRING WAS CORRODED. WATER REMOVE D AND CONNECTOR WILL BE REPLACED. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2004080500070 20040805 00070 NE 2004 8 5 CA040609010 2 20040527 G 7200 ENGINE AMD FALC20 FALCON20D5 2730003 EU GE CF700 CF7002D2 30010 NE NR 1 FLAMED OUT W A UNSCHED LANDING X J ENGINE FLAMEOUT WARNING INDICATION CL CLIMB 1 CA 245U150 (CAN) ON CLIMB OUT THE NR 1 ENGINE (S/N 245U150) EXPERIENCED A FLAME-OUT. CREW WAS ABLE TO RE-LIGHT THE ENGINE AND RETUR N WITHOUT FURTHER INCIDENTS. ON 26 MAY 04, ANOTHER CREW HAD EXPERIENCED A FLAMEOUT. THE FCU WAS SUBSQUENTLY CHANGED, AIR CRAFT WAS GROUND RUN AND CHECKED SERVICEABLE. WITH SECOND FLAMEOUT (ON 27 MAY) ENGINE HAS BEEN REMOVED AND WILL BE ROUT ED TO OVERHAUL SHOP FOR FURTHER ANALYSIS. FINDINGS, REPORT TO FOLLOW. 2 L 7 2 4F 4 F RT A7EU E7EA 2004080500071 20040805 00071 NE 2004 8 5 CA040609012 2 20040606 G 7314 5905587 FILTER BFGOODRICH AEROSP ATR42 ATR42300 8680920 EU PWA 120 PW120 NE HAMSTD 14SF 14SF5 NE FUEL PUMP FAILED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) ON TAKEOFF, THE CREW OBSERVED A FUEL FILTER CAUTION ON NR 1 ENGINE. THE AIRCRAFT RETURNED TO POINT OF DEPARTURE. M AINTENANCE REPLACED THE HIGH PRESSURE FILTER ON THE ENGINE PUMP AND THE AIRCRAFT WAS RETURNED TO SERVICE. 2 H 7 2 4T 4 T RT A53EU E20NE 6 C P7NE 2004080500072 20040805 00072 SO 2004 8 5 CA040609013 1 20040527 G 7603 455360 THROTTLE CABLE PIPER PA32 PA32RT300T 7103216 SO LYC O540 TIO540S1AD 41532 EA HARTZL HCE2Y HCE2YR1BF GL CNTRL LEVER END BROKEN W O OTHER O OTHER TX TAXI/GRND HDL 1 CA (CAN) AFTER A PREFLIGHT CHECK, THE PILOT COMPLAINED OF AN EXTREMELY LOOSE THROTTLE CONTROL. AFTER FURTHER INSPECTION, T HE CONTROL CABLE WAS DETERMINED TO BE INTERNALLY BROKEN. THE CABLE WAS REMOVED AND THE CONTROL LEVER END OF THE CABLE P ULLED OUT OF THE EXTERNAL CASE EXPOSING THE INTERNAL CABLE STRANDS. TWO OF THESE STRANDS WERE BENT OVER SUGGESTING THEY WERE BROKEN FOR SOME TIME. PILOT HAS NEVER COMPLAINED OF A STIFF THROTTLE CONDITION. 1 L 7 1 3O 3 O A3SO E14EA 5 C P9EA 2005012400033 20050124 00033 NM 2005 1 24 CA040609014 1 20040609 G 7810 65MK7823113 TAILPIPE BOEING 737 737201 1384454 NM PWA JT8 JT8D9A 52048 NE NR 2 ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 63233 (CAN) DURING ROUTINE MAINTENANCE A 5-6 IN CRACK AT THE 6 O’CLOCK POSITION AND A 4 IN CRACK AT THE 12 O’CLOCK POSITION, OF THE NR 2 ENGINE TAILPIPE WAS FOUND. BOTH CRACKS REPAIRED IAW MFG MM 78-38-43. 2 L 7 2 4F 4 F A16WE E2EA 2005012400039 20050124 00039 EU 2005 1 24 CA040609015 1 20040609 G 3220 LANDING GEAR AIRBUS 320 A320211 3930320 EU CFMINT CFM56 CFM565A1 NE NOSE FAILED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) FAULT: THE NOSE GEAR DID NOT RETRACT AFTER DEPARTURE. THE FLT CREW RETURNED TO DEPARTURE AND LANDED WITHOUT FURTHE R INCIDENT. NO ADDITIONAL INFORMATION WAS PROVIDED BY THE FLIGHT CREW. AIRCRAFT OUT OF SERVICE FOR INVEST. NOTE: MORE INFO WILL FOLLOW WHEN AVAILABLE. 2 L 7 2 4F 4 F RT A28NM E29NE 2005012400040 20050124 00040 EA 2005 1 24 CA040609016 1 20040609 G 2750 CONTROL UNIT CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE TE FLAPS INOPERATIVE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN)THE AIRCRAFT PERFORMED A FLAP 0 LANDING. DURING DESCENT THE FLT CREW RECEIVED A FLAP MSG. THE AIRCRAFT LANDED WI THOUT FURTHER INCIDENT. ALTHOUGH THE FLT CREW DID DECLARE AN EMERGENCY, THEY DID REQUEST THAT THE CFR'S. SYSTEM RESET IAW AOM INSERT 126. 2 L 7 2 4F 4 F RT A21EA E15NE 2005012400041 20050124 00041 SO 2005 1 24 CA040609017 2 20040604 G 8530 401852 STUD CONT IO240B DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240B 17063 SO SNSNCH W69EK W69EK63 EA ROCKER COVER BROKEN W E ENGINE SHUTDOWN E VIBRATION/BUFFET AP APPROACH 1 CA 635724461 (CAN) ENGINE RAN ROUGH ON FINAL APPROACH AND STOPPED ON ROLL OUT. ENGINE RESTARTED TO TAXI IN AND RAN VERY ROUGH AND BA CKFIRED. EXHAUST VALVE ON CYLINDER NR 3 DID NOT MOVE WHEN ENGINE TURNED OVER. FOUND ROCKER AND SHAFT LOOSE IN ROCKER C OVER. 1 L 7 1 3O 3 O NT TA4CH E7SO 5 N TA4CH 2005012400042 20050124 00042 WP 2005 1 24 CA040609018 2 20040601 G 7320 89711019 FUEL CONTROL CESSNA 441 441 2076020 CE GARRTT TPE331 TPE33110 01514 WP MCAULY 4HFR34 4HFR34C660 NE ENGINE FAILED W E ENGINE SHUTDOWN X J ENGINE FLAMEOUT WARNING INDICATION AP APPROACH 1 CA P7763 (CAN) DESCENDING THROUGH 7000 FEET ON APPROACH THE RT ENGINE SPOOLED DOWN. WHEN AUTO IGNITION WOULD NOT RELIGHT IT, THE CAPTAIN SECURED THE ENGINE AND LANDED WITHOUT FURTHER INCIDENT. THE ENGINE WOULD NOT RESTART ON THE GROUND. MAINTENANCE TROUBLESHOT THE PROBLEM TO THE FCU AND REPLACED IT WITH AN OVERHAULED UNIT. THE FAILED UNIT HAD BEEN OVERHAULED 10/24/02 AND INSTALLED 04/22/03. A TEARDOWN REPORT HAS BEEN REQUESTED. 1 L 7 2 3T 4 T RT A28CE E4WE 5 C 3PNE 2005012400043 20050124 00043 WP 2005 1 24 CA040610001 1 20040604 G 2910 A10070 CHECK VALVE CVAC 580 580 2422806 WP ALLSN 501D 501D13 03004 GL ALLSN A6441 A6441FN606 GL HYD SYSTEM FAILED W O OTHER K FLUID LOSS LD LANDING 1 CA (CAN) UPON LANDING, CREW DISCOVERED BRAKES INEFFECTIVE AND STEERING UNRESPONSIVE. AFTER STOPPING A/C USING PNEUMATIC BRA KES, CREW FOUND HYDRAULIC RESERVOIR NEAR EMPTY. AFTER TOWING A/C TO RAMP, MAINTENANCE FOUND THE GROUND BLOWER CHECK VALV E CRACKED. MAINTENANCE DE-ACTIVATED THE GROUND BLOWER, SERVICED THE HYDRAULIC SYSTEM, AND DISPATCHED A/C TO A MAINTENAN CE FACILITY FOR PART REPLACEMENT. 2 L 7 2 4T 4 T RT E282 6 C P898 2005012400044 20050124 00044 EA 2005 1 24 CA040610003 2 20040519 G 7230 BLADE BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU 1 ST STAGE BROKEN W E ENGINE SHUTDOWN A Y FLAME/FIRE ENGINE STOPPAGE CL CLIMB 1 CA (CAN) DURING CLIMB OUT IN THE MORNING, CREW HEARD A BANG FROM ENGINE NR 1. CAPTAIN LOOKED OUT, THE ENGINE HAD STOPPED AND THE FIRE WARNING WAS ILLUMINATING. INSPECTIONS HAVE REVEALED A BROKEN 1ST STAGE LOW PRESS COMPRESSOR BLADE AND THIS HAS MOST PROBABLY CAUSED A COMPRESSOR STALL DUE TO SEVERE DAMAGE AND A COMPRESSOR SUDDEN STOPPAGE. FRACTURE SURFACE IN DICATES FATIGUE FRACTURE AND THIS WE HAVE REPORTED SEPARATELY TO DIFFERENT MFG. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2005012400045 20050124 00045 SW 2005 1 24 CA040610004 1 20040531 G 6310 CL422501 CLUTCH BELL BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL OUTER RACE CRACKED W E ENGINE SHUTDOWN J WARNING INDICATION TX TAXI/GRND HDL 1 CA BLA50028 (CAN) ON START-UP THE PILOT HAD A CHIP LIGHT INDICATION, IMMEDIATELY SHUTDOWN AND INSPECTED THE FREEWHEEL CHIP DETECTOR. METAL CHIPS WERE FOUND. 1 G 7 1 3U 3 U H2SW E4CE 2005020100024 20050201 00024 SW 2005 2 1 CA040610005 1 20040607 G 2613 434422123 SWITCH SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP HARTZL HCE4N HCE4N3 NE LT WING LE FAULTY W E A ENGINE SHUTDOWN UNSCHED LANDING N FALSE WARNING CL CLIMB 1 CA (CAN) SHORTLY AFTER TAKEOFF, WHILE STILL CLIMBING, THE LT WING LOWER HEAT BEGAN TO FLASH. THE LT BLEED AIR AND THE LT GE NERATOR WERE TURNED OFF FLIGHT MANUAL PROCEDURES, AND THE AIRCRAFT TURNED BACK FOR THE DEPARTURE POINT. AFTER THREE MINU TES THE LIGHT CONTINUED TO FLASH SO THE CAPTAIN SHUT DOWN THE LT ENGINE AS REQUIRED, AND LANDED WITHOUT FURTHER INCIDENT . MAINTENANCE DISCOVERED THAT THE LT WING LEADING EDGE SENSOR SWITCH WAS ACTIVATING AT 140 F INSTEAD OF THE RATED 250 F. THE SWITCH WAS REPLACED AND THE SYSTEM TESTED SERVICEABLE. 2 L 7 2 4T 4 T RT A8SW E4WE 5 C P10NE 2005020100026 20050201 00026 EA 2005 2 1 CA040610006 2 20040609 G 7230 BLADE BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU COMPRESSOR DEPARTED W F A ACTIVATE FIRE EXT. UNSCHED LANDING A Y J FLAME/FIRE ENGINE STOPPAGE WARNING INDICATION CR CRUISE 1 CA FA0016 (CAN) AN AIRCRAFT CARRIED AN EMERGENCY LANDING AFTER EXPERIENCING A NR 2 ENGINE FIRE INDICATION. PRELIMINARY INFORMATIO N ADVISES LPC BLADE DEPARTURE AND COMPRESSOR SEIZURE. OIL WAS FOUND IN AND AROUND THE ENGINE AND NACELLE AREA AND HEAT DAMAGE WAS ALSO FOUND ON THE WIRING HARNESSES. FIRE BELIEVED TO HAVE BEEN CONTAINED WITHIN ENGINE. MFG INVESTIGATING THE ISSUE. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2005020100027 20050201 00027 EA 2005 2 1 CA040610007 1 20040608 G 7997 3043110 WIRE HARNESS DHAV DHC3 DHC3 2800202 EA PWA PT6 PT6A135 52043 NE HARTZL HCB3T HCB3TN3 GL ENGINE LOOSE W O OTHER N FALSE WARNING CR CRUISE 1 CA (CAN) ENGINE TEMPERATURE STARTED TO FLUCTUATE IN FLIGHT, MAINTENANCE TROUBLESHOT AND TRACED PROBLEM TO ENGINE, SPLIT TH E ENGINE AND FOUND THE TERMINAL END WAS LOOSE. THE FACTORY HAD NOT SOLDERED THE END ON PROPERLY. REPLACED THE HARNESS AN D RETURNED PART TO MFG FOR WARRANTY. 1 H 7 1 3R 4 T A815 E4EA 6 C P15EA 2005020100028 20050201 00028 2005 2 1 CA040610008 4 20040609 G 6113 055032111 BULKHEAD CESSNA CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA MCAULY 1A170 1A170E GL PROP SPINNER BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THE CORNER SECTION OF SPINNER AT LEADING EDGE OF PROPELLER BLADE CUT-OUT BADLY BENT (PEELED BACK) BY CENTRIFUGAL F ORCE. THIS WAS CAUSED BY THE ADJACENT CORNER SECTION OF THE BACKPLATE (AROUND ANCHOR NUT) BREAKING OFF DURING OPERATION. NEW BACKPLATE DESIGN USED. (MOST CURRENT PN 0550321-12) 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P857 2005020100029 20050201 00029 NM 2005 2 1 CA040610009 1 20040606 G 2913 661732 PUMP BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU NR 2 HYD SYSTEM FAILED W O OTHER K J FLUID LOSS WARNING INDICATION CL CLIMB 1 CA (CAN) DURING CLIMB FROM AIRPORT, NR 2 ENG HYD PUMP AND ASSOCIATED FLIGHT CONTROL CAUTION LIGHTS ALL ON HYD QTY 75 PERCEN T. ACTIVATED PTU, THEN PRESSURE RETURNED TO NORMAL. AFTER LDG AND FLAPS SELECTED FOR LANDING, HYD QTY DECREASED TO 30 PERCENT. FLIGHT CONTROL C/LS ILLUMINATED AGAIN. CONTINUED LANDING WITHOUT FURTHER INCIDENT. STOPPED ON TAXIWAY FOR TOW ING TO GATE, AT THAT TIME HYD QTY WAS 0 PERCENT. FOUND NR 2 EDP HANGER TRUNNION SCREWS, 1 MISSING AND 3LOOSE AND PACKI NG BLOWN OUT. REPLACED EDP. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2005020100030 20050201 00030 CE 2005 2 1 CA040610010 1 20040610 G 2820 040031158 LINE CESSNA 150 150M 2071830 CE CONT O200 O200A 17020 SO MCAULY 1A102 1A102OCM GL FUEL SYSTEM CORRODED W K NONE K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA 10205 (CAN) FUEL LINE ASSEMBLY LOCATION/LOCATED UNDER FLOOR AND UNDER CENTER CONSOLE. THIS LINE IS DIRECTLY FORWARD OF THE BEL LY DRAIN. IT IS UP STREAM FROM THE GASCOLATOR AND DOWN STREAM OF THE FUEL SHUT-OFF. FUEL SMELL WAS DETECTED. FUEL STAIN ING WAS PRESENT. THE LINE PASSES THROUGH A BULKHEAD. THE LINE IS PROTECTED BY A GROMMET WHICH WAS INTACT. THE LINE HA D BECOME CORRODED AND PITTED AROUND THE GROMMET AREA AND DEVELOPED A PIN HOLE LEAK. LINE WAS REPLACED. 1 H 7 1 3O 3 O 3A19 E252 5 N P918 2005020100052 20050201 00052 NE 2005 2 1 CA040610011 3 20040512 G 6110 8173881 SEAL HAMSTD 14SF23 DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE NR 4 BLADE INADEQUATE W K NONE K FLUID LOSS IN INSP/MAINT 1 CA 20010523 (CAN) DURING POST FLIGHT WALK AROUND OF AC FOLLOWING ARRIVAL, CREW IDENTIFIED CONSIDERABLE QTY OF LUBRICATING OIL HAD BE EN LIBERATED FROM LT PROPELLER. CREW TERMINATED FLIGHT AND CALLED FOR ENGINEERING ASSISTANCE. ENGINEERING INVESTIGATION REVEALED FAILURE OF PROP HUB TO PROP BLADE SEAL AT NR 4 BLADE POSITION. NEW SEAL INSTALLED, FOLLOWING CONSIDERABLE CLE AN UP, AC WAS RETURNED TO SERVICE. INSP OF REMOVED SEAL REVEALED SEAL TO BE FOR A 14SF TYPE PROP WITH A 14RF TYPE PROP GLAND SPRING SUPPLIED. SEAL IS FULLY TRACEABLE AND WAS SUPPLIED TO AIRLINE BY MFG AFTER ALLEGEDLY BEING INSPECTED BY MF G FOR CORRECT CONFORMANCE OF SPRING ASSY. 14RF GLAND SPRING IS OF SMALLER DIAMETER WHEN COMPARED TO 14SF GLAND SPRING. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005020100054 20050201 00054 NE 2005 2 1 CA040610012 3 20040516 G 6110 8173881 SEAL HAMSTD 14SF23 DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE NR 4 BLADE TORN W K NONE K FLUID LOSS IN INSP/MAINT 1 CA 20030916 (CAN) DURING POST FLIGHT WALK AROUND OF AC FOLLOWING ARRIVAL , CREW IDENTIFIED THAT CONSIDERABLE QTY OF LUBRICATING OIL HAD BEEN LIBERATED FROM THE LT PROPELLER. CREW TERMINATED FLIGHT AND CALLED FOR ENGINEERING ASSISTANCE. ENGINEERING INVE STIGATION REVEALED FAILURE OF PROP HUB TO PROP BLADE SEAL AT NR4 BLADE POSITION. NEW SEAL WAS INSTALLED, FOLLOWING CONS IDERABLE CLEAN UP, AC WAS RELEASED TO SERVICE. ON ARRIVAL TO BASE AC WAS WITHDRAWN FROM SERVICE AND ALL PROP BLADES WER E REMOVED IN PRESENCE OF THE LOCAL MFG FIELD SERVICE REP. SEALS WERE FOUND TO BE 14SF TYPE PROP SEALS RELEASED WITH 14R F TYPE PROP SEAL GARTER SPRINGS INSTALLED. NONCONFORMING BLADE SEAL WAS REPLACED. AC HAS BEEN RETURNED TO SERVICE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005020100055 20050201 00055 EA 2005 2 1 CA040610013 2 20040520 G 7414 67542 BEARING PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA HARTZL HCE2Y HCE2YR2 GL LT MAGNETO LOOSE W K NONE O OTHER IN INSP/MAINT 1 CA 226 L858848 (CAN) AFH: 8900.9 DATE: MAY 20 RT ENGINE -- LT MAGNETO, DAMAGE WAS DISCOVERED DURING A 100HR INSPECTION. DECIDED TO RE MOVE THE LT MAGNETO FOR INSPECTION OF THIS AREA. (HAVE ADDED THIS TO OUR INSPECTION PROGRAM) WHEN THE MAGNETO WAS REMOVE D THE MAGNETO GEAR RETAINER ASSY AND BEARING PULLED OUT OF THE ENGINE TOGETHER WITH THE DRIVE COUPLING YET AGAIN. UPON FURTHER INSPECTION NO DAMAGE TO ENGINE. ENGINE WAS REMOVED AND SENT FOR REPAIR TO THE BEARING RECESS AREA (MFG SI-1140) REPAIR WAS CARRIED OUT. ENGINE WAS RE-INSTALLED TO AIRCRAFT. THE BEARING HAS 226. 5 HOURS. THE ENGINE WAS REPAIRED (C RANKCASE) BUT NOT OVERHAULED. ENGINE TOTAL TIME 1337.0 1 L 7 2 3O 3 O 1A10 1E4 5 C P9EA 2005020100056 20050201 00056 EU 2005 2 1 CA040610014 1 20040607 G 3231 HC323L0001000 SPRING BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE NLG FAILED W O OTHER D INFLIGHT SEPARATION CL CLIMB 1 CA 35708 (CAN) UPON DEPARTURE, THE CREW REPORTED LOUD CLUNK NOISE UNDER FLIGHT DECK DURING GEAR RETRACTION. MAINTENANCE INSPECTE D AIRCRAFT AND FOUND LT NLG ASSIST SPRING ASSEMBLY HAD FAILED AND CAUSED A 12 X 8 HOLE IN UPPER NOSE WELL. ASSISTOR SPR ING WAS REPLACED AND HOLE WAS REPAIRED IAW THE PRINCIPALS OF RIL HC537H9252 AT ISSUE 1 IN REFERENCE TO BARA/AVR/6774/04- DC. GEAR SWINGS WERE CARRIED OUT AS SERVICEABLE AND AIRCRAFT WAS RETURNED TO SERVICE. TIMES FOR THIS PART ARE LISTED A S AIRCRAFT TIMES. 2 H 7 4 4F 4 F A49EU E6NE 2005020100057 20050201 00057 NM 2005 2 1 CA040611001 1 20040607 G 3310 RV4NBYSD502A SWITCH BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU READING LIGHT BURNED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) PILOT REPORTED BURNING SMELL IN THE COCKPIT. MAINTENANCE FOUND THE DIMMER SWITCH OF THE CO-PILOTS READING LIGHT B URNED THE SWITCH PN RV4NBYSD502A WAS REPLACED AND A FUNCTION CHECK CARRIED OUT. NO FURTHER PROBLEMS. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2005020100058 20050201 00058 SO 2005 2 1 CA040611002 2 20040513 G 7414 10357164 COIL BENDIX S4LN21 UNIVAR 415 415C 0420302 NM CONT A75 C7512 17005 SO MCAULY 1B90 1B90CM GL MAGNETO CRACKED W O OTHER O OTHER TX TAXI/GRND HDL 1 CA 540710 (CAN) AIRCRAFT HARD TO START WHEN ENGINE IS HOT. CHECKED MAGNETO TO ENGINE TIMING. COULD NOT GET RT MAGNETO (S/N 540710 ) POINTS TO OPEN OR CLOSE. REMOVED MAGNETO FROM ENGINE AND FOUND GROUND ON COIL MISSING SCREW. COIL FOUND TO BE CRACKED AND OPAQUE IN COLOR INDICATING AD 94-01-03R2 AND MSB 644 HAD NOT BEEN ACCOMPLISHED. TECHNICAL RECORDS INDICATE ENGINE J UST HAD FIELD OVERHAUL. TIME ON ENGINE IS ONLY 14.3 HOURS. 1 L 7 1 3O 3 O A718 E233 5 N P842 2005020100059 20050201 00059 WP 2005 2 1 CA040611003 2 20040607 G 7250 310117015 PIN SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP HARTZL HCE4N HCE4N3 NE ENGINE LOOSE W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA P54202 (CAN) AC HAD A CHIP LIGHT ILLUMINATE DURING CRUISE. PREVIOUS DAY A CHIP LIGHT ILLUMINATED AND A SMALL SLIVER OF METAL W AS FOUND ON CHIP DETECTOR. AN OIL SAMPLE WAS TAKEN AND SENT FOR ANALYSIS. AFTER ILLUMINATION OF CHIP LIGHT, ENGINE WAS REMOVED FOR INSP. UPON INSP IT WAS FOUND THAT HIGH SPEED PINION GEAR HAD COME LOOSE. MOUNTING NUTS WERE FOUND IMPROPERLY TORQUED, LOCK PINS HOLDING NUTS WERE FOUND INTACT BUT NUTS COULD STILL BE MOVED FREELY BY HAND. BEARING RACE AND PINIO N GEAR HAD INDICATIONS OF EXCESSIVE WEAR: 016 NUT MOVING WIDTH OF LOCK PIN BY HAND. 017 NOTE POSITION OF STAKE COMPARED TO 018018, COMPARE TO 017012, CLEARANCE BETWEEN NUT AND RACE. 013 CLEARANCE BETWEEN GEAR AND RACE. 2 L 7 2 4T 4 T RT A8SW E4WE 5 C P10NE 2005020100060 20050201 00060 WP 2005 2 1 CA040611004 2 20040611 G 7250 310117017 PINION GEAR SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP HARTZL HCE4N HCE4N3 NE ENGINE WORN W K NONE O OTHER IN INSP/MAINT 1 CA P54043 (CAN) OIL SAMPLE ANALYSIS FINDING RECEIVED FROM WEAR CHECK TO INSPECT ENG DUE TO SILVER IN OIL SAMPLE. DURING TEARDOWN, FOUND PINION GEAR BEARING CAGES, WHICH HAVE SILVER COATING APPLIED DURING MFG. COATING HAD STARTED TO FLAKE OFF, CONTAM INATING OIL. MFG OF BRGS AND VENDOR WHO APPLIES SILVER TREATMENT HAVE BEEN NOTIFIED OF PROBLEM. OUR STORES DEPT DOES N OT HAVE ANY BEARINGS OF THIS TYPE IN STOCK, MFG HAS RESOLVED PROBLEM WITH SILVER TREATMENT PROCESS . OTHER BEARINGS OF T HIS TYPE ARE INSTALLED IN ENGINE FLEET DO NOT APPEAR TO HAVE ANY PROBLEMS. FURTHER BEARING PROBLEMS WILL APPEAR IN OIL SAMPLES AND CAN BE REPAIRED AS NEEDED WITHOUT ANY IMPACT ON SAFETY. 2 L 7 2 4T 4 T RT A8SW E4WE 5 C P10NE 2005020100061 20050201 00061 NM 2005 2 1 CA040611005 1 20040608 G 2780 10608197 SWITCH BOEING 727 727225 1384077 NM PWA JT8 JT8D15A 52051 NE KRUEGER FLAP INOPERATIVE W A UNSCHED LANDING J F WARNING INDICATION FLT CONT AFFECTED CL CLIMB 1 CA (CAN) AFTER TAKE OFF AND DURING CLIMB IT WAS OBSERVED THAT THE LT OB KRUGER FLAP WAS NOT RETRACTED. BOTH INDICATIONS SH OWED THE KRUGER WAS STILL EXTENDED. THE AIRCRAFT MADE AN UNSCHEDULED LANDING WITHOUT INCIDENT. JUMPER ASSY WAS INSTALL ED IAW B727-27-80-02, L/E FLAP JUMPER CABLE INSTALLATION, AND CHECKED SERVICEABLE. THE AIRCRAFT WAS RELEASED FOR SERVIC E. NO FURTHER PROBLEMS DURING SUBSEQUENT FLIGHT. 2 L 7 3 4F 4 F A3WE E2EA 2005020100080 20050201 00080 NM 2005 2 1 CA040611006 1 20040518 G 2612 82455014003 FIRE DETECTOR DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE NR 1 ENGINE FAILED W F A ACTIVATE FIRE EXT. UNSCHED LANDING N FALSE WARNING CR CRUISE 1 CA 32830 32830 (CAN) DURING CRUISE FLIGHT NR 1 ENGINE FIRE WARNING , NR 1, NR 2 FIRE BOTTLES BLOWN TO NR 1 ENGINE, NO SMELL OR VISUAL I NDICATION OF SMOKE/FIRE. FIRE INDICATION PERSISTED, NR 1 ENGINE SHUT DOWN, AIRCRAFT DIVERTED TO NEARBY AIRPORT. NORMAL LANDING CARRIED OUT WITH GROUND FIRE/RESCUE IN ATTENDANCE. NO EVIDENCE OF FIRE. MAINTENANCE INSPECTION FOUND NO EVIDEN CE OF FIRE, FIRE DETECTION LOOP FOUND FAULTY. FIRE DETECTION LOOP AND FIRE BOTTLES REPLACED. AIRCRAFT RETURNED TO SERVI CE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005020100082 20050201 00082 EU 2005 2 1 CA040611007 2 20040530 G 7510 DEICE SYSTEM BRAERO 748 HS7482A 4231001 EU RROYCE DART DART5342 EU ROTOL R4304 R2124304 EU RIGHT INOPERATIVE W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) RT ENGINE DE-ICE FOUND INOPERATIVE, RETURNED TO DEPARTURE, STA NR 2 RELAY P/N CZ105648-2 REPLACED ENGINE INLET DE- ICE RING COWL REPLACED. HARNESS, P/N 6V10659 REPLACED FUNCTION TEST, SERVICEABLE 2 L 7 2 3T 4 T A24EU A196 6 C P899 2005020100083 20050201 00083 EA 2005 2 1 CA040611008 1 20040608 G 5554 AB4A BEARING DHAV DHC6 DHC6300 2802606 EA PWA PT6 PT6A27 52043 EA HARTZL HCB3T HCB3TN3 GL RUDDER UNSERVICEABLE W O OTHER D INFLIGHT SEPARATION NR NOT REPORTED 1 CA 23353 (CAN) PILOT DISCOVERED RUDDER MAKING SNAPPING NOISE WHILE CHECKING FREEDOM OF MOVEMENT AND RANGE FOR TRAVEL DURING PRE F LIGHT WALK AROUND. LOWER ATTACH BEARING OF RUDDER, FOUND TO HAVE FAILED ALLOWING RUDDER TO RUB ON ATTACHMENT MOUNT. RU DDER REMOVED AND BEARING REPLACED. LOWER RUDDER ATTACHMENT MOUNT INSPECTED, NO FAULTS FOUND. RUDDER RE-INSTALLED, RUDD ER, RUDDER TRIM AND RUDDER GEARED TAB RIGGING CHECKED SERVICEABLE. 1 H 7 2 3T 4 T RT A9EA E4EA 6 C P15EA 2005020100084 20050201 00084 NE 2005 2 1 CA040613001 2 20040611 G 7260 755469D IDG CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE NR 1 INOPERATIVE W C ABORTED TAKEOFF J WARNING INDICATION TO TAKEOFF 1 CA 2555 (CAN) NR 1 IDG CAUTION MESSAGE CAME ON DURING TAKEOFF ROLL AND CREW ELECTED TO REJECT TAKEOFF. ON WEEK PRIOR OR(JUNE 5) , THE CREW RECEIVED A CAUTION MESSAGE (DURING CRUISE AT 31000 FEET) ON EICAS FOR APPROX 30 SECONDS WITH SYNOPTIC CHANGIN G FROM GREEN TO YELLOW WHILE THE OUTPUT VOLTAGE REMAINED STEADY. MAINTENANCE CARRIED OUT A VISUAL INSPECTION AND THEN A S THE SNAG REOCCURRED, INITIALLY THE SYSTEM WAS DEFERRED IAW AS MEL PROCEDURE AND IDG WAS REPLACED AT THE SAME NIGHT HOU RS SINCE INSTALLATION OF IDG. TT 2555.34 AND 1576 CYCLES ON A 381 DAY PERIOD. 2 L 7 2 4F 4 F RT A21EA E15NE 2005020100085 20050201 00085 NE 2005 2 1 CA040614001 2 20040610 G 7314 5008269H PUMP DHAV DHC8 DHC8311 1386006 EA PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE FUEL SYSTEM FAILED W A UNSCHED LANDING Y J ENGINE STOPPAGE WARNING INDICATION CL CLIMB 1 CA (CAN) 2 MIN AFTER T/O, NR 2 ENG TORQUE WAS LOCKED AT 64 PERCENT. NO CHANGE WITH THROTTLE MVMT. NR 2 ENG FLAMED OUT. CR EW WENT THROUGH EMERG CHECK LIST, SHUT ENGINE DOWN. EMERGENCY WAS DECLARED, FLIGHT WAS GIVEN PRIORITY FOR LANDING. FLI GHT LANDED WITHOUT FURTHER INCIDENT. UPON INVEST MAINT ISOLATED FAULT TO MECH FCU AND FUEL PUMP, BOTH REPLACED. AC WAS RELEASED FOR TEST FLIGHT, WHILE ATTEMPTING TO DO SO THE FLIGHT CREW REJECTED T/O AS THEY COULD NOT GET AUTO FEATHER TO ARM. UPON FURTHER INVESTIGATION, MAINT VERIFIED RIGGING ON NR 2 ENG. REPLACED BOTH TORQUE SIGNAL CAUTION UNITS P/N 30 005-0000-34 AND THE NR 2 ENG CONTROL UNIT P/N 798213-2-002 . THE A/C WAS RELEASED FOR SECOND TEST FLIGHT. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005031000006 20050310 00006 NE 2005 3 10 CA040614002 2 20040614 G 7200 9324M70G06 ENGINE AIRBUS A340 A340313 EU CFMINT CFM56 CFM565C4 13802 NE NR 4 FOD W E ENGINE SHUTDOWN M OVER TEMP DE DESCENT 1 CA 741520 (CAN) APPROX 30 MINS FROM DEPARTURE, NR 4 ENG EGT OVERTEMPED AND CLIMBED TO 946 DEGREES AND WAS SHUT DOWN. THERE WAS NO LOUD NOISE OR SHAKING. THE AC MADE A NORMAL LANDING AND THE CFR WERE NOT CALLED OUT. AC REMOVED FROM SERVICE AND CP CONTACTED TO CARRY OUT T/SH. NR 4 ENG PRELIMINARY BOROSCOPE INSPECTION SHOWS SIGNS OF METAL IN COMPRESSOR. BORO PICTU RES BEING E-MAILED TO MOC FOR ENGINEERING EVALUATION. 2 L 7 4 4F 4 F RT A197 E37NE 2005020100086 20050201 00086 SW 2005 2 1 CA040614003 1 20040610 G 6120 8975428 BETA SWITCH SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE3311 01514 WP MCAULY 4HFR34 4HFR34C652 NE ENGINE INTERMITTENT W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA P44663C (CAN) LT BETA LIGHT ILLUMINATED IN FLIGHT. AIRCRAFT RETURNED TO BASE, SWITCH REPLACED AND AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4T 3 T RT A8SW E3WE 6 C 3PNE 2005020100123 20050201 00123 CE 2005 2 1 CA040614004 1 20040610 G 5751 262400724 BELLCRANK CESSNA 208 208B 2073701 CE PWA PT6 PT6A114A 52043 NE MCAULY 3AF34C 3GFR34C703 GL AILERON MISMANUFACTURED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING COMPLETION OF MFG BULLETIN CAB03-4 ONE WELD WAS FOUND TO BE MISSING. THE MISSING WELD WAS ON THE LOWER ARM INNER SURFACE DESCRIBED AS ITEM 6 IN FIGURE 1 OF CAB03-4. ALL OTHER WELDS WERE PRESENT AND THE BELLCRANK SHOWED NO OBV IOUS DAMAGE OR DISTORTION CAUSED BY THE MISSING WELD. 1 H 7 1 3T 3 T A37CE E4EA 5 C P60GL 2005020100135 20050201 00135 NE 2005 2 1 CA040614005 2 20040612 G 8550 153084 TUBE DOUG DC4 C54 3021506 WP PWA R2000 R20007M2 52023 NE OIL DRAIN INOPERATIVE W E A ENGINE SHUTDOWN UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA (CAN) DURING CRUISE THE PILOTS NOTICED A DROP IN OIL QUANTITY ON THE NR 2 ENGINE. THE ENGINE WAS SHUTDOWN AND PROPELLER FEATHERED. MAINTENANCE WAS CONTACTED AT ARRIVAL, THE OIL DRAIN TUBE WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 2 L 7 4 4R 4 R A762 5E5 2005020100139 20050201 00139 NM 2005 2 1 CA040614007 1 20040611 G 7500 BELLOWS DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE BLEED SYSTEM CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 33393 33393 (CAN) WHEN TAXING FOR DEPARTURE BOTH ENGINES WENT TO MANUAL MODE ON ECU. MAINTENANCE INSPECTION FOUND ECU'S HAD GONE TO MANUAL DUE TO IN EXCESS OF 49 DEG C ON SAT AIR PROBE. FURTHER INSPECTION FOUND CROSSOVER BLEED PIPE ABOVE FUESLAGE JUST FORWARD OF DORASL FIN HAD CRACKED BELLOWS LEAKING HIGH TEMP BLEED AIR INTO WING CENTER SECTION , HEATING SAT AIR PROBE FROM THE BACK SIDE. BLEED PIPE REPLACED. AIRCRAFT RETURNED TO SERVICE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005020100140 20050201 00140 EA 2005 2 1 CA040614008 1 20040607 G 2460 2TC125 CIRCUIT BREAKER DHAV DHC7 DHC7102 2802708 EA PWA PT6 PT6A50 52043 EA HAMSTD 24PF 24PF305 GL COCKPIT FAILED W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA 34992 (CAN) IN ORDER TO INSTALL A LIGHT ASSEMBLY IN THE NOSE COMPARTMENT THE L4 (CB) WAS PULLED IN THE COCKPIT. AFTER INSTALLA TION WAS COMPLETED, CB WAS PUSHED BACK IN TO TEST SYSTEM, BY THE TIME THE INDIVIDUAL WALKED FROM THE COCKPIT BACK TO THE NOSE COMPARTMENT THERE WAS A BURNING ODOR AND THE WIRES GOING TO THE LIGHT WERE HOT. THE INDIVIDUAL RAN BACK TO THE CO CKPIT TO PULL THE CB AND FOUND IT SMOKING. AFTER AN UNSUCCESSFUL ATTEMPT TO MANUALLY OPEN THE CB, THE ONLY OTHER OPTION WAS TO SHUTOFF THE AIRCRAFT POWER TO STOP THE CURRENT FLOW TO THE SHORTED CIRCUIT. CB WAS OLD, DIRTY AND CORRODED. ALT HOUGH THE SHORT CIRCUIT WAS CAUSED BY HUMAN ERROR THE CB SHOULD HAVE TRIPPED AND STOPPED THE CURRENT FLOW TO THE LIGHT. 2 H 7 4 4T 4 T A20EA E4EA 6 C P1NE 2005020100141 20050201 00141 NM 2005 2 1 CA040614009 1 20040610 G 5751 SKIN DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE AILERON TIP LIGHTNING STRIKE W O OTHER O OTHER AP APPROACH 1 CA 31484 31484 (CAN) DURING APPROACH AIRCRAFT STRUCK BY LIGHTNING ,BOTH DC GENERATORS WENT OFF LINE. NR 2 DC GEN RE-SET, AIRCRAFT CONTI NUED FOR NORMAL APPROACH AND LANDING. NR 1 DC GENRE-SET AFTER ARRIVAL. INSPECTION FOUND DAMAGE TO THE RT AILERON TIP , LOSS OF MOST OB STATIC WICK , FIBERGLASS T/E SPLIT OPEN APPROX. 6 INCHES, DAMAGE/PITTING TO AILERON OB BEARING. AILER ON AND BEARING REPLACED. AIRCRAFT RETURNED TO SERVICE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005020100142 20050201 00142 EU 2005 2 1 CA040615001 1 20040615 G 2750 CONTROL UNIT AIRBUS 320 A320211 3930320 EU CFMINT CFM56 CFM565A1 NE TE FLAPS FAILED W K NONE F FLT CONT AFFECTED IN INSP/MAINT 1 CA (CAN) FAULT: ON FINAL APPROACH, WHEN FLAP 1 SELECTED, ONLY SLATS CAME OUT. NO FLAPS, RECYCLED TWICE NOJOY. SLATS ONLY LA NDING CARRIED OUT. ACFT OUT OF SERVICE FOR INVESTIGATION. COMMENTS: FURTHER INFO WILL FOLLOW. 2 L 7 2 4F 4 F RT A28NM E29NE 2005020100179 20050201 00179 SW 2005 2 1 CA040615002 1 20040611 G 5210 206031620101 PIN BELL 206 206B1 1181503 SW DOOR HANDLE IMPROPER PART W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) CREW AND PASSENGER, INTERIOR (D) SHAPED DOOR HANDLES FOUND TO HAVE LOCKING (SPRING PINS) TOO SHORT INSTALLED BY TH E MANUFACTURER. MS171525 (.438 INCH LONG) INSTALLED INSTEAD OF MS171526 (.500 INCH LONG). 1 G 7 1 3U H2SW 2005020100195 20050201 00195 EU 2005 2 1 CA040615003 1 20040603 G 6710 12TW13 SWITCH SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE COLLECTIVE INOPERATIVE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHEN PILOT PERFORMED THE HYDRAULIC ACCUMULATOR TEST THE HORN MALFUNCTIONED. THEN CARRIED OUT THE PRESSURE ISOLATIO N CHECK ( NO HORN WHEN HYDRAULICS SWITCHED BACK ON). ALL TEST WERE PERFORMED AGAIN AND HORN WAS NOT FUNCTIONING. SWIT CH ON PILOT COLLECTIVE WAS CHANGED AND AIRCRAFT WAS TESTED SERVICABLE AND RETURNED TO SERVICE. 1 G 7 1 3U 3 U NC H9EU E19EU 2005020100196 20050201 00196 SO 2005 2 1 CA040615004 2 20040610 G 8530 ROCKER BOSS CONT CESSNA 180 180 2072602 CE CONT O470 O470K 17026 SO HARTZL HC82V HC82V* GL CYLINDER EXHAUST BROKEN W A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CL CLIMB 1 CA 35074 (CAN) ROCKER BOSSES BROKE OFF, FOR ROCKER SHAFT ON EXHAUST VALVE. 1 H 7 1 3O 3 O NC 5A6 E273 5 C P23EA 2005031000007 20050310 00007 NM 2005 3 10 CA040615005 1 20040611 G 3310 RV4NBYSD502A RHEOSTAT DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE LIGHT UNSERVICEABLE W H DEACTIVATE SYST/CIRCUITS B O SMOKE/FUMES/ODORS/SPARKS OTHER CR CRUISE 1 CA 38676 (CAN) RHEOSTAT (P/N RV4NBYSD502A) F/O OVERHEAD MAP LIGHT HAD SMOKE COMING FROM THE LIGHT AFTER IT WAS SWITCHED ON AND C B P3 POPPED SHORTLY THERE AFTER. OFFENDING PART POTENTIO METER 3311-R4 IPC REF 33-11-00 FIG 5 ITEM 75 NHA 82415155-001 CABLE ASSY, RHEOSTAT WAS REPLACED AND SYS WAS FUNCTIONED WITH NO REOCCURRENCE OF PROBLEM, AND AC WAS RETURNED TO SERVICE . INCIDENT HAS BEEN BROUGHT TO THE ATTENTION OF OUR FLEET GROUP AND THEY IN-TURN SENT OUT EMAIL TO THE MFG, AS THIS HA S BEEN THE SECOND OCCURRENCE WE HAVE HAD. INFORMATION WAS REQUESTED AS TO WHETHER OR NOT ANY OF THE OTHER OPERATORS HAV E BEEN EXPERIENCING THE SAME FAULT AND IF THERE HAS BEEN ANY CHANGE AS OF LATE TO THE VENDOR OF THIS PARTICULAR PART. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005020100197 20050201 00197 SO 2005 2 1 CA040615007 2 20040513 G 7414 10357164 COIL BENDIX UNIVAR 415 415C 0420302 NM CONT A75 C7512 17005 SO MCAULY 1B90 1B90CM GL MAGNETO CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 540756 (CAN) AIRCRAFT HARD TO START WHEN ENGINE IS HOT. CHECKED MAGNETO TO ENGINE TIMING AND COULD NOT GET RT MAGNETO (S/N 5407 10) POINTS TO OPEN OR CLOSE. REMOVED LT MAGNETO (S/N 540756) DUE TO PROBLEMS FOUND IN RT MAGNETO. FOUND COIL CRACKED AN D OPAQUE. AD 94-01-03R2 AND SB 644 HAD NOT BEEN ACCOMPLISHED IN LT MAGNETO S/N 540756. TECHNICAL RECORDS INDICATE ENGINE JUST HAD OVERHAUL TTSN 14.3 HOURS. 1 L 7 1 3O 3 O A718 E233 5 N P842 2005020100198 20050201 00198 EA 2005 2 1 CA040615008 1 20040527 G 3244 H29X901516 TIRE CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE MLG SEPARATED W A UNSCHED LANDING E VIBRATION/BUFFET CL CLIMB 1 CA (CAN) NR 2 MLG TIRE SEPARATION/ RUPTURE ENGINE VIBRATION (N1) WAS DEPICTED ON EICAS AND FELT THROUGHOUT THE AIRCRAFT. TH E FLIGHT CREW RETARDED THE POWER LEVERS TO REDUCE N1 VIB. TO WITHIN LIMITS. (FYI:AT 42 PERCENT N1 = 3.9 MILS). A/C DIVER TED. FLIGHT CREW POST FLIGHT CHECK WITNESSED 3 FAN BLADES SEVERELY DAMAGED INDUCED BYTHE NR 2 TIRE SEPARATION AND RUPTU RE. THE IB FLAP SURFACE HAS SUSTAINED DAMAGE AS WELL. FYI: THIS IS THE SIXTH OCCURRENCE SINCE MAY 11TH, 2004, ASSOCIATE D WITH THIS MFG TIRE SEPARATION. 2 L 7 2 4F 4 F RT A21EA E15NE 2005020100199 20050201 00199 EA 2005 2 1 CA040615009 1 20040513 G 3244 H29X901516 TIRE CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE MLG SEPARATED W O OTHER O OTHER TX TAXI/GRND HDL 1 CA (CAN) DURING PASSENGER DEPLANING, A RAMPER REPORTED THE LT IB TIRE SHOWN TIRE SEPARATION (TREAD MISSING) AND THE CORD SE CTION WAS SHREDDED AND THE TIRE HAD POPED OUT IN SEVERAL AREAS. UPON A CLOSURE LOOK, THE FLIGHT CREW NOTICED THE LT IB FLAP SURFACE HAD SUSTAINED DAMAGED AS WELL. LT NR 1 AND NR 2 TIRES REPLACED. FLAP SURFACE PN 601R14002-1, SN SB/RJ/777 REPLACED. LT ENGINE INSPECTED AND NO DAMAGE WAS FOUND. 2 L 7 2 4F 4 F RT A21EA E15NE 2005031000008 20050310 00008 EA 2005 3 10 CA040615010 1 20040520 G 3244 H29X901516 TIRE CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE MLG SEPARATED W O OTHER O OTHER LD LANDING 1 CA (CAN) ON LANDING VIBRATION DETECTED. PILOTS' POST FLIGHT INSPECTION NOTICED NR 3 MLG TIRE HAD SEPARATED AND RUPTURED. R T IB FLAP WAS DAMAGED AS A RESULT. 2 L 7 2 4F 4 F RT A21EA E15NE 2005031000009 20050310 00009 EA 2005 3 10 CA040615011 1 20040504 G 5610 NP1393225 WINDOW CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE COCKPIT DAMAGED W H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA (CAN) SMOKE IN COCKPIT DUE TO LT WINDOW HEATER. EMERGENCY DECLARED DUE TO DAMAGED INSULATION BLOCK, REPLACEMENT OF LT S IDE WINDOW AND CONTINUITY CHECK OF SUPPLY WIRES NECESSARY. TROUBLESHOOTING POINTS TO INTERNAL FAULT OF THE HEATER ELEME NT TERMINAL BLOCK AT WINDOW 'MPE4HC'. LT SIDE WINDOW REMOVED ACC. AMM 56-12-01-000-801. LT SIDE WINDOW IAW AMM 56-12-01 -400-801 INSTALLED. 2 L 7 2 4F 4 F RT A21EA E15NE 2005031000010 20050310 00010 GL 2005 3 10 CA040615012 1 20040615 G 5753 14573002 HINGE CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO HARTZL HCJ3Y PHCJ3YF1 GL TE FLAP CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) FLAP HINGE ASSEMBLY HAS INTERGRANULAR CORROSION ON THE FORWARD EDGE OF THE HINGEJUST BELOW THE BOTTOM WING SKIN AB OVE THE HINGE FAIRING. 1 L 7 1 3O 3 O NT A00009CH E3SO 5 C P36EA 2005031000011 20050310 00011 GL 2005 3 10 CA040615013 1 20040615 G 5753 14572002 HINGE CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO HARTZL HCJ3Y PHCJ3YF1 GL TE FLAP CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) FLAP HINGE ASSEMBLY HAS INTERGRANULAR CORROSION ON THE FORWARD EDGE OF THE HINGEJUST BELOW THE BOTTOM WING SKIN AB OVE THE HINGE FAIRING. 1 L 7 1 3O 3 O NT A00009CH E3SO 5 C P36EA 2005031000012 20050310 00012 GL 2005 3 10 CA040615014 1 20040615 G 5753 14571003 HINGE CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO HARTZL HCJ3Y PHCJ3YF1 GL TE FLAP CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) FLAP HINGE ASSEMBLY HAS INTERGRANULAR CORROSION ON THE FORWARD EDGE OF THE HINGEJUST BELOW THE BOTTOM WING SKIN AB OVE THE HINGE FAIRING. 1 L 7 1 3O 3 O NT A00009CH E3SO 5 C P36EA 2005031000013 20050310 00013 GL 2005 3 10 CA040615015 1 20040615 G 5753 14571004 HINGE CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO HARTZL HCJ3Y PHCJ3YF1 GL TE FLAP CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WING FLAP HINGE HAS INTERGRANULAR CORROSION ON THE LEADING EDGE OF HINGE JUST BELOW THE WING SKIN AND FLAP HINGE F AIRING. 1 L 7 1 3O 3 O NT A00009CH E3SO 5 C P36EA 2005031000014 20050310 00014 NM 2005 3 10 CA040615016 1 20040615 G 2120 MS3106R10SL3S CONNECTOR DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE VALVE OVERHEATED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) AFTER TAKE-OFF THE CREW NOTED THE NR1 BLEED CONT CIRCUIT BREAKER POPPED. UPON RETURN TO DEPARTING AIRPORT MAINTEN ANCE FOUND THAT THE CONNECTOR PLUG CONNECTED TO THE BLEED PRESSURE REGULATING SHUT-OFF VALVE HAD BECOME OVERHEATED AND H AD LOST IT'S INSULATING PROPERTIES. THIS PLUG IS SUBJECT TO HIGH HEAT WHEN THE VALVE IS POWERED IN THE OFF SELECTED MOD E. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005030800070 20050308 00070 2005 3 8 CA040615017 4 20040615 G 2562 LR20 BATTERY DORNEMARGLN ELT LEAKING W K NONE K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA 42232 UNIT INSPECTED FOR CERTIFICATION AND BATTERY REPLACEMENT. FOUND DURACELL BATTERIES (D-CELLS) LEAKING IN BATTERY COMPART MENT. BATTERIES REMOVED, AREA CLEANED, ALSO NOTED SURFACE CORROSION ON BATTERY CONTACT SPRING. CORROSION REMOVED WITH ACID BRUSH AND IPA (ALCOHOL). BATTERY BOX RE-INSPECTED, NEW BATTERIES INSTALLED, UNIT FUNCTION TESTED AND MET SPECIFICA TIONS. 2005031000015 20050310 00015 SW 2005 3 10 CA040616001 1 20040420 G 6410 206016201131 BLADE BELL 206 206B 1181511 SW TAIL ROTOR DEBONDED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) TAILROTOR BLADE OB DOUBLER, NEAR ROOT END OF BLABE, FOUND DEBONDED ON APPROX 6 INCHES. 1 G 7 1 3U H2SW 2005030800071 20050308 00071 GL 2005 3 8 CA040616002 2 20040615 G 7200 TURBINE WHEEL BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL ENGINE BURNED W O OTHER O OTHER NR NOT REPORTED 1 CA CAT24288 (CAN) MAIN ROTOR WAS HARD TO TURN BACKWARDS INDICATING CARBON PROBLEMS. AIRCRAFT WAS GROUND RUN AS PER MANUFACTURES REC OMENDATIONS AND RELEASED FOR SERVICE AS TURBINE HAD FREED UP. COMPANY HAD REMOVED AIRCRAFT FROM SERVICE AND RETURNED IT TO BASE. ON REMOVAL OF TURBINE (TO SEND IT IN FOR CLEANING). IT APPEARED TO HAVE PARTS OF TURBINE BLADES IN BURNER CA N SECTION. 1 G 7 1 3U 3 U H2SW E4CE 2005030800072 20050308 00072 EU 2005 3 8 CA040616003 1 20040609 G 3230 9740926112 RELAY PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL MLG FROZEN W H DEACTIVATE SYST/CIRCUITS J WARNING INDICATION LD LANDING 1 CA LANDING GEAR MOTOR CONTINUED TO RUN AFTER LANDING GEAR WAS DOWN AND LOCKED. AIRCRAFT LANDED AND TAXIED TO APRON. FLIGH T CREW TURNED OFF MASTER TO STOP MOTOR FROM RUNNING. MAINTENANCE WAS CALLED TO PULL UNDER FLOOR POWER PACK CIRCUIT BREA KER. MAINTENANCE CHECKED POWER PACK FOR A POSSIBLE OVER TEMPERATURE CONDITION BUT FOUND POWER PACK COOL. AIRCRAFT TAXI ED TO HANGAR. LANDING GEAR MOTOR RELAY CONTACTS FOUND FROZEN IN THE CLOSED POSITION. MAIN GEAR RELAY REPLACED, SYSTEM FUNCTION TESTED SERVICEABLE IAW PC12/45 MAINTENANCE MANUAL ATA CHAPTER 29. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005030800073 20050308 00073 EU 2005 3 8 CA040616004 1 20040604 G 2750 9733031216 SWITCH PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL TE FLAPS STICKING W O OTHER O OTHER NR NOT REPORTED 1 CA FLAP DOWN SWITCH IS STICKING IN ALL ENVIRONMENTAL CONDITIONS CAUSING FLAP FAILURES BOTH IN FLIGHT AND ON THE GROUND. BE TTER SEALS OR DUST CAPS MAY SOLVE THE PROBLEM. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005030800074 20050308 00074 EU 2005 3 8 CA040616005 1 20040603 G 3246 15702100 FAIRING PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 10271 CRACKS FOUND AROUND SCREW HOLES ON MAIN WHEEL FAIRING. REOCCURRING PROBLEM ON MANY OF OUR AIRCRAFT. AVERAGING 600 TO 7 00 HOURS PER FAIRING. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005030800075 20050308 00075 SW 2005 3 8 CA040616006 1 20040615 G 3230 UPLOCK HOOK SWRNGN SA227 SA227* SW MCAULY 4HFR34 4HFR34C652 NE MLG LACK OF LUBE W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA AFTER THE AIRCRAFT TOOK OFF AND THE CREW SELECTED GEAR UP THE 'UNSAFE' GEAR WARNING LIGHTS REMAINED ON. THE CREW SELECT ED DOWN AND OBTAINED 3 GREEN LIGHTS AND RETURNED TO BASE. MAINTENANCE WAS ABLE TO REPEAT THE PROBLEM ON THE GROUND ON G EAR SWINGS. THE UPLOCK HOOKS WERE NOT FULLY ENGAGING ON THE UPLOCK ROLLERS. THE MECHANISMS WERE CLEANED AND LUBRICATED AND THE GEAR SWINGS WERE SERVICEABLE. AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4T RT A5SW 6 C 3PNE 2005030800076 20050308 00076 EU 2005 3 8 CA040616007 1 20040609 G 3220 5322012078 BUSHING PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL NLG WORN W O OTHER O OTHER NR NOT REPORTED 1 CA EXCESSIVE UP AND DOWN MOVEMENT FOUND IN STEERING SECTION OF NOSE LANDING GEAR. BRONZE BUSHINGS FOUND TO BE WORN (P/N 53 2.20.12.078) IT IS BELIEVED THAT WHEN GREASING THE NOSE GEAR ASSEMBLY, THE CONTACT SURFACES OF THE BUSHINGS ARE NOT GETT ING PROPER LUBRICATION BECAUSE THE SPLIT PINS THAT ARE USED TO RETAIN THE BUSHINGS ARE ALLOWING GREASE TO ESCAPE AND THE REFORE GREASE IS NOT GETTING BETWEEN THE SURFACES. PLUGGING THE HOLES IN THE SPLIT PINS MAY SOLVE THE PROBLEM BECAUSE T HE GREASE WILL THEN BE FORCED UP TO THE BEARING CONTACT SURFACES. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005030800077 20050308 00077 EU 2005 3 8 CA040616008 1 20040603 G 5210 5521012187 HANDLE PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL PAX DOOR BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA INNER PASSENGER DOOR HANDLE BROKE OFF WHEN TRYING TO OPEN DOOR. THIS IS A REOCCURRING PROBLEM BELIEVED TO BE CAUSED BY A COMBINATION OF FACTORS INCLUDING:1) CONDENSATION IN THE DOOR CAUSES TO UNLOCKING MECHANISM CABLE TO FREEZE.2) THE SPRI NG USED ON THE SECONDARY LOCKOUT IS TOO WEAK.3) AND EXCESSIVE MACHINING OF THE DOOR HANDLE ITSELF. BY INCREASING THE SP RING TENSION AND REDUCING THE MACHINING DONE TO THE DOOR HANDLE THIS PROBLEM MAY BE REMEDIED. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005030800078 20050308 00078 EU 2005 3 8 CA040616010 1 20040603 G 5210 5521012179 BRACKET PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL PAX DOOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA COUNTERBALANCE BRACKET ON PASSENGER DOOR FOUND CRACKED ON SCHEDULED INSPECTION. THE BRACKET IS OFTEN FOUND LOOSE DUE TO THE RIVETS USED ON INSTALLATION ARE NOT OF SUFFICIENT STRENGTH. RECOMMEND USING STRUCTURAL SCREWS OR BOLTS TO SECURE B RACKET TO PREVENT FURTHER OCCURRENCES. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005030800079 20050308 00079 CE 2005 3 8 CA040616011 1 20040519 G 5220 50111302 DOOR CESSNA 401 401B 207590E CE CONT O520 TSIO520EB 17040 SO EMERGENCY EXIT SEPARATED W B A EMER. DESCENT UNSCHED LANDING D INFLIGHT SEPARATION CR CRUISE 1 CA AFTER TAKEOFF A GROWING WHISTLING SOUND DEVELOPED IN INTENSITY OVER PILOTS LEFT SHOULDER. THERE WAS A LOUD POP OF A NOI SE AND THE PILOT SAW THE STARBOARD EMERGENCY EXIT SELF EJECT OUT AND BACK FROM THE REST OF THE PLANE. AIRSPEED WAS REDU CED 170 MPH. PLANE WAS CLEARED TO LAND WHICH WAS UNEVENTFUL. 1 L 7 2 3O 3 O A7CE E8CE 2005030800080 20050308 00080 WP 2005 3 8 CA040617001 1 20040610 G 3260 WARNING LIGHT DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE MLG ILLUMINATED W L ABORTED APPROACH J WARNING INDICATION AP APPROACH 1 CA NOSE GEAR UNSAFE LIGHT ON WITH GEAR HANDLE DOWN DURING APPROACH IN XXX. AIRCRAFT OVERSHOOT. GEAR RESELECTED UP AND DOW N WITH 3 LIGHTS ON. MAINTENANCE DID A PSEV BITE CHECK AND ALL NOSE GEAR SWITCHES CHECKED FOR CORRECT GAP DISTANCE AND O PERATION AND NO FAULT FOUND. 2 L 7 2 4F 4 F RT A6WE E9NE 2005030800081 20050308 00081 WP 2005 3 8 CA040617002 2 20040616 G 7250 310117017 BEARING SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP ENGINE MAKING METAL W K NONE O OTHER IN INSP/MAINT 1 CA P54043 AN IMMEDIATE ENGINE INSPECTION WAS REQUESTED BY WEAR CHECK DUE TO MAJOR SILVER CONTENT IN THE OIL SAMPLE. UPON INSPECTI ON OF THE ENGINE GEAR CASE THE HIGH SPEED PINION BEARING AND CAGE WERE FOUND TO HAVE THE SILVER COATING FLAKING OFF. T HIS PROBLEM IS IDENTICAL TO SDR20040611003. ENGINE HAS BEEN REMOVED FROM THE AIRCRAFT FOR REPAIRS. PICTURES: 019 HOLE IN OUTER RACE.020 ROLLERS SCRATCHED. 021 SILVER COMING OFF CAGE .022 SILVER COMING OFF CAGE. 2 L 7 2 4T 4 T RT A8SW E4WE 2005030800082 20050308 00082 WP 2005 3 8 CA040617003 2 20040615 G 7250 310117015 BEARING GARRTT TPE331 TPE33110UA 01514 WP ENGINE OVERHEATED W K NONE O OTHER IN INSP/MAINT 1 CA P54019 DURING A SCHEDULED ENGINE INSPECTION OF THE HIGH SPEED PINION ASSY A BRIGHT BLUECOLOR WAS NOTICED ON THE PINION GEAR. T HE HIGH SPEED PINION SUFFERED SEVERE HEAT DAMAGE CLOSE TO THE POINT OF FAILURE. THIS PART WAS PURCHASED THROUGH AN AMER ICAN PARTS DISTRIBUTOR AND CERTIFIED BY AN AMERICAN GARRETT OVERHAUL FACILITY. 4 T E4WE 2005030800083 20050308 00083 SW 2005 3 8 CA040617004 1 20040614 G 3242 V151000 MASTER CYLINDER SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP BRAKES LOCKED W O OTHER O OTHER TX TAXI/GRND HDL 1 CA DURING A MAINTENANCE RUN-UP AND SUBSEQUENT TAXI, THE BRAKES LOCKED UP AND THE AIRCRAFT COULD NOT BE MOVED. BRAKE PRESSU RE WAS RELIEVED AT THE BRAKE ASSY AND WAS FOUND THE NR 1 BRAKE MASTER CYLINDER HAD MALFUNCTIONED AND CAUSED THE BRAKES T O LOCK UP. REFERENCE AD 2002-08-02 ISSUED FOR THIS PROBLEM. THIS AIRCRAFT IS IN COMPLIANCE WITH THIS AD. 2 L 7 2 4T 4 T RT A8SW E4WE 2005030800084 20050308 00084 SW 2005 3 8 CA040617005 1 20040614 G 3213 2752529003 PIN SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP SCISSOR LINK BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA DURING A DAILY INSPECTION, IT WAS NOTICED THAT THE RT MAIN LANDING GEAR SCISSOR LINK UPPER PIN WAS FOUND BROKEN. THE PI N BROKE AT THE RETAINING HOLE IN WHICH A ROLL PIN IS INSTALLED. IT WAS ALSO DETERMINED THAT THIS PIN WAS FOR A NOSE GEA R INSTALLATION. ALTHOUGH IT IS THE SAME SIZE AND FIT AS THE MAIN GEAR SCISSOR PIN THIS PART NUMBER PIN IS NOT ELIGIBLE FOR INSTALLATION ON THE MAIN GEAR SCISSOR LINK AS PER THE MANUFACTURERS IPC. THE PIN WAS MOST LIKELY FRACTURED AT SOME POINT FROM REMOVAL OR INSTALLATION OF THE ROLL PIN WITH THE USE OF A PIN PUNCH. 2 L 7 2 4T 4 T RT A8SW E4WE 2005030800085 20050308 00085 EU 2005 3 8 CA040617006 1 20040608 G 2530 KR906931 RELAY AIRBUS 330 A330322 3930325 EU PWA 4168 PW4168 NE COFFEEMAKER FAILED W K NONE O OTHER IN INSP/MAINT 1 CA 0106 COFFEEMAKER WAS REMOVED DUE TO TRIPPING CIRCUIT BREAKER. STRIP REPORT REVEALED THAT THE UNAPPROVED RELAY WAS FITTED TO THE COFFEEMAKER. CORRECT P/N KR-90693-1 P/N FOUND KR 14DGE24. 2 L 7 2 4F 4 F RT A46NM E36NE 2005030800086 20050308 00086 EA 2005 3 8 CA040617007 2 20040610 G 7322 324475319 FUEL CONTROL DHAV DHC7 DHC7103 2802710 EA PWA PT6 PT6A50 52043 EA HAMSTD 24PF 24PF305 GL ENGINE FAILED W E A ENGINE SHUTDOWN UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 CA PCE86031 SHORTLY AFTER TAKEOFF, ON CLIMBING THROUGH 6,000 FT, PILOT NOTICED OVER TORQUE LIGHT ON FOR ENGINE NR 4. A QUICK GLANCE AT OTHER ENGINE GAUGES TO CONFIRM ENGINE OVERSPEED, AND PULLED BACK THE POWER LEVER FOR NR 4 ENGINE TO SEE IF THERE WAS ANY RESPONSE. PILOT THEN PULLED TEE HANDLE TO SHUT NR 4 ENGINE DOWN. REST OF FLT AND LANDING UNEVENTFUL. UPON INSPEC TION OF ENGINE AND SUBSEQUENT REMOVAL OF FUEL CONTROL UNIT, DRIVE SHAFT BETWEEN THE FCU AND HP FUEL PUMP, FOUND TO BE SH EARED OFF AND SO CAUSING ENGINE TO OVERSPEED. DRIVE SHAFT SHEARED OFF WHERE DRIVE SPRING RETAINING CLIP GROOVE WAS ON D RIVE SHAFT. ENGINE AND ITS COMPONENTS WERE REPLACED WITH SERVICEABLE UNITS, AND GROUND RUNS CARRIED OUT SERVICEABLE. 2 H 7 4 4T 4 T A20EA E4EA 6 C P1NE 2005030800087 20050308 00087 2005 3 8 CA040618002 4 20040617 G 3130 S703100000 RECORDER BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE CABIN BURNED W A UNSCHED LANDING B H SMOKE/FUMES/ODORS/SPARKS ELECT. POWER LOSS-50 PC CR CRUISE 1 CA CREW ESTABLISHED CRUSIE AT 16000 FEET, AC BUSS DETECTED ERRORS CAUSING SEVERAL AC RELATED COMPONENTS TO BECOME ERRONEOUS . CREW NOTED SMELL AND BLUE HAZE. EVENTUALLY THE FDR 115AC C/B OPENED. RETURNED TO DEPARTURE AIRPORT FOR INVESTIGATIO N. MAINTENANCE FOUND THE POWER SUPPLY BOARD WITHIN THE FDR HAD BLOWN A TRANSORB CAUSING THE ELECTRICAL SMELL AND SMOKE. ONCE THE 115AC HAD OPENED, THE VOLTAGE VARIATIONS BEING CREATED STOPPED AND ALL SYSTEMS RETURNED TO NORMAL, SAVE THE F DR WHICH WAS LEFT UNPOWERED. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2005030800088 20050308 00088 CE 2005 3 8 CA040618003 1 20040616 G 3340 S21605 SWITCH CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA LANDING LIGHT FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA STUDENT PILOT AND INSTRUCTOR NOTED SMOKE COMING FROM LANDING LIGHT SWITCH AREA. RETURNED TO BASE AND NOTIFIED MAINTENAN CE. SWITCH FOUND U/S, CIRCUIT BREAKER HAD NOT POPPED. THIS HAS HAPPENED NUMEROUS TIMES BEFORE TO THIS TYPE OF SWITCH. 1 H 7 1 3O 3 O NT 3A19 E223 2005030800089 20050308 00089 EA 2005 3 8 CA040618004 2 20040616 G 7322 ACCELL PUMP MARVELSCHEBX CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA CARBURETOR SEPARATED W O OTHER E VIBRATION/BUFFET AP APPROACH 1 CA DT0105 ACCELERATOR PUMP ON THIS CARBURETOR PUSHES FUEL THRU A BRASS TUBE APPROX 3' LONG. TUBE IS PERMANENTLY MOUNTED TO CARB BO DY AT LOWER SECTION OF VENTURI ADJACENT TO ACCELERATOR PUMP. TUBE HAS A 90 DEGREE BEND NEAR WHERE IT ATTACHES TO CARB B ODY & THEN TRAVELS VERTICALLY UP VENTURE APPROX 2'. TIP OF TUBE IS SHAPED TO FORM JET. PARTS CAT FOR CARB DOES NOT SHOW A PN FOR TUBE. PN 105055 IN THIS INSTANCE, CAME UNFASTENED FROM CARBURETOR & APPARENTLY SUCKED UP VENTURI & BECAME LO DGED IN THROTTLE VALVE. PILOT NOTED UNABLE TO PULL THROTTLE CONTROL BACK TO LESS THAN 2000 RPM. BY CLIMBING, PILOT ABL E TO SLOW AIRCRAFT ENOUGH TO SELECT FLAPS DOWN & MAKE A RELATIVELY NORMAL LANDING. CARB REPLACED WITH SERVICEABLE. 1 H 7 1 3O 3 O NT 3A19 E223 2005030800090 20050308 00090 2005 3 8 CA040618005 4 20040618 G 2562 AK450 ELT AMERIKING CABIN FAILED W K NONE L NO TEST IN INSP/MAINT 1 CA UPON ANNUAL INSPECTION ELT, IT WAS NOTED THAT THE MODULATION WOULD FAIL AFTER 10 SEC OF USE. THE SOUND HEARD WOULD REMA IN AS A ELT WARBLE WITH REDUCED VOLUME. THIS FAULT HAD BEEN NOTED ON ONE OTHER UNIT EARLIER THIS YEAR. 2005030800091 20050308 00091 SW 2005 3 8 CA040618006 1 20040610 G 2710 2771004073 LINK ASSY SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP AILERONS CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 27030 FOUND LEFT AND RIGHT LINK ASSY ON AILERON PUSH PULL TUBES CORRODED AND CRACKED ON ALL FOUR SIDES. PARTS WERE REMOVED AN D A NEW LINK ASSY WERE INSTALLED. 2 L 7 2 4T 4 T RT A8SW E4WE 2005030800092 20050308 00092 NE 2005 3 8 CA040618007 2 20040617 G 7421 REB37E SPARK PLUG DOUG DC4 C54 3021506 WP PWA R2000 R20007M2 52023 NE NR 4 ENGINE FOULED W E ENGINE SHUTDOWN R E PARTIAL RPM/PWR LOSS VIBRATION/BUFFET CR CRUISE 1 CA DURING CRUISE, THE PILOTS NOTICED THE NR 4 ENGINE STARTING TO BACKFIRE, THE BACK FIRING WAS GETTING OUT OF CONTROL SO TH E ENGINE WAS SHUT DOWN AND THE PROPELLER FEATHERED. DURING THE INSPECTION OF THE NR 4 ENGINE IT WAS FOUND THAT THE FRON T AND REAR SPARKS FOR THE NR 2 CYLINDER WERE FOULED. THE PLUGS WERE REPLACED AND ENGINE RUN-UP WAS FINE. 2 L 7 4 4R 4 R A762 5E5 2005030800093 20050308 00093 CE 2005 3 8 CA040621001 1 20040618 G 2730 CONTROL CABLE CESSNA 500 550 2076604 CE PWA 530 PW530A NE ELEVATOR CHAFED W K NONE O OTHER IN INSP/MAINT 1 CA ELEVATOR MAIN TRIM CABLE FOUND RIDING BETWEEN ELECTRONIC TRIM SERVO DRUM AND GUARD. 1 L 7 2 4F 4 F A22CE E00053EN 2005030800094 20050308 00094 EU 2005 3 8 CA040621002 1 20040603 G 2750 5275212154 DRIVE ASSY PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL FLAP CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA RT INBOARD FLAP DRIVE ARM FOUND CRACKED DURING SCHEDULED MAINTENANCE AT THE ATTACHMENT POINT OF THE FLAP INTERCONNECT CA BLE. FREQUENT FREEZING OF THE FLAP INTERCONNECT CABLE BELIEVED TO BE THE CAUSE OF PROBLEM. PILATUS SB 27-010 STATES TH AT THE DISCONNECTION OF THE INTERCONNECT CABLE WILL HAVE 'NO EFFECT ON AIRCRAFT SAFETY'. THEREFORE, THE MAINTENANCE DEP ARTMENT AND THE FLIGHT CREWS HAVE COME TO THE CONSENSUS THAT THE CABLE SHOULD BE PERMANENTLY REMOVED AND AN AMENDMENT MA DE TO THE PILOTS OPERATING HANDBOOK. REMOVAL OF CABLE CANNOT BE ACCOMPLISHED UNTIL APPROVAL IS GIVEN BY PILATUS. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005030800095 20050308 00095 SO 2005 3 8 CA040621003 1 20040616 G 2612 5064200 FIRE DETECTOR PIPER PA42 PA42720 7104212 SO PWA PT6 PT6A61 52043 EA RT ENGINE SHORTED W E ENGINE SHUTDOWN N FALSE WARNING AP APPROACH 1 CA DURING APPROACH FOR LANDING, THE RT ENGINE FIRE WARNING ANNUNCIATOR ACTIVATED. THE PILOT DEPLOYED THE ENGINE FIRE BOTTLE , SECURED THE ENGINE AND DECLARED AN EMERGENCY. THE LANDING CONTINUED UNEVENTFUL. MX INSPECTED THE ENGINE AND FOUND NO E VIDENCE OF FIRE. THE FIRE DETECTION SYSTEM WAS INSPECTED AND EACH PROBE (3) WAS INDIVIDUALLY TESTED WITH THE MEGGER. TWO OF THE THREE WERE OK BUT ONE SHOWED A FAULT. FIRST ON THE LOW 0-200 OHMS RANGE AND IT SHOWED A RESISTANCE OF ABOUT 1 ME G OHM AND IT SHOULD BE INFINITE OR OPEN. THEN I CHECKED IT AT THE 250 V SETTING AND THE RESISTANCE DROPPED TO BASICALLY NOTHING INDICATING SHORTED OR CORRODED CONTACTS. THE FAULTY PROBE WAS REPLACED NEW AND CIRCUIT TESTS C/O SATISFACTORY. A 1 L 7 2 4T 4 T A23SO E4EA 2005030800096 20050308 00096 EU 2005 3 8 CA040621004 1 20040604 G 2751 9733031215 SWITCH PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL TE FLAPS STICKING W K NONE O OTHER IN INSP/MAINT 1 CA FLAP UP SWITCH STICKING IN ALL ENVIRONMENTAL CONDITIONS CAUSING FLAP FAILURES IN FLIGHT AND ON GROUND. FLIGHT CREWS SHO ULD BE AWARE THAT IF FAILURE OCCURS AND FLAPS ARE SET AT 15, 30 OR 40. THE ONBOARD COMPUTER WILL NOT GIVE THE AIRSPEED WARNING AT 165 KTS. BETTER SEALS OR DUST CAPS MAY SOLVE THE PROBLEM. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005030800105 20050308 00105 EU 2005 3 8 CA040621005 1 20040609 G 2932 9738114304 PRESSURE SWITCH PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL HYD SYSTEM LEAKING W K NONE O OTHER IN INSP/MAINT 1 CA 11297 LOW PRESSURE HYDRAULIC SWITCH (P/N 973.81.14.304) LEAKING FROM VENT HOLE. SIMILAR PROBLEMS FOUND WITH HIGH PRESSURE SWIT CH (P/N 973.81.14.306). 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005030800106 20050308 00106 CE 2005 3 8 CA040621006 1 20040617 G 3320 2064862 RECEPTACLE BEECH 200 B200 1152922 CE PWA PT6 PT6A42 52043 NE DOOR LIGHT CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA COURTESY AND ENTRANCE DOOR LIGHTS REPORTED U/S. TROUBLESHOOTING LED TO CONNECTOR P406 LOCATED IN THE AIRCRAFT SIDEWALL FORWARD OF THE ENTRANCE DOOR. FOUND CONNECTOR PINS CORRODED, PRIMARILY PIN 7 THATSUPPLIES 28VDC TO THE CIRCUIT. WIRING REPAIRED AND AIRCRAFT RELEASED. 1 L 7 2 4T 4 T A24CE E4EA 2005030800107 20050308 00107 EU 2005 3 8 CA040621007 1 20040604 G 3260 9733033111 PROXIMITY SWITCH PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL NLG FAILED W O OTHER P NO WARNING INDICATION DE DESCENT 1 CA NOSE GEAR DOWN PROXIMITY SWITCH NOT GIVING DOWN AND LOCKED INDICATIONS ON NOSE GEAR. REOCCURRING PROBLEM AROUND THE 900 0-10000 CYCLE RANGE ON PC-12'S. PC-12'S INCORPORATE THESE SWITCHES IN THE NOSE GEAR UP AND DOWN LOCK INDICATION POSITIO NS THE MAIN GEAR UPLOCK POSITIONS AND THE MAIN GEAR WEIGHT ON WHEEL POSITIONS. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005030800110 20050308 00110 SW 2005 3 8 CA040621008 1 20040618 G 2910 206076022005 POWERPACK BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL HYD SYSTEM FAILED W E ENGINE SHUTDOWN F FLT CONT AFFECTED TX TAXI/GRND HDL 1 CA IT APPEARS THAT THE HYDROPACK HAD AN INTERNAL GEAR FAILURE. THE AIRCRAFT HAD NR INDICATIONS BUT NO HYDRAULIC PRESSURE. HYDROPACK WAS CHANGED AND AIRCRAFT RETURNED TO SERVICE. 1 G 7 1 3U 3 U H2SW E4CE 2005030800112 20050308 00112 CE 2005 3 8 CA040621010 1 20040621 G 7603 2520851 THROTTLE CONTROL CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA COCKPIT LOOSE W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA THROTTLE CONTROL WAS REPLACED AT A SCHEDULED INSPECTION RECENTLY AND HAS ALREADY COME LOOSE AT THE CRIMPED PIVOT END AFT ER ONLY APPROX 160 HOURS TIS. THIS PART WAS INSTALLED AS A NEW PART SUPPLIED FROM THE MANUFACTURER. DEFECTIVE PART REM OVED AND TO BE REPLACED WITH NEW PART 1 H 7 1 3O 3 O NT 3A12 E274 2005030800124 20050308 00124 CE 2005 3 8 CA040621011 1 20040617 G 2752 511523716 ACTUATOR CESSNA 401 401B 207590E CE CONT O520 TSIO520EB 17040 SO MCAULY 2D36C 2D36C* GL TE FLAP WORN W O OTHER F FLT CONT AFFECTED AP APPROACH 1 CA ON APPROACH, THE FLAPS WERE LOWERED TO 45 DEG BUT ONLY WENT TO 30 DEG. THE AIRCRAFT LANDED SAFELY. THE FLAP ACTUATOR I NTERNAL GEARS WERE FOUND STRIPPED. THE ACTUATOR WAS REPLACED WITH AN OVERHAULED UNIT. 1 L 7 2 3O 3 O A7CE E8CE 5 C P901 2004072900008 20040729 00008 NM 2004 7 29 CA040622001 1 20040621 G 2910 DSC252B40124 HOSE DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE NR 2 HYD SYSTEM LEAKING W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA (CAN) ENROUTE, THE CREW NOTICED SLOW BUT STEADY DEPLETION OF HYDRAULIC SYSTEM 2 . THE QUANTITY DOWN TO 2 QUARTS. CREW R ETURNED AIRCRAFT BACK WHERE MAINTENANCE PERSONAL UPON INVESTIGATION FOUND THE HOSE TO THE DRAG STRUT ACTUATOR IN THE NOS E GEAR BAY LEAKING. THE HOSE WAS REPLACED WITH A NEW UNIT AND TESTS PERFORMED IAW ATA 32-30-31 AND A/C WAS RETURNED TO S ERVICE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004072900009 20040729 00009 EA 2004 7 29 CA040622002 1 20040608 G 3246 BRACKET DHAV DHC2 DHC2MK1 2800102 EA PWA R985 R985AN14B 52008 NE HAMSTD 2D 2D30 NE LT FLOAT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 385 (CAN) LT FLOAT REAR DOCK FITTING SADDLE BRACKETS CRACKED AT BOLT HOLES. 1 H 7 1 3R 3 R A806 5E1 5 C P206 2004072900012 20040729 00012 CE 2004 7 29 CA040622005 1 20040606 G 2410 539547310 BELT CESSNA 210 T210L 2073449 CE CONT O520 TSIO520H 17040 SO MCAULY 3A32C D3A32C88 GL ALTERNATOR FAILED W A UNSCHED LANDING H J ELECT. POWER LOSS-50 PC WARNING INDICATION CR CRUISE 1 CA (CAN) THE ALTERNATOR DRIVE BELT CAME OFF IN FLIGHT. 1 H 7 1 3O 3 O 3A21 E8CE 5 C P21EA 2004072900045 20040729 00045 CE 2004 7 29 CA040622006 1 20040611 G 5551 04320049 BRACKET CESSNA CESSNA 150 A152 2071836 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL HORIZONTAL STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 10465 (CAN) THE BRACKET OF THE STABILIZER ASSEMBLY WAS FOUND CRACKED. 1 H 7 1 3O 3 O 3A19 E223 5 N P50GL 2004072900053 20040729 00053 NE 2004 7 29 CA040622007 2 20040622 G 7530 311269001 VENTURI DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE ADAPTER FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AFTER SHUTDOWN DUE TO UNSUCCESSFUL TRIM RUNS, IT WAS DISCOVERED THAT THE ADAPTER VENTURI P3 BLEED AIR PIPE LOCATED ON THE NR 1 ENGINE (S/N TM123038) THERE WAS 1 INCH X 1 INCH HOLE IN THE PIPE. THERE IS A CRACK THAT HAS PROPOGATED AND CAUSED THE PIPE TO FAIL. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004072900054 20040729 00054 EA 2004 7 29 CA040623001 1 20040621 G 1430 AN316 NUT FOUND FBA FBA2C 3640102 EA LYC O540 IO540D4A5 41532 EA HARTZL HCC3Y HCC3YR GL CONTROL CABLE LOOSE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING A ROUTINE INSPECTION THE JAM NUTS THAT SECURE THE PROP CONTROL CABLE TO AN ATTACHMENT BRACKET AT THE PROP G OVERNOR WERE FOUND LOOSE. THE LOWER JAM NUT HAD BACKED OFF COMPLETELY AND THE CABLE WAS FREE TO MOVE, BUT IN ONE DIRECTI ON ONLY. THE CONTROL CABLE IS SECURED TO THE ATTACHMENT BRACKET WITH JAM NUTS THAT ARE SECURED WITH INTERNAL TOOTH LOCK WASHERS, BUT DO NOT HAVE HOLES FOR SECURING WITH LOCKWIRE. 1 H 7 1 3O 3 O A7EA 1E4 5 C P25EA 2004080400210 20040804 00210 NE 2004 8 4 CA040623002 2 20040605 G 7321 586982 DUMP VALVE SKRSKY S64 S64E 8142604 NE PWA JFTD12 JFTD12A4A 52047 NE ENGINE FUEL MALFUNCTIONED W E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION DE DESCENT 1 CA 638341 (CAN) AS COLLECTIVE WAS LOWERED FLIGHT CREW HEARD A (WHOOSH) SOUND FOLLOWED BY AN ENG N1 UNDER-SPEED WARNING AUDIO. FLIG HT CREW VERIFIED ENG, IMMEDIATELY EXECUTED AN IN-FLIGHT SHUTDOWN OF NR 1 ENG TO PREVENT OVER-TEMP CONDITION. WITH NR 1 E NG SHUTDOWN, AC RETURNED TO ITS SERVICE AREA WITHOUT FURTHER INCIDENT. INSP OF ENG, ITS RELATED CONTROL LINKAGES REVEA LED NOTHING ABNORMAL. ENG FUEL PRESSURIZING, DUMP VALVE (P&D VALVE) WAS CHANGED AS A STANDARD PROCEDURE IN A SOFT STALL OCCURRENCE. ADDITIONALLY, FCU WAS ALSO CHANGED AS PRECAUTIONARY MEASURE. ENG WAS RESTARTED, GROUND-RUN, FOUND TO BE ACC EPTABLE AC WAS RELEASED FOR FLIGHT. THE SUSPECT COMPONENTS WERE RETURNED TO MFG FOR INTERNAL INSPECTION, EVALUATION. 2 G 7 2 4U 4 U H4EA E15EA 2004072900055 20040729 00055 NM 2004 7 29 CA040623004 1 20040525 G 3250 89925 LINK DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE NLG STEERING CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING A ROUTINE LAYOVER CHECK THE STEERING LINK ON THE NOSE STEERING ACTUATOR WAS DISCOVERED TO HAVE A CRACKED EN D FITTING WHERE THE CENTER PIVOT PIN PASSES THROUGH AND MATES WITH THE ADJOINING LINK. THE END FITTING WAS STRETCHED OP EN AND THE THIN RING END BROKEN AWAY. ALL LINKS AND PINS WERE REMOVED AND INSPECTED WITH NO ADDITIONAL DAMAGE DETECTED. THE DEFECTIVE LINK WAS REPLACED. THERE WAS NO INDICATION OF A STEERING PROBLEM REPORTED BY THE FLIGHT CREW. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004072900056 20040729 00056 EA 2004 7 29 CA040623005 1 20040623 G 3242 260414126629 HOUSING BFGOODRICH CNDAIR CL215 CL2151A10 1900320 EA PWA R2800 CA18 52026 NE HAMSTD 43E 43E60 NE PISTON CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 0721 (CAN) HOUSING CRACKS FOUND AT OVERHAUL DURING LPI NDT OF BRAKE UNIT. THERE HAS BEEN PREVIOUS FINDINGS OF CRACKS IN SERVI CE AND AT OVERHAULS OF OTHER BRAKE UNITS. LEAKING BRAKE COULD BE INDICATION OF CRACKED BRAKE HOUSING. EXCESSIVELY WORN BRAKE COULD PROMOTE DISTORTION OF HOUSING, CREATING CRACKING. 2 H 7 2 4R 4 R RT A14EA E231 6 C P871 2004072900084 20040729 00084 EA 2004 7 29 CA040623006 1 20040604 G 1430 NAS620760D BOLT CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE PAX DOOR SEIZED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) PILOT REPORTED MAIN PASSENGER DOOR DIFFICULT TO OPEN FROM OUTSIDE, HAD TO ENTER FROM SERVICE DOOR TO ACCESS AIRCRA FT. TRIED TO OPEN DOOR AND HANDLE WAS DIFFICULT TO TURN. MAINTENANCE FOUND AIRSTAIR PIVOT FITTING ASSEMBLY WAS SEIZED. UPON DISMANTLING THE ASSEMBLY, IT WAS NOTED THAT THE BOLT P/N NAS6207-60D WAS CORRODED AND SEIZED PREVENTING FREE OPERA TION WITHIN THE PHENLOIC BUSHING. ASSEMBLY WAS REPLACED. 2 L 7 2 4F 4 F RT A21EA E15NE 2004072900086 20040729 00086 SW 2004 7 29 CA040623009 1 20040623 G 6410 206016201131 BLADE BELL 206 206L 1181522 SW ALLSN 250C 250C20R2 GL TAIL ROTOR PERFORATED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHILE CARRYING OUT REQUIREMENTS OF AD CF-2004-05(BHTC ASB 206L-04-127 REV A) A PIN HOLE IN THE EPOXY FILLER, APPRO XIMATELY .012 IN. DIA, INTRUDING INTERNALLY, WAS FOUND. WATER WAS OBSERVED DRAINING FROM THE HOLE. BLADE HAS BEEN SCRA PPED. 1 G 7 1 3U 3 U H2SW E4CE 2004072900087 20040729 00087 CE 2004 7 29 CA040624001 1 20040617 G 7120 R2070011 MOUNT BEECH 200 B200C 1152924 CE PWA PT6 PT6A42 52043 NE HARTZL HCD4N3 HCD4N3A GL ENGINE MISMANUFACTURED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) DURING ENGINE MOUNT REPLACEMENT IT WAS NOTICED THAT THE NEW MOUNTS WERE MANUFACTURED WITH THE BEVEL ON THE WRONG S IDE OF THE METAL PART OF THE CORE (R20700-11). THE CORE IS MADE OF RUBBER SANDWICHED BETWEEN TWO PIECES OF METAL. THE B EVEL IS THERE TO ALLOW THE INSERTION OF THE HAT BUSHING, THESE PARTS ARE ASSEMBLED WITH AN INTERFERENCE FIT, WITHOUT THE BEVEL IT IS VERY DIFFICULT/ IMPOSSIBLE TO INSERT THE BUSHING. STOCK WAS CHECK AND THREE MORE KITS WERE FOUND IN THE SAM E CONDITION. THE PARTS WERE REJECTED. 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2004072900088 20040729 00088 EA 2004 7 29 CA040624003 2 20040617 G 7313 25245009 INJECTOR PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL ENGINE MALFUNCTIONED W B A EMER. DESCENT UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 CA (CAN) ENGINE EXPERIENCED POWER LOSS. MANIFOLD PRESSURE WENT FROM 32 - 20 INCHES. FLIGHT CREW MADE UNSCHEDULED LANDING WITHOUT INCIDENT. ENGINEER FOUND THAT SERVO FUEL INJECTOR WAS THE PROBLEM AND HAD FLOODED OUT THE ENGINE. ENGINEER REPL ACED SERVO FUEL INJECTOR WITH SERVICEABLE UNIT. RAN UP A/C ALL CHECKED OUT AND A/C RETURNED WITHOUT FURTHER PROBLEMS. A/ C HAS BEEN FLYING SERVICEABLE SINCE THEN. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004072900089 20040729 00089 EU 2004 7 29 CA040624004 1 20040614 G 2572 DHS78212010 HOLDER UROCOP EC155 EC155B 8681000 EU TMECA ARRIEL ARRIEL2B NE FUSE LOOSE W A UNSCHED LANDING N FALSE WARNING CR CRUISE 1 CA (CAN) AC HAS THREADED TYPE FUSE HOLDERS. IN CRUISE, LOST OIL PRESSURE INDICATION ON NR 2 ENGINE. LOW PRESSURE LIGHT DID NOT COME ON, (IT'S ON A SEPARATE PRESS SWITCH). PILOT REDUCED NR 2 ENG TO IDLE. TEMP REMAINED NORMAL WITH NO OTHER CHA NGES IN SYSTEMS. AN UNEVENTFUL LANDING WAS COMPLETED. INVESTIGATION REVEALED FUSE HOLDER HAD VIBRATED LOOSE AND CAUSED FUSE FOR OIL PRESSURE INDICATION TO LOSE CONTACT CAUSING A POWER LOSS FOR THE INDICATOR. ABOUT 10 OTHER FUSE HOLDER CAP S WERE ALSO FOUND LOOSE. FUSE HOLDER HAS NO POSITIVE LOCKING FEATURE AND AS A RESULT, NOW WILL BE CHECKING PERIODICALLY . THOUGH NOT A TERRIBLY SERIOUS ISSUE IT IS ONE THAT DESERVED MENTION AS OTHER MFG PRODUCTS MAY USE SAME FUSE HOLDER. 1 G 7 2 3U 3 U H10EU E00054EN 2004072900090 20040729 00090 SW 2004 7 29 CA040624005 1 20040524 G 5302 206030329103 FITTING BELL 206 206L1 1182107 SW ALLSN 250C 250C28B 03013 GL TAILBOOM CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) FORWARD UPPER LT TAILBOOM ATTACHMENT FITTING FOUND CRACKED DURING 200 HOUR INSPECTION. MFG INSPECTION CALLS FOR S PECIAL ATTENTION TO THIS AREA DURING THE INSPECTION. THIS IS A KNOWN PROBLEM AREA. 1 G 7 1 3U 3 U H2SW E1GL 2004072900091 20040729 00091 CE 2004 7 29 CA040624006 1 20040623 G 3230 583800901 MOTOR BEECH 95 D95A 1153408 CE LYC O360 IO360B1B 41514 EA HARTZL HCC2Y HCC2YK2 GL MLG FAILED W O OTHER W INADEQUATE Q C NR NOT REPORTED 1 CA (CAN) UPON REPLACEMENT, TESTING OF LANDING GEAR MOTOR RECEIVED FROM AN APPROVED OH FACILITY IT WAS DETERMINED MOTOR WAS SPINNING IN REVERSE DIRECTION. MOTOR WAS REMOVED AND BENCH TESTED TO ELIMINATE AN AC WIRING PROBLEM. MOTOR ROTATED IN WRONG DIRECTION AGAIN DURING BENCH TEST AS WELL. MAJOR DAMAGE TO LANDING GEAR COMPONENTS CAN OCCUR DUE TO REVERSE OPERAT ION OF THIS MOTOR. DUE TO PROPER TESTING BY MAINT MOTOR WAS NOT ALLOWED TO RUN LONG ENEOUGH TO CAUSE ANY DAMAGE TO THE LANDING GEAR COMPONENTS. THE OVERHAUL FACILITY WAS CONTACTED AND ADVISED OF THE PROBLEM AND WERE HELPFUL IN DETERMINING THE PROBABLE CAUSE OF THE MOTOR MALFUNCTION. THE MOTOR HAS BEEN RETURNED TO OVERHAUL FACILITY FOR TESTING AND REPAIR. 1 L 7 2 3O 3 O 3A16 1E10 5 C P920 2004072900092 20040729 00092 EU 2004 7 29 CA040624007 3 20040621 G 6111 STRIP ROTOL R212 BRAERO 748 HS7482A 4231001 EU RROYCE DART DART5342 EU ROTOL R4304 R2124304 EU PROP BLADE LE SEPARATED W A UNSCHED LANDING E VIBRATION/BUFFET CL CLIMB 1 CA DRG56567 (CAN) DEPARTING, AN UNUSUAL NOISE WAS DETECTED FROM THE NR 2 ENGINE. THE AIRCRAFT RETURNED TO POINT OF DEPARTURE. THE LE ADING EDGE PROTECTION STRIP ON ONE BLADE WAS SEPARATED 6 INCHES AT THE OB END. MAINTENANCE REMOVED THE STRIPS FROM ALL 4 BLADES AND THE AIRCRAFT WAS RETURNED TO SERVICE AFTER GROUND RUN YIELDED NO VIBRATION OR UNUSUAL NOISE. 2 L 7 2 3T 4 T A24EU A196 6 C P899 2004080500026 20040805 00026 NE 2004 8 5 CA040624008 2 20040622 G 7200 ENGINE BOEING 727 727225 1384077 NM PWA JT8 JT8D15A 52051 NE MALFUNCTIONED W A UNSCHED LANDING M J OVER TEMP WARNING INDICATION CL CLIMB 1 CA (CAN) DURING TAKE-OFF, THE CREW REPORT THAT THEY HAD HEARD A BANG. ALL ENGINE PARAMETERS WERE NORMAL. THE AIRCRAFT MAD E AN UNSCHEDULED LANDING. ALL ENGINES WERE PHYSICALLY INSPECTED WITH NO APPARENT DAMAGE. ALL 3 ENGINES WERE STARTED, POWERED UP AND REVERSERS DEPLOYED. ALL ENGINES WERE CHECKED SERVICEABLE IAW MM 71-00 AND PWA MM 71-00-00. THE AIRCRAFT WAS RELEASED AND NO FURTHER INCIDENT DURING SUBSEQUENT FLIGHT. 2 L 7 3 4F 4 F A3WE E2EA 2004101800040 20041018 00040 CE 2004 10 18 CA040624009 1 20040513 G 7500 W99124CE COUPLING CESSNA 525 525 2076601 CE WILINT FJ44 FJ441A GL BLEED AIR SYS FAILED W K NONE M OVER TEMP IN INSP/MAINT 1 CA (CAN)A/C HAD BEEN MODIFIED AT FACTORY TO REMOVE FLEX COUPLING AND TUBE ARRANGEMENT OF S/N 0001 THRU 0129 BLEED AIR SYSTE MS (REF. IPC36-10-00-01 SHEET 1 OF 4 DETAIL B) AND INSTALL FLEX COUPLING AND TUBE ARRANGEMENT OF S/N'S 0130 THRU 0184. THIS UPGRADED ARRANGEMENT HAS SOME INHERENT ALIGNMENT DIFFICULTIES. ON TWO OCCASIONS (ONCE ON LT ENGINE AND SECOND ON R T ENGINE) COUPLING P/N W991-24CE FAILED TO REMAIN LATCHED AND JOINT SPREAD OPEN RESULTING IN A BLEED AIR LEAK. PILOT NO TICED A SHARP INCREASE IN ITT WITH POWER LEVER ADVANCES. ON BOTH OCCASIONS THE FAILURE OCCURRED DURING THE PREFLIGHT RU N UP. INSPECTION OF THE COUPLINGS DID NOT REVEAL SIGNIFICANT WEAR. COUPLINGS AND SEALS WERE REPLACED WITH NEW PARTS. 1 L 7 2 4F 4 F RT A1WI E3GL 2004080500033 20040805 00033 NM 2004 8 5 CA040625001 1 20040423 G 2910 3158223 CHECK VALVE DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE HYD SYSTEM LEAKING W O OTHER K J FLUID LOSS WARNING INDICATION AP APPROACH 1 CA (CAN) ON APPROACH AND AFTER LANDING GEAR DOWN SELECTION COMPLETED, NR 2 HYDRAULIC SYSTEM INDICATED LOSS OF ALL FLUID. AP PROACH TO LANDING WAS CONTINUED, FOLLOWING A NORMAL LANDING, CREW INSPECTED AC AND CONFIRMED A SIGNIFICANT HYD LEAK FROM AIRCRAFT'S EMPENNAGE AREA. FLIGHT WAS TERMINATED AND ENGINEERING ASSISTANCE REQUESTED. ENGINEERING INVESTIGATION CONFIR MED METAL FATIGUE FAILURE OF A CHECK VALVE BODY, WHICH ALLOWED LIBERATION OF ALL OF NR 2 HYDRAULIC SYSTEM FLUID TO ATMOS PHERE. FAILED CHECK VALVE WAS REPLACED AND FOLLOWING SERVICING OF THE NR 2 HYDRAULIC SYSTEM AIRCRAFT WAS RETURNED TO SE RVICE. IT WAS NOTED THAT INSIDE OF THE VALVE SHOWED SIGNS OF CORROSION. TSN=11366.21 HRS 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004080500034 20040805 00034 NM 2004 8 5 CA040625002 1 20040624 G 2612 FIRE LOOP BOEING 727 727260 NM PWA JT8 JT8D17 52049 NE NR 3 ENGINE MALFUNCTIONED W E ENGINE SHUTDOWN N FALSE WARNING CR CRUISE 1 CA (CAN) DURING FLIGHT, NR 3 ENGINE FIRE WARNING INDICATION WAS ACTIVATED. BELL WAS INTERMITTENT BUT BECAME A LITTLE MORE STEADY. EMERGENCY PROCEDURES WERE INITIATED AND NR 3 ENGINE WAS SHUTDOWN. FIRE HANDLE WAS PULLED BUT NOT TO RELEASE EX TINGUISHING AGENT. ATC WAS NOTIFIED. AIRCRAFT LANDED WITHOUT INCIDENT WITH EMERGENCY VEHICLES ON SITE. AIRCRAFT WAS S HUTDOWN. MTCE ACCESSED THE SITUATION. AN ELECTRICAL SHORT WAS FOUND IN THE NR 3 ENGINE FIRE LOOP SYSTEM. THE AIRCRAFT WAS RUN UP WITH NO FURTHER PROBLEMS. THE AIRCRAFT WAS RELEASED. NO FAULT DURING SUBSEQUENT FLIGHT. 2 L 7 3 4F 4 F RT A3WE E2EA 2004080500035 20040805 00035 NM 2004 8 5 CA040625003 1 20040624 G 5530 CASTING BOEING 737 737201 1384454 NM PWA JT8 JT8D9A 52048 NE VERTICAL STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING MAINTENANCE CHECK A CRACK WAS FOUND ON THE SPIDER CASTING AT RUDDER STATION 23.27 BELOW THE STANDBY RUDDER PCU IN THE VERTICAL STABILIZER. THE CRACK IS 3 INCHES IB OF OUTER EXTREMITIES, 7 INCHES FORWARD OF THE LOWER RUDDER HI NGE POINT APPROX 1.5 INCHES LONG AND .6250 INCHES FROM THE BASE. CRACK REPAIRED WITH AN EXTRUSION ANGLE IAW INSTRUCTION S FROM MFG MESSAGE 1-31239593. TIMES, 61592.12 CYCLES 59677. 2 L 7 2 4F 4 F A16WE E2EA 2004080500036 20040805 00036 NM 2004 8 5 CA040625004 1 20040624 G 2782 ACTUATOR BOEING 737 737217 1384464 NM PWA JT8 JT8D17 52049 NE SLAT INOPERATIVE W O OTHER J F WARNING INDICATION FLT CONT AFFECTED CL CLIMB 1 CA (CAN) NR 6 LEADING EDGE SLAT WAS SLOW TO RETRACT ON DEPARTURE. AFTER IT DID RETRACT IT RE-EXTENDED FOR ABOUT 5 MINUTES T HEN RETRACTED AGAIN. CREW WAS ALERTED BY SLAT INDICATION OF THE REDEPLOYMENT AND VISUALLY CONFIRMED THE EXTENSION AND RE TRACTION. NO OTHER ACTION TAKEN AND THE CREW CONTINUED TO DESTINATION. MAINTENANCE REPLACED THE NR 6 SLAT ACTUATOR AND THE AIRCRAFT WAS RELEASED FOR SERVICE. ACTUATOR SENT TO SHOP FOR EVALUATION AND A FULL REPORT HAS BEEN REQUESTED. 2 L 7 2 4F 4 F A16WE E2EA 2004080500037 20040805 00037 NE 2004 8 5 CA040625005 2 20040622 G 7510 39271611 MODULATING VALVE BOEING 727 727260 NM PWA JT8 JT8D17 52049 NE NR 1 BLEED SYS LEAKING W O OTHER M J OVER TEMP WARNING INDICATION CL CLIMB 1 CA (CAN) DURING CLIMB IT WAS OBSERVED THAT THE NR 1 ENGINE STRUT OVERHEAT LIGHT CAME ON. IAW OPS CHECKLIST, SYSTEM CHECK C ARRIED OUT AND FLIGHT CONTINUED WITHOUT INCIDENT. AFTER LANDING, INSPECTION WAS CARRIED OUT AND THE HIGH PRESSURE MODULA TING AND SHUTOFF VALVE WAS FOUND LEAKING. THE VALVE WAS REPLACED. LEAK CHECK CARRIED OUT AND CHECKED SERVICEABLE IAW M M 26-12-41. 2 L 7 3 4F 4 F RT A3WE E2EA 2004080500038 20040805 00038 NE 2004 8 5 CA040625006 2 20040624 G 7510 600231 SHUTOFF VALVE BOEING 727 727260 NM PWA JT8 JT8D17 52049 NE 13TH STAGE DUCT LEAKING W A UNSCHED LANDING M J OVER TEMP WARNING INDICATION CL CLIMB 1 CA (CAN) DURING CLIMB NR 1 ENGINE STRUT OVERHEAT LIGHT ILLUMINATED. OPS CHECKLIST CARRIED OUT. AIRCRAFT WAS RETURNED TO BA SE DUE TO SECOND INCIDENT IN 2 DAYS. DURING INSPECTION, NR 1 ANTI ICE VALVE SEALS WERE REPLACED. NR 1 BLEED SHUT OFF VA LVE WAS REPLACED IAW MM 36-10-01. HIGH POWER RUNS WERE CARRIED OUT. NO LEAKS FOUND AND NR 1 ENGINE STRUT OVERHEAT LIGH T DID NOT ILLUMINATE AFTER THE 15 MINUTE RUN. NO FURTHER PROBLEM DURING SUBSEQUENT FLIGHT. 2 L 7 3 4F 4 F RT A3WE E2EA 2004080500039 20040805 00039 GL 2004 8 5 CA040625007 2 20040623 G 7200 ENGINE EMB 145 EMB145XR 3260214 SO ALLSN AE300 AE3007A GL NR 2 FAILED W O OTHER Y J ENGINE STOPPAGE WARNING INDICATION DE DESCENT 1 CA CAE312406 (CAN) PRELIMINARY REPORT THE CREW REPORTED THAT ON DESCENT, THE NR 2 ENGINE FAILED (UNCOMMANDED SHUT DOWN). THE AIRCRAFT LANDED WITHOUT INCIDENT. ON GROUND, THE FAN WOULD NOT ROTATE FREELY, BUT CORE COULD NOT BE ROTATED VIA PMA SHAFT. ENG INE ALLOCATED TO RRC, FURTHER DETAIL WILL BE SUBMITTED AFTER ENGINE STRIP. 2 L 7 2 4F 4 F RT TE6CH 2004080500060 20040805 00060 SO 2004 8 5 CA040625008 1 20040624 G 3720 441CC7 DRIVE SHAFT PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL VACUUM PUMP SHEARED W O OTHER J WARNING INDICATION TX TAXI/GRND HDL 1 CA 109514 (CAN) ON LT ENGINE WARMING UP, FOUND LIGHT WARNING INDICATION (ON) IN RANGE OF RPM. WHILE TROUBLESHOOTING FOUND LT VAC UUM PUMP DRIVE SHAFT SHEARED. NO OTHER DAMAGE FOUND AT VISUAL INSPECTION. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004080500073 20040805 00073 NM 2004 8 5 CA040625009 1 20040623 G 2910 AE2463510E0124 HOSE DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE HYD SYSTEM LEAKING W O OTHER K J FLUID LOSS WARNING INDICATION CL CLIMB 1 CA 33370 33370 (CAN) ON SELECTING GEAR RETRACTION AFTER TAKE-OFF , LOSS OF 32 SYSTEM HYDRAULIC FLUID. CAUTION LIGHTS FOR NR 2 HYD ISOL ATION SYSTEM AND NR 2 HYD PUMP. AIRCRAFT RETURNED TO DEPARTURE AIRPORT AND USED ALTERNATE GEAR EXTENSION SYSTEM. NORMA L LANDING. MAINTENANCE INSPECTION FOUND NLG UP LOCK HYDRAULIC LINE FAILED. LINE REPLACED, HYDRAULIC SYSTEM SERVICED AND AIRCRAFT RETURNED TO SERVICE. THIS PART IS TRACKED AS AN EXPENDABLE AND ACCURATE PART. COMPANY HAS IN HOUSE TASK TO R EPLACE THIS LINE AT A C1 CHECK IF MANUFACTURE DATE CODE IS IN EXCESS OF 8 YEARS. LAST C1 CHECK ON THIS AIRCRAFT NOV/200 3. HOSE DATE CODE 1/97. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004080500074 20040805 00074 NE 2004 8 5 CA040628001 2 20040616 G 8500 R1340S3H1G ENGINE DHAV DHC3 DHC3 2800202 EA PWA R1340 R1340AN1 52016 NE HAMSTD 23D 23D40 NE FAILED W A UNSCHED LANDING Y J ENGINE STOPPAGE WARNING INDICATION CR CRUISE 1 CA R327203 (CAN) ENGINE SEIZED IN CRUISE FLIGHT. CASE BROKEN. 1 H 7 1 3R 3 R A815 5E2 6 C P719 2004080500075 20040805 00075 EA 2004 8 5 CA040628002 1 20040626 G 2497 AA4N CONTACTOR DHAV DHC8 DHC8311 1386006 EA PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE ENGINE NACELLE FAILED W E ENGINE SHUTDOWN N FALSE WARNING TX TAXI/GRND HDL 1 CA (CAN) AFTER ENGINE START AND GPU REMOVAL THE PASS DOOR, BAG DOOR, FWD DOOR, AND SERVICE DOOR LIGHTS WERE FLASHING, WE RE CONNECTED THE GPU, AND SHUTDOWN THE BOTH ENGINES. LIGHT SMOKE WAS OBSERVED FROM THE LT NACELLE AIRCRAFT WAS DEPLANED. TH E AMOUNT OF SMOKE INCREASED AND FIRE BOTTLES WERE DICHARGED AND ALL POWER SHUT OFF. FOUND THE 2431K1 RELAY SHORTED, REL AY AND STARTER REPLACED. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004080500076 20040805 00076 NM 2004 8 5 CA040628003 1 20040624 G 2421 69432851 DUCT BOEING 737 7372T2 1384491 NM PWA JT8 JT8D17 52049 NE GENERATOR COOL CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) FLT CREW FELT A TRANSIENT VIBRATION ON ENGINE SPOOL-UP, WITH NO INDICATION FROM EITHER ENGINE VIBRATION METER. ALS O SLIGHT VIBRATION IN CRUISE, WITH NO INDICATION ON EITHER ENGINE VIBRATION INDICATOR. FLT CREW ISOLATED THE PROBLEM TO NR 2 ENGINE. AC WAS SWAPPED AFTER MAINT DISCOVERED THAT AC GENERATOR COOLING DUCT PLATE WAS BROKEN AND CAUSING A LARGE C OOLING AIR LEAK. PLATE WAS REPLACED AND GROUND RUNS CONFIRM NO VIBRATION. OPERATOR WILL ISSUE A FLEET CAMPAIGN TO INSPE CT AC GENERATOR COOLING DUCT PLATES OF REMAINING AIRCRAFT. THIS FLEET CAMPAIGN WILL BE COMPLETED WITHIN 60 DAYS. THE FOL LOWING IS AN EXACT FROM THE IPC. ITEM NR 170 PN 69-43285-1 IS THE PART WHICH FAILED. 2 L 7 2 4F 4 F RT A16WE E2EA 2004080500077 20040805 00077 CE 2004 8 5 CA040628004 1 20040628 G 7603 2520851 CONTROL CABLE CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA MCAULY 1C160 1C160DTM GL THROTTLE WORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THIS IS THE SECOND OCCURRENCE OF SUCH A DEFECT NOTED BY THE SAME OPERATOR WITHIN THE PAST FEW WEEKS. THE SWAGED SW IVEL JOINT ON THE THROTTLE CONTROL WAS NOTED TO BE WORN TO THE POINT WHERE THE BALL END COULD BE REMOVED FROM ITS SWAGED SOCKET WITH EASE. DEFECT WAS DISCOVERED DURING ROUTINE INSPECTION. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2004080500078 20040805 00078 WP 2004 8 5 CA040628005 1 20040625 G 7922 315341 DOOR CVAC 440 440 2422902 WP ALLSN 501D 501D13D 03004 GL OIL COOLER FAILED W E ENGINE SHUTDOWN J WARNING INDICATION CL CLIMB 1 CA (CAN) DURING CLIMB OUT THE FLT CREW NOTICED THE OIL TEMPERATURE RISING TO THE RED LINE. THE OIL COOLER SWITCH WAS SELECT ED FROM (AUTO) TO (MANUAL) OPEN WITH NO RESOMNSE. THE OIL TEMPERATURE CONTINUED TO CLIMB. THE ENGINE WAS SHUT DOWN ANDTH E PROP WAS FEATHERED. THE AIRCRAFT RETURNED TO BASE. DURING TROUBLESHOOTING, MAINTENANCE STAFF FOUND THE OIL COOLER DOOR ACTUATOR WAS INOPERATIVE. THE OIL COOLER DOOR ACTUATOR WAS REPLACED AND THE AIRCRAFT WAS RETURNED TO SERVICE. 2 L 7 2 4R 4 T 6A6 E282 2005012400020 20050124 00020 NE 2005 1 24 CA040628006 2 20040625 G 8550 493476 O-RING PWA CNDAIR CL215 CL2151A10 1900320 EA PWA R2800 CA3 52026 NE HAMSTD 43E 43E60 NE ENGINE FAILED W E ENGINE SHUTDOWN K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA NK510954 (CAN) DURING A PRESCOOP GEOGRAPHICAL CHECK, THE FIRST OFFICER NOTED A MAJOR OIL LEAK ON THE NR 2 ENGINE. THE ENGINE WAS SHUTDOWN, THE PROP WAS FEATHERED AND THE AIRCRAFT RETURNED TO BASE. UPON INVESTIGATION BY MAINTENANCE, IT WAS NOTED THAT ONE OF THE BMEP PLUG O-RINGS HAD FAILED CAUSING THE OIL LEAK. THE O-RING WAS REPLACED ENGINE GROUND RUN AND LEAK CHECKE D SERVICEABLE. THE AIRCRAFT WAS RETURNED TO SERVICE. 2 H 7 2 4R 4 R RT A14EA E231 6 C P871 2005020100036 20050201 00036 CE 2005 2 1 CA040628008 1 20040628 G 5330 SKIN BEECH 200 B200 1152922 CE PWA PT6 PT6A42 52043 NE HARTZL HCB3T HCB3TN3 GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) COMBINATION VHF/GPS ANTENNA DOUBLER AND FUSELAGE SKIN CRACKED UNDER ANTENNA WHICH WAS ENGINEERED AND INSTALLED IAW LSTC NR C-LSA01-625/D. FUSELAGE REPAIRED AND ANTENNA REMOVED. NEW REPAIR DOUBLER INSTALLED. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2005020100037 20050201 00037 CE 2005 2 1 CA040628009 1 20040628 G 5330 SKIN BEECH 200 B200 1152922 CE PWA PT6 PT6A42 52043 NE HARTZL HCB3T HCB3TN3 GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) COMBINATION VHF/GPS ANTENNA DOUBLER AND FUSELAGE SKIN CRACKED UNDER COMANT ANTENNA WHICH WAS ENGINEERED AND INSTAL LED IAW LSTC NR C-LSA01-625/D. FUSELAGE REPAIRED AND ANTENNA REMOVED. NEW REPAIR DOUBLER INSTALLED. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2005020100038 20050201 00038 SO 2005 2 1 CA040628010 1 20040624 G 2750 HANDLE MAULE M5 M5235C 5460135 SO LYC O540 O540J1A5 41532 EA HARTZL HCC2Y HCC2YR1 GL TE FLAPS BROKEN W A UNSCHED LANDING F FLT CONT AFFECTED DE DESCENT 1 CA (CAN) UPON DESCENT, THE PILOT PULLED ON THE FLAPS, ONLY TO FIND THAT THE HANDLE BROKE AWAY AFTER THE FIRST KNOTCH WAS AC HIEVED. MADE A SLOW TRIP BACK TO BASE, WHERE AFTER EXAMINATION, THE HANDLE WAS FOUND BROKEN AT THE BOTTOM HOLE WHERE TH E FLAP RATCHET ACTUATING ROD EXITS THE HANDLE. HANDLE WAS SUBSQUENTALLY REPAIRED AND RETURNED TO SERVICE. 1 H 7 1 3O 3 O 3A23 E295 5 C P920 2005020100039 20050201 00039 GL 2005 2 1 CA040629001 2 20040629 G 7200 ENGINE EMB 135 EMB135ER 3260203 SO ALLSN AE300 AE3007A GL MAKING METAL W E ENGINE SHUTDOWN J WARNING INDICATION CR CRUISE 1 CA CAE311394 (CAN) PRELIMINARY REPORT, HIGH OIL TEMPERATURE, LOW OIL PRESSURE AND IMPENDING BYPASS MESSAGE. PILOT COMMANDED THE IFSD DURING CRUISE. EMERGENCY DECLARED AND UNEVENTFUL LANDING. REPORTED METAL DEBRIS ON OIL TANK CHIP DETECTOR AND NOT ABLE TO ROTATE FAN OR CORE. ENGINE ALLOCATED. FURTHER INFO WILL BE PROVIDED WHEN ENGINE STRIP HAS BEEN COMPLETED. 2 L 7 2 4F 4 F RT T00011AT TE6CH 2005020100040 20050201 00040 GL 2005 2 1 CA040629002 2 20040629 G 7250 BEARING ALLSN AE3007 AE3007C GL NR 4 FAILED W E ENGINE SHUTDOWN J WARNING INDICATION CR CRUISE 1 CA CAE330102 (CAN) DURING CRUISE AT 43,000 FT, CREW RECEIVED CHIP DETECTOR MESSAGE, FOLLOWED BY AN OIL FILTER BYPASS MESSAGE ON THE R T ENGINE. A/C WAS BEING FLOWN FOR MAINTENANCE VISIT TO THE MFG SERVICE CENTER. CREW ELECTED TO CONTINUE F LIGHT AFTER RECEIVING THE ABOVE MESSAGES. 15 MINUTES AFTER RECEIVING THE OIL FILTER BYPASS MESSAGE, OIL PRESSURE BEGAN TO DROP AND THE CREW ELECTED TO SHUTDOWN THE ENGINE. CREW ELECTED TO CONTINUE SINGLE ENGINE FLIGHT TO DESTINATION. INITIAL INVESTI GATION INDICATES A NR 4 BEARING FAILURE. ENGINE SENT TO FOR REPAIR, FURTHER DETAIL WILL BE SUBMITTED UPON DISASSEMBLY O F ENGINE. 4 F TE6CH 2005020100041 20050201 00041 EA 2005 2 1 CA040629003 2 20040521 G 8530 TISN04OCA CYLINDER PIPER PA28 PA28140 7102802 SO LYC O320 O320E2A 41508 EA SNSNCH 74DM M74DM EA ENGINE PEELING W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) CERMINIL COATING PEELED OFF OF ABOUT 10 PERCENT OF THE BARREL, SUSPECT CAUSING METAL CONTAMINATION THROUGHOUT THE ENGINE. 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 2005020100042 20050201 00042 WP 2005 2 1 CA040629004 2 20040623 G 7321 8978017 FCU SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP HARTZL HCE4N HCE4N3 NE ENGINE UNSERVICEABLE W E ENGINE SHUTDOWN M OVER TEMP TX TAXI/GRND HDL 1 CA P50004 (CAN) DURING THE ATTEMPTED ENGINE START, THE EGT ROSE RAPIDLY TOWARDS REDLINE AND THE ENGINE WAS SHUTDOWN. TOO MUCH FUEL WAS BEING INTRODUCED DURING THE START SEQUENCE THEREFORE CAUSING THE OVERTEMP PROBLEM. THE FUEL CONTROL WAS REPLACED. ENCOUNTER THIS PROBLEM NUMEROUS TIMES A YEAR WITH DIFFERENT FUEL CONTROL UNITS AND UPON RETURN TO THE MANUFACTURER FOR R EPAIR THE UNIT TESTS FINE AND IS RETURNED TO SERVICE ONLY TO FAIL AGAIN A SHORT TIME LATER. THE OVERTEMP PROBLEM IS USUA LLY AN INTERMITTENT FAILURE. HAVE ISSUED SEVERAL SDR'S IN THE PAST ON THIS ISSUE AND WILL CONTINUE TO DO SO AS THEY ARIS E. A TEARDOWN REPORT FROM THE MFG HAS BEEN ATTACHED. 2 L 7 2 4T 4 T RT A8SW E4WE 5 C P10NE 2005020100043 20050201 00043 NM 2005 2 1 CA040629005 1 20040629 G 3233 NAS7512017 BUSHING DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE MLG MISSING W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING MAINT INSP AND GREASING OF RT MLG RETRACTION ACTUATOR , ACTUATOR WOULD NOT ACCEPT GREASE. DURING REMOVAL O F ACTUATOR IT WAS DISCOVERED THAT UPPER ATTACHMENT BOLT TO NACELLE BRACKET, RETENTION NUT WAS CRACKED. BOLT WAS RETAINE D IN PLACE BY COTTER PIN, HOLDING NUT ON. DISASSEMBLY FOUND BUSHING P/N NAS75-12-017 MISSING. THIS ALLOWED BOLT P/N 8321 0090-101 TO MOVE IN BRACKET P/N 85411783-005 CAUSING DAMAGE ( ELONGATION OF HOLE) TO BRACKET, DAMAGE TO RETRACTION ACTUA TOR ASSY AS IT WAS NOT CENTERED IN BRACKET CORRECTLY. ACTUATOR ASSEMBLY, BOLT AND MOUNTING BRACKET REPLACED. INSPECTIO N OF LT GEAR ON THIS SAME AC FOUND THE SAME CONDITION. AC HAD TASK 3230/ 18 CARRIED OUT DURING C-CHECK, 1803 CYCLES. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005020100053 20050201 00053 NM 2005 2 1 CA040629006 1 20040626 G 2421 73664E IDG BOEING 757 757* NM RROYCE RB211 RB211535E437 54555 NE RT GENERATOR FAILED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) RT GEN FAILED ON CLIMBOUT. COULD NOT RESET, QRH CARRIED OUT. AIRCRAFT RETURNED TO DEPARTURE. ETOPS DOWNGRADED T O 120MIN. OPERATE IAW MEL 24-00-1. 2 L 7 2 4F 4 F RT A2NM E12EU 2005020100064 20050201 00064 CE 2005 2 1 CA040629007 1 20040625 G 2430 S19151 CAPACITOR AERO CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA MCAULY 1C235 1C235LFA GL ALTERNATOR CHAFED W A UNSCHED LANDING H J ELECT. POWER LOSS-50 PC WARNING INDICATION CR CRUISE 1 CA (CAN) INTERMITTANT OCCURRENCE OF ALTERNATOR FAILING TO STAY ON LINE. INCORRECT POSITIONING OF CAPACITOR ALLOWED UNIT TO CHAFE AGAINST ENGINE BAFFLING UNTIL INTERNAL PORTION WAS EXPOSED CAUSED INTERMITTENT SHORT. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P12EA 2005020100067 20050201 00067 EA 2005 2 1 CA040629008 2 20040617 G 8520 LW11625 PLUG CESSNA 150 A152 2071836 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL PISTON PIN WORN W K NONE O OTHER IN INSP/MAINT 1 CA L2236815 (CAN) A FEW PIECES OF NON-FERROUS MATERIAL WERE FOUND AT 1375.8 HOURS. FILTER RE-INSPECT SCHEDULED. SUBSEQUENT FILTER INSPECTION SHOWED HEAVY CONTAMINATION. ALL CYLINDERS REMOVED, FOUND PISTON PINS AND PLUGS NOT FLOATING. TWO PLUGS WERE WORN EXTENSIVELY. ALL PISTONS REMOVED FOR INSPECTION AND CLEANING, NO DAMAGE NOTED TO CYLINDER WALLS. PISTONS RE-INST ALLED WITH NEW PLUGS. ACCESSORY DRIVE COVER AND SUMP REMOVED FOR INSPECTION AND CLEANING. NO FURTHER EVIDENCE OF CONTA MINATION FOUND. NO FURTHER DAMAGE FOUND. 1 H 7 1 3O 3 O 3A19 E223 5 N P50GL 2005020100068 20050201 00068 CE 2005 2 1 CA040629009 1 20040628 G 5553 BOLT BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE VERTICAL STAB UNDERTORQUED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) IN REFERENCE TO AN MAINTENANCE ALERT, AN INSPECTION WAS CARRIED OUT TO THE VERTICAL STABILIZER FRONT SPAR ATTACHME NT BOLTS FOR SECURITY AND TORQUE OF AIRCRAFT. ONE AIRCRAFT WAS FOUND WITH BOLT TORQUE UNDER THE SPECIFIED TORQUE ON THE RT SIDE UPPER AND LT SIDE LOWER. THE BOLTS WERE RE-TORQUED AND A CONTINUING INSPECTION WAS SET UP TO THE FLEET AT 1000 HOUR INTERVALS. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2005020100069 20050201 00069 NE 2005 2 1 CA040629010 2 20040629 G 8520 MAIN BEARING CNDAIR CL215 CL2151A10 1900320 EA PWA R2800 CA3 52026 NE HAMSTD 43E 43E60 NE RT ENGINE FAILED W E A ENGINE SHUTDOWN UNSCHED LANDING E VIBRATION/BUFFET CL CLIMB 1 CA P31501 (CAN) WHILE CLIMBING AWAY FROM A WATER SCOOP, THE CREW NOTICED THAT THE RT ENGINE WAS BECOMING UNCONTROLLABLE, ROUGH RUN NING AND LOSING POWER. THE CREW DROPPED THE LOAD AND SHUTDOWN THE RT ENGINE AND FEATHERED THE PROPELLER. THE AIRCRAFT MADE THE SINGLE ENGINE LANDING WITHOUT INCIDENT, AND THE AIRCRAFT RETURNED TO THE HANGER FOR INVESTIGATION. 2 H 7 2 4R 4 R RT A14EA E231 6 C P871 2005020100070 20050201 00070 NM 2005 2 1 CA040630001 1 20040624 G 2910 82960010203 LINE DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE HYD SYSTEM LEAKING W O OTHER K J FLUID LOSS WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) DURING OPERATION, THERE APPEARED TO BE HYDRAULIC FLUID COMING FROM THE TAIL SECTION OF THE AIRCRAFT. UPON FURTHER INVESTIGATION , IT WAS FOUND THAT THE LINE WAS LEAKING AND IT WAS REPLACED WITH FLEX LINE AE24600160720 IAW MM 20-50-52 . 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005020100124 20050201 00124 SO 2005 2 1 CA040630002 2 20040630 G 8520 CRANKCASE CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO MCAULY D3A34 D3A34C404 GL ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING UNSCHEDULED MAINTENANCE 3 CRACKS WERE NOTICED ON CRANKSHAFT NEAR PROP FLANGE. TWO CRACKS WERE APPROXIMATELY 2 INCHES IN LENGTH PARALLEL TO EACH OTHER WITH SMALLER CRACKS EXTENDING. ONE CRACK IS ALSO APPROXIMATELY 2 INCHES IN LE NGTH AND ABOUT 1 INCH FROM THE OTHER TWO CRACKS. THESE CRACKS RUN ALONG THE CIRCUMFERANCE OF THE CRANKSHAFT. 1 H 7 1 3O 3 O A4CE E5CE 5 C P47GL 2005020100145 20050201 00145 EU 2005 2 1 CA040630003 1 20040629 G 2131 9599091141 CONTROLLER PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL OUTFLOW VALVE MALFUNCTIONED W O OTHER J WARNING INDICATION DE DESCENT 1 CA (CAN) DURING DESCENT CABIN PRESSURE WAS LEADING PRESSURE DIFFERENTIAL MORE RAPIDLY AND GREATER THAN NORMAL. DETERMINED THAT THE OUTFLOW VALVE CONTROLLER WAS NOT CONTROLLING OUTFLOW VALVE MOVEMENT PROPERLY. NO OVERPRESSURES (DIFFERENTIAL) WERE NOTED. PART WAS REPLACED WITH SERVICEABLE CONTROLLER AND ALL SYSTEM FUNCTIONS RETURNED TO NORMAL. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005020100147 20050201 00147 EU 2005 2 1 CA040630004 1 20040628 G 7810 5781012041 TUBE PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL EXHAUST CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) CRACK WAS DISCOVERED AT INSPECTION NEXT TO EXHAUST TUBE USED TO SUPPLY ENGINE EXHAUST TO COWLING LIP DEICE. ABOUT ONE INCH FROM ENGINE MOUNTING FLANGE , CRACK WAS ABOUT ONE AND A QUARTER INCH LONG. REPAIR PERFORMED IAW MM CHAPTER 78 10-01. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005020100148 20050201 00148 EU 2005 2 1 CA040630005 1 20040629 G 2910 A5784365500400 FITTING AIRBUS 310 A310304 3930339 EU GE CF6 CF680C2* GL PRESSURE LINE LOOSE W L ABORTED APPROACH K J FLUID LOSS WARNING INDICATION AP APPROACH 1 CA (CAN) ON FINAL APPROACH, WHEN FLAP/SLAT WERE EXTENDED, THE HYDRAULIC RESERVOIR LOW LEVEL ECAM WARNING CAME ON. AIRCRAFT OVERSHOT AND CHECKLIST PROCEDURE INDICATE A FAILURE OF GREEN HYDRAULIC SYSTEM. ALTERNATE GEAR EXTENSION PERFORMED. D URING INVESTIGATION, FOUND THE GREEN SYSTEM PRESSURE LINE FITTING LOOSE ON THE RT KRUGER FLAP ACTUATOR. LINE TIGHTENED AND SYSTEM WAS VERIFIED SERVICEABLE IAW THE MM. 2 L 7 2 4F 4 F RT A35EU E23EA 2005020100149 20050201 00149 EU 2005 2 1 CA040630006 1 20040628 G 3242 30244 BRAKE ASSY PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL MLG FAILED W D RETURN TO BLOCK D INFLIGHT SEPARATION TX TAXI/GRND HDL 1 CA (CAN) WHILE ON TAXI FROM THE HANGER RAMP TO TAXI WAY, THE AIRCRAFT MADE A SUDDEN MOVE TO THE RT AND A LOUD GRINDING META LLIC SOUND WAS HEARD IN THE AIRCRAFT. THE AIRCRAFT ENGINE WAS SHUT DOWN ON THE TAXIWAY AND AN INVESTIGATION WAS CONDUCTE D IN THE AREA OF THE RT LANDING GEAR. THE RT BRAKE UNIT WAS NOTED TO HAVE LOOSE PARTS (BRAKE PAD) BETWEEN THE DISK PLAT ES. THE AIRCRAFT WAS TOWED BACK TO THE HANGER AND A NEW BRAKE UNIT WAS INSTALLED. THE AIRCRAFT WAS RETURNED TO SERVICE W ITH NO FURTHER ACTION REQUIRED. THE BRAKE UNIT S/N 1099 WAS FURTHER EXAMINED AND IT WAS NOTED THAT A BRAKE PAD HAD SHEAR ED ITS RIVETS AND WAS LODGE IN BETWEEN THE PRESSURE PLATES. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005020100150 20050201 00150 EA 2005 2 1 CA040630007 1 20040628 G 7334 21550724 INDICATOR CNDAIR CL215 CL2151A10 1900320 EA PWA R2800 CA3 52026 NE HAMSTD 43E 43E60 NE PRESS TRANSMITER DEFECTIVE W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) AFTER TAKE-OFF, THE RT FUEL PRESSURE INDICATOR WAS 1 PSI LOWER THAN PREVIOUS FLIGHTS. THE CREW ELECTED TO PROCEED FOR MAINTENANCE. AFTER CRUSING FOR AWHILE THEY NOTICED ANOTHER DROP IN FUEL PRESSURE AND ELECTED TO SHUT DOWN THE RT E NGINE. THEY LANDED SAFELY FOR MAINTENANCE. MAINTENANCE CHECKED THE RT FUEL SYSTEM FOR LEAKS AND NONE WERE FOUND. THE F UEL PRESSURE INDICATING SYSTEM WAS CHECKED AND THE TRANSMITTER WAS FOUND DEFECTIVE. THE TRANSMITTER WAS REPLACED AND GR OUND CHECKED SERVICABLE. THE A/C WAS RETURNED TO SERVICE. 2 H 7 2 4R 4 R RT A14EA E231 6 C P871 2005020100180 20050201 00180 WP 2005 2 1 CA040702001 1 20040630 G 2421 BEARING ELECTROSYS ROBSIN R44 R44 7640120 WP LYC O540 O540F1B5 41532 EA ALTERNATOR A WORN W E ENGINE SHUTDOWN H J ELECT. POWER LOSS-50 PC WARNING INDICATION TX TAXI/GRND HDL 1 CA 7050657 (CAN) AFTER THE ALTERNATOR BELT BROKE FOR THE SECOND TIME IN 8 HOURS, IT WAS NOTICED THAT THE ALTERNATOR PULLEY, ALTHOUG H SMOOTH WHEN TURNED BY HAND, WAS ABLE TO MOVE SIDEWAYS ABOUT AN EIGHT OF AN INCH. WE DID NOT DISSASSEMBLE THE UNIT BU T IT IS SAFE TO ASSUME THE COMUTATOR BEARINGS ARE WORN OUT. 1 G 7 1 3O 3 O H11NM E295 2005031000016 20050310 00016 NE 2005 3 10 CA040702002 2 20040627 G 7322 C2E2215 BELLOWS DHAV DHC2 DHC2* 2800108 EA PWA R985 R985AN1 52008 NE HAMSTD 2D 2D30 NE CARBURETOR FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) HAVE DETERMINED THAT CARB HEAT BELLOWS P/N C2E2215 AS RECEIVED WAS ACQUIRED DIRECTLY WITHOUT GOING THROUGH QA INSP ECTION AND CERTIFICATION. PART BEARS DHC-2 PN STAMP AND APPEARS GENUINE. PART PLACED IN QUARATINE. 1 H 7 1 3R 3 R A806 5E1 5 C P206 2005031000017 20050310 00017 GL 2005 3 10 CA040702003 2 20040630 G 7310 6654777 BAR CVAC 440 440 2422902 WP ALLSN 501D 501D13D 03004 GL ALLSN A6441 A6441FN606 GL FUEL FILTER BROKEN W E A ENGINE SHUTDOWN UNSCHED LANDING O OTHER CR CRUISE 1 CA (CAN) DURING CRUISE THE FLIGHT CREW NOTICED SEVERE SURGING ON THE NR 1 ENGINE. THE FUEL FLOW WAS ALSO DROPPING AND SURGI NG. THE ENGINE WAS SHUT DOWN AND THE PROPELLER WAS FEATHERED. THE AIRCRAFT RETURNED TO DEPARTURE. DURING INVESTIGATION M AINTENANCE CREW FOUND THE BAR ASSY THAT SECURES THE FILTER BOWL TO THE HOUSING WAS BROKEN AT THE THREADS. THE BOWL WAS D ISCOVERED HANGING BY THE LOCKWIRE. GASKET P/N 30865 WAS ALSO MISSING. REF MFG IPC 73-00-00FIG 5 ITEMS 9, 10 AND 16. THE PARTS WERE REPLACED AS REQUIRED AND THE AIRCRAFT WAS RETURNED TO SERVICE. 2 L 7 2 4R 4 T 6A6 E282 6 C P898 2005031000018 20050310 00018 WP 2005 3 10 CA040702004 1 20040628 G 3233 MS28775212 O-RING GRUMAN TS2 TS2ACALFORST 3951102 WP WRIGHT R1820 982C9HE2 67020 EA HAMSTD 43D 43D51 NE ACTUATOR FAILED W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA 36 (CAN) DURING CRUISE THE PILOT NOTED A RAPID DROP IN HYDRAULIC PRESSURE ON BOTH THE LT AND RT SIDE. THE AIRCRAFT DIVERTED COURSE. THE RETARDANT LOAD WAS JETTISONED AND THE FLAPS AND LANDING GEAR WERE LOWERED USING THE EMERGENCY HAND PUMP. TH E AIRCRAFT LANDED WITHOUT INCIDENT. DURING INVESTIGATION BY MAINTENANCE IT WAS NOTED THAT THE SEAL IN THE NOSE LANDING G EAR ACTUATOR HAD FAILED CAUSING THE HYDRAULIC FLUID LOSS. THE ACTUATOR WAS REPLACED, AND A GEAR SWING WAS ACCOMPLISHED A FTER THE HYDRAULIC SYSTEM WAS PURGED AND REPLENISHED. THE AIRCRAFT WAS RETURNED TO SEVICE. 2 H 7 2 4R 4 R A25WE E259 6 C P8879 2005031000019 20050310 00019 WP 2005 3 10 CA040702005 1 20040622 G 8011 SWITCH CVAC 340 340CVAC 242270A WP ALLSN 501D 501D22 03005 GL HAMSTD 54H 54H60 NE AIR STARTER FAULTY W E A ENGINE SHUTDOWN UNSCHED LANDING N FALSE WARNING CR CRUISE 1 CA P15827C (CAN) DURING CRUISE THE LT STARTER OVERSPEED LIGHT ILLUMINATED. THE ENGINE WAS SHUT DOWN AND THE PROPELLER WAS FEATHERED AS A PRECAUTION. THE AIRCRAFT RETURNED TO BASE. THE STARTER WAS REMOVED AND NO DAMAGE WAS NOTED. THE LIGHT SYSTEM WAS CHECKED FOR FAULTS NONE NOTED. IT WAS DETERMINED THAT THE INTERNAL SWITCH WAS CAUSING THE LIGHT ILLUMINATION. THE START ER HAS BEEN SENT TO THE REPAIR SHOP FOR INVESTIGATION. THE STARTER WAS REPLACED AND THE AIRCRAFT WAS RETURNED TO SERVIC E. 2 L 7 2 4R 4 T 6A6 E282 6 C P906 2005031000065 20050310 00065 EA 2005 3 10 CA040704001 1 20040630 G 5610 NP13932112 WINDSHIELD CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE COCKPIT CRACKED W A UNSCHED LANDING O OTHER CR CRUISE 1 CA (CAN) ENROUTE THE F/O'S WINDSHIELD SHATTERED, CREW ELECTED TO DIVERT. MAINTENANCE REPLACED WINDSHIELD.(SEE ALSO: US NR 2 004071600072) 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2005030800204 20050308 00204 CE 2005 3 8 CA040705001 1 20040610 G 3233 NUT BEECH 100 A100 1152915 CE PWA PT6 PT6A28 EA MCAULY 4HFR34 4HFR34C762 NE MLG ACTUATOR DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA DURING RECTIFICATION OF A SNAG GEAR HANDLE LIGHT STAYING ON WHEN GEAR RETRACTED, A/C JACKED UP AND L/G SWINGS WERE COMPL ETED. NOTED THAT LT L/G DOORS WAS HANGING OPEN WITH GEAR RETRACTED. ACT REMOVED DUE TO SUSPICION IT HAD SLIPPED INTERN ALLY, CAUSING IT TO BE OUT OF SYNC WITH NOSE AND RT MAIN GEAR ACTUATORS. INSPECTION OF ACT AFTER REMOVAL SHOWED ACT TO H AVE AN EXCESSIVE AMT OF INTERNAL RESISTANCE. SENT TO OVERHAUL FACILITY FOR EVALUATION. OVERHAUL FACILITY HAS DISASSEMBLE D ACT AND FOUND EXCESSIVE WEAR AND STRIPED THREADS ON NUT AND SCORING ON SCREW THREADS. THIS UNIT IS BEING SENT TO RAYT HEON FOR FURTHER ANALYSIS. 1 L 7 2 3T 4 T A14CE E4EA 6 C 3PNE 2005031000066 20050310 00066 CE 2005 3 10 CA040705002 1 20040630 G 3040 11418002823 BOOT BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE LEFT TORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) CREW NOTICED A TEAR IN THE LT IB DEICE BOOT DURING WALKAROUND. THE AIRCRAFT WAS FERRIED AND THE BOOT WAS REPLACED. REASON FOR TEAR UNKNOWN. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2005031000067 20050310 00067 CE 2005 3 10 CA040705003 1 20040615 G 3231 4532103045002 BELLCRANK LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE7312 01518 WP MLG DOOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) BELLCRANK CRACKED AT PIVOT POINT NEW BELLCRANK PT NR 4532103045-004 INSTALLED GEAR SWINGS COMPLETED. 2 L 7 2 4F 4 F RT T00008WI E6WE 2005031000068 20050310 00068 SW 2005 3 10 CA040705004 1 20040630 G 3250 STEERING SYS SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP HARTZL HCB3T HCB3TN5 GL NLG INOPERATIVE W E ENGINE SHUTDOWN O OTHER LD LANDING 1 CA (CAN) UPON LANDING, WHEN SPEED LEVERS SELECTED TO LOW AT 70 KIAS, NOSE WHEEL STEERING WAS ARMED AND THE AIRCRAFT VEERED SHARPLY RT AND DEPARTED THE RUNWAY. THE ENGINES WERE SHUTDOWN AS A PRECAUTIONARY MEASURE. NO DAMAGE NOTED. THE AIRCRA FT STOPPED ON THE ADJACENT TAXIWAY. WILL REPORT FURTHER WHEN THE SOURCE OF THE PROBLEM IS DISCOVERED. AIRCRAFT HAS BEE N REMOVED FROM SERVICE SINCE. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P15EA 2005030800207 20050308 00207 GL 2005 3 8 CA040705005 2 20040624 G 7200 ENGINE BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL NR 2 FAILED W O OTHER X B ENGINE FLAMEOUT SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA CAT33576 ON STARTING NR 2 ENG THE WIND UP TO FUEL INTRODUCTION WAS NORMAL ENGINE LIGHT-OFF AND INITIAL SURGE WAS NORMAL, THEN THE N1 ACTUALLY DROOPED, THE ENG FLAMED OUT MOMENTARILY, CAUGHT AGAIN (WITH A LARGE PUFF OF SMOKE) ACCELERATED A LITTLE, TH EN DROOPED AGAIN AND THE START WAS ABORTED. MOTORING THE STARTER AFTERWARDS PRODUCED A LOT OF NOISE WITH VERY RAPID DEC ELERATION ONCE THE STARTER WAS DISENGAGED. THE STARTER WAS REMOVED AND CHECKED OK. THE TRANSMISSION COWLING WAS REMOVED AND THE COMPRESSOR WAS TURNED BY HAND, IT WAS VERY STIFF AND NOISY. THE NOISE APPEARING TO COME FROM THE TURBINE. THE B URNER CAN AND LINER WAS REMOVED AND THE COMPRESSOR WAS TURNED BY HAND . IT WAS CONFIRMED THAT THE TURBINE WAS RUBBING. 1 G 7 2 3U 3 U H3EU E4CE 2005031000069 20050310 00069 CE 2005 3 10 CA040705006 1 20040630 G 2823 1013890253 SHUTOFF VALVE BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA HARTZL HCB3T HCB3TN3 GL FUEL FAILED W K NONE L NO TEST IN INSP/MAINT 1 CA (CAN) DURING PILOTS START CHECKS RT HAND FUEL SHUT-OFF VALVE FAILED IN OPEN POSITION. UNABLE TO TURN LOW PRESSURE LIGHT ON. REPLACED VALVE. AIRCRAFT RETURNED TO SERVICE. 1 L 7 2 3T 4 T RT 3A20 E4EA 6 C P15EA 2005031000070 20050310 00070 CE 2005 3 10 CA040705007 1 20040622 G 3233 6632303003001 SWITCH PNEUDRAULICS LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE7312 01518 WP ACTUATOR OUT OF TOLERANCE W O OTHER J WARNING INDICATION TO TAKEOFF 1 CA 0149 (CAN) GEAR WOULD NOT RETRACT ON 1ST ATTEMPT, 2ND ATTEMPT WAS SUCCESSFUL FOUND ACTUATOR SWITCH OUT OF TOLERANCE ACTUATOR REPLACED WITH OVERHAULED UNIT GEAR SWINGS COMPLETED. 2 L 7 2 4F 4 F RT T00008WI E6WE 2005031000071 20050310 00071 CE 2005 3 10 CA040705008 1 20040610 G 2750 C1444831 POWER UNIT LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE7312 01518 WP TE FLAPS NOISY W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) FLAP POWER UNIT NOISY/SLOW, REPLACED WITH OVERHAULED UNIT. 2 L 7 2 4F 4 F RT T00008WI E6WE 2005030800209 20050308 00209 2005 3 8 CA040705009 4 20040703 G 3442 20675680501 ANTENNA BOEING 737 737201 1384454 NM PWA JT8 JT8D9A 52048 NE WX RADAR SYS INTERMITTENT W A UNSCHED LANDING P NO WARNING INDICATION CR CRUISE 1 CA AIRCRAFT DEPARTED AND ONCE AIRBORNE THE CREW FOUND THE WEATHER RADAR TO BE INTERMITTENT WITH INCORRECT READINGS. DUE TO THE WEATHER FORECASTED AT THE DESTINATION THE CREW RETURNED TO BASE. MAINTENANCE FOUND THAT THE RADAR ANTENNA WAS AT F AULT. THE SYSTEM WORKED SERVICEABLE AFTER REPLACEMENT OF THE ANTENNA. THIS UNIT WAS INSTALLED TO CORRECT THE SAME SNAG DURING TROUBLESHOOTING ON JUNE 10TH. THIS INTRODUCED THE SAME SNAG AND MADE THE SNAG VERY DIFFICULT TO TROUBLESHOOT AND CORRECT. THE RADAR RT, DISPLAY, RADOME, WAVE GUIDE, ADI, CONTROL PANEL WERE REPLACED IN EFFORTS TO TROUBLESHOOT AND CORR ECT THE SNAG. 2 L 7 2 4F 4 F A16WE E2EA 2005030800210 20050308 00210 NE 2005 3 8 CA040706001 1 20040610 G 7600 37C800410P101 ROD SKRSKY S61 S61N 8142104 NE GE CT58 CT581401 30011 NE ACTUATOR STRIPPED W E ENGINE SHUTDOWN E VIBRATION/BUFFET TX TAXI/GRND HDL 1 CA SVA PILOT VALUE FEEDBACK CABLE ROD THREADS EXCESSIVELY WORN CAUSING ENGINE TO SURGE. 2 G 7 2 4U 4 U 1H15 1E3 2005030800222 20050308 00222 EA 2005 3 8 CA040706002 2 20040601 G 7322 1060301 CARBURETOR HUGHES 269 269C1 8059504 SW LYC O360 HO360C1A 41514 EA ENGINE FAILED W K NONE O OTHER IN INSP/MAINT 1 CA HIGH MANIFOLD PRESSURE. REPLACED CARBURETOR. 1 G 7 1 3O 3 O O 4H12 E286 2005030800223 20050308 00223 EA 2005 3 8 CA040706003 2 20040614 G 7414 S4LN204 MAGNETO ROBSIN R22 R22BETA 7640110 NM LYC O320 O320B2C 41508 EA ENGINE FAILED W K NONE O OTHER IN INSP/MAINT 1 CA HIGH ENGINE RPM. REPLACED MAGNETO. 1 G 7 1 3O 3 O H10WE E274 2005030800224 20050308 00224 EA 2005 3 8 CA040706004 2 20040616 G 7322 A5224 CABLE ROBSIN R22 R22BETA 7640110 NM LYC O320 O320B2C 41508 EA CARB HEAT FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) CARB HEAT CABLE BROKEN. REPLACED CARB HEAT CABLE. 1 G 7 1 3O 3 O H10WE E274 2005030800225 20050308 00225 EA 2005 3 8 CA040706005 2 20040617 G 7520 BLADE ROBSIN R22 R22BETA 7640110 NM LYC O320 O320B2C 41508 EA ENGINE FAN CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA CRACKED BLADE. REPLACED FAN WHEEL. 1 G 7 1 3O 3 O H10WE E274 2005030800226 20050308 00226 SW 2005 3 8 CA040707001 1 20040312 G 6520 406340105101 SEAL BELL 206 206B 1181511 SW T/R GEARBOX WORN W K NONE O OTHER IN INSP/MAINT 1 CA TAIL ROTOR GEARBOX CHIP DETECTOR HAS ILLUMINATED IN FLIGHT. THE GEARBOX WAS SUBSEQUENTLY REMOVED FROM AIRCRAFT, REPLACE D WITH SERVICEABLE UNIT AND AIRCRAFT WAS RETURNED TO SERVICE. UPON DISMANTLING OF THE GEARBOX IT WAS DISCOVERED THAT TH E SEALING LIP WORE THROUGH ALLOWING THE TENSION SPRING TO CONTACT WEAR SLEEVE, RESULTING IN THE GENERATION OF METALLIC P ASTE/SLUDGE. 1 G 7 1 3U H2SW 2005030800227 20050308 00227 CE 2005 3 8 CA040707002 1 20040701 G 2912 KIT11480221S FILTER BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA HYD SYSTEM SEPARATED W O OTHER O OTHER NR NOT REPORTED 1 CA DURING SCHEDULED INSPECTION OF THE INLINE HYD FILTERS (INSTALLED USING RAYTHEON KIT NR 114-8022-1S) IT WAS DISCOVERED TH AT TWO OF THE FILTERS HAD SEPARATED FROM THERE CONICAL END AND HAD MIGRATED DOWN THE HYD RETURN LINE ABOUT 2 INCHES FROM THERE NORMAL POSITION. IT IS SUSPECTED THAT THIS DEFECT COULD POTENTIALLY BLOCK THE RETURN LINE FOR THE GEAR ACTUATORS AND CAUSE THE GEAR TO FAIL IN THE UP POSITION IN WHICH CASE THE MANUAL EXTENSION WOULD ALSO FAIL. THE INLINE HYD FILTER S WERE REMOVED FROM THIS A/C PENDING FINDINGS OF THIS SDR. OPERATOR NOTE: REFERENCE BEECHCRAFT OPTIONAL SERVICE BULLETIN 2403 FOR INSTALLATION OF THIS KIT. ACTUAL FILTER PART NUMBER IS NOT KNOWN AT THIS TIME. 2 L 7 2 4T 4 T RT A24CE E4EA 2005030800228 20050308 00228 WP 2005 3 8 CA040707003 2 20040706 G 7310 31024741 MANIFOLD BEECH 100 B100 1152919 CE GARRTT TPE331 TPE331* 01514 WP HARTZL HCB4T HCB4TN5 GL FUEL DISTRIBUTIO CRACKED W O OTHER K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS DE DESCENT 1 CA SLIGHT FUEL ODOR IN CABIN WHEN AIRCRAFT SLOWED FOR LANDING. THE CREW NOTICED FUEL DRIPPING FROM THE RT ENGINE AFTER SHU TDOWN. MAINTENANCE FOUND A CRACKED FUEL MANIFOLD INLET ELBOW. THE MANIFOLD WAS REPLACED. 1 L 7 2 4T 3 T A14CE E2WE 6 C P40EA 2005030800229 20050308 00229 NE 2005 3 8 CA040707005 1 20040707 G 6700 S614062122000 BELLCRANK SKRSKY S61 S61A 814210C NE FLT CONTROLS MISMANUFACTURED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA BELLCRANK CONTACTING LINK ASSY CAUSING UNWANTED MOVEMENT OF EITHER CYCLIC OR COLLECTIVE CONTROLS. BELLCRANK DIMENSIONALL Y CHECKED AGAINST SIKORSKY DRAWING NR S6140-62122 AND FOUND TO BE NONCONFORMING FROM MANUFACTURE. BELLCRANK ASSEMBLY I S TRIANGULAR IN SHAPE. IT HAS ONE BEARING INSTALLED AT ITS AXIS, AND TWO OTHER HOLES ARE MACHINED FOR ATTACHMENT TO OTH ER FLT CONTROL ITEMS. LOCATION OF THESE HOLES DEVIATES AS MUCH AS .064 FROM THE DRAWING, AND IT IS BELIEVED THAT THIS DE VIATION CAUSES CONFLICT IN FLT CONTROL SYSTEM. THIS DEVIATION APPEARS TO HAVE BEEN FROM MANUFACTURE AS NO SIGNS OF WEAR ARE PRESENT. BELLCRANK IS NOT SERIALIZED YET IS IDENTIFIED WITH A P/N 'S6140-62122-001' AND A VENDOR CODE '782861'. 2 G 7 2 4U H2EA 2005030800230 20050308 00230 CE 2005 3 8 CA040707006 1 20040701 G 3230 571302 MOTOR BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE MLG UNSERVICEABLE W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA GEAR UNSAFE LIGHT CAME ON IN FLIGHT WITH AUTO FEATHER OFF ANNUNCIATOR ALSO. GEAR HAD TO BE MANUALLY EXTENDED. REPLACED LANDING GEAR POWER PACK MOTOR WITH O/H UNIT. FUNCTIONAL TEST OF SYSTEM CARRIED OUT. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2005030800231 20050308 00231 EU 2005 3 8 CA040708001 1 20040703 G 7120 10560386 BUSHING BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL ENGINE MOUNT DEBONDED W O OTHER O OTHER NR NOT REPORTED 1 CA A SERVICEABILITY INSPECTION WAS CARRIED OUT FOLLOWING THE LAST FLIGHT OF THE DAY AND IT WAS FOUND THAT THE LEFT ENGINE O UTBOARD MOUNT HAD VISIBLY DROPPED. THE ELASTOMER MATERIAL WAS COMPLETELY DEBONDED FROM THE METAL INNER PORTION OF THE M OUNT BUSHING P/N 105-60386 (CHAPTER 60-00-00, FIG. 14, ITEM 280, BO-105 PARTS BOOK) AND WAS EXTRUDING OUT OF THE SHELL. 1 G 7 2 3U 3 U H3EU E4CE 2005030800232 20050308 00232 NM 2005 3 8 CA040708002 1 20040625 G 5310 85320534103 DOOR FRAME DHAV DHC8 DHC8101 2809002 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE EMERGENCY EXIT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 38342 RT EMERGENCY EXIT DOOR REMOVED TO GAIN ACCESS TO LEVELLING DATUM PLATE TO JACK AIRCRAFT, A CRACK WAS DISCOVERED IN FRAME ON AFT SIDE OF THE DOOR. CRACK EXTENDS FROM LIGHTENING HOLE BETWEEN STRINGERS 22P AND 23P THROUGH THE FRAME RETURN ON THE INBOARD SIDE. FRAME WAS REPLACED WITH POST MODSUM 8/0427 FRAME P/NO.85320534-107A. THE LIGHTENING HOLE IS DELETED ON THE POST MOD 8/0427 FRAME.NOTE: MODSUM 8/0427 (FUSELAGE FRAME FLANGES AT OUTBOARD SEAT RAIL BRACKET ATTACHMENT AREA) INTRODUCED A NEW FRAME AT THIS LOCATION ALONG WITH NUMEROUS STRUCTURAL IMPROVEMENTS ALONG THE FUSELAGE DUE TO CRACKING O F FRAMES IN THE FATIGUE SPECIMEN. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005030800233 20050308 00233 GL 2005 3 8 CA040708004 3 20040629 G 6114 DOWEL PIN CESSNA 182 182A 2072704 CE CONT O470 O470L 17026 SO HARTZL HC82V HC82V* GL PROPELLER MISSING W B A EMER. DESCENT UNSCHED LANDING E VIBRATION/BUFFET CL CLIMB 1 CA T2089N PROPELLER INSTALLED AFTER OVERHAUL USING CESSNA MAINTENANCE MANUAL AS REFERENCE. AIR TEST AFTER INSTALLATION REFLECTS P ROPELLER VIBRATION SHORTLY AFTER TAKEOFF. AIRCRAFT LANDED IMMEDIATELY. PROPELLER REMOVED. INSPECTED BY A-1 PROPELLER SERVICES. DETERMINED DOWELS FOUND MISSING UPON RETURN FROM OVERHAUL. CESSNA MAINTENANCE MANUAL LACKING IN DETAIL WITH RESPECT TO DOWEL INSTALLATION. WRONG DOWELS MISTAKENLY DRIVEN. CESSNA PARTS MANUAL SHOWS ALL DOWELS AS PART OF PROELLE R ASSEMBLY. 1 H 7 1 3O 3 O NT 3A13 E273 5 C P23EA 2005030800234 20050308 00234 NM 2005 3 8 CA040708006 1 20040704 G 2913 6617302 PUMP BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA HYD SYSTEM INOPERATIVE W O OTHER J WARNING INDICATION CR CRUISE 1 CA DURING CRUISE, NR 1 HYDRAULIC CAUTION LIGHT ILLUMINATED, CONFIRMED NR 1 HYDRAULIC SYSTEM HAD NO PRESSURE. FOLLOWED QRH AND MADE NORMAL LANDING. FOUND QUILL SHAFT FOR PUMP COMPLETELY SHEARED. 2 H 7 2 4T 4 T RT A13NM E00062EN 2005030800235 20050308 00235 EA 2005 3 8 CA040708007 2 20040706 G 7200 ENGINE EMB 110 EMB110P1 3260122 SO PWA PT6 PT6A34 52043 EA HARTZL HCB3T HCB3TN3 GL LEFT FAILED W E A ENGINE SHUTDOWN UNSCHED LANDING M J OVER TEMP WARNING INDICATION CR CRUISE 1 CA DURING CRUISE FLIGHT, THE CREW OBSERVED THE LT ENGINE T5 TEMPERATURE STARTING TOFLUCTUATE FOLLOWED BY A COMPLETE LOSS OF T5 TEMPERATURE INDICATION. ONCE ON THE GROUND, DURING A TROUBLESHOOTING MAINTENANCE RUN, IT WAS ALSO OBSERVED THAT THE ENGINE WAS MAKING ABNORMAL 1 L 7 2 4T 4 T A21SO E4EA 6 C P15EA 2005030800236 20050308 00236 NM 2005 3 8 CA040708008 1 20040705 G 2913 6617302 PUMP BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA NR 2 HYD SYSTEM INOPERATIVE W O OTHER O OTHER NR NOT REPORTED 1 CA NR 2 HYDRAULIC SYSTEM CASE DRAIN FILTER BYPASS INDICATOR POPPED SEVERAL TIMES DURING THE DAY. FOUND FILTER CONTAMINATED WITH METAL. REPLACED HYDRAULIC PUMP AS PRECAUTION DUE TO 2 FAILURES ON OTHER AIRCRAFT. 2 H 7 2 4T 4 T RT A13NM E00062EN 2004072900013 20040729 00013 CE 2004 7 29 CA040708009 1 20040611 G 5753 SKIN CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160DTM GL RT FLAP CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) SMALL CRACKS AT RIVETS, 4 PLACES, WERE FOUND ON THE RT FLAP. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2004072900014 20040729 00014 NM 2004 7 29 CA040708010 1 20040706 G 2913 6617302 PUMP BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU NR 2 HYD SYSTEM FAILED W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA (CAN) DURING TEST FLIGHT, NR 2 HYD CAUTION LIGHT ILLUMINATED. CONFIRMED NO PRESSURE ON SYSTEM. QRH AND DIVERTED TO BA SE. VERIFIED PUMP QUILL SHAFT SHEARED. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2004072900015 20040729 00015 NE 2004 7 29 CA040708011 2 20040705 G 8530 28151 SEAL DOUG A26 A26* WP PWA R2800 R280079 52026 NE HAMSTD 23E 23E50 NE CYLINDER FAILED W E ENGINE SHUTDOWN E VIBRATION/BUFFET CL CLIMB 1 CA FPO27892 (CAN) NR 1 ENGINE WAS RUNNING ROUGH AT CLIMB POWER ABOUT FOUR MINUTES AFTER TAKE OFF, THE ENGINE CONTINUED TO RUN ROUGH AT REDUCED POWER. THE PILOT SHUT DOWN THE ENGINEAND SECURED IT AND RETURNED TO BASE WITHOUT INCIDENT. MAINTENANCE FOUND TRACES OF OIL IN THE INTAKES AND THE CYLINDERS WHICH POINTS TO THE BLOWER SEAL. ENGINE CHANGE SCHEDULED. 2 M 7 2 4R 4 R L34 5E8 6 C P603 2004072900016 20040729 00016 SW 2004 7 29 CA040708012 1 20040705 G 2821 222366621 DRAIN VALVE BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL FUEL SYSTEM LEAKING W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING MAINTENANCE GROUND RUN IAW MM-1-5/27, THE ENGINE FLAMED OUT WHEN THE BOOST PUMPS WERE SHUT OFF. THIS FAILUR E WAS REPEATABLE. TROUBLE SHOOTING REVEALED AIR ENTERING THE FUEL SYSTEM THROUGH THE AIRFRAME FUEL FILTER ASSEMBLY DRAIN VALVE. THE AIRFRAME FUEL FILTER ASSEMBLY P/N 222-366-621-001 WAS REPLACED WITH P/N 222-366-621-003 AND THE AIRCRAFT WAS RUN IAW MM-1-5/27. THE PROBLEM WAS RECTIFIED. THE DEFECTIVE PART TRACEABILITY IS BEING REVIEWED. 1 G 7 1 3U 3 U H2SW E4CE 2004072900017 20040729 00017 EA 2004 7 29 CA040709001 2 20040629 G 8530 SL32006WA21P CYLINDER LYC O320 O320* 41508 EA ENGINE FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) NEW CYLINDER ASSEMBLIES (2), REMOVED FROM BOXES AND INSPECTED & MEASURED TO FIT RINGS. BARRELS FOUND TO BE AT SERI CE LIMIT WITH .010 CHOKE AND .008 TO .010 OUT OF ROUND. NEW CYLINDERS OUT OF LIMITS. NO APPARENT PHYSICAL DAMAGE, QUALIT Y CONTROL PROBLEM. 3 O E274 2004072900018 20040729 00018 SO 2004 7 29 CA040709002 2 20040623 G 8530 649199P10A1 CYLINDER HEAD CESSNA 185 A185F 2072821 CE CONT O520 IO520D 17032 SO MCAULY 2A34C D2A34C58 GL ENGINE CRACKED W O OTHER E VIBRATION/BUFFET DE DESCENT 1 CA AR34880 (CAN) CRACKED COMPLETELY THROUGH FROM ONE SPARK PLUG HOLE TO THE EXHAUST VALVE SEAT TOTHE OTHER SPARK PLUG HOLE. CYLINDE R WAS REPAIRED 25.6 HOURS PREVIOUS. (DUE TO EXHAUST VALVE PROBLEMS) NOTE: LOGBOOK INCORRECTLY STATED CYLINDER WAS OVERHA ULED. CYLINDER WAS ACTUALLY REPAIRED 25.6 HOURS PREVIOUS. CYLINDER FAILURE OF THIS TYPE IS NOT UNCOMMON ON LARGER 6 CYL INDER ENGINES. 1 H 7 1 3O 3 O 3A24 E5CE 5 C P3EA 2004072900019 20040729 00019 SO 2004 7 29 CA040709003 2 20040701 G 8550 642335 SCREW CESSNA 206 U206 2073306 CE CONT O550 IO550F 17042 SO MCAULY D3A34 D3A34C401 GL OIL VALVE WORN W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) DURING ENGINE START, FIRST FLIGHT OF THE DAY, OIL PRESSURE WAS OBSERVED AS BEING TOO HIGH (75 PSI AT IDLE). SYSTE M BLOCKAGE WAS SUSPECTED, OIL FILTER INSPECTED (CLEAR), OIL DRAINED AND INSPECTED (CLEAR), PRESSURE CHECKED AT OTHER PRE SSURE POINTS IAW MFG SERVICE REP. INSTRUCTIONS. (AIRFRAME INDICATOR ACCURACY CONFIRMED.) NIL DEFECT FOUND. OIL PRESSURE RELIEF VALVE REMOVED, VISUALLY INSPECTED (NIL DEFECTS OBSERVED, REINSTALLED. ENGINE GROUND RUN, NIL CHANGE IN OIL PRES SURE. RELIEF VALVE ADJUSTING SCREW TURNED OUTWARD TO STOP. OIL PRESSURE OBSERVED (JUST IN RANGE). VALVE ASSEMBLY REPLA CED WITH SERVICEABLE UNIT, OPERATION NORMAL. 1 H 7 1 3O 3 O A4CE E3SO 5 C P47GL 2004072900046 20040729 00046 SO 2004 7 29 CA040709004 1 20040626 G 7797 WIRE PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA HARTZL HCE2Y HCE2YR2 GL CHT PROBE CUT W A UNSCHED LANDING N FALSE WARNING CR CRUISE 1 CA (CAN) IN FLIGHT, THE PILOT NOTICED THAT THE LT ENGINE CYLINCER TEMPERATURE WAS ABNORMALLY HIGH. ALL OTHER PARAMETERS WE RE IN THE GREEN. THE PILOT ASKED FOR A PRIORITY LANDING. WE DISCOVERED THAT THE WIRING FOR THE CHT PROBE WAS CUT. THE TERMINAL WAS REPLACED, EVERYTHING BACK TO NORMAL. 1 L 7 2 3O 3 O 1A10 1E4 5 C P9EA 2005030800237 20050308 00237 SO 2005 3 8 CA040709005 1 20040420 G 5730 4065903 SKIN PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA RT WING CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA UPPER SKIN ON RT WING FOUND TO HAVE HAIR LINE CRACKS AT STA 174.50 AND STA 160.50 ONE RIVET FORWARD OF STRINGER IMMEDIAT ELY FORWARD OF MAIN SPAR. 1 L 7 2 3O 3 O A20SO E14EA 2004072900047 20040729 00047 SW 2004 7 29 CA040709006 1 20040628 G 8200 WATER INJECTION SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP MCAULY 4HFR34 4HFR34C652 NE ENGINE INOPERATIVE W C ABORTED TAKEOFF J WARNING INDICATION TO TAKEOFF 1 CA (CAN) WATER METHANOL DID NOT WORK ON TAKE OFF ROLL. LT AND RT PUMP LIGHTS WERE ON. AIRCRAFT RETURNED TO GATE. MAINTEN ANCE BLED AIR FROM SYSTEM AND BELLY DRAINS. AIRCRAFT RUNUP AND SYSTEM FUNCTIONED NORMALLY. AIRCRAFT RETURNED TO SERVIC E. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C 3PNE 2005030800238 20050308 00238 SO 2005 3 8 CA040709007 1 20040528 G 5730 4065903 SKIN PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL LT WING CRACKED W O OTHER O OTHER NR NOT REPORTED 1 CA LT WING AT STA 174.50 FOUND TO HAVE HAIR LINE CRACK FROM RIVET FORWARD OF STRINGER AHEAD OF THE MAIN SPAR. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004072900048 20040729 00048 2004 7 29 CA040709008 4 20040708 G 3421 WARNING FLAG BFGOODRICH PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL STBY ATTITUDE IN MALFUNCTIONED W K NONE N FALSE WARNING IN INSP/MAINT 1 CA 25109 (CAN) (OFF) WARNING FLAG DOES NOT COMPLETELY GO OUT OF VIEW. GYRO WAS FUNCTIONING NORMALLY AND FLAG SEEMS TO BE DISLOCA TED TOO FAR TO THE RIGHT AS COMPARED TO A SERVICEABLE UNIT. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004080400209 20040804 00209 EU 2004 8 4 CA040709009 1 20040629 G 2750 9787320003 PDU PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL TE FLAPS FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) FLAPS WERE SELECTED UP, RETRACTED NORMALLY. FLAPS WERE SELECTED DOWN, EXTENDED NORMALLY. FLAPS WERE RETRACTED ONCE MORE, OPS WERE NORMAL. FLAPS WERE SELECTED DOWN, WHEN THEY REACHED 15 DEGREE POINT, STARTED TO BIND AND FLAP RESET WAS PERFORMED. FLAPS WERE SELECTED TO 30 DEGREES. FLAPS OPERATED, BUT CUT IN AND OUT. FLAPS WERE SELECTED TO 40 DEGREES, OPE RATED NORMALLY. WHEN SELECTED DOWN, STARTED TO BIND BETWEEN 15 DEGREES, 30 DEGREES, RCCB POPPED. BINDING NOISE CAME FR OM RT FLAP. FLOOR ACCESS PANEL TO FLAP PWR DRIVE UNIT WAS REMOVED. FLAP PWR DRIVE UNIT WAS HOT AND THERE WAS STRONG ELE CTRICAL SMELL FROM PDU. FLAP PWR DRIVE UNIT WAS REPLACED, FLAPS OPERATED NORMAL. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004072900049 20040729 00049 SO 2004 7 29 CA040709010 1 20040614 G 2751 1766903 INDICATOR PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA HARTZL HCE2Y HCE2YR2 GL TE FLAPS INOPERATIVE W O OTHER P NO WARNING INDICATION CR CRUISE 1 CA (CAN) LANDING GEAR LIGHTS WOULD NOT WORK. NOTICED FLAP INDICATOR DARK IN COLOR. DISCONNECTED WIRE FROM THE FLAP INDICA TOR AND GEAR LIGHTS WORKED. REPLACED INDICATOR AND SYSTEM WORKED NORMAL. 1 L 7 2 3O 3 O 1A10 1E4 5 C P9EA 2004072900050 20040729 00050 EA 2004 7 29 CA040712001 1 20040618 G 2810 CAP DHAV DHC6 DHC6300 2802606 EA PWA PT6 PT6A27 52043 EA HARTZL HCB3T HCB3TN3 GL AFT TANK FUEL LEAKING W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CL CLIMB 1 CA (CAN) LANDED BACK TO THE BASE, DUE TO FUEL LEAKAGE FROM FUEL CAP INTO THE CABIN. ON ARRIVAL FOUND SIGN OF FUEL LEAKAGE AT AFT TANK CAP TO THE ADJACENT PAX DOOR INTO THE CABIN. AFT TANK WAS FULL ON DEPARTURE, SUSPECT FUEL SEEPAGE FROM THE TANK CAP DUE TO SEAL WAS NOT IN GOOD CONDITION. TANK CAP REPLACED. 1 H 7 2 3T 4 T RT A9EA E4EA 6 C P15EA 2004072900051 20040729 00051 NM 2004 7 29 CA040712002 1 20040707 G 1420 MS347L2255PN CONNECTOR DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE LT WING ROOT FAILED W C ABORTED TAKEOFF O OTHER TO TAKEOFF 1 CA (CAN) ON TAKE OFF ROLL 40-50 KNOTS THE NR 1 PROPELLER GAUGE WENT TO ZERO ON BOTH DIGITAL AND ANALOG DISPLAYS. ALL OTHER ENGINE GAUGES NORMAL. MAINTENANCE CARRIED OUT AN INSPECTION AN FOUND TWO PINS (Z AND FF) IN CONNECTOR 9811-P13 (P/N MS3 476L22-55PN) TO BE CORRODED AND TO BE AT FAULT WHEN MEGGARED. CONNECTOR REPLACED. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004072900052 20040729 00052 EU 2004 7 29 CA040712003 1 20040630 G 6320 4638302024 BEARING RACE BOLKMS 105 BO105C 5626005 EU TRANSMISSION SPALLED W K NONE O OTHER IN INSP/MAINT 1 CA 1190 (CAN) TRANSMISSION SENT FOR OVERHAUL DUE TO METAL CONTAMINATION DETECTED WITH A CHIP LIGHT INDICATION. AFTER DISSASSEMB LY BEARING OUTER RACE FOUND TO HAVE SPALLING DAMAGE. 1 G 7 2 3U H3EU 2005030800241 20050308 00241 EU 2005 3 8 CA040712004 1 20040708 G 3040 BYLB51824 VALVE PIAGIO P180 P180 6960204 EU PWA PT6 PT6A66 52043 NE HARTZL HCE5N HCE5N3 GL DE-ICE SYSTEM FAILED W O OTHER J WARNING INDICATION CR CRUISE 1 CA PILOTS REPORTED GREEN WING DE-ICE LIGHT CAME ON LEFT SIDE AFTER WING DE-ICE WAS SELECTED OFF AND REMAINED ON FOR FLIGHT. THE LEFT WING VALVE WAS REMOVED AND FOUND TO BE NOT COMPLETELY CLOSED. 1 H 7 2 3O 4 T RT A59EU E26NE 5 C PZONE 2004072900085 20040729 00085 EU 2004 7 29 CA040712005 1 20040625 G 6730 10546682 SERVO VALVE BOLKMS 117 BK117A1 5626010 EU HYD ACTUATOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 100821 (CAN) DURING A ROUTINE INSPECTION A MARK WAS DISCOVERED ON THE ATTACHMENT HEAD OF THE SLIDER OF THE SERVO VALVE. THE SL IDER INSPECTED WITH LIQUID PENETRANT WHICH INDICATED THAT THE SLIDER WAS CRACKED. 1 G 7 2 3U H13EU 2004080500004 20040805 00004 EU 2004 8 5 CA040712006 1 20040710 G 2160 9599020135 VALVE PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL TEMP CONTROL FAILED W K NONE O OTHER IN INSP/MAINT 1 CA 0151 (CAN) TEMP CONTROL VALVE FOUND TO BE AT FAULT AFTER CREW COMPLAINED OF ECS HEAT NOT RESPONSIVE. VALVE REPLACED WITH REPA IRED UNIT, RETURNED TO SERVICE. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004080500005 20040805 00005 WP 2004 8 5 CA040712007 1 20040707 G 8012 980109000 START VALVE DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE RT STARTER MALFUNCTIONED W C ABORTED TAKEOFF J WARNING INDICATION TO TAKEOFF 1 CA (CAN) RT START VALVE OPEN ANNUNCIATOR LIGHT CAME ON DURING TAKE OFF ROLL. TAKE OFF REJECTED AND AIRCRAFT BACK TO THE GA TE. AIRCRAFT HAS BEEN DISPATCHED IAW MEL 80-1. START VALVE HAS BEEN REPLACED ON JULY 09/04. 2 L 7 2 4F 4 F RT A6WE E9NE 2004080500006 20040805 00006 NE 2004 8 5 CA040712008 2 20040711 G 8530 356995 CYLINDER DOUG DC6 DC6B 3021712 WP PWA R2800 CB3 52026 NE HAMSTD 43E 43E60 NE EXHAUST CRACKED W E ENGINE SHUTDOWN J WARNING INDICATION CL CLIMB 1 CA P30959 (CAN) DURING CLIMB AFTER A RETARDANT DROP ON A FIRE, NR 3 ENGINE BMEP BECAME ERRATIC AND A THUMPING WAS FELT AND BACKFIR E HEARD. THE REMAINING RETARDANT LOAD WAS JETTISONED AND THE NR 3 ENGINE WEAS SHUT DOWN AND THE PROPELLER WAS FEATHERED . THE AIRCRAFT RETURNED TO BASE. DURING INVESTIGATION BY THE MAINTENANCE CREW, IT WAS DISCOVERED THAT NR 14 CYLINDER EXH AUST EAR WAS CRACKED. THE CYLINDER WAS REPLACED, ENGINE WAS GROUND RUN AND THE AIRCRAFT WAS RETURNED TO SERVICE. 2 L 7 4 4R 4 R 6A4 E264 6 C P871 2005030800242 20050308 00242 SW 2005 3 8 CA040712009 1 20040602 G 5753 240014901 BLOCK MOONEY M20 M20E 5870212 SW LYC O360 IO360A1A 41514 EA MCAULY C3D36C C3D36C41582 NE TE FLAP HINGE CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 3 HINGE BLOCKS HAD SEVERE EXFOLIATION CORROSION OVER MUCH OF THEIR SURFACE. ONE BLOCK WAS SPLIT IN HALF AT THE LEADING EDGE. THE FLAP ITSELF HAD MINOR SURFACE CORROSION. THE LEFT FLAP WAS FOUND IN NORMAL CONDITION. THE HINGE BLOCKS WILL BE REPLACED WITH NEW ONES BY AMO 1 L 7 1 3O 3 O 2A3 1E10 5 N SA645NE 2005020100121 20050201 00121 CE 2005 2 1 CA040713001 1 20040712 G 2823 1013890253 SHUTOFF VALVE BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA HARTZL HCB3T HCB3TN3 GL FUEL SELECTOR FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) FAILED FUNTIONAL TEST IAW PILOTS CHECK LIST. REPLACED 1 L 7 2 3T 4 T RT 3A20 E4EA 6 C P15EA 2004080500007 20040805 00007 SO 2004 8 5 CA040713002 1 20040630 G 7810 99044004 EXHAUST STACK PIPER PA28 PA28140 7102802 SO LYC O320 O320E3D 41508 EA SNSNCH 74D 74DM EA ENGINE CRACKED W O OTHER B E SMOKE/FUMES/ODORS/SPARKS VIBRATION/BUFFET DE DESCENT 1 CA (CAN) UNDISTINGUISHABLE ODOR OF SOMETHING BURNING, FOLLOWED BY STIFF CARB HEAT CABLE AND ENGINE RUNNING ROUGH WITH CARB HEAT APPLICATION. THE RT EXHAUST STACK HAD CRACKED, HIDDEN BY THE CARBURETOR HEAT SHROUD. DURING FLIGHT, THE HEAT FROM THE EXHAUST BEING EXPELLED FROM THE CRACKED STACK, MELTED THE TOP OF THE CARB HEAT SHROUD (APPROXIMATELY .5000 INCH WID E AND 4 INCHES LONG). THE EXHAUST ESCAPING FROM THE CARB HEAT SHROUD BLISTERED THE PAINT ON THE FIREWALL, MELTED THE CAR B HEAT CABLE GROMMET LOCATED ON THE FIREWALL AND RENDERED THE CARB HEAT CABLE INOPERATIVE IN THE CLOSED POSITION. 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 2004080500008 20040805 00008 CE 2004 8 5 CA040713003 1 20040605 G 3244 173K233 TIRE LEAR 35 35LEAR 5170600 CE GARRTT TFE731 TFE73122B 01518 WP MLG CUT W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING DAILY INSPECTION, FOUND NR 2 MLG WHEEL TIRE CUT. THE CUT WAS LOCATED ON THE SIDE WALL. WHEEL ASSEMBLY REPL ACED. 2 L 7 2 4F 4 F A10CE E6WE 2004080500009 20040805 00009 EA 2004 8 5 CA040713004 1 20040630 G 1430 AW46 BOLT DHAV DHC2 DHC2MK1 2800102 EA PWA R985 R985AN14B 52008 NE HAMSTD 2D 2D30 NE RT ELEVATOR WORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING SCHEDULED INSPECTION RT ELEVATOR FOUND SLIGHTLY LOOSE AT TORQUE TUBE. NUT COULD NOT BE TIGHTENED DUE TO EX CESSIVELY WORN BOLT AW4-6. BOLT REPLACED AND NUT AN320-4. ELEVATORS MUST BE REMOVED EVERY 400 HOURS TO ACCOMPLISH AD 8 0-25. REPEATED REMOVAL AND INSTALLATION OF ELEVATOR CAUSING PREMATURE WARE OF THESE BOLTS AND POSSIBLE SUBSEQUENT ELONG ATION OF HOLES TORQUE TUBE. SUGGEST REVIEW OF AD 80-25 IS IT NECESSARY SO OFTEN. 1 H 7 1 3R 3 R A806 5E1 5 C P206 2004080500010 20040805 00010 EA 2004 8 5 CA040713005 2 20040708 G 8530 PUSHROD CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160DTM GL ENGINE CYLINDER BENT W O OTHER E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 CA (CAN) PILOT WAS 10 MILES FROM AIRPORT. WHEN A POWER LOSS AND ENGINE VIBRATION WAS NOTED. PILOT INFORMED ATC OF SITUATION AND LANDED AT AIRPORT WITHOUT INCIDENT. UPON INVESTIGATION NOTICED NO COMPRESSION AND BENT PUSH ROD AND PUSHROD HOUSIN G ON NR 4 CYLINDER. NR 4 CYLINDER REPLACED WITH SERVICEABLE CYLINDER AND AIRCRAFT WAS RETURNED TO SERVICE. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2004080500011 20040805 00011 EA 2004 8 5 CA040713006 2 20040620 G 7320 32447531917 FCU DHAV DHC7 DHC7102 2802708 EA PWA PT6 PT6A50 52043 EA HAMSTD 24PF 24PF305 GL ENGINE FAILED W E A ENGINE SHUTDOWN UNSCHED LANDING E VIBRATION/BUFFET CR CRUISE 1 CA (CAN) AT CRUISE ALTITUDE AT FL110 ON A MEDEVAC FLIGHT DESCENT CHECKS WERE CARRIED OUT. AS TURBULENCE WAS EXPECTED A RATE OF 500 RPM AND SPEED OF 170 KIAS WAS BRIEFED AFTER DESCENT. CLEARANCE RECEIVED POWER LEVERS WERE PULLED BACK TO APPROX 3000 TORQUE. NR 3 ENG TORQUE, RPM, T5 AND NG REMAINED AT CRUISE POWER. SEVERAL POWER LEVER EXCURSIONS WERE CARRIED OUT BUT THERE WAS NO CHANGE. CAPT CALLED FOR QRH ACTION. ENGINE NR 3 SHUT DOWN IAW QRH. ATC NOTIFIED. ERV REQUESTED. A 3 ENG LANDING CARRIED OUT. AFTER AC SHUT DOWN ON RAMP, MAINTENANCE STAFF REMOVED NR 3 COWLING TO DETERMINE IF LINKAGE HAD FAI LED. INITIAL ASSESSMENT WAS FAILURE OF FUEL CONTROL UNIT. SUBSEQUENT APPROVAL RECEIVED TO CONDUCT 3 ENGINE FERRY FLIGHT. 2 H 7 4 4T 4 T A20EA E4EA 6 C P1NE 2004080500012 20040805 00012 NE 2004 8 5 CA040713007 2 20040705 G 8530 AE92181ER CYLINDER HEAD DHAV DHC3 DHC3 2800202 EA PWA R1340 S3H1G 52016 NE HAMSTD 23D 23D40 NE ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) CRACK IN HEAD WALL BETWEEN FINS 11 AND 12 COUNTING FROM BARREL, ON EXHAUST SIDE OF CYLINDER. 1 H 7 1 3R 3 R A815 E142 6 C P719 2005020100178 20050201 00178 CE 2005 2 1 CA040713008 1 20040712 G 5210 1294000371 SEAL BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE PAX DOOR TORN W B EMER. DESCENT W INADEQUATE Q C CR CRUISE 1 CA (CAN) DURING CRUISE FLIGHT THE CREW NOTED AN INCREASED NOISE FROM THE MAIN DOOR AND WAS UNABLE TO MAINTAIN CABIN PRESSUR E APPROPRIATE FOR 170 ALTITUDE. THE AIRCRAFT WAS DESCENDED TO 100 AND THE FLIGHT CONTINUED TO DESTINATION. MAINTENANCE WAS DISPATCHED AND FOUND THE MAIN DOOR PRESSURE SEAL HAD TORN ALLOWING THE SEAL TO COLLAPSE. DEBRIS IN THE FORM OF GRA VEL WAS FOUND, WHICH MAY HAVE CONTRIBUTED TO THE SEAL FAILURE. THE SEAL WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVIC E. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2004080500040 20040805 00040 EU 2004 8 5 CA040713009 1 20040712 G 7810 5781012041 EXHAUST STACK PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL LT ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) LT EXHAUST STACK CRACKED FROM ONE MOUNTING HOLE OUTWARDS. STACK REPLACED WITH SERVICEABLE UNIT. CRACK DISCOVERED DURING ENGINE INSPECTION. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004080500041 20040805 00041 EU 2004 8 5 CA040713010 1 20040712 G 3340 9736142510 SWITCH PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL EXTERIOR LIGHTS INTERMITTENT W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHILE PERFORMING DAILY INSPECTION AND REPORTED INTERMITTENTLY BY PILOT THAT TWO LIGHT SWITCHES ON CONTROL PANEL. OCCASIONALLY WILL NOT SWITCH (OFF) OR SOMETIMES WILL NOT REMAIN IN (ON) POSITION THIS WOULD OCCUR INTERMITTENTLY AND IT WAS DISCOVERED. PROBLEM IS AN INTERNAL MALFUNCTION. THIS OCCURRED ON (STROBE/BEACON) SWITCH AND (TAXI/LOGO) LIGHT SWITCH . BOTH SWITCHES ARE THE SAME PN. SWITCHES REPLACED WITH NEW. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004080500042 20040805 00042 NM 2004 8 5 CA040713011 1 20040713 G 3260 1EN161RB1 SWITCH BOEING 727 727225 1384077 NM PWA JT8 JT8D9A 52048 NE MLG FAILED W A UNSCHED LANDING N FALSE WARNING CL CLIMB 1 CA (CAN) AFTER TAKEOFF WHEN THE GEAR WAS RETRACTED, THE LEFT MAIN GEAR DOOR LIGHT ON THE ENGINEERS PANEL AND THE DOOR UNSAF E LIGHT REMAINED ILLUMINATED. THE CREW CYCLED THE GEAR AND THE LIGHT REMAINED ON, THE CREW ELECTED TO RETURN TO THE POIN T OF ORIGIN. THE SWITCH AND CONNECTOR WERE REPLACED AND THE AIRCRAFT DEPARTED. 2 L 7 3 4F 4 F A3WE E2EA 2004080500043 20040805 00043 EA 2004 8 5 CA040714001 2 20040707 G 7314 RG9080J4AM PUMP PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL ENGINE FUEL LEAKING W O OTHER K FLUID LOSS NR NOT REPORTED 1 CA (CAN) DURING SCHEDULED MAINTENANCE THE FUEL PUMP WAS NOTED AS LEAKING FUEL. THIS PUMP IS NOT COVERED BY THE AD 2003-14-0 3 AS IT IS MODIFIED. PUMP REPLACED BEFORE FURTHER FLIGHT. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2005030800244 20050308 00244 2005 3 8 CA040714002 4 20040713 G 2215 7002260723 SERVO DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE AUTO PILOT INOPERATIVE W O OTHER F FLT CONT AFFECTED AP APPROACH 1 CA 26173 88072197 THE FLIGHT CREW REPORTED A INTERMITTENT BINDING IN ROLL CONTROL ON APPROACH, ESPECIALLY TO THE RIGHT. MILD FORCE WAS RE QUIRED TO OVERCOME, THE PILOT NOTED THAT IT DOES NOT APPEAR TO SIMPLY BE HEAVY AERODYNAMIC LOADING. THE MAINTENANCE AFT ER TROUBLESHOOTING POINTED THE PROBLEM TO BE THE SERVO AND REPLACED IT 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004080500044 20040805 00044 2004 8 5 CA040715001 4 20040713 G 2330 50401100003 DISPLAY BOEING 737 73776N 13844CH NM CFMINT CFM567 CFM567B22 13802 NE ENTERTAIN SYS SMOKE W H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA (CAN) FLT UPON ARRIVAL, GUEST INFORMED FLIGHT CREW SMOKE WAS COMING FROM THE (LIVE TV) VIDEO DISPLAY UNIT (TV SCREEN). C APTAIN IMMEDIATELY TURNED OFF POWER TO SYSTEM AND AIRCRAFT PROCEEDED TO GATE AND DEPLANED GUESTS. LIVE TV TECHNICIAN, TR AVELING ONBOARD AIRCRAFT AS PART OF INITIAL INSTALLATION SUPPORT PROGRAM REPLACE DVDU SCREEN FROM SEAT BACK IAW LTV-AMM- 23-32-03 AND ISSUED MEL 25-10-5.AIRCRAFT RETURNED TO SERVICE WITH NO FURTHER INCIDENTS TO REPORT. DURING RON THAT EVENI NG, LIVE TV TECHNICIAN COMPLETED LIVE TV 1ST LEVEL OPERATIONAL CHECK IAW LIVE TV AMM-23-32-03 -SYSTEM CHECKED SERVICEABL E. VDU RE-CONNECTED, MEL CLEARED AND AIRCRAFT RETURNED TO SERVICE WITH NO FURTHER INCIDENTS TO REPORT. 2 L 7 2 4F 4 F RT A16WE E00055EN 2005030800247 20050308 00247 NM 2005 3 8 CA040715002 1 20040710 G 2752 734181D BALLSCREW DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE TE FLAPS DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA WHILE PERFORMING THE REPEAT INSPECTION REQUIREMENTS OF CF-2002-26R1 THE NR 4 RT BALLSCREW ACTUATOR WAS FOUND TO HAVE A T OTAL FREEPLAY BACKLASH OF .192 INCH. THE LAST INSPECTION HAD BEEN DONE 997 HRS AND 863 CYC PREVIOUSLY AND AT THAT TIME WAS .030 INCH. THE ACTUATOR WAS REPLACED WITH AN OVERHAULED UNIT FROM HAMILTON SUNDSTRAND. THE AD REQUIREMENTS INVOLVE THE MEASURING OF THE BACKLASH BETWEEN THE SCREW JACK ROD AND THE NUT WHICH WAS STILL FOUND TO BE WITHIN SERVICEABLE LIM ITS HOWEVER THE TOTAL FREEPLAY BACKLASH WHICH COMPRISES OF THIS BACKLASH MEASUREMENT AS WELL AS THE FREEPLAY BETWEEN THE BALLSCREW NUT AND THE ACTUATOR BODY WAS FOUND TO BE EXCESSIVE. THE INSERVICE LIMIT FOR THIS MEASUREMENT IS .057 INCH. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005030800251 20050308 00251 2005 3 8 CA040715003 4 20040714 G 2397 WIRE HARNESS CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE COMMS CHAFED W K NONE O OTHER IN INSP/MAINT 1 CA UPON VISUAL INSPECTION OF THE RADIO MANAGEMENT UNITS (RMU) WIRE BUNDLES, A WIRE IN THE NR 1 RMU BUNDLE WAS FOUND TO BE D AMAGED BEYOND THE POINT OF EXPOSURE OF BARE WIRE AND APPEARS TO BE CHAFED APPROXIMATELY ONE QUARTER THE WAY THROUGH. TH E CHAFFING OCCURRED AGAINST A STATIC SOURCE TEE FITTING BEHIND AND TO THE RIGHT OF THE NUMBER ONE RMU. 1 L 7 2 4F 4 F A22CE E1NE 2005030800254 20050308 00254 CE 2005 3 8 CA040715004 1 20040707 G 2432 7624308001001 BATTERY LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE731* 01518 WP EMERGENCY INOPERATIVE W O OTHER H ELECT. POWER LOSS-50 PC TX TAXI/GRND HDL 1 CA DURING ENGINE START WITH GROUND POWER UNIT AND AVIONICS ON, ALL 4 DISPLAY UNITS WENT BLACK AND THEN LIT UP AGAIN AFTER E NGINE STARTED. MAINTENANCE DISCOVERED WITH A CAPACITY CHECK ON THE EMERGENCY BATTERY THAT 1 CELL HAD FAILED WHICH CAUSE D THE VOLTAGE TO DROP BELOW 22 VOLTS UNDER A HEAVY LOAD. EMERGENCY BATTERY REPLACED. EMERGENCY BATTERY IS AN ON CONDIT ION ITEM WITH A CAPACITY CHECK EVERY 3 MONTHS. AS THIS BATTERY WAS OVER 5.5 YEARS OLD WE WOULD RECOMMEND A LIFE LIMIT O F NO MORE THAN 5 YEARS PUT ON THESE BATTERIES. 2 L 7 2 4F 4 F RT T00008WI E6WE 2004080500045 20040805 00045 NM 2004 8 5 CA040715005 1 20040714 G 1420 CONNECTOR BOEING 737 7372H4 138448C NM PWA JT8 JT8D9A 52048 NE NR 2 ENGINE CONTAMINATED W E B ENGINE SHUTDOWN EMER. DESCENT M J OVER TEMP WARNING INDICATION CL CLIMB 1 CA 666325 (CAN) AC RETURNED BECAUSE OF A NR 2 ENG OVERHEAT LIGHT ILLUMINATING AT 23,000 FT. AND WOULD NOT EXTINGUISH. ENG WAS SHUT DOWN IN FLIGHT IAW QRC AND LANDED WITH INCIDENT, CFR FOLLOWED AC TO THE GATE. AFTER TAXIING TO GATE, NR 3 AND NR 4 MAIN WHEEL FUSE PLUGS LET LOOSE. BOTH MAIN WHEELS REPLACED. ON ENGINE OVERHEAT SYSTEM, MAINT FOUND OIL CONTAMINATION IN ONE OF THE ENGINE CONNECTORS. MAINT CLEANED CONNECTORS AND OTHER THAN THAT COULD NOT FAULT SYSTEM. MAINT REPLACED FIRE DETEC TION UNIT FOR TROUBLESHOOTING PURPOSES. AC GROUND CHECKS SERVICEABLE AND IS BEING POSITIONED THIS AFTERNOON FOR SCHEDUL ES FLIGHT PLAN. WILL KEEP AN EYE ON THIS ONE AND ADVISE OF ANY FURTHER DEVELOPMENT SHOULD THEY RE-OCCUR. 2 L 7 2 4F 4 F A16WE E2EA 2004080500046 20040805 00046 WP 2004 8 5 CA040715006 1 20040715 G 1430 65678 BOLT GRUMAN TS2 TS2ACALFORST 3951102 WP WRIGHT R1820 982C9HE2 67020 EA HAMSTD 43D 43D51 NE ROCKER ARM BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING INSPECTION, AN OIL LEAK WAS DISCOVERED ON THE RT ENGINE CYLINDER POSITION NR 2. UPON INVESTIGATION AND REC TIFICATION, THE MAINTENANCE CREW WAS ATTEMPTING TO REPLACE THE O-RINGS ON THE EXHAUST ROCKER ARM RETAINING BOLT. THE RET AINING NUT AND COTTER PIN CAME OFF AS A COMPLETE UNIT. IT WAS NOTED THAT THE BOLT HAD SHEARED AT THE FIRST ROW OF THREAD S. THE BOLT WAS REPLACED AND THE AIRCRAFT WAS RETURNED TO SERVICE. 2 H 7 2 4R 4 R A25WE E259 6 C P8879 2005030800257 20050308 00257 CE 2005 3 8 CA040716001 1 20040716 G 5312 PRESSURE BLKHD LEAR 35 35A 5170602 CE GARRTT TFE731 TFE73122B 01518 WP FUSELAGE TORN W K NONE O OTHER IN INSP/MAINT 1 CA 18669 AIRCRAFT WAS PARKED ON THE RAMP. MAINTENANCE PERSONNEL WANT TO TOW THE AIRPLANE. WHEN STARTING TO PULL THE AIRPLANE THE NOSE LANDING GEAR ACTUATOR UPPER ATTACHMENT BRACKET FAILED. AFTER THE INCIDENT THE PRESSURE BULKHEAD FOUND TO BE TORN AT THE B.L 0.0 AT THE UPPER SECTIONS. ALSO, THE ACTUATOR UPPER ATTACHMENT SUPPORT BRACKET WAS TORN AT THE CONNECTION TO THE PRESSURE BULKHEAD. THE PARKING BRAKE WAS LEFT APPLIED. 2 L 7 2 4F 4 F A10CE E6WE 2005030800259 20050308 00259 NM 2005 3 8 CA040716002 1 20040715 G 3234 7SC0143 SELECTOR VALVE DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE MLG FAILED W O OTHER O OTHER NR NOT REPORTED 1 CA 433 AFTER THE ABOVE AIRCRAFT WAS FERRIED DUE TO A GEAR INDICATION PROBLEM, THE LANDING GEAR SELECTOR VALVE WAS FOUND AT FAUL T. UPON REPLACING THE INITIAL SELECTOR VALVE (P/N 7SC0143) WITH THE ABOVE (S/N 433) AND GEAR SWINGS WERE CARRIED OUT IT WAS DISCOVERED THAT WHEN THE GEAR WAS SELECTED UP THE GEAR WOULD GO DOWN AND WHEN THE GEAR WAS SELECTED DOWN THE GEAR W OULD GO UP. A SECOND LANDING GEAR SELECTOR VALVE WAS INSTALLED GEAR SWINGS CARRIED OUT AND THE AIRCRAFT WAS RETURNED TO SERVICE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005030800262 20050308 00262 SW 2005 3 8 CA040716004 1 20040628 G 2460 51509002R CONTROL UNIT BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA DC SYSTEM MALFUNCTIONED W O OTHER J WARNING INDICATION TX TAXI/GRND HDL 1 CA GENERATOR WOULDN'T COME ONLINE, NR 1 AND NR 1 SWAPPED FOR TROUBLESHOOTING, CONTROL CONFIRMED TO BE AT FAULT. CONTROL UN IT REPLACED, GENERATOR BALANCING C/O AND A/C RETURNED TO SERVICE. THIS UNIT CONTAINED WATER WHEN REMOVED. 1 G 7 1 4U 4 U H4SW E22EA 2005012400021 20050124 00021 NE 2005 1 24 CA040716007 2 20040712 G 8500 DIAPHRAGM PWA DOUG DC4 C54 3021506 WP PWA R2000 R20007M2 52023 NE ACCELERATOR PUMP DAMAGED W E ENGINE SHUTDOWN E VIBRATION/BUFFET CR CRUISE 1 CA (CAN) DURING CRUISE THE NR 4 ENGINE STARTED TO BACKFIRE AND SHAKE. THE ENGINE WAS SHUTDOWN AND THE PROPELLER FEATHERED. THE FLIGHT RESUMED WITHOUT INCIDENT. 2 L 7 4 4R 4 R A762 5E5 2005012400022 20050124 00022 NE 2005 1 24 CA040716008 2 20040712 G 8500 R20007M2 ENGINE DOUG DC4 C54 3021506 WP PWA R2000 R20007M2 52023 NE HAMSTD 23E 23E50 NE NR 4 MALFUNCTIONED W E A ENGINE SHUTDOWN UNSCHED LANDING E J VIBRATION/BUFFET WARNING INDICATION CL CLIMB 1 CA BP700326 (CAN) DURING CLIMB THE NR 4 ENGINE STARTED TO BACKFIRE AND SHAKE. THE ENGINE WAS SHUT DOWN AND THE PROPELLER FEATHERED. THE FLIGHT RESUMED WITHOUT INCIDENT. 2 L 7 4 4R 4 R A762 5E5 6 C P603 2005012400023 20050124 00023 NE 2005 1 24 CA040716009 2 20040714 G 8500 CASE DOUG DC4 C54 3021506 WP PWA R2000 R20007M2 52023 NE HAMSTD 23E 23E50 NE NR 4 ENGINE FAILED W E A ENGINE SHUTDOWN UNSCHED LANDING W E INADEQUATE Q C VIBRATION/BUFFET CL CLIMB 1 CA (CAN) DURING CLIMB THE NR 4 ENGINE WOULD NOT GOVERN, THE ENGINE WAS SHUTDOWN AND THE PROPELLER FEATHERED. THE AIRCRAFT RETURNED TO BASE WITHOUT FURTHER INCIDENT. 2 L 7 4 4R 4 R A762 5E5 6 C P603 2004123000131 20041230 00131 SW 2004 12 30 CA040719001 1 20040715 G 2432 1656 BATTERY BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL MASTER OVERHEATED W A H UNSCHED LANDING DEACTIVATE SYST/CIRCUITS J WARNING INDICATION CR CRUISE 1 CA THE 'BATTERY TEMP' WARNING LIGHT ILLUMINATED ON ROUTE. THE BATTERY WAS TURNED OFF FOR THE REMAINDER OF THE FLIGHT. UPO N LANDING AND SHUTTING DOWN , THE PILOT NOTICED THAT THE BATTERY FELT VERY HOT TO THE TOUCH. WHILE TALKING TO THE MAINT ENANCE DEPT ON THE PHONE, THE 'BATTERY HOT' LIGHT CAME ON. THE BATTERY WAS REPLACED WITH A SERVICEABLE ONE BEFORE FURTHE R FLIGHT. THE VOLTAGE REGULATOR WAS CHECK ED DURING THE GROUND RUN FOUND TO BE WITHIN LIMITS. 1 G 7 1 3U 3 U H2SW E4CE 2004123000132 20041230 00132 SW 2004 12 30 CA040719002 1 20040712 G 5220 2722181 DOOR SWRNGN SA227 SA227AC 8780603 SW MCAULY 4HFR34 4HFR34C652 NE EMERGENCY EXIT OUT OF POSITION W O OTHER O OTHER LD LANDING 1 CA UPON LANDING, THE LT EMERGENCY EXIT HATCH OPENED AND FELL OUT OF POSITION. MX ENGINEER INSPECTED THE ESCAPE HATCH AND F OUND NO EVIDENCE OF DAMAGE. HATCH WAS INSTALLED AND FURTHER INCIDENT HAS OCCURRED. 2 L 7 2 4T RT A8SW 6 C 3PNE 2004123000133 20041230 00133 CE 2004 12 30 CA040719003 1 20040719 G 2731 A41015455400 RELAY BEECH 100 A100 1152915 CE PWA PT6 PT6A28 EA HARTZL HCB3T HCB3TN3 GL ELEVATOR TRIM INTERMITTENT W H DEACTIVATE SYST/CIRCUITS F FLT CONT AFFECTED CR CRUISE 1 CA CREWS REPORT THAT DURING CRUISE, THE MAIN ELECTRIC STABILIZER TRIM WOULD NOT TRIM NOSE DOWN. CREW THEN DEACTIVATED THE MAIN TRIM SYSTEM AND ENGAGED STANDBY TRIM SYSTEM. STANDBY SYSTEM FUNCTIONED NORMAL. AIRCRAFT CONTINUED AND LANDED WITH NO FURTHER FAULTS. MAINTENANCE T/S FOUND REALLY P/N A410-1545654-00 INTERMITTENT. REPLACED. 1 L 7 2 3T 4 T A14CE E4EA 6 C P15EA 2005030800264 20050308 00264 EA 2005 3 8 CA040719004 2 20040716 G 7414 D6LN3200 MAGNETO PIPER PA31 PA31 7103102 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCC4Y HCC4YR2 GL ENGINE WORN W K NONE O OTHER IN INSP/MAINT 1 CA OIL LEAK WAS DISCOVERED AT MAGNETO MOUNTING FLANGE GASKET. UPON REMOVAL OF UPPER AND LOWER MAGNETO MOUNT CLAMPS (P/N 66 M19385), WEAR AND FRETTING OF THE MAGNETO MOUNTING FLANGE WAS DISCOVERED. WHEN CHECKED, THE MAGNETO WAS STILL CORRECTLY TIMED TO THE ENGINE AND NO EXPLANATION CAN BE OFFERED AS TO WHY THE MAGNETO DID NOT PARTIALLY ROTATE AND AFFECT IGNITIO N TIMING. IN ADDITION, THE NUT AND LOCKWASHER WAS STILL HOLDING THE CLAMP TIGHT TO THE ENGINE. THE SUBMITTER HAS NEVER SEEN A SIMILAR PROBLEM ON MAGNETOS ATTACHED WITH OLDER STYLE (P/N 75965) MOUNT CLAMPS. 1 L 7 2 3O 3 O A20SO E14EA 5 C P52GL 2005030800265 20050308 00265 EA 2005 3 8 CA040719005 2 20040716 G 7414 D6LN3200 MAGNETO PIPER PA31 PA31 7103102 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCC4Y HCC4YR2 GL ENGINE WORN W K NONE O OTHER IN INSP/MAINT 1 CA OIL LEAK WAS DISCOVERED AT MAGNETO MOUNTING FLANGE GASKET. UPON REMOVAL OF UPPER AND LOWER MAGNETO MOUNT CLAMPS (P/N 66 M19385), WEAR AND FRETTING OF THE MAGNETO MOUNTING FLANGE WAS DISCOVERED. WHEN CHECKED, THE MAGNETO WAS STILL CORRECTLY TIMED TO THE ENGINE AND NO EXPLANATION CAN BE OFFERED AS TO WHY THE MAGNETO DID NOT PARTIALLY ROTATE AND AFFECT IGNITIO N TIMING. IN ADDITION, THE NUT AND LOCKWASHER WAS STILL HOLDING THE CLAMP TIGHT TO THE ENGINE. THE SUBMITTER HAS NEVER SEEN A SIMILAR PROBLEM ON MAGNETOS ATTACHED WITH OLDER STYLE (P/N 75965) MOUNT CLAMPS. 1 L 7 2 3O 3 O A20SO E14EA 5 C P52GL 2005030800266 20050308 00266 WP 2005 3 8 CA040719006 1 20040716 G 7810 NAS27844 TURNBUCKLE CVAC 440 440 2422902 WP ALLSN 501D 501D13D 03004 GL TAIL PIPE SHEARED W K NONE O OTHER IN INSP/MAINT 1 CA DURING INSPECTION MAINTENANCE CREW NOTED THAT THE RIGHT HAND ENGINE OUTBOARD EXHAUST SUPPORT TURNBUCKLE HAD SHEARED CAUS ING THE TAILPIPE TO REST ON THE BOTTOM OF THE EXHAUST SHROUD INSTEAD OF BEING SUPPORTED IN THE CENTER. THE TURNBUCKLE W AS REPLACED WITH A SERVICEABLE PART AND THE AIRCRAFT WAS RETURNED TO SERVICE. 2 L 7 2 4R 4 T 6A6 E282 2005030800267 20050308 00267 GL 2005 3 8 CA040720001 3 20040713 G 6110 SKIN MTSBSI MU2 MU2B60 5780460 CE GARRTT TPE331 TPE33110 01514 WP HARTZL HCB4T HCB4TN5 GL PROPELLER LIGHTNING STRIKE W O OTHER C F.O.D. CR CRUISE 1 CA IN CRUISE OUT OF JFK NOTICED LIGHTNING STRIKE ON LEFT PROP/SITUATION WAS EVALUATED AND ALL PARAMETERS WERE NORMAL. FLIG HT WAS CONTINUED AND UPON LANDING ON YOW BASE NOTICED UPON CLOSE INSPECTION: LEFT PROP BLADE DAMAGED, PROP REPLACED. LE FT OUTBOARD AILERON TAB DAMAGED, TAB REPLACED. REAR ELEVATOR QUADRANT DAMAGED, QUADRANT REPLACED. LOWER ELEVATOR CABLE DAMAGED, CABLE REPLACED. ELEVATOR SERVO CABLE DAMAGED, CABLE REPLACED. REAR NAV LIGHT DAMAGED, NAV LIGHT ASSEMBLY REP LACED. LEFT ENGINE REMOVED FOR INTERNAL INSPECTION, IAW/MM-CH 72-00-27R10 AND PARTS REPLACED AS REQUIRED. 1 H 7 2 3T 4 T RT A10SW E4WE 6 C P40EA 2005030800268 20050308 00268 SO 2005 3 8 CA040720002 1 20040713 G 5711 68621003 SPAR PIPER PA34 PA34200T 7103406 SO CONT O360 LTSIO360EB 17025 SO HARTZL HCC2Y BHCC2YF2 GL RT WING WORN W K NONE O OTHER IN INSP/MAINT 1 CA DURNG 100 HOURS INSPECTION, RT WING REAR SPAR ATTACHMENT BOLT P/N NAS464P6LA6 FOUND LOOSE. BOLT WAS REMOVED AND FOUND S EVERLY DAMAGED (DEFORMED) AND BOTH SPAR FITTINGS P/N 68621-003 AND 66762-000 BOLT HOLES FOUND ELONGATED. BOTH SPAR FITT INGS WERE REPLACED, NEW BOLTS INSTALLED AND AIRCRAFT RETURNED TO SERVICE. 1 L 7 2 3O 3 O A7SO E9CE 5 C P920 2005030800269 20050308 00269 NM 2005 3 8 CA040720003 1 20040717 G 2110 COMPRESSOR BOEING 727 727225 1384077 NM PWA JT8 JT8D15A 52051 NE CABIN AIR ODOR W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 CA DURING TAKEOFF, THE CREW REPORTED A RUSH OF HOT AIR IN THE COCKPIT AND A BURNING ODOR. THE CREW DECIDED TO RETURN TO BA SE. AIRCRAFT LANDED WITHOUT INCIDENT. MX APPLIED MEL 36-06 WITH THE NR 1 BLEED CLOSED AND THE LT NR 2 ENGINE/APU BLEED OPENED AFTER TAKEOFF. THIS IS THE SAME SCENARIO AS THE PILOT'S QRH. THE AIRCRAFT WAS DISPATCHED AND NO FURTHER INCIDE NT DURING SUBSEQUENT FLIGHT. FURTHER TROUBLESHOOTING FOUND THAT THE NR 1 AIR CYCLE MACHINE WAS UNSERVICEABLE, REPLACED AND THE MEL CLEARED. 2 L 7 3 4F 4 F A3WE E2EA 2005030800270 20050308 00270 CE 2005 3 8 CA040720004 1 20040710 G 2421 10300B ALTERNATOR CESSNA 172 172N 2072434 CE LYC O320 O320D2G 41508 EA MCAULY 1C160 1C160DTM GL ENGINE FAILED W A UNSCHED LANDING H J ELECT. POWER LOSS-50 PC WARNING INDICATION CR CRUISE 1 CA IN CRUISE, THE PILOT NOTICED THAT THE ALTERNATOR FAILED. DECIDED TO LAND AT THE NEAREST AIRPORT. ON SITE, NOTICED THAT THE ALTERNATOR GROUND WIRE WAS CUT AND WAS CONTACTING THE POSITIVE WIRE, WHICH IN TURN CAUSED THE CONTROL BOX TO FAIL. REPLACED THE ALTERNATOR, THE VOLTAGE REGULATOR AND ALL THE ELECTRICAL CONNECTIONS, AIRCRAFT SERVICEABLE. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2005030800272 20050308 00272 2005 3 8 CA040720005 4 20040717 G 6122 A6441FN606 PROPELLER LKHEED 188 188A 5262602 WP ALLSN 501D 501D13 03004 GL ALLSN A6441 A6441FN606 GL ENGINE MALFUNCTIONED W E ENGINE SHUTDOWN W INADEQUATE Q C DE DESCENT 1 CA HC2754 PROPELLER OVERSPEED ON DESCENT INTO XXXX, THE ENGINE WAS SHUT DOWN AND AIRCRAFT LANDED WITHOUT INCIDENT. PROP ASSEMBLY WAS CHANGED, GROUND RUN AND PITCH LOCK TESTED SERVICABLE. AIRCRAFT WAS RETURNED TO SERVICE. 2 L 7 4 4T 4 T RT 4A22 E282 6 C P898 2005030800274 20050308 00274 SO 2005 3 8 CA040720006 1 20040712 G 1430 LW25063 SCREW PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2B 41532 EA HARTZL HCE3Y HCE3YR2A GL ACCESSORY HOUSIN SEPARATED W A UNSCHED LANDING Y ENGINE STOPPAGE CL CLIMB 1 CA THESE TWO BOLTS HOLD THE FUEL PUMP IDLER GEAR SHAFT TO THE ACCESSORY HOUSING. FAILURE OF THE BOLTS ALLOWED THE IDLER GE AR AND SHAFT TO DROP TO THE BOTTOM OF THE ACCESSORY CASE. THE FUEL PUMP STOPPED TURNING AND THE ENGINE QUIT. ENGINE RE STARTED, USING ELECTRIC PUMP AND AIRCRAFT RETURNED TO XXX. BOTH BOLTS WERE DISCOLORED AT FRACTURE SITE. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2005030900001 20050309 00001 CE 2005 3 9 CA040720007 1 20040621 G 3260 YZ2RQ1T UPLOCK SWITCH CESSNA 337 337G 2075730 CE CONT O360 IO360GB 17025 SO MCAULY 2AF34C D2AF34C306 GL RT MLG CRACKED W O OTHER O OTHER NR NOT REPORTED 1 CA DISCOVERED SWITCH CRACKED ALONG MATING HALVES. SWITCH HALVES DO NOT APPEAR TO HAVE BEEN BONDED PROPERLY. 1 H 7 2 3O 3 O A6CE E1CE 5 C P5EA 2005030900002 20050309 00002 CE 2005 3 9 CA040720008 1 20040713 G 3220 04425037 FORK CESSNA CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL NLG STRUT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 13096 NOSE GEAR FORK WAS FOUND 2 INCH CRACK IN THE RADIUS. 1 H 7 1 3O 3 O NT 3A19 E223 5 N P50GL 2005030900003 20050309 00003 NM 2005 3 9 CA040720009 1 20040717 G 3310 RV4NBYSD502A RHEOSTAT DHAV DHC8 DHC8301 1386003 NM HAMSTD 14SF 14SF23 NE COCKPIT BURNED W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) PILOTS REPORTED SMOKE IN COCKPIT DURING FLIGHT, EMERGENCY LANDING CARRIED OUT. INVESTIGATION FOUND BURNT RHEOSTAT FOR THE PILOTS READING LIGHT. 2 H 7 2 4T RT A13NM 6 C P7NE 2005030900004 20050309 00004 EA 2005 3 9 CA040720010 1 20040718 G 5270 215260994 BRACKET CNDAIR CL215 CL2151A10 1900320 EA PWA R2800 CA3 52026 NE HAMSTD 43E 43E60 NE DOOR SENSOR BROKEN W O OTHER O OTHER NR NOT REPORTED 1 CA DURING FOREST FIRE SUPPRESSION ACTION, THE PILOTS NOTICED THAT THE LT BOMB DOOR INDICATOR LIGHT ON THE ANNUNCIATOR PANEL DISPLAYED A 'DOOR UNLOCKED' INDICATION. FIRE SUPPRESSION ACTION WAS ABORTED AND THE AIRCRAFT RETURNED TO BASE FOR MAIN TENANCE. AMES INSPECTED THE WATER DROP SYSTEM AND FOUND THE BRACKET THAT HOLDS THE LT WATER DOOR LOCKED INDICATION MICR OSWITCH WAS BROKEN.(SEE ITEM 71 IN ATTACHED FIGURE). A NEW BRACKET WAS INSTALLED, MICROSWITCH ADJUSTED AND THE SYSTEM F UNCTION TESTED. AIRCRAFT WAS RELEASED FOR RETURNED TO SERVICE. IT APPEARS FROM OBSERVING THE LACK OF 'FRESH BREAKAGE M ETAL' ON THE BROKEN BRACKET THAT THE BRACKET MAY HAVE BEEN CRACKED FOR SOME TIME BEFORE IT FAILED. 2 H 7 2 4R 4 R RT A14EA E231 6 C P871 2005030900005 20050309 00005 CE 2005 3 9 CA040721001 1 20040720 G 2150 24192273 DRAIN LINE LEAR 35 35LEAR 5170600 CE GARRTT TFE731 TFE73122B 01518 WP AIR CON BURST W K NONE O OTHER IN INSP/MAINT 1 CA DURING A SCHEDULE INSPECTION, FOUND AIR CONDITIONING DRAIN LINE BURST. THE INSPECTION OF THE CHECK VALVE WAS CARRIED AN D VALVE FOUND TO BE OPERATIVE. DRAIN TUBE WAS REPLACED. 2 L 7 2 4F 4 F A10CE E6WE 2005030900006 20050309 00006 SO 2005 3 9 CA040721002 1 20040711 G 3230 42042 STRUCTURE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 19930 WHILE INSPECTING GEAR A CRACK WAS NOTICED IN THE PAINT. CRACK EXTENDS FROM INSIDE CURVE HALF WAY TO BOLT HOLE. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2005030900007 20050309 00007 NE 2005 3 9 CA040721003 2 20040716 G 8520 PN15373 PISTON NAMER T6 HARVARDMK4 1922828 GL PWA R1340 S3H1 52016 NE NR 1 CYLINDER BROKEN W C ABORTED TAKEOFF O OTHER TO TAKEOFF 1 CA PILOT EXPERIENCED PARTIAL POWER INTERUPTION ON TAKEOFF. ABORTED TAKEOFF. BORESCOPE INSPECTION DISCOVERED BROKEN PISTON IN NR 1 CYLINDER. PISTON REPLACED WITH OVERHAULED ASSEMBLY AND ENGINE RE-ASSEMBLED AND TESTED SERVICEABLE. 1 L 7 1 3R 3 R EXPA1L71 E143 2005030900008 20050309 00008 EA 2005 3 9 CA040722001 1 20040721 G 1430 711731 BOLT DHAV DHC6 DHC6300 2802606 EA PWA PT6 PT6A27 52043 EA HARTZL HCB3T HCB3TN3 GL NLG SCISSOR LINK SHEARED W K NONE O OTHER IN INSP/MAINT 1 CA DURING THE DAILY INSPECTION, IT WAS DETECTED THE TOP BOLT IN THE NOSE GEAR SCISSOR LINK WAS SHEARED. THE GEAR WAS INSPE CTED AND NO DEFECTS NOTED. THE BOLT WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. (HAVE SEEN THIS ONCE BEFORE ON A NOTHER TWIN OTTER ABOUT 6 MONTHS AGO) THE BOLT SHEARS WHERE THERE IS A GROOVE CUT IN THE SHANK FOR LUBRICATION. 1 H 7 2 3T 4 T RT A9EA E4EA 6 C P15EA 2005030900009 20050309 00009 NM 2005 3 9 CA040722002 1 20040719 G 1430 BACB30MT7T23 BOLT BOEING 737 737204 1384458 NM PWA JT8 JT8D15 52051 NE STAB FITTING SHEARED W K NONE O OTHER IN INSP/MAINT 1 CA WHEN THIRD PARTY AMO WAS INSPECTING THE FWD STABILIZER FITTINGS ATTACHED TO THE AFT SPAR FOR SB737-57A1266 ON A/C 743 FO UND THE O/B FITTING CRACKED. ON FURTHER INVESTIGATION, FOUND THAT ALL FOUR BOLT HEADS ON THE AFT O/B FITTING WERE SHEAR ED OFF, AND THE FITTING BEGINNING TO LIFT OFF THE BEAM. THIS FITTING IS NOT PART OF THE SB. AS THE BOLT HEADS ARE MISS ING CAN ONLY PROVIDE THE PART NUMBERS PER THE IPC. AS THIS IS NOT PART OF ANY SB THAT CAN FIND, BUT THE SB THEY WERE WO RKING FROM DESCRIBES SERIOUS MLG FAILURE AND/OR LOSS OF HYDRAULIC FLUID AS A FACTOR, SHOULD A BRACKET FAIL, THOUGHT THAT AN SDR WAS APPROPRIATE. UNFORTUNATELY HAD REMOVED THE BRACKET BEFORE COULD GET ANY BETTER PICTURES, BUT HAVE RETAINED 2 L 7 2 4F 4 F A16WE E2EA 2005030900010 20050309 00010 2005 3 9 CA040722003 4 20040627 G 3418 6005915229 COMPUTER CNDAIR CL601 CL6013A 8070802 EA STALL WARNING MALFUNCTIONED W H A DEACTIVATE SYST/CIRCUITS UNSCHED LANDING N FALSE WARNING CL CLIMB 1 CA CREW REPORTED ON ROTATION, STICK SHAKER ACTIVATED EVEN THOUGH A/C WASN`T IN A STALL. SHAKER CONTINUED UNTIL POINT C/B`S WERE OPENED AS RECOMMENDED IN AFM. CREW ELECTED TO RETURN TO AIRPORT & LANDED UNEVENTFULLY. INVEST REVEALED THAT PRIO R TO FLT, PILOTS STALL PROTECTION SYSTEM IND NEEDLE SHOWING IN RED (PUSHER) ZONE AS SOON SINGLE CHANNEL SELF-TEST INITIA TED, WHICH IS NOT PER AFM & SHOULD HAVE INITIATED SOME CONCERNS AT THAT POINT. IT IS BELIEVED THAT THE PILOTS SPS INDIC ATOR NEEDLE WAS IN RED POSITION AT ROTATION, WHICH GENERATED THE SHAKER ACTIVATION. THE SPS COMPUTER WAS REPLACED, FUNC TIONAL TEST WERE COMPLETED NORMALLY. 2 L 7 2 4F RT A21EA 2004101300018 20041013 00018 NE 2004 10 13 CA040722004 2 20040713 G 7250 311899101 TURBINE BLADES PWA PT6A67D BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4N HCE4N3 NE HOT SECTION MISMANUFACTURED W K NONE O OTHER IN INSP/MAINT 1 CA PCEPS0161 (CAN) THE ENGINE HAD LANDED AFTER A FLIGHT AND WAS LOADED WITH FREIGHT. AFTER AN UNSUCCESSFUL START ATTEMPT (ONLY 5 PER CENT NG REACHED), A STARTER-GENERATOR WAS REPLACED. THE ENGINE WOULD NOT START SINCE IT WAS SEIZED. A SUBSEQUENT INVEST IGATION SHOWED THAT THE AFT SIDE OF THE CT DISK HAD RUBBED AGAINST THE CT STATOR AIR SEAL. THE ROOT CAUSE WAS BELIEVED TO BE TIGHT CLEARANCES BETWEEN THE TWO COMPONENTS DUE TO A STEP AT THE INTERFACE OF THE FIR TREE AND THE BLADE PLATFORM. THE STEP APPEARS TO BE MATERIAL LEFT OVER FROM AN INCOMPLETE MACHINING PROCESS DURING MANUFACTURE. OTHER BLADES OF T HE SAME PN DO NOT HAVE THE STEP. CT BLADE PN 3118591-01 IS ALSO BELIEVED TO BE AFFECTED. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2004101300021 20041013 00021 NE 2004 10 13 CA040722005 2 20040713 G 7210 MS949034 BOLT PWA PWA PT6 PT6A65AR 52043 NE RGEARBOX FAILED W E ENGINE SHUTDOWN D E W INFLIGHT SEPARATION VIBRATION/BUFFET INADEQUATE Q C CR CRUISE 1 CA PCE97494 (CAN) THE ENGINE WAS IN FLIGHT WHEN IT SUFFERED A FAILURE. THE ENGINE WAS SHUTDOWN AND THE AIRCRAFT LANDED. AN INVESTI GATION FOUND THAT THE BOLT HEAD OF A 1ST STAGE CARRIER MACHINE HEX BOLT HAD FAILED. IT WAS INGESTED BY THE 1ST STAGE PL ANETARY GEAR SYSTEM. THE SUBSEQUENT FAILURE ON THE 1ST STAGE SUN GEAR AND 1ST STAGE PLANETARY GEARS CAUSED EXCESSIVE VI BRATION AND AN OVERSPEED CONDITION. 4 T E4EA 2004101300022 20041013 00022 NE 2004 10 13 CA040722006 2 20040722 G 8510 519593 NOSE COWL CNDAIR CL215 CL2151A10 1900320 EA PWA R2800 R2800CA3 52026 NE HAMSTD 43E 43E60 NE ENGINE FAILED W E A ENGINE SHUTDOWN UNSCHED LANDING W K INADEQUATE Q C FLUID LOSS CL CLIMB 1 CA NK510954 (CAN) AIRCRAFT WAS ON CLIMB OUT AFTER WATERSCOOPING OPERATION. THE RT ENGINE OVERSPED BEYOND 3400 RPM AT 20. 2 H 7 2 4R 4 R RT A14EA 5E8 6 C P871 2005030900011 20050309 00011 2005 3 9 CA040722007 1 20040702 G 1430 08515591 LOCK TAB CONT O470 IO470* 17026 SO ENGINE MT BOLTS MISSING W K NONE O OTHER IN INSP/MAINT 1 CA ON THE FOLLOWING CESSNA AIRCRAFTS, FOUND THE LOCK TABS FOR ENGINE MOUNT BOLTS TO BE EITHER MISSING, BROKEN, OR INCORRECT HARDWARE USED TO REPLACE THEM. C-205 IO470C-180 I0470C-182 IO470C-185 IO520C-206 IO550 WOULD LIKE TO NOTIFY ALL AI RCRAFT OWNERS THAT USE THESE BOLT LOCK TABS TO INSPECT THEM. 3 O E1CE 2004101300023 20041013 00023 CE 2004 10 13 CA040723001 1 20040722 G 2435 BEARING 23085001 BEECH B300 B300B350C CE PWA PT6 PT6A60A 52043 NE HARTZL HCB4M HCB4MP3 GL STARTER GEN FAILED W O OTHER E VIBRATION/BUFFET CR CRUISE 1 CA Y0195 (CAN) WITH AIRCRAFT IN CRUISE FLIGHT A (LT GEN TIE OPEN) ANNUNCIATOR LIGHT CAME ON. GENERATOR TIE RESET AS IAW CHECK LI ST. SHORTLY THEREAFTER THE (LT GEN TIE OPEN) CAME ON FOLLOWED BY THE (LT GEN FAIL) LIGHT ANNUNCIATOR. AIRCRAFT SECURED IAW CHECK LIST AND AIRCRAFT RETURNED TO BASE. SHORTLY BEFORE LANDING THE AIRCRAFT EXPERIENCED LT ENGINE VIBRATION AND TORQUE FLUCTUATIONS AT LOW POWER SETTINGS. AIRCRAFT LANDED UNEVENTFUL. MAINTENANCE REMOVED SUSPECT GENERATOR AND FOUND END BEARING FAILED. GENERATOR REPLACED WITH OVERHAULED UNIT. AIRCRAFT GROUNDRUN, VIBRATION AND TORQUE APPEARED NORMAL . AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2004101300024 20041013 00024 EU 2004 10 13 CA040723002 1 20040719 G 5610 350902001 TRACK SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE WINDOW DEPARTED W O OTHER D INFLIGHT SEPARATION CR CRUISE 1 CA (CAN) FORWARD LT WINDOW SLIDER DEPARTED WHILE AIRCRAFT IN FLIGHT. THE FELT ON THE SLIDER WINDOW WAS WORN OR MISSING, WH ICH CAUSES AN EXCESSIVE GAP BETWEEN THE SLIDER WINDOW AND THE TRACK. THE SLIDER WINDOW, NOW LOOSE, VIBRATES WHILE IN FL IGHT AND CAUSES THE LOWER PORTION OF THE SLIDER WINDOW TRACK TO FRACTURE. THE SLIDER WINDOW MIGRATES OUT THROUGH THE CR ACKED TRACK AND DEPARTS THE AIRCRAFT. 1 G 7 1 3U 3 U NC H9EU E19EU 2004101300025 20041013 00025 CE 2004 10 13 CA040723003 1 20040712 G 3297 WIRE CESSNA 310 T310R 2074246 CE CONT O520 TSIO520B 17040 SO MCAULY 3AF32C 3AF32C* GL WARNING HORN FAILED W O OTHER N FALSE WARNING CL CLIMB 1 CA (CAN) TAKEOFF, LANDING GEAR FAILED TO RETRACT. GEAR CB POPPED IMMEDIATELY ON SELECT UP, CAUSED 3 GREEN (SAFE GEAR) LIGH TS TO GO OUT. THE CB WAS RESET, IMMEDIATELY RE-POPPED. MOMENTARY 3 GREEN INDICATION OF LIGHTS WHEN BREAKER WAS RESET IN DICATING GEAR WAS STILL DOWN, LOCKED. VISUAL, INDICATED DOWN, LOCKED. VISUAL INSP OF BOTH MAIN, NOSE GEAR WITH IT INDI CATED GEAR WAS DOWN, LOCKED. THERE WAS AN ELECTRICAL FAULT WITH GEAR,COULD NOT BE RESOLVED IN FLIGHT. GEAR NEVER RETRACT ED FROM INITIAL GEAR UP SELECT. FLYBY DETERMINED GEAR LOOKED DOWN, LOCKED, LANDED. ONE OF CRIMPED CONNECTOR ENDS HAD C OME LOOSE FROM WIRING CAUSING ELECTRICAL FAULT. NEW END WAS ATTACHED TO GEAR HORN, PROBLEM RECTIFIED, SERVICEABLE. 1 L 7 2 3O 3 O 3A10 E8CE 5 C P22EA 2004101300026 20041013 00026 EU 2004 10 13 CA040723004 1 20040517 G 6220 BUSHING AEROSP AS355 AS355F2 8680812 EU ALLSN 25OC 250C20R GL STARFLEX LOOSE W K NONE O OTHER IN INSP/MAINT 1 CA M495U (CAN) ALL 3 BUSHINGS FOUND LOOSE ON D.I. STARFLEX WAS REPLACED. 1 G 7 2 3U 3 U H11EU E4CE 2004101300027 20041013 00027 SO 2004 10 13 CA040723005 2 20040710 G 7414 M3590 SPRING CESSNA 172 172 2072402 CE CONT O300 O300A 17022 SO MCAULY 1A170 1A170DM GL RT MAGNETO BROKEN W E ENGINE SHUTDOWN R PARTIAL RPM/PWR LOSS TX TAXI/GRND HDL 1 CA (CAN) NO POWER TO RT MAGNETO DUE TO BROKEN IMPULSE SPRING RETARDING TIMING. 1 H 7 1 3O 3 O NT 3A12 E253 5 N P857 2004101300063 20041013 00063 CE 2004 10 13 CA040723006 1 20040628 G 7120 075100125 MOUNT CESSNA 180 180C 2072608 CE CONT O470 O470L 17026 SO MCAULY 2A34C 2A34C66 GL ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) A SMALL CRACK (LESS THAN 2MM) WAS DISCOVERED ON THE ENGINE MOUNT DURING SERVICING. THE CRACK IS LOCATED ON THE LT SIDE, ON THE UPPER TUBING WHICH RUNS FORE AND AFT IN BETWEEN THE FORWARD AND REAR ENGINE MOUNT PADS. THE EXACT LOCATION IS ONE INCH FORWARD OF THE GUSSET PLATE FOR THE REAR MOUNT PAD. 1 H 7 1 3O 3 O 5A6 E273 5 C P3EA 2004101300068 20041013 00068 CE 2004 10 13 CA040723007 1 20040722 G 7603 V31 SWITCH BEECH 99 99 1154002 CE PWA PT6 PT6A28 EA HARTZL HCB3T HCB3TN3 GL RT POWER LEVER STUCK W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) ON CLIMB THE PILOT REPORTED THE GEAR IN TRANSIT LIGHT WAS ON. LANDING GEAR WAS EXTENDED WITH NO DIFFICULTIES AND MAINTENNACE WAS CONTACTED. AIRCRAFT RETURNED TO BASE. AIRCRAFT WAS PUT ON JACKS AND THE RT POWER LEVER 70 PERCENT SWITC H WAS FOUND STUCK. SWITCH WAS REPLACED AND GEAR SWINGS CHECKED SERVICIBLE. 1 L 7 2 3T 4 T A14CE E4EA 6 C P15EA 2004101300069 20041013 00069 GL 2004 10 13 CA040726001 2 20040719 G 7320 23072725 HYDROMECH UNIT BELL 407 407 1182206 SW ALLSN 250C 250C47B GL ENGINE INOPERATIVE W C ABORTED TAKEOFF J WARNING INDICATION TO TAKEOFF 1 CA (CAN) DURING ADVANCING THROTTLE TO 100 PERCENT FOR TAKEOFF, N2 DECREASED. 1 G 7 1 3U 3 U O H2SW E1GL 2004101300070 20041013 00070 SW 2004 10 13 CA040726002 1 20040706 G 6320 407040006 TRANSMISSION BELL 407 407 1182206 SW ALLSN 250C 250C47B GL MAIN ROTOR MAKING METAL W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA (CAN) TRANSMISSION CHIP LIGHT, TRANSMISSION SENT TO OVERHAUL SHOP. 1 G 7 1 3U 3 U O H2SW E1GL 2004101300071 20041013 00071 WP 2004 10 13 CA040726003 2 20040723 G 7250 31070367 BEARING CAGE GARRTT TPE331 TPE33110UA 01514 WP ENGINE WORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) UPON RECEIVING A REQUEST, FROM WEAR CHECK, DUE TO A BAD ENGINE OIL SAMPLE, A TEAR DOWN OF THE SUSPECT ENGINE REVEA LED THAT THE HIGH SPEED PINION BEARING AND CAGE WERE WORN AND THE SILVER COATING FLAKINGOFF OF THE COMPONENTS. THE PINIO N HAS BEEN REPLACED. TWO SIMILAR SDR'S HAVE BEEN ISSUED WITH THIS SAME PROBLEM BY PERIMETER. 4 T E4WE 2004101300072 20041013 00072 2004 10 13 CA040726004 4 20040704 G 2397 RMU850 WIRE HARNESS CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE NR 1 RMU CHAFED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) THE PILOT REPORTED THAT THE NR 1 RMU FLASHED RED AND THAT THEY COULD SMELL SOMETHING BURNING WITH NO VISIBLE SMOKE . THE NR 1 RMU WAS REMOVED AND INSPECTED WITH NOTICEABLE DAMAGE APPARENT. AN INSPECTION OF THE WIRE BUNDLE CONNECTING T HE UNIT WAS CARRIED OUT AND TWO DC POWER WIRES WERE FOUND CHAFED THROUGH THE INSULATION. THE REQUIRED REPAIRS WERE CARRI ED OUT AND THE AIRCRAFT WAS RETURNED TO SERVICE. 1 L 7 2 4F 4 F A22CE E1NE 2004101300073 20041013 00073 EU 2004 10 13 CA040726005 1 20040719 G 1420 103871501 CONNECTOR BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL EXCITER BOX DEBONDED W H DEACTIVATE SYST/CIRCUITS O OTHER TX TAXI/GRND HDL 1 CA (CAN) THE FLIGHT CREW WAS UNABLE TO START NR 1 ENGINE. NR 1 IGNITION EXCITER UNIT WAS DETERMINED TO HAVE FAILED. UPON INVESTIGATION IT WAS FOUND THAT THE CONNECTOR PLUG ATTACHMENT ON THE EXCITER BOX HAD DEBONDED CAUSING THE FAILURE. THE U NIT WAS REPLACED. 1 G 7 2 3U 3 U H3EU E4CE 2004101300074 20041013 00074 EU 2004 10 13 CA040726007 1 20040719 G 2435 BEARING PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL STARTER GEN FAILED W O OTHER J WARNING INDICATION TX TAXI/GRND HDL 1 CA 639 93767 (CAN) GENERATOR HAD BEEN REPAIRED, WO NR 12585, MAR 18,2004. INSTALLED ON VKC WITH 442.9 TSO AND 0 HOURS SINCE REPAIR. APPARENT BEARING FAILURE. WOULD NOT ENGAGE/TURN ON, AN ATTEMPTED START. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004101300075 20041013 00075 EU 2004 10 13 CA040726008 1 20040718 G 6220 350A31191600 STARFLEX SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE MAIN ROTOR HEAD UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) STARFLEX ARM END BUSHING ON YELLOW BLADE ARM BECAME LOOSE AROUND ADHESIVE JOINT OF CARBIDE BUSH AND A GAP, BEYOND SERVICEABLE LIMITATIONS, DEVELOPED. STARFLEX REPLACED WITH NEW PART IAW AS 350MWC. 1 G 7 1 3U 3 U H9EU E19EU 2004101300136 20041013 00136 SW 2004 10 13 CA040726009 1 20040624 G 6330 SUPPORT BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA PYLON DAMPER CRACKED W O OTHER D INFLIGHT SEPARATION CR CRUISE 1 CA (CAN) PILOT REPORTED THAT THE AIRCRAFT WOULD ENTER INTO PYLON ROCK VERY EASILY. TRANSMISSION MOUNTS AND FRICTION DAMPERS WERE BEING REPLACED WHEN IT WAS FOUND THAT THE FRICTION DAMPER MOUNT SUPPORTS WERE CRACKED AND AS A RESULT NOT ATTACHED TO THE AIRFRAME. SUPPORTS WERE REPLACED, NEW MOUNTS AND DAMPERS INSTALLED. A/C TEST FLOWN, PYLON ROCK WAS NO LONGER PRE SENT, A/C RETURNED TO SERVICE. 1 G 7 1 4U 4 U H4SW E22EA 2004101800041 20041018 00041 EU 2004 10 18 CA040726010 1 20040611 G 2821 222366621101 BOWL SNIAS 350 AS350B 8680801 EU TMECA ARRIEL ARRIEL1B 6OO30 NE FUEL FILTER LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) BOWL ASSEMBLY LEAKING FROM ELECTRICAL CONNECTOR AT TOP OF BOWL. REPLACED WITH NEW BOWL ASSEMBLY. 1 G 7 1 3U 3 U H9EU E19EU 2005020100014 20050201 00014 2005 2 1 CA040727002 4 20040721 G 2562 DK100 CASE FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE ACOUSTIC BEACON DAMAGED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) UNDERWATER ACOUSTIC BEACON DK100, S/N DJ6834, HAS BEEN ALTERED TO REPLACE BATTERY, BY DRILLING HOLES IN BATTERY CO VER END CAP (TO RECEIVE A SPANNER WRENCH). THIS ALTERATION HAS UNDERMINED INTEGRITY OF BEACON. REPLACEMENT BATTERY KITS SUPPLIED BY OEM ARE APPROVED FOR MODEL DK120 ONLY. MFG OF MODEL DK100, PROHIBITS REPLACEMENT OF BATTERIES IN FIELD, DOE S NOT PROVIDE INSTRUCTIONS FOR FIELD REPLACEMENT, DK100 MODELS MUST BE RETURNED TO FACTORY FOR SERVICE (REF: MFG TECH MA NUAL). INFORMAL INVESTIGATION REVEALED; AMO WHO SERVICED PART DID NOT HAVE AUTHORITY NOR AN UP-TO-DATE CMM FOR PART. U NDERWATER ACOUSTIC BEACON DK100, S/N DJ6834, WAS DECLARED UNSERVICEABLE AND IS HELD IN QUARANTINE. 2 L 7 2 4F 4 F RT E25NE 2005031000072 20050310 00072 NE 2005 3 10 CA040727003 2 20040720 G 7210 BOLT PWA PWA PT6 PT6A67D NE RGB FAILED W E ENGINE SHUTDOWN D E W INFLIGHT SEPARATION VIBRATION/BUFFET INADEQUATE Q C CR CRUISE 1 CA 15234 PS114332 DURING OVERHAUL ASSY OF THE POWER SECTION AND 1ST STAGE REDUCTION CARRIER MACHINE HEX BOLT P/N MS9490-34 FAILED IN THE T HREADED PORTION OF THE BOLT UNDER APPLIED TORQUE DURING INSTALLATION. THE BOLT IS USED IN THE ASSEMBLY OF THE 1ST STAGE REDUCTION GEARING CARRIER IAW P&WC O/H MANUAL P/N 3038337, SECTION 72-10-00, PAGE 503, PARAGRAPH NR B. THERE ARE TOTAL QTY. 6 BOLTS INSTALLED IN THE CARRIER WITH KEY-WASHERS AND ARE TORQUED TO 75 TO 85 IN-LBS. THE BROKEN PARTS HAVE BEEN D ISPATCH TO P&WC FOR FAILURE INVESTIGATION. NOTE: THE ENGINE HAD PREVIOUSLY BEEN INVOLVED IN A PT BLADE FAILURE. 4 T E26NE 2004101800042 20041018 00042 NE 2004 10 18 CA040727004 2 20040724 G 8550 125754 GASKET CNDAIR CL215 CL2151A10 1900320 EA PWA R1340 CWASP 52016 NE HAMSTD 43E 43E60 NE MAIN OIL SCREEN LEAKING W E A ENGINE SHUTDOWN UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CL CLIMB 1 CA (CAN) AC WAS ON A ROUTINE FLIGHT, WHEN SHORTLY AFTER TAKE OFF, CREW NOTICED THE RT ENGINE OIL PRESSURE DROPPING AND OIL QUANTITY INDICATION SHOWING A RAPID LOST OF ENGINE OIL. VISUAL CONFIRMATION OF A MASSIVE OIL LEAK FROM NACELLE VENT LINE WAS MADE BY THE ENGINEER ON BOARD. CREW SHUT DOWN AND SECURED THE ENGINE AND RETURNED TO DEPARTURE AND LANDED WITHOUT I NCIDENT. AN INSPECTION OF THE RT ENGINE REVEALED THAT THE MAIN OIL SCREEN GASKET HAD RUPTURED WHICH CAUSED THE LARGE OIL LEAK. THE SCREEN WAS REMOVED AND INSPECTED WITH NO FAULT FOUND. THE OLD GASKET WAS REMOVED AND THE SURROUNDING AREA AND COVER WAS INSPECTED. A NEW GASKET WAS INSTALLED AND ENGINE GROUND RUNS CARRIED OUT. THE ENGINE WAS CHECKED SERVICEABLE. 2 H 7 2 4R 3 R RT A14EA ATC14 6 C P871 2004101800043 20041018 00043 GL 2004 10 18 CA040727005 2 20040722 G 7230 23059594 RETAINING RING ALLSN BELL 206 206L3 1182108 SW ALLSN 250C 250C30P 03013 GL NR1 BRG HSG BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA CAC91624 (CAN) DURING COMPRESSOR DISASSEMBLY ONE PIECE OF NR 1 BEARING HOUSING RETAINING RING WAS FOUND. IMPELLER ASSEMBLY WAS B ADLY DAMAGED DUE TO FOD. 1 G 7 1 3U 3 U H2SW E1GL 2005012100160 20050121 00160 SW 2005 1 21 CA040727006 1 20040603 G 7933 206075187001 INDICATOR BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL ENGINE OIL TEMP INOPERATIVE W K NONE N FALSE WARNING IN INSP/MAINT 1 CA (CAN) FOUND ON TROUBLESHOOTING THAT NORMAL INDICATION EXISTED WITH GENERATOR OFF. ONCE GENERATOR WAS SWITCHED ON, THE OI L TEMPERATURE INCREASED CONTINUOUSLY UNTIL OVER THE RED LINE. INDICATOR HAD RECENTLY BEEN REPLACED FOR A PRESSURE INDICA TION PROBLEM. INDICATOR REPLACED, FUNCTIONALLY TESTED OK AND A/C RETURNED TO SERVICE. 1 G 7 1 3U 3 U H2SW E4CE 2004101800044 20041018 00044 WP 2004 10 18 CA040727007 1 20040723 G 2913 AS664114S666 PUMP DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE HYD SYS INOPERATIVE W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) DURING CLIMB, RT HYDRAULIC SYSTEM PRESSURE DECREASED TO ZERO WITH APPROPRIATE EOHP ANNUNCIATOR LIGHT ILLUMINATED. AIRCRAFT LANDED BACK TO THE STATION. THE RT HYDRAULIC SYSTEM FILTERS REMOVED AND INSPECTED. NO CONTAMINATION FOUND. AIRCRAFT DISPATCHED IAW MEL 29-5. THE RT EDP WAS REPLACED ON THE FOLLOWING DAY TO RECTIFY THE DEFECT. 2 L 7 2 4F 4 F RT A6WE E9NE 2004101800076 20041018 00076 SW 2004 10 18 CA040727008 1 20040603 G 2550 AN9601016 WASHER BELL BELL 206 206L 1181522 SW ALLSN 250C 250C20R2 GL CARRIAGE ROLLERS MISSING W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AFTER FINDING MISSING CARRIAGE ROLLER WASHERS ON ANOTHER LONG RANGER, INSPECTED AND FOUND IT TO BE THE SAME, NO WASHERS. 1 G 7 1 3U 3 U H2SW E4CE 2004101800077 20041018 00077 EU 2004 10 18 CA040727009 1 20040528 G 2822 BYPASS SWITCH SNIAS 350 AS350B 8680801 EU TMECA ARRIEL ARRIEL1B 6OO30 NE BOOST PUMP STUCK W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) A FILTER ASSEMBLY PN 222-366-621-101 WAS RECEIVED ON CHL PO NR 514815 AND INSTALLED. DURING TESTING IT WAS DISCOV ERED THE BYPASS LIGHT WAS ON ALL THE TIME. TROUBLESHOOTING DETERMINED THE BYPASS SWITCH IS STUCK CLOSED. AS WELL THE DRA IN VALVE WAS LEAKING UNDER NORMAL BOOST PUMP PRESSURE. 1 G 7 1 3U 3 U H9EU E19EU 2004101800078 20041018 00078 NE 2004 10 18 CA040727010 2 20040428 G 7310 174025120 PRESSURE VALVE SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE FUEL SYSTEM UNSERVICEABLE W K NONE L NO TEST IN INSP/MAINT 1 CA (CAN) FUEL LEAKING INTO FUEL WHEEL LINE WITH BOOST PUMP PRESSURE. ENGINE LIGHTING OFF FUEL WHEEL. VALVE REPLACED , NOW L IGHTS OFF AT NEAR 17 PERCENT NG. 1 G 7 1 3U 3 U NC H9EU E19EU 2004101800079 20041018 00079 NE 2004 10 18 CA040727011 2 20040401 G 7321 0164448430 FUEL CONTROL SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE ENGINE UNSERVICEABLE W O OTHER R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 CA (CAN) NG FLUCTUATIONS OF 2 PERCENT. FUEL CONTROL REPLACED. 1 G 7 1 3U 3 U NC H9EU E19EU 2004101800080 20041018 00080 NE 2004 10 18 CA040727012 2 20040423 G 7310 0174025120 PRESSURE VALVE SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE ENGINE FUEL UNSERVICEABLE W E ENGINE SHUTDOWN O OTHER TX TAXI/GRND HDL 1 CA (CAN) FUEL ENTERING WHEEL EARLY, VALVE CHANGED. LIGHT OFF OCCURING NOW AT 17 PERCENT NG (NORMAL). 1 G 7 1 3U 3 U H9EU E19EU 2004101800081 20041018 00081 NE 2004 10 18 CA040727013 2 20040520 G 7532 9550161210 BLEED VALVE SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE ENGINE UNSERVICEABLE W O OTHER J WARNING INDICATION CR CRUISE 1 CA (CAN) PILOT REPORTED BLEED VALVE APPEARED TO BE CLOSING LATE. SNAG CONFIRMED WHEN PLOTTED IN THE 1D1 MAINTENANCE MANUAL . BLEED VALVE REPLACED. 1 G 7 1 3U 3 U H9EU E19EU 2004101800082 20041018 00082 EU 2004 10 18 CA040727014 1 20040715 G 6220 LB412311 SPHERICAL STOP SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE ELASTIMERIC UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) SEPARATION OF ELASTAMERIC NOTICED VISUALLY DURING (S) TYPE INSPECTION. VERY TOP MOST OB LAMINATION OF THE SHERICAL STOP WAS NOTED TO EXCEED PUBLISHED LIMITS. NO MENTION OF INFLIGHT VIBRATIONS. THE PART WAS REPLACED. 1 G 7 1 3U 3 U H9EU E19EU 2004101800083 20041018 00083 EA 2004 10 18 CA040728001 1 20040719 G 2432 601R593251 CHARGER CNDAIR CL604 CL604 1900301 EA GE CF34 CF343B1 NE MAIN BATTERY FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) MAIN BATTERY CHARGER FAILED, NO FAULT CODES, REPAIRED UNIT, INSTALLED F/T OK. 2 L 7 2 4F 4 F RT A21EA E15NE 2004101800084 20041018 00084 2004 10 18 CA040728002 4 20040727 G 2300 6229852124 CONTROL UNIT CNDAIR CL604 CL604 1900301 EA GE CF34 CF343B1 NE RADIO TUNING FAILED W K NONE L NO TEST IN INSP/MAINT 1 CA (CAN) DISPLAY BLANK. REPAIRED UNIT, INSTALLED F/T, OK (RADIO TUNING UNIT). 2 L 7 2 4F 4 F RT A21EA E15NE 2004101800104 20041018 00104 CE 2004 10 18 CA040728003 1 20040726 G 2910 B-NUT CESSNA 185 A185F 2072821 CE CONT O520 IO520D 17032 SO MCAULY 2A34C D2A34C58 GL HYDRAULIC LINE SEPARATED W O OTHER K J FLUID LOSS WARNING INDICATION DE DESCENT 1 CA (CAN) PILOT WAS UNABLE TO HAVE GEAR DOWN INDICATION WITH BOTH ELECTRIC AND MANUAL EXTENSION. WHEEL RETRACTED BACK INSID E WHEEL WELL ON LANDING. INSPECTION FOUND HYDRAULIC LINE INSIDE THE AIRFRAME BELLY TO RT FLOAT HAD BROKEN OFF FROM THE B-NUT. IT APPEARED THE FLARE IS WORN TO PAPER THIN CAUSING THE FLARE TO FAIL WHILE PRESSURIZED. 1 H 7 1 3O 3 O 3A24 E5CE 5 C P3EA 2005031000073 20050310 00073 EU 2005 3 10 CA040728004 1 20040528 G 6730 AC67244 SERVO SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE CYCLIC STICK MALFUNCTIONED W O OTHER F FLT CONT AFFECTED TX TAXI/GRND HDL 1 CA PILOT REPORTED THAT THE CYCLIC WAS STIFF IN LT QUADRANT. REPLACED THE LEFT HAND SERVO FIRST. THIS DID NOT SOLVE PROBLE M. REINSTALLED LEFT SERVO AND REPLACED RIGHT HAND SERVO. THE DEFECT WAS CORRECTED. 1 G 7 1 3U 3 U H9EU E19EU 2005031000074 20050310 00074 SW 2005 3 10 CA040728005 1 20040506 G 2911 212076007003 ACCUMULATOR BELL 212 212 1181420 SW PWA PT6T PT6T3B 52045 NE HYD SYSTEM LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA 0.5 L OF HYDRAULIC FLUID LOST FROM NR 2 SYSTEM IN 1 HOUR OF FLIGHT. LEAK ISOLATED TO NR 2 ACCUMULATOR. ACCUMULATOR REP LACED AND A/C RETURNED TO SERVICE. 1 G 7 1 4U 4 U H4SW E22EA 2005031000075 20050310 00075 WP 2005 3 10 CA040728006 1 20040726 G 3246 34479 BEARING RACE CVAC 340 340CVAC 242270A WP ALLSN 501D 501D13D 03004 GL MLG WHEEL CORRODED W O OTHER D INFLIGHT SEPARATION LD LANDING 1 CA DURING LANDING, THE FLIGHT CREW NOTICED A MAIN WHEEL SHIMMY. UPON INVESTIGATION BY MAINTENANCE, NR 2 MAIN WHEEL MADE RU MBLING SOUNDS AND AXLE VIBRATED WHEN SPUN BY HAND. UPON INSPECTION OF THE BEARING, GREASE WAS FOUND TO BE BLACK IN COLO R. INNER BEARING RACE WAS FOUND TO BE CORRODED ON THE BEARING SEAT AREA AROUND THE FULL CIRCUMFERENCE. THE MAIN WHEEL WAS REPLACED WITH A SERVICEABLE UNIT. THE REMAINING AIRCRAFT IN THE FLEET WERE INSPECTED WITH NO OTHER DEFECTS NOTED. 2 L 7 2 4R 4 T 6A6 E282 2005031000076 20050310 00076 NE 2005 3 10 CA040728007 2 20040422 G 7230 IMPELLER TMECA SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE COMPRESSOR FOD W K NONE O OTHER IN INSP/MAINT 1 CA M824 AFTER REMOVAL OF THE ENGINE COWLING TO DO A 100 HOUR INSPECTION, IT WAS DISCOVERED THAT THE AXIAL COMPRESSOR HAD SUFFERE D SEVERE FOREIGN OBJECT DAMAGE. 1 G 7 1 3U 3 U NC H9EU E19EU 2005031000077 20050310 00077 WP 2005 3 10 CA040728008 1 20040724 G 2420 9068D093 RELAY DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE GENERATOR FAILED W A UNSCHED LANDING H ELECT. POWER LOSS-50 PC CR CRUISE 1 CA DURING CRUISE, THE RT GENERATOR DID NOT POWER THE BUSS. APU STARTED BUT HAD TO SHUT DOWN DUE TO HIGH OIL TEMP. AIRCRAF T HAD TO DIVERTED TO XXX. MAINTENANCE FOUND THE RT GEN POWER RELAY IN FAULT. RELAY REPLACED AND GENERATOR POWER CHECKE D SERVICEABLE. THE APU OIL LEVEL FOUND HIGH AND OIL RESERVICED AS PER MM. AIRCRAFT DISPATCHED SERVICEABLE. 2 L 7 2 4F 4 F RT A6WE E9NE 2005031000078 20050310 00078 NE 2005 3 10 CA040728009 2 20040723 G 7421 70BM031090 MODULE SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE ENGINE UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 CA 416 MODULE 3 SUFFERED IMPACT DAMAGE ON 1ST STAGE BLADES. THE IGNITER HAD DISINTEGRATED. 1 G 7 1 3U 3 U NC H9EU E19EU 2005031000079 20050310 00079 EA 2005 3 10 CA040728010 1 20040727 G 2913 MS2877810 O-RING CNDAIR CL215 CL2151A10 1900320 EA HAMSTD 43E 43E60 NE HYD PUMP BLOWN W O OTHER K FLUID LOSS AP APPROACH 1 CA THE AIRCRAFT WAS ON APPROACH TO THE AIRPORT. THERE WAS A LOSS OF HYDRAULIC PRESSURE. THE AIRCRAFT LANDED WITHOUT INCID ENT. UPON INVESTIGATION BY MAINTENANCE STAFF THE RT ENGINE DRIVEN HYDRAULIC PUMP O-RING AT THE PRESSURE LINE FITTING HA D BLOWN ALLOWING THE HYDRAULIC FLUID TO LEAK OUT UNDER PRESSURE. THE FAILED O-RING WAS REPLACED WITH A SERVICEABLE O-RI NG AND THE HYDRAULIC SYSTEM WAS REPLENISHED. THE RT HYDRAULIC PUMP CHECKED SERVICEABLE. THE LT PUMP WAS REPLACED AND T HE AIRCRAFT WAS RETURNED TO SERVICE. 2 H 7 2 4R RT A14EA 6 C P871 2005031000080 20050310 00080 2005 3 10 CA040729001 4 20040726 G 6122 7897501 GOVERNOR DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE PROPELLER MALFUNCTIONED W A UNSCHED LANDING E VIBRATION/BUFFET CL CLIMB 1 CA IN CLIMB-OUT, WHILE SETTING PROP LVRS FROM 1200 TO 900 RPM, TQ INCREASED TO 105 PERCENT. DETERMINED THAT THE NR 1 ENGIN E WAS THE SOURCE OF THE PROBLEM. MX REPLACED THE NR 1 PROP CONTROL UNIT, ENG ECU HARNESS, AND TQ SIGNAL CONDITION UNIT. GROUND RUNS WERE COMPLETED WITH NO FAULTS AND THE A/C WAS RETURNED TO SERV. TEARDOWN REPORTS HAVE BEEN REQUESTED FOR THE REPLACED COMPONENTS AND AN UPDATE WILL BE PROVIDED WHEN AVAILABLE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005031000081 20050310 00081 EA 2005 3 10 CA040729002 1 20040727 G 2420 GENERATOR CNDAIR CL601 CL6012A12 1900303 EA GE CF34 CF341A NE AC SYS FAILED W H DEACTIVATE SYST/CIRCUITS L NO TEST CR CRUISE 1 CA DURING A ROUTINE POST MAJOR MAINTENANCE FLIGHT CHECK OF THE AIR DRIVEN TURBINE GENERATOR SYSTEM, THE SYSTEM FAILED TO TA KE THE ELECTRICAL LOAD, AS INDICATED BY THE AMMETER AND THE VOLTMETER, WHEN THE TURBINE WAS MANUALLY DEPLOYED. MAINTENA NCE FINDINGS:- ADG OUTPUT WIRING AT CONNECTOR P1XC WAS FOUND TO BE ENTIRELY BURNT OFF AND ALSO THE BACKSHELL PRONG FOR P ROVIDING STRAIN RELIEF FOR THE WIRING WAS PARTIALLY DESTROYED BY ARCING. THE WIRING WAS BURNT OFF FLUSH WITH THE CONNECT OR PINS. CONTINUITY CHECKS WERE CARRIED OUT BETWEEN THE PINS AND NO 2 L 7 2 4F 4 F RT A21AE E15NE 2005031000082 20050310 00082 GL 2005 3 10 CA040729003 2 20040528 G 7230 STATOR BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL FAILED W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA 11399 CAE802180A AIRCRAFT HAD ENGINE DECEL IN FLIGHT AND AUTOROTATION. INITIAL FIELD INSPECTION FOUND DAMAGE AS FOLLOWS: - ENGINE COMPRE SSOR FOD FOUND COULD BE SEEN ON 2ND, 3RD AND 4TH STAGES- KAFLEX DRIVE SHAFT CONTACTED ISOLATION MOUNT-TXMN DRAG PIN CONT ACTED STRIKER PLATE, 2 OF 8 RIVETS FOUND SHEARED - LT CHIN BUBBLE CRACKED. 1 G 7 1 3U 3 U H2SW E4CE 2005031000083 20050310 00083 NM 2005 3 10 CA040730001 1 20040729 G 5260 85217051101 GOOSENECK ASSY BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA AIRSTAIR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA FORWARD AIRSTAIR DOOR GOOSENECK FOUND CRACKED. THIS IS THE FIFTH OCCURRENCE OF THE GOOSENECK CRACKING. IT WAS ALSO FOU ND ON TWO AIRCRAFT THAT THE FASTENERS WERE CORRODED AT THE DOOR PIVOT POINT. A FLEET CAMPAIGN TO INSPECT AND LUBE THESE FASTENERS IS BEING CARRIED OUT. 2 H 7 2 4T 4 T RT A13NM E00062EN 2005031000084 20050310 00084 EU 2005 3 10 CA040730002 1 20040725 G 2160 959902013 CONTROL VALVE PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL TEMP INOPERATIVE W O OTHER O OTHER CR CRUISE 1 CA DURING CRUISE, THE AIR TEMP SELECTOR WHILE IN AUTO MODE WAS MOVED TO A MORE COOL POSITION, WITH NO EFFECT. ECS SWITCH W AS MOVED TO MANUAL MODE AND MORE COOL WAS TOGGLE WITH THE MANUAL SWITCH. AIR TEMP STILL NOT GETTING COOLER. MINUTES LA TER THE ECS CAUTION AMBER ADVISORY LIGHT LIT AND FLIGHT WAS RESUMED TO HOME BASE AS PER FLIGHT MANUAL. THIS PROCEDURE W AS TRIED A FEW TIMES WHILE EN ROUTE WITH THE SAME RESULT. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005031000085 20050310 00085 SO 2005 3 10 CA040730003 2 20040123 G 8530 631619 EXHAUST VALVE CESSNA 150 150L 2071826 CE CONT O200 O200A 17020 SO MCAULY 1A101 1A101HCM GL ENGINE DEFORMED W O OTHER O OTHER NR NOT REPORTED 1 CA ON 200 HOUR INSPECTION, BOTH LEFT SIDE EXHAUST VALVES FOUND TO BE DEFORMED AT TOP OF STEM BELOW VALVE SEAT CYLINDERS 2 A ND 4, JAN 12/04. ENGINE TIME AT INSPECTION 1506.5. ENGINE OVERHAULED SEPT. 20/90 BY VOWELL AVIATION. TTSB 4724,5. EXHAU ST VALVES REPLACED. CYLINDERS AND ONGOING INSPECTED BEFORE INSTALLATION IN AIRCRAFT MAY 19/00. ENGINE GIVEN COMPLETE O VERHAUL AS PER ENGINE MANUFACTURER OVERHAUL MANUAL DUE TO CRACKED CRANKCASE. CRANKCASE REPLACED WITH SERVICEABLE ONE OB TAINED FROM VALLEY AERO ENGINES LANGLEY. ENGINE RETURNED TO SERVICE ZERO TIME SINCE OVERHAUL. 1 H 7 1 3O 3 O 3A19 E252 5 N P918 2005020100112 20050201 00112 CE 2005 2 1 CA040730004 1 20040727 G 3242 1338931 STATOR BFGOODRICH CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE BRAKE SYSTEM CRACKED W K NONE O OTHER TX TAXI/GRND HDL 1 CA 2386 (CAN) DURING TAXI PILOT NOTICED MORE THRUST THAN NORMAL WAS NEEDED TO TAXI AND AIRCRAFT WAS DIFFICULT TO TURN TO THE RT. MAINTENANCE INSPECTION DISCOVERED CRACKED STATOR WHICH WARPED CAUSING BRAKE TO BIND UP. 1 L 7 2 4F 4 F A22CE E1NE 2005020100116 20050201 00116 SO 2005 2 1 CA040730005 2 20040523 G 8520 CRANKCASE CESSNA 337 337D 2075717 CE CONT O360 IO360C 17025 SO MCAULY 2AF34C D2AF34C59 GL ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 513309C (CAN) ENGINE OIL LEAK DETECTED ON REAR ENGINE SUCTION INSPECTED FOUND 1.5 INCH LONG CRACK IN CASE BETWEEN NR 3 AND NR 5 CYLINDER. NO OTHER REPORTED DAMAGE. ENGINE REMOVED. 1 H 7 2 3O 3 O A6CE E1CE 5 C P5EA 2005020100117 20050201 00117 NE 2005 2 1 CA040730006 2 20040717 G 8530 12973 ROCKER DHAV DHC3 DHC3 2800202 EA PWA R1340 R134059 52016 NE HAMSTD 23D 23D40 NE ENGINE BROKEN W B A EMER. DESCENT UNSCHED LANDING D INFLIGHT SEPARATION CL CLIMB 1 CA (CAN) IN CLIMB, ABOUT 60-70 FEET ABOVE WATER (OTTER ON FLOATS) A LOUD BANG WAS HEARD, ENGINE LOST POWER. PILOT DESCENDED RAPIDLY, AND LANDED SAFELY. GROUND RUN LATER, ENGINE WOULD NOT GO OVER 1400 RPM, AND VERY ROUGH BETWEEN 1200 AND 1400. LATER INVESTIGATION SHOWED NR 4 CYLINDER EXHAUST ROCKER ARM BROKEN, NOT ALLOWING EXHAUST VALVE TO OPEN. ALL EXHAUST FR OM NR 4 WAS GOING INTO INTAKE VALVE, CAUSING ENGINE TO QUIT OVER 1400 RPM. 1 H 7 1 3R 3 R A815 5E2 6 C P719 2005020100118 20050201 00118 CE 2005 2 1 CA040730007 1 20040727 G 2731 TRIM SYSTEM CESSNA 180 180H 2072618 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C66 GL ELEV TRIM WHEEL CONTAMINATED W K NONE F FLT CONT AFFECTED IN INSP/MAINT 1 CA (CAN) ELEVATOR TRIM WHEEL WOULD ONLY MOVE .5 INCH. FOUND DEBRIS CONSISTING OF GRASS, PEANUT SHELLS ETC. A SQUIRRELS N EST JAMMING THE CHAIN (CABLE ATTACHED TO CHAIN) ON THE GEAR WHICH ACTIVATES THE WORM GEAR TO MOVE THE ELEVATOR UP AND DO WN. BECAUSE OF THE LOCATION UNDER THE CENTER OF THE ELEVATOR, BETWEEN TWO BULKHEADS. IT WAS DIFFICULT TO REMOVE. IT W AS COMPLETELY (ALL) REMOVED, USING MIRRORS, VACUUM CLEANER. ALL PARTS WHERE IN EXCELLENT CONDITION. 1 H 7 1 3O 3 O 5A6 E273 5 C P3EA 2005031000086 20050310 00086 2005 3 10 CA040730008 4 20040621 G 3425 066302710 HSI BEECH 100 A100 1152915 CE PWA PT6 PT6A28 EA MCAULY 4HFR34 4HFR34C762 NE DME DISPLAY OVERHEATED W A E UNSCHED LANDING ENGINE SHUTDOWN B N SMOKE/FUMES/ODORS/SPARKS FALSE WARNING CL CLIMB 1 CA (CAN) ON CLIMB, BURN ODOR, SMOKE WHERE DETECTED IN COCKPIT. PILOT ADVISED ATC, DIVERTED TO ALTERNATE AIRPORT WHICH HAD V FR CONDITIONS AT TIME. WHILE FLYING INTO HEAVY RAIN, TURBULENT AIR, RT ENG FIRE WARNING LIGHT ILLUMINATED. RT ENG WAS I MMEDIATELY SHUTDOWN. AC LANDED WITHOUT INCIDENT. INSP OF RT ENG DID NOT SHOW ANY SIGNS OF FIRE, SMOKE, OR BLEED AIR LEA K. FIRE DET SYS WAS TESTED USING AC FIRE DETECTOR TEST SWITCH. FIRST TIME, RT NR2 FIRE DET INDICATED U/S. MALF COULD NOT BE DUPLICATED. BURN ODOR AND SMOKE WAS FOUND TO BE COMING FROM DISTANCE MEASURING EQUIPMENT (DME) DISPLAY SECTION OF H ORIZ SITUATION INDICATOR (HSI) CIRCUIT BOARDS. DME CB WAS PULLED, GROUND RUN CARRIED OUT, AC FERRIED FOR REPAIR. 1 L 7 2 3T 4 T A14CE E4EA 6 C 3PNE 2005031000087 20050310 00087 EU 2005 3 10 CA040730009 1 20040727 G 5540 555401203 SKIN PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL RUDDER WORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THE UPPER ATTACHMENT HOLE WAS FOUND WORN. THE HOLE WAS SO LARGE THAT IT COULD NOT BE REPAIRED IAW MFG TECH MEMO E CE-12-TM-02-327. IN ORDER TO SEE THE BOLT AND DAMAGE AREA, PANEL 32AT HAD TO BE REMOVED TO SEE THE DEFECT. THIS PANEL I S NOT NORMALLY CALLED UP FOR REMOVAL ON ANY INSPECTIONS, BUT ONLY TO REMOVE THE RUDDER. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005020100143 20050201 00143 EU 2005 2 1 CA040730010 1 20040729 G 2710 9408328011 BEARING PILATS PILATS PC6T PC6BH2 7090210 EU PWA PT6 PT6A27 52043 EA HARTZL HCB3T HCB3TN3 GL PUSHROD ASSY LOOSE W K NONE F FLT CONT AFFECTED IN INSP/MAINT 1 CA (CAN) DURING 100 HR INSPECTION, RT AILERON OUTER PUSHROD WAS FOUND TO HAVE A LOOSE BEARING, ALLOWING ROD END TO FLOAT SI DEWAYS ON BEARING. BEARING REMOVED, ROD END INSPECTED FOR DAMAGE, NONE FOUND. NEW BEARING INSTALLED AND CHECKED SERVIC ABLE. PUSH ROD ASSY FOUND TO HAVE 86 HRS TSN. PUSHROD ASSY SUPPLIED FROM AN APPROVED VENDOR. 1 H 7 1 3T 4 T 7A15 E4EA 6 C P15EA 2005020100181 20050201 00181 EU 2005 2 1 CA040730011 1 20040729 G 2710 9408328011 BEARING PILATS PILATS PC6T PC6BH2 7090210 EU PWA PT6 PT6A27 52043 EA HARTZL HCB3T HCB3TN3 GL BELLCRANK LOOSE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING 100 HR INSPECTION - LT IB AILERON CONTROL BELLCRANK WAS FOUND TO HAVE LOOSE FITTING BEARING. ALLOWING AILE RON CONTROL ROD TO FLOAT UP AND DOWN, CONTACTING THE BELLCRANK ASSEMBLY. BEARING REMOVED, BELLCRANK AND CONTROL ROD CHE CKED FOR DAMAGE, NONE FOUND. NEW BEARING INSTALLED AND CHECKED SECURE. BELLCRANK ASSEMBLY FOUND TO HAVE 86 HRS TSN. B ELLCRANK ASSEMBLY SUPPLIED FROM APPROVED VENDOR. 1 H 7 1 3T 4 T 7A15 E4EA 6 C P15EA 2005020100182 20050201 00182 NM 2005 2 1 CA040801001 1 20040731 G 3411 STATIC WICK DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE AILERON BURNED OUT W O OTHER O OTHER AP APPROACH 1 CA (CAN) DURING DECENT AND THROUGH APPROX 17000 FEET , THE A/C WAS APPARENTLY HIT BY LIGHTNING. NR ONE DC GENERATOR WAS KN OCKED OFF-LINE. THE CREW RECYCLED THE SWITCH IAW QRH (QUICK REFERENCE HANDBOOK) AND THE DC GENEARATOR CAME BACK ON LINE. FURTHER INVESTIGATION BY MAINTENANCE REVEALED LT AILERON OB STATIC WICK WAS BURNED OUT. ALL STATIC WICKS ON BOTH AILE RONS WERE REPLACED. ALSO, A BURNED RIVET FOUND ON RT IB FLAP AT ABOUT 10 INCHES FWD OF THE TRAILING EDGE WHICH WAS REPL ACED. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005020100183 20050201 00183 EA 2005 2 1 CA040802001 1 20040730 G 5512 SKIN CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE HORIZ STAB LIGHTNING STRIKE W O OTHER O OTHER DE DESCENT 1 CA (CAN) THE FLIGHT CERW REPORTED A POSSIBLE LIGHTINING STRIKE , UPON INSPECTION BY MAINTENANCE IT WAS FOUND THAT THERE WAS DAMAGE TO NR 2 DME ANTENNA , NR 2 COMM ANTENNA AND NR 1 AND 2 ATC ANTENNES WHICH WERE REPLACED AND TESTED . ALSO FOUND STRUCTURAL DAMAGE ON RT HORIZONTAL STABLILIZER WHICH WAS REPAIRED IAW MFG EO 601R-55-11-129. 2 L 7 2 4F 4 F RT A21EA E15NE 2005020100184 20050201 00184 EU 2005 2 1 CA040803001 1 20040723 G 2432 BATTERY BRAERO 748 HS7482A 4231001 EU RROYCE DART DART5342 EU ROTOL R4304 R2124304 EU MASTER INOPERATIVE W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) AFTER DEPARTURE, THE CREW OBSERVED THAT THE STBD CHARGE RATE WAS NOT DECLINING BELOW 10 AMPS. THE AIRCRAFT RETURN ED TO POINT OF DEPARTURE. MAINTENANCE REPLACED THE STBD BATTERIES AND THE AIRCRAFT WAS RETURNED TO SERVICE. 2 L 7 2 3T 4 T A24EU A196 6 C P899 2005020100185 20050201 00185 SO 2005 2 1 CA040803002 1 20040727 G 6120 582855 VALVE LKHEED 382 382G 526414U SO ALLSN 501D 501D22A 03006 GL HAMSTD 54H 54H60117 NE PROPELLER FAILED W E ENGINE SHUTDOWN E VIBRATION/BUFFET DE DESCENT 1 CA (CAN) ON DESCENT, NR 4 PROP INDICATED 97 PERCENT PITCH LOCK CHECK WAS CARRIED OUT AND ENGINE SHUTDOWN. PROPELLER VALVE WAS REPLACED, AIRCRAFT GROUND RUN AND RETURNED TO SERVICE. 2 H 7 4 4T 4 T A1SO E282 6 C P906 2005020100186 20050201 00186 NE 2005 2 1 CA040803004 2 20040713 G 7200 ENGINE SNIAS 350 AS350B 8680801 EU TMECA ARRIEL ARRIEL1B 6OO30 NE FAILED W K NONE O OTHER IN INSP/MAINT 1 CA 4532 (CAN) ENGINE START CYCLE INCONSISTANT AFTER OVERHAUL. MANY FUEL SYSTEM COMPONENTS CHANGED WITH NO CONSISTANT RESULTS. 1 G 7 1 3U 3 U H9EU E19EU 2005020100187 20050201 00187 EU 2005 2 1 CA040803005 1 20040719 G 2916 350A25103000 RESERVOIR SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE HYD SYSTEM LEAKING W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) HYDRAULIC RESERVOIR PN 350A25-1030-00 ( PLASTIC TYPE ) WAS FOUND TO CONSTANTLY WEEP FLUID. IT WAS DETERMINED TO H AVE A CRACK NEAR THE BOTTOM OUTLET PORT THAT FEEDS THE HYDRAULIC FLUID TO THE PUMP. A NEW METAL RESERVOIR WAS INSTALLED. 1 G 7 1 3U 3 U NC H9EU E19EU 2005031400075 20050314 00075 EU 2005 3 14 CA040803006 1 20040724 G 2432 15700 BATTERY SNIAS 350 AS350B 8680801 EU TMECA ARRIEL ARRIEL1B 6OO30 NE MASTER UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) A/C BATTERY IS WEAK. IT WILL NOT START THE A/C TWICE WITHIN 5 MINUTES. BATTERY HAS ONLY AVERAGED 115 HOURS OF LIFE IN THE LAST 6 INSTALL 1 G 7 1 3U 3 U H9EU E19EU 2005031400100 20050314 00100 NE 2005 3 14 CA040803007 2 20040712 G 7421 9550175400 IGNITER SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE ENGINE BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING A 100 HOUR INSPECTION IT WAS DISCOVERED THE TIP OF THE IGNITER WAS MISSING. 1 G 7 1 3U 3 U NC H9EU E19EU 2005031400101 20050314 00101 CE 2005 3 14 CA040803008 1 20040730 G 7120 44911601 CASTING BARRYCTRLS BEECH 100 A100 1152915 CE PWA PT6 PT6A28 EA HARTZL HCD4N3 HCD4N3A GL ENGINE MOUNT SEPARATED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ENGINE WAS FOUND SAGGING. UPON INVESTIGATION THE UPPER ENGINE MOUNT WAS FOUND BROKEN OFF. ALL 3 MOUNTS REPLACED AND CHECKED OK NOTE THESE MOUNTS WERE INVOLVED IN A SUDDEN STOPPAGE, 243 HOURS PRIOR. 1 L 7 2 3T 4 T A14CE E4EA 5 C STC 2005031400102 20050314 00102 NE 2005 3 14 CA040803009 2 20040729 G 7310 A69351039 VENT LINE FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE RT WING DISCONNECTED W D RETURN TO BLOCK K FLUID LOSS TX TAXI/GRND HDL 1 CA (CAN) DEFECT WAS RECORDED, RT FUEL LEAK REPORTED FROM RT NACA FUEL VENT . THIS WAS SECOND OCCURRENCE. AFTER INSPECTION , MAINT DISCOVERED THAT FUEL VENT LINE WAS DISCONNECTED (SEPARATED) AND NOT LINED UP, (TO SHORT). PROBLEM WAS RELATED TO THE MFG NOT DELIVERING VENT LINES IAW DRAWING SPECIFICATIONS. AFTER MEASURING VENT LINES AND FIT CHECKS OF SEVERAL AC. IT APPEARED THAT BUILDING TOLERANCES WERE IN FACT CAUSING THE VENT LINES TO BE INSTALLED UNDER STRAIN AND IN COMBINATIO N WITH AC WING DYNAMICS DURING ITS OPERATION, THE VENT LINES MAY DISCONNECT FROM THEIR COUPLINGS, RESULTING IN FUEL LEAK ING THROUGH VENT LINE FLAME ARRESTER. A REPAIR TO THE FUEL VENT LINE WAS CARRIED OUT IAW MFG LETTER TS04.52975. FO100. 2 L 7 2 4F 4 F RT E25NE 2005041400124 20050414 00124 EA 2005 4 14 CA040803010 1 20040723 G 5311 FRAME CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA DURING INSPECTION AS PER AD CF-2003-12, MAINTENANCE FOUND CRACKS IN THE LT AND RT FRAME AND REINFORCING ANGLE AT STATION FS 640 BETWEEN STRINGER 9 AND STRINGER 12. REPAIR WORK IS CURRENTLY IN PROGRESS, AND SDR WILL BE UPDATED UPON COMPLETI ON OF REPAIR. AIRCRAFT HOURS WERE 11985 AIRCRAFT CYCLES WERE 9553 2 L 7 2 4F 4 F RT A21EA E15NE 2005031400103 20050314 00103 WP 2005 3 14 CA040804001 1 20040803 G 2610 24346300C GASKET CVAC 440 440 2422902 WP ALLSN 501D 501D13D 03004 GL ALLSN A6441 A6441FN606 GL LT ENGINE MISSING W E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION DE DESCENT 1 CA (CAN) DURING DESCENT THE LT ENGINE ZONE 2 FIRE ALARM ACTIVATED. 2 L 7 2 4R 4 T 6A6 E282 6 C P898 2005031400104 20050314 00104 SW 2005 3 14 CA040804002 1 20040728 G 6410 206016201131 BLADE BELL 206 206L3 1182108 SW ALLSN 250C 250C30P 03013 GL TAIL ROTOR DEFORMED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) TRAILING EDGE SKIN WHERE THE BALANCE WEIGHTS ARE ATTACHED, WAS FOUND DISPLACED APPROXIMATELY 0.080 INCH FROM THE C HORD-LINE. DISCREPANCY WAS DETECTED WHEN A BONDING FAILURE WAS NOTICED IB FROM THE WEIGHTS ON THE BLADE ROOT CLOSE-OUT . THERE WAS NO INDICATION THAT THIS AREA WAS SUBJECT TO IMPACT DAMAGE, WHICH LEADS TO THE POSSIBILITY THAT THE DAMAGE W AS CAUSED AT THE INSTALLATION OF THE BALANCE WEIGHTS. 1 G 7 1 3U 3 U H2SW E1GL 2005031400105 20050314 00105 NE 2005 3 14 CA040804003 2 20040723 G 8530 R985 CYLINDER HEAD R985 DHAV DHC2 DHC2* 2800108 EA PWA R985 R985AN14BM1 52008 NE HAMSTD 2D 2D30 NE ENGINE BROKEN W B EMER. DESCENT E K VIBRATION/BUFFET FLUID LOSS CR CRUISE 1 CA (CAN) NR 5 CYLINDER STUDS BROKE AND CYLINDER THEN DETACHED FROM CASING, RESULTING IN EMERGENCY LANDING AND LOSS OF OIL. 1 H 7 1 3R 3 R A806 5E1 5 C P206 2005031400106 20050314 00106 EU 2005 3 14 CA040804004 1 20040721 G 7931 642790041 TRANSMITTER SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE OIL PRESS ERRATIC W K NONE N FALSE WARNING IN INSP/MAINT 1 CA (CAN) ENGINE OIL PRESSURE WAS ERRATIC THEN IT WENT FULLSCALE. TRANSMITTER REPLACED WITH UNIT FROM FPBA. NEW ONE ORDERE D AND INSTALLED IN PBA. 1 G 7 1 3U 3 U H9EU E19EU 2005041400125 20050414 00125 GL 2005 4 14 CA040804005 2 20040514 G 7250 23074872 CHECK VALVE BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL TURBINE SECTION OUT OF RIG W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHILE DOING 100 HOUR INSPECTION ITEMS DUE TO ENGINE SWAP TO ALTERNATE A/C, FOUND THAT THE TURBINE CHECK VALVE 230 74872 WAS SEIZED WHEN THE CLAMP MS 122911 WAS TIGHTENED. VALVE/CLAMP CONFIGUATION IS CORRECT IAW IPC/CEB1349. CHECK VAL VE WOULD FUNCTION WITH CLAMP LOOSE. A NEW CLAMP (P/O 360804) WAS TRIED WITH THE SAME RESULT. THESE CLAMPS ARE FLATTEN ED IN SHAPE, BY REWORKING CLAMP TO A ROUNDER FORM, THE VALVE WOULD THEN FUNCTION NORMALLY WHEN INSTALLED. THIS WAS VERI FIED BY REMOVAL OF THE OIL SUPPLY LINE TO THE VALVE. 1 G 7 1 3U 3 U H2SW E4CE 2005041400126 20050414 00126 EA 2005 4 14 CA040804006 2 20040727 G 7322 30804 FLOAT PRECISION MA4SPA PIPER PA28 PA28140 7102802 SO LYC O320 O320E2A 41508 EA SNSNCH 74D 74DM EA CARBURETOR FAILED W K NONE O OTHER IN INSP/MAINT 1 CA DC0244 (CAN) A FLOAT FOUND IN A PRECISION FACTORY REMAN CARB WAS FOUND TO BE FLOODED WITH FUEL IN ONE OF THE PANTOONS. THIS CAU SED THE ENGINE TO RUN RICH BECAUSE OF THE FLOAT SINKING. THE FLOAT IS MFG NEW STYLE THAT IS AVAILABLE ON MA CARBURETOR. THIS DEFECTIVE ONE HAS A CODE OF (5346) ON IT. 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 2005041400127 20050414 00127 NE 2005 4 14 CA040804007 2 20040717 G 7532 9550158260 BLEED VALVE SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE ENGINE FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) BLEED VALVE NOT CLOSING. REPLACED BLEED VALVE. 1 G 7 1 3U 3 U NC H9EU E19EU 2005041400128 20050414 00128 EU 2005 4 14 CA040804008 1 20040717 G 7714 0177555150 TACH GENERATOR SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE ENGINE FAILED W K NONE O OTHER IN INSP/MAINT 1 CA TACH BOX INTERNAL MALFUNCTION. REPLACED TACH BOX. CAUSE PROBLEM: DUE TO BLEED VALVE UNSERVICEABLE SHORTED THE TACH BOX . 1 G 7 1 3U 3 U NC H9EU E19EU 2005041500001 20050415 00001 NE 2005 4 15 CA040804009 2 20040625 G 7532 4020T35G04 REGULATOR CNDAIR CL600 CL6002B16 1900305 EA GE CF34 CF343A1 30015 NE BLEED AIR SYSTEM DEFECTIVE W E ENGINE SHUTDOWN B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA 807136 APPROX 1 - 2 MINUTES AFTER ENGINE START, CREW NOTED SMOKE IN THE CABIN. ENGINES AND APU WERE SHUTDOWN AND A/C EVACUATED. SMOKE WAS TRACED TO THE BLEED AIR OF THE RT ENGINE. MX FOUND A DEFECTIVE CARBON SEAL PRESSURE REGULATING VALVE. THE V ALVE WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT A21EA E15NE 2005041500002 20050415 00002 CE 2005 4 15 CA040804010 1 20040715 G 5344 071103720 HINGE CESSNA 182 R182 2072734 CE LYC O540 O540J3C5 41532 EA MCAULY 2D34C B2D34C214 GL PAX DOOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA DOOR HINGE WAS NOTED AS CRACKED. UPON REMOVAL OF DOOR TO REPLACE HINGE, CRACKS WERE ALSO FOUND IN THE MATING PART OF TH E HINGE (0711037-11) AND IN THE UPPER AFT HINGE (0711037-16). THE DOOR RIGGING IS SUCH THAT THE EDGES OF THE DOOR AND A IR FRAME SKINS COME INTO CONTACT WHEN CLOSING, AND PLACE UNDUE FORCES ON THE HINGES. 1 H 7 1 3O 3 O RT 3A13 E295 5 C P7EA 2005041500003 20050415 00003 EA 2005 4 15 CA040804011 2 20040803 G 7321 25244394 FUEL CONTROL DHAV DHC6 DHC6200 2802620 EA PWA PT6 PT6A20 52043 EA ENGINE FAILED W O OTHER E VIBRATION/BUFFET AP APPROACH 1 CA 21928 (CAN) WHEN THE FLIGHT CREW REDUCED POWER ON FINAL APPROACH, NR 1 ENGINE FAILED TO RESPOND TO POWER LEVEL INPUT, AND REMA INED AT 15 LBS TORQUE. THE TORQUE THEN SLOWLY DROPPED TO IDLE WITHOUT ANY POWER LEVER INPUT AND A LANDING WAS COMPLETED WITHOUTFURTHER INCIDENT. INVESTIGATION REVEALED THAT THE F.C.U. HAD FAILED INTERNALLY. 1 H 7 2 3T 3 T RT A9EA E4EA 2005041500004 20050415 00004 2005 4 15 CA040804012 4 20040804 G 2562 BS2173 BATTERY PACK ELT LEAKING W K NONE L NO TEST IN INSP/MAINT 1 CA (CAN) IN THIS LAST WEEK WE HAVE FOUND TWO REPLACEMENT BATTERY PACKS FOR THE DORNE& MARGOLIN DM ELT6, DM ELT 6.1, AND DM ELT8 SERIES OF ELTS, LEAKING CAUSING INTERNAL CASE CORROSION. IN ONE CASE ONE OF THE POWER WIRES COMING OUT OF THE BATTE RY HAD CORRODED OFF THE BATTERY PACK. ONE BATTERYHAS A MANUFACTURING DATE OF MAY 2003, (EXPIRY DATE OF JUN 2005) AND SE COND ONE, HAS A MANUFACTURING DATE OF JUNE2003(EXPIRY DATE JUL 2005). 2005041500005 20050415 00005 NE 2005 4 15 CA040805001 2 20040721 G 7220 UL16113 FAIRING BOEING 757 757* NM RROYCE RB211 RB211535E4 54555 NE ENGINE FAILED W C ABORTED TAKEOFF B SMOKE/FUMES/ODORS/SPARKS TO TAKEOFF 1 CA 52914 30534 (CAN) ENGINE EXPERIENCED A SPINNER FAIRING FAILURE ON THE T/O ROLL. PILOT ADVISED BY TOWER OF SPARKS AND FLAMES FROM JET PIPE AS REPORTED BY ANOTHER A/C & THE TAKE OFF WAS ABORTED. SPINNER FAIRING IS OF THE OLD FABRICATED SHORT FAIRING STAN DARD & FAIRING UNZIPPED ABOUT 40 PERCENT AROUND STITCH WELD DUE TO A CRACK WHICH PROPAGATED REARWARDS FROM ONE OF THE BO LT H OLES. CRACKING OF THE SPINNER FAIRING IS A KNOWN PROBLEM WHICH WAS MANAGED BY ROUTINE INSPECTIONS FOR CRACKING. NMS B 72-C322 CALL FOR REPETITIVE INSPECTION OF THE NOSE CONE FAIRING FOR CRACK. THE ENGINE HAS SUFFERED EXTENSIVE FAN BLADE AND ATTRITION LINER DAMAGE. THE FAILURE WAS FULLY CONTAINED AND THE UNZIPPED MATERIAL SEEMS TO HAVE GONE DOWN THE BY-PA 2 L 7 2 4F 4 F RT A2NM E12EU 2004101300019 20041013 00019 CE 2004 10 13 CA040805002 1 20040804 G 8011 539785 GEAR CESSNA 206 TU206G 2073357 CE CONT O520 TSIO520M 17040 SO MCAULY D3A34 D3A34C402 GL STARTER ADAPTER BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THE AIRCRAFT COMPLETED ITS FIRST FLIGHT OF THE DAY WITHOUT INCIDENT. ON THE SECOND START OF THE DAY THE PILOT HEAR D THE STARTER MOTOR RUNNING BUT THE ENGINE WAS NOT ROTATING. INSPECTION AND TROUBLESHOOTING PROCEDURES WERE CARRIED OUT . THE MECHANIC FOUND THE STARTER ADAPTER GEAR P/N 539785 BROKEN AND SOME DAMAGE INSIDE THE ADAPTER HOUSING. THE ENGINE OIL FILTER WAS REMOVED AND INSPECTED WITH NO INDICATION OF METAL CONTAMINATION. THE ENGINE OIL WAS CHANGED AND A NEW FIL TER INSTALLED AS A PRECAUTIONARY MEASURE. 1 H 7 1 3O 3 O A4CE E8CE 5 C P47GL 2004101300030 20041013 00030 NM 2004 10 13 CA040805003 1 20040715 G 3246 WHEEL BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AN OPERATOR HAS EXPERIENCED CRACKING OF THE 32-INCH MAIN LANDING GEAR WHEEL ASSEMBLY P/N 3-1575. THE CRACKS START AT THE WHEEL BOLT HOLES (FAYING SURFACE) AND EXTEND TO THE CUT-OUTS. THE CAUSE OF THE CRACKING IS NOT KNOWN AND IS CU RRENTLY UNDER INVESTIGATION BY MANUFACTURERS. AOM NR 133 HAS BEEN ISSUED. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2004101300031 20041013 00031 EU 2004 10 13 CA040805004 1 20040730 G 2421 23085024 GENERATOR PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL AC SYSTEM DAMAGED W O OTHER L NO TEST TX TAXI/GRND HDL 1 CA (CAN) GENERATOR WAS OVERHAULED AND INSTALLED ON THE AIRPLANE ON JULY 13TH 2004. ON JULY 30TH, (85.2) FLIGHT HOURS LATER THE STARTER DID NOT TURN DURING A ATTEMPTED ENGINE START AND AFTER TROUBLESHOOTING IT WAS DISCOVERED THAT THE STARTER HA D FAILED. THIS IS THE 2ND FAILURE IN LESS THEN A MONTH THAT WE HAVE HAD ON THIS TYPE OF GENERATOR OVERHAULED BY THIS FAC ILITY. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004101300032 20041013 00032 NE 2004 10 13 CA040805005 2 20040804 G 7200 ENGINE DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE ODOR W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) AUGUST 04, AIRCRAFT, EN ROUTE, DIVERTED TO NEAREST ALTERNATE AIRPORT. WHEN THE CABIN CREW REPORTED A BURNING SMEL L (PLASTIC) IN THE AFT RT CABIN NEAR THE LAVATORY. MAINTENANCE PERSONNEL OPENED THE AISLE CEILING, REMOVED THE TOILET SHROUD (BOLSTER), OPENED THE LAVATORY CEILING AND THEN CARRIED OUT A HIGH POWER RUN WITH PACKS ON, IN ORDER TO DUPLICATE THE SMELL, NO BURNING SMELL WAS DETECTED. AS A PRECAUTIONARY MEASURE A TECHNICIAN BOARDED THE AIRCRAFT FOR THE REMAIND ER OF THE FLIGHT. NO FINDINGS WERE REPORTED. 2 L 7 2 4F 4 F RT A6WE E9NE 2004101300033 20041013 00033 EU 2004 10 13 CA040805006 1 20040510 G 6730 ACCUMULATOR AC67246 SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE ROTOR SERVO UNSERVICEABLE W E ENGINE SHUTDOWN F FLT CONT AFFECTED TX TAXI/GRND HDL 1 CA PC438 (CAN) CYCLIC OSCILLATION WHEN ACCUMULATORS BLED DOWN. 1 G 7 1 3U 3 U H9EU E19EU 2004101300034 20041013 00034 NE 2004 10 13 CA040805007 2 20040409 G 7313 0283317500 INJECTOR SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE ENGINE MALFUNCTIONED W E ENGINE SHUTDOWN R PARTIAL RPM/PWR LOSS TX TAXI/GRND HDL 1 CA (CAN) POOR STARTS REPORTED. SPRAY PATTERN ON START INJECTORS FOUND POOR. NEW INJECTORS INSTALLED AND SHIMMED. 1 G 7 1 3U 3 U H9EU E19EU 2004101300035 20041013 00035 EU 2004 10 13 CA040805008 1 20040317 G 6420 350A3321501 BEARING SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE SWASHPLATE WORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHILE PERFORMING A 100 HOUR INSPECTION THE TAIL ROTOR SPIDER WAS DISCONNECTED FROM THE INPUT BELLCRANK TO CHECK TH E SPIDER SWASHPLATE BEARING. NOTICED THAT THE BALL END BEARING ON THE SWASHPLATE INPUT WAS WORN OUT. ( IPC 65.20.30 FIG 1A ITEM 95 ) MEASUREMENT WITH A DIAL INDICATOR SHOWED AN AXIAL PLAY OF APPROXIMATELY 1.4MM. 1 G 7 1 3U 3 U H9EU E19EU 2004101300036 20041013 00036 NE 2004 10 13 CA040805009 2 20040308 G 7322 LINE SNIAS 350 AS350B 8680801 EU TMECA ARRIEL ARRIEL1B 6OO30 NE FUEL CONTROL SPLIT W K NONE K FLUID LOSS IN INSP/MAINT 1 CA C658B (CAN) OVERHAULED FUEL CONTROL RECEIVED FROM MFG ON PS CC/F01782. FOUND TO BE LEAKING AT HOUSING SPLIT LINE HALVES DURIN G GROUND RUN/ LEAK CHECK. PART REMOVED AND RENTAL UNIT REINSTALLED. 1 G 7 1 3U 3 U H9EU E19EU 2004101300037 20041013 00037 CE 2004 10 13 CA040805010 1 20040831 G 2612 WARNING LIGHT BEECH 99 99A 1154003 CE PWA PT6 PT6A28 EA HARTZL HCB3T HCB3TN3 GL LT ENGINE ILLUMINATED W O OTHER N FALSE WARNING TX TAXI/GRND HDL 1 CA (CAN) ON START-UP, THE LT FIRE WARNING LIGHT ILLUMINATED BEFORE FUEL WAS INTRODUCED TO THE ENGINE. PILOT ABORTED START. MAINTENANCE CHECKED ALL APPLICABLE SYSTEMS AND FOUND NO FAULTS. NO EVIDENCE OF FIRE WAS FOUND. MULTIPLE STARTS WERE C ARRIED OUT AND NO FAULTS FOUND. A/C WAS RETURNED TO SERVICE. 1 L 7 2 3T 4 T A14CE E4EA 6 C P15EA 2004101300038 20041013 00038 EU 2004 10 13 CA040805011 1 20040801 G 2150 CASTING SNIAS 350 AS350B 8680801 EU TMECA ARRIEL ARRIEL1B 6OO30 NE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) CRACK FOUND ON WEB CASTING DURING A 100 HOUR INSPECTION. (BUTTERFLY) PLATE VERY LOOSE (WORN OUT END BUSHINGS). 1 G 7 1 3U 3 U H9EU E19EU 2004101300096 20041013 00096 WP 2004 10 13 CA040805012 1 20040804 G 2750 CONTROL UNIT DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE TE FLAPS MALFUNCTIONED W C ABORTED TAKEOFF J WARNING INDICATION TO TAKEOFF 1 CA (CAN) FLAPS WERE SELECTED AT 24, FOR TAKE OFF ON RUNWAY 24 (6150 FT). WHEN FLAPS WERE INITIALLY SELECTED, THE SLATS EXTE NDED TO LAND. THE FLAPS WERE CYCLED AND 24/24 TAKE OFF WAS DISPLAYED. WHEN THROTTLES WERE ADVANCED FOR T/O, THE SLATS E XTENDED TO LAND AND THE CHIME WAS HEARD. THE T/O WAS ABORTED AT LESS THEN 60 KNOTS. THE FLAPS WERE CYCLED AGAIN AND THE THROTTLES WERE ADVANCED SLIGHTLY TO ENSURE THE SLATS REMAINED AT TAKE OFF. THROUGH 90 KNOTS THE SLATS EXTENDED AND THE T AKE OFF WAS REJECTED. MAINTENANCE ADJUSTED THE FLAP SWITCH (S1-467) IAW THE AMM AND CHECKED SERVICEABLE. ALSO AN AUTOPIL OT CHECK CARRIED OUT IAW AMM 22-10-00. AIRCRAFT WAS RELEASED WITH NO FURTHER FAULTS. 2 L 7 2 4F 4 F RT A6WE E9NE 2004101300097 20041013 00097 EU 2004 10 13 CA040805013 1 20040727 G 8012 350A67511001 RELAY SNIAS 350 AS350B 8680801 EU TMECA ARRIEL ARRIEL1B 6OO30 NE STARTER FAULTY W O OTHER O OTHER TX TAXI/GRND HDL 1 CA (CAN) WHEN START BUTTON PRESSED THE STARTER RELAY WOULD ONLY CHATTER. TROUBLESHOOTING DETERMINED A FAULTY RELAY 23K. PR INTED CIRCUIT BOARD REPLACED. 1 G 7 1 3U 3 U H9EU E19EU 2004101300098 20041013 00098 EU 2004 10 13 CA040805014 1 20040628 G 7931 642790041 TRANSMITTER SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE OIL PRESSURE INOPERATIVE W E ENGINE SHUTDOWN N FALSE WARNING TX TAXI/GRND HDL 1 CA (CAN) NO OIL PRESSURE INDICATION ON DASH GAUGE (ENGINE PRESSURE WARNING LIGHT GOES OUT). 1 G 7 1 3U 3 U H9EU E19EU 2004101300099 20041013 00099 NE 2004 10 13 CA040805015 3 20040726 G 6114 660710840 HUB SAAB SF340 SF340A 7850100 EU GE CT7TP CT75A2 30030 NE ROTOL R389 R3894123F25 NE RT PROPELLER CRACKED W O OTHER E VIBRATION/BUFFET LD LANDING 1 CA DRG869386 (CAN) ON LANDING, PILOTS FELT A LIGHT VIBRATION ON THE RT PROPELLER WHEN FEATHERING. AFTER INVESTIGATION FOUND PROPELLE R HUB MATING FACE AND PGB FLANGE WITH A LIGHT PLAY. 6 ATTACH BOLTS OUT OF 12 WERE FOUND TO BE 1 TURN LOOSE ALTHOUGH THE SAFETY WIRE WAS STILL INTACT. SOME BOLTS WERE JAMMED AND COULD NOT BE REMOVED. PROPELLER REMOVED AND FOUND STRETCHED T HREADS IN HOLES AND ALSO 3 CRACKS FOUND BY NDT AROUND DOWEL PIN HOLE. WE ARE ASSUMING THAT THE HUB BOLT HOLES STRETCHE D, THERE ARE SOME SB'S REGARDING THIS ISSUE THAT WERE ALREADY ACCOMPLISHED. NOTE THAT THIS HUB WAS NEW AND INSTALLED AT LAST OVERHAUL. 2 L 7 2 4T 4 T RT A52EU E8NE6 6 C P30NE 2004101300100 20041013 00100 CE 2004 10 13 CA040805016 1 20040804 G 2612 3001129 SENSOR BEECH 200 B200 1152922 CE PWA PT6 PT6A42 52043 NE HARTZL HCE4N HCE4N3 NE FIRE DETECTOR FAULTY W K NONE L NO TEST IN INSP/MAINT 1 CA PCE94792 (CAN) UPON REGULAR PHASE INSPECTION, THE FIRE DETECTION SYSTEM FAILED TO TEST CORRECTLY ON RT ENGINE. TROUBLESHOT AND F OUND SENSOR AT FAULT. REPLACED SENSOR, OPERATION RESTORED TO NORMAL. 1 L 7 2 4T 4 T A24CE E4EA 5 C P10NE 2004101300101 20041013 00101 CE 2004 10 13 CA040805017 1 20040805 G 5320 97430000150 CROSS TIE BEECH B300 B300B350C CE PWA PT6 PT6A60A 52043 NE FUSLEAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) UPON REMOVING THE LT EMERGENCY EXIT FOR UNRELATED ROUTINE MAINTENANCE, PERSONNEL DISCOVERED A CRACK IN THE LT FUSE LAGE CROSSTIE AT STATION 201.775. THE CRACK LOCATION IS NEAR THE LOWER AFT CORNER OF THE LT EMERGENCY EXIT HATCH. CRAC K IS APPROX .375 INCH IN LENGTH AND TRAVELS FROM THE MATERIAL EDGE TO THE NEAREST RIVET HOLE AND SLIGHTLY PAST. CROSSTI E TO BE REPLACED. 2 L 7 2 4T 4 T RT A24CE E4EA 2004101300102 20041013 00102 CE 2004 10 13 CA040805018 1 20040826 G 2722 991444014 PCU CESSNA 750 750 2076810 CE ALLSN AE3007 AE3007C GL RUDDER LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) DURING SCHEDULED MAINTENANCE, A SMALL LEAK WAS NOTICED COMING FROM THE RUDDER. 2 L 7 2 4J 4 F RT T00007WI TE6CH 2004101300103 20041013 00103 WP 2004 10 13 CA040806001 1 20040803 G 7921 315341 ACTUATOR CVAC 440 440 2422902 WP ALLSN 501D 501D13D 03004 GL ALLSN A6441 A6441FN606 GL OIL COOLER DOOR FAILED W E ENGINE SHUTDOWN J WARNING INDICATION CR CRUISE 1 CA (CAN) DURING CRUISE THE FLIGHT CREW NOTICED THAT THE OIL TEMPERATURE ON THE LT ENGINE WAS CLIMBING. THE CREW TRIED TO M ANUALLY CONTROL THE OIL TEMP BUT WAS UNSUCCESSFUL. THE ENGINE WAS SHUT DOWN AND THE PROP WAS FEATHERED AS A PRECAUTION. THE AIRCRAFT RETURNED TO BASE. OIL COOLER DOOR ACTUATOR WAS REPLACED WITH A SERVICEABLE UNIT, AND THE AIRCRAFT WAS RE TURNED TO SERVICE. 2 L 7 2 4R 4 T 6A6 E282 6 C P898 2005041500006 20050415 00006 EU 2005 4 15 CA040806002 1 20040703 G 6730 F1688 SERVO SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE FLIGHT CONTROL FAILED W O OTHER F FLT CONT AFFECTED HO HOVERING 1 CA DURING HYD TESTS PRIOR TO FLTS IAW CF-2003-15R1, CYCLIC CONTROL FOUND COMPROMISED. AT 100 PERCENT NR, 'HYD TEST' SELECTE D, CYCLIC TESTED FOR PROPER CNTRL MOVEMENTS ON ACCUMULATOR PRESS PRIOR TO HYD ASSIST DEPLETION. LATERAL ACCUMULATORS DE PLETED AFTER APPROX 8 CYCLES, CYCLIC ENCOUNTERED A VIOLENT UNCOMMANDED RT MOVEMENT. SUBSTANTIAL FORCE REQUIRED TO KEEP CYCLIC IN PLACE & GREATER FORCE REQUIRED TO CENTER CONTROL. AFTER FORCING CONTROL THRU CENTER POSITION, INTO LT AREA & RE-CENTERING CONTROL, PHENOMENON DISAPPEARED. DURING RE-CHARGING OF ACCUMULATORS, CYCLIC VIOLENTLY MOVED LT UNTIL HYD AS SIST SUPPLIED. RT INPUT PHENOMENON WOULD ONLY SHOW UP WHEN 'HYD TEST' USED. COLLECTIVE DUMP YIELDED NO DISCREPANCIES. 1 G 7 1 3U 3 U NC H9EU E19EU 2004101800047 20041018 00047 CE 2004 10 18 CA040806003 1 20040805 G 5610 1013840212 WINDSHIELD BEECH B300 B300B350C CE PWA PT6 PT6A60A 52043 NE HARTZL HCB4M HCB4MP3 GL COCKPIT BROKEN W O OTHER O OTHER CR CRUISE 1 CA (CAN) AT CRUISE ALTITUDE THE LT WINDSHIELD SHATTERED. FLIGHT CREW DESCENT TO 16000 FEET ALTITUDE AND LANDED AT SAFELY. WINDSHIELD ASSY WILL BE REPLACED. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2004101800048 20041018 00048 EA 2004 10 18 CA040806004 2 20040722 G 8520 SL78027 BOLT SL78027 CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160CTM GL CONECTING ROD FAILED W A UNSCHED LANDING D E INFLIGHT SEPARATION VIBRATION/BUFFET CL CLIMB 1 CA (CAN) THE PILOT DEPARTED AIRPORT: AT 2100 FT AND 4 MILES SOUTH OF DEPARTED AIRPORT, ENGINE STARTED TO RUN ROUGH, PARTIAL POWER LOSS. THE PILOT LANDED AT SAME AIRPORT WITHOUT ANY DIFFICULTY. UPON INVESTIGATION OF ENGINE, FOUND THAT THE CONNE CTING ROD BOLTS P/N SL78027 FAILED AND SEPARATION OF CONNECTING ROD CUP. ENGINE SENT FOR FURTHER INVESTIGATION. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2004101800049 20041018 00049 EU 2004 10 18 CA040806005 1 20040517 G 6220 BUSHING AEROSP AS355 AS355F2 8680812 EU ALLSN 25OC 250C20R GL STARFLEX LOOSE W K NONE O OTHER IN INSP/MAINT 1 CA M495U (CAN) ALL 3 BUSHINGS FOUND LOOSE ON D.I. STARFLEX WAS REPLACED. 1 G 7 2 3U 3 U H11EU E4CE 2004122900166 20041229 00166 SO 2004 12 29 CA040806006 2 20040726 G 8520 SADDLE CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO HARTZL HCJ3Y PHCJ3YF1 GL CRANKCASE FAILED W A UNSCHED LANDING K FLUID LOSS CR CRUISE 1 CA CRANKCASE FAILURE (7TH STUD CRANKCASE) CRANKCASE FRETTING ON NR 2 & 3 INTERMEDIATE BEARING SADDLE THRU-BOLT PADS. THE OI L SUPPLY TO THE NR 2 CONNECTING ROD JOURNAL WAS EITHER CUT OFF COMPLETELY OR DRASTICALLY REDUCED CAUSING OIL STARVATION TO THE CONNECTING ROD BEARINGS. THIS IN TURN CREATED EXCESSIVE FRICTION AND HEAT CAUSING THE CONNECTING ROD TO FAIL AND EXIT THROUGH THE CRANKCASE RESULTING IN A CATASTROPHIC FAILURE OF THE ENGINE. 1 H 7 1 3O 3 O A4CE E5CE 5 C P36EA 2004101800050 20041018 00050 SW 2004 10 18 CA040806007 1 20040417 G 7120 206063110001 FITTING BELL 206 206L 1181522 SW ALLSN 250C 250C20R2 GL GEARBOX MOUNT MISINSTALLED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AFTER A VISUAL INSPECTION, ENGINE GB MOUNT FITTING 206-063-110-003 (RT) AND FITTING 206-063-110-001 (BOTTOM) WERE FOUND INTERMIXED. BOTTOM FITTING IS 0.4 INCH LONGER THAN THE SIDE ONES. REINSTALLED THE FITTINGS PROPERLY AFTER INSPE CTION OF THE A/F ENGINE MOUNT ATTACHMENT POINTS (VISUAL WITH BOROSCOPE). NO CRACK OR DAMAGE FOUND. ALSO INSPECTED THE SHORT STEEL SHAFT TOMMAS COUPLINGS. NO DAMAGE FOUND. A/C RETURNED TO SERVICE, MAINTENANCE LOG ENTRY. 1 G 7 1 3U 3 U H2SW E4CE 2004101800085 20041018 00085 SO 2004 10 18 CA040806009 1 20040810 G 3230 4032705 HOUSING PIPER PA31T PA31T2 7103127 SO PWA PT6 PT6A135 52043 NE HARTZL HCB3T HCB3TN3 GL DRAG BRACE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 15000 (CAN) DURING A WALKAROUND, THE PILOT NOTICED THE LT OLEO WAS LOWER THAN THE RT. AT THE MAINTENANCE BASE THE AME INSPECTE D THE LT OLEO WHICH WAS COMPLETELY FLATNOW. UPON FURTHER INSPECTION BY THE AME, FOUND HYDRAULIC FLUID IN THE WHEEL WELL AND DOWN THE GEAR LEG. IT WAS ALSO FOUND A 6 INCH VERTICAL CRACK ALONG SIDE THE DRAG BRACE ATTACHMENT POINT. THE AME CLEANED THE PAINT OFF TO MAKE SURE IT WAS A CRACK IN THE HOUSING AND NOT IN THE PAINT. NITROGEN WAS ADDED BUT LEAKED OUT THROUGH THE CRACK. A SERVICEABLE HOUSING WAS INSTALLED AND THE AIRCRAFT WAS PUT BACK IN SERVICE. 1 L 7 2 3T 4 T RT A8EA E4EA 6 C P15EA 2004102000189 20041020 00189 EU 2004 10 20 CA040806010 1 20040805 G 5340 350A35101700 SUPPORT SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE PUMP CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) HYDRAULIC PUMP SUPPORT HOUSING HAD A CRACK ON FLANGE, CAUSING PUMP AND BEARING ASSEMBLY TO VIBRATE. HYDRAULIC BEA RING (704A33-651-206) FOR THE POLY (V) BELT WAS REPLACED AT THIS TIME TO ENSURE THAT NO DAMAGE MAY HAVE BEEN CAUSED TO T HIS BEARING DUE TO VIBRATION. AIRCRAFT RETURNED TO SERVICE. 1 G 7 1 3U 3 U NC H9EU E19EU 2004101800086 20041018 00086 CE 2004 10 18 CA040809001 1 20040803 G 2820 LINE CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL FUEL SYSTEM CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) APPROXIMATELY 1-5 INCH CRACK ALONG FLANGE. FUEL STAINING NOTED IN AREA. ROUGH RUNNING ENGINE. PIPE ASSEMBLY RE PLACED. 1 H 7 1 3O 3 O NT 3A19 E223 5 N P50GL 2004101800087 20041018 00087 WP 2004 10 18 CA040809002 1 20040802 G 7430 A1661 IGNITION SWITCH ROBSIN R44 R44 7640120 WP LYC O540 O540F1B5 41532 EA INSTRUMENT PANEL OVERHEATED W B EMER. DESCENT B SMOKE/FUMES/ODORS/SPARKS AP APPROACH 1 CA (CAN) DURING APPROACH, AN ENGINEER ONBOARD SMELLED ODOR OF BURNING ELECTRICAL WIRES. THE AIRCRAFT LANDED WITHOUT FURTHER INCIDENT. FURTHER INVESTIGATION FOUND IGNITION SWITCH WAS THE CULPRIT. THE CONTACTS OVERHEATED CAUSING THE PLASTIC TO S LIGHTLY BURN. ONE MAG CONTACT WAS FOUND GROUNDED DURING FUNCTION TEST OF SWITCH. THE SWITCH WAS REPLACED AND NO FURTHER DEFECTS WERE NOTICED, FLIGHT CONTINUED. THE COMPANY HAS NOTIFIED MFG AND INCORPORATED AN INSPECTION ON THE IGNITION SWIT CHES. IGNITION SWITCH P/N A166-1, ALT P/N 10-357200-1. 1 G 7 1 3O 3 O H11NM E295 2004102000190 20041020 00190 WP 2004 10 20 CA040809003 1 20040802 G 2510 C6284 BUCKLE ROBSIN R44 R44 7640120 WP LYC O540 O540F1B5 41532 EA PILOT SEAT CRACKED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) DURING A 100 HOUR INSPECTION, ENGINEER FOUND CRACKS PROPAGATED FROM TWO RIVETS UNDER BUCKLE. PLASTIC COVER WAS MO VED BACK AND FURTHER CRACKS WERE FOUND ALONG RIVET LINE OF THE STAINLESS ADAPTER TO PIVOT POINT OF THE BELT ASSEMBLY. TW O OTHER CASES HAVE BEEN FOUND SINCE. THE CAUSE COMES FROM WHEN PILOTS TRY TO INSERT TONGUE IN TO BUCKLE ASSY. BUCKLE AS SY IS FLEXED TO ACCOMPLISH THE FASTENING OF THE SEAT BELT. OVER TIME THE STAINLESS ADAPTER IS STRESSED AND CRACKS OCCUR . PARTICULAR CARE HAS BEEN TAKEN REGARDING INSPECTION CRITERIA. A LETTER HAS BEEN SENT TO MFG, HOPING TO GET SOME INP UT/CHANGE TO ACCESSIBILITY TO BUCKLE ASSEMBLY. 1 G 7 1 3O 3 O H11NM E295 2004101800088 20041018 00088 CE 2004 10 18 CA040809004 1 20040802 G 2701 SPACER CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160DTM GL CONTROL YOKE BRG LOOSE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) YOKE FOUND TO HAVE EXCESSIVE MOVEMENT DURING INSPECTION. SOURCE DETERMINED TO BE LACK OF WELDING AT LT SIDE OF LOW ER BEARING CONTROL YOKE SPACER ASSEMBLY TO THE CONTROL YOKE SHAFT ITSELF. MFG HAS PROVIDED APPROPRIATE DATA TO COMPLETE THE WELDMENTS. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2004101800089 20041018 00089 CE 2004 10 18 CA040809005 1 20040802 G 3251 C109 ROD END CESSNA CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA MCAULY 1C160 1C160DTM GL STEERING ARM WORN W D RETURN TO BLOCK L NO TEST TX TAXI/GRND HDL 1 CA (CAN) ON GROUND ROLL, THE PILOT WAS UNABLE TO TURN THE AIRCRAFT TO THE RT. AFTER INSPECTION OF THE STEERING SYSTEM, DISC OVERED A STEERING ARM DISCONNECTED IN LOCATION OF THE PEDALS. THE ROD END THAT ATTACHES TO THE PEDALS WAS WORN, WHICH CA USED THE STEERING ARM TO DISCONNECT. THE ROD END WAS REPLACED. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2004101800090 20041018 00090 CE 2004 10 18 CA040809006 1 20040809 G 5210 50430043547 HINGE BEECH B300 B300B350C CE PWA PT6 PT6A60A 52043 NE HARTZL HCB4M HCB4MP3 GL PAX DOOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) INSPECTION OF THE CABIN DOOR HINGE REVEALED CRACKING OF THE DOOR HALF AFT TWO SECTIONS. FUSELAGE HINGE HALF UNDAMA GED. DOOR HINGE HALF AND PIN TO BE REPLACED NEW. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2004101800105 20041018 00105 EU 2004 10 18 CA040809007 1 20040807 G 6320 PINION GEAR SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE TRANSMISSION VIBRATION W O OTHER D INFLIGHT SEPARATION CR CRUISE 1 CA M1571 (CAN) AIRCRAFT HAD 3 PER VIBRATION APPEAR DURING FORWARD FLIGHT. PILOT LANDED AT DESTINATION AND PHONED IN FOR A PRECAUT IONARY MEASURE. COMPANY DISPATCHED ANOTHER AIRCRAFT AND ENGINEER TO ACCESS THE PROBLEM. TRANSMISSION WAS CHANGED AND AI RCRAFT WAS RETURNED TO SERVICE. 1 G 7 1 3U 3 U NC H9EU E19EU 2005021400200 20050214 00200 NM 2005 2 14 CA040810001 1 20040809 G 3230 841005 PSEU DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE MLG FALSE INDICATION W O OTHER N FALSE WARNING AP APPROACH 1 CA 20510 (CAN) DURING APPROACH , THE NOSE GEAR FAILED TO EXTEND , THE CREW CARRIED OUT ALTERNATE GEAR EXTENSION AND A/C LANDED SA FELY . DURING THE SAME FLIGHT , AFTER TAKEOFF(ABOUT 5 MINUTES) THE LANDING GEAR CAUTION LIGHT CAME ON AND WENT OUT AFTER ONE MINUTE. MAINTENANCE CREW FOUND ERRONIOUS FAULT CODES ON THE PSEU( PROXIMITY SENSING ELECTRONIC UNIT ) AND REPLACED THE UNIT . SEVERAL GEAR RETRACTIONS CARRIED OUT ON JACKS AND THE FAULTS COULD NOT BE DUPLICATED. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005021400201 20050214 00201 CE 2005 2 14 CA040810002 1 20040804 G 2612 24412886 FIRE LOOP BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE RT ENGINE BROKEN W K NONE L NO TEST IN INSP/MAINT 1 CA (CAN) CREW NOTED THAT THE RT FIRE LOOP WOULD NOT TEST. MAINTENANCE FOUND THE FWD FIRE WIRE LOOP PARTIALLY BROKEN PREVENT ING CONTINUITY. THE WIRE WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2005021400202 20050214 00202 EU 2005 2 14 CA040810003 1 20040807 G 2910 O-RING AEROSP ATR42 ATR42300 8680920 EU PWA 120 PW120 NE HAMSTD 14SF 14SF5 NE HYD SYSTEM FAILED W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CL CLIMB 1 CA (CAN) ENROUTE, (GREEN SYS) LOW LEVEL PRESS INDICATION OBSERVED. THE CREW ACCOMPLISHED THE CHECK LIST AND CONTINUED TO YZ F. THE AIRCRAFT LANDED WITHOUT INCIDENT AND WAS TOWED FROM THE RUNWAY. THE O-RING AND BACK-UP RING AT THE ACCUMULATOR F ITTING WERE REPLACED, THE AIRCRAFT WAS LEAK CHECKED AND RETURNED TO SERVICE. 2 H 7 2 4T 4 T RT A53EU E20NE 6 C P7NE 2005021400209 20050214 00209 EA 2005 2 14 CA040810004 2 20040806 G 7310 11492000023 LINE BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA HARTZL HCB4M HCB4MP3 GL ENGINE FUEL WORN W K NONE O OTHER IN INSP/MAINT 1 CA 35350 (CAN) WHEN INSTALLING INSPECTION PANEL ON LT OB NACELLE FOUND FUEL LINE FROM FUEL BOWL FORWARD TO ENGINE WAS CHAFING ON BULKHEAD IN SIDE OF NACELLE. THE LINE WAS WORN ABOUT A QUARTER OF ITS WALL THICKNESS. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2005021400214 20050214 00214 CE 2005 2 14 CA040810005 1 20040719 G 3252 26430096 SHIMMY DAMPENER CESSNA 208 208B 2073701 CE PWA PT6 PT6A114A 52043 NE MCAULY 3AF34C 3GFR34C703 GL MLG BROKEN W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) SHIMMY DAMPENER BARREL END ENTIRELY BROKE OFF AT CIRCLIP GROOVE. ALL FLUID LOST,CIRCLIP MISSING, BROKEN PIECE MISS ING. NO EVIDENCE OF PRIOR OVERSTEER. 1 H 7 1 3T 3 T A37CE E4EA 5 C P60GL 2005021400215 20050214 00215 NE 2005 2 14 CA040810006 2 20040809 G 7414 SB9RU3 MAGNETO DHAV DHC2 DHC2* 2800108 EA PWA R985 R985AN14B 52008 NE HARTZL HCB3R HCB3R302 GL ENGINE FAILED W A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 CA 1784N (CAN) DURING A LOCAL FLIGHT THE PILOT ENCOUNTERED A ROUGH RUNNING CYCLE, RETURNED TO BASE AND LANDED EVENTUALLY. MAINT ENANCE INVESTIGATION RELEALED THAT THE RT MAGNETO HAD FAILED INTERNALLY. MAGNETO WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. TEARDOWN REPORT TO FOLLOW. 1 H 7 1 3R 3 R A806 5E1 5 C P28EA 2005021400216 20050214 00216 CE 2005 2 14 CA040810007 1 20040806 G 3242 1338932 DISK BFGOODRICH CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE BRAKE STATOR BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA 2393 (CAN) WHILE PUSHING THE AIRCRAFT WITH A TUG THE LT BRAKE LOCKED UP. ON INSPECTION IT WAS DISCOVERED THAT ONE OF THE STA TOR DISKS HAD BROKEN AND JAMMED THE BRAKE. THE BRAKE WAS REPLACED WITH AN OVERHAULED UNIT. AD2004-09-05 WHICH ADDRESSES MFG BRAKE STATORS BREAKING HAD BEEN ACCOMPLISHED RECENTLY AND PASSED THE INSPECTION AS CALLED OUT. BOTH STATORS ARE STAM PED 'CHANGE D', SO NO FURTHER ACTION WAS REQUIRED. IN LIGHT OF THIS INCIDENT THE REPLACEMENT CRITERIA SHOULD POSSIBLY BE CHANGED. 1 L 7 2 4F 4 F A22CE E1NE 2005021400217 20050214 00217 EA 2005 2 14 CA040811001 1 20040727 G 5610 NP13932111 WINDSHIELD CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE COCKPIT CRACKED W B EMER. DESCENT O OTHER CR CRUISE 1 CA 10219 (CAN) CAPTAINS WINDSHIELD SHATTERED, OCCURRED AT FL330, CREW DESCENDED TO FL100, W/S HEAT ON LOW, MFG P: 7.2 WHEN WINDOW SHATTERED. WINDSHIELD REPLACED. (SEE ALSO: US NR 2004081200104) 2 L 7 2 4F 4 F RT A21EA E15NE 2005020400001 20050204 00001 EA 2005 2 4 CA040811002 1 20040729 G 2612 47259701 CONTROL UNIT CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE NR 1 ENGINE FAILED W A UNSCHED LANDING N FALSE WARNING CL CLIMB 1 CA 20493 (CAN) FLT DIVERTED, EMERGENCY DECLARED. ON CLIMBOUT RECEIVED NUMEROUS FIRE FAIL MSGS., CAUTION MSG, THEY ALL DISAPPEARED . WE THEN RECEIVED A LH ENG FIRE WARNING AND WE SHUT DOWN NR 1 ENGINE. ON APPROACH WE RECEIVED A RH ENGINE FIRE WARNING MSG, ON LANDING WE RECEIVED A APU FAIL MSG, WHICH DISCHARGED THE BOTTLE. MTCE R/R THE FIREX CONTROLLER AND APU FIRE BOTT LE. 2 L 7 2 4F 4 F RT A21EA E15NE 2005020400002 20050204 00002 EA 2005 2 4 CA040811003 1 20040725 G 5414 22850080158 NOSE COWL CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE NACELLE DAMAGED W O OTHER O OTHER CR CRUISE 1 CA (CAN) PILOT REPORTED LOUD NOISE AND SOME LOSS OF ENGINE POWER ON THE RT ENGINE AT CRUISE. UPON LANDING, THE TOWER INFOR MED THE AIRCRAFT THAT A COWLING FELL OFF AT LANDING. ENGINE LOWER NOSE COWLING PANEL WAS RECOVERED.MTC LOOKED AT THE AIR CRAFT AND FOUND THE RT ENGINE UPPER AND LOWER NOSE COWLINGS MISSING. LOWER WAS RECOVERED FROM THE RUNWAY. UPPER WHERE AB OUTS STILL UNKNOWN. MANY OF THE CAM LOCK FASTENERS ARE STILL IN PLACE. SOME ARE MISSING AND 1 OR 2 FEMALE SOCKETS ARE NO T DAMAGED. 2 L 7 2 4F 4 F RT A21EA E15NE 2005031400034 20050314 00034 NE 2005 3 14 CA040811004 2 20040721 G 7310 0301007720 LINE SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE ENGINE FUEL CRACKED W E ENGINE SHUTDOWN K J FLUID LOSS WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) FUEL LEAK DISCOVERED AT LT INJECTOR ON START UP. START ABORTED. UPON INSPECTION, FUEL SUPPLY LINE WAS FOUND CRAC KED AT FLARE. LINE REPLACED, A/C RETURNED TO SERVICE. A NUMBER OF THIS PARTICULAR P/N LINES HAVE FAILED IN THE PAST. RECOMMEND USING ADDITIONAL CLAMPING OR DIFFERENT LINE ALTOGETHER. 1 G 7 1 3U 3 U NC H9EU E19EU 2005031400035 20050314 00035 EU 2005 3 14 CA040811005 1 20040809 G 3244 85010 TIRE PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL MLG LEAKING W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) TIRE WAS LOOSING AIR PRESSURE, ON INVESTIGATION IT WAS NOTED THAT THE AIR WAS LEAKING FROM HOLES THAT ARE LOCATED JUST UP FROM THE BEAD/SEAT AREA, APPARENTLY TO VENT AIR FROM BETWEEN THE LAYERS OF THE RUBBER. THIS IS THE THIRD TIME T HAT WE HAVE CHANGED A MFG TIRE FOR THIS REASON. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005031400036 20050314 00036 EU 2005 3 14 CA040811006 1 20040724 G 5240 HC524H0344002 ARM BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE SERVICE DOOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 40117 40117 (CAN) CABIN CREW REPORTED RT FORWARD SERVICE DOOR DIFFICULT TO CLOSE. MAINTENANCE INSPECTION FOUND DOOR 1R UPPER HINGE A RM ASSEMBLY CRACKED. UPPER HINGE ARM ASSEMBLY REPLACED. AIRCRAFT RETURNED TO SERVICE. 2 H 7 4 4F 4 F A49EU E6NE 2005020100152 20050201 00152 2005 2 1 CA040811007 4 20040702 G 2216 62701135 CABLE PIPER PA32 PA32RT300T 7103216 SO LYC O540 TIO540S1AD 41532 EA HARTZL HCE2Y HCE2YR1BF GL AUTOPILOT WORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) STAB TRIM STIFF WHEN COLD, PILOT SUSPECTED AFT TRIM DRUM INSPECTION OF COMPLETE CONTROL SYSTEM. FOUND CABLE (NR 62 701-135) FRAYED OVER 60 PERCENT AT AREA OF ELECTRIC AUTOPILOT MOTOR. SUSPECTED LOW TEMP AND LOW CABLE TENSION CAUSED CAB LE TO JAM AROUND THE SEVERED PULLEY WINDINGS AT THE TRIM MOTOR. NEW CABLE INSTALLED TO CORRECT TENSION AND SYSTEM FUNCT IONS NORMAL. ELECTRIC TRIM MOTOR HIDDEN FROM DIRECT VIEW UNDER AFT EDGE OF CARGO AFT WALL. 1 L 7 1 3O 3 O A3SO E14EA 5 C P9EA 2005020100188 20050201 00188 EU 2005 2 1 CA040811008 1 20040805 G 6322 355A340109 BLOWER AEROSP AS355 AS355F1 8680810 EU ALLSN 250C 250C20F 03013 GL OIL COOLER DAMAGED W A UNSCHED LANDING O OTHER CR CRUISE 1 CA (CAN) DURING OPERATION A NOISE WAS HEARD FROM THE BACK OF THE AIRCRAFT, AIRCRAFT WAS LANDED AND DURING INSPECTION TO DET ERMINE THE ORIGIN OF THE SOUND IT WAS NOTED THAT THE OIL COOLER BLOWER ASSY WAS DAMAGED AND HAD SEVERAL PIECES MISSING. THE AIRCRAFT WAS RETURNED TO BASE BY ROAD AND WAS DISASSEMBLED TO THE EXTENT REQUIRED TO INSPECT FOR OTHER DAMAGE. ONCE THE BLOWER WAS REMOVED IT WAS NOTED THAT THE FIRST STAGE OF THE ASSY HAD 2 SMALL NICKS ON 2 OF THE ROTATING BLADES. THE FIRST STAGE STATOR CASE, THE SECOND STAGE ROTATING AND STATIONARY COMPONENTS HAD EXTENSIVE DAMAGE AND WERE FOUND IN SEV ERAL PIECES. SUSPECT DAMAGE COULD HAVE BEEN CAUSED BY FOD. 1 G 7 2 3U 3 U H11EU E4CE 2005020100190 20050201 00190 SW 2005 2 1 CA040811009 1 20040726 G 6720 CLAMP BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL TAIL ROTOR PEDAL MISSING W O OTHER D F INFLIGHT SEPARATION FLT CONT AFFECTED DE DESCENT 1 CA (CAN) ON DECENT PILOT FELT A TAP ON THE TAIL ROTOR PEDALS, AND LOOKED INTO HIS SLINGING MIRROR AND DETERMINED THAT THE L T BEAR PAW WAS MISSING. AFTER LANDING HE NOTICED DAMAGE TO TAIL ROTOR BLADES, AND VERTICLE FIN. ON INSPECTION, IT WAS FOUND THAT A CLAMP THAT WOULD PREVENT THE BEAR PAW FROM SLIPPING OFF WAS MISSING FROM THE INSTALLATION. 1 G 7 1 3U 3 U H2SW E4CE 2005020100191 20050201 00191 NM 2005 2 1 CA040812001 1 20040729 G 2910 65178444440 B-NUT BOEING 727 727243 138408D NM PWA JT8 JT8D15 52051 NE HYDRAULIC LINE CRACKED W H DEACTIVATE SYST/CIRCUITS K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA (CAN) CREW REPORTED 'A' SYSTEM HYDRAULIC FLUID LOSS IN FLIGHT. MAINTENANCE FOUND LEAK AT B-NUT END FITTING AT 'A' SYSTE M MODULE. LINE REPLACED. 2 L 7 3 4F 4 F RT A3WE E2EA 2005020100192 20050201 00192 EU 2005 2 1 CA040812002 1 20040602 G 2822 P94C16612 PUMP UROCOP EC120 EC120B 8680987 EU TMECA ARRIUS ARRIU2F NE FUEL BOOST CONTAMINATED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ALUMINUM PARTICLES FOUND IN FUEL LINE AND MAIN FILTER. PUMP REPLACED (EXCHANGE WITH MFG). 1 G 7 2 3U 3 U NC R0001RD E34NE 2005020100193 20050201 00193 SW 2005 2 1 CA040812003 1 20040719 G 5302 212030156047 BULKHEAD BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA TAILBOOM CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) BULKHEAD FRAME CRACKED ADJACENT TO RT UPPER TAILBOOM ATTACH BOLT. FRAME REPLACED. 1 G 7 1 4U 4 U H4SW E22EA 2005020100194 20050201 00194 EU 2005 2 1 CA040812004 1 20040620 G 3246 431304 BOLT BFGOODRICH 31530 AIRBUS 320 A320214 3930316 EU CFMINT CFM56 CFM565B4 NE MLG WHEEL BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA 2550 (CAN) ON WALK AROUND PILOT FOUND 2 TIE BOLTS (P/N 43-1304) BROKEN ON THE NR 1 MAINWHEEL ASSY, TOTAL CYCLES ON MAIN WHEEL ASSY SINCE LAST RE-FURB 427, TOTAL TIME ON TIE BOLTS UNKN. 2 L 7 2 4F 4 F RT A28NM E38NE 2005031400076 20050314 00076 SW 2005 3 14 CA040812005 1 20040723 G 5320 206031200118S STRAP BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) FOUND STRAP CRACKED AT 100 HOUR INSPECTION. PART REPLACED. 1 G 7 1 3U 3 U H2SW E4CE 2005041500007 20050415 00007 SW 2005 4 15 CA040812006 1 20040719 G 2810 205031709052S ANGLE BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA FUEL CAP CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 17470 (CAN) DURING IMPORT INSPECTION, RT FUEL CELL CAVITY AFT CAP ANGLE FOUND BADLY CORRODED (EXFOLIATION). PART REPLACED. 1 G 7 1 4U 4 U H4SW E22EA 2005041500008 20050415 00008 SW 2005 4 15 CA040812007 1 20040720 G 5302 206031004113 SKIN BELL BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL TAILBOOM CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA BCJN06506 (CAN) DURING 100 HOUR INSPECTION, CRACK IN PAINT FORWARD OF NR3 HANGAR SUPPORT BRACKET. BRACKET REMOVED, PAINT REMOVED AND AREA FLUORESCENT PENETRANT INSPECTED. CRACK APPROXIMATELY 1.5 INCH. 1 G 7 1 3U 3 U H2SW E4CE 2005041500009 20050415 00009 NE 2005 4 15 CA040812008 2 20040805 G 7310 0319738340 MANIFOLD UROCOP EC120 EC120B 8680987 EU TMECA ARRIUS ARRIU2F NE FUEL INLET CHAFED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING RECEIVING INSPECTION A 0.010 (DAMAGE TO FUEL MANIFOLD), 1 G 7 2 3U 3 U NC R0001RD E34NE 2005041500010 20050415 00010 NM 2005 4 15 CA040812009 1 20040621 G 2910 114087005 BYPASS VALVE AIRBUS A319 A319114 3930350 NM CFMINT CFM56 CFM565A1 NE HYD SYSTEM LEAKING W D RETURN TO BLOCK K J FLUID LOSS WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) GREEN HYDRAULIC LOW LEVEL, LOST ALL GREEN HYDRAULIC PRESSURE WHILE TAXING, DOOR BY-PASS VALVE LEAKING MPN 11408700 5 S/N CWDDDH8197 2 L 7 2 4F 4 F RT A28NM E29NE 2005041500011 20050415 00011 NM 2005 4 15 CA040812010 1 20040625 G 7334 41817054 TRANSMITTER BOEING 767 767375 1385217 NM GE CF6 CF680C2B6F 30025 NE FUEL PRESSURE LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) NR 1 ENGINE FUEL PRESSURE TRANSMITTER FOUND LEAKING TOTAL TIME ON PART 20349.7HRS TOTAL TIME SINCE INSTALL 3445.2 HRS 2 L 7 2 4F 4 F RT A1NM E13NE 2005041500012 20050415 00012 SO 2005 4 15 CA040813001 1 20040813 G 2910 4085400 LINE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HYD HAND PUMP CRACKED W O OTHER K J FLUID LOSS WARNING INDICATION LD LANDING 1 CA (CAN) A/C WAS UNABLE TO EXTEND GEAR. FOUND HYDRAULIC HAND PUMP PRESSURE LINE WAS CRACKED JUST ABOVE FIRST CHECK VALVE. A LL HYDRAULIC FUEL LEAKED OUT. 1 L 7 2 3O 3 O A20SO E14EA 2005041500013 20050415 00013 NE 2005 4 15 CA040813002 2 20040731 G 7230 BLADE BOEING 717 717200 1383700 NM RROYCE BR700 BR700715A130 NE COMPRESSOR DAMAGED W E ENGINE SHUTDOWN J WARNING INDICATION CR CRUISE 1 CA 13348 (CAN) ENGINE 11348 HAD A COMMANDED IFSD AT 33,000 FT WHEN LEFT ENGINE SURGE IN FLT. ENGINE WAS SHUT DOWN AS IT CONTINUE TO SURGE. BOROSCOPE REVEALED SEVERE HPC DAM AGE FROM STAGE 2 TO STAGE 10, WITH BLADES HEAVILY DAMAGED AND MISSING. ENGIN E ENROUTE FOR RRC, FURTHER REPORT WILL BE SUBMITTED UPON ENGINE DISASSEMBLY. 2 L 7 2 4F 4 F TR A6WE E00061EN 2005041500014 20050415 00014 NM 2005 4 15 CA040813003 1 20040628 G 5610 N141T480149 WINDSHIELD BOEING 767 767375 1385217 NM COCKPIT CRACKED W O OTHER O OTHER CR CRUISE 1 CA 24333 (CAN) WHILE IN CRUISE CAPT'S WINDSHIELD CRACKED. 2 L 7 2 4F RT A1NM 2005041500015 20050415 00015 NM 2005 4 15 CA040813004 1 20040628 G 3240 058002003 SELECTOR AIRBUS A319 A319114 3930350 NM PARK BRAKE MALFUNCTIONED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHILE STARTING ENG NR 1, PARKING BRAKE WOULD NOT SET. FOOT BRAKES WERE FINE, JUST PARK BRAKE HANDLE WOULD NOT SET UNTIL ENG NR 1 FULLY STARTED. CARRIED OUT OPERATIONAL TEST AS PER AMM. CONFIRMED NO POWERFROM 'NORMAL' SOURCE. REPLACED PARK BRAKE CONTROL VALVE-NIL FIX. REPLACED PARK BRAKE SELECTOR SWITCH-OPS CHK'D SERV. 2 L 7 2 4F RT A28NM 2005041500016 20050415 00016 EA 2005 4 15 CA040813005 1 20040813 G 2731 ARM DHAV DHC3 DHC3 2800202 EA PWA PT6 PT6A34 52043 EA RUDDER TRIM MISSING W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THE AIRCRAFT WAS UNDERGOING A GENERAL INSPECTION MAINTANCE OBSERVED THE VIKING AIR FLUTTER PREVENTION MODIFICATION RUDDER TRIM TAB ARM WAS MISSING THE AIRCRAFT HAD BEEN INSPECETED SOME 50.0 HOURS EARLER WITH NO DEFECTS NOTED 1 H 7 1 3R 4 T A815 E4EA 2004101300020 20041013 00020 EA 2004 10 13 CA040814001 1 20040813 G 7110 40S16111AA CAMLOCK CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE COWL WEAK W K NONE O OTHER IN INSP/MAINT 1 CA C0484 (CAN) UPON INSPECTION OF AIRCRAFT DURING ROUTINE MAINTENANCE, THE LT ENGINE FORWARD LOWER COWL WAS FOUND TO HAVE 3 CAMLO CK FASTENERS UNDONE ON THE FORWARD IB SIDE. THE COWL WAS REMOVED, INSPECTED AND THE THREE CAMLOCKS (ONE LONG PN:40S5-11 , THE REST SHORT PN: 40S161-1-1AA) AND GROMMETS AS WELL AS SELECTED OTHERS WERE REPLACED, AS THEY WERE FOUND TO WORN OUT . THE COWL WAS REINSTALLED AND THE AIRCRAFT WAS RETURNED TO SERVICE. AIRCRAFT HOURS: 8758, CYCLES: 6474. 2 L 7 2 4F 4 F RT A21EA E15NE 2004101300047 20041013 00047 EA 2004 10 13 CA040814002 1 20040813 G 1430 40G15160S FASTENER CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE CAMLOCK WORN W K NONE O OTHER IN INSP/MAINT 1 CA 11474 11474 (CAN) UPON INSP OF AC DURING ROUTINE MAINTENANCE, THE RT ENGINE FORWARD LOWER COWL WAS FOUND TO HAVE 3 CAMLOCK FASTENERS PULLED THROUGH THE COWL WHILE STILL LOCKED IN THEIR RECEPTACLES, ON THE IB TRAILING EDGE. THE COWL WAS REMOVED, INSPEC TED, AND THE THREE AS WELL AS OTHER CAMLOCKS, AND GROMMETS WERE REPLACED. CLOSER INSPECTION REVEALED GROMMETS TO BE WOR N, WHICH ALLOWED THE CAMLOCKS TO PULL THROUGH. THE COWL WAS REINSTALLED AND THE AIRCRAFT WAS RETURNED TO SERVICE. AIRCR AFT HOURS: 11489, CYCLES: 8993 2 L 7 2 4F 4 F RT A21EA E15NE 2004101300048 20041013 00048 EA 2004 10 13 CA040815001 1 20040808 G 5610 601R330311 WINDOW CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE LT SIDE CRACKED W A UNSCHED LANDING O OTHER CR CRUISE 1 CA (CAN) PILOT'S SIDE WINDOW CRACKED DURING CRUISE. SIDE WINDOW WAS REMOVED AND REPLACED. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2004101300049 20041013 00049 SW 2004 10 13 CA040816001 1 20040816 G 2750 19023 CONTROL CABLE BBAVIA 8 8GCBC 1220803 SW LYC O360 O360C2E 41514 EA MCAULY 1A200 1A200* GL FLAP CONTROL FRAYED W K NONE P NO WARNING INDICATION IN INSP/MAINT 1 CA (CAN) LT AND RT CABLES FRAYED AT WING ROOT PULLEYS. CABLES REPLACED WITH GALVANIZED. 1 H 7 1 3O 3 O A21CE E286 5 N P874 2004101300050 20041013 00050 EA 2004 10 13 CA040816002 2 20040816 G 7200 PW150A ENGINE BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU NR 1 FAILED W A UNSCHED LANDING Y D B ENGINE STOPPAGE INFLIGHT SEPARATION SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 CA (CAN) ON TAKE-OFF FROM BASE, AT 1000 FT, THE NR 1 ENGINE OIL PRESSURE CAUTION LIGHT CAME ON, THE PILOT WENT FOR MANUAL A ND BEFORE GETTING TO IT THE NR 1 ENGINE OIL TEMP BEGAN TO RISE RAPIDLY SO HE IMMEDIATELY STARTED TO PERFORM THE EMERGE NCY SHUT DOWN PROCEDURE. BUT BEFORE HE COULD PERFORM THE TASK THERE WAS A LOUD BANG AND FLAMES SHOT OUT OF THE INTAKE AN D THE ENGINE SHUT DOWN. THE PILOT DECLARED AN EMERGENCY AND LANDED. UPON LANDING THERE WAS A CDS MESSAGE FOR NL SHAFT SHEARED AND ALL THE CHIP DETECTORS WERE FLAGGED. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2004101300051 20041013 00051 EA 2004 10 13 CA040816003 1 20040701 G 3234 750006000 VALVE CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE NLG FAILED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA 0044 (CAN) THE NOSE GEAR WOULD NOT RETRACT AFTER TAKEOFF ACCOMPANIED BY A (GEAR DISAGREE) WARNING. NOSE LANDING GEAR DOOR SE LECTOR VALVE REPLACED LANDING GEAR OPERATION CHECK SERVICE. 2 L 7 2 4F 4 F RT A21EA E15NE 2004101300052 20041013 00052 GL 2004 10 13 CA040816004 2 20040427 G 7240 23064570 COMBUSTION LINER BELL 407 407 1182206 SW ALLSN 250C 250C47B GL ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA CAE847080 (CAN) CRACK FOUND DURING REMOVAL FOR UNRELATED SCHEDULED MAINTENANCE. 1 G 7 1 3U 3 U O H2SW E1GL 2004101300053 20041013 00053 GL 2004 10 13 CA040816005 2 20040304 G 7240 23064570 COMBUSTION LINER BELL 407 407 1182206 SW ALLSN 250C 250C47B GL ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA CAE847297 (CAN) COMBUSTION LINER FOUND CRACKED DURING TURBINE REMOVAL. NO CRACKS ALLOWED IN THIS AREA. 1 G 7 1 3U 3 U O H2SW E1GL 2004101300054 20041013 00054 2004 10 13 CA040816006 4 20040811 G 3497 WIRE HARNESS CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE ADI DAMAGED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) WHILE CARRYING OUT COMPANY CAMPAIGN NOTICE 851-34-10-24, FOUND NO DAMAGE ON THE WIRE BUNDLE FOR THE HSI. HOWEVER THERE WAS DAMAGE FOUND ON THE ADI WIRE BUNDLE. SEVERAL WIRES IN THE BUNDLE SHOWED EVIDENCE OF SHIELD DAMAGE AND ONE SING LE WIRE SHOWED EXPOSED CORE. ALL NECESSARY WIRES WERE REPAIRED AND THE AIRCRAFT WAS RETURNED TO SERVICE. 1 L 7 2 4F 4 F A22CE E1NE 2004101300104 20041013 00104 GL 2004 10 13 CA040816007 2 20040406 G 7240 23064570 COMBUSTION LINER BELL 407 407 1182206 SW ALLSN 250C 250C47B GL ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA CAE847194 (CAN) CRACK FOUND IN COMBUSTION LINER WHEN REMOVED FOR TURBINE INSPECTION. NO CRACKS ALLOWED IN THIS AREA. 1 G 7 1 3U 3 U O H2SW E1GL 2004101300105 20041013 00105 GL 2004 10 13 CA040816008 2 20040127 G 7240 23030911 COMBUSTION LINER BELL 407 407 1182206 SW ALLSN 250C 250C47B GL ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA CAE847194 (CAN) CRACKS FOUND IN OUTER COMBUSTION CASE ARMPIT AREA ON NORMAL DAILY INSPECTION. NO CRACKS ALLOWED IN THIS AREA. 1 G 7 1 3U 3 U O H2SW E1GL 2004101300106 20041013 00106 CE 2004 10 13 CA040816009 1 20040812 G 3246 950476 BEARING BEECH 99 B99 1154004 CE PWA PT6 PT6A28 EA HARTZL HCB3T HCB3TN3 GL MLG WHEEL FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) LT IB WHEEL ASSY INNER BEARING FAILED, ALLOWING WHEEL TO MOVE SUFFICIENT TO ALLOW CONTACT OF THE INNER RIM TO NON ROTATING BRAKE COMPONENTS DAMAGING INNER HALF OF WHEEL ASSY. 1 L 7 2 3T 4 T A14CE E4EA 6 C P15EA 2004101300108 20041013 00108 NE 2004 10 13 CA040817002 2 20040730 G 7532 SWITCH SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE BLEED VALVE INOPERATIVE W E ENGINE SHUTDOWN J WARNING INDICATION AP APPROACH 1 CA 47 (CAN) BLEED VALVE LIGHT MICROSWITCH CAME APART. THE BROKEN PIECES OF THE ROLLER JAMMED BETWEEN THE PLUNGER AND HOUSING P REVENTING SMOOTH BLEED VALVE BUTTERFLY OPENING AND CLOSING. BUTTERFLY WAS FOUND PARTIALLY CLOSED CAUSING COMPRESSOR STAL L WHEN ATTEMPTING THROTTLE INCREASE. BUTTERFLY WAS OPENING ENOUGH FOR BLEED VALVE LIGHT TO BE ON INDICATING IT WAS FULLY OPEN. 1 G 7 1 3U 3 U NC H9EU E19EU 2004101300109 20041013 00109 EU 2004 10 13 CA040817003 1 20040714 G 6210 355A11002009 BLADE SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE MAIN ROTOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING A 100 HOUR INSPECTION A 5.500 INCH (138MM) CRACK WAS DISCOVERED ON THE UPPER SURFACE IN ZONE C OF ONE MAIN ROTOR BLADE. THE CRACK WAS BEYOND THE LIMIT OF 100 MM FOR THIS AREA. 1 G 7 1 3U 3 U NC H9EU E19EU 2004101300110 20041013 00110 EU 2004 10 13 CA040817004 1 20040812 G 2913 S40 SPLINE SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE HYD PUMP WORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) NO LUBRICATION FOUND ON PUMP SPLINES. PUMP SPLINES WORN . NO SPLINES FOUND INSIDE THE S40 PUMP DRIVE DUE TO POOR LUBRICATION. HYDRAULIC PUMP AND S 40 DRIVE REPLACED. 1 G 7 1 3U 3 U H9EU E19EU 2004101300111 20041013 00111 EU 2004 10 13 CA040817005 1 20040811 G 2510 9593001131 SEAT PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL COCKPIT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING INSPECTION OF THE CREW SEATS IAW MFG SB 25-031, THE SEAT PANS WERE FOUND TO BE CRACKED ON THE OB FWD CORNER AREA. MFG SL 072 COVERS REPAIRS OF THE SEAT PANS IN QUESTION BUT IN A DIFFERENT AREA FOR CRACKING. BOTH THE CAPTAINS AND CO-PILOTS SEATS WERE FOUND LIKE THIS PN 959.30.01.131 AND .132 RESPECTIVELY. VENDOR PN ARE 5PC41000-505 AND -506. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004101300137 20041013 00137 SW 2004 10 13 CA040817006 1 20040816 G 5740 31692 ATTACH FITTING BBAVIA 7 7ECA 21101NN SW LYC O235 O235K2C 41505 EA SNSNCH 72C 72CK EA WING CHAFED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THE STRUT ATTACH FITTING ON FORWARD SPAR OF THE RH WING WAS CHAFED BY THE LEADING EDGE SKIN, WHICH HAD NOT BEEN TR IMMED ADEQUATELY DURING MANUFACTURE. THE CHAFING LEFT A SMALL DIMPLE THAT COULD LEAD TO CRACKING OF THE FITTING. 1 H 7 1 3O 3 O A759 E223 5 N P9045 2004101800055 20041018 00055 GL 2004 10 18 CA040817007 2 20040807 G 7314 68992253 PUMP BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL FUEL SYSTEM MALFUNCTIONED W O OTHER D INFLIGHT SEPARATION TX TAXI/GRND HDL 1 CA (CAN) ON STARTUP OF THE ENGINE THERE WAS A HOWLING NOISE COMING FROM THE ENGINE. THE NOISE WOULD ONLY BE ON STARTUP AND WOULD GO AWAY ONCE THE ENGINE WAS RUNNING. IT WAS DETERMINED THAT THE NOISE WAS COMING FROM THE FUEL PUMP AND WAS REPLA CED. 1 G 7 1 3U 3 U H2SW E4CE 2004101800056 20041018 00056 EA 2004 10 18 CA040817008 1 20040811 G 5710 600151103 STRUCTURE CNDAIR CNDAIR CL604 CL604 1900301 EA GE CF34 CF343B1 NE WINGLET TIP FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING THE POST FLIGHT INSPECTION THE RT AND LT WINGLET TIPS WERE FOUND TO BE DAMAGED BY STATIC DISCHARGE. THE RES IN MATERIAL WAS WAS BLOWN AWAY EXPOSING THE CARBON FIBERS AND LEAVING THE TRAILING EDGE FRAYED. CREW DID NOT EXPERIENCE LIGHTNING ON THE LAST TRIP BUT DID FLY IN LIGHT PRECIPITATION. THE STATIC WICKS TESTED SERVICEABLE. THE TIPS HAD EXTRA STATIC WICKS INSTALLED PREVIOUSLY IAW SB 23-006. 2 L 7 2 4F 4 F RT A21EA E15NE 2004101800057 20041018 00057 CE 2004 10 18 CA040818001 1 20040813 G 3244 178K235 TIRE LEAR 35 35A 5170602 CE GARRTT TFE731 TFE73122B 01518 WP MLG DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) PILOTS NOTICED ON THEIR WALK AROUND, DURING A FUEL STOP THAT THE RT IB MAIN TIRE HAD LOST ITS TREAD AROUND THE COM PLETE CIRCUMFERENCE OF THE TIRE AT THE SIDEWALL. 2 L 7 2 4F 4 F A10CE E6WE 2004101800058 20041018 00058 2004 10 18 CA040818002 4 20040721 G 3418 3995100208 COMPUTER CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE STALL WARNING INOPERATIVE W O OTHER F FLT CONT AFFECTED AP APPROACH 1 CA 12401 (CAN) DURING APPROACH AT 2500 FEET, THE STICK SHAKER AND STICK PUSHER WERE ENGAGED SIMULTANEOUSLY, FOLLOWING BY THE DE-C ONNECTION OF THE AUTOPILOT. THIS INDUCED A LITTLE VARIATION OF THE AIRCRAFT NOSE DOWN. THE FIRST OFFICER IMMEDIATELY CO MPENSATED THIS VARIATION. THE FLIGHT CREW PROCEEDED WITH THE LANDING WHICH OCCURRED WITHOUT FURTHER INCIDENT. STALL CO MPUTER WAS REPLACED. 2 L 7 2 4F 4 F RT A21EA E15NE 2004101800059 20041018 00059 NE 2004 10 18 CA040818003 2 20040818 G 8510 260483 SHAFT PWA PWA R2800 R2800* 52026 NE REDUCTION GEAR SHEARED W K NONE P NO WARNING INDICATION IN INSP/MAINT 1 CA (CAN) TWO PINION SHAFTS FOUND SHEARED WHEN REDUCTION GEAR SECTION REMOVED. ALL BROKEN PARTS FOUND AND ENGINE CLEANED F OR REASSEMBLY. GEAR SECTION SENT TO OVERHAUL SHOP FOR REPAIR. 4 R 5E8 2004101800091 20041018 00091 WP 2004 10 18 CA040818004 1 20040817 G 5230 DOOR CVAC 340 340CVAC 242270A WP ALLSN 501D 501D13D 03004 GL ALLSN A6441 A6441FN606 GL C1 CARGO OPEN W A UNSCHED LANDING W J INADEQUATE Q C WARNING INDICATION CL CLIMB 1 CA (CAN) AFTER TAKEOFF, CREW NOTICED A (CARGO DOOR UNSAFE) LIGHT AND THE A/C WAS NOT PRESSURIZING. THE A/C RETURNED TO THE AIRPORT WHERE THE UPPER FWD CARGO DOOR WAS FOUND UNLOCKED. DOOR WAS LOCKED AND A/C CONTINUED ON FLIGHT. 2 L 7 2 4R 4 T 6A6 E282 6 C P898 2004101800095 20041018 00095 EU 2004 10 18 CA040818005 1 20040511 G 3260 UC702322 LEVER BRAERO 748 HS7482A 4231001 EU RROYCE DART DART5342 EU ROTOL R4304 R2124304 EU NLG OBSTRUCTED W A UNSCHED LANDING N FALSE WARNING CL CLIMB 1 CA (CAN) THE NOSE U/C INDICATOR LIGHT REMAINED GREEN DURING ALL PHASES OF U/C OPERATION. INVESTIGATION REVEALED A SMALL ST ONE WEDGED UNDER THE SWITCH OPERATING LEVER. WITH THE STONE REMOVED THE INDICATION SYSTEM WORKED NORMALY. 2 L 7 2 3T 4 T A24EU A196 6 C P899 2004101800096 20041018 00096 EU 2004 10 18 CA040818006 2 20040517 G 8560 AGS6056 CLAMP BRAERO 748 HS7482A 4231001 EU RROYCE DART DART5342 EU ROTOL R4304 R2124304 EU SUPERCHARGER LOOSE W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) AN INTERMITTENT BURNING SMELL WAS NOTICED BY THE FLIGHT CREW. INVESTIGATION REVEALED THE RT AIR CONDITIONING SUPER CHARGER OUTLET DUCT SLEEVE CLAMP WAS LOOSE. SINCE THE CLAMP WAS RESECURED THERE HAVE BEEN NO FURTHER REPORTS OF BURNING ODORS IN THE COCKPIT. 2 L 7 2 3T 4 T A24EU A196 6 C P899 2004101800097 20041018 00097 NE 2004 10 18 CA040818008 2 20040812 G 7230 305309CL1 SEGMENT CESSNA 208 208B 2073701 CE PWA PT6 PT6A114A 52043 NE MCAULY 3AF34C 3GFR34C703 GL COMPRESSOR TURB SHIFTED W A UNSCHED LANDING J M WARNING INDICATION OVER TEMP CL CLIMB 1 CA (CAN) WHILE INCREASING POWER FOR CLIMB, THE PILOT NOTICED AN ITT OVERTEMP INDICATION. AIRCRAFT RETURNED TO AIRPORT UNDER REDUCED POWER TO REMAIN BELOW MAXIMUM CONTINUOUS ITT. MAINTENANCE SPLIT THE ENGINE AND FOUND THAT A SHROUD SEGMENT HAD SHIFTED AND CONTACTED THE COMPRESSOR TURBINE BLADES CAUSING CONSIDERABLE LOSS OF BLADE TIP MATERIAL AND DISCOLORATION. E NGINE REMOVED FOR OVERHAUL AND FURTHER INVESTIGATION. 1 H 7 1 3T 3 T A37CE E4EA 5 C P60GL 2004101800098 20041018 00098 NE 2004 10 18 CA040818009 2 20040817 G 7420 10878451 LEAD R2800CB3 DOUG DC6 DC6B 3021712 WP PWA R1340 CWASP 52016 NE HAMSTD 43E 43E60 NE ENGINE BROKEN W E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA P33489 (CAN) DURING TAKEOFF FOR A PRACTICE, NR 2 ENGINE BACKFIRED. THE LOAD OF WATER WAS JETTISONED, THE ENGINE WAS SHUTDOWN AN D THE PROPELLER WAS FEATHERED. THE AIRCRAFT RETURNED TO BASE. UPON INVESTIGATION BY MAINTENANCE CREW, A BROKEN LOW TENSI ON IGNITION LEAD WAS FOUND. THE LEAD WAS REPLACED. THE AIRCRAFT WAS RETURNED TO SERVICE. 2 L 7 4 4R 3 R 6A4 ATC14 6 C P871 2004101800099 20041018 00099 SO 2004 10 18 CA040819001 2 20040610 G 7322 MA3SPA CARBURETOR CESSNA 172 172H 2072424 CE CONT O300 O300D 17022 SO MCAULY 1C172 1C172EM GL ENGINE FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ENGINE REPORTED RUNNING INTERMITTENTLY. MIXTURE OPERATES ONLY THROUGH LIMITED RANGE. INSPECTION REVEALS LARGE MOUS E NEST IN AIR BOX AND CARBURETOR AS FAR AS VENTURI. SEVEN DEAD INFANT MICE FOUND IN NEST. ENTRY TO CARB THROUGH CABIN HEATER DUCTING. AIRCRAFT LAST FLOWN APRIL 3, 2004. SOLUTION: ENSURE CABIN HEAT CONTROL IN CLOSED POSITION. 1 H 7 1 3O 3 O NT 3A12 E253 5 N P910 2004101800100 20041018 00100 SW 2004 10 18 CA040819002 1 20040808 G 6220 206011139001 RESTRAINT BELL BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL ROTOR HEAD DELAMINATED W K NONE O OTHER IN INSP/MAINT 1 CA AAB05286 (CAN) DURING DAILY INSPECTION IT WAS NOTED THE FLAP RESTRAINT HAD BECOME DELAMINATED AT BEARING HOUSING. 1 G 7 1 3U 3 U H2SW E4CE 2004101800101 20041018 00101 NM 2004 10 18 CA040819003 1 20040729 G 3232 69378776 FITTING BOEING 737 737275 1384485 NM PWA JT8 JT8D17 52049 NE MLG ACTUATOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 50515 36641 (CAN) CRACKED FITTING FOUND DURING CPCP INSPECTION. RT MAIN LANDING GEAR ACTUATORS WING LINK FORWARD ATTACH FITTING (TO WING REAR SPAR ATTACH). 2 L 7 2 4F 4 F A16WE E2EA 2004101800121 20041018 00121 CE 2004 10 18 CA040819004 1 20040807 G 5210 NAS51733 SCREW BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA MCAULY 4HFR34 4HFR34C754 NE DOOR LATCH BENT W B EMER. DESCENT D INFLIGHT SEPARATION CR CRUISE 1 CA (CAN) WHILE IN CRUISE OF FL270 THE PILOT HEARD A BANG AND EXPERIENCED A PARTIAL LOSS OF PRESSURIZATION. HE INITIATED AN EMERGENCY DESCENT AND LANDED AT DESTINATION WITHOUT INCIDENT. UPON INVESTIGATION IT WAS NOTED THAT THE FORWARD UPPER LAT CH PLATE HAD SHIFTED AND THAT ONE OF THE FOUR ATTACH SCREWS WAS MISSING. THE REMAINING THREE SCREWS, ONE WAS BENT. THER E WERE NO VISIBLE IDENTIFICATION MARKINGS ON THE REMAINING SCREWS BUT THEY APPEAR TO BE AN507 SCREWS RATHER THAN THE REQ UIRED NAS517. THE FORWARD UPPER LATCH HOOK BELLCRANK, P/N 50-430031-15, WAS ALSO DAMAGED. 1 L 7 2 4T 4 T A24CE E4EA 6 C 3PNE 2005031100013 20050311 00013 EU 2005 3 11 CA040819005 1 20040721 G 7931 704A37642043 PRESSURE SENSOR SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE ENGINE OIL FAILED W K NONE J WARNING INDICATION IN INSP/MAINT 1 CA (CAN) OIL PRESSURE NO READING. REPLACED ENGINE OIL PRESSURE SENSOR. 1 G 7 1 3U 3 U NC H9EU E19EU 2005031100023 20050311 00023 NM 2005 3 11 CA040819006 1 20040818 G 5330 SKIN BOEING 737 737201 1384454 NM PWA JT8 JT8D9A 52048 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING ROUTINE CHECK A 2.7500 INCH CRACK WAS FOUND ON THE OUTER FUSELAGE SKIN AT FS 847 STRINGER 24L. CRACK REPAI RED IAW SRM REV 85.53-30-3,FIG 48 SHT 33. TIMES 59257.06 CYCLES 55392. 2 L 7 2 4F 4 F A16WE E2EA 2005041500017 20050415 00017 SO 2005 4 15 CA040819007 2 20040812 G 8520 654101A7R CRANKCASE CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO HARTZL HCJ3Y PHCJ3YF1 GL ENGINE FAILED W K NONE O OTHER IN INSP/MAINT 1 CA 291429R A/C ENG CRANKCASE FAILURE AS A RESULT OF A RECENT FAILURE DESCRIBED IN SDR CA040806006 SUBMITTED 08/6/2004, A VOLUNTARY INSPECTION CARRIED OUT BY OPERATOR AT REQUEST OF OVERHAUL FACILITY. CYLINDERS NR 1 & 3 REMOVED SO THAT NR 2 & 3 INTERMED IATE BEARING SADDLE COULD BE VIEWED. INSPECTION CONCLUDED THAT MOVEMENT OF BEARINGS HAD OCCURRED & TEAR DOWN OF ENG WOU LD BE REQUIRED FOR FURTHER INVESTIGATION. UPON TEAR DOWN, FOUND FRETTING OF CRANKCASE ON NR 2 & NR 3 INTERMEDIATE MAIN BEARING THRU-BOLT PADS. 1 H 7 1 3O 3 O A4CE E5CE 5 C P36EA 2005031400065 20050314 00065 EA 2005 3 14 CA040819008 2 20040809 G 8530 LW11485 HOUSING CESSNA 182 R182 2072734 CE LYC O540 O540J3C5 41532 EA MCAULY 2D34C B2D34C214 GL PUSHROD LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA L2037340A (CAN) ON INSPECTION, LT ENGINE SIDE FOUND VERY OILY, AFTER CLEANING, RUN UP TEST C/O AND OIL LEAK FOUND ON NR2 INTAKE VA LVE PUSH ROD HOUSING. A SMALL PIN HOLE FOUND ON THE TUBE (VISIBLE ONLY WITH A MAGNIFYING GLASS). NEW TUBE P/N LW11485 INSTALLED, OPERATIONAL TEST C/O AND NO LEAK NOTED. 1 H 7 1 3O 3 O RT 3A13 E295 5 C P7EA 2005041500018 20050415 00018 EA 2005 4 15 CA040819009 2 20040804 G 7200 ENGINE PWA PT6 PT6A50 52043 EA LACK OF LUBE W K NONE O OTHER IN INSP/MAINT 1 CA 23405 86034GG ENG REMOVED FROM WING WHEN OPERATOR FOUND BETA CONTROL SYSTEM JAMMED. ENG SHIPPED TO ENGINE AMO FOR INVESTIGATION & REP AIR. SEIZED BETA CONTROL LINKAGE RESULT OF HEAVY CONTACT WEAR BETWEEN REAR SEALING LAND OF BETA TRANSFER SLEEVE & PROP S HAFT. REASON FOR SEIZURE WAS A LACK OF LUBE. 4 T E4EA 2005031400066 20050314 00066 EU 2005 3 14 CA040819010 1 20040818 G 3411 853BR PROBE FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE PITOT UNSERVICEABLE W C ABORTED TAKEOFF J WARNING INDICATION TO TAKEOFF 1 CA (CAN) NO AIRSPEED INDICATION ON F/O SIDE DURING T/O. T/O REJECTED. MAINTENANCE DID A PITOT/STATIC TESTED AND SYSTEM FOUN D NORMAL. BOTH ADC COMPUTER INTERCHANGED FORT/S. THE FOLLOWING T/O WAS ALSO REJECTED FOR THE SAME REASON. MAINTENANCE F OUND THE RT F/O INTERNAL PITOT PROBE CONTAMINATED WITH RUST. THE PITOT PROBE WAS REPLACED AND AIRCRAFT DISPATCHED SERVI CEABLE. 2 L 7 2 4F 4 F RT E25NE 2005031400067 20050314 00067 NM 2005 3 14 CA040819011 1 20040813 G 2910 SM601BA20A1 RCCB DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE HYD SYSTEM INOPERATIVE W K NONE L NO TEST IN INSP/MAINT 1 CA (CAN) THE NR 2 STANDBY HYD PUMP WOULD NOT COME ON LINE WHEN SELECTED. THE CAUSE WAS DETERMINED TO BE A FAILED REMOTE CON TROL CIRCUIT BREAKER. THE UNIT HAD ONLY 24.7 HOURS. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005031400068 20050314 00068 WP 2005 3 14 CA040819012 1 20040805 G 3150 WARNING SWITCH DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE TAIL CONE INCORRECT W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) DURING CLIMB, TAIL CONE ANNUNCIATOR UNSAFE LIGHT WENT ON. AIRCRAFT LANDED BACK TO DEPARTING AIRPORT. MAINTENANCE FOUND THE TAIL CONE SAFETY LOCK CABLE BALL END NOT SEATED PROPERLY TO CONTACT THE WARNING SWITCH. THE INVESTIGATION RE VEALED THAT AN INSPECTION/TEST OF TAIL CONE RELEASE MECHANISM WAS PERFORMED ON THE PREVIOUS DAY. IT HAS BEEN CONCLUDED THAT THE WARNING SWITCH WAS NOT PROPERLY ENGAGED. 2 L 7 2 4F 4 F RT A6WE E9NE 2005031400069 20050314 00069 WP 2005 3 14 CA040819013 1 20040817 G 2910 9036261 LINE CVAC 440 440 2422902 WP ALLSN 501D 501D13D 03004 GL ALLSN A6441 A6441FN606 GL HYD PRESS RUPTURED W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA (CAN) AC WAS ORBITING OVER FIRE. A LOUD SURGING SOUND WAS HEARD. A CHECK OF HYDRAULIC RESERVOIR INDICATED THAT NO HYDRA ULIC FLUID WAS REMAINING. FLAPS WERE SELECTED FROM 15 TO 0 DEGREES. HYD BYPASS WAS SELECTED UP. RETARDANT LOAD WAS JETT ISONED. AC RETURNED TO BASE. FLAPS WERE SELECTED TO 15 DEGREES, GEAR WAS SELECTED DOWN. UPON LANDING A VIOLENT NOSE WHEE L SHIMMY WAS EXPERIENCED. EMERGENCY AIR BRAKE SYS WAS USED TO BRING AC TO A STOP. NO DC PUMP PRESSURE WAS AVAILABLE DUE TO FLUID LOSS. AC STOPPED SAFELY. UPON INVESTIGATION BY THE MAINT, MAIN HYDR PRESS LINE WAS FOUND BURST CAUSING FLUID LO SS. LINE WAS REPLACED WITH A SERVICEABLE COMPONENT. AC SYSTEM WAS LEAK CHECKED AND THE AC WAS RETURNED TO SERVICE. 2 L 7 2 4R 4 T 6A6 E282 6 C P898 2005031400070 20050314 00070 CE 2005 3 14 CA040820001 1 20040818 G 3510 2519C5912 LINE LEAR 35 35A 5170602 CE GARRTT TFE731 TFE73122B 01518 WP OXYGEN SYS CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHILE SERVICING THE TAIL MOUNTED OXYGEN BOTTLE, AFTER REPLACEMENT OF THE FILLER FITTING, AT ABOUT 300 PSI A LEAK W AS HEARD AND SMALL FLAME SEEN AT THE LINE LEADING TO THE CABIN, FORWARD OF THE BOTTLE. SYSTEM TURNS OFF. THE LINE HAD THREE CRACKS ON THE B-NUT FITTING. LINE REPLACED. 2 L 7 2 4F 4 F A10CE E6WE 2005031400078 20050314 00078 2005 3 14 CA040820002 4 20040815 G 2397 FIN6208VC CONNECTOR AIRBUS 330 A330243 3930330 EU RROYCE RB211 RB211TRENT77 NE LCD MONITOR BURNED W K NONE H M ELECT. POWER LOSS-50 PC OVER TEMP IN INSP/MAINT 1 CA (CAN) AIRCRAFT ARRIVED WITH AN INOPERATIVE LCD MONITOR FOR PASSENGER ENTERTAINMENT SYSTEM. AFTER INVESTIGATION, FOUND O NE OF THE ENTERTAINMENT CONNECTORS BADLY BURNED WITH SEVERAL PINS COMPLETELY GONE, IN THE PASSENGER COMPARTMENT CEILING. CONNECTOR WAS REPLACED AND COMPLETE SYSTEM WAS VERIFIED. A FLEET CAMPAIGN WAS INITIATED AND A ROUTINE INSPECTION WAS INTRODUCED IN THE A CHECK MAINTENANCE PROGRAM. 2 L 7 2 4F 4 F RT A46NM E39NE 2005041500019 20050415 00019 SW 2005 4 15 CA040820003 1 20040818 G 6100 SHAFT GULSTM 690TP 690 0141720 SW GARRTT TPE331 TPE3315251K NM HARTZL HCB3T HCB3TN5 GL PROPELLER SEIZED W A UNSCHED LANDING E D J VIBRATION/BUFFET INFLIGHT SEPARATION WARNING INDICATION CR CRUISE 1 CA P40355 (CAN) RETURNING FROM A FIRE ACTION, IN CRUISE AT 9500 FEET ASL, THERE WAS A LOSS OF POWER FROM THE RT ENGINE ACOMPANIED BY VIBRATION AND NOISE. THE RT ENGINE SHUT DOWN, THE PILOT COMPLETED THE EMERGENCY CHECK LIST AND ACCOMPLISHED AN UNEVE NTFUL LANDING. MAINTENANCE FOUND THE PROP SHAFT SEIZED AND A HOLE IN THE PROP REDUCTION GEARBOX. 1 H 7 2 3T 4 T 2A4 E2WE 6 C P15EA 2005041500020 20050415 00020 WP 2005 4 15 CA040820004 1 20040817 G 6320 C0066 TRANSMISSION ROBSIN R44 R44 7640120 WP LYC O540 O540F1B5 41532 EA MAIN ROTOR NOISY W O OTHER E VIBRATION/BUFFET LD LANDING 1 CA (CAN) DURING LANDING THE HEARD GRINDING NOISE. FURTHER INVESTIGATION REVEALED NOISE WAS COMING FROM MAIN ROTOR TRANSMIS SION. TRANSMISSION WAS REPLACED AND NO FURTHER OCCURRENCES AND WILL SUBMIT FURTHER INFORMATION WHEN TEAR DOWN OF TRANSMI SSION REPORT BECOMES AVAILABLE. 1 G 7 1 3O 3 O H11NM E295 2005041500021 20050415 00021 NE 2005 4 15 CA040820005 2 20040818 G 8530 CYLINDER DOUG A26 A26CSHIELDS 3020506 WP PWA R2800 R280079 52026 NE HAMSTD 23E 23E50 NE ENGINE CRACKED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA FP028246 (CAN) DURING A FOREST FIRE ACTION, THE PILOT NOTICED AN OIL LEAK COMING FROM THE TOP OF THE LT ENGINE. SHUT THE ENGINE DOWN AND RETURNED TO THE FIELD MAINTENANCE BASE WITH OUT INCIDENT. MAINTENANCE FOUND TWO CRACKED CYLINDERS. THEY CHANGED THE CYLINDERS AND GROUND CHECKED THE ENGINE AND FOUND IT TO BE SERVICEABLE. 2 M 7 2 4R 4 R L34 5E8 6 C P603 2005041500022 20050415 00022 WP 2005 4 15 CA040820006 1 20040726 G 2410 GENERATOR DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE RIGHT OVERHEATED W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA (CAN) RT GEN FAILED DURING TAXI TO GATE. GEN DISCONNECTED & QRH PROCEDURE COMPLETED BY CREW. FOR FOLLOWING FLT, A/C DI SPATCHED IAW MEL 24-1. 4 HOUR FLT CONDUCTED TO NEXT STA & ON ARRIVAL, MX NOTICED SMOKE COMING FROM NR 2 ENG. INVEST RE VEALED PAINT BLISTERING ON LOWER COWL IN VICINITY OF GEN. A/C GEN FOUND SMOLDERING & EMITTING HIGH LEVELS OF HEAT & GEN HOUSING FOUND DISCOLORED. CSD NOT DISCONNECTED & IS NOT REQUIRED TO BE DISCONN IAW QRH & MEL PROCEDURES. WITHOUT DISCO NNECTING DRIVE, GEN WILL CONTINUE TO SPIN. TO AVOID SUCH THIS, OPS WILL REVISED QRH & MEL PROCEDURES IN ORDER TO DISCONN ECT CSD FOLLOWING GEN DISCONNECT. 2 L 7 2 4F 4 F RT A6WE E9NE 2005041500023 20050415 00023 NE 2005 4 15 CA040820007 2 20040729 G 7261 FILTER DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE ENGINE OIL CLOGGED W C ABORTED TAKEOFF J WARNING INDICATION TO TAKEOFF 1 CA 36699 (CAN) DURING TAKE OFF ROLL, RT ENG OIL FILTER CLOG LIGHT ILLUMINATED. TAKE OFF WAS REJECTED. ENGINE RUN UP CONDUCTED WIT H NO LIGHT REILLUMINATED. AIRCRAFT TOOK OFF AND THEN FLOWN TO THE SCHEDULED STATION ( MAIN BASE ) WITHOUT LIGHT REILLUM INATING. AT THE MAIN BASE, THE OIL FILTER WAS REMOVED AND FOUND WITH CARBON DEPOSIT. NEW OIL FILTER INSTALLED. THE ENG INE HAS BEEN SCHEDULED TO BE REPLACED AS PRECAUTIONARY BECAUSE THIS PROBLEM IS RECURRENT. 2 L 7 2 4F 4 F RT A6WE E9NE 2005041500024 20050415 00024 SW 2005 4 15 CA040821001 1 20040820 G 6420 212010783101 SPHERICAL BEARIN BELL 205 205A1 1181414 SW LYC T53 T5313B 41549 NE T/R PITCH LINK FAILED W B EMER. DESCENT F FLT CONT AFFECTED CL CLIMB 1 CA (CAN) A/C WAS CLIMBING AFTER FILLING THE WATER BUCKET WHEN HE LOST COMPLETE TAIL ROTORAUTHORITY.THE A/C MADE SEVERAL 360 DEGREE TURNS AFTER COMING TO REST IN A CON FINED AREA. SUBSTANTIAL DAMAGE WAS DONE TOTHE MAIN ROTOR BLADES AS THEY STRU CK A TREE UPON LANDING.ONE OF THE TAIL ROTOR PITCH LINKS WAS FOUND TO HAVE AN EXTREMELY WORN OFF SPHERICAL BEARING WHICH LED TO THE PITCH LINK SHIFTING CLOSE TO THE TRUNNION. THE PITCH LINK LEFT SEVERAL MARKS ON THE TRUNNION BEFORE IT WAS J AMMED BETWEEN THE PITCHHORN AND THE TRUNNION DURING T/R PITCH CHANGE WHICH LED TO THE PITCH LINK BREAK ING CLEAN OFF. 1 G 7 1 4U 4 U H1SW E17EA 2005041500025 20050415 00025 NM 2005 4 15 CA040823001 1 20040820 G 2910 82910009123 LINE DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE HYD SYSTEM CRACKED W O OTHER K B J FLUID LOSS SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION AP APPROACH 1 CA (CAN) DURING FINAL APPROACH, PILOT REPORTED SMOKE IN COCKPIT AND PERFORMED AN UNEVENTFUL EMERGENCY LANDING. THE 'SMOKE' REVEALED TO BE HYDRAULIC FLUID MIST, WHICH SPREAD ALL OVER IN THE COCKPIT. ON GROUND WE FOUND A HYDRAULIC LINE BELOW THE COCKPIT CRACKED NEAR THE BEND RADIUS. BOMBARDIER AEROSPACE IS INVESTIGATING THIS EVENT. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004101300028 20041013 00028 WP 2004 10 13 CA040823002 1 20040819 G 7921 D6752110 CIRCUIT BREAKER CVAC 440 440 2422902 WP ALLSN 501D 501D13D 03004 GL OIL COOLER DOOR STICKING W E A ENGINE SHUTDOWN UNSCHED LANDING M J OVER TEMP WARNING INDICATION CR CRUISE 1 CA (CAN) DURING CRUISE THE OIL TEMPERATURE ON THE LT ENGINE CLIMBED TO LIMITS. THE OIL COOLER DOOR WAS NOT OPERATING. THE E NGINE WAS SHUT DOWN AND THE PROPELLER WAS FEATHERED AS A PRECAUTION. THE AIRCRAFT RETURNED TO BASE. UPON INVESTIGATION B Y MAINTENANCE THE CIRCUIT BREAKER WAS EXERCISED AND THE SYSTEM OPERATED NORMALLY. A CIRCUIT BREAKER WAS SHIPPED AND THE BREAKER WAS REPLACED. THE AIRCRAFT WAS RETURNED TO SERVICE. 2 L 7 2 4R 4 T 6A6 E282 2004101300076 20041013 00076 WP 2004 10 13 CA040823003 1 20040820 G 2150 20495055 ACM DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE LEFT SEIZED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) FLOW LIGHT (PRESSURIZATION) CAME ON AFTER TAKEOFF. AIRCRAFT LANDED BACK FROM DEPARTURE. MAINTENANCE FOUND ONE CL AMP NOT PROPERLY INSTALLED ON OUTLET OF LT ACM. ACM WAS PREVIOUSLY REPLACED FOLLOWING DISCREPANCY. CLAMP HAS BEEN SEC URED FOLLOWED WITH PRESSURIZATION TEST AND AIRCRAFT DISPATCHED SERVICEABLE. A SECOND AIR TURNBACK HAPPENED THE FOLLOWI NG DAY FOR THE SAME REASON (PRESSURE FLOW LIGHT ON). MAINTENANCE FOUND THE LT ACM SEIZED. ACM HAS BEEN REPLACED. ACM IS UNDER INVESTIGATION. 2 L 7 2 4F 4 F RT A6WE E9NE 2004101300077 20041013 00077 EA 2004 10 13 CA040823004 2 20040820 G 7322 MA4SPA CARBURETOR SLNSBY T67 T67C EU LYC O320 O320D2A 41508 EA SNSNCH 74D 74DM EA ENGINE FAILED W B EMER. DESCENT E VIBRATION/BUFFET CR CRUISE 1 CA (CAN) DURING A LOCAL FLIGHT, PILOT REPORTED THAT THE THROTTLE WAS BINDING. AIRCRAFT LANDED SAFELY. THE MAINTENANCE INVES TIGATION INDICATED THAT THE CARBURETOR BUTTERFLY VALVE WAS EXTREMELY STIFF. THIS CARBURETOR WAS INSTALLED PRIOR TO THIS FLIGHT AND UPON RUN UP SHOWED NO STIFFNESS OR BINDING. THE CARBURETOR IN QUESTION AND THE ONES IN STORES FROM THE SAME R EPAIR/OVERHAUL SHOP WERE SENT BACK FOR INVESTIGATION AND CONFIRMATION OF AIRWORTHINESS. WE WILL SUBMIT AN ATTACHMENT TO THIS SDR, AS SOON AS WE GET THE RESULTS FROM THE REPAIR/OVERHAUL SHOP. 1 L 7 1 3O 3 O NT A73EU E274 5 N P88614 2004101300078 20041013 00078 NE 2004 10 13 CA040823005 2 20040804 G 7200 ENGINE DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE ODOR W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) AUGUST 04, AIRCRAFT, EN ROUTE, DIVERTED TO NEAREST ALTERNATE AIRPORT. WHEN THE CABIN CREW REPORTED A BURNING SMEL L (PLASTIC) IN THE AFT RT CABIN NEAR THE LAVATORY. MAINTENANCE PERSONNEL OPENED THE AISLE CEILING, REMOVED THE TOILET SHROUD (BOLSTER), OPENED THE LAVATORY CEILING AND THEN CARRIED OUT A HIGH POWER RUN WITH PACKS ON, IN ORDER TO DUPLICATE THE SMELL, NO BURNING SMELL WAS DETECTED. AS A PRECAUTIONARY MEASURE A TECHNICIAN BOARDED THE AIRCRAFT FOR THE REMAIND ER OF THE FLIGHT. NO FINDINGS WERE REPORTED. 2 L 7 2 4F 4 F RT A6WE E9NE 2004101300079 20041013 00079 NM 2004 10 13 CA040823006 1 20040709 G 2910 LINE DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE HYD SYSTEM FAILED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) AFTER ENGINE SHUT DOWN AT THE GATE, HYDRAULIC FLUID WAS NOTED LEAKING FROM THE NOSE GEAR AREA. NOSE GEAR DRAG STRU T ACTUATOR HOSE REPLACED DUE TO LEAKING P/N DSC252B40124. DAMAGE FOUND TO BRAIDING JUST AFT OF THE COLLAR DEFECT NR 416 542. GEAR RETRACTION CHECKS COMPLETED AND NO LEAKS DETECTED. AIRCRAFT RETURNED TO SERVICE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004101300080 20041013 00080 EA 2004 10 13 CA040823007 2 20040810 G 7414 D4RN3000 MAGNETO CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA MCAULY 1C160 1C160DTM GL ENGINE MIGRATED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) ATTACH NUTS ON CLAMP BLOCK WERE TIGHT. MAGNETO ROTATED TO CAUSE RPM DROP. THE MAGNETO HAD 386.6 HOURS SINCE LAST REMOVAL. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2005020700005 20050207 00005 CE 2005 2 7 CA040823BB 1 20040820 G 5343 1216012 FITTING CESSNA 206 U206B 2073322 CE MCAULY 3A32C D3A32C90 GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING THE 100 HOUR INSPECTION THE RH MAIN GEAR OUTBOARD FITTING WAS FOUND CRACKED AT THE UPPER AFT RADIUS OF THE FITTING OPENING.THE FITTING WAS REPLACED IN ACCORDANCE WITH CESSNA'S RECOMMENDATIONS (OBTAINED FROM CESSNA) WITH A USED SERVICEABLE CUSTOMER SUPPLIED UNIT AFTER NDT INSPECTION. 1 H 7 1 3O A4CE 5 C P21EA 2004101300081 20041013 00081 NM 2004 10 13 CA040824001 1 20040427 G 3297 461515 WIRE HARNESS BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R320 CR3204123F1 GL MLG DAMAGED W O OTHER O OTHER CL CLIMB 1 CA (CAN) UNABLE TO RETRACT NOSE GEAR AFTER TAKE OFF. GEAR RECYCLED, WITH UNSUCCESSFUL RESULT. NO AMBER GEAR DOOR LIGHT PR ESENT FOR NOSE GEAR DOORS WHEN GEAR IN TRANSITION. HARNESS ASSY WOW NR 2/CENTER REPLACED ACC AMM 32-21-11. OPERATIONAL TEST OF THE LANDING GEAR SYSTEM PERFORMED ACC 32-31-00-710-801. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P5NE 2004101300082 20041013 00082 NM 2004 10 13 CA040824002 1 20040505 G 3234 483001 SELECTOR VALVE BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R320 CR3204123F1 GL LANDING GEAR MALFUNCTIONED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) AFTER TAKEOFF WHEN SELECTING GEAR UP, ALL GEAR INDICATIONS WAS TRANSIT, RED AND YELLOW. GEAR SELECTED DOWN, GAVE 3 GREEN SAFE INDICATIONS. GEAR SELECTED UP AGAIN GAVE MAIN GEAR UP INDICATIONS, BUT NOSE GEAR WAS STILL SHOWING TRANSIT, RED AND YELLOW. GEAR WAS AGAIN SELECTED DOWN, GIVING 3 SAFE INDICATIONS, AND A/C RETURNED TO BASE FOR NORMAL LANDING. TA XI TO GATE REVEALED NO UNUSUAL INDICATIONS. LANDING GEAR SELECTOR VALVE REPLACED ACC AMM 32-31-06. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P5NE 2004101500079 20041015 00079 NM 2004 10 15 CA040824003 1 20040512 G 3260 401020101 SENSOR BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU NLG LOCKED FAILED W O OTHER O OTHER TX TAXI/GRND HDL 1 CA (CAN) ON GROUND, WHILE PREPARING FOR THE RETURN FLIGHT WITH ENGINES OFF AND GPU CONNECTED, GEAR UNSAFE LIGHT FOR NOSEWHE EL AND LANDING GEAR SELECTOR LIGHTS FLASHED ONCE OR TWICE AND WENT OUT. NOSE GEAR WAS EXAMINED DURING PFI WITH NO REMAR KS. DURING START UP NOSE GEAR ADVISORY LIGHT AND GEAR UNSAFE LIGHT CAME ON INTERMITTENTLY SEVERAL TIMES AND WE COULD HE AR THE GEAR DOORS OPEN AND CLOSE. THIS WAS CONFIRMED BY THE GROUND PERSONAL. NOSE GEAR LOCK NR 1 SENSOR REPLACED ACC AM M 32-61-06. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2004101800060 20041018 00060 NM 2004 10 18 CA040824004 1 20040519 G 3260 401020101 PROXIMITY SENSOR BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU NLG OPEN W C ABORTED TAKEOFF O OTHER TO TAKEOFF 1 CA (CAN) AFTER GEAR UP SELECTION PILOTS RECEIVED BOTH SAFE AND UNSAFE LIGHTS (GREEN/RED) ON GEAR INDICATION PANEL BUT NO DO OR LIGHTS (ORANGE). AFTER ONE RECYCLE PILOTS LEFT THE GEAR DOWN WITH 3 GREEN LIGHTS AND PROCEEDED TO DESTINATION. PROX IMITY SENSOR ELECTRONIC UNIT (PSEU) CONSULTED FOR FAULTS. (NWCENT PROX SENSOR OPEN) FOUND PRESENT. NOSE WHEEL CENTERING PROXIMITY SENSOR REPLACED ACC AMM 32-61-06. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2004101800061 20041018 00061 2004 10 18 CA040824005 4 20040824 G 2312 6226152001 TRANSCEIVER BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE NR 1 COMMS UNSERVICEABLE W O OTHER B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA (CAN) AFTER CLEARING RUNWAY AND PROCEEDING WITH AFTER LANDING CHECKS COMM NR 1 STARTED TO SMOKE. CAPTAIN STOPPED THE A IRCRAFT AND CALLED FROM ELECTRICAL SMOKE CHECKLIST. LIST COMPLETED, THE AVIONICS WAS SHUT DOWN, AND THE SMOKE CEASED. COMM NR 1 ISOLATED BY PULLING THE CIRCUIT BREAKER AND THE AVIONICS WAS RESTORED TO CONTACT ATC. EMERGENCY VEHICLES ES CORTED A/C TO GATE. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2004101800062 20041018 00062 CE 2004 10 18 CA040825001 1 20040817 G 7120 04112816 BRACKET CESSNA 170 170B 2072306 CE CONT O300 O300A 17022 SO MCAULY 1A175 1A175DM GL ENGINE MOUNT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) CHANGED LT UPPER ENGINE RAIL BRACKET. PN 0411281-6 REPLACED WITH NEW PART. NEW HARDWARE USED. 1 H 7 1 3O 3 O A799 E253 5 N P857 2004101800063 20041018 00063 CE 2004 10 18 CA040825002 1 20040406 G 5551 07321014 BRACKET CESSNA 185 A185F 2072821 CE CONT O520 IO520D 17032 SO MCAULY 2A34C D2A34C58 GL HORIZONTAL STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) REPAIRED HORIZONTAL STABILIZER. AFT ATTACHMENT POINT REINFORCEMENT BRACKETS 0732101-4 AND 0732106 REPLACED WITH N EW PARTS. ADJACENT RIVETS REPLACED. TAIL REASSEMBLED. 1 H 7 1 3O 3 O 3A24 E5CE 5 C P3EA 2004101800094 20041018 00094 CE 2004 10 18 CA040825003 1 20040506 G 5510 07321014 BRACKET CESSNA 180 180H 2072618 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C203 GL HORIZONTAL STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) TAIL REMOVED TO CHANGE BROKEN BRACKETS. PN 0712302-1 LT BRACKET AND 0732101-4 REINFORCEMENT REPLACED WITH NEW PAR TS. ADJACENT RIVETS REPLACED. TAIL REASSEMBLED AND DUAL INSPECTED. 1 H 7 1 3O 3 O 5A6 E273 5 C P3EA 2005012400034 20050124 00034 CE 2005 1 24 CA040825004 1 20040805 G 5520 051042 BRACKET CESSNA 170 170B 2072306 CE LYC O360 IO360A1A 41514 EA MCAULY 1A200 1A200DFA GL LT ELEVATOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ELEVATOR REMOVED TO CHANGE BRACKET. CHANGED LT ELEVATOR BRACKET. PN 051042 REPLACED WITH NEW PART. ADJACENT RIV ETS REPLACED. REASSEMBLED AND DUAL INSPECTED. 1 H 7 1 3O 3 O A799 1E10 5 N P874 2005012400035 20050124 00035 NE 2005 1 24 CA040825005 2 20040824 G 7261 CAP CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE OIL FILTER DEBONDED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 723 (CAN) WHEN (OIL) FILTER WAS RUN THROUGH THE BACK FLUSH MACHINE - ON THE FIRST CYCLE OF AIR AGITATION, THE FILTER SCREENS EXPANDED AND THE TOP BECAME DETACHED. THERE WAS NO SIGN OF EXCESSIVE CONTAMINATION NOR WAS THE MACHINE MALFUNCTIONING. ANOTHER FILTER WAS INSTALLED IN THE BACK FLUSH MACHINE AND OPERATED NORMALLY. IT APPEARED THAT THE BOND JOINT BETWEEN TH E FILTER SCREENS AND THE FILTER CAP FAILED LEAVING NO ADHESIVE ON THE CAP. THE NEW FILTER INSTALLED IN THE ENGINE WAS CO NSTRUCTED WITH A MACHINED CAP UNLIKE THE FAILED FILTER WHICH HAD A PRESSED ON CAP. 1 L 7 2 4F 4 F A22CE E1NE 2005020100025 20050201 00025 NE 2005 2 1 CA040825006 2 20040811 G 8550 177770 CASE CNDAIR CL215 CL2151A10 1900320 EA PWA R2800 CA3 52026 NE HAMSTD 43E 43E60 NE RT ENGINE LEAKING W O OTHER K FLUID LOSS IN INSP/MAINT 1 CA P32623 (CAN) AFTER A DROP DURING FIRE BOMBING OPERATIONS, THE CAPTAIN AND FO PERFORMED ENGINE VISUAL CONDITION CHECK. THE FO N OTED A LARGE AMOUNT OF OIL LEAKING FROM THE RT ENGINE. OIL TEMPERATURE, PRESSURE AND QUANTITY WERE CLOSELY MONITORED ON THE 20 MIN. FLIGHT BACK TO THE MAINTENANCE BASE. MAINTENANCE FOUND OIL LEAKING FROM AN INSERT ON THE FRONT NOSE CASE . THE NOSE CASE WAS REPLACED AND THE A/C RETURNED TO SERVICE. 2 H 7 2 4R 4 R RT A14EA E231 6 C P871 2005041500026 20050415 00026 EA 2005 4 15 CA040825007 2 20040712 G 8520 CRANKSHAFT CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL ENGINE OUT OF ADJUST W E ENGINE SHUTDOWN J WARNING INDICATION NR NOT REPORTED 1 CA 1387815 1387815 (CAN) ON ENGINE RUNUP, AFTER ENGINE OVERHAUL, THE OIL PRESSURE WAS NOTED TO BE BELOW THE PRESCRIBED LIMIT. ENGINE WAS D ISASSEMBLED. THE CRANKSHAFT MAIN JOURNALS WERE NOTED TO HAVE BEEN PREVIOUSLY GROUND TO .010. 1 H 7 1 3O 3 O NT 3A19 E223 5 N P50GL 2005041500027 20050415 00027 NE 2005 4 15 CA040825008 2 20040812 G 8500 R280079 ENGINE DOUG B26 B26C 3200524 WP PWA R2800 R280079 52026 NE HAMSTD 23E 23E50 NE RIGHT FAILED W E C ENGINE SHUTDOWN ABORTED TAKEOFF J WARNING INDICATION TO TAKEOFF 1 CA FP063306 (CAN) ON TAKEOFF ROLL THE RT ENGINE STARTED TO BACKFIRE AND LOOSE POWER, AT 90 KTS THE TAKEOFF WAS ABORTED MIXTURES TO I DLE CUT OFF,THE LOAD WAS DUMPED. THE A/C WENT OFF THE END OF THE RUNWAY, AT 1000 FEET BEYOND THE RUNWAY THE A/C IMPACTED A DITCH. THE PILOT GOT OUT OF THE A/C AND WAITED FOR ASSISTANCE. THE A/C HAS BEEN DISMANTLED AND TRANSPORTED TO RED DEE R,THE ENGINES ARE SCHEDULED FOR INVESTIGATION. 2 M 7 2 4R 4 R L34 5E8 6 C P603 2005041500028 20050415 00028 NM 2005 4 15 CA040825009 1 20040818 G 2761 66227741 CAP BOEING BOEING 737 7372Q8 138448K NM PWA JT8 JT8D15 52051 NE ACTUATOR LEAKING W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CL CLIMB 1 CA 1029 (CAN) AIRCRAFT TURN BACK DUE TO LOSS OF HYDRAULIC FLUID SYSTEN B IN FLIGHT. ON INSPECTION FOUND PLUG ON NR2 SPOILER ACTU ATOR LEAKING. REPLACED PLUG P/N 66-22774-1 IAW CMM OVH 27-60-41. B SYSTEM CASE DRAIN FILTER TO B SYSTEM PRESS FILTERS CHECKED FOR CONTAMINATION. NO CONTAMINATION FOUND. FUNCTION CHECKED SPOILERS AND LEAKED CHECKED. OK FOR SERVICE. CARR IED OUT RII INSPECTION. OK. 2 L 7 2 4F 4 F RT A16WE E2EA 2005041500029 20050415 00029 NM 2005 4 15 CA040825010 1 20040821 G 2910 BACH8B04NN02 LINE BOEING 737 737281 138448P NM PWA JT8 JT8D17 52049 NE HYDRAULIC SYS RUPTURED W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CL CLIMB 1 CA (CAN) HYDRAULIC QUANTITY INDICATOR SHOWED RAPID DEPLETION TO 1 GAL AFTER TAKEOFF. FOUND RUPTURED HYDRAULIC LINE P/N BACH 8B04NN0214T IN NOSE LANDING GEAR WHEEL WELL.LINE REPLACED IAW 20-10-52. ENGINE HYDRAULIC CASE DRAIN FILTERS CHECKED FOR METAL CONTAMINATION, NO CONTAMINATION FOUND. ENGINE RUN REQUIRED TO LEAK CHECK CASE DRAIN FILTERS AND CONFIRM PROPER HYD RAULIC PUMP OPERATION. HYDRAULIC PUMP OPERATION NORMAL ON BOTH ENGINE DRIVEN PUMPS. 2 L 7 2 4F 4 F A16WE E2EA 2005041500030 20050415 00030 NM 2005 4 15 CA040825011 1 20040824 G 5542 SKIN BOEING BOEING 737 737204 1384458 NM PWA JT8 JT8D15 52051 NE RUDDER DELAMINATED W K NONE O OTHER IN INSP/MAINT 1 CA ZH5540001007 (CAN) DURING A B-CHECK, WALKAROUND FOUND LT SIDE OF THE RUDDER DELAMINATED. FURTHER INSPECTION FOUND DELAMINATION TO BE BEYOND LIMITS OF SRM 55-40-1 FIG 1,K. THE DELAMINATION IS CENTERED AT THE BAYAPPROX. RUDDER STATION 121. FERRY FLIGHT AU THORIZED FROM XXX TO XXX WITH NO STOPS IAW THE RESTRICTIONS CONTAINED IN THE SPECIAL FLIGHT PERMIT, TO ACCOMPLISH PERMAN ENT REPAIR PER SRM. 2 L 7 2 4F 4 F A16WE E2EA 2005041500031 20050415 00031 EA 2005 4 15 CA040825012 2 20040825 G 7200 ENGINE BEECH 90 65A90 1152908 CE PWA PT6 PT6A20 52043 EA LEFT SHUTDOWN W E C ENGINE SHUTDOWN ABORTED TAKEOFF R PARTIAL RPM/PWR LOSS TO TAKEOFF 1 CA 13780 PCE20891 (CAN) THE AIRCRAFT WAS ON THE TAKE OFF ROLE IN LUTSLE KE (SNOWDRIFT) TO FLY TO EKATI (YOA). AT 80 KNOTS A LARGE DROP IN POWER WAS FELT ON THE LEFT SIDE WITH A YAW TOTHE LEFT. THE TAKE OFF WAS REJECTED ANDTHE AIRCRAFT BROUGHT TO A STOP SAF ELY ON THE RUNWAY. THE ENGINE WAS SHUT DOWN AT THAT TIME AS THE EGT WAS OBSERVED TO BE CLIMBING TO 1050. PRELIMINARY INV ESTIGATIONS INDICATE AN INTERNAL FAILURE. MORE INFORMATION WILL BE ATTACHED AS WE HAVE IT. 1 L 7 2 3T 3 T 3A20 E4EA 2004101300029 20041013 00029 WP 2004 10 13 CA040825013 1 20040825 G 6510 369D25430 SHAFT HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL TAIL ROTOR BROKEN W O OTHER D INFLIGHT SEPARATION DE DESCENT 1 CA (CAN) PILOT REPORTED THAT WHEN DESCENDING RAPIDLY, COLLECTIVE BOTTOMED OUT AND RT PEDAL INPUT, THE PEDALS WOULD VIBRATE AND THE AIRFRAME WOULD VIBRATE AND WITH A LITTLE COLLECTIVE INPUT AND LT PEDAL THE VIBRATION WOULD GO AWAY. THE SAME COU LD BE INDUCED ON THE GROUND WITH RT PEDAL INPUT AND NR BEEPED TO MAX. UPON INVESTIGATION OF TAIL ROTOR GEARBOX THE OUTP UT SHAFT HAD BROKE OFF WHERE THE INNER RACE FOR THE ALIGNMENT ROLLER BEARING IS PRESSED ONTO THE IB END OF THE OUTPUT SH AFT. 1 G 7 1 3U 3 U H3WE E4CE 2004101300084 20041013 00084 EU 2004 10 13 CA040826001 1 20040824 G 5311 FRAME FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 27343 (CAN) DURING INSPECTION, AD 2001-21-04 WAS PERFORMED ON FUSELAGE FRAME STRIPS AT STA 3820 THRU STA 3870 AT THE AFT SIDE OF THE NLG BAY IAW NDTM PART 6 AND AD2001-21-04. 2 CRACKS WERE FOUND, RT 0.650 LONG AND LT 0.600 INCH LONG. 2 L 7 2 4F 4 F RT E25NE 2004101300085 20041013 00085 NM 2004 10 13 CA040827001 1 20040826 G 5230 DOOR BOEING 727 727223 1384074 NM PWA JT8 JT8D15 52051 NE MAIN CARGO OUT OF ADJUST W A UNSCHED LANDING N FALSE WARNING CR CRUISE 1 CA (CAN) IN CRUISE, CREW NOTICED THE MAIN CARGO DOOR UNSAFE LIGHT ILLUMINATED. IAW CHECKLIST, CREW DEPRESSURIZED AND DESCEN DED INTO NEAREST AVAILABLE MAINTENANCE BASE. DOOR WAS VISUALLY INSPECTED AND A/C RETURNED TO SERVICE. UPON COMPLETION OF FINAL LEG, MAINTENANCE CHECKED AND ADJUSTED RIGGING OF DOOR SAFETY LOCK/SWITCHES. 2 L 7 3 4F 4 F A3WE E2EA 2004101300086 20041013 00086 NM 2004 10 13 CA040827002 1 20040827 G 5620 WINDOW BOEING 727 727227 1384078 NM PWA JT8 JT8D9A 52048 NE CABIN DISLODGED W A UNSCHED LANDING D INFLIGHT SEPARATION CL CLIMB 1 CA (CAN) AT TOP OF CLIMB, A LENGTH OF WINDOW SEALANT FROM THE R1 WINDOW BECAME DISLODGED AND BEGAN SLAPPING THE GLASS. CREW ELECTED TO RETURN, WHERE THE WINDOW WAS INSPECTED AND LOOSE SEALANT REMOVED. A/C RETURNED TO SERVICE AND WINDOW WAS R ESEALED AT THE NEXT MAINTENANCE FACILITY. 2 L 7 3 4F 4 F A3WE E2EA 2004101300087 20041013 00087 CE 2004 10 13 CA040827003 1 20040825 G 7120 05131323 RAIL CESSNA 172 172K 2072430 CE LYC O320 O320E2D 41508 EA MCAULY 1A175 1A175* GL LT ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 14120 (CAN) THE LT UPPER ENGINE RAIL WAS FOUND TO BE CRACKED DURING SCHEDULED MAINTENANCE. PN 0513132-3 WAS REPLACED WITH NEW PART. NEW HARDWARE WAS INSTALLED. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P857 2004101500080 20041015 00080 NE 2004 10 15 CA040827005 2 20040823 G 7300 CONNECTOR FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE FUEL PILOT VALVE MISINSTALLED W A UNSCHED LANDING K FLUID LOSS CL CLIMB 1 CA (CAN) DURING TAKE OFF, TOWER REPORTED VAPOR TRAILING FROM WING. AC BACK FROM DEPARTURE. APROX 2000 LBS OF FUEL LOST. MAINT FOUND AUTO FEED SYS IN FAULT, CAUSING FUEL FROM CENTER TANK TRANSFERRED TO WING. A CONNECTOR AT REAR SPAR FOR PIL OT VALVE FOUND NOT PROPERLY INSTALLED. ALSO SUSPECT THAT POWER SWITCH AT FUEL CONTROL PANEL KEPT ENERGIZED WITH ACCESS PANEL CLOSED, (SWITCH SHOULD BE FLIPPED OFF BY A CAM AT ACCESS DOOR IF SWITCH NOT MANUALLY PUT OFF IN ORDER TO PREVENT F UEL SPILLAGE FROM WINGS DURING TAKE OFF, IAW SL ). THE SAME EVENT REOCCURRED ON AUG 27. TAKE OFF WAS REJECTED. THE FUE L CONTROL PANEL WAS REPLACED FOR TROUBLESHOOTING AND AS PRECAUTIONARY MEASURE, AUTO FUEL FEED SYSTEM WAS DEACTIVATED. 2 L 7 2 4F 4 F RT E25NE 2004101500082 20041015 00082 SO 2004 10 15 CA040827006 1 20040709 G 5753 AN33A BOLT EMB 110 EMB110P1 3260122 SO PWA PT6 PT6A34 52043 EA HARTZL HCB3T HCB3TN3 GL FLAP DEFECTOR LOOSE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ON A WALK AROUND INSPECTION ONE OF FOUR BOLTS FOR THE OB LT FLAP DEFECTER WAS FOUND TO HAVE BACKED OFF. 1 L 7 2 4T 4 T A21SO E4EA 6 C P15EA 2004101500083 20041015 00083 SO 2004 10 15 CA040827008 1 20040825 G 2913 1213HBG310A PUMP PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL HYDRAULIC FAILED W K NONE L NO TEST IN INSP/MAINT 1 CA (CAN) THE PUMP FAILED OPERATIONAL CHECK, GEAR SELECT. HANDLE DID NOT RETURN TO NEUTRAL POSITION. PUMP WAS OVERHAULED REC ENTLY, WAS IN SERVICE FOR 423.7 HRS. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004101500084 20041015 00084 NE 2004 10 15 CA040829001 2 20040827 G 7200 ENGINE DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE NR 1 MAKING METAL W D RETURN TO BLOCK Y E ENGINE STOPPAGE VIBRATION/BUFFET TX TAXI/GRND HDL 1 CA 37148 30728 (CAN) DURING ENGINE START, THE PILOT WAS UNABLE TO START THE NR 1 ENGINE. A RUMBLING NOISE WAS HEARD FROM THE ENGINE AN D IT WOULD NOT SPOOL GREATER THAN 16 PERCENT NH. MAINTENANCE REPLACED THE STARTER GENERATOR WITH NO FIX. FURTHER INVES TIGATION REVEALED THE NR 1 ENGINE OIL TANK CHIP DETECTOR FLAGGED. THE CHIP DETECTOR AND OIL PUMP SCREEN WERE REMOVED AND CATEGORY 2 DEBRIS (LARGE FUZZ), AND CATEGORY 3 DEBRIS (LARGE CHIPS AND FLAKES) WERE DISCOVERED. THE ENGINE WAS REMOVED FROM SERVICE AND RESULTS FROM TEAR DOWN REPORTS WILL BE SUBMITTED WHEN AVAILABLE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004101500085 20041015 00085 EA 2004 10 15 CA040829002 1 20040826 G 2197 MS220735 WIRE CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE PRSOV BURNED W O OTHER B S SMOKE/FUMES/ODORS/SPARKS AFFECT SYSTEMS DE DESCENT 1 CA (CAN) IN DESCENT THROUGH 20-25, 000A STRONG TOXIC SMELL WAS PRESENT. SIMULTANEOUSLY, NR 1 JET OVHT FAIL CAUTION MESSAGE APPEARED FOR 10 SECONDS AND DISAPPEARED. ECS PAGE WAS SELECTED, IT WAS NOTICED THAT NR 1 PACK WAS NOT OPERATING. NR 1 PACK WAS SELECTED OFF AND SMELL DISSIPATED. MAINT FOUND CIRCUIT BREAKER AT POSITION J1 ON PANEL CB1 BURNED (LT AIR CON D UNIT). CIRCUIT BREAKER WAS REPLACED BUT WOULD NOT RESET. FURTHER INVESTIGATION REVEALED 4 DAMAGED WIRES AT LT ENGIN E PYLON CLOSE TO THE NR 1 PRSOV TWO WIRES WERE CHAFFED, TWO WIRES WERE SHORTED OUT ON THE LT PRESSURE TRANSDUCER P2H6 AN D P7H6 HARNESS, WIRES WERE REPAIRED. AC WAS RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT A21EA E15NE 2004101500086 20041015 00086 SO 2004 10 15 CA040830001 2 20040827 G 8530 646612 EXHAUST VALVE CESSNA 150 150M 2071830 CE CONT O200 O200A 17020 SO ENGINE ERODED W K NONE O OTHER IN INSP/MAINT 1 CA 251443A48 (CAN) ENGINE PLACED ON (PISTON ENGINE ON CONDITION PROGRAM). DURING ON-CONDITION 100 HOUR INSPECTION, THE NR 2 CYLINDER COMPRESSION TEST WAS LOW AND LEAKING FROM VALVES. ON FURTHER INSPECTION, EXHAUST VALVE STEM WAS FOUND TO BE ERODED TO A BOUT HALF OF DIAMETER OF STEM. THE OTHER 3 CYLINDERS WERE INSPECTED AND FOUND EXHAUST VALVE STEMS TO BE ERODED AS WELL. OPERATOR OF THIS AIRCRAFT, HAS A STANDARD PRACTICE TO LEAN THE AIRCRAFT DURING TAXI AND IN FLIGHT. THIS MAY HAVE LEAD T O THIS FAULT FROM IMPROPER LEANING PROCEDURES FROM STUDENT PILOT'S. INSTRUCTORS HAVE BEEN MADE AWARE OF PROPER LEANING PROCEDURES. THE ENGINE WAS OPERATED 282.5 HOURS BEYOND TBO. AIRCRAFT WAS REMOVED FROM SERVICE. 1 H 7 1 3O 3 O 3A19 E252 2004101500087 20041015 00087 SO 2004 10 15 CA040830002 1 20040826 G 1430 NUT PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360EB 17025 SO HARTZL HCC2Y BHCC2YF2 GL RT FWD TRUNNION FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DISCOVERED RT FWD TRUNION FITTING ATTACH BOLT ANCHOR NUT NOT RETAINING TORQUE DURING INSPECTION OF LANDING GEAR. LANDING GEAR REMOVED TO FACILITATE ANCHOR NUT REPLACEMENT. ALL ANCHOR NUTS REPLACED ON BOTH MLG FWD FITTINGS. ALSO FOU ND HEAVY CORROSION ON INNER BORE OF LT AND RT RETAINER ASSEMBLIES (P/N 67502-00). BOTH WERE REPLACED. 1 L 7 2 3O 3 O A7SO E9CE 5 C P920 2004101500088 20041015 00088 GL 2004 10 15 CA040830003 2 20040816 G 7230 COMPRESSOR HUGHES 369 369E 4470707 WP ALLSN 250C 250C20B 03013 GL ENGINE STALLED W O OTHER R J PARTIAL RPM/PWR LOSS WARNING INDICATION NR NOT REPORTED 1 CA (CAN) AIRCRAFT WAS EQUIPPED WITH A MIST ELIMINATOR THAT WAS REMOVED IN THE SPRING OF 2003. WHAT REMAINED WAS THE WEATHE R STRIPPING THAT SEALED THE MIST ELIMINATOR TO THE BACK OF THE PARTICLE SEPARATOR. THE WEATHER STRIPPING HAS A SELF ADHE SIVE AND WAS ATTACHED TO THE BACK OF THE PARTICLE SEPARATOR. ON A 26 DEGREE CELSIUS DAY, SEVERE COMPRESSOR STALL WAS EX PERIENCED WHEN THE ENGINE INJESTED ABOUT A 1.5 METER LENGTH OF WEATHER STRIPPING. THE COMPRESSOR WAS GUMMED UP AND THE B LEED VALVE SLOT WAS PLUGGED. 1 G 7 1 3U 3 U H3WE E4CE 2005020700004 20050207 00004 2005 2 7 CA040830004 4 20040803 G 2350 7511001915 PANEL CESSNA 500 560CESSNA 2076750 CE PWA 530 PW535A NE AUDIO CONTROL INOPERATIVE W O OTHER H ELECT. POWER LOSS-50 PC CR CRUISE 1 CA (CAN) FRONT PANEL OF AUDIO CONTROL UNIT DOES NOT ILLUMINATE ON NIGHT SETTING. 2 L 7 2 4F 4 F RT A22CE E00053EN 2005012400032 20050124 00032 CE 2005 1 24 CA040830005 1 20040408 G 3320 M835369024 RELAY CESSNA 500 560CESSNA 2076750 CE PWA 530 PW535A NE CABIN LIGHTS FAILED W K NONE H ELECT. POWER LOSS-50 PC IN INSP/MAINT 1 CA (CAN) CABIN INDIRECT LIGHTING WOULD NOT SHUT OFF. REPLACEMENT OF RELAY K162 RECTIFIED PROBLEM. 2 L 7 2 4F 4 F RT A22CE E00053EN 2005020100035 20050201 00035 CE 2005 2 1 CA040830006 1 20040709 G 3246 49330 PLUG CESSNA 500 560CESSNA 2076750 CE PWA 530 PW535A NE MAIN WHEEL LEAKING W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) MAIN WHEEL/TIRE ASSEMBLY LEAKING AIR 2-4 PSI PER DAY. REPLACED THERMAL RELIEF PLUG ASSEMBLY. THIS IS THE SECOND P LUG ASSEMBLY TO BE REPLACED ON THIS WHEEL (THERE ARE THREE PLUGS PER WHEEL ASSEMBLY). 2 L 7 2 4F 4 F RT A22CE E00053EN 2005041500032 20050415 00032 CE 2005 4 15 CA040830007 1 20040811 G 2130 471319X VALVE CESSNA 500 560CESSNA 2076750 CE PWA 530 PW535A NE CABIN PRESSURE FAILED W O OTHER D P INFLIGHT SEPARATION NO WARNING INDICATION DE DESCENT 1 CA (CAN) EMERGENCY PRESSURIZATION VALVE CAME ON UNCOMMANDED ONCE FOR SEVERAL SECONDS IN FLIGHT. VALVE WAS REPLACED.NOTE: MF G REPORTS THIS IS A FLEET WIDE PROBLEM AND A NEW VALVE IS UNDERGOING CERTIFICATION. 2 L 7 2 4F 4 F RT A22CE E00053EN 2005041500033 20050415 00033 2005 4 15 CA040830008 4 20040713 G 3160 DISPLAY HONEYWELL CESSNA 500 560CESSNA 2076750 CE PWA 530 PW535A NE RMU FAILED W O OTHER H ELECT. POWER LOSS-50 PC TX TAXI/GRND HDL 1 CA 02113663 (CAN) DISPLAY SCREEN WENT INCREASINGLY BRIGHT. BLUE AND THEN DIMMED TO GREEN. REPLACED RADIO MANAGEMENT UNIT. BEFOR E COMPLETE FAILURE OF DISPLAY. 2 L 7 2 4F 4 F RT A22CE E00053EN 2005041500034 20050415 00034 GL 2005 4 15 CA040830009 3 20040604 G 6114 SEAL CESSNA 207 207A 2073604 CE CONT O520 IO520F 17032 SO HARTZL HCJ3Y PHCJ3YF1 GL PROPELLER HUB LEAKING W O OTHER W K E INADEQUATE Q C FLUID LOSS VIBRATION/BUFFET CR CRUISE 1 CA 282942R (CAN) IN CRUISE, PRIOR TO DESCENT, AUDIBLE AND INDICATED. PROP SURGE AND RPM DECREASE OF APPROXIMATELY 200 RPM OCCURRED . PROP PITCH WAS ADJUSTED TO FULL FINE POSITION. NO RESPONSE TO BLADE CHANGE WAS NOTED. DURING DESCENT PRIOR TO APPROA CH, PROP SLOWLY INCREASED PITCH APPROXIMATELY 100 RPM. APPROACH WAS CONTINUED AND LANDING WAS COMPLETED SUCCESSFULLY. MA INTENANCE INSPECTION REVEALED ENGINE OIL LEAKING FROM PROP GREASE FITTINGS. AN INTERNAL HUB SEAL LEAK WAS DETERMINED AN D CONFIRMED BY PROP OVERHAUL FACILITY. PROP REMOVED. 1 H 7 1 3O 3 O A16CE E5CE 5 C P36EA 2005041500035 20050415 00035 SO 2005 4 15 CA040830010 2 20040812 G 8530 6524518 PUSHROD CESSNA 320 320A 2074506 CE CONT O470 TSIO470B 17026 SO HARTZL HCA2V HCA2VF2 GL RT ENGINE BROKEN W E D ENGINE SHUTDOWN RETURN TO BLOCK K E FLUID LOSS VIBRATION/BUFFET TX TAXI/GRND HDL 1 CA (CAN) PILOT PARKED THE AIRCRAFT BECAUSE OF OIL LEAKING AND RT ENGINE RUNNING ROUGH. THE RT ENGINE NR4 CYLINDER WAS FOUND TO HAVE A BROKEN INTAKE PUSHROD, BROKEN EXHAUST PUSHROD AND BROKEN PUSHROD TUBE THAT CAUSED OIL TO LEAK FROM ENGINE. IT WAS FOUND THAT BOTH PUSHROAD TUBES WERE SLIGHTLY DENTED CAUSING THE PUSHRODS TO RUB AND OVER TIME WEAKEN AND BREAK. W HEN THE PUSHRODS BROKE THEY PUNCHED HO LES INTO THE PUSHROD TUBES AND OIL LEAKED OUT OF THE ENGINE.THE ENGINES ARE INSTA LLED VERY CLOSE TO BOTTOM COWLINGS, BOTTOM COWLINGS ARE NOTREMOVABLE MAKING IT VERY DIFFICULT TO WORK WITH HAND TOOLS. 1 L 7 2 3O 3 O 3A25 3E3 5 C P24EA 2005041500036 20050415 00036 EA 2005 4 15 CA040830011 1 20040806 G 2434 1381 GENERATOR DHAV DHC2 DHC2* 2800108 EA PWA R985 R985AN14B 52008 NE FAILED W K NONE O OTHER TX TAXI/GRND HDL 1 CA (CAN) AFTER LANDING PILOT NOTICED VOLTAGE READING WAS AT 0. GENERATOR WAS REPLACED ANDAIRCRAFT WAS RETURNED TO SERVICE. 1 H 7 1 3R 3 R A806 5E1 2005041500037 20050415 00037 NE 2005 4 15 CA040830012 2 20040815 G 8520 27056 PISTON DHAV DHC2 DHC2* 2800108 EA PWA R985 R985AN14B 52008 NE ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHEN CARRYING OUT COMPRESSION TEST #3 CYLINDER WAS FOUND TO HAVE LOW COMPRESSION. #3 CYLINDER WAS REMOVED AND PIST ON WAS FOUND CRACKED. SERVICEABLE PISTON AND CYLINDER WERE INSTALLED AND AIRCRAFT RETURNED TO SERVICE. 1 H 7 1 3R 3 R A806 5E1 2004111500084 20041115 00084 SO 2004 11 15 CA040830013 2 20040824 G 8520 654101A7R CRANKCASE CESSNA 206 U206F 2073333 CE CONT O520 IO520F 17032 SO HARTZL HCJ3Y PHCJ3YF1 GL ENGINE UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 CA 282615R (CAN) CRANKCASE FAILURE (7TH STUD CRANKCASE) INSP WAS CARRIED OUT. CYLS NR1, NR3 WERE REMOVED SO NR2, NR3 INTERMEDIATE BRG SADDLE COULD BE VIEWED. MOVEMENT OF BRGS HAD OCCURRED, TEAR DOWN WOULD BE REQUIRED FOR FURTHER INVEST. IT WAS FOUN D THAT THERE WAS FRETTING OF CRANKCASE ON NR2, NR3 INTERM MAIN BRG THRU-BOLT PADS. PINCH FIT IS LOST ON MAIN BRGS IN TH ESE POSITIONS, BECOME LOOSE. BRGS ON BOTH SIDES OF CRANKCASE WERE MOVING IN NR2, NR3 INTERM BRG POSITIONS. BRG IS ABLE TO MOVE BACK AND FORTH IN BRG SADDLE (NOT ROTATIONAL). OPER WOULD HAVE ALLOWED INCREASED MOVEMENT OF BRG, BLOCKING OR R ESTRICTING OIL FEED GALLERY IN SADDLE AND CAUSE OIL STARVATION. THIS WOULD LEAD TO CATASTROPHIC FAILURE. 1 H 7 1 3O 3 O A4CE E5CE 5 C P36EA 2004101300090 20041013 00090 SO 2004 10 13 CA040830014 1 20040824 G 2710 40599003 CONTROL ROD PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2C 41532 EA HARTZL HCE3Y HCE3YR2A GL RT AILERON CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 13529 (CAN) ON INSPECTION, FOUND THE RT AILERON CONTROL ROD CRACKED ON THE OUTER THREADED PORTION OF THE ROD WHERE THE ROD END THREADS INTO THE ROD. THE CRACK WAS APPROXIMATLEY 1 INCH IN LENGTH LONGITUDINALY WITH THE ROD. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004101300091 20041013 00091 NE 2004 10 13 CA040830015 2 20040808 G 7230 BLADE CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE COMPRESSOR WHEEL DAMAGED W C ABORTED TAKEOFF E VIBRATION/BUFFET TO TAKEOFF 1 CA (CAN) DURING TAKEOFF ROLL, CREW NOTED VIBRATION FROM NR 2 ENGINE, FOLLOWED BY ENGINE SURGE AND UNCOMMANDED POWER ROLL-B ACK. THE NR 1 ENGINE WENT INTO APR MODE AND THE TAKEOFF WAS ABORTED. BORESCOPE INSPECTION OF THE NR2 ENGINE COMPRESSOR REVEALED MOST BLADES BETWEEN 1ST AND 5TH STAGES TO BE DAMAGED, POSSIBLE BY FOD ALTHOUGH THIS HAS NOT BEEN ESTABLISHED. THE NR 2 ENGINE HAS BEEN REPLACED, THE FDR REMOVED FROM THE AC FOR ANALYSIS AND THE AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2004101300092 20041013 00092 EU 2004 10 13 CA040831001 1 20040823 G 3230 9740926112 RELAY PILATS PC12 PC12 7090550 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL POWER PACK BURNED W L ABORTED APPROACH J WARNING INDICATION AP APPROACH 1 CA (CAN) UPON APPROACH GEAR DOWN POSITION WAS SELECTED AND THE POWERPACK FAILED TO OPERATE THE MAIN GEAR EXTENDED FULLY AS DESIGNED AND THE NOSE GEAR FAILED TO GIVE A GREEN DOWN AND LOCKED POSITION INDICATION. THE APPROACH WAS ABORTED AND A G O AROUND WAS CARRIED OUT. THE MANUAL GEAR EXTENSION PUMP WAS USED TO EXTEND THE NOSE GEAR WITH SUCCESS. INSPECTION REV EALED THE POWER PACK RELAY HAD FAILED TO MAKE CONTACT DUE TO EROSION OF THE CONTACTS. A NEW UNIT WAS INSTALLED AND FUNC TION TESTED. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004101400006 20041014 00006 GL 2004 10 14 CA040831002 2 20040824 G 7397 23065805 WIRE HARNESS BELL 407 407 1182206 SW ALLSN 250C 250C47B GL FADEC FAILED W H DEACTIVATE SYST/CIRCUITS J WARNING INDICATION DE DESCENT 1 CA CAE847044 (CAN) PRIOR TO FINAL APPROACH, FADEC FAIL WARNING HORN AND LIGHTS ACTIVATED. ENGINE AUTOMATICALLY REVERTED TO MANUAL MOD E. PILOT SELECTED AUTO/MANUAL SWITCH TO SILENCE WARNING HORN, RETARDED THROTTLE TO PREVENT NP OVERSPEED. CONTINUED APPRO ACH, LANDING IN MANUAL MODE WITHOUT INCIDENT. ANALYSIS USING MAINT TERMINAL SOFTWARE INDICATED (AUTO/MANUAL SOLENOID FA ULT) (AMSOLFIT). TRACED DEFECT TO DEGRADED CIRCUIT CONTINUITY IN ENG HARNESS ASSY P/N 23065805. HARNESS WAS REPLACED P/ N 23072014. TEST USING MAINT TERMINAL SHOWED ALL FAULTS CLEARED. SATISFACTORY START, GROUND RUN, MANUAL MODE TEST, AUTOM ATIC MODE SHUTDOWN AND FADEC INDICATION CHECK COMPLETED WITH NO ANOMALIES OR DEFECTS. AIRCRAFT RETURNED TO SERVICE. 1 G 7 1 3U 3 U O H2SW E1GL 2004101300093 20041013 00093 EA 2004 10 13 CA040831003 1 20040813 G 5521 C2TE29ND RIB DHAV DHC2 DHC2* 2800108 EA PWA R985 R985AN14B 52008 NE HAMSTD 22D 22D30 NE ELEVATOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 22875 (CAN) DURING REGULAR 100 HOUR INSPECTION AD CF-80-25 COMPLETED AND CRACK FOUND ON LT ELEVATOR IB RIB AT ATTACHMENT BOLT. CRACK WAS LARGER AND MORE VISIBLE ON DOUBLER. REMOVAL OF DOUBLER REVEALED CRACK ON RIB AS WELL. RIB REPLACED AND DOU BLER TOO. 1 H 7 1 3R 3 R A806 5E1 5 C P736 2004122900179 20041229 00179 EA 2004 12 29 CA040831004 1 20040817 G 2497 WIRE HARNESS NOORDN UC64 UC64AS 6330208 EA PWA R1340 S3H1 52016 NE HAMSTD 3D 3D40 NE ALTERNATOR FAILED W C ABORTED TAKEOFF B SMOKE/FUMES/ODORS/SPARKS TO TAKEOFF 1 CA 0502232 THE AREA OF DIFFICULTY APPEARS TO HAVE ORIGINATED WITHIN A WIRE BUNDLE THAT SERVICES THE ALTERNATOR. THIS BUNDLE OF WIRE S (4 WIRES OF AWG 20 SIZE EACH, APPROX 4 FT), RUNS FROM THE VOLT REG LOCATED ON THE UPPER LT SIDE OF THE FIREWALL, TO TH E ALTERNATOR, WHICH IS LOCATED ON THE UPPER PORTION OF THE REAR CASE ON A P&W 1340 ENG. TO FURTHER DESCRIBE THE WIRE BUN DLE, THE 4 WIRES WITHIN HAD BEEN LIGHTLY TWISTED TOGETHER AND THIS ASSY HAD BEEN PLACED WITHIN A SLEEVE/TUBING OF SHIELD ING- GROUNDING BRAIDED WIRE. IT APPEARS VIBRATION HAD CAUSED SOME CHAFING TO OCCUR WITHIN THE BUNDLE AND , POWER WENT TO GROUND AND THE WIRES MELTED, CAUSING THE SMOKE AND ODOR. 1 L 7 1 3R 3 R A2578 E143 6 C A815 2004101300094 20041013 00094 EA 2004 10 13 CA040831005 2 20040819 G 7200 ENGINE BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA POWER SECTION FAILED W B A EMER. DESCENT UNSCHED LANDING Y D ENGINE STOPPAGE INFLIGHT SEPARATION HO HOVERING 1 CA 10031 CPPS60404 (CAN) DURING HIGH HOVER (LONG LINE) TO PICK UP LOAD, NR1 POWER SECTION FAILED. INITIAL COMPRESSOR INLET INSPECTION (PLEN UM AREA) REVEALED MOLTEN PARTICLES. FURTHER INVESTIGATION ON POWER SECTION REMOVAL/TEARDOWN INSPECTION. 1 G 7 1 4U 4 U H4SW E22EA 2004101300095 20041013 00095 WP 2004 10 13 CA040831006 1 20040829 G 5610 5912290506 WINDSHIELD DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE COCKPIT CRACKED W A UNSCHED LANDING O OTHER CR CRUISE 1 CA (CAN) DURING CRUISE, AIRCRAFT HAD TO TURNED BACK TO DEPARTURE DUE TO F/O WINDSHIELD CRACKED. WINDSHIELD HAS BEEN REPLAC ED AND THE WINDOW HEAT CONTROLLER WAS REPLACED AS PRECAUTIONARY. 2 L 7 2 4F 4 F RT A6WE E9NE 2004101500081 20041015 00081 SO 2004 10 15 CA040831008 1 20040820 G 1430 AN546 BOLT PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2B 41532 EA HARTZL HCE3Y HCE3YR2A GL DOWNLOCK SEIZED W L ABORTED APPROACH J WARNING INDICATION AP APPROACH 1 CA (CAN) WHEN THE PILOT SELECTED GEAR DOWN, THE RT GEAR LIGHT DID NOT ILLUMINATE.AFTER NUMEROUS RETRACTIONS AND EXTENSIONS NEAR THE AIRPORT, THE LIGHT NEVER CAME ON. AFTER LANDING THE RT DOWNLOCK HOOK WAS NOT COMPLETELY ENGAGED. WERE MOVED THE BOLT AND REPLACED WITH NEW AND LUBRICATED, CARRIED OUT RETRACTIONS AND EVERYTHING WAS SERVICEABLE. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004101800064 20041018 00064 EU 2004 10 18 CA040831009 1 20040831 G 3251 Z4242170001 SPRING ZLIN 242 Z242L 9970204 EU LYC O360 AEIO360A1B6 41514 EA MUHBR MTV MTV9* EU NLG STEERING BROKEN W D RETURN TO BLOCK O OTHER TX TAXI/GRND HDL 1 CA (CAN) DURING TAXI A STUDENT PILOT NOTICED THAT THE AIRCRAFT WAS DIFFICULT TO STEER. IT WAS ALSO NOTICED THAT THE RUDDER PEDALS FELT DIFFERENT. MAINTENANCE WAS NOTIFIED AND IT WAS FOUND THAT THE RT STEERING SPRING WAS BROKEN. THE SPRING W AS REPLACED IAW THE MM WITH THE PROPER GAP BETWEEN THE SPRINGS. THE STUDENTS WERE REMINDED OF THE PROPER TAXI TECHNIQUE S WITH THE AIRCRAFT, STARTING THE ROLL BEFORE TURNING THE NOSE GEAR TO REDUCE STRESS ON THE SPRINGS. 1 L 7 1 3O 3 O 0 A76EU 1E10 5 C P24NE 2004101800065 20041018 00065 NM 2004 10 18 CA040831010 1 20040830 G 5753 ATTACH BRACKET BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ACTUATOR MISSING W O OTHER D F INFLIGHT SEPARATION FLT CONT AFFECTED TX TAXI/GRND HDL 1 CA (CAN) DURING DELIVERY FLIGHT FROM THE AIRCRAFT MANUFACTURER, TECHNICAL LOG ENTRY FOR THIS AIRCRAFT STATED (FLAP POWER CA UTION LIGHT ON) DURING TAXI IN WHEN FLAPS SELECTED ZERO. FLAPS STOPPED AT ABOUT 8 DEGREES. ON FURTHER INVESTIGATION OU TER RT FLAP SEEN TO BE AT ABNORMAL ANGLE. RT FLAP ACTUATOR NR 4 (PN C148661-2) WAS FOUND TO HAVE MIGRATED REARWARDS. F URTHER INVESTIGATION REVEALED THE ACTUATOR UPPER ATTACHMENT BRACKET IS MISSING. 2 H 7 2 4T 4 T RT A13NM E00062EN 2004101800066 20041018 00066 NE 2004 10 18 CA040831011 2 20040829 G 7230 FAN BLADE DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE ENGINE DAMAGED W A UNSCHED LANDING C E F.O.D. VIBRATION/BUFFET CR CRUISE 1 CA P728045 (CAN) DURING CRUISE, NR 1 ENGINE HAD VIBRATION AND SURGE. AIRCRAFT LANDED BACK TO DEPARTURE AIRPORT WITH ENGINE RUNNING AT IDLE. FOUND SPINNER AND 3 FAN BLADES DAMAGED BY FOD. THERE WAS NO TRACE OF BLUE ICE OR BIRD STRIKE. ENGINE HAS BEEN REPLACED. 2 L 7 2 4F 4 F RT A6WE E9NE 2004101800067 20041018 00067 EA 2004 10 18 CA040831012 2 20040618 G 8520 LW72877 TAPPET CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA MCAULY 1C160 1C160DTM GL ENGINE CRACKED W A UNSCHED LANDING E VIBRATION/BUFFET CR CRUISE 1 CA L1149739A (CAN) HEAD OF CAM FOLLOWER (TAPPET BODY) CRACKED OFF AND FELL INTO SUMP. VALVE COULD NOT ACTIVATE, SO LOST POWER FROM TH AT CYLINDER. ON ENGINE TEAR DOWN, 3 OTHER FOLLOWERS WERE FOUND PARTIALLY CRACKED OR PIECES MISSING. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2004101800068 20041018 00068 NM 2004 10 18 CA040831013 1 20040829 G 2910 LINE BOEING 737 737204 1384458 NM PWA JT8 JT8D15 52051 NE HYDRAULIC SYS LEAKING W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CL CLIMB 1 CA (CAN) LOST (A) SYSTEM HYDRAULICS. FOUND RT MLG UPLOCK HYDRAULIC LINE LEAKING AT ACTUATOR. LINE REPLACED IAW AMM 32-32- 11 P/N BACH8A0LEE0260T. RT MLG UPLOCK LINE PRESSURIZED AND LEAK CHECKED SERVICEABLE. NR 1,2 ENG PRESS FILTERS CHECK OK IAW MM 29-11-71 NR 1 ENG CASE DRAIN FILTER CHECKED OK NR 2 ENGINE CASE DRAIN FILTER FOUND CONTAMINATED. LINE FLUSHED IAW MM 29-11-0 FILTER REPLACED IAW 29-11-41. NR 2 ENGINE HYDRAULIC PUMP REPLACE IAW MM 29-11-31 PN ON/OFF 55098-08 S/N OFF 101752A S/N ON 124354K8G HJKYZ. NR 1, 2 ENGINE PRESSURE FILTERS AND CASE DRAIN FILTER LEAK CHECKED, NO LEAKS NOTED. CA SE DRAIN FILTERS REPLACED IAW MM 29-11-41 P/N ON 65-90305-12. NO LEAKS NOTED. 2 L 7 2 4F 4 F A16WE E2EA 2004101800069 20041018 00069 EU 2004 10 18 CA040831014 1 20040828 G 2797 9714231712 TERMINAL BLOCK PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL AILERON TRIM SYS SHORTED W K NONE L NO TEST IN INSP/MAINT 1 CA (CAN) THE AILERON TRIM FUNCTIONED ONLY IN ONE DIRECTION. THE TERMINAL BLOCK ON THE ELECTRIC CIRCUIT WAS FOUND BURNED (S HORTED) AND WAS REPLACED. AN OPERATIONAL TEST WAS CARRIED OUT OLD PART WAS REPLACED BY A NEW PART AND THE SYSTEM WAS FO UND SATISFACTORY. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004101800122 20041018 00122 NE 2004 10 18 CA040831015 2 20040830 G 7200 CFM567B22 ENGINE BOEING 737 737724 13844BY NM CFMINT CFM567 CFM567B22 13802 NE NR 2 MALFUNCTIONED W O OTHER N FALSE WARNING TX TAXI/GRND HDL 1 CA (CAN) AIRCRAFT RETURNED TO GATE. NR 2 ENGINE FAULT 77-10852 (749.5) SENSOR OUT OF RANGE. CARRIED OUT FIM TASK 77-21 TA SK 802. PERFORMED EEC TEST IAW 73-21-00-700-804-FO FAULT IS NOT ACTIVE, MEASURED 7.852 AT CONNECTOR DP0909. CLEANED CON NECTORS DP0909 AND DP0913. SYSTEM TESTS SERVICEABLE. DMI CLEARED. ENGINE NR 2 HAD FLASHING WHITE EGT BOX ON STARTUP. ABORTED ENGINE START. FIM TASK 77-21 T. 801 CARRIED OUT. LONGTIME EGT FAULT 77-10852 INDICATED. DEFERED TO MCC N/R TO BE RECTIFIED WITHIN 42.5 HOURS. 2 L 7 2 4F 4 F RT A16WE E00055EN 2005012400030 20050124 00030 EU 2005 1 24 CA040831016 1 20040830 G 3230 9740926112 RELAY PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL MLG INOPERATIVE W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) LIGHT IN THE CAWS PANEL ILLUMINATED INDICATING TO THE PILOT A PROBLEM OF LAND GEAR. PILOT LANDED AND AWAITED A FL IGHT PERMIT TO ALLOW GEAR DOWN RETURN TO BASE. AFTER INVESTIGATION, THE RELAY OF THE HYDRAULIC PUMP WAS FOUND INOPERATI VE AND REPLACED. A TEST OF RETRACTION /EXTENSION WAS CARRIED OUT AND FOUND SATISFACTORY. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005012400031 20050124 00031 CE 2005 1 24 CA040831017 1 20040828 G 5347 05112421 STOP CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA MCAULY 1C160 1C160DTM GL SEAT TRACK MISINSTALLED W O OTHER O OTHER TX TAXI/GRND HDL 1 CA (CAN) THE CREW REPORTED THAT THE PILOTS SEAT HAD FALLEN OFF THE RAILS WHEN ADJUSTED AFT. THE TECHNICIAN INVESTIGATING T HE REPORTED DEFECT NOTICED THAT THE AFT SEAT STOP WAS NOT INSTALLED IN ITS USUAL POSITION. THE MOUNTING SCREW AND HALF OF THE STOP WERE LOCATED UNDER THE CARPET ADJACENT TO THE NORMAL INSTALLATION AREA. THE STOP HAD APPARENTLY FRACTURED ACROSS THE THREADED SCREW MOUNTING HOLE PROBABLY FROM FREQUENT USE. THE STOP WAS REPLACED WITH A NEW PART AND NEW SCREW INTO THE AFT POSITION ON THE LT OB SEAT RAIL. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2005020100044 20050201 00044 WP 2005 2 1 CA040831018 1 20040824 G 7603 CONTROL CABLE DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE LT THROTTLE KINKED W K NONE E VIBRATION/BUFFET TX TAXI/GRND HDL 1 CA (CAN) FOLLOWING ONE FLIGHT, LT THROTTLE WAS VERY STICKY ON GROUND, NO PROBLEM IN FLIGHT. MAINTENANCE FOUND THE REAR CAR GO CEILING PANEL OBSTRUCTING THE LT ENGINE PUSH/PULL CABLE QUADRANT. THE CEILING PANEL WAS KINKED BY LUGGAGE. STILL UN DER INVESTIGATION FOR THE PANEL/INSTALLATION CONFORMITY. 2 L 7 2 4F 4 F RT A6WE E9NE 2005041500038 20050415 00038 EA 2005 4 15 CA040831020 2 20040830 G 8500 ENGINE ROBSIN R44 R44 7640120 WP LYC O540 O540F1B5 41532 EA MAKING METAL W K NONE O OTHER IN INSP/MAINT 1 CA L2476640A MAINTENANCE WAS CONDUCTING A 50 HR INSPECTION AND EXCESSIVE METAL IN FILTER. THE ENGINE WAS REMOVED FROM THE AIRCRAFT A ND SENT TO AN OVERHAUL FACILITY. THE ENGINE WAS TORN DOWN AND INTERNAL COMPONENTS REVEALED THAT THE MAIN BEARING HAD FA ILED DUE A OVERSPEED CONDITION. THE ENGINE DRIVETRAIN SHOWED HEAVY DAMAGE TO THE CRANKSHAFT. THE A/C WILL NOW GO THROU GH A SUSPECT OVERSPEED CONDITION. 1 G 7 1 3O 3 O H11NM E295 2005041500039 20050415 00039 2005 4 15 CA040831021 4 20040830 G 3457 066040340204 GPS BEECH 200 B200 1152922 CE PWA PT6 PT6A42 52043 NE HARTZL HCB3T HCB3TN3 GL COCKPIT OUT OF ADJUST W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) PILOT REPORTS GPS 60 DEGREES OFF TRACK. T/S INDICATES CALIBRATION OF UNIT 60 DEGREES OUT. RECALIBRATED. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2005041500040 20050415 00040 EA 2005 4 15 CA040831022 2 20040825 G 8560 LINE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA NR 1 ENGINE UNSERVICEABLE W A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 CA L8323 (CAN) CLIMB AFTER TAKE-OFF, CREW NOTED THAT THE NR 1 ENGINE LOST TURBO BOOST ABD THE AIRCRAFT YAWED TO THE LT. PILOT RET URNED TO AIRPORT. FOUND MANIFOLD PRESSURE SENSE LINE FROM ENGINE INDUCTION TO DIFFERENTIAL PRESSURE CONTROLLER SHEARED O FF ANDTHE SENSE LINE SENSING AMBIANT AIR PRESSURE AND NOT BOOSTED PRESSURE. LINE DAMA GED DUE TO HEAT STRESS NEAR EXHAUS T SYSTEM. LINE REPLACED. NO FURTHER FAULTS. 1 L 7 2 3O 3 O A20SO E14EA 2005041500041 20050415 00041 SO 2005 4 15 CA040901001 1 20040818 G 3222 9572000 TUBE PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360E 17025 SO NLG OUT OF TOLERANCE W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) TUBE PURCHASED NEW. INSTALLED NEW. TEE SHOOTING AT VARIOUS REPAIR STATIONS DISCOVER CIRCLIP GROOVE TOO SMALL TO AC COMODATE FULL CLIP SEATING. (GROOVE UNDERSIZED)NEW TUBE PURCHASED AND REPLACED. NO FAULT TO DATE. INITIAL RECURRING FAU LTS INC LUDED, LOSS OF FLUID, PRESSURE AND TOTAL COLLAPSE OF NOSE OLEO DURING DIFFERENT PHASES OF OPERATIONS. REPAIRS I NCLUDED REPLACEMENT OF CIRCLIP, N2 SERVICING, O-RING INSPECTION ETC. 1 L 7 2 3O 3 O A7SO E9CE 2005041500042 20050415 00042 SW 2005 4 15 CA040901002 1 20040820 G 6310 206040015103 DRIVE ASSY BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL TRANSMISSION DAMAGED W K NONE K J FLUID LOSS WARNING INDICATION IN INSP/MAINT 1 CA (CAN) TWICE WITHIN A 20 HOUR PERIOD,THE YELLOW TEMP INDICATERS CHANGED COLOUR, AND GREASE WAS LEAKING FROM THE FWD. END OF THE DRIVE SHAFT. THE SHAFT WAS REPLACED AND NO FURTHER PROBLEMS HAVE BEEN REPORTED.THE SPHERICAL COUPLING WAS REPLACE D ON THE PROBLEM SHAFT,AND WAS INSTALLED ON ANOTHER HELICOPTER, WITHOUT AND REOCCURENCE. 1 G 7 1 3U 3 U H2SW E4CE 2004101300039 20041013 00039 SW 2004 10 13 CA040901003 1 20040704 G 6210 204011250113 BLADE BELL 204 204B 1181404 SW LYC T53 T5313B 41549 NE MAIN ROTOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) MAIN ROTOR BLADE FOUND CRACKED ON THE TOP SURFACE 90 INCHES FROM THE TIP. ABOUT 70 HOURS BEFORE, A CRACK ON THE BL ADE PAINT WAS FOUND, AT THAT TIME NO CRACK WAS FOUND IN THE BLADE SKIN. IAW ASB204-49-96 PT I AND II, THE BLADE WAS INS PECTED DAILY (PART I) AND EACH 25 HOURS (PART II). 8 FLIGHT HOURS BEFORE THE BLADE WAS FOUND SERVICEABLE WITH NO APPARE NT CHANGE. THE PILOT REPORTED, FLEW IN TURBULENT CONDITIONS THAT DAY. IN THE DAILY INSPECTION THE HAIRLINE CRACK ON THE PAINT WAS EXTENDED ALMOST ALL ACROSS THE BLADE. 1 G 7 1 4U 4 U H1SW E17EA 2004101300121 20041013 00121 NM 2004 10 13 CA040901004 1 20040830 G 2720 682015 SWITCH DHAV DHC8 DHC8101 2809002 NM PWA PW121 PW121 52124 NE HAMSTD 14SF 14SF7 NE RUDDER TRIM HUNG UP W O OTHER F FLT CONT AFFECTED CR CRUISE 1 CA 31490 (CAN) DURING FLIGHT, CREW REPORTED HAVING A RUDDER TRIM ACTUATOR RUNAWAY CONDITION. CREW FOLLOWED THE ABNORMAL PROCEDUR ES CHECKLIST AND CONTINUED THE FLIGHT WITHOUT FURTHER INCIDENT. MAINTENANCE FOUND THE RUDDER TRIM SWITCH TO BE HANGING UP WHEN SELECTED TOWARDS THE LT POSITION. SWITCH WAS REMOVED AND REPLACED. SYSTEM WAS OPERATIONAL CHECKED. ALL CHECKS GOOD. AIRCRAFT RETURNED TO SERVICE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004101300122 20041013 00122 SW 2004 10 13 CA040901005 1 20040718 G 2424 15891F VOLT REGULATOR BELL 204 204B 1181404 SW LYC T53 T5313B 41549 NE ELECTRICAL FAILED W E C ENGINE SHUTDOWN ABORTED TAKEOFF B H SMOKE/FUMES/ODORS/SPARKS ELECT. POWER LOSS-50 PC TO TAKEOFF 1 CA (CAN) VOLTAGE REGULATOR DELIVERING OVER 30 VOLTS. THE AIRCRAFT WAS READY TO TAKE OFF WHEN THE PILOT SMELLED A STRONG ODO R IN THE COCKPIT. ASSUMING IT WAS THE BATTERY, HE SHUT DOWN THE ENGINE. IN THE INSPECTION THE BATTERY WAS FOUND TOO HOT AND THE VOLTAGE DELIVERED BY THE VOLTAGE REGULATOR WAS OVER 30 VOLTS. THIS HIGH VOLTAGE MADE THE INVERTER NR 1 FAIL TO (WAS DELIVERING OVER 150 VOLTS). WITH THIS HIGH VOLTAGE IN BOTH SYSTEMS (28VDC AND 115VAC) THE AUDIO BOX WAS BURNED OUT , THE BATTERY HAD THE VOLTAGE BUT NOT THE CAPACITY AND THE RMI FAILED. NO CIRCUIT BREAKER STRIPPED AT THE TIME. 1 G 7 1 4U 4 U H1SW E17EA 2004121000054 20041210 00054 NE 2004 12 10 CA040901006 3 20040831 G 6111 SFA13M1R0AD BLADE DHAV DHC8 DHC8* NM HAMSTD 14SF 14SF7 NE PROPELLER CORRODED W O OTHER O OTHER NR NOT REPORTED 1 CA 900946 (CAN) BLADE RECEIVED FOR REPAIR OF FIBERGLASS DAMAGE ON THE OUTER SURFACE. DURING INITIAL INSPECTION, THE PLUG FOR THE BLADE TAPER BORE WAS REMOVED, FOUND THAT THE TAPER BORE WAS PRESSURIZED AS THE PLUG POPPED OUT WHEN RETAINING RING WAS REMOVED. FOUND CORROSION BY PRODUCTS, AND CORROSION DAMAGE INSIDE OF THE TAPER BORE. PER CMM 61-13-02, REPAIR 5-5, ZONE 4 IS ALLOWED 0.014 INCHES OF CORROSION DAMAGE DEPTH, THAT MUST BE REMOVED, THIS DEPTH WAS NOT MEASURED, BUT APPEARS TO EXCEED THE MAXIMUM DEPTH. 2 H 7 2 4T RT A13NM 6 C P7NE 2004101300123 20041013 00123 EA 2004 10 13 CA040901007 2 20040719 G 8550 77517 SUMP LYC O540 IO540L1A5 41532 EA ENGINE LEAKING W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA L2954548A (CAN) AT A RECEIVING INSPECTION OF A NEW, ZERO TIME ENGINE, NUMEROUS VOIDS IN THE CASTING WERE DISCOVERED ON THE ENGINE SUMP. PORT SIDE NEAR PLUG AREA. THE TWO BIGGER ONES HAD A DEPTH MEASUREMENT OF .110 AND .070 RESPECTIVELY. ENGINE MANU FACTURER WAS CONTACTED AND IT WAS DETERMINED TO REPLACE THE SUMP PRIOR TO ENGINE BEING INSTALLED. A NEW SUMP WAS OBTAINE D FROM THE MANUFACTURER AND INSTALLED IAW APPLICABLE MANUAL INSTRUCTIONS. NOTE: THERE WAS NO VISUAL EVIDENCE OF CASTING VOIDS ON THE INTERNAL WALLS OF THE OIL SUMP CASE. 3 O 1E4 2004101300124 20041013 00124 SW 2004 10 13 CA040901008 1 20040929 G 5302 2050328193 PANEL BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA TAILBOOM CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING ROUTINE INSPECTION AME DISCOVERED A CRACK SURROUNDING ELEVATOR CONTROL SUPPORT (P/N 205-001-920-001) IN A F WD AND AFT SKIN OF TAILBOOM PANEL (205-032-819-3). PANEL REPLACED, A/C RETURNED TO SERVICE. 1 G 7 1 4U 4 U H4SW E22EA 2004101300125 20041013 00125 CE 2004 10 13 CA040901009 1 20040916 G 2752 100384040 MOTOR BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCD4N3 HCD4N3A GL TE FLAPS FAILED W O OTHER J WARNING INDICATION CL CLIMB 1 CA (CAN) SHORTLY AFTER AIRCRAFT DEPARTURE, THE AIRCRAFT RETURNED DUE TO FLAP PROBLEMS. THE FLAP MOTOR WAS REPLACED AND THE AIRCRAFT WAS RETURNED TO SERVICE. 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2004101300126 20041013 00126 NE 2004 10 13 CA040902001 2 20040902 G 7250 TURBINE BOEING 717 717200 1383700 NM RROYCE BR700 BR700715A130 NE HPC FAILED W C ABORTED TAKEOFF X J ENGINE FLAMEOUT WARNING INDICATION TX TAXI/GRND HDL 1 CA 13266 (CAN) ENGINE WAS REMOVED DUE TO TURBINE AND HPC FAILURE. THIS ENGINE IS BEING ROUTED CANADA (MONTREAL) MFG FOR INVESTIGA TION AND REPAIR. EVENT: 8/22/04, AIRCRAFT, NR 2 POSITION. WHILE SPOOLING THE ENGINES UP FOR THE TAKOFF ROLL, A LOUD BAN G WAS HEARD FROM THE REAR OF THE AIRCRAFT. AN AIRCRAFT BEHIND IMMEDIATELY REPORTED FLAMES COMING FROM NR 2 ENGINE TAILPI PE. THE ENGINE WAS SHUTDOWN ON THE RUNWAY AND TAKEOFF ABORTED. MCD WAS CHECKED AND FOUND CLEAN. THE N1 ROTOR WAS SPUN A ND SPUN FREELY. THE N2 ROTOR COULD NOT BE TURNED BY HAND CRANKING. INSPECTION OF THE TAILPIPE REVEALED METAL PARTICLES AND DAMAGE TO LPT 3RD STAGE BLADES. 2 L 7 2 4F 4 F TR A6WE E00061EN 2004101300127 20041013 00127 NM 2004 10 13 CA040902002 1 20040902 G 3230 656021132 ACCESSORY UNIT BOEING 727 727227 1384078 NM PWA JT8 JT8D9A 52048 NE LANDING GEAR FAILED W J A DUMP FUEL UNSCHED LANDING N FALSE WARNING CL CLIMB 1 CA (CAN) UPON SELECTION OF GEAR UP, CREW NOTICED THE RT MLG INDICATION SHOWED BOTH (DOWN AND LOCKED) (GREEN LIGHT) AND (UNS AFE) (RED LIGHT) AT THE SAME TIME. FOLLOWING THEIR CHECKLIST, THE CREW DUMPED FUEL AND RETURNED TO BASE WHERE THE GEAR WAS INSPECTED, THE LANDING GEAR ACCY UNIT WAS REPLACED AND THE A/C RETURNED TO SERVICE. 2 L 7 3 4F 4 F A3WE E2EA 2004101300128 20041013 00128 SW 2004 10 13 CA040902003 1 20040812 G 5302 206031403001 FITTING BELL BELL 206 206L4 1182110 SW ALLSN 250C 250C30 03013 GL TAILBOOM CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 52149 (CAN) TAIL BOOM FITTINGS P/N 206-031-403-001 AND 206-032-409-001 LT SIDE TOP AND BOTTOM CRACKED. 1 G 7 1 3U 3 U NC H2SW E1GL 2004101800106 20041018 00106 SO 2004 10 18 CA040902004 1 20040823 G 1430 BOLT PRESTOLITE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL STARTER MISSING W K NONE O OTHER IN INSP/MAINT 1 CA A164921 (CAN) STARTER, ALL BOLTS LOOSE AND TWO MISSING. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2005030300146 20050303 00146 SO 2005 3 3 CA040902005 1 20040625 G 1430 AN522 BOLT PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA SNSNCH 74D 74DM EA SCISSOR LINK SHEARED W A UNSCHED LANDING O OTHER LD LANDING 1 CA 16432 (CAN) BOLT SHEARED ON TAKEOFF. THIS IS BOLT FROM OTHER GEAR HAS SAME TOTAL TIME. 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 2005030300147 20050303 00147 NE 2005 3 3 CA040902006 2 20040827 G 7250 TURBINE BLADES PWA JD15 JT15D1A NE ENGINE FAILED W K NONE O OTHER IN INSP/MAINT 1 CA 76509 DISCOVERED HPT BLADE DAMAGE. CONFIRMED HPT BLADES DAMAGED WITH 1 BLADE MISSING ENTIRE TIP SECT. GAS GEN DEFLECTOR SEG F OUND MISSING SECTIONS & SIGNIFICANT NR OF RIVETS. EXAM OF FRACTURED BLADE SHOWED HIGH STRESS RAPID YIELD FRACTURE WITH NO EVIDENCE OF FATIGUE. FRONT SECT OF BLADE CONVEX SIDE (SUCTION SURFACE) ADJACENT TO FRACTURE BENT TOWARDS PRESSURE SU RFACE AWAY FROM DIRECTION OF ROTATION AS WOULD OCCUR IF BLADE SUSTAINED A SIGNIFICANT IMPACT. BLADE NOT PRIMARY FAILURE & 2NDRY DAMAGE CAUSED FROM LIBERATED MATERIAL. MATERIAL BECAME DISLODGED & ENTERED THROUGH COMBUSTION CHAMBER LINER & T RAVELLED THROUGH GAS PATH CAUSING SEVERE HPT BLADE DAMAGE, AND MINOR IMPACT DAMAGE ON DOWNSTREAM COMPONENTS. 4 F E25EA 2005030300148 20050303 00148 EU 2005 3 3 CA040902007 1 20040831 G 5523 1G3161 TRIM TAB BRAERO 748 HS7482A 4231001 EU RROYCE DART DART5342 EU ROTOL R4304 R2124304 EU RT ELEVATOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ON PREFLIGHT INSPECTION THE RT IB ELEVATOR TRIM TAB HINGE WAS FOUND TO BE LOOSE AND WOULD FLEX UNDER SIDE LOAD. U PON FURTHER INSPECTION IT WAS NOTICED THAT THE TRIM TAB SPAR WAS CRACKED ALONG THE LOWER EDGE BESIDE THE BOLTED ON HINGE POINT. 2 L 7 2 3T 4 T A24EU A196 6 C P899 2005030300150 20050303 00150 CE 2005 3 3 CA040902009 1 20040802 G 5610 1013840252 WINDSHIELD BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL COCKPIT CRACKED W O OTHER O OTHER DE DESCENT 1 CA (CAN) ON DECENT, THE CREW HEARD A BANG AND THE PILOTS SIDE WINDSHIELD WAS CRACKED. THE CREW CONTINUED THE DECENT AND LAN DED NORMALLY. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2005030300151 20050303 00151 CE 2005 3 3 CA040902010 1 20040830 G 3221 B66 BEARING RAYTHN BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL CHAIN SPROCKET FAILED W O OTHER J WARNING INDICATION DE DESCENT 1 CA WHEN MLG EXTENDED ON ARRIVAL, GEAR CAME OUT OF WW & STOPPED. CREW EXTENDED MLG WITH THE EMERGENCY EXTENTION SYSTEM. CRE W FOUND IT VERY HARD TO MOVE HANDLE FOR 1ST FEW STROKES. WERE ABLE TO KEEP GOING UNTIL 3 GREEN LIGHTS. LANDED A/C NORMA LLY. A/C PUT ON JACKS & 60 AMP C/B UNDER FLOOR FOUND BLOWN. C/B RESET & GEAR SELECTED UP. GEAR WENT UP NORMALLY. GEA R SELECTED DOWN & GEAR MOVED SAME AMOUNT & STOPPED. MLG MOTOR STILL TRYING TO MOVE GEAR, BUT FRICTION CLUTCH IN GEARBOX SLIPPING. NLG CHAIN REMOVED IN ABLE TO SPLIT UP SYS FOR TROUBLESHOOTING. MLG FUNCTIONED NORMALLY. NLG SYSTEM TALKEN A PART & A BEARING IN 1 OF CHAIN SPROCKETS FOUND FAILED. A NEW SPROCKET & BEARING INSTALLED & MLG FUNCTIONED NORMALLY. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2005030300152 20050303 00152 CE 2005 3 3 CA040902011 1 20040901 G 5610 1013840252 WINDSHIELD BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL COCKPIT CRACKED W O OTHER O OTHER DE DESCENT 1 CA (CAN) ON DECENT, THE CREW NOTICED A CRACK IN THE PILOTS WINDSHIELD. THE CREW CONTINUEDAND LANDED NORMALLY. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2005041100210 20050411 00210 EA 2005 4 11 CA040903003 2 20040826 G 7200 ENGINE PWA PT6 PT6A50 52043 EA FAILED W K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 CA 24535 86084 ENG REMOVED WHEN BETA CONTROL SYS JAMMED. SEIZED BETA CONTROL LINKAGE RESULT OF HEAVY CONTACT WEAR BETWEEN THE REAR SEA LING LAND OF BETA TRANSFER SLEEVE AND PROP SHAFT. A PREVIOUS SIMILAR FAILURE INVESTIGATION HAD CONCLUDED THAT FAILURE RE LATED TO LACK OF LUBRICATION SO A CHECK MADE TO SEE IF ANY OIL SUPPLY ROUTES WERE BLOCKED. AGAIN TWO SMALL HOLES IN PRO P SHAFT THAT FEED CENTER PART OF BETA CONTROL SLEEVE WITH OIL WERE FOUND TO BE PLUGGED WITH SOME SOFT MATERIAL. 4 T E4EA 2004101300129 20041013 00129 CE 2004 10 13 CA040904001 1 20040820 G 5551 12120031 DOUBLER CESSNA 207 207 2073602 CE CONT O520 IO520F 17032 SO HARTZL HCC3Y HCC3YF1 GL HS BULKHEAD CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THE BULKHEAD DOUBLER REINFORCES THE HOLE WHERE THE HORIZONTAL STAB ATTACHES. DOUBLER SPLIT IN TWO THROUGH ANCHOR NUT RIVET HOLE. THIS DOUBLER ONLY FOUND ON THE FIRST MODELS. LATER MODELS HAD TWO DOUBLERS. OLDER MODELS HAVE THE SAME SINGLE DOUBLER INSTALLED. 1 H 7 1 3O 3 O A16CE E5CE 5 C P25EA 2004101300130 20041013 00130 CE 2004 10 13 CA040907001 1 20040901 G 5551 0432001646 RIB CESSNA 150 150L 2071826 CE CONT O200 O200A 17020 SO MCAULY 1A101 1A101HCM GL EMPENAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) PART NUMBER 0432001-46 & 0432001-6 LEADING EDGE RIB ASSEMBLIES (FIGURE 18, ITEM 18 & 17 CESSNA PARTS MANUAL) ARE V ERY DIFFICULT TO SEE. THE USE OF A MIRROR THROUGH THE HORIZONTAL SPAR AND RIB LIGHTNING HOLES IS THE ONLY WAY TO SEE THE CRACKS ALONG THE TABS. WE BELIEVE THE RIBS ARE CRACKING DUE TO IMPROPER GROUND HANDLING. THE PRACTICE OF PUSHING THE AI RCRAFTS TAIL DOWN BY ITS SPAR IN ORDER TO ROTATE THE AIRCRAFT IN POSITION MAY BE DAMAGING THESE RIBS. BOTH RIBS WERE REP LACED WITH NEW. THE TAIL SURFACES WERE REMOVED AND RE-INSTALLED. 1 H 7 1 3O 3 O 3A19 E252 5 N P918 2004101300131 20041013 00131 CE 2004 10 13 CA040907002 1 20040825 G 2421 X660007 ALTERNATOR CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA MCAULY 1A170 1A170E GL ENGINE DAMAGED W D RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TX TAXI/GRND HDL 1 CA (CAN) ALTERNATOR CHARGING SYSTEM WOULD NOT COME ONLINE. TROUBLESHOOTING REVEALED THAT EVERYTHING SHOULD BE WORKING NORMA LLY. HOWEVER SYSTEM WOULD NOT CHARGE. ALL VOLTAGES (IAW M.M.) APPEARED TO BE NORMAL BUT STILL THE CHARGING SYSTEM WAS SHOWING A DISCHARGE. VOLTAGE WAS CHECKED AT THE OUTPUT SIDE OF THE ALTERNATOR CONTACTOR AND WAS FOUND TO BE NORMAL. HOW EVER THERE WAS LITTLE TO KNOW CURRENT FLOW. ASSUMED THAT THE CONTACTOR (INTERNALLY) HAD A BUILT UP LAYER OF CARBON FRO M ARCHING. REPLACED THE ALTERNATOR CONTACTOR X66-0007 AND THE SYSTEM BEGAN TO OPERATE WELL WITH-IN ITS OPERATING RANGE . CHECKS OK. WE ALLOWED THE AIRCRAFT TO FLY A FEW DAYS AND IT CONTINUED TO CHARGE NORMALLY. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P857 2004101300132 20041013 00132 EA 2004 10 13 CA040907003 1 20040906 G 7921 10750F OIL COOLER DHAV DHC8 DHC8311 1386006 EA PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE ENGINE LEAKING W K NONE K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA 30284 (CAN) THICK WHITE SMOKE COMING FROM THE RT ENGINE BREATHER TUBE. ENGINE OIL FOUND CONTAMINATED BY FUEL. FUEL COOLED OI L COOLER (PN 10750F SN 440) REPLACED IAW MM GROUND RUNS CARRIED NO AICRAFT RETURNED TO SERVICE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004101300133 20041013 00133 EA 2004 10 13 CA040907004 1 20040906 G 7921 10750F OIL COOLER DHAV DHC8 DHC8311 1386006 EA PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE ENGINE LEAKING W O OTHER K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA 30284 (CAN) AFTER ENGINE START THICK WHITE SMOKE NOTICED COMING FROM THE ENGINE NR 2 BREATHER TUBE. OIL FOUND CONTAMINATED WI TH FUEL. FUEL COOLED OIL COOLER (PN 10750F SN 440) REPLACED IAW MM AIRCRAFT RETURNED TO SERVICE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004121000066 20041210 00066 2004 12 10 CA040907005 4 20040907 G 3416 7000700647 ADC AMD FALC50 FALCON900 2700160 EU GARRTT TFE731 TFE7315BR WP COCKPIT MALFUNCTIONED W O OTHER H ELECT. POWER LOSS-50 PC CR CRUISE 1 CA (CAN) DURING CRUISE FLIGHT THE CO-PILOT ALTIMETER SHOWED A GRADUAL LOSS OF 60' - 80'COMPARED TO THE PILOT'S ALTIMETER. I T REMAINED AT THE LOWER ALTITUDE FOR SEVERAL MINUTES BEFORE MATCHING UP WITH THE PILOT'S SIDE. THIS OCCURRED INTERMITTEN TLY OVER SEVERAL MONTHS. BOTH AIR DATA COMPUTERS WERE REPLACED, ALTIMETERS EXCHANGED SIDE TO SIDE AND FULL OPERATIONAL T ESTS AND LEAK TESTS OF BOTH PITOT-STATIC SYSTEMS WERE CARRIED OUT. NO FAULTS WERE FOUND AND THE PROBLEM REMAINED. WHEN T HE FAULT WAS PRESENT ATC CONFIRMED THE DIFFERENCE BETWEEN THE SYSTEMS THROUGH TRANSPONDER ENCODER SELECTION. AFTER SEVER AL CONTACTS WITH THE HONEYWELL ENGINEERING DEPARTMENT A TECHNICAL NEWSLETTER (A23-1980-04) CAME TO LIGHT WHICH PINPOINTE 2 L 7 3 4F 4 F RT A46EU E6WE 2004101300134 20041013 00134 WP 2004 10 13 CA040907006 2 20040907 G 7261 ENGINE AMD FALC50 FALCON900 2700160 EU GARRTT TFE731 TFE7315BR WP LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) FOLLOWING INSPECTION (OVERHAUL) OF ENGINES, OIL WAS SEEN DRIPPING FROM THE BREATHER VENT AFTER ENGINES SAT FOR 3-4 DAYS. AT REQUEST OF OVERHAUL AGENCY AND THE MFG, A PROCEDURE WAS FOLLOWED TO ENSURE CORRECT OIL LEVELS IN ENGINES. ENG INES WERE FOUND TO BE SERVICED TO CORRECT LEVEL BUT PROBLEM PERSISTED. THE OIL LOSS CAN BE SUBSTANTIAL (UP TO 500 ML. O VERNIGHT IAW ENGINE) AND POSSIBLE PROBLEMS DUE TO THE FLOODING OF THE GEARBOX WITH OIL PRIOR TO ENGINE START, HAVE NOT B EEN ASSESSED. INFORMED BY THE MFG THAT AT LEAST 10 ENGINES HAVE SEEN PROBLEM BUT TO DATE NO COMMON THREAD HAS BEEN IDE NTIFIED TYING THEM TOGETHER, IE. SAME REPAIR AGENCY, SAME DATE OF REPAIR, MOD STATUS. 2 L 7 3 4F 4 F RT A46EU E6WE 2004101300135 20041013 00135 NM 2004 10 13 CA040907007 1 20040829 G 3411 PITOT TUBE BOEING 727 727227 1384078 NM PWA JT8 JT8D9A 52048 NE PITOT STATIC SYS CONTAMINATED W C ABORTED TAKEOFF H ELECT. POWER LOSS-50 PC TO TAKEOFF 1 CA (CAN) F/O'S AIRSPEED INDICATED 0 KNOTS DURING TAKEOFF ROLL. UPON RETURN TO RAMP, MAINTENANCE INSPECTED F/O PITOT TUBE A ND FOUND DEBRIS INSIDE. LINE AND TUBE BLOWN OUT WITH DRY NITROGEN. PITOT STATIC TESTS CARRIED IAW M/M. AIRCRAFT DECLA RED SERVICEABLE. 2 L 7 3 4F 4 F A3WE E2EA 2004101800107 20041018 00107 EU 2004 10 18 CA040908001 1 20040904 G 1420 CONNECTOR AIRBUS 330 A330243 3930330 EU RROYCE RB211 RB211TRENT77 NE POWER UNIT BURNED W O OTHER B SMOKE/FUMES/ODORS/SPARKS DE DESCENT 1 CA (CAN) DURING DESCENT, FLIGHT ATTENDANT HAS REPORTED SPARK COMING OUT OF THE FASTEN SEAT BELT/NO SMOKING SIGN AT ROW 31 D EF. AFTER INVESTIGATION, FOUND THE READING LIGHT POWER UNIT BURNED AT ROW 31 DEF. POWER UNIT WAS DEACTIVATED AND REPLA CED AT NEXT MAINTENANCE STATION. DURING INVESTIGATION, FOUND A LOT OF CONDENSATION IN THE CABIN CEILING ABOVE THE POWER UNIT. INSULATION WAS ALSO FOUND WET. PROBLEM IS UNDER REVIEW WITH ENGINEERING AND MFG. 2 L 7 2 4F 4 F RT A46NM E39NE 2005031100052 20050311 00052 EU 2005 3 11 CA040908002 1 20040903 G 6120 580500018 CONTROL UNIT PIAGIO P180 P180 6960204 EU PWA PT6 PT6A66 52043 NE HARTZL HCE5N HCE5N3 GL LT PROPPELLER FROZEN W O OTHER E VIBRATION/BUFFET CR CRUISE 1 CA (CAN) LT CONDITION LEVER FROZEN, BECAME INOPERABLE AT ALTITUDE. 1 H 7 2 3O 4 T RT A59EU E26NE 5 C PZONE 2005012400024 20050124 00024 2005 1 24 CA040908003 4 20040907 G 3432 GLIDE SLOPE BEECH 200 B200 1152922 CE PWA PT6 PT6A42 52043 NE HARTZL HCB3T HCB3TN3 GL RIGHT ERRATIC W O OTHER O OTHER AP APPROACH 1 CA (CAN) RT GLIDESLOPE INDICATION VERY ERRATIC AND NO WARNING FLAP IN VIEW TELLING PILOT SIGNAL INVALID. MEL'ED SYSTEM AND TROUBLESHOOTING IN PROGRESS. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2005020100045 20050201 00045 EA 2005 2 1 CA040908004 2 20040903 G 8530 05K21108 CYLINDER PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL ENGINE SEPARATED W E A ENGINE SHUTDOWN UNSCHED LANDING E VIBRATION/BUFFET CR CRUISE 1 CA L91568A (CAN) DURING CRUISE FLIGHT MANIFOLD PRESSURE DROP WAS NOTICED. THROTTLE WAS INCREASED BUT PRESSURE WAS STILL DROPPING. A VIBRATION WAS NOTICED IN THE ENGINE AND AIR FRAME. THE ENGINE WAS SHUTDOWN AND SECURED AND A NORMAL LANDING CARRIED OUT. NR ONE CYLINDER ON THE RT ENGINE WAS FOUND TO HAVE ALL THE STUDS BROKEN ON IT EXCEPT FOR THE THROUGH BOLTS. THE C YLINDER HAD PULLED SLIGHTLY AWAY FROM THE ENGINE. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2005031000088 20050310 00088 EA 2005 3 10 CA040908005 2 20040819 G 7250 TURBINE BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA ENGINE FAILED W B A EMER. DESCENT UNSCHED LANDING Y D ENGINE STOPPAGE INFLIGHT SEPARATION HO HOVERING 1 CA 10031 DURING HIGH HOVER (LONG LINE) TO PICK UP LOAD, NR 1 POWER SECTION FAILED. INITIAL COMPRESSOR INLET INSPECTION (PLENUM A REA) REVEALED MOLTEN PARTICLES. FURTHER INVESTIGATION WILL COMMENCE ON POWER SECTIONREMOVAL/TEARDOWN INSPECTION. (ALTSN -6421.0). 1 G 7 1 4U 4 U H4SW E22EA 2005041500229 20050415 00229 2005 4 15 CA040909004 4 20040906 G 2200 3905300101 CONTROL UNIT AIRBUS 310 A310304 3930339 EU GE CF6 CF680C2A5 NE NR 5 SPOILER MALFUNCTIONED W O OTHER O OTHER CR CRUISE 1 CA (CAN) IN CRUISE, NR 5 SPOILER EXTENDED MOMENTARY FOLLOWED BY SPOILER 5FAULT ON ECAM. SPOILER PANEL RETRACTED ON IT S O WN. SPOILER RESET AFTER LANDING AND CHECKED OK.TROUBLING SHOOTING INDICATED NR 2 EFCU AT FAULT. NR 2 EFCU REPLACED AND D FDR REMOVED AND SENT FOR READ OUT. FLIGHT CREW CONFIRMED MOMENTARY ROLL OF THE AIRCRAFT. 2 L 7 2 4F 4 F RT A35EU E13NE 2005041500230 20050415 00230 EU 2005 4 15 CA040909005 1 20040905 G 6220 350A37150802 PITCH LINK AEROSP AS355 AS355F1 8680810 EU ALLSN 250C 250C20F 03013 GL MAIN ROTOR HEAD BROKEN W A UNSCHED LANDING F FLT CONT AFFECTED CR CRUISE 1 CA (CAN) DURING CRUISE FLIGHT PILOT FELT SUDDEN VIBRATION IN THE M/R FLIGHT CONTROLS SYSTEM. A/C LANDED AT FIRST SUITABLE SITE. UPON INSPECTION, AME DISCOVERED THAT THE 'SCREW IN' RETAINING CUPS ON ONE OF THE M/R PITCH LINKS LOWER ROD ENDS D ISINTEGRATED THUS ALLOWING THE BEARING INNER RACE TO SLIP OUT OF THE OUTER RACE.THE ANTI-ROTATION PINS IN ROD END WERE I NTACT(REFER TO ATTACHED PHOTOS. SOME DAMAGETOTHE ROTATING SWASHPLATE HORNS WAS ALSO SUSTAINED.THIS PARTICULAR P/N ROD E ND IS SUBJECT OF EUROCOPTER AS355 SB 05.19. IT HAS BEEN FURTHER DETERMINED THAT THE ANTI-ROTATION RIVET WAS NOT ENGAGED IN N EITHER THE OUTER RACE' NOR ROD END'STHREADS - THUS NO LOCKING ACTION. 1 G 7 2 3U 3 U H11EU E4CE 2004101300040 20041013 00040 NE 2004 10 13 CA040909006 1 20040611 G 6230 SB1562101 BEARING SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30S 03013 GL M/R SWASHPLATE SPALLED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING ROUTINE 3 YEAR INSPECTION OF THE MAIN ROTOR SWASHPLATE DUPLEX BEARING AME DISCOVERED ONE OF THE BALLS TO BE SEVERELY SPALLED, BEARING WAS REPLACED AND A/C RETURNED TO SERVICE. SUBSEQUENTLY THE OUTER RACE WAS CUT OPEN REVEALING NO OTHER DAMAGE TO EITHER THE INNER OR OUTER RACES. 1 G 7 2 3U 3 U H1NE E1GL 2005011100018 20050111 00018 2005 1 11 CA040909008 4 20040828 G 3457 KLN90B GPS PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL COCKPIT INTERMITTENT W K NONE H ELECT. POWER LOSS-50 PC IN INSP/MAINT 1 CA (CAN) SECOND OCCURENCE OF GPS SCREEN MOMENTARILY GOING BLANK, THEN BACK ON NORMAL.GPS UNIT WAS REPLACED WITH SERVICEABLE UNIT.FUNCTION CHECKS NORMAL. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005012100162 20050121 00162 EU 2005 1 21 CA040909009 1 20040903 G 3242 PISTON PARKERHANFIN PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL BRAKE ASSY LEAKING W O OTHER K FLUID LOSS TX TAXI/GRND HDL 1 CA 1028 (CAN) WHILE TOWING AIRCRAFT INTO HANGAR, FLUID WAS OBSERVED ON THE RT MAIN WHEEL TIRE. INSPECTION REVEALED THE FLUID WA S COMING FROM ONE OF THE BRAKE PISTONS. BRAKE ASSY WAS REPLACED. NOTE: THERE WAS STILL 9MM OF THE WEAR INDICATOR SHOWIN G. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005031100041 20050311 00041 EU 2005 3 11 CA040909010 1 20040908 G 3060 4E305110 BOOT PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL PROPELLER MALFUNCTIONED W O OTHER J WARNING INDICATION DE DESCENT 1 CA (CAN) PILOT REPORTED A PROP DEICE MALFUNCTION AS INDICATED ON THE CAWS PANEL. ONE PROP BOOT WAS FOUND WITH AN OPEN CIRC UIT. BOOT REPLACED WITH NEW, RETURNED TO SERVICE. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005041500231 20050415 00231 EA 2005 4 15 CA040910000 2 20040908 G 7314 RG9080J4AM PUMP PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL ENGINE FUEL LEAKING W O OTHER R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 CA (CAN) PILOT FOUND THAT FUEL PRESSURE IN CRUISE WAS FLUCTUATING AND AT IDLE THE FUEL PUMP DID NOT MAINTAIN RATED PRESSURE . DURING INSPECTION OF THE PUMP FOUND FUEL STAINS ON PRESSURE RELIEF VALVE, THE VALVE WAS LEAKING AT ITS FLANGE. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2005041500232 20050415 00232 CE 2005 4 15 CA040910001 1 20040909 G 3320 1015307641 FIXTURE BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA HARTZL HCB3T HCB3TN3 GL CABIN LIGHT MELTED W O OTHER M B OVER TEMP SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 CA PLASTIC HOUSING OF THE LIGHT SHIELD P/N 101-530764-1 HAS MELTED DUE TO THE HEAT PRODUCED BY THE HIGH WATTAGE RESISTOR MO UNTED ON THE LIGHT ASSY PRINTED CIRCUIT BOARD P/N PW2014. IT HAD MELTED ENOUGH TO DISFIGURE THE SHIELD AND PRODUCE AN EL ONGATED HOLE THE LENGTH OF THE RESISTOR. APPROX 2 INCHES. THE PROBLEM WAS DISCOVERED ON THE REPLACEMENT OF THE FLOURESCE NT BULB P/N 5108WW. THERE HAD BEEN NO REPORT OF A BURNING SMELL BY ANY OF THE VARIOUS AIRCREWS, WHO HAVE FLOWN THIS AIRC RAFTI NSPECTION OF OTHER LIGHTS IN THE SAME AIRCRAFT AND ANOTHER SIMILAR AIRCRAFT REVEALS THAT THERE EXISTS A FLEETPROBL EM. RAYTHEON BEECH KINGAIR ENGINEERING HAS BEEN ADVISED OF THE PROBLEM. REFERENCES:- IPC 33-20-00-01 PAGES 0 AND 1 ITE 1 L 7 2 3T 4 T RT 3A20 E4EA 6 C P15EA 2005041500233 20050415 00233 SW 2005 4 15 CA040910002 1 20040824 G 2910 7012J220W234 HOSE BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA HYD SYSTEM BURST W D RETURN TO BLOCK K F FLUID LOSS FLT CONT AFFECTED TX TAXI/GRND HDL 1 CA BEFORE FIRST FLIGHT DURING HYDRAULIC TESTING, PILOT SWITCHED 'OFF' NR 2 HYDRAULIC SYSTEM. AFTER THE SYSTEM WAS SWITCHED BACK 'ON' PRESSURE INDICATION FELL OFF TOZERO. A/C WAS SHUTDOWN. SUBSEQUENT INSPECTION REVEALED THAT THE BRAIDED NR 2 HYDRAULIC HOSE FROM THE PUMP TO MIXING VALVE WAS BURST AT THE 45 DEGREE FITTING (SEE ATTACHED PHOTO). HOSE REPLACED, A /C RETURNED TO SERVICE. 1 G 7 1 4U 4 U H4SW E22EA 2005041500234 20050415 00234 EA 2005 4 15 CA040910003 2 20040908 G 8500 ENGINE ROBSIN R44 R44 7640120 WP LYC O540 O540F1B5 41532 EA MAKING METAL W K NONE O OTHER IN INSP/MAINT 1 CA L2599340A (CAN) DURING AN SCHEDULED INSPECTION, THE OIL FILTER WAS LITTERED WITH METAL CONTAMINATION. THERE WAS EVIDENCE OF BRASS, ALUMINUM AND FERRIOUS METAL. THE ENGINE WAS REMOVED AND WILL BE SENT TO THE OVERHAUL SHOP FOR FURTHER INVESTIGATION. TH E PISTON PIN PLUGS ARE A DEFINITE SUSPECT IN REGARDS TO THE BRASS FLAKES. ONCE THE ENGINE IS DISASSEMBLED, FURTHER REASO NS FOR THE CONTAMINATION WILL BE AVAILABLE. 1 G 7 1 3O 3 O H11NM E295 2005041500235 20050415 00235 EU 2005 4 15 CA040910004 1 20040907 G 2750 CONTROL SYSTEM PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL TE FLAPS MALFUNCTIONED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) WHILE RETRACTING FLAPS AFTER TAKEOFF , 'FLAPS' CAUTION ILLUMINATED , FLAP OPERATION STOPPED.AIRCRAFT RETURNED FOR LANDING , FLAP ASSYS INSPECTED FOR OBVIOUS DEFECTS , FLAPSMEASURED FOR POSSIBLE ASSYMETRY , SATISFACTORY. GROUND RESET FUNCTIONED NORMAL . AFTER RETURNING TO BASE , FLAP SYSTEM WAS FUNCTION TESTED , A ZERO SET WAS ALSO PERFORMED. NO ADDIT IONAL FAULTS DETECTED. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005041500236 20050415 00236 NE 2005 4 15 CA040910005 2 20040910 G 7250 TURBINE BLADES BOEING 727 72725C 138400H NM PWA JT8 JT8D7B 52053 NE NR 1 ENGINE DAMAGED W C ABORTED TAKEOFF D E INFLIGHT SEPARATION VIBRATION/BUFFET TO TAKEOFF 1 CA 64195 655161 (CAN) AFTER TAKEOFF POWER WAS SET A LOUD BANG AND VIBRATION WAS EXPERIENCED FROM THE NR 1 ENGINE. TAKEOFF REJECTED. ENGI NE SECURED AND AIRCRAFT RETURNED TO RAMP. VISUALINSPECTION UP TAILPIPE REVEALED ENGINE HAD FAILED INTERNALLY. TURBINE BL ADES MISSING. 2 L 7 3 4F 4 F A3WE E2EA 2004101300041 20041013 00041 EU 2004 10 13 CA040910006 1 20040827 G 2912 P1110 FILTER SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE HYD SYSTEM DEBONDED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING A SCHEDULED INSPECTION AME ATTEMPTED TO REMOVE HYDRAULIC FILTER ELEMENT. THE SREW IN PLUG PORTION SEPARATE D FROM THE FILTER ELEMENT THAT REMAINED IN THE FILTER BOWL. THE SYSTEM WAS FLUSHED, FILTER REPLACED AND A/C RETURNED TO SERVICE. 1 G 7 1 3U 3 U NC H9EU E19EU 2004123000122 20041230 00122 EU 2004 12 30 CA040910007 1 20040827 G 7400 IGNITION UNIT PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL ENGINE MALFUNCTIONED W K NONE O OTHER IN INSP/MAINT 1 CA UNCOMMANDED DISCHARGE OF ENG IGNITERS DURING ROUTINE 100 HR MX WHILE PERFORMING FUNCTION CHECK OF PROBES ELEMENTS, AN UN COMMANDED DISCHARGE OF THE IGNITERS OCCURRED. GROUND POWER WAS APPLIED AND ON, PROBES SWITCH TURNED ON AT PANEL FOR APP X 30 SECS. BY PILOT IN COCKPIT WHILE MX CONDUCTED A WALK AROUND TO VERIFY PROBES ELEMENT HEAT.ONFINAL STAGE OF CHECK AT OR BEYOND TIME PROBES SWITCH SET TO OFF A D DISSIPATING DISCHARGE SOUND WAS HEARD FROM/AROUND THE ENG (APPX 5-6 FLASHES) THEN STOPPED. THE ENG WAS COMPLETELY DE-COWLED. ENGINE MX PERFORMED EARLIER IN THE DAY, COMPLETE WITH A FUNCTION CHECK O F THE IGNITERS. THEY WERE SECURELY INSTALLED AT THE TIME OF THE INCIDENT. THIS ANOMALY HAS OCCURRED 3 TIMES PREVIOUSLY. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005041800001 20050418 00001 NM 2005 4 18 CA040911001 1 20040910 G 2400 ELECTRICAL SYS DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE DAMAGED W K NONE G S MULTIPLE FAILURE AFFECT SYSTEMS IN INSP/MAINT 1 CA (CAN) WHILE AIRCRAFT PARKED ON APRON , UPON CREW ARRIVAL TO GET READY FOR DEPARTURE , THE CREW NOTICED SEVERAL CIRCUT BR EAKERS WERE POPPED AND THE ATTEMPT TO RESET WAS NOT SUCCESFUL . MAINTENANCE SUSPECT THE FAULT TO BE WITH THE GROUND POWE R UNIT WHICH WAS ATTACHED TO AIRCRAFT , HOWEVER THE FOLLOWING PARTS NEEDED TO BE REPLACED PIROR TO RETURN AIRCRAFT TO SE RVICE 1- BOTH FUEL FLOW INDICATORS P/N SEL-OC8J 2- CABIN PRESSURE CONTROLLER P/N SET LOCH20F 3- FLIGHT. GUIDANCE CONTROL LER P/N 7003975-901 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005031100090 20050311 00090 CE 2005 3 11 CA040911002 1 20040910 G 2752 A31691 ACTUATOR BEECH 100 100BEECH 1152916 CE PWA PT6 PT6A28 EA HARTZL HCD4N3 HCD4N3A GL TE FLAPS BENT W O OTHER O OTHER AP APPROACH 1 CA (CAN) FLAPS STOPPED AT APPROACH POSITION AND COULD NOT BE LOWERED ANY FURTHER. SINCE AIRCRAFT WAS LANDING NO OTHER ACTIO N WAS TAKEN WHILE IN FLIGHT. ON GROUND IT WAS DETERMINED THAT FLAPS WOULD NOT LOWER OR RETRACT. FURTHER INVESTIGATION DETERMINED THE FLAP ACTUATOR HAD INTERFERED WITH THE RT IB FLAP WHILE IT WAS BEING LOWERED. SINCE THE LIMIT SWITCHES ARE LOCATED ON THE IB RT FLAP THE FLAP MOTOR AND DYNAMIC FLAP RELAY OVERHEATED BEFORE THE CIRCUIT BREAKER TRIPPED. THE FLA P ACTUATOR WAS RETURNED TO ITS PROPER POSITION AND THE FLAP MOTOR AND FLAP RELAY WERE REPLACED WITH SERVICEABLE UNITS. 1 L 7 2 3T 4 T A14CE E4EA 5 C STC 2005041800002 20050418 00002 EU 2005 4 18 CA040913002 1 20040901 G 7712 TORQUEMETER SNIAS 350 AS350B3 8680954 EU TMECA ARRIEL ARRIEL2B NE COCKPIT LOOSE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THE RESULTS FROM A ROUTINE POWER CHECK ON ENGINE SHOWED A BAD TORQUE MARGIN. OTHER PARAMETERS WERE CONSISTENT WIT H PREVIOUS POWER CHECKS. TROUBLESHOOTING REVEALED A MISPLACED OR MISSING PIN ON TORQUEMETER REFERENCE SHAFT. DURING TRO UBLESHOOTING, WASHER WAS FOUND IN MODULE 01 SCAVANGE OIL STRAINER. ENGINE WAS REMOVED FROM AIRFRAME AND POWER SHAFT ASSY REPLACED. UPON REMOVAL, ALTHOUGH NOT MISSING ANY PINS, IT WAS CONFIRMED THAT TORQUEMETER REFERENCE SHAFT HAD PLAY, THU S GIVING ERRATIC TORQUE READING. WASHER FOUND IN SCAVANGE OIL STRAINER WILL BE ANALYZED BY ENGINE MFR LABORATORY TO DET ERMINE ITS ORIGIN. ENGINE WAS REINSTALLED AND A POWER CHECK PERFORMED. ALL PARAMETERS WERE NORMAL. 1 G 7 1 3U 3 U H9EU E00054EN 2005041800003 20050418 00003 CE 2005 4 18 CA040913003 1 20040911 G 2710 07606331 BLOCK CESSNA 182 182Q 2072732 CE CONT O470 O470U 17026 SO MCAULY 2A34C C2A34C204 GL AILERON CONTROL WORN W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) AILERON SYSTEM CONTROL TUBE ASSEMBLY FORWARD SHAFT P/N 1260141-6/10 WAS WORN 25-30% DUE TO A FAILED CORRODED SUPPO RT BEARING P/N 0760633-1. SOME NEEDLES FROM THE BEARING ASSEMBLY WERE MISSING. 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 2005032400022 20050324 00022 EA 2005 3 24 CA040913004 1 20040904 G 5510 F5131 HINGE FOUND FBA FBA2C 3640102 EA LYC O540 IO540* 41532 EA HARTZL HCC3Y HCC3YR GL TRIM HINGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA DURING A ROUTINE MX INSPECTION, CRACK WAS DISCOVERED ON THE STABILIZER TRIM HINGE ASSY, (PORT SIDE) P/N: F513-1. TOTAL TIME ON AIRFRAME (AND PART) WAS 802 HOURS. THE CRACK WAS LOCATED BETWEEN THE RADIUS OF THE HINGE ARM AND LIGHTENING HOL E OF HINGE BODY. REPLACEMENT PARTS WERE INSTALLED AS PER MANUF INSTRUCTIONS PRIOR TO NEXT FLT. A/C MANUF HAS ISSUED S/ B SB-55-02 HORIZ STABILIZER HINGE MOD FOR ALL MODELS FAC 2C1 A/C. THIS IS A 2-PART SERVICE BULLETIN. THE FIRST PART IS AN IMMEDIATE INSPECTION PRIOR TO NEXT FLT AND RE-INSPECTION EVERY 50 HOURS THEREAFTER UNTIL REPLACEMENT OF HINGES. THE SECOND PART OF THE SB IS IMMEDIATE REPLACEMENT OF HINGES IF CRACKS ARE DISCOVERED OR MANDATORY REPLACEMENT ON OR BEFORE 1 H 7 1 3O 3 O A7EA 1E4 5 C P25EA 2005032400023 20050324 00023 NE 2005 3 24 CA040913005 2 20040901 G 8530 399353 CYLINDER HEAD DHAV DHC2 DHC2* 2800108 EA PWA R985 R985AN14B 52008 NE HAMSTD 22D 22D30 NE ENGINE SEPARATED W B A EMER. DESCENT UNSCHED LANDING R PARTIAL RPM/PWR LOSS CR CRUISE 1 CA CYLINDER HEAD CRACKED 360 DEGREES WHILE AIRCRAFT WAS IN CRUISE FLIGHT. AIRCRAFT WAS ABLE TO MAKE IT BACK TO BASE. CYLI NDER WAS CHANGED BY KOBY'S AIRCRAFT. IT WAS THEN GROUND RUN AND FOUND TO BE SERVICEABLE AND RETURNED TO SERVICE. 1 H 7 1 3R 3 R A806 5E1 5 C P736 2005041800004 20050418 00004 EU 2005 4 18 CA040913006 1 20040830 G 2750 U2801 STARTER UNIT BRAERO 748 HS7482A 4231001 EU RROYCE DART DART5342 EU TE FLAPS MALFUNCTIONED W O OTHER F FLT CONT AFFECTED AP APPROACH 1 CA (CAN) AFTER LANDING, THE CREW WAS ABLE TO RETRACT FLAPS BEYOND 22 DEGREES. THE AIRCRAFT WAS MOVED TO XXX FOR FERRY PERMI T. MAINTENANCE REPLACED THE FLAP STARTER UNIT AND THE AIRCRAFT WAS RETURNED TO SERVICE 2 L 7 2 3T 4 T A24EU A196 2004101300042 20041013 00042 NM 2004 10 13 CA040913007 1 20040905 G 2782 BEARING BOEING 727 727233 138408A NM PWA JT8 JT8D15A 52051 NE SLAT ACTUATOR SEPARATED W J A DUMP FUEL UNSCHED LANDING F J FLT CONT AFFECTED WARNING INDICATION CL CLIMB 1 CA DA4735 (CAN) DURING DEPARTURE, THE CREW OBSERVED A CONTINUOUS SLAT PROBLEM INDICATION. THE AIRCRAFT RETURNED TO POINT OF DEPART URE. MAINTENANCE FOUND THE NR 5 SLAT ROD END BEARING SEPARATED FROM THE PISTON, AND THE SLAT DAMAGED BY THE PISTON. THE ACTUATOR AND SLAT ASSYS WERE REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. THE ATTACH POINT OF THE ROD END BEARING TO THE PISTON ON THIS UNIT WAS ENCLOSED IN SHRINK SLEEVE AND THE CONDITION WAS NOT READILY EVIDENT. A FLEET INSPECTION HAS BEEN INITIATED. 2 L 7 3 4F 4 F RT A3WE E2EA 2004101800142 20041018 00142 EA 2004 10 18 CA040913008 2 20040910 G 8530 LW16740 VALVE LYC PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL CYLINDER WORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING A CYLINDER CHANGE ON THE ENGINE THE EXHAUST RISERS WERE REMOVED TO ALLOW FOR INSTALLATION. WHILE CHECKING THE EXHAUST PORTS FOR FOD IT WAS NOTICED THAT THERE WAS ABNORMAL WEAR ON THE NR 3 EXHAUST VALVE JUST ABOVE THE MUSHROOM. FURTHER INSPECTION FOUND THAT THE EXHAUST VALVE ON THE NR 6 CYLINDER HAD THE SAME PROBLEM. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2005020100047 20050201 00047 NE 2005 2 1 CA040914001 2 20040914 G 7200 ENGINE DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE NR 2 FAILED W A UNSCHED LANDING Y J ENGINE STOPPAGE WARNING INDICATION CR CRUISE 1 CA 12367 (CAN) AIRCRAFT EXPERIENCED AN UNCOMMANDED IN-FLIGHT SHUTDOWN OF THE NR 2 ENGINE, UNEVENTFUL SINGLE ENGINE LANDING WAS PE RFORMED. MECHANICS FOUND PLENTY OF CHIPS IN THE OIL COOLER AND AT THE POWER TURBINE. POWER TURBINE AND LPC 1 IS JAMMED WHILE THE PROPELLER CAN STILL BEING TURNED (WITH A SQUEAKING NOISE) SEEMS THE POWER TURBINE SHAFT IS FRACTURED, MAYBE D UE TO A BLOWN BEARING. THE OVERHAULED ENGINE WAS INSTALLED ON 11.OCT 2001. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005041800005 20050418 00005 2005 4 18 CA040914002 4 20040806 G 2562 BS2173 BATTERY PACK DORNEMARGLN ELT81 ELT LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA 23160E (CAN) UPON YEARLY INSPECTION, BATTERY PACK REFERENCED ABOVE WAS FOUND TO BE LEAKING ON MAIN CIRCUIT BOARD CAUSING THE BO ARD TO SHORT CIRCUIT AND MALFUNCTION. NOTE TH AT THIS WAS A PASSIVE FAILURE AND THAT THE ELT WAS NOT TRANSMITTING UNCOMM ANDED. PREVIOUS CERTIFICATION ON AUGUST 5, 2003 REFERENCE. 2005032400025 20050324 00025 NE 2005 3 24 CA040914003 2 20040903 G 7314 P94C16612 PUMP UROCOP EC120 EC120B 8680987 EU TMECA ARRIUS ARRIU2F NE ENGINE SHORTED W O OTHER J WARNING INDICATION NR NOT REPORTED 1 CA DURING START SEQUENCE, ELECTRIC BOOST PUMP TRIPPPED CIRCUIT (3A) BREAKER. PUMP REPLACED.AF FUEL SYSTEM FILTER CONTAINED APPROXIMATELY 10 SMALL, NON-FERROUS, METAL SLIVERS. PRESUMED TO BE ALUMINUM. (PRIOR START PUMP CHANGED DUE TO NON-FERR OUS METAL GENERATION.) 1 G 7 2 3U 3 U NC R0001RD E34NE 2005032400026 20050324 00026 EU 2005 3 24 CA040914004 1 20040910 G 2421 B3508 GENERATOR BRAERO 748 HS7482A 4231001 EU RROYCE DART DART5342 EU ROTOL R4304 R2124304 EU PORT SIDE INOPERATIVE W E ENGINE SHUTDOWN H J ELECT. POWER LOSS-50 PC WARNING INDICATION TX TAXI/GRND HDL 1 CA PORT GENERATOR WON'T COME ON LINE. PORT GENERATOR REPLACED S/N OFF 1878. GROUND RUN CHECK SERVICEABLE. 2 L 7 2 3T 4 T A24EU A196 6 C P899 2005041800006 20050418 00006 EU 2005 4 18 CA040914005 1 20040908 G 5610 C561S1101202 WINDSHIELD UROCOP EC120 EC120B 8680987 EU TMECA ARRIUS ARRIU2F NE COCKPIT DEBONDED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WINDOW LT UPPER PN C561S3101202, DEBONDING 11. 1 G 7 2 3U 3 U NC R0001RD E34NE 2005041800007 20050418 00007 NE 2005 4 18 CA040914006 2 20040831 G 7200 ENGINE PWA JT15 JT15D4 52112 NE FAILED W K NONE C F.O.D. IN INSP/MAINT 1 CA 70884 (CAN) ENGINE WAS REMOVED FROM THE WING AFTER REPORTED HIGH VIBRATIONS. ENGINE SUFFERED AN IMPELLER FAILURE CAUSING SECO NDARY DAMAGE TO DOWNSTREAM COMPONENTS. WITH THE MISSING MATERIAL FROM THE IMPELLER AND THE DAMAGE FOUND THE HIGH TURBINE BLADES, HIGH ROTOR BALANCE WOULD BE ADVERSELY AFFECTED AND THIS WAS LIKELY THE CAUSE OF THE HIGH VIBRATIONS.THE IMPELLE R INSTALLED IN THIS ENGINE WAS P/N 3028345, PRE SB 7187. THESE IMPELLERS ARE PRONE TO FAILURE SIMILAR TO THE FAILURE ON THIS ENGINE. NO DAMAGE UP STREAM OF THE IMPELLER WAS FOUND TO INDICATE FOD DAMAGE.THE ENGINE WILL REQUIRE HPT BLADE AND IMPELLER REPLACEMENT, AND WILL UNDERGO A HSI TO DETERMINE WHICH COMPONENTS MAY BE RE-INSTALLED, REPLACED OR REPA IRED PR 4 F E1NE 2004101300043 20041013 00043 EU 2004 10 13 CA040914007 1 20040913 G 3210 LANDING GEAR FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE OUT OF POSITION W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) MAIN GEAR UNSAFE APPEARED ON MFDS AFTER GEAR RETRACTION. AIRCRAFT LANDED BACK TO DEPARTURE AIRPORT. MAINTENANCE FOUND THE LANDING HYDRAULIC TEST VALVE LT IN (GROUND ONLY) POSITION. THE VALVE WAS LEFT IN THAT POSITION FOLLOWING A GE AR RETRACTION/EXTENSION TEST AND WAS OMITTED TO BE RE-POSITIONED TO NORMAL. THE (GROUND ONLY) POSITION RESTRICTS THE HY DRAULIC FLOW FOR A SAFE GROUND OPERATION. 2 L 7 2 4F 4 F RT E25NE 2004101800136 20041018 00136 GL 2004 10 18 CA040914008 3 20040908 G 6114 FLANGE CESSNA 150 150J 2071820 CE CONT O200 O200A 17020 SO MCAULY 1A101 1A101DCM GL PROPELLER CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA G7462 (CAN) PROPELLER REMOVED FOR CORROSION INSPECTION UNDER CAR 625, APPENDIX C, PARA 5. MOUNTING FLANGE CORRODED BEYOND REP AIR. 1 H 7 1 3O 3 O 3A19 E252 5 N P918 2004102000195 20041020 00195 NE 2004 10 20 CA040914009 1 20040910 G 6520 7665005801112 SERVO SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30S 03013 GL TAIL ROTOR LEAKING W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA (CAN) AIRCRAFT IS CURRENTLY ON THAI REGISTRY BUT WE HAVE SUBMITTED THIS SDR AS THIS IS THE SECOND OCCURRENCE OF THIS TYP E IN THE PAST 2 YEARS. A/C RETURNED TO BASE REPORTING HYDRAULIC SYSTEM LIGHT. INVESTIGATION REVEALED TGB (OVERFILLED ) IT WAS CONCLUDED THAT TAIL ROTOR SERVO HAD MASSIVE INTERNAL LEAK THAT CONSEQUENTLY FILLED UP TGB. TAIL ROTOR SERVO WA S REPLACED. QUICK RIGGING CHECK WAS CARRIED OUT AIRCRAFT WAS TEST FLOWN SATISFACTORY AND RETURNED TO SERVICE. 1 G 7 2 3U 3 U H1NE E1GL 2004101800137 20041018 00137 EA 2004 10 18 CA040915001 1 20040913 G 2720 SDBA6709340001 LIMITER CNDAIR CL600 CL6002C10 1390015 EA RUDDER MALFUNCTIONED W A UNSCHED LANDING F FLT CONT AFFECTED CR CRUISE 1 CA 10166 (CAN) RUDDER LIMITER CAUTION MESSAGE POSTED IN FLIGHT WITH FLAP AT 1220 KNOTS WHILE CONDUCTING RUDDER LIMITER CHECK IAW MANUFACTURING FUNCTIONAL TEST PROCEDURE, RTL REDUCED TO .1250 BEFORE OPENING FULLY. 2 L 7 2 4F RT A21EA 2005041800008 20050418 00008 EU 2005 4 18 CA040915002 1 20040910 G 1430 HL720PN1630 LOCK BOLT BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE RT WING CORRODED W O OTHER O OTHER NR NOT REPORTED 1 CA 39581 39581 (CAN) DURING REPAIR OF RIGHT WING FUEL LEAK, THE HEAD OF THE LOWER HYLOCK BOLT ATFUSELAGE TO WING ATTACHMENT ASSEMBLY AT STATION 29 WAS DISLODGED BY A PLASTIC P RC SCRAPER (REF IPC 53-30-01-15 PAGE 0 ITEM 75).FURTHER INVESTIGATION FOUND THE HEAD OF THE BOLT SEPARATED FROM THE SHANK DUE TOSEVERE CORROSION, AND THE BOLT HOLE PITTED. THE BOLT HOLE WAS CLEANED O UT, NDTINSPECTED, AND A NEW FASTENER INSTALLED PER SRM 51-45-00 WITH NO FURTHER FAULTS. 2 H 7 4 4F 4 F A49EU E6NE 2005041800009 20050418 00009 2005 4 18 CA040915003 4 20040914 G 3418 9754421421 SENSOR PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL AOA VANE FAILED W K NONE L NO TEST IN INSP/MAINT 1 CA (CAN) VANE/WING HEATING SECTION HAD FAILED, AOA VANE ASSEMBLY REPLACED WITH NEW 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005041800010 20050418 00010 NM 2005 4 18 CA040915004 1 20040911 G 2913 570717570729 COUPLER DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE HYD PUMP WORN W O OTHER J WARNING INDICATION LD LANDING 1 CA MX425297D (CAN) THE CREW OF OVERSHOT RUNWAY DUE TO AN UNSPECIFIED PROBLEM. THE CREW ADVISED THATERS WAS NOT REQUIRED AND LANDED 20 MINUTES LATER WITHOUT INCIDENT. NO OPERATION AL IMPACT. ENTRY FROM MAINTENANCE OPS SUMMARY DURING GEAR EXTENSION CREW REPORTED THEY HAD A YELLOW GEAR DOOR LIGHT AND PRESSURE DROPPED TO ZERO. CREW ELECTED TO CARRY OUT ALTERNATE GEAR EXTENS ION AND NOTICED NR 2 EDP CAUTION LIGHT ILLUMINATED J/L NR 2 DEFECT 414058 LANDING GEAR WOULD NOT EXTEND NORMALLY AMBER DOOR LIGHTS AND A LOUD GRINDING NOISE. NO NR 2 STANDBY OR MAIN PRESS. COMPLETED EMERG. CHKLIST & ALT GEAR EXT.RECTIFICAT ION REPLACED NR 2 ENGINE DRIVEN HYD PUMP DUETO SHAFT SPLINE WEAR. A/C GRD RAN, HYDRAULICS FUNCTIONED & LEAK CHECKED. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005041800011 20050418 00011 NE 2005 4 18 CA040915005 2 20040915 G 8530 399359 CYLINDER DHAV DHC3 DHC3 2800202 EA PWA R1340 R1340AN1 52016 NE ENGINE CRACKED W A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 CA 6447 (CAN) CYLINDER EXHAUST VALVE EAR BROKEN OFF. CRACK INITIATED FROM THE ROCKER SHAFT BUSHING AREA AND CRACKED AROUND TO OP POSITE SIDE. COMPLETE TOP CAME OFF FROM BUSHING TO BUSHING. 1 H 7 1 3R 3 R A815 5E2 2005041800012 20050418 00012 CE 2005 4 18 CA040915006 1 20040910 G 2752 505212223 ACTUATOR BEECH 100 A100 1152915 CE PWA PT6 PT6A28 EA TE FLAPS MALFUNCTIONED W O OTHER F J FLT CONT AFFECTED WARNING INDICATION AP APPROACH 1 CA (CAN) ON APPROACH FOR A MX CHECK, FLAPS WERE EXTENDED IAW CHECKLIST. A RUDDER CORRECTION REQUIRED TO KEEP ACRFT ON APPR OPRIATE TRACK. AN UNEVENTFUL LANDING COMPLETED AND ACRFT SNAGGED. UPON INSPECTION IT WAS DETERMINED THAT THE FLAP ACTUAT OR FOR THE LT, I/B FLAP HAD FAILED IN THE DRIVE AREA. IT WAS DETERMINED THAT THE 90 DEGREE DRIVE IN THE ACTUATOR HAD FAI LED AND INPUT TO THE ACTUATOR WAS TURNING BUT IT WAS NOT DRIVING THE ACTUATOR DOWN. AS A RESULT, THERE WAS AN ASYMETRIC FLAP CONDITION ON LANDING REQUIRING THE RUDDER CORRECTION. IT SHOULD BE NOTED THAT THERE IS NO INDICATION OR OTHER SYSTE M TO SHOW AN ASYMETRIC FLAP SITUATION OR TO STOP THE FLAPS FROM EXTENDING BEYOND A CERTAIN POINT IN THE AIRCRAFT. 1 L 7 2 3T 4 T A14CE E4EA 2005041800013 20050418 00013 EA 2005 4 18 CA040915007 1 20040806 G 2140 576 EXHAUST STACK DHAV DHAV DHC2 DHC2* 2800108 EA PWA R985 R985AN14B 52008 NE CABIN HEATER BULGED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) UNIT IS CALLED A COFFEE CAN TYPE CABIN HEATER, CRACK ONLY VISIBLE WHEN THE UNIT WAS REMOVED FROM THE AIRCRAFT EX HAUST SYSTEM (C2EE249). THE DEFECT WAS NOTED DIRECTLY BEHIND THE TRIANGULAR AIR DEFLECTOR AT THE AIR INLET TO THE CABIN HEATER. THE CRACK WAS NOT VISIBLE WHILE THE EXTERNAL HEAT SHROUD WAS REMOVED FOR INSPECTION (CF-90-03-R2). RECOMMEND A D ETAILED INTERNAL INSPECTION OF THE EXHAUST STACK FOR FUTURE INSPECTIONS OF THIS STYLE OF DHC2 CABIN HEATER. 1 H 7 1 3R 3 R A806 5E1 2004101300044 20041013 00044 CE 2004 10 13 CA040915008 1 20040430 G 3246 16449 STRAP CESSNA 180 180J 2072622 CE CONT O470 O470S 17026 SO MCAULY 2A34C 2A34C203 GL FLOAT CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 1113 (CAN) SLIGHT BULGE WAS NOTED ON EDGE OF STRAP (PN 16449) EXTERIOR OF FLOAT SKIN. FURTHER INVESTIGATION INVOLVED REMOVIN G STRAP ASSY FROM FLOAT SKIN, INVESTIGATION REVEALED EXTENSIVE CORROSION, TO POINT THAT FLOAT HULL SKIN WAS SEVERELY DEF ORMED(BEING PUSHED INWARD FROM CORROSION PROCESS HAPPENING UNDER STRAP). VERY FEW VISUAL CLUES WERE PRESENT ON EXTERIOR OF FLOAT. ONLY WAY POSITIVE ID WAS PREFORMED WAS TO REMOVE SPREADER BARS FROM FLOATS AND CONDUCT DETAILED VISUAL INSP ON UNDER SIDE OF STRAP ATTACHING POINTS. RECOMMEND THIS DETAILED INSP AT TIME OF MAJOR OVERHAUL. NOTE: THIS SET OF FLO ATS HAD OPERATED FOR MOST OF THEIR LIFE IN FRESH WATER ENVIRONMENT, FOR LAST 8 YEARS HAVE BEEN OPERATED IN SALTWATER. 1 H 7 1 3O 3 O 5A6 E273 5 C P3EA 2004101800133 20041018 00133 EA 2004 10 18 CA040915009 1 20040826 G 5521 GUSSET DHAV DHAV DHC2 DHC2* 2800108 EA PWA R985 R985AN14B 52008 NE HAMSTD 2D 2D30 NE LT ELEVATOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA SA397LH (CAN) LT TOP ELEVATOR TIP GUSSET (LOCATED BETWEEN ELEVATOR TIP SKIN AND ELEVATOR SPAR) WAS FOUND CRACKED DURING INSPECTI ON. NOTE: THE PROPELLER WAS REMOVED AND OVERHAULED, AFTER 30.0 HRS SMOH,THE PROPELLER WAS REMOVED FOR REBALANCING DUE TO VIBRATION ISSUES. THIS WAS A MAJOR CONTRIBUTING FACTOR IN THIS INCIDENT. 1 H 7 1 3R 3 R A806 5E1 5 C P206 2004101800134 20041018 00134 CE 2004 10 18 CA040915010 1 20040902 G 7120 TUBE CESSNA CESSNA 180 180J 2072622 CE CONT O470 O470* 17026 SO MCAULY 2A34C 2A34C203 GL ENGINE MOUNT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ENGINE MOUNT LT LONGITUDINAL TUBE CRACKED AND DEFORMED AT THE REAR ATTACH CLUSTER. DAMAGE CONSISTENT WITH THAT FO UND AFTER A HARD LANDING, AIRFRAME AND ENGINE INSPECTED FOR RELATED DAMAGE AND NONE FOUND. NO REPORT OF A HARD LANDING FORTH COMING FROM FLIGHT OPERATIONS. 1 H 7 1 3O 3 O 5A6 E273 5 C P3EA 2005041800014 20050418 00014 CE 2005 4 18 CA040916002 1 20040915 G 3246 99800311 WHEEL BEECH 99 B99 1154004 CE PWA PT6 PT6A28 EA MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) R/H OUTBOARD MAIN WHEEL ASSEMBLY. THE INNER HUB HAD A LONG 4 INCHES CRACK. AS WELL 6 OF THE 9 BOLT HOLES HAD CRACK S AROUND THEM. THE LONG CRACK APPEARED TO BE AN OLD CRACK. THE TUBE WAS EVENTUALLY PINCHED WHICH CAUSED A FLAT TIRE. 1 L 7 2 3T 4 T A14CE E4EA 2005041800015 20050418 00015 2005 4 18 CA040916003 4 20040801 G 2565 D17926101 RESERVOIR AIRCRUISERS AIRBUS 310 A310304 3930339 EU ESCAPE SLIDE DISCHARGED Z A UNSCHED LANDING O OTHER CR CRUISE 1 CA 0356 (CAN) FL320, AROUND 2 HRS PRIOR TO ARRIVAL IN YYZ, LT OVERWING EMERGENCY EVACUATION SLIDE HAD STARTED TO PARTIALLY INFLA TE IN FLIGHT. CREW DECIDED TO LAND AT CLOSEST SUITABLE AIRPORT WITH MX. AFTER ALL PAX DEPLANNED, DISARMED LT OVERWING DO OR & OPENED IT NORMALLY. AFTER INVESTIGATION FOUND MAIN AUTOMATIC INFLATION CO2 BOTTLE ON LT OVERWING DOOR PARTIALLY DIS CHARGED IN THE RED BAND WITHOUT ANY VISUAL SIGN OF BOTTLE RUPTURE OR ANY EXTERNAL SIGN OF BOTTLE DAMAGE. SLIDE REMOVED I AW AMM AND A/C DISPATCHED IAW CZECH AIRLINES MEL BOOK. CSA STILL INVESTIGATE ON THIS INCIDENT BUT SUSPECT THE VALVE REGU LATOR ASSEMBLY INSTALLED ON THE RESERVOIR WHICH IS SUPPOSE TO RETAINS THE GAS PRESSURE WHEN THE SLIDE IS UNDER NORMAL CO 2 L 7 2 4F RT A35EU 2005041800016 20050418 00016 SO 2005 4 18 CA040916004 1 20040904 G 2740 3839903 TRIM TAB PIPER PA44 PA44180 7104402 SO RIGHT CRACKED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) DURING ROUTINE INSPECTION THE LOWER INBOARD SIDE OF THE RIGHT TRIM TAB WAS FOUNDCRACKED ABOUT 0.750 INCHES LONG. U PON REMOVAL THE TAB WAS FOUND TO BE CRACKED ALSO IN T HE RIB AS WELL AS THE SKIN. 1 L 7 2 3O A19S0 2005041800017 20050418 00017 NE 2005 4 18 CA040916005 2 20040902 G 8530 71167 EXHAUST VALVE PWA DHAV DHC3 DHC3 2800202 EA PWA R1340 S3H1G 52016 NE CYLINDER DESTROYED W A UNSCHED LANDING B R SMOKE/FUMES/ODORS/SPARKS PARTIAL RPM/PWR LOSS CR CRUISE 1 CA 619 (CAN) ENGINE RAN ROUGH AND SMOKING IN FLIGHT, LANDED ON LAKE, INSPECTION REVEALED EXHAUST VALVE FAILURE AND RESULTED IN SEVERE PISTON DAMAGE. CYLIDER REPLACED AND AIRCRAFT RETURNED TO MAIN BASE. 1 H 7 1 3R 3 R A815 E142 2005041800018 20050418 00018 NE 2005 4 18 CA040916006 2 20040904 G 8500 ENGINE DHAV DHC3 DHC3 2800202 EA PWA R1340 S3H1G 52016 NE FAILED W C ABORTED TAKEOFF J WARNING INDICATION TO TAKEOFF 1 CA (CAN) FOLLOWING INSPECTION AND REPAIRS AS A RESULT OF EXHAUST VALVE FAILURE AIRCRAFT TAXIED ON WATER FOR TAKEOFF AND OIL PRESSURE DROPPED BELOW LIMITS. TAKEOFF ABORTED AND ENGINE REMOVED. 1 H 7 1 3R 3 R A815 E142 2004120900133 20041209 00133 EU 2004 12 9 CA040916007 1 20040903 G 2915 NE15FBATI1TFGNO SWITCH SNIAS 350 AS350B 8680801 EU TMECA ARRIEL ARRIEL1B 6OO30 NE HYD SYSTEM MALFUNCTIONED W B EMER. DESCENT J F I WARNING INDICATION FLT CONT AFFECTED FLT. ATTITUDE INST. CL CLIMB 1 CA SHORTLY AFTER T/O, WARNING HORN & NOTICED 'HYD CAUTION LIGHT' ON. A FEW SECONDS LATER, ERRATIC CYC MOVEMENT FELT. RETU RNED & LANDED W/O INCIDENT. MX INSPECT DID NOT ISOLATE CAUSE FOR MALFUNCTION. HYD SYS CK APPEARED TO BE NORM. HYD PUMP SPLINES INSPECTED & FOUND LUBED & SERVICEABLE. ELECT CHECKS CARRIED OUT SAT. VISUAL INSPECT OF WIRE HARNESS REVEALED N O DISCREPANCY. GROUND RUN CARRIED OUT. ALL TESTS TURNED OUT NORM, HYD PUMP REPLACED. ACCUMULATOR'S PRESS CHECKED AT 17 0 PSI FOR 18 DEG C. ACCUMULATORS RE-CHARGED TO CORRECT PRESS. HYD TEST 'PUSH BUTTON' SWITCH REPLACED. ANOTHER GROUND RUN REVEALED NO DISCREPANCY. COLLECTIVE DUMP SWITCH REPLACED, GROUND RUN, NO DISCREPANCY. A/C RETURNED TO SERVICE. 1 G 7 1 3U 3 U H9EU E19EU 2004123000093 20041230 00093 EU 2004 12 30 CA040916008 2 20040729 G 8550 LINE ROTAX 914 ROTAX914UL EU OIL PRESSURE CRACKED W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) DURING NORMAL FLIGHT, PILOT SMELLED SMOKE IN THE COCKPIT, FOLLOWED SHORTLY AFTER BY A LOW OIL PRESSURE WARNING LIG HT ILLUMINATING. AN UNSCHEDULED LANDING WAS MADE WITH NO DAMAGE OR INJURIES. UPON EXAMINATION THE TURBO OIL PRESSURE LIN E WAS FOUND CRACKED AT THE TURBO FITTING. 5 CLAMPS DESIGNED TO SUPPORT THE TURBO OIL LINES WERE FOUND MISSING. THE ABS ENCE OF THESE CLAMPS ALLOWED VIBRATION TO HARDEN THE PRESSURE OIL LINE AND A CRACK FORMED AT THE TURBO FITTING CAUSING A N OIL LEAK AND AN OIL PRESSURE LOSS. 3 O EXPE3I 2004102700077 20041027 00077 NE 2004 10 27 CA040916009 1 20040914 G 6420 S611033003000 HUB SKRSKY SKRSKY S61 S61N 8142104 NE GE CT58 CT581401 30011 NE TAIL ROTOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA A126581 (CAN) DURING NDT INSPECTION THE HUB WAS FOUND TO HAVE A CRACK INDICATION ON ONE OF THE EARS. THE INDICATION WAS BLENDED , WITH APPROX. .010-.015 INCH OF MATERIAL BEING REMOVED. THE HUB WAS THEN RE-INSPECTED AND INDICATIONS OF THE DEFECT WE RE STILL EVIDENT UNDER BLACK-LIGHT CONDITIONS. 2 G 7 2 4U 4 U 1H15 1E3 2004101800135 20041018 00135 CE 2004 10 18 CA040916010 1 20040916 G 3340 CM35895 SWITCH CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA MCAULY 1C235 1C235LFA GL LANDING LIGHT WORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHILE PERFORMING ROUTINE MAINTENANCE ON THE AIRCRAFT, IT WAS NOTED THAT THE LANDING LIGHT SWITCH WAS FUNCTIONING I NTERMITTENTLY. PREVIOUS EXPERIENCE WITH THIS TYPE OF DEFECT URGED US TO REPLACE THE SWITCH WITH A NEW PART. THE OLD SW ITCH WAS OPENED UP TO DETERMINE THE CAUSE OF THE MALFUNCTION WHICH REVEALED ONE OF THE COPPER BRAIDS SEPARATED FROM ITS POINT OF ATTACHMENT. THIS DEFECT HAS PROBABLY OCCURRED TWO OR THREE TIMES WITH THIS ORGANIZATION. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P12EA 2005012100161 20050121 00161 CE 2005 1 21 CA040916011 1 20040914 G 5344 504300431329 CHANNEL RAYTHN BEECH B300 B300B350C CE PWA PT6 PT6A60A 52043 NE HARTZL HCB4M HCB4MP3 GL CABIN DOOR CRACKED W O OTHER D INFLIGHT SEPARATION CR CRUISE 1 CA (CAN) THE CREW REPORTED THAT THE CABIN DOOR APPEARED TO BE LEAKING AROUND ITS LOWER AFT CORNER. MAINTENANCE DISCOVERED A 1-INCH CRACK IN THE CABIN DOOR SKIN AT THE LOWER AFT CORNER. THE CRACK RUNS THROUGH THE AFT-MOST HINGE ATTACHMENT RIV ET. WHEN THE DOOR WAS DISASSEMBLED TO REPAIR THE CRACK, THEY DISCOVERED THAT THE DOOR HINGE ALSO HAD A ONE-INCH CRACK A T THAT SAME LOCATION. THE DOOR HINGE SUPPORT CHANNEL HAS AN .1250 INCH CRACK AND DEFORMATION ALONG THE HINGE RIVET LINE . THE CRACK RUNS THROUGH 9 OF THE RIVET HOLES IN THE CHANNEL. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2005041800019 20050418 00019 WP 2005 4 18 CA040917001 1 20040914 G 2421 GENERATOR DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE AC SYSTEM FAILED W A UNSCHED LANDING G J MULTIPLE FAILURE WARNING INDICATION CL CLIMB 1 CA (CAN) FLT CREW DECIDED TO LAND BACK TO DEPARTURE AIRPORT FOLLOWING 3 DISCREPANCIES: TAIL COMPARTMENT OVERTEMP LIGHT CAM E ON AFTER ROTATION.THE LT PACK WAS SELECTED OFF TO CONTINUE FLIGHT. LATER ON THE LT CSD OIL OUTLET TEMP WENT HIGH.THE CSD WAS DISCONNECTED AND THE APU WAS STARTED AS REQUESTED BY PROCEDURES AND SHUT DOWN DUE TO GENERATOR OUT OF FREQUENCY. ALL 3 DISCREPANCIES WERE RECTIFIEDAS FOLLOW:SOME DUCT CLAMPS WERE FOUND LOOSE IN TAIL COMPARTMENT LT PACK ANDSECURED.THE CSD OIL LEVEL WAS FOUND OVER SERVICED AND OIL LEVEL WAS RE SERVICED AS PER MM.APU GENERATOR FREQUENCY ADJUSTED AS REQUI RED. 2 L 7 2 4F 4 F RT A6WE E9NE 2005041800020 20050418 00020 2005 4 18 CA040917002 4 20040915 G 2230 AUTOTHROTTLE SYS FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE NR 2 MALFUNCTIONED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) DURING CLIMB, AIRCRAFT HAD NR 2 AUTO THROTTLE (A/T) AFCAS FAULT, FOLLOWED BY NR 1 AND 2 STAB TRIM DOUBLE CHANNEL I N FAULT. AIRCRAFT LANDED BACK TO DEPARTUREAIRPORT. THE A/T DEFECT WAS DISPATCHED AS PER MEL AND RECTIFIED THE DAY AFTER B Y ADJUSTING THE NR 2 POWER LEVER ANGLE SWITCH LOCATED IN PEDESTAL. THE STAB TRIM WAS FUNCTIONAL TESTED AS PER MM AN D FOUND SATISFACTORY 2 L 7 2 4F 4 F RT E25NE 2005041800021 20050418 00021 CE 2005 4 18 CA040917003 1 20040830 G 2432 32638002 CELL BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA BATTERY REVERSED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 10001681 (CAN) AIRCREW REPORTED LOAD METERS NOT INDICATING BATTERY CHARGE FOR NORMAL PERIOD OF TIME OR NORMAL LEVEL OF CHARGE. UP ON INSPECTION NR 9 CELL FOUND INSTALLED IN REVERSE POLARITY ORIENTATION. 1 L 7 2 3T 4 T RT 3A20 E4EA 2004101300045 20041013 00045 CE 2004 10 13 CA040917004 1 20040830 G 3234 1013841377 SWITCH BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA HARTZL HCB3T HCB3TN3 GL CONTROL HANDLE FAILED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) LANDING GEAR FAILED TO EXTEND WHEN SELECTED DUE TO FAILURE OF SWITCH IN LANDING GEAR CONTROL HANDLE. 1 L 7 2 3T 4 T RT 3A20 E4EA 6 C P15EA 2004102000191 20041020 00191 SW 2004 10 20 CA040917005 1 20040831 G 6700 MOUNT BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL LOWER BASE MISALIGNED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) LOWER MOUNTING BASE WAS FOUND TO BE INSTALLED 90 DEGREES FROM CORRECT ALIGNMENT TO ALLOW ENGAGEMENT OF LOCK PIN. 1 G 7 1 3U 3 U H2SW E4CE 2004101800128 20041018 00128 CE 2004 10 18 CA040917006 1 20040903 G 3213 07416011 LEG ASSY CESSNA 182 182E 2072712 CE CONT O470 IO470D 17026 SO MCAULY 2A34C 2A34C66 GL LT MLG BROKEN W C ABORTED TAKEOFF O OTHER TX TAXI/GRND HDL 1 CA (CAN) WHEN TURNING TO ALIGN AIRCRAFT FOR TAKEOFF ON THE GRASS STRIP AT CPE7 THE LT MAIN LANDING GEAR LEG SNAPPED OFF AT THE OB CHANNEL. THE AIRCRAFT COLLAPSED, THE ENGINE WAS STOPPED WITHOUT A PROP STRIKE BUT THE WING EXTENSION AND TIP WER E DAMAGED AS WELL AS THE TAIL PLANE. NO PREVIOUS EVIDENCE OF CRACKING OR CORROSION IN THIS AREA. 1 H 7 1 3O 3 O NT 3A13 3E1 5 C P3EA 2004102000192 20041020 00192 CE 2004 10 20 CA040918001 1 20040916 G 2120 24192273 TUBE LEAR 35 35A 5170602 CE GARRTT TFE731 TFE73122B 01518 WP WHEEL WELL RUPTURED W K NONE O OTHER IN INSP/MAINT 1 CA 13557 (CAN) CLEAR FLUID WAS SEEN RUNNING FROM LT WHEEL WELL AFTER EXTENDED GROUND RUNNING WITH AIR CONDITIONING OPERATING. IT WAS DETERMINED TO BE WATER THAT WAS DRAINING FROM THE AIR CONDITIONING EVAPORATOR INTO WHEEL WELL INSTEAD OF THROUGH OV ERBOARD DRAIN. CHECK/DRAIN VALVE WAS FOUND TO BE INOPERATIVE (FAILED CLOSED - CORRODED). THIS HAD ALLOWED CONDENSATION TO COLLECT IN ALUMINUM TUBE ASSY, WHICH HAD FROZEN AT ALTITUDE, RUPTURING TUBE IN TWO PLACES. THIS DRAIN TUBE IS OUTSI DE PRESSURE VESSEL, UPSTREAM OF CHECK/DRAIN VALVE WHICH IS NORMALLY CLOSED IN FLIGHT (OPEN ON GROUND WHEN A/C IS NOT PRE SSURIZED). FAILURE OF TUBE RESULTS IN AN EXCESSIVE CABIN PRESSURIZATION LEAK. PARTS REPLACED WITH NEW. 2 L 7 2 4F 4 F A10CE E6WE 2004101800129 20041018 00129 EA 2004 10 18 CA040918002 1 20040916 G 2740 70744 CONTROL UNIT CNDAIR CL600 CL6002D24 1390016 EA GE CF34 CF348C1 NE MACH TRIM FAILED W A UNSCHED LANDING F FLT CONT AFFECTED CL CLIMB 1 CA (CAN) WHILE CLIMBING THROUGH 7200 FEET, THE CAPTAIN WAS MAKING SMALL INPUTS TO STAB TRIM. MACH TRIM CAUTION MESSAGE APPE ARED FOLLOWED RIGHT AFTER BY A STAB TRIM CAUTION. THE STAB WAS NOT RESPONDING TO INPUTS. PILOT TRIED TO RE-ENGAGE THE STAB AND NEITHER CHANNEL WOULD. AIRCRAFT RETURNED TO BASE. THE LANDING WAS UNEVENTFUL. FOLLOWING TROUBLESHOOTING, MAIN TENANCE REPLACED THE MCU AND THE NR 1 SSCU. AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2005020100051 20050201 00051 NM 2005 2 1 CA040920001 1 20040617 G 2742 251T43101 ACTUATOR BOEING 767 767233 1385113 NM PWA JT9 JT9D7R4D 52054 NE STABILIZER TRIM CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 63979 (CAN) WATER INGRESS INTO GEAR BOX CAUSED EXTENSIVE CORROSION, INVESTIGATION ON GOING WITH MFG (STAB TRIM ACTUATOR). 2 L 7 2 4F 4 F RT A1NM E3NE 2005041200041 20050412 00041 SO 2005 4 12 CA040920002 2 20040913 G 7421 URHB32E SPARK PLUG CESSNA 206 U206A 2073316 CE CONT O520 IO520F 17032 SO HARTZL HCC3Y HCC3YF1 GL NR 4 CYLINDER BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHEN REMOVING NR 4 CYLINDER LOWER SPARK PLUG, BROKE COMPLETELY OFF, JUST ABOVE BASE AND BELOW HEX DRIVE PORTION. 1 H 7 1 3O 3 O A4CE E5CE 5 C P25EA 2005041800022 20050418 00022 SW 2005 4 18 CA040920003 1 20040906 G 2435 DRIVE SHAFT SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP MCAULY 4HFR34 4HFR34C652 NE STARTER GEN SHEARED W O OTHER O OTHER TX TAXI/GRND HDL 1 CA 14311 (CAN) PILOT ATTEMPTED TO START LT ENGINE, PROP STARTED TO ROTATE THEN STOPPED. UPON OPENING THE ENGINE COWL, IT WAS FOUN D THAT THE FRICTION DISC WAS IN PIECES IN THE BOTTOM OF THE COWL. WHEN THE STARTER WAS REMOVED, THE DRIVE SHAFT WAS FOU ND SHEARED. THE TORLON INSERT WAS ALSO FOUND DAMAGED EXTENSIVELY ALONG WITH THE DRIVE GEAR IN THE ENGINE. THE DRIVE HAD TO BE REPLACED DUE TO THE STARTER DRIVE SHAFT CAUSING DAMAGE WHEN THE TORLON INSERT WAS NOT LONGER DOING IT'S JOB. STA RTER TURNED OVER BY HAND AND IT WAS NOT SEIZED. STARTER SENT TO OVERHAUL FACILITY FOR FURTHER INVESTIGATION. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C 3PNE 2005041800023 20050418 00023 SW 2005 4 18 CA040920004 1 20040916 G 7714 2719157005 INDICATOR SWRNGN SA227 SA227* SW GARRTT TPE331 TPE33111U 01514 WP MCAULY 4HFR34 4HFR34C652 NE LT RPM INOPERATIVE W C ABORTED TAKEOFF P NO WARNING INDICATION TO TAKEOFF 1 CA (CAN) DURING TAKE OFF THE LH RPM INDICATION WENT TO ZERO. THE RPM INDICATOR WAS JUST INSTALLED AND HAD TESTED SERVICIBL E DURING THE GROUND RUNS. 2 L 7 2 4T 4 T RT A5SW E4WE 6 C 3PNE 2005041800024 20050418 00024 SO 2005 4 18 CA040921001 1 20040408 G 5540 40040009 TORQUE TUBE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA RUDDER CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 13722 (CAN) INTERNAL INSPECTION OF RUDDER REVEALED SURFACE CORROSION AND SURFACE PITTING. TORQUE TUBE REPLACED WITH NEW P/N 40 040-009. 1 L 7 2 3O 3 O A20SO E14EA 2005041800025 20050418 00025 SO 2005 4 18 CA040921002 1 20040504 G 2752 475212 MOTOR PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA TE FLAP CONTROL BURNED OUT W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) DURING ROUTINE MAINTENANCE THE FLAP OPERATION WAS OBSERVED TO BE NOISY. MOTOR WAS FOUND TO BE INTERNALLY BURNED. M OTOR WAS REPLACED. 1 L 7 2 3O 3 O A20SO E14EA 2004101300064 20041013 00064 SO 2004 10 13 CA040921003 1 20040719 G 3246 40141 WHEEL PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 16219 (CAN) LT TIRE WENT FLAT WHILE PARKED. FURTHER INVESTIGATION REVEALED A CRACKED WHEEL IN FLANGE AREA. WHEEL, TIRE AND TUB E WERE REPLACED. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004101800125 20041018 00125 SO 2004 10 18 CA040921004 1 20040704 G 3210 CH20261 TORQUE LINK PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING ROUTINE INSPECTION THE MAIN LANDING GEAR TORQUE LINK WAS FOUND CRACKED. THESE P/N CH2026-1 TORQUE LINKS AR E PART OF BOUNDARY LAYER RESEARCH HEAVY LANDING GEAR KIT FOR STC NR SA00202SE. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004101800126 20041018 00126 SO 2004 10 18 CA040921005 2 20040903 G 8530 CNF71ER CYLINDER CESSNA 185 A185F 2072821 CE CONT O520 IO520D 17032 SO MCAULY 2A34C D2A34C58 GL ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) CYLINDER ASSEMBLY FOUND CRACKED FROM SPARK PLUG HOLE. 1 H 7 1 3O 3 O 3A24 E5CE 5 C P3EA 2005041800026 20050418 00026 2005 4 18 CA040921006 4 20040827 G 6122 BEARING WOODWARD PIPER PA34 PA34200T 7103406 SO CONT O360 LTSIO360EB 17025 SO GOVERNOR DESTROYED W O OTHER O OTHER NR NOT REPORTED 1 CA 1490162B (CAN) PILOT REPORTED MINOR DIFFICULTY IN MAINTAINING A CONSTANT: RPM SELECTION, RPM WOULD WANDER +/- 50 RPM (RT SIDE. PROPS NEW. CONTROL LINKAGE AND GOVERNORS INSPECTED, NIL DEFECTS FOUND. GOVERNOR SENT TO O/H SHOP FOR REPAIR. O/H SHOP STATES BEARING DESTROYED. HOUSING, BODY, BASE IDLER AND DRIVE GEARS ALL DAMAGED DUE TO FAILED BEARING. PARTS AVAILABLE AT THE FACILITY. GOVERNOR REPLACED WITH O/H UNIT. 1 L 7 2 3O 3 O A7SO E9CE 2005041800027 20050418 00027 GL 2005 4 18 CA040921007 2 20040916 G 7532 23053190 BLEED VALVE BELL 206 206L 1181522 SW ALLSN 25OC 250C20R GL COMPRESSOR FAILED W A UNSCHED LANDING X J ENGINE FLAMEOUT WARNING INDICATION CR CRUISE 1 CA (CAN) ENGINE FLAMED OUT TWICE DURING TEST FLIGHT FOR BLEED VALVE CHANGE AND RELIGHT ON BOTH OCCATIONS BY AUTO RELIGHT. 1 G 7 1 3U 3 U H2SW E4CE 2005012100170 20050121 00170 CE 2005 1 21 CA040921008 1 20040920 G 5610 10138402521 WINDSHIELD BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL COCKPIT BROKEN W O OTHER O OTHER CR CRUISE 1 CA (CAN) IN FLIGHT WINDSHIELD INNER PANE SHATTERED, PLANE RETURNED TO BASE. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2005012100171 20050121 00171 CE 2005 1 21 CA040922001 1 20040921 G 3230 NAS5150 SNAP RING BEECH 200 B200C 1152924 CE PWA PT6 PT6A42 52043 NE HARTZL HCD4N3 HCD4N3A GL MLG OUT OF POSITION W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING ENDPLAY CHECK (1000 CYCLES) ON LT MAIN GEAR ACTUATOR, INPUT GEAR WAS FOUND TO HAVE 0.090 INCH ENDPLAY. THIS CHECK USED TO VERIFY THAT THRUST BEARING IS PROPERLY INSTALLED, MAXIMUM ENDPLAY IS 0.050. THESE ACTUATORS ARE OVERHAUL ED AT 7500 CYCLES, TSO FOR THIS ONE WAS ONLY 894. FURTHER INVESTIGATION REVEALED THAT THE SNAP RING P/N NAS 51-50 WAS NO T IN ITS GROOVE ALLOWING THE INPUT GEARS TO MOVE MORE THAT NORMAL. UNKNOWN IF THE SNAP RING WAS IMPROPERLY INSTALLED AT OVERHAUL OR IF IT CAME OUT LATER, SINCE THERE IS A POSSIBILITY THAT OTHER INTERNAL PARTS WERE DAMAGED, THE ACTUATOR WAS REMOVED FROM SERVICE AND WILL BE RETURNED TO THE OVERHAUL FACILITY FOR FURTHER INVESTIGATION. 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2005041800028 20050418 00028 NM 2005 4 18 CA040922002 1 20040915 G 5230 ROD END BOEING 727 727227 1384078 NM PWA JT8 JT8D9A 52048 NE CARGO DOOR SHEARED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING ROUTINE OPENING OF THE CARGO DOOR FOR LOADING OF THE AIRCRAFT, A WIND GUST BLEW THE DOOR FULLY OPEN, AND SH EARED ALL FOUR ACTUATOR LINK RODS. THE DOOR ENDED UP IN A VERTICAL POSITION. THE WIND VELOCITY AND GUSTS WERE CHECKED WI TH THE CONTROL TOWER PRIOR TO OPENINGTHE DOOR SO AS NOT TO EXCEED GUST LIMITS. THE GUSTS WERE WITHIN THE MANUFACTURE RS MAXIMUM GUST LIMITS. A THOROUGH INSPECTION OF THE ACTUATORS AND STRUCTURE WAS CARRIED OUT, NO FURTHERDAMAGE FOUND. THE D OOR WAS LOWERED AND WAS FOUND TO OPERATE NORMALLY. THE BROKEN LINK RODS WERE REPLACED. 2 L 7 3 4F 4 F A3WE E2EA 2005041800029 20050418 00029 CE 2005 4 18 CA040922003 1 20040724 G 5753 0512128 PULLEY BRACKET CESSNA 185 A185F 2072821 CE CONT O520 IO520D 17032 SO MCAULY D3A34 D3A34C403 GL TE FLAPS FAILED W O OTHER F FLT CONT AFFECTED CL CLIMB 1 CA (CAN) AFTER TAKE-OFF, WHEN RAISING FLAPS FROM 100 TO 00, PILOT FELT A RELEASE OF TENSION AND A/C BANKED LT, UNTIL FLAP H ANDLE LOCKED IN AT 00 POSITION. PILOT CHECKED FLT CONTROLS & ALL APPEARED NORMAL, PILOT SUSPECTED SOMETHING WRONG WITH F LAPS. A/C FLOWN TO BASE, & BEFORE LANDING, PILOT DECIDED TO CHECK FLAPS. AS SOON AS FLAP HANDLE MOVED FROM 00 LATCH TOWA RDS 100 LATCH A/C WANTED TO BANK LT AGAIN, SO PILOT SET FLAPS BACK TO 00 & DID AN UNEVENTFUL FLAPLESS LANDING. MX NOTIFI ED & UPON INSPECTION OF FLAP SYSTEM, FOUND TABS OF A PULLEY BRACKET ON A MAIN BULKHEAD AT STA 65.33, HAD BROKEN AWAY. 1 H 7 1 3O 3 O 3A24 E5CE 5 C P47GL 2005041800030 20050418 00030 EA 2005 4 18 CA040922004 2 20040922 G 7412 312241307 EXCITER BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA NR 2 ENGINE FAILED W O OTHER E J VIBRATION/BUFFET WARNING INDICATION DE DESCENT 1 CA (CAN) DURING A TEST FLT REQUIRED FOR JAPANESE ANNUAL C OF A RENEWAL, AT APPROX 12,500 FT, THE NR 2 ENGINE WAS SHUT DOWN AND A ALTERNATE LANDING GEAR EXTENSION WAS CARRIED OUT. THE CREW THEN ATTEMPTED TO RESTART THE NR 2 ENGINE IN FLT, BUT WERE UNSUCCESSFUL. THE AIRCRAFT MADE A SUCCESSFUL SINGLE ENGINE LANDING. FAULT CODES REPORTED WERE 910 & 969. NR 2 ENGIN E IGNITION EXCITER WAS REPLACED, FAULT CODESCLEARED AND ENGINE STARTS NORMALLY. 2 H 7 2 4T 4 T RT A13NM E00062EN 2005012100172 20050121 00172 CE 2005 1 21 CA040922005 1 20040921 G 3233 508202085 ACTUATOR BEECH 200 B200C 1152924 CE PWA PT6 PT6A42 52043 NE HARTZL HCD4N3 HCD4N3A GL NLG WORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING ROUTINE 1000 CYCLE ENDPLAY CHECK OF THE NOSE GEAR ACTUATOR, THE ACTUATOR FAILED WITH 0.020 OF AN INCH ENDPL AY THE MAX ALLOWABLE IS 0.016. THIS UNIT ONLY HAD 997 CYCLES SINCE OVERHAUL (OVERHAUL DUE AT 7500 CYCLES). THE ACTUATOR WAS REMOVED FROM SERVICE AND WILL BE RETURNED TO THE OVERHAUL FACILITY FOR FURTHER INVESTIGATION. THE ACTUATOR ALSO HAD CORROSION ON THE HOUSING UNDER THE BEARING JOURNAL. 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2005041800031 20050418 00031 NM 2005 4 18 CA040922006 1 20040629 G 3260 401020101 PROXIMITY SENSOR BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA NLG WHEEL CENTER FAILED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) UNABLE TO SELECT GEAR UP. RECEIVED THREE GREEN INDICATION LIGHTS ALONG WITH THREE RED INDICATION LIGHTS AND AMBER GEAR HANDLE LIGHT. PERFORMED RETURN TO LANDING CHECKLIST. NORMAL LANDING PERFORMED. NLG CENTERING PROXIMITY SENSOR FO UND SHORTED. SENSOR REPLACED AND ADJUSTED TO 8.602 MH IAW AMM 32-61-03. 2 H 7 2 4T 4 T RT A13NM E00062EN 2004101300065 20041013 00065 NM 2004 10 13 CA040923001 1 20040627 G 6120 699018002 CONTROL UNIT BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU AUTO FEATHER FAILED W C ABORTED TAKEOFF E VIBRATION/BUFFET TO TAKEOFF 1 CA (CAN) AUTO FEATHER SYSTEM FAILED TO ARMED WHEN TAKE-OFF POWER WAS APPLIED. TAKE-OFF ABORTED AT APPROX 60 KTS. RETURNED TO GATE. AC GROUNDED. RT PROPELLER ELECTRONIC CONTROL UNIT (PECU) REPLACED IAW AMM 61-20-36. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2004101800123 20041018 00123 SO 2004 10 18 CA040923002 2 20040916 G 8530 AEC631397ST712B CYLINDER CESSNA 402 402CESSNA 207590K CE CONT O520 TSIO520E 17040 SO ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 514517 (CAN) AT THE 50 HRS INSPECTION OF THE AIRCRAFT, DURING ENGINE CYLINDER COMPRESSION TEST, MADE ENGINE SB M91-6, AND THE TEST FAILED BECAUSE FOUND AIR LEAK AT THE JUNCTION OF THE CYLINDER BARREL AND THE TOP CYLINDER HEAD (BETWEEN FINS). THE ENGINE AND CYLINDER HAD ONLY 90.5 HRS. REPLACED CYLINDER AND RETURNED AIRCRAFT TO SERVICE AFTER THE INSPECTION. 1 L 7 2 3O 3 O A7CE E8CE 2005021400190 20050214 00190 EA 2005 2 14 CA040923003 1 20040922 G 7933 523281 INDICATOR DHAV DHC8 DHC8311 1386006 EA PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE OIL SYSTEM READS HIGH W E ENGINE SHUTDOWN N FALSE WARNING CR CRUISE 1 CA 30718 30718 (CAN) DURING CRUISE FLIGHT NR 2 ENGINE OIL TEMP CLIMB ABOVE RED LINE ON INDICATOR TO 125 DEG C. NR 2 ENGINE SHUTDOWN A S PRECAUTION . FLIGHT CONTINUED TO SCHEDULED DESTINATION FOR NORMAL LANDING. MAINTENACE REPLACED NR 2 OIL PX/TEMP GAUG E , AIRCRAFT RETURNED TO SERVICE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005050300199 20050503 00199 EA 2005 5 3 CA040923004 1 20040904 G 3246 AN679AC6000 TIE ROD DHAV DHC3 DHC3 2800202 EA WALTER M601 M601E11 EU RT MLG BROKEN W O OTHER O OTHER LD LANDING 1 CA (CAN) PILOT NOTICED TIE ROD BROKEN UPON RETURN TO BASE. NO DIFFICULTY WITH THIS LANDING OR PREVIOUS LANDINGS WHERE NOTED BY PILOT. PART WAS REPLACED AND AIRCRAFT WAS RETURNED TO SERVICE. PLEASE ADVISE WHERE PARTS CAN BE SENT FOR EXAMINATION . HAVE NOT SEEN A FAILURE OF THIS TYPE IN NORMAL OPERATION IN OVER 30 YEARS OF AIRCRAFT MAINTENANCE. 1 H 7 1 3R 3 T A815 E00048EN 2005041800032 20050418 00032 NM 2005 4 18 CA040923005 1 20040917 G 7333 30B350604 TRANSMITTER DORNER DO32 DO328300 NM PWA 306 PW306B NE FUEL FLOW CRACKED W O OTHER K J FLUID LOSS WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) FUEL FLOW TRANSMITTER END CAP CRACKED WITH RESULTANT FUEL LEAKAGE INTO NACELLE. 2 H 7 2 4T 4 F RT A55NM E35NE 2005041800033 20050418 00033 NM 2005 4 18 CA040923006 1 20040725 G 3260 401020101 PROXIMITY SENSOR BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA NLG CENTERING SHORTED W A UNSCHED LANDING N FALSE WARNING CL CLIMB 1 CA (CAN) UNABLE TO RETRACT LANDING GEAR DURING CLIMB. GEAR DOORS LOCKED. NO TRANSITION, NO YELLOW LIGHTS. THREE GREEN LIGHT S REMAINED CONSTANT ON. RECYCLED WITHOUT SUCCESS. RETURNED TO BASE. NLG CENTERING PROXIMITY SENSOR FOUND SHORTED. SENSOR REPLACED ACC AMM 32-61-03. 2 H 7 2 4T 4 T RT A13NM E00062EN 2005041800034 20050418 00034 NM 2005 4 18 CA040923007 1 20040923 G 3220 B273201201 DRAG BRACE BOEING 727 727233 138408A NM PWA JT8 JT8D15 52051 NE NLG LACK OF LUBE W O OTHER W J INADEQUATE Q C WARNING INDICATION LD LANDING 1 CA (CAN) ON FINAL APPROACH, SELECTED GEAR DOWN. NOSE GEAR DOORS DID NOT OPEN AND THE NOSE GEAR RED LIGHT REMAINED ILLUMINA TED WITH THE NOSE GEAR GREEN LIGHT OUT. EXECUTED A MISSED APPROACH AND THE GEAR RETRACTED NORMALLY. RESELECTED GEAR DOWN AND GEAR EXTENDED NORMALLY AND LANDED UNEVENTFULLY. AIRCRAFT WAS GROUNDED UNTIL A NLG INSPECTION AND GEAR SWINGS COULD BE ACCOMPLISHED. THE NLG INSPECTION FOUND THE NLG DRAG BRACE KNUCKLE HAD VERY LITTLE LUBRICANT. NLG DRAG BRACE KNUCKLE L UBRICATED AND NUMEROUS GEAR SWINGS ACCOMPLISHED, NLG SYSTEM COULD NOT BE FAULTED. AIRCRAFT RETURNED TO SERVICE. 2 L 7 3 4F 4 F RT A3WE E2EA 2005041800035 20050418 00035 2005 4 18 CA040923008 1 20040923 G 2497 U384U CONNECTOR ELECTRICAL MISMANUFACTURED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) PRIOR TO REPLACING CONNECTOR, WE VERIFIED WITH A DMM CONTINUITY FROM CONNECTOR END TO SOLDER TERMINALS. (6) CONNE CTORS WERE FOUND INPROPERLY MANUFACTURED, THE ORIENTATION OF THE SOLDER TERMINALS DID NOT MATCH THE CONNECTOR. I HAVE C ONTACTED THE QUALITY CONTROL MANAGER AT NEXUS AND NOTIFIED HIM OF THE FINDING. PARTS REMOVED FROM QUARANTINED AND SHIPPE D TO NEXUS FOR ANALYSIS. 2005041800036 20050418 00036 EU 2005 4 18 CA040924001 1 20040918 G 2120 A28110280000 VAPOR BARRIER AIRBUS 310 A310304 3930339 EU GE CF6 CF680C2A5 NE LT A/C PACK DAMAGED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) DURING INVEST OF A PNEUMATIC LEAK AT LT A/C PACK DISCHARGE DUCT HEAT EXCHANGER CONNECTOR, FUEL VAPOR BARRIERS FOUN D DAMAGED ABOVE THIS AREA. METAL FUEL VAPOR BARRIER HAD DAMAGE OF APPROX 2 SQ FT. FIBER FUEL VAPOR BARRIER PUNCTURED 2 SQ. IN. FUEL VAPOR BARRIER REPLACED & PNEUMATIC DUCT COUPLING ALSO REPLACED. FIBER FUEL VAPOR BARRIER REPAIRED IAW MM . A FLEET CAMPAIGN IN PROGRESS TO REPLACE ALL COUPLINGS IN A/C BAY AREA BUT ACRFT HAD NOT YET BEEN DONE. UNABLE TO DET ERMINE IF FUEL VAPOR BARRIER DAMAGE CAUSED BY PNEUMATIC LEAK AT HEAT EXCHANGER COUPLING. A VISUAL INSPECT OF BARRIERS C ARRIED OUT IN 08/04 DURING ROUTINE A-CHECK & NO FAULT NOTICED. AIRBUS CONTACTED & ASSIST REQUESTED IN EVAL OF FAILURE. 2 L 7 2 4F 4 F RT A35EU E13NE 2004101300066 20041013 00066 EU 2004 10 13 CA040924002 1 20040908 G 2750 SP10CCH614301 LEVER HWKSLY DH125 DH125400A 4230140 EU TE FLAPS CORRODED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) AFTER AIRCRAFT STRIPPED AND BEFORE PAINT, THIS INCIDENT OCCURRED. WHEN SELECTING FLAPS TO DUMP MODE WE FOUND THE F LAPS WOULD NOT MOVE AT ALL. INVESTIGATION FOUND THAT THE BAULK VALVE LATCH LEVER WOULD NOT MOVE. TECHNICIAN TOOK BAULK V ALVE LATCH LEVER ATTACH PIN APART AND FOUND EXTENSIVE CORROSION UNDER CLEVIS PIN WASHER. WE DETERMINED THAT THE CORROS ION PREVENTED THE BAULK LEVER FROM MOVING WHEN THE FLAPS WERE SELECTED TO DUMP MODE. THE PARTS WERE REMOVED, CLEANED, LU BRICATED AND REASSEMBLED BACK TO SERVICEABLE CONDITION. 2 L 7 2 4J A3EU 2005041800037 20050418 00037 NM 2005 4 18 CA040924003 1 20040617 G 3260 401020101 PROXIMITY SENSOR BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA NLG CENTERING FAILED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) UNABLE TO SELECT MLG GEAR UP DURING CLIMB. AFTER CONSULTING THE TECHNICAL DEPARTMENT WE TRIED RECYCLING BUT WITH NO SUCCESS. RETURNED TO BASE. NOSE GEAR CENTERING PROXIMITY SENSOR REPLACED ACC AMM 32-61-06. 2 H 7 2 4T 4 T RT A13NM E00062EN 2004101800131 20041018 00131 NE 2004 10 18 CA040924004 2 20040919 G 7310 FK20824 LINE AIRBUS A330 A330* EU RROYCE RB211 RB211TRENT77 NE LP FUEL LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) FUEL LEAK DISCOVERED IN THE AREA COVERED BY AD (CAMPAIGN) NR 9-0065. 2 L 7 2 4F 4 F RT A46NM E39NE 2004111000058 20041110 00058 NM 2004 11 10 CA040924005 1 20040521 G 3260 401020101 SENSOR BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU NLG CENTERING SHORTED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) UNABLE TO SELECT MLG GEAR UP DURING CLIMB. GEAR RECYCLED ONCE WITHOUT SUCCESS. RETURNED TO LAND AT OUR BASE. NW C SENSOR FOUND SHORTED. NOSE WHEEL CENTERING PROXIMITY SENSOR REPLACED ACC AMM 32-61-06. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2005012100169 20050121 00169 CE 2005 1 21 CA040924006 1 20040924 G 1430 AN34A BOLT CESSNA CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO HARTZL HCJ3Y PHCJ3YF1 GL TE FLAP STRIPPED W K NONE O OTHER IN INSP/MAINT 1 CA 10029 (CAN) AN3-4A BOLTS ATTACHING IB BRACKET TO FLAP FOUND STRIPPED. BOLTS REPLACED WITH NEW AN3-4A. END OF DEFECT. 1 H 7 1 3O 3 O A4CE E5CE 5 C P36EA 2005021400191 20050214 00191 SO 2005 2 14 CA040924007 2 20040913 G 8530 537296 TUBE CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO HARTZL HCJ3Y PHCJ3YF1 GL PUSHROD CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) NR 5 CYLINDER PUSH ROD TUBE HOUSINGS FOUND 1 CRACKED, AT CYLINDER HEAD END, THE OTHER WAS BENT AT OB END OF SPRING RETAINER. 1 H 7 1 3O 3 O A4CE E5CE 5 C P36EA 2005031100031 20050311 00031 CE 2005 3 11 CA040924008 1 20040924 G 3211 12116013 FITTING CESSNA 12910606 CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO HARTZL HCJ3Y PHCJ3YF1 GL LT MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 10029 (CAN) LT MAIN LANDING GEAR OB FITTING FOUND CRACKED. 1 H 7 1 3O 3 O A4CE E5CE 5 C P36EA 2005020100159 20050201 00159 EU 2005 2 1 CA040927001 1 20040924 G 2161 5829C000 CONTROL VALVE PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL TEMP CONTROL INTERMITTENT W O OTHER J WARNING INDICATION CR CRUISE 1 CA (CAN) AUTO TEMP. FUNCTION OF ECS NOT WORKING PROPERLY DURING FLIGHT AND MANUAL SIDE INTERMITTENT. AIRCRAFT FINISHED FL IGHT AND TEMPERATURE CONTROL VALVE ASSY (PN 5829C000) TESTED AND REPLACED. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005020100160 20050201 00160 CE 2005 2 1 CA040927002 1 20040921 G 5320 97430000115 CROSS TIE BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL FUSLEAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 14205 (CAN) DURING MAINTENANCE, A CRACK WAS DISCOVERED IN A FUSELAGE CROSS TIE FOR THE UPPER RT FUSELAGE, IMMEDIATELY AFT OF T HE EMERGENCY EXIT WINDOW. NEW PART HAS BEEN ORDERED AND WILL BE INSTALLED TO RECTIFY THIS DEFECT. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2005020100161 20050201 00161 EU 2005 2 1 CA040927003 1 20040922 G 2161 9599020135 CONTROL VALVE PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL TEMP CONTROL INOPERATIVE W O OTHER J WARNING INDICATION CR CRUISE 1 CA (CAN) CONTROL VALVE FOUND INOPERATIVE AFTER CREW COMPLAINED OF TROUBLE CONTROLLING HEAT. THE VALVE WAS REPLACED AND AIRC RAFT RETURNED TO SERVICE. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004101800132 20041018 00132 EU 2004 10 18 CA040927004 1 20040922 G 3060 4E305110 BOOT PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL PROPELLER DEICE MALFUNCTIONED W J A DUMP FUEL UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA (CAN) CREW REPORTED PROP DEICE MALFUNCTION. ONE BOOT WAS FOUND FAILED. BOOT REPLACED AND AIRCRAFT RETURNED TO SERVICE. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004111000059 20041110 00059 EU 2004 11 10 CA040927005 1 20040922 G 3397 L40B16L41A16N WIRE PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL LANDING LIGHT BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) TAXI LIGHT FOUND TO BE UNSERVICEABLE. INVESTIGATION REVEALED BROKEN WIRES L40B16 AND L41A16N AT THE PIVOT AREA OF THE NLG. THE WIRES WERE REPAIRED AND THE AIRCRAFT RETURNED TO SERVICE 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005012100175 20050121 00175 SW 2005 1 21 CA040927006 1 20040920 G 8200 2767030389 LINE SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP MCAULY 4HFR34 4HFR34C652 NE ENGINE NACELLE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WATER METHANOL SYSTEM WAS MEL'D ON LT ENGINE. LATER INVESTIGATION REVEALED A BROKEN RIGID LINE IN THE LT ENGINE N ACELLE. LINE WAS REPLACED AND AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C 3PNE 2005021400197 20050214 00197 CE 2005 2 14 CA040927007 1 20040924 G 5210 50430043663 DOOR BEECH 99 99 1154002 CE PWA PT6 PT6A20 52043 EA HARTZL HCB3T HCB3TN3 GL LT AFT FUSELAGE INOPERATIVE W O OTHER O OTHER AP APPROACH 1 CA (CAN) ON APPROACH, AT 20 MILES OUT AND 2500 FT ASL THE CABIN DOOR OPENED. FLIGHT SERVICES WAS INFORMED AND THE AIRCRAFT LANDED UNEVENTFULLY. THE COPILOT CLOSED THE DOOR AFTER LANDING. THE DOOR AND SURROUND WERE INSPECTED NO DAMAGE FOUND. 1 L 7 2 3T 3 T A14CE E4EA 6 C P15EA 2005020100101 20050201 00101 CE 2005 2 1 CA040927008 1 20040927 G 3242 224110213 PIVOT ASSY CESSNA CESSNA 182 TR182 2072735 CE LYC O540 O540L3C5 41532 EA MCAULY 2D34C B2D34C219 GL MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) RT BRAKE CONTINUALLY LOOSING FLUID. CENTER SECTION AT GEAR PIVOTS ALWAYS WET. BRAKE SWIVEL NOT LEAKING. PIVOT ASS EMBLY REMOVED AND CHECKED BY DYE PENETRATE INSPECTION FOUND TO BE CRACKED. INSTALLED NEW PIVOT ASSEMBLY IAW MAINTENANCE MANUAL. 1 H 7 1 3O 3 O 3A13 E295 5 C P7EA 2005020100162 20050201 00162 EA 2005 2 1 CA040927009 1 20040917 G 5510 C2TP159 ATTACH BRACKET DHAV DHC2 DHC2* 2800108 EA PWA R985 R985AN14B 52008 NE HARTZL HCB3R HCB3R304 GL LT STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) CRACK LOCATED ON THE REAR FACE OF THE LT STAB ATTACH BRACKET, THE CRACK PARALLELS THE OB ATTACH FLANGE (ANCHOR NUT ATTACH SIDE) FOR 1.3750. THE CRACK HAD STARTED AT THE TOP OF THE STAB ATTACH BRACKET AND HAD WORKED ITS WAY DOWN. THE C RACK ON THE BRACKET WAS ONLY VISIBLE ONCE THE BRACKET WAS REMOVED FROM THE FRONT SPAR FOR SPECIAL INSPECTION CF-91-42. 1 H 7 1 3R 3 R A806 5E1 5 C P28EA 2005021400198 20050214 00198 NE 2005 2 14 CA040928001 2 20040912 G 7200 ENGINE BOEING 717 717200 1383700 NM RROYCE BR700 BR700715A130 NE FAILED W E A ENGINE SHUTDOWN UNSCHED LANDING M E J OVER TEMP VIBRATION/BUFFET WARNING INDICATION CL CLIMB 1 CA 13355 (CAN) IN FLIGHT SHUT DOWN AND AIR TURN BACK. IN CLIMB LOUD BANG AND TGT INCREASED TO 1000 DEG C. PILOT SHUT DOWN ENGINE AND RETURNED TO ORIGIN. ON GROUND, DEBRIS FOUND IN TAIL PIPE. ENGINE WILL BE INDUCTED IN OCTOBER. SUSPECT ED HPT BLADE FAILURE, FURTHER INFO WILL BE PROVIDED AT ENGINE STRIP. 2 L 7 2 4F 4 F TR A6WE E00061EN 2005020100163 20050201 00163 NE 2005 2 1 CA040928002 2 20040723 G 8530 11768 CAM DHAV DHC3 DHC3 2800202 EA PWA R1340 S3H1G 52016 NE HAMSTD 23D 23D40 NE EXHAUST WORN W A UNSCHED LANDING O OTHER CR CRUISE 1 CA P325832 (CAN) DURING FLIGHT ENGINE DEVELOPED UNUSUAL DRONING NOISE FROM ENGINE. SUSPECT WORN CAM LOBE. CAM REMOVED AND FOUND TO BE WORN ON SEVERAL EXHAUST CAM LOBES. SERVICEABLE CAM, ROLLERS AND PINS INSTALLED. ENGINE GROUND RUN SATISFACTORY. AIRCRAFT RELEASED. SATISFACTORY FLIGHT TEST CONDUCTED. 1 H 7 1 3R 3 R A815 E142 6 C P719 2005020100164 20050201 00164 NE 2005 2 1 CA040928003 2 20040826 G 7414 383021 SEAL DHAV DHC2 DHC2* 2800108 EA PWA R985 R985AN14B 52008 NE HAMSTD 22D 22D30 NE MAG DRIVE LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA 201831 (CAN) DURING INSPECTION, OIL WAS FOUND DRIPPING FROM THE MAG DRIVE ON LT MAG. MAG DRIVE SEAL FOUND TO BE LEAKING. REP LACED SEAL. ENGINE GROUND RUN SATISFACTORY. 1 H 7 1 3R 3 R A806 5E1 5 C P736 2005041800038 20050418 00038 NE 2005 4 18 CA040928004 2 20040925 G 7250 ENGINE DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE NR 2 FAILED W A UNSCHED LANDING Y D ENGINE STOPPAGE INFLIGHT SEPARATION CL CLIMB 1 CA 18420 728098 (CAN) A LOUD BANG WAS HEARD DURING CLIMB AT 100 AGL. NR 2 ENGINE FAILED AND RELIT AUTOMATICALLY. AIRCRAFT RETURNED BAC K FOR LANDING WITH ENGINE NR 2 AT IDLE WITH ALL PARAMETERS AT NORMAL EXCEPT THAT EGT REACH LIMITS WHILE THROTTLE WAS ADV ANCED. THE TURBINE WAS FOUND DAMAGED. THE ENGINE ASSY WILL BE REPLACED. AN ENGINE INVESTIGATION WILL FOLLOW. 2 L 7 2 4F 4 F RT A6WE E9NE 2005021400199 20050214 00199 NE 2005 2 14 CA040928005 2 20040908 G 8520 19559 IMPELLER DHAV DHC2 DHC2* 2800108 EA PWA R985 R985AN14B 52008 NE HAMSTD 22D 22D30 NE ENGINE FAILED W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CL CLIMB 1 CA 201831 (CAN) DURING CLIMB THE ENGINE LOST POWER AND HAD MAJOR OIL LEAKAGE. THE AIRCRAFT LANDED WITHOUT INCIDENT AND WAS RETURNE D TO DOCK. INSPECTION FOUND THAT THE IMPELLER ASSY HAD FAILED RESULTING IN ENGINE POWER LOSS AND OIL LEAKAGE. ENGINE REM OVED AND IS TO BE SENT TO OVERHAUL FACILITY FOR TEARDOWN AND REPAIR. 1 H 7 1 3R 3 R A806 5E1 5 C P736 2005041800039 20050418 00039 WP 2005 4 18 CA040928006 1 20040924 G 3244 TIRE DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE NLG FAILED W C ABORTED TAKEOFF E VIBRATION/BUFFET TO TAKEOFF 1 CA (CAN) HIGH VIBRATION REPORTED FROM NOSE WHEEL DURING TAKE OFF ROLL. THE TAKE OFF WAS ABORTED. BOTH NOSE WHEELS FOUND O UT OF ROUND. BOTH WHEELS REPLACED AND AIRCRAFT DISPATCHED SERVICEABLE. 2 L 7 2 4F 4 F RT A6WE E9NE 2004121000036 20041210 00036 EA 2004 12 10 CA040928007 1 20040920 G 2731 C3CF4205 ROD END DHAV DHC3 DHC3 2800202 EA ELEVATOR SERVO WORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AFT ROD END ON PUSH ROD PN F3I-14 WORN OUT AND STC ROD END PN M34-14. ALSO, FOUND WORN OUT PLUS ELEVATOR HINGE PI N C2TP199 AND HINGE PIN C3TF7-5 AND OUTER BEARING KP5A, ALL FOUND WITH EXCESSIVE WEAR AFTER ONLY 100 HOURS OF OPERATION UNDER STC SA01059SE. 1 H 7 1 3R A815 2005041800040 20050418 00040 EU 2005 4 18 CA040928008 1 20040927 G 2913 40165 PUMP BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE HYD SYSTEM NOISY W K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 CA (CAN) DURING DAILY INSPECTION PILOT NOTICED AN UNUSUAL WHINING NOISE COMING FROM THE NR 1 HYDRAULIC PUMP WHILE HE WAS TU RNING THE MAIN ROTOR BLADES. THE HYDRAULIC PUMPS ARE DRIVEN BY THE MAIN TRANSMISSION AND WILL BE DRIVEN WHENEVER THE ROT OR SYSTEM IS TURNED. THE PILOT CONTACTED ENGINEERING AND THE AIRCRAFT WAS GROUNDED. RESEARCH SHOWED THAT THIS PUMP WAS ONLY 78.4 HRS, 8 CALENDAR MONTHS TIME SINCE REPAIR BY VENDOR. A REPLACEMENT PUMP WAS ORDERED AND THE FAULTY PUMP SENT BACK FOR INSPECTION/REPAIR. AWAITING EVALUATION. 1 G 7 2 3U 3 U H13EU E5NE10 2005012100182 20050121 00182 SW 2005 1 21 CA040928009 1 20040927 G 5302 206031314037 LONGERON BELL 206 206L1 1182107 SW ALLSN 250C 250C28B 03013 GL TAILBOOM SUPPORT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THE MAINTENANCE CREW WERE DOING A 600 HOUR INSPECTION ON THE AIRFRAME AS PART OF THE INSPECTION. THE FUSELAGE TO TAILBOOM SUPPORT REQUIRES A VISUAL INSPECTION. FOUND A SLIGHT BLACK MARK NEAR THE UPPER FUSELAGE SUPPORT FOR THE TAILBO OM. THE AREA WAS CLEANED UP AND INSPECTED AGAIN AND WITH A MAGNIFYING GLASS IT WAS DETERMINED THAT THE CHANNEL OR LONGER ON WAS CRACKED. 1 G 7 1 3U 3 U H2SW E1GL 2005041800041 20050418 00041 EA 2005 4 18 CA040928010 2 20040927 G 7230 3024211 COMPRESSOR PWA PT6T PT6T6 52045 EA ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THE COMPRESSOR TURBINE DISK WAS INSTALLED ON AGUSTA BELL AB212. A CRACK INDICATION WAS FOUND DURING OVERHAUL NDT. PWC WILL CONDUCT INVESTIGATION TO ESTABLISH ROOT CAUSE. 4 U E22EA 2005041800042 20050418 00042 2005 4 18 CA040928011 3 20040927 G 6110 310703601 SHAFT DHAV DHC8 DHC8103 1386005 NM PWA PW121 PW121 52124 NE PROPELLER CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THE PROP SHAFT FOUND TO HAVE CRACKED ADJACENT TO A PREVIOUSLY REPAIRED DIAMETER (OVERHAUL, NOV 2001). PWC WILL INV ESTIGATE TO ESTABLISH ROOT CAUSE. 2 H 7 2 4T 4 T RT A13NM E20NE 2005012100184 20050121 00184 EA 2005 1 21 CA040928012 1 20040520 G 2730 C2CF815A CONTROL CABLE DHAV DHC2 DHC2* 2800108 EA PWA R985 R985AN14B 52008 NE HAMSTD 2D 2D30 NE LT ELEVATOR FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA 1236 (CAN) DURING INSPECTION THE LT ELEVATOR CONTROL CABLE WAS FOUND FRAYED AT FWD PULLEY (LOCATED UNDER BATTERY BOX COMPARTM ENT). BATTERY ACID CORROSION NOT EVIDENT AT LOCATION OF FRAYED CABLE. REPLACED CABLE. 1 H 7 1 3R 3 R A806 5E1 5 C P206 2004122900148 20041229 00148 EA 2004 12 29 CA040928013 1 20040730 G 2432 WIRE DHAV DHC2 DHC2* 2800108 EA PWA R985 R985AN14B 52008 NE ALTERNATOR GROUNDED W A UNSCHED LANDING H ELECT. POWER LOSS-50 PC CR CRUISE 1 CA (CAN) DURING VFR FLIGHT THE ELECTRICAL CHARGING SYSTEM FAILED. AIRCRAFT LANDED AT MAINTENANCE FACILITY. VOLTAGE CONTROLL ER FOUND TO BE BURNED INTERNALLY PROBABLY DUE TO GROUNDED FIELD WIRE IN ALTERNATOR. FIELD WIRE IN ALTERNATOR REPAIRED. I NSTALLED NEW VOLTAGE CONTROLLER.GROUND RUN SATISFACTORY. AIRCRAFT RETURNED TO SERVICE. 1 H 7 1 3R 3 R A806 5E1 2005041800043 20050418 00043 EA 2005 4 18 CA040928014 2 20040927 G 7200 ENGINE DHAV DHC6 DHC6200 2802620 EA PWA PT6 PT6A20 52043 EA LEFT FAILED W A UNSCHED LANDING Y ENGINE STOPPAGE DE DESCENT 1 CA (CAN) ON DESCENT TO LAND, THE PILOT HEARD A LOUD BANG AND LOSS OF TQ IN THE LT ENGINE. ALL OTHER INDICATIONS WERE NORMAL . THEY SECURED THE LEFT ENGINE AND MADE A NORMAL LANDING. 1 H 7 2 3T 3 T RT A9EA E4EA 2004101300067 20041013 00067 GL 2004 10 13 CA040928015 2 20040928 G 7261 CHECK VALVE ALLSN 250B 250B* GL ENGINE OIL MISINSTALLED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA CAT34998 (CAN) OIL CHECK VALVE INSTALLED BACKWARDS RESULTING NR 8 BEARING FAILURE. 3 T E10CE 2004101800109 20041018 00109 EA 2004 10 18 CA040928016 2 20040719 G 7250 3017393 LINE BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA AFCU BROKEN W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA (CAN) UNCOMANDED DECEL TO IDLE. PART CHANGED, ENGINE RETURNED TO NORMAL OPS. 1 G 7 1 4U 4 U H4SW E22EA 2005020700001 20050207 00001 NE 2005 2 7 CA040929001 2 20040924 G 7200 ENGINE CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE NR 2 INOPERATIVE W A UNSCHED LANDING D Y INFLIGHT SEPARATION ENGINE STOPPAGE CL CLIMB 1 CA 873018 (CAN) AT 500 FT THERE WAS A LOUD BANG AND THE NR 2 ENGINE SHUT DOWN, DECLARED AN EMERGENCY. LANDED WITHOUT INCIDENT. E NGINE REPLACED. OVERWEIGHT LANDING INSPECTION ALSO REQUIRED. 2 L 7 2 4F 4 F RT A21EA E15NE 2005020700002 20050207 00002 CE 2005 2 7 CA040929002 1 20040928 G 5343 2310537 WEB LEAR 35 35LEAR 5170600 CE GARRTT TFE731 TFE73122B 01518 WP FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 19903 (CAN) DURING A SCHEDULE INSPECTION, (AIRFRAME 3 MONTHS HUMP IRN G3200000) LOOSENESS WAS FOUND ON THE NOSE LANDING GEAR A CTUATOR UPPER ATTACHMENT POINT. THE ACTUATOR WAS REMOVED FOR ACCESS. DETAIL EXAMINATIONON THE UPPER ATTACHMENT BRACKET AND ACTUATOR HOUSING WAS COMPLETED. THE TWO WEBS P/N 2310532-11 AND -12 WERE FOUND CRACKED. THE TWO CHANNELS P/N 2410510 -8 AND -9 WERE ALSO FOUND CRACKED. THE PARTS ATTACH ON THE FORWARD PRESSURE BULKHEAD (FRAME 5). 2 L 7 2 4F 4 F A10CE E6WE 2005012100177 20050121 00177 EU 2005 1 21 CA040929003 1 20040927 G 6710 350A37150803 ROD END SNIAS SNIAS 350 AS350D 8680803 EU LYC LTS101 LTS101600A 41560 NE PITCH LINK SEPARATED W K NONE D INFLIGHT SEPARATION IN INSP/MAINT 1 CA (CAN) VIBRATION ANALYSIS EQUIPMENT WAS INSTALLED ON THE AIRCRAFT AFTER THE PILOT COMPLAINED IT WAS GETTING ROUGH. THE FI RST FLIGHT REVEALED THE A/C WAS INDEED ROUGH AND WHEN A PITCH LINK ADJUSTMENT WAS MADE, THE LOWER ROD END ON THE BLUE PI TCH LINK WAS FOUND TO HAVE SEPARATED FROM THE SPHERICAL BEARING. THE SWASH PLATE ASSY SUFFERED OUT OF LIMIT DAMAGE DUE T O THE ROD END RUBBING ON IT. THE SWASH PLATE ASSY AND THE THREE PITCH LINKS ARE IN THE PROCESS OF BEING REPLACED. 1 G 7 1 3U 3 U H9EU E5NE 2004111000060 20041110 00060 CE 2004 11 10 CA040929004 1 20040925 G 7921 509102751229 SCOOP BEECH BEECH 99 99 1154002 CE PWA PT6 PT6A28 EA HARTZL HCB3T HCB3TN3 GL OIL COOLER DEPARTED W O OTHER D INFLIGHT SEPARATION AP APPROACH 1 CA 30318 (CAN) ON APPROACH TO AIRPORT THE LT OIL SCOOP DEPARTED THE AIRCRAFT. THE SECURING FASTENERS WERE FOUND STILL ATTACHED T O THE BOTTOM OF THE NACELLE. PIECES OF FIBERGLASS WERE STILL UNDER THE HARDWARE. THERE WAS SLIGHT SHEET METAL DAMAGE T O THE BOTTOM OF THE NACELLE. 1 L 7 2 3T 4 T A14CE E4EA 6 C P15EA 2004101800110 20041018 00110 NE 2004 10 18 CA040929005 2 20040723 G 7310 31J251302 MANIFOLD CESSNA 500 550 2076604 CE PWA 530 PW530A NE FUEL SYSTEM LEAKING W A UNSCHED LANDING K X J FLUID LOSS ENGINE FLAMEOUT WARNING INDICATION CL CLIMB 1 CA (CAN) INVESTIGATION OF AN UNCOMMANDED ENGINE IFSD REVEALED FUEL LEAKAGE AT THE ENGINE FUEL MANIFOLD. THE MANIFOLD IS UN DER INVESTIGATION AT MFG. THIS REPORT WILL BE SUPPLEMENTED TO PROVIDE ROOT CAUSE, ONCE ESTABLISHED. 1 L 7 2 4F 4 F A22CE E00053EN 2004101800111 20041018 00111 GL 2004 10 18 CA040929006 3 20040929 G 6114 D613276C0 HUB MCAULY MAULE M5 M5210C 5460134 SO CONT O360 IO360D 17025 SO MCAULY 2A34C D2A34C67 GL PROPELLER UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 CA 774272 (CAN) PROPELLER WAS REMOVED FROM AIRCRAFT FOR 10 YR. CALENDAR O/H. UPON INSPECTION THE HUB WAS FOUND TO BE CORRODED EXT ERNALLY BEYOND REPAIR LIMITS. BLADE S/N K32294YS WAS FOUND TO BE CORRODED IN THE BLADE THREADS IN A LOCATION WHERE NO R EPAIR IS ALLOWED. THE MANUFACTURER RECOMMENDED CALENDAR O/H IS 60 MONTHS. 1 H 7 1 3O 3 O 3A23 E1CE 5 C P3EA 2004101800112 20041018 00112 GL 2004 10 18 CA040929007 3 20040929 G 6114 D6132 HUB MAULE M5 M5210C 5460134 SO CONT O360 IO360D 17025 SO MCAULY 2A34C D2A34C67 GL PROPELLER UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 CA 774272 (CAN) PROPELLER WAS REMOVED FOR 10 YR. CALENDAR O/H. UPON INSPECTION THE HUB WAS FOUND TO BE CORRODED BEYOND REPAIRABLE LIMITS. ALSO DURING THIS INSPECTION BLADE M/N76C-0, S/N K32294YS WAS FOUND TO HAVE CORROSION BELOW THE BLADE THREAD PITC H LINE IN AN AREA WHERE NO REPAIR IS ALLOWED. THIS PROPELLER HAS EXCEEDED THE MANUFACTURERS RECOMMENDED CALENDAR TBO OF 60 MONTHS BY 60 MONTHS. 1 H 7 1 3O 3 O 3A23 E1CE 5 C P3EA 2005031100042 20050311 00042 EA 2005 3 11 CA040929008 2 20040913 G 7250 COVER BEECH 100 A100 1152915 CE PWA PT6 PT6A28 EA NR 3 BEARNG OUT OF ADJUST W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) PILOTS NOTED THE ENGINE OIL GETTING DARKER AND THE ENGINE ITT GETTING HIGHER. MAINTENANCE INSPECTED THE ENGINE AN D FOUND THAT THE NR3 BRG COVER HAD TURNED AND CAUSED THE EXHAUST DUCT TO CRACK AND SEPARATE INTERNALLY. THE PT BLADES HA D RUB MARK AND ALSO THE PT DISK WAS SCRAPPED. PARTS WERE REPLACED AND RETURNED TOO SERVICE. THE EXHAUST DUCT DID NOT HAV E SB1430 ACCOMPLISHED WHICH STOPS THIS FROM HAPPENING. 1 L 7 2 3T 4 T A14CE E4EA 2005041800044 20050418 00044 SO 2005 4 18 CA040930001 1 20040922 G 8120 4091709001 TURBOCHARGER PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL ENGINE LEAKING W O OTHER O OTHER NR NOT REPORTED 1 CA L787161A (CAN) AFTER A SCHEDULED LANDING THE PILOTS FOUND A POOL OF OIL UNDER THE RIGHT HAND ENGINE. MAINTENANCE FOUND THE NEWLY INSTALLED TURBOCHARGER HAD THE OIL SEAL FAIL IN THE INTAKE SIDE PUMPING EXCESSIVE OILINTO THE ENGINE. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2005020100128 20050201 00128 CE 2005 2 1 CA040930002 1 20040929 G 5730 14220006 SKIN CESSNA 337 T337G 2075726 CE CONT O360 TSIO360CB 17025 SO MCAULY 2AF34C D2AF34C303 GL LT WING CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING INSPECTION, CRACKS WERE DISCOVERED AT THE IB END OF THE LT AND RT UPPER OB WING SKINS WHERE THEY UNDERLAP T HE FUEL TANK BAY COVERS. THE CRACKS ARE LOCATED IN THE RADIUS OF CUTOUT AREAS IN THE SKINS WHERE THE STINGERS JOIN AT WI NG STATION 150.0. THE AIRCRAFT IS EQUIPPED WITH FLINT WING TIP FUEL TANKS THAT WERE INSTALLED APPROXIMATELY 800 HOURS A GO. IT IS NOT KNOWN IF THIS IS A CONTRIBUTING FACTOR. 1 H 7 2 3O 3 O A6CE E9CE 5 C P5EA 2005041800045 20050418 00045 EU 2005 4 18 CA040930003 1 20040929 G 5610 1379628C402 WINDOW BAG JETSTM JETSTM3212 1500217 EU COCKPIT CRAZED W O OTHER O OTHER CR CRUISE 1 CA (CAN) AT 21000 FT IN CRUISING CONFIGURATION, THE RT WINDSHIELD SUDDENLY CRAZED. THE WINDSHIELD RETAINED ITS SHAPE AND TH ERE WAS NO CHANGE IN CABIN PRESSURE. DESCENT WAS COMMENCED AND THE CABIN ALTITUDE WAS INCREASED TO REDUCE DIFFERENTIAL P RESSURE. QRH WAS CONSULTED AND A NORMAL DESCENT AND LANDING WAS CARRIED OUT AT FORT SMITH AIRPORT WITH NO FURTHER CHANGE IN THE STATUS OF THE WINDSHIELD. A MAINTENANCE INSPECTION CONFIRMED THE OUTER AND INNER PLY TO BE INTACT. THIS WINDSH IELD HAD BEEN REPAIRED JANUARY 2004 AND INSTALLED IN THE AIRCRAFT MARCH 2004. 2 L 7 2 4T RT BA15CAA 2005041800046 20050418 00046 EA 2005 4 18 CA040930004 2 20040914 G 8530 74636 ROCKER CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160DTM GL CYLINDER SPLIT W A UNSCHED LANDING R E PARTIAL RPM/PWR LOSS VIBRATION/BUFFET CL CLIMB 1 CA L3418227A ON CLIMB-OUT, ENG RUNNING ROUGH, BACKFIRING, SHAKING VIOLENTLY. INSTRUCTOR LEVELED OFF & REDUCED POWER, ENG SMOOTHED OUT BUT STILL RAN ROUGH. A/C RETURNED & LANDED W/O INCIDENT. ENGINEERS IDENTIFIED A PROBLEM WITH NR 2 CYLINDER. INVEST CYLI NDER FOUND EXHAUST ROCKER ARM SPLIT & BENT ACROSS UNDERSIDE BY OIL LUBE HOLE. EXHAUST VALVE LEFT IN CLOSED POSITION BY R OCKER FAILURE. INTAKE AIR INLET SCREEN FOUND BULGED OUT BUT NO OTHER DAMAGE FOUND. ENG SHOP INFORMED & NEW PARTS INSTALL ED. ENG HAS 2343 HRS SINCE O/H. AFFECTED CYLINDER HAD BEEN REPLACED RECENTLY WITH AN OVERHAULED ONE & HAD ONLY FLOWN 28. 0 HRS. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2005020100129 20050201 00129 GL 2005 2 1 CA040930006 3 20040924 G 6111 P5855BSW PAD CESSNA 402 402B 207590P CE MCAULY 3AF32C 3AF32C87 GL PROP DEICE MISSING W K NONE O OTHER IN INSP/MAINT 1 CA 842046 (CAN) AFTER FLIGHT, PILOT SAW ON RT PROPELLER, ONE PROP DE-ICE PAD MISSING ON ONE BLADE. AFTER INSPECTION OF THE DEFECT , WE SAW THE GLUE WAS NOT HARD. THE DE-ICE PAD WAS INSTALLED AT O/H SHOP WITH NEW KIND OF GLUE. WE REMOVED THE OLD GLUE AND REINSTALLED A NEW DE-ICE PAD WITH CONTACT GLUE (3M 1300L). AIRCRAFT RETURNED TO SERVICE AFTER REPAIR.NOTE: IT'S NOT THE FIRST TIME THIS PROBLEM APPEAR DUE TO THIS NEW KIND OF GLUE. 1 L 7 2 3O A7CE 5 C P22EA 2005012100178 20050121 00178 GL 2005 1 21 CA040930007 1 20040928 G 2750 763077J CONTROL UNIT BOMBDR BD700 BD7001A10 1390006 GL RROYCE BR700 BR700710A220 09500 NE SLAT/FLAPS BURNED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING ROUTINE MAINTENANCE, THE CREW REPORTED THAT THE NR 2 SFCU CIRCUIT BREAKER POPPED TWICE AND WERE RESET TWICE . THEY THEN SMELLED SMOKE COMING FROM THE AVIONICS BAY. THE SOURCE OF SMOKE WAS TRACED BACK TO THE SFCU. THE SFCU WAS REMOVED AND WAS FOUND TO HAVE TWO (2) HOLES BURNED THROUGH ON THE SIDE. THE BOX WAS REMOVED FROM THE RACK. 2 L 7 2 4F 4 F RT T00003NY E00061EN 2005012100165 20050121 00165 SO 2005 1 21 CA041001002 1 20040921 G 3230 4194902 DOWNLOCK ARM PIPER PA31 PA31325 7103105 SO LYC O540 LTIO540F2BD 41533 EA HARTZL HCE3Y HCE3YR2A GL LT MLG STUCK W E ENGINE SHUTDOWN J WARNING INDICATION AP APPROACH 1 CA (CAN) LT GEAR DOWN LOCK ROD FOUND STUCK IN RETACT POSITION. REMOVED ROD, CLEANED LUBRICATED AND CYCLED LANDING GEAR. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2005020100104 20050201 00104 SO 2005 2 1 CA041001003 1 20040928 G 5311 6269504 FRAME PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA SNSNCH 74D 74DM EA FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 11251 (CAN) FUSELAGE FRAME, PN 62695-04 AT STA 73.04 FOUND CRACKED, BUCKLED 4.5 IN FROM OUTER EDGE ON RT SIDE. THIS CHANNEL IS IN SHAPE OF A HAT SECTION AND WAS COMPLETELY CRACKED FROM FLANGE TO FLANGE. THIS CHANNEL SUPPORTS WING FWD ATTACHMENT L UG, IB OF FITTING PBN 62448-03. FRAME IS 6.75 FT WIDE AND WAS BUCKLED FROM TOP TO BOTTOM. CRACK EXTENDED THROUGH BOTTOM FLANGE RIVETED TO OUTER SKIN AND ROSE 2' UP WEB OF FRAME. THIS FRAME SUPPORTS WING REAR ATTACHMENT LUGS THROUGH FITTINGS PN 62448-03 AND 62448-02. FITTINGS ARE STEEL AND RIVETED TO ALUMINUM CHANNEL. RIVETS WERE CORRODED TO POINT MANY HEADS FELL OFF. AC OPERATED IN SALT WATER, WINDOWS ABOVE STRUCTURE LEAKED ALLOWING WATER AND SALT TO ENTER CABIN AREA. 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 2005020100134 20050201 00134 NE 2005 2 1 CA041001004 2 20040929 G 7230 ENGINE BOEING 737 737* NM CFMINT CFM567 CFM567B22 13802 NE NR 1 FAILED W A UNSCHED LANDING B J SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CL CLIMB 1 CA 891269 (CAN) AIRCRAFT REPORTED STRONG ODOR THROUGHOUT THE CABIN AND FLIGHT DECK IN CLIMB. NO SMOKE VISIBLE. CREW RAN AIR CONDIT IONING IN MANUAL/AIR MIX VALVES COLD, SMELL DISSIPATED. AIRCRAFT RETURNED TO DEPARTURE AND LANDED WITHOUT INCIDENT. NO EMERGENCY WAS DECLARED. MAINTENANCE CONDUCTED ENGINE RUNS ON BOTH ENGINES AT 70 PERCENT N2 FOR 10 MINUTES WITH EACH CORR ESPONDING PACK RUNNING IN HOTMODE. ODOR DISSIPATED GRADUALLY. SYSTEM CHECKED SERVICEABLE. AIRCRAFT RETURNED TO SERVICE WITH NO FURTHER INCIDENTS TO REPORT. NOTE: PREVIOUS NIGHT MAINTENANCE INCLUDED NR 1 ENGINE FAN BLADE LUBE/INSPECTION T ASK NR 95-072-00-01. 2 L 7 2 4F 4 F RT A16WE E00055EN 2005012100179 20050121 00179 NM 2005 1 21 CA041001005 1 20040913 G 2751 2061131 INDICATOR BOEING 727 727223 1384074 NM PWA JT8 JT8D15A 52051 NE FLAP POSITION FAILED W J DUMP FUEL F FLT CONT AFFECTED CL CLIMB 1 CA (CAN) AFTER TAKE-OFF DURING FLAP RETRACTION, BOTH IB AND OB FLAPS STOPPED BETWEEN FLAP POSITION 5 AND 2. AIRCRAFT DUMPE D FUEL AND RETURNED TO STATION. RECTIFICATION AFTER SEVERAL SUCCESSFUL ATTEMPTS, FAULT DUPLICATED ON GROUND FAULTING TH E IB FLAP POSITION INDICATOR. POSITION INDICATOR REPLACED, SYSTEM CHECK SERVICEABLE IAW MM27-52-1-11. SUBSEQUENT RIGGI NG OF FLAP CONTROLS WAS CARRIED OUT. 2 L 7 3 4F 4 F A3WE E2EA 2004111000062 20041110 00062 SW 2004 11 10 CA041001006 1 20040921 G 2842 206063613003 DETECTOR BELL 206 206L3 1182108 SW ALLSN 250C 250C30 03013 GL FUEL SYSTEM LEAKING W K NONE K P FLUID LOSS NO WARNING INDICATION IN INSP/MAINT 1 CA (CAN) WHILE RESEARCHING ASB 206L-04-132, FOUND LOW FUEL DETECTOR SEEPING. DRAINED FUEL SYSTEM TO CHECK LOW LEVEL INDICAT OR OPERATIONS AND QUANTITY. LOW FUEL LIGHT FOUND DISCONNECTED. UPON CONNECTING, LOW FUEL LIGHT WOULD NOT GO OUT AFTER 11 0LBS FUEL ADDED TO TANK. DETECTOR REMOVED, FOUND TO HAVE POOR REPAIRS. ITEM SEALED WITH SILICONE LEAKED. SUBSEQUENTLY TH E SWITCH FELL APART WHEN HANDLED. NEW SWITCH INSTALLED AND OPERATIONS CHECKED FOR CORRECT INDICATION. 1 G 7 1 3U 3 U H2SW E1GL 2004111000063 20041110 00063 SO 2004 11 10 CA041001007 1 20040927 G 5320 4177100 BRACKET PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL NG UP SWITCH BENT W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA (CAN) AFTER GEAR UP SELECTED, FLT CREW DISCOVERED THE GEAR IN TRANSIT IND. ILLUMINATED. A/C RETURNED WITH 3 GREENS. A/C WAS PUT ON JACKS, GEAR CYCLED AND NOTICED THE NLG TORQUE TUBE SWITCH BRACKET WAS BENT RESTRICTING THE UP-LOCK SWITCH FRO M CONTACTING. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004111000064 20041110 00064 EA 2004 11 10 CA041001008 1 20040929 G 1430 B42624 BARREL NUT DHAV DHC6 DHC6300 2802606 EA PWA PT6 PT6A27 52043 EA HARTZL HCB3T HCB3TN3 GL ENGINE MOUNT DAMAGED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) WHEN TORQUE CHECK OF ENGINE MOUNT BOLTS PERFORMED OB BOLT CORRECT TORQUE COULD NOT BE ACHIEVED. BARREL NUT REMOVE D AND FOUND TO HAVE DAMAGED THREADS AND WAS OF FIBER LOCK STYLE. BARRREL NUT AND BOLT REPLACED WITH IPC REQUIRED PARTS. 1 H 7 2 3T 4 T RT A9EA E4EA 6 C P15EA 2005020100146 20050201 00146 SO 2005 2 1 CA041001011 2 20040913 G 7414 6310 MAGNETO CESSNA 185 A185F 2072821 CE CONT O520 IO520D 17032 SO MCAULY D3A34 D3A34C403 GL RIGHT ARCED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) PILOT REPORTED A 200 RPM DROP ON RT MAGNETO. TROUBLESHOOTING REVEALED THAT TOP IGNITION WIRE ON NR 5 CYLINDER WAS UNSERVICEABLE. WHEN HARNESS WAS REMOVED FROM MAGNETO, EVIDENCE OF HEAVY ARCING WAS NOTED IN THE NR 5 LEAD OUTLET AREA O F THE DISTRIBUTOR BLOCK. 1 H 7 1 3O 3 O 3A24 E5CE 5 C P47GL 2004122300025 20041223 00025 NE 2004 12 23 CA041001012 2 20040921 G 7200 ENGINE PWA JD15 JT15D1A NE FAILED W K NONE O OTHER IN INSP/MAINT 1 CA 77128 ENGINE WAS REMOVED FROM THE WING AFTER THE CUSTOMER THOUGHT THAT THE ENGINE HAD SUSTAINED A HIGH TURBINE BLADE FAILURE. THE ENGINE WAS SHIPPED TO ATLANTIC TURBINES FOR INVESTIGATION AND REPAIR. NO SIGNIFICANT DAMAGE WAS FOUND UPSTREAM OF THE HIGH PRESSURE TURBINE IT HAS BEEN CONCLUDED THAT THIS ENGINE DID SUSTAIN A HIGH TURBINE BLADE FAILURE. IT IS ATLANT IC TURBINES OPINION THAT THIS ENGINE DID SUFFER AN HP TURBINE BLADE FAILURE SINCE THERE WAS NO UPSTREAM DAMAGE PRIOR TO THE HPT DISK. ALL DAMAGE DOWNSTREAM IS THOUGHT TO BE SECONDARY DAMAGE CAUSED BY THE LIBERATED MATERIAL FROM THE HIGH TU RBINE BLADES. THE SECONDARY DAMAGE IS CONCENTRATED MAINLY TO THE 2ND STAGE STATOR AND ROTOR. 4 F E25EA 2004111000065 20041110 00065 CE 2004 11 10 CA041001013 1 20040928 G 5740 351150582 FITTING BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL WING CHAFED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING THE WING BOLT INSPECTION, THE LT LOWER AFT BATHTUB FITTING WAS FOUND TO HAVE CHAFE MARK FROM CONTACT WITH T HE CLIP ON THE WING FITTING COVER. ONE MARK EXTENDED INTO THE FITTING RADIUS. MFG WAS CONSULTED AND SENT OUT A FIELD REP AIR TO REMOVE THE DAMAGE. EACH BATHTUB FITTING COVER IS HELD IN PLACE BY A SPRING STEEL CLIP THAT GRIPS THE WING FITTING AT ONE END WHILE THE OTHER END IS HELD IN PLACE BY A SCREW. IT APPEARS THAT THE COVER MAY HAVE BEEN A LITTLE LOOSE ALL OWING IT TO FLUTTER OR VIBRATE AND CAUSING THE CLIP TO CHAFE THE WING FITTING. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2005012100163 20050121 00163 EA 2005 1 21 CA041001014 1 20040928 G 7110 A33721 STRUT CNDAIR CL604 CL604 1900301 EA GE CF34 CF343B1 NE UPPER CORE COWL UNSECURE W E ENGINE SHUTDOWN E VIBRATION/BUFFET CL CLIMB 1 CA (CAN) DURING A FLIGHT AFTER MAINTENANCE, AIRCRAFT WAS IN CLIMB TO FL330 WHEN THROTTLES WERE PULLED BACK. CREW WAS UNABL E TO RETARD LT ENGINE THROTTLE. AIRCRAFT DESCENDED TO FL100 WHERE AN EMERGENCY WAS DECLARED AND THE LT ENGINE FIRE SHU TOFF, PBA WAS PUSHED. AN UNEVENTFUL LANDING WAS MADE. MAINTENANCE FOUND THE UPPER COWL SUPPORT STRUT NOT SECURED AND FOULING THE FUEL CONTROL UNIT LEVER ARM. THE AIRCRAFT THROTTLE SYSTEM WAS CHECKED FOR DAMAGE. AIRCRAFT RETURNED TO SER VICE. 2 L 7 2 4F 4 F RT A21EA E15NE 2004121000047 20041210 00047 NM 2004 12 10 CA041004001 1 20041002 G 2932 7G772 PRESSURE SWITCH DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE HYD SYSTEM FAILED W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA (CAN) APPROXIMATELY 45 NAUTICAL MILES NORTH EAST OF BASE, THE 'NR 2 RUD HYD' CAUTION LIGHT ILLUMINATED. FOLLOWING COMPLE TION OF QRH DRILLS THE CREW ELECTED TO RETURN THE AIRCRAFT TO BASE WHERE A NORMAL APPROACH AND LANDING WAS CARRIED OUT. ENGINEERING INVESTIGATION REVEALED THAT THE NUMBER TWO RUDDER HYDRAULIC PRESSURE SWITCH HAD FAILED. THE PRESSURE SWITCH WAS REPLACED AND FOLLOWING REQUIRED FUNCTIONAL CHECKS THE AIRCRAFT WAS RETURNED TO SERVICE WITHOUT FURTHER INCIDENT. AIR CRAFT STATISTICS:TTSN = 12504 HRSTCSN = 11315 CYC. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005012100164 20050121 00164 EA 2005 1 21 CA041004002 2 20041001 G 8520 LW18402 CRANKCASE CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA MCAULY 1C160 1C160DTM GL ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 1067239A (CAN) RT CRANKCASE IS CRACKED AT THE ALTERNATOR TENSIONING ARM ATTACHMENT BOSS. CRACK APPROX .5 IN LONG BEGINS AT THE B OLT HOLE WHERE TENSIONING ARM ATTACHES TO CRANKCASE AND EXTENDS IN AN AFT DIRECTION. ENGINE REMOVED FOR REPAIR. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2005021400193 20050214 00193 CE 2005 2 14 CA041004003 1 20040926 G 3242 114800817 DISC BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA HARTZL HCB4M HCB4MP3 GL BRAKES FRACTURED W K NONE O OTHER IN INSP/MAINT 1 CA AUG951916 (CAN) ON PUSH BACK INTO THE HANGAR AN UNUSUAL NOISE WAS HEARD FROM NR 2 MAINWHEEL. ON REMOVING THE MAIN WHEEL, A SECTION OF THE STATIONARY DISC FELL OUT OF THE BRAKE ASSEMBLY. WHEN THE BRAKE ASSY WAS REMOVED THE REST OF THE STATIONARY DISC WAS REMOVED WITHOUT DISSAMBLY OF THE BRAKE. THE INNER HALF OF THE MAIN WHEEL WAS SCORED BY THE BRAKE DISC AND WAS REPLA CED ALONG WITH THE BRAKE ASSEMBLY. WHEN THE BRAKE WAS LAST REPAIRED THE DISC WAS EXAMINED AND FOUND TO BE SERVICABLE TO CONTINUE IN SERVICE WITHOUT REPLACING THE PADS. THEREFORE NDT WAS NOT REQUIRED. THE BRAKE HAD COMPLETED 963.2 HRS AND 8 51 CYCLES DURING THIS INSTALLATION. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2005021400192 20050214 00192 GL 2005 2 14 CA041004004 2 20040921 G 7314 PUMP CVAC 440 440 2422902 WP ALLSN 501D 501D13D 03004 GL ALLSN A6441 A6441FN606 GL FUEL PRESS OUT OF ADJUST W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CL CLIMB 1 CA 59552 (CAN) AIRCRAFT DISPATCH LIKE USUAL FROM HANGAR WITH 28 PASSENGER ONBOARD AND CAME BACK DUE TO FUEL UNBALANCE AND ONE PAS SENGER HAD REPORT SEEING FUEL COMING OUT OF RT HAND TANK OVERWING FUEL CAP AND CREW REALIZED IT HAD TAKEN OFF WITH FUEL CROSS-FEED OPEN. MAINTENANCE TRANSFERED SOME FUEL FROM RT TO LT USING TRANSFER HOSE. OVERWEIGHT LANDING INSPECTION C/O. AIRCRAFT RETURN TO SERVICE FOR THE FLIGHT. ON RETURN MAINTENANCE INVESTIGATION REVEAL , LT PUMP PRESSURE WAS AT 21 PSI AND RT WAS AT 16 PSI. C/O FUEL PUMP PRESSURE ADJUSTMENT ON BOTH SIDES IAW APJCB 10-21. 2 L 7 2 4R 4 T 6A6 E282 6 C P898 2005031100026 20050311 00026 GL 2005 3 11 CA041004006 1 20040908 G 2497 770699A CONNECTOR BOMBDR BD700 BD7001A10 1390006 GL RROYCE BR700 BR700710A220 09500 NE P1 BURNED W A UNSCHED LANDING B H SMOKE/FUMES/ODORS/SPARKS ELECT. POWER LOSS-50 PC CL CLIMB 1 CA (CAN) THE CREW SMELLED SMOKE IN THE COCKPIT AND RETURNED TO THE AIRPORT JUST AFTER TAKEOFF. THEY HAD SEVERAL CIRCUIT BR EAKER TRIPPED FOR THE DC BUS 1 ON THE EMSCDU AND EVENTUALLY THE DC BUSS 1 FEED 4, WHICH FEED SPDA 4 TRIPPED AS WELL. SE VERAL ANOMALIES WERE NOTED IN THE COCKPIT, SUCH AS LIGHTS AND SOME AVS EQUIPMENT GOING OFF. UPON INSPECTION, THE P1 CON NECTOR WAS FOUND BURNED ON SPDA 4. THE CONNECTOR SEEMED TO BE WELDED TO THE SPDA. THE SPDA WAS REMOVED WITH THE CONNECT OR STILL ATTACHED. A NEW SPDA AND P1 WERE INSTALLED AND THE AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT T00003NY E00061EN 2005031400038 20050314 00038 NE 2005 3 14 CA041005001 2 20041002 G 8520 11768 CAM DHAV DHC3 DHC3 2800202 EA PWA R1340 S3H1G 52016 NE HAMSTD 23D 23D40 NE ENGINE DAMAGED W A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 CA 89046 (CAN) THE ENGINE DEVELOPED A NOISE INDICATING A WORN CAM LOBE OR ROLLER. SMALL AMOUNT OF METAL (STEEL ) FOUND IN ENGINE SUMP. TRACE AMOUNT OF METAL FOUND IN OIL SCREEN. CAM REMOVED AND FOUND TO BE DAMAGED ON ONE EXHAUST LOBE. INSTALLED N EW CAM AND ROLLERS ON EXHAUST TAPPET ASSY. ENGINE GROUND RUN SATISFACTORY. FLIGHT TEST WAS SATISFACTORY. SUMPS AND S CREENS RECHECKED NO METAL PRESENT. 1 H 7 1 3R 3 R A815 E142 6 C P719 2004121000044 20041210 00044 WP 2004 12 10 CA041005002 1 20040908 G 5230 DOOR CVAC 440 440 2422902 WP ALLSN 501D 501D13D 03004 GL CARGO OUT OF RIG W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) AIRCRAFT DISPATCH WITH 29 PASSENGER ABOARD AT 13:32 GMT AND CAME BACK AT 14:14 WITH C2 DOOR OPEN. MAINTENANCE DISC OVERED THAT THE C2 DOOR COULD BE CLOSE IMPROPERLY IN SOME OCCASION AND NO DAMAGE WAS FOUND. MAINTENANCE CLOSE THE DOOR A ND CONFIRM THE LOCK HAD ENGAGED, AIRCRAFT RETURN TO XXX NORMALLY. A VISUAL INSPECTION WAS C/O AGAIN OF THE DOOR AND DOOR FRAME, NO DAMAGE WAS FOUND. COMPLETE RIGGING OF DOOR WAS C/O IAW MAINTENANCE MANUAL AND AIRCRAFT RETURN TO SERVICE. 2 L 7 2 4R 4 T 6A6 E282 2005020100113 20050201 00113 SW 2005 2 1 CA041005004 1 20040923 G 6420 406012102109 HUB BELL 407 407 1182206 SW TAIL ROTOR HEAD OVERSIZED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) T/R HUB FOUND TO HAVE 1.6255 - 1.6260, INTERNAL DIAMETER FOR ELASTOMERIC FLAPPING BEARING INSTALL, OVERSIZE FROM .0002 TO .0007. 1 G 7 1 3U O H2SW 2005020400006 20050204 00006 WP 2005 2 4 CA041005005 1 20041002 G 5230 SEAL DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE CARGO DOOR DAMAGED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) DURING CLIMB, PRESSURE FLOW LIGHT CAME ON THRU 9000 FT AND COULD NOT PRESSURIZE THE AIRCRAFT. AIRCRAFT LANDED BAC K TO DEPARTURE AIRPORT. MAINTENANCE FOUND THE MID CARGO DOOR SEAL AND THE EE COMPARTMENT DOOR SEAL NOT PROPERLY INSTALL ED AND DAMAGED. BOTH SEALS REPAIRED AND AIRCRAFT DISPATCHED SERVICEABLE. 2 L 7 2 4F 4 F RT A6WE E9NE 2005020100136 20050201 00136 SW 2005 2 1 CA041006001 1 20040928 G 2741 A21810064603 TRIM SWITCH HUGHES 269 269C1 8059504 SW LYC O360 HO360C1A 41514 EA STABILIZER STICKS W O OTHER F FLT CONT AFFECTED LD LANDING 1 CA (CAN) TRIM SWITCH STICKS WHEN PULLED FOR REAR ACTIVATION. REPLACED SWITCH. 1 G 7 1 3O 3 O O 4H12 E286 2004111000066 20041110 00066 NM 2004 11 10 CA041006002 1 20040921 G 2750 65404494 CONTROL VALVE BOEING 727 727223 1384074 NM PWA JT8 JT8D15A 52051 NE TE FLAPS FAILED W O OTHER J WARNING INDICATION CL CLIMB 1 CA (CAN) AFTER TAKE-OFF DURING FLAP RETRACTION, BOTH IB AND OB FLAPS STOPPED BETWEEN FLAP POSITION 5 AND 2. RECTIFICATION AFTER EXTENSIVE TROUBLESHOOTING CARRIED OUT. BOTH FLAP CONTROL VALVES WERE REPLACED. THE AIRCRAFT WAS TEST FLOWN WITHOUT ANY FURTHER PROBLEMS. 2 L 7 3 4F 4 F A3WE E2EA 2005012100166 20050121 00166 EA 2005 1 21 CA041006003 1 20040917 G 2435 03600923 BEARING DHAV DHC8 DHC8311 1386006 EA PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE STARTER GEN FAILED W K NONE J WARNING INDICATION IN INSP/MAINT 1 CA Y20071R (CAN) NR 2 STARTER GEN CAUTION LIGHT ILLUMINATED DURING FLIGHT. STARTER GEN REMOVED AND SENT TO COMPONENT SHOP. UPON D ISASSEMBLY THE BEARING FAILURE WAS CONFIRMED ON THE ANTI-DRIVE END HOUSING. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005031400039 20050314 00039 SW 2005 3 14 CA041006004 1 20041004 G 5313 206032308003 LONGERON BELL 206 206L1 1182107 SW ALLSN 250C 250C28B 03013 GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) IN THE TASK OF CHANGING THE LONGERON, IT WAS VISUALLY NOTED THAT THIS FRAME WAS CRACKED IN TWO PLACES. THE CRACKS WERE NEAR THE UPPER TWO ATTACHMENT POINTS OUT OF THE 4 ATTACHMENT POINTS. 1 G 7 1 3U 3 U H2SW E1GL 2005020100125 20050201 00125 SO 2005 2 1 CA041006005 2 20040922 G 7261 5100106236 LINE CESSNA 414 414 2075908 CE CONT O520 TSIO520N 17040 SO MCAULY 3AF32C 3AF32C505 GL LT ENG OIL CORRODED W E A ENGINE SHUTDOWN UNSCHED LANDING O OTHER CR CRUISE 1 CA (CAN) PILOT AND AME FLYING HOME TO BASE OBSERVED THE LT ENGINE OIL PRESSURE DECREASING AT A SLOW RATE, UNTIL DECISION MA DE TO SHUT DOWN THE ENGINE AND LAND AT THE NEAREST AIRFIELD. INVESTIGATION ON THE GROUND REVEALED OIL TO BE LEAKING FRO M THIS LINE. LINE REPLACED AND CONDITIONS RETURNED TO NORMAL. CONTINUED ON HOME. NO FURTHER ACTION REQUIRED. 1 L 7 2 3O 3 O RT A7CE E8CE 5 C P22EA 2004111500103 20041115 00103 NM 2004 11 15 CA041006006 1 20041005 G 2742 251T43101 ACTUATOR BOEING 767 767233 1385113 NM PWA JT9 JT9D7R4D 52054 NE STABILIZER TRIM CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 63609 (CAN) INSPECTION OF HORIZONTAL STABILIZER SCREWJACK DURING M01CHECK REVEALED EVIDENCE OF INTERNAL CORROSION AS A RESULT OF DISCOLORATION IN LUBRICANT. 2 L 7 2 4F 4 F RT A1NM E3NE 2004122200173 20041222 00173 EA 2004 12 22 CA041006007 2 20040928 G 7200 PT6A27 ENGINE PWA PT6 PT6A27 52043 EA FAILED W O OTHER X J ENGINE FLAMEOUT WARNING INDICATION CR CRUISE 1 CA 22317 (CAN) ENG REMOVED FROM WING DUE TO INFLT SHUTDOWN CAUSED BY A POWER SECTION SEIZURE. ENG SENT TO ATLANTIC TURBINES FOR I NVEST. POWER SECTION, POWER TURBINE & RIB, SUFFERED DAMAGE. POWER TURBINE DISK WAS NO LONGER COUPLED TO RIB INDICATES TH AT A POSSIBILE PT OVERSPEED AFTER IT DECOUPLED. THIS WOULD BE SUFFICIENT TO CAUSE PT BLADES TO FRACTURE & DEPART DISK. T HIS WOULD RESULT IN FRACTURES AT SIMILAR LOCATIONS ON ALL BLADES WHICH IS NOT SEEN HERE. EVIDENCE OF SUDDEN STOPPAGE CAU SED BY 1ST STAGE GEARING. DAMAGE TO SUN GEAR & 1ST STAGE PLANET GEARS RESPONSIBLE FOR AMOUNT OF METAL CONTAMINATION. ATL ANTIC TURBINES IS CONTINUING ITS INVESTI TO ATTEMPT TO DETERMINE WHAT THE PRIMARY FAILURE THAT CAUSED OTHER DAMAGE. 4 T E4EA 2005031400040 20050314 00040 CE 2005 3 14 CA041006008 1 20040917 G 7603 MCC29950501 THROTTLE CABLE CESSNA 206 U206F 2073333 CE CONT O550 IO550F 17042 SO HARTZL HCC3Y HCC3YF1 GL ENGINE BROKEN W B EMER. DESCENT E VIBRATION/BUFFET AP APPROACH 1 CA (CAN) PILOT MAKING AN APPROACH TO SCHEDULED LANDING WHEN ENGINE POWER WENT TO IDLE WITH NO RESPONSE TO ACTIONS OF THROTT LE CONTROL. PILOT ELECTED TO LAND IN FIELD SHORT OF RUNWAY AND EXPERIENCED NO DIFFICULTY. AIRCRAFT EQUIPPED WITH TUNDRA TIRES. MAINTENANCE DETERMINED THE THROTTLE CABLE AT THE ENGINE CONNECTION HAD FAILED. THROTTLE CABLE WAS REPLACED AND AIRCRAFT FLOWN FROM FIELD. NO FURTHER ACTION REQUIRED. P/N MCC299505-01 IS A PMA PART. 1 H 7 1 3O 3 O A4CE E3SO 5 C P25EA 2005031400041 20050314 00041 NM 2005 3 14 CA041007001 1 20041005 G 4997 WIRE GARRTT BOEING 727 727227 1384078 NM PWA JT8 JT8D9A 52048 NE APU CHAFED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) JUST PRIOR TO ENGINE START AT AN OUTBASE, THE A/C APU SHUT DOWN ON ITS OWN. GROUND EQUIPMENT WAS USED TO POWER AN D START THE A/C, AND THE FLIGHT CONTINUED. AT THE TERMINATING BASE, MAINTENANCE PERSONNEL FOUND 2 WIRES AT THE APU THAT HAD CHAFED AND SHORTED AGAINST EACH OTHER. THE WIRES WERE REPAIRED AND THE A/C RETURNED TO SERVICE. 2 L 7 3 4F 4 F A3WE E2EA 2005071200027 20050712 00027 SW 2005 7 12 CA041007002 1 20041006 G 6420 206011810117 TAIL ROTOR BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL MISRIGGED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) TAIL ROTOR FLAPPING ANGLE FOUND SET TO 18 DEGREES INSTEAD OF THE CORRECT ANGLE OF 12 DEGREES ALLOWING POSSIBLE COT ACT WITH TAILBOOM 1 G 7 1 3U 3 U H2SW E4CE 2005031400042 20050314 00042 NE 2005 3 14 CA041007003 2 20040929 G 7261 DSC3912 HOSE DHAV DHC8 DHC8201 2809001 NM PWA 120 PW123D 52152 NE HAMSTD 14SF 14SF23 NE ENGINE OIL RUPTURED W E A ENGINE SHUTDOWN UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CL CLIMB 1 CA 15305 (CAN) THE NR2 ENGINE OIL PRESSURE WARNING LIGHT ILLUMINATED WITH A CORRESPONDING FALLING OIL PRESSURE GAUGE READING. US ING QRH PROCEDURES THE NR2 ENGINE WAS SHUT DOWN AND A PAN DECLARED. THE CREW THEN RETURNED THE AIRCRAFT TO BASE WHERE A SINGLE ENGINE APPROACH AND LANDING WAS CARRIED OUT WITHOUT INCIDENT. A LARGE QUANTITY OF ENGINE OIL LOSS WAS IDENTIFIE D ON THE ENGINE AND ENGINEERING INVESTIGATION REVEALED A RUPTURE, FAILURE OF THE OB ENGINE OIL TANK TO OIL COOLER FLEXIB LE HOSE ASSEMBLY. THE FAILED HOSE ASSEMBLY WAS REPLACED AND FOLLOWING SATISFACTORY COMPLETION OF REQUIRED MAINTENANCE CH ECKS THE AIRCRAFT WAS RELEASED BACK TO SERVICE WITHOUT FURTHER INCIDENT. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005020100126 20050201 00126 GL 2005 2 1 CA041007004 2 20040927 G 7261 3579501200 GEAR BELL 206 206BELL 1181502 SW ALLSN 250C 250C18 03011 GL OIL PUMP WORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THIS IS THE OIL PUMP GEAR THAT DRIVES THE HYDRAULIC PUMP ON THE AC, GREASING INTERVAL IS 300 HRS. THIS SHAFT WAS GREASED EVERY 100 HRS AND HAS TOTALLY WORN OUT. THIS SHAFT ALSO WEARS OUT THE COUPLING IT ATTACHES TO, AS WELL. 1 G 7 1 3U 3 U H2SW E4CE 2004111500104 20041115 00104 CE 2004 11 15 CA041007005 1 20041006 G 3243 98820125 PISTON CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA MCAULY 1C160 1C160DTM GL MASTER CYLINDER BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA 10460 (CAN) PISTON BROKE IN THREADED PORTION, OUTSIDE OF MASTER CYLINDER, IMMEDIATELY BELOW JAM NUT. NO EVIDENCE OF FRETTING T HAT WOULD INDICATE AN EARLIER PARTIAL BREAK. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2005020100132 20050201 00132 NE 2005 2 1 CA041007006 2 20040922 G 7322 7423461 SLEEVE CESSNA 500 560CESSNA 2076750 CE PWA JT15 JT15D5 52112 NE THROTTLE CABLE WORN W O OTHER X J ENGINE FLAMEOUT WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) DURING GROUND RUN OPERATIONS CHECK AFTER STARTER GENERATOR CHANGE THROTTLE WAS ADVANCED TO 70 PERCENT THEN RETARDE D TO IDLE QUICKLY (1 SEC.). ENGINE FLAMED OUT. ENGINE RIGGING WAS CHECKED, THEN THE INNER CABLE OF THE AFT THROTTLE CABL E WAS REMOVED AND INSPECTED. FOUND THAT THE OUTSIDE SLEEVE ASSEMBLY COULD BE REMOVED EVEN WITH THE LOCK BOLT TIGHT AND THAT THE INNER CABLE WAS BEING PULLED OUT WHEN THE THROTTLE WAS QUICKLY RETARDED TO IDLE. 2 L 7 2 4F 4 F RT A22CE E25EA 2004111500105 20041115 00105 NM 2004 11 15 CA041007007 1 20041006 G 5751 NAS427K23 GUARD DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE AILERON MISSING W A UNSCHED LANDING F FLT CONT AFFECTED CL CLIMB 1 CA (CAN) THE AIRCRAFT DEPARTED AIRPORT AND REPORTED AILERON CONTROLS STIFF. THE AIRCRAFT RETURNED TO WITHOUT FURTHER INCIDE NT. UPON INVESTIGATION IT WAS FOUND THAT AN AILERON CABLE IN THE LT WING WAS DISLODGED FROM THE PULLEY. FURTHER INVESTIG ATION SHOWED THE CABLE GUARD WAS MISSING. THE CABLE WAS INSPECTED AND REPOSITIONED ON THE PULLEY. WHEN CABLE TENSION WAS VERIFIED IT WAS FOUND BELOW LIMITS. THE ENTIRE AILERON CABLE SYSTEM WAS INSPECTED, RIGGED AND TENSIONED. NO OTHER FAULT S WERE FOUND AND THE AIRCRAFT WAS RETURNED TO SERVICE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005020100167 20050201 00167 SW 2005 2 1 CA041007008 1 20041007 G 6710 212076101001 CONTROL TUBE BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA MAIN ROTOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WE ARE PRESENTLY DOING A 3000 HOUR AIRFRAME INSPECTION. THIS VERTICAL UPPER SERVO CONTROL TUBE WAS SENT TO A NDT SHOP FOR INSPECTION. THE NDT SHOP STATED THAT THEIR WAS A LONGDITUDANAL CRACK ON THE UPPER END OF CONTROL TUBE. SINCE T HE LAST INSPECTION THE TUBE HAS 2617 HOURS ON IT. THE AIRFRAME TIME IS 28,644 HOURS. 1 G 7 1 4U 4 U H4SW E22EA 2005012100168 20050121 00168 SW 2005 1 21 CA041007009 1 20040929 G 5302 222035115103 SKIN BELL BELL 222 222U 1182140 SW LYC LTS101 LTS101750C1 41560 NE TAILBOOM CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) CARRYING OUT A DAILY CHECK IT WAS OBSERVED THAT A VERTICAL LATERAL CRACK HAD DEVELOPED ON THE LOWER SKIN OF TAILBO OM JUST 5 INCHES AFT OF THE HORIZONTAL STABILIZER. THE SKIN IS 2024 T3 .032 IN. 1 G 7 2 3U 3 U H9SW E5NE 2004111500106 20041115 00106 WP 2004 11 15 CA041008001 1 20041005 G 2510 C3485 ANCHOR ROBSIN R44 R44 7640120 WP LYC O540 O540F1B5 41532 EA SEAT BELT BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING A ROUTINE INSPECTION THE PILOTS IB SEAT BELT ATTACHMENT POINT HAD BEEN FOUND CRACKED. THE ANCHOR HAD BEEN P ULLED SLIGHTLY AND THE ANCHOR BROKE COMPLETELY OFF. DURING INSPECTION SCHEDULES, THE CONCERNED AREA IS BEING CLOSELY MON ITORED. 1 G 7 1 3O 3 O H11NM E295 2004111500107 20041115 00107 SW 2004 11 15 CA041008002 1 20041006 G 7334 8944416 REGULATOR SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP HARTZL HCE4N HCE4N3 NE FUEL SYSTEM LEAKING W O OTHER K J FLUID LOSS WARNING INDICATION LD LANDING 1 CA (CAN) UPON LANDING THE FLIGHT CREW NOTICED FUEL RUNNING OUT OF THE ENGINE COWLING AND DRIPPING FROM THE LT WHEEL WELL. MAINTENANCE WAS INFORMED AND DISCOVERED THAT THE START FUEL PRESSURE REGULATOR WAS LEAKING FUEL OUT OF THE ELECTRICAL CO NNECTOR PORTION OF THE VALVE. MAINTENANCE REPLACED THE REGULATOR VALVE AND GROUND RUN AND LEAK CHECKS WERE COMPLETED. THE NATURE OF THIS PROBLEM IS THE SAME AS A THE PROBLEM IDENTIFIED IN SB TPE331-73-026, UNFORTUNATLY THIS VALVE DOES NOT FALL WITHIN THE PN OR SN APPLICABILITY RANGE OF THIS SERVICE BULLETIN. 2 L 7 2 4T 4 T RT A8SW E4WE 5 C P10NE 2004111500108 20041115 00108 NE 2004 11 15 CA041008003 2 20041005 G 7200 ENGINE CESSNA 500 560CESSNA 2076750 CE PWA 545 PW545A NE FAILED W E A ENGINE SHUTDOWN UNSCHED LANDING B J SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CR CRUISE 1 CA (CAN) DURING CRUISE AT FL 410 THE N1 BEGAN FALLING BELOW 92 PERCENT. CREW SECURED ENGINE WITH N1 AT 20 PERCENT AND 6000 FT AGL. PILOT DIVERTED AND LANDED WITHOUT INCIDENT. UPON LANDING PILOT NOTED SMOKE COMING FROM THE INLET AND EXHAUST OF THE ENGINE. THE ENGINE WILL BE INVESTIGATED BY MFG TO ESTABLISH ROOT CAUSE OF THE INCIDENT. THIS SDR WILL BE UPDATE D ONCE CAUSE HAS BEEN ESTABLISHED. 2 L 7 2 4F 4 F RT A22CE E00059EN 2005041800047 20050418 00047 EA 2005 4 18 CA041010001 1 20041007 G 5610 NP1393211 WINDSHIELD CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE COCKPIT CRACKED W A UNSCHED LANDING O OTHER CR CRUISE 1 CA (CAN) IN CRUISE AT FL360 AND 0.74 MACH, THE PILOT'S WINDSHIELD CRACKED. DIVERTED FOR MAINTENANCE. WINDSHIELD REPLACED, AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT A21EA E15NE 2005041800048 20050418 00048 NE 2005 4 18 CA041010002 2 20041006 G 7230 COMPRESSOR CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE RT ENGINE STALLED W C ABORTED TAKEOFF R J PARTIAL RPM/PWR LOSS WARNING INDICATION TO TAKEOFF 1 CA 965296 (CAN) DURING TAKE-OFF, THE RT ENGINE EXPERIENCED COMPRESSOR STALLS. MAINTENANCE BORESCOPED THE RT ENGINE AND FOUND FOD DAMAGE IN THE COMPRESSOR SECTION. ENGINE WAS THEN REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2005041800049 20050418 00049 EA 2005 4 18 CA041010003 1 20041006 G 3230 533415 VALVE CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE DOWNLOCK LEAKING W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA (CAN) CREW REPORTED HYD 2 LOW PRESS, NR 2 EDP FAIL, IB AND OB SPOILERS FAIL, NR 2 HYD QUANTITY READING ZERO. AIRCRAFT DIVERTED, DUE TO WEATHER. MAINTENANCE FOUND THE MLG DOWNLOCK ASSIST VALVE LEAKING. MAINTENANCE REPLACED THE DOWNLOCK A SSIST VALVE, THE SYSTEM WAS TESTED AND THE AIRCRAFT WAS DECLARED SERVICEABLE. NOTE: THE BYPASS VALVE (P/N 53342-3) WAS ALSO REPLACED AS A PRECAUTION DUE A MINOR LEAK. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2005041800050 20050418 00050 NM 2005 4 18 CA041012001 1 20041011 G 2422 DH103024600C INVERTER DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE PRIMARY FAILED W G A O2 MASK DEPLOYED UNSCHED LANDING B H J SMOKE/FUMES/ODORS/SPARKS ELECT. POWER LOSS-50 PC WARNING INDICATION CL CLIMB 1 CA APPROXIMATELY 150 NM FROM BASE, CRUISING AT FL 230, WHEN CO-PILOT NOTICED A SUDDEN PUFF OF SMOKE FROM BEHIND CAPTAIN'S S EAT. A LOUD BANG & PRIMARY & AUXILIARY INVERTER LIGHTS ILLUMINATED. ADDITIONAL WARNING LIGHTS ASSOCIATED WITH THESE FA ILURES ALSO ILLUMINATED. OXYGEN DRILL CARRIED OUT FOLLOWED BY FUSELAGE FIRE OR SMOKE DRILL. IDENTIFIED PROBLEM AS PRIM ARY INVERTER & AFTER COMPLETING THAT DRILL FROM QRH, AUX INVERTER RE-INSTATED. UNSCHEDULED LANDING CARRIED OUT. MX PER SONNEL INSPECTION A/C & PERFORMED TROUBLESHOOTING ON INVERTER SYS. FROM THIS, PRIMARY INVERTER CONFIRMED AT FAULT. PRI MARY INVERTER THEN REPLACED. AIRCRAFT HAS RETURNED TO SERVICE WITHOUT FUTHER INCIDENT. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005041800051 20050418 00051 NM 2005 4 18 CA041012002 1 20041009 G 2910 65448917 HYDRAULIC SYSTEM BOEING 737 737201 1384454 NM PWA JT8 JT8D9A 52048 NE A-SYSTEM INOPERATIVE W O OTHER K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA (CAN) LOSS OF SYSTEM A-HYDS AT FL270, INDICATED BY SYSTEM A-FLT CONTROL LOW PRESSURE & FEEL DIFF PRESSURE LIGHT AND A-QT Y AT .5 GALLONS. ACRFT RETURNED TO AIRPORT. FLT CONTROL MODULE A-SYS REPLACED. ALSO BOTH A & B CASE DRAIN FILTERS & BO TH A-SYS HYD EDPS REPLACED. TIMES- 58129.50 CYCLES- 54334. 2 L 7 2 4F 4 F A16WE E2EA 2005041800052 20050418 00052 CE 2005 4 18 CA041012004 1 20040930 G 5610 0413419201 WINDSHIELD CESSNA 150 150L 2071826 CE CONT O200 O200A 17020 SO MCAULY 1A102 1A102OCM GL COCKPIT FAILED W A UNSCHED LANDING D INFLIGHT SEPARATION CR CRUISE 1 CA DURING A ROUTINE TRAINING FLT FOR A-CLASS IV INSTRUCTOR RATING, WINDSHIELD CRACKED AND BLEW IN. PRIOR TO WINDSHIELD BRE AKING, INSTRUCTOR CANDIDATE HAD BEEN PERFORMING SPIRAL DIVE LESSON DEMONSTRATION WHEN THE WINDSHIELD BROKE, AND HAD JUST COMPLETED A RECOVERY. DURING FLIGHT, AIR SMOOTH & MAXIMUM SPEED ESTIMATED AT 140 MPH (WELL BELOW THE VNE OF 162 MPH) A ND AT NO TIME WERE ANY EXCESS G FORCES EXERTED ON THE AIRFRAME. PRIOR TO THE BREAKAGE, THERE WAS NO EVIDENCE OF A CRACK OR DAMAGE TO THE WINDSHIELD. AIRCRAFT WAS INSPECTED FOR OVERSTRESS OF THE AIRFRAME WITH NO FAULT FOUND. PIECES RECOVE RED OF THE WINDSHIELD SHOWED NO SIGN OF HEAVY CRAZING OR STRESS. WINDSHIELD REPLACED AND AIRCRAFT RETURNED TO SERVICE. 1 H 7 1 3O 3 O 3A19 E252 5 N P918 2004122300026 20041223 00026 NM 2004 12 23 CA041012005 1 20040907 G 2761 A44700009 ACTUATOR DHAV DHC8 DHC8101 2809002 NM PWA PW121 PW121 52124 NE HAMSTD 14SF 14SF7 NE RT WING SPOILER CRACKED W D RETURN TO BLOCK K F FLUID LOSS FLT CONT AFFECTED TX TAXI/GRND HDL 1 CA 35120 PILOT REPORTED THAT WHILE CARRYING OUT PRE FLIGHT FULL AND FREE MOVEMENT OF FLT CONTROL SURFACES THAT RT OUTBOARD ROLL S POILER ACTUATOR POSITION INDICATOR WAS NOT INDICATING MOVEMENT WHEN THE FLIGHT CONTROLS WERE MOVED. A/C RETURNED TO THE BAY FOR FURTHER INVESTIGATION. PILOTS REPORTED THAT HYD FLUID WAS RUNNING THE RT SIDE OF THE #2 ENGINE NACELLE AND CONT ACTED ENGINEERING'. ENGINEERING CONDUCTED AN INVESTIGATION OF THE DEFECT AND DISCOVERED THAT THE RT OUTBOARD ROLL SPOILE R ACTUATOR WAS LEAKING EXCESSIVE AMOUNTS OF FLUID DUE TO A FAILURE OF THE HOUSING. ROLL SPOILER ACTUATOR WAS REMOVED AND THE ACTUATOR END CAP ITEM 560 OF CMM 27-60-02 WAS FOUND TO HAVE SEPARATED THE HOUSING DUE TO A FAILURE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005012100180 20050121 00180 CE 2005 1 21 CA041012006 1 20041004 G 3340 CM358910 SWITCH CESSNA 182 182S 2072701 CE LYC O540 IO540AB1A5 EA MCAULY 3D36C B3D36C431 GL MLG LIGHT OVERHEATED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) SWITCH WAS HOT TO THE TOUCH DURING GROUND FUNCTIONAL TEST. SWITCH DID NOT TRIP. SWITCH WENT OPEN CIRCUIT AFTER C OUPLE MINUTES. 1 H 7 1 3O 3 O NT 3A13 1E4 5 C 2005012100181 20050121 00181 NM 2005 1 21 CA041012007 1 20041008 G 2134 7G959 PRESSURE SWITCH DHAV DHC8 DHC8201 2809001 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE CABIN AIR OUT OF TOLERANCE W O OTHER O OTHER DE DESCENT 1 CA 16890 (CAN) CABIN ALTITUDE CLIMBED DURING DESCENT WITH LOW ENGINE POWER SELECTED. CABIN ALTITUDE WARNING (CABIN PRESS) LIGHT I LLUMINATED AND CREW USED FIXED OXYGEN SYSTEM UNTIL CABIN ALTITUDE WAS RESTORED. OPERATIONAL CHECK OF ENGINE HP VALVES CA RRIED OUT IAW AMM 21-00-00 UNABLE TO FAULT. BOTH LT AND RT ENGINE 55 PSI BLEED AIR PRESSURE SWITCHES REPLACED AND SYST EM TEST CARRIED OUT. AIRCRAFT SERVICEABLE, NO FURTHER DEFECTS EVIDENT. PRESSURE SWITCHES OUT OF TOLERANCE SUSPECTED TO BE CAUSING DEFECT. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005031400086 20050314 00086 EA 2005 3 14 CA041013001 1 20041010 G 2760 270007 PCU CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE SPOILER FAILED W O OTHER F FLT CONT AFFECTED CR CRUISE 1 CA (CAN) RT FLT SPOILER DEPLOYED MOMENTARILY DURING FLIGHT CAUSING ROLL. FLT SPOILER FAULT MSG APPEARED. REMOVED AND REPLA CED RT IB FLT SPOILER PCU. 2 L 7 2 4F 4 F RT A21EA E15NE 2005041800053 20050418 00053 SW 2005 4 18 CA041013002 1 20041013 G 3220 315434 LEAF SPRING BBAVIA 8 8GCBC 1220803 SW LYC O360 O360C2E 41514 EA TAIL WHEEL BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) MAIN LEAF SPRING BROKEN AT TOW BRIDLE CAGING BOLT. APPROX. 4 INCHES AFT OF SPRING ASSYU BAR. THESE ARE RECENTLY PU RCHASED, NEW BATCH TYPE, LEAF SPRINGS. 1 H 7 1 3O 3 O A21CE E286 2005041800054 20050418 00054 SW 2005 4 18 CA041013003 1 20041013 G 3220 31543456 LEAF SPRING BBAVIA 8 8GCBC 1220803 SW LYC O360 O360C2E 41514 EA TAIL WHEEL BROKEN W E ENGINE SHUTDOWN P NO WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) 4, MAIN LEAF SPRING, BROKEN APPROX 4 INCHES AFT OF U BAR. -5 AND -6 SPRINGS BROKEN AT AFT EDGE OF U BAR AND -6, TO P SPRING, PUSHING UP AGAINST BOTTOM OF RUDDER HORN. THESE ARE RECENTLY PURCHASED NEW BATCH TYPE LEAF SPRINGS. 1 H 7 1 3O 3 O A21CE E286 2005031400087 20050314 00087 SW 2005 3 14 CA041013004 1 20041013 G 3220 315434 LEAF SPRING BBAVIA 8 8GCBC 1220803 SW LYC O360 O360C2E 41514 EA MCAULY 1A200 1A200* GL TAIL WHEEL BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) MAIN LEAF SPRING BROKEN AT TOW BRIDLE CAGING BOLT. APPROX 4 INCHES AFT OF SPRING ASSY U BAR. THESE ARE RECENTLY PU RCHASED NEW BATCH TYPE SPRINGS. 1 H 7 1 3O 3 O A21CE E286 5 N P874 2005031400088 20050314 00088 CE 2005 3 14 CA041013005 1 20040924 G 3246 49330 PLUG CESSNA 500 560CESSNA 2076750 CE PWA 530 PW535A NE WHEEL LEAKING W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) MAIN WHEEL ASSEMBLY LEAKING 1-2 PSI PER DAY. REPLACED 2 THERMAL RELIEF PLUGS AND LEAK CHECKED. OK. 2 L 7 2 4F 4 F RT A22CE E00053EN 2005020100156 20050201 00156 WP 2005 2 1 CA041013006 1 20040928 G 6210 369D21100517A BLADE HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL MAIN ROTOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) HELICOPTER WAS FLYING WITH EXTERNAL LOAD WHEN THE PILOT FELT A (BUMP) IN THE CONTROLS. THE WEATHER WAS DETERIOATIN G WHERE HE WAS OPERATING SO HE RETURNED TO THE STAGING AREA. THE PILOT INSPECTED THE BLADES AFTER SHUTDOWN AND FOUND A 4 .5 INCH CRACK 19 INCHES OUTBOARD FROM THE ROOT END, ONE BLADE ON THE BOTTOM STARTING FROM THE TRAILING EDGE. THE BLADE W AS REMOVED AND REPLACED WITH A SERVICEABLE UNIT AND THE AIRCRAFT RETURNED TO SERVICE. THE SAFETY BOARD WAS NOTIFIED AND THE UNSERVICEABLE BLADE WAS SENT TO THEM FOR INSPECTION. 1 G 7 1 3U 3 U H3WE E4CE 2005020100157 20050201 00157 SO 2005 2 1 CA041013007 1 20040916 G 2910 FITTING CONT PIPER PA28 PA28RT201T 7102817 SO CONT O360 TSIO360FB 17025 SO HARTZL HCC3Y PHCC3YF1 GL FUEL PUMP CRACKED W E ENGINE SHUTDOWN K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA H069709BR (CAN) BRASS OUTLET ANGLE FITTING ON FUEL PUMP CRACKED CAUSING FUEL TO LEAK OUT IN FLIGHT. 1 L 7 1 3O 3 O 2A13 E9CE 5 C P25EA 2005031400081 20050314 00081 EA 2005 3 14 CA041013008 1 20041005 G 2913 6305402 PUMP DHAV DHC7 DHC7102 2802708 EA PWA PT6 PT6A50 52043 EA HAMSTD 24PF 24PF305 GL HYDRAULIC SYS FAILED W A UNSCHED LANDING K FLUID LOSS CR CRUISE 1 CA (CAN) WHILE THE AIRCRAFT WAS IN CRUISE AT 15,000 FEET, NR 4 HYDRAULIC PUMP CAUTION LIGHT ILLUMINATED, FOLLOWED 5 MINUTES LATER BY NR 3 HYDRAULIC PUMP CAUTION LIGHT COMING ON. ALL HYDRAULIC PRESSURE WAS LOST ON NR 2 HYDRAULIC SYSTEM AND AL TERNATE LANDING GEAR EXTENSION WAS CARRIED OUT AND THE AIRCRAFT LANDED WITHOUT INCIDENT. HYDRAULIC PUMP P/N 63054-02/05 NR 4 HYDRAULIC PUMP P/N 225961- NR 4 PUMP PRESSURE DROP TO ZERO. NR3 HYDRAULIC PUMP P/N 167136- NR 3 PUMP SHAFT BR OKEN PRESSURE DROP TO ZERO. 2 H 7 4 4T 4 T A20EA E4EA 6 C P1NE 2005031400082 20050314 00082 2005 3 14 CA041013009 4 20041007 G 2300 M880511104 SWITCH SCHLER HUGHES 269 269C1 8059504 SW LYC O360 HO360C1A 41514 EA GRIP MALFUNCTIONED W C ABORTED TAKEOFF H ELECT. POWER LOSS-50 PC NR NOT REPORTED 1 CA (CAN)TRIGGER SWITCH MALFUNCTION, NO TRANSMISSION. REPLACED SWITCH P/N M8805/111-04. 1 G 7 1 3O 3 O O 4H12 E286 2005031400083 20050314 00083 NM 2005 3 14 CA041013010 1 20041013 G 5755 65449617 ACTUATOR BOEING 737 737275 1384485 NM PWA JT8 JT8D9A 52048 NE SPOILERS CRACKED W O OTHER J WARNING INDICATION CR CRUISE 1 CA (CAN) A SYSTEM HYDRAULIC LIGHTS ILLUMINATED, A SYSTEM QTY READ ZERO. NR 8 SPOILER ACTUATOR FOUND CRACKED. ACTUATOR RE PLACED MM 27-62-91. CARRIED OUT RII INSPECTION. 2 L 7 2 4F 4 F A16WE E2EA 2005041800055 20050418 00055 SW 2005 4 18 CA041013011 1 20041013 G 3211 ES12404 ARM GULSTM 690TP 690A 0141722 SW GARRTT TPE331 TPE3315251K NM HARTZL HCB3T HCB3TN5 GL MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA DURING ACCOMPLISHEMENT OF TWIN COMMANDER SL376 INSPECTION OF MLG CLEVIS AND DRAGBRACE, 2 CRACKS WERE NOTED DURING COMPLE TION OF EDDY CURRENT INSPECTION OF THE LEFT HAND MLG. THE CRACKS ARE LOCATED AT THE MOUNTING HOLE FOR THE EYE BOLT P/N 330085-43. ATTACHED 3 PHOTOS FOR REVIEW. THE AIRCRAFT HAS ACCUMULATED 165.5 HRS AND 146 CYCLES SINCE THE LAST COMPLIAN CE WITH THE SERVICE LETTER. 1 H 7 2 3T 4 T 2A4 E2WE 6 C P15EA 2005041800056 20050418 00056 EU 2005 4 18 CA041014001 1 20041013 G 6520 7052A3632279 MAGNETIC PLUG UROCOP UROCOP EC120 EC120B 8680987 EU TMECA ARRIUS ARRIU2F NE T/R GEARBOX CRACKED W K NONE N W FALSE WARNING INADEQUATE Q C IN INSP/MAINT 1 CA M195 PILOT REPORTED INTERMITTENT INDICATION OF GEARBOX CHIP DETECTOR. ON INSPECTION NO CHIP FOUND. A LOOSE CONNECTION BETWEE N ELECTRICAL PORTION OF CHIP PLUG & MAGNETIC PART ALLOWED FOR A FALSE INDICATION. THE SWAGGED CONNECTION BETWEEN THE TW O PARTS CRACKED & BROKEN. IN 2002 A SIMILAR PROBLEM HAD OCCURRED, BUT THIS PARTICULAR PLUG MANUFACTURED IN 2003. NEW P LUG ORDERED & UPON RECEIVING NEW PART IT TOO WAS CRACKED. EUROCOPTER CANADA CONTACTED AND A THIRD PLUG SENT. AGAIN UPON INSPECTION IT TOO WAS CRACKED IN SAME SWAGED LOCATION. A CONTINUED LACK OF Q/A BETWEEN MANUFACTURER & EUROCOPTER HAS AL LOWED THIS KNOWN PROBLEM TO PERSIST FOR OVER TWO YEARS. CURRENTLY WE ARE WAITING FOR YET ANOTHER CHIPPLUG. 1 G 7 2 3U 3 U NC R0001RD E34NE 2005031400084 20050314 00084 2005 3 14 CA041014002 4 20040926 G 2311 W31M30 MASTER SWITCH CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160DTM GL ON RADIO PANEL FAILED W A UNSCHED LANDING H ELECT. POWER LOSS-50 PC CR CRUISE 1 CA (CAN) RADIO MASTER SWITCH CONTROLLING POWER TO ALL RADIOS E.G. DUAL NAV COM, VDR, TRANSPONDER, BECAME INTERMITTENT THEN FINALLY FAILED SHUTTING POWER OFF TO ALL THE RADIOS. MINIMAL PLAY IN TOGGLE SWITCH EVIDENT. REPLACED SWITCH AND NO MOR E FAULT. TIME ON ORIGINAL PART UNKNOWN BUT AIRCRAFT BASED IN FLYING SCHOOL, THEREFORE MANY CYCLES SUSPECTED PERHAPS INTO THE THOUSANDS. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2005041800057 20050418 00057 NM 2005 4 18 CA041014003 1 20041008 G 6120 699018002 CONTROL UNIT BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R4304 R4304* EU PROPELLER MALFUNCTIONED W E A ENGINE SHUTDOWN UNSCHED LANDING E VIBRATION/BUFFET CL CLIMB 1 CA (CAN) DURING CLIMB, AN AIRCRAFT EXPERIENCED AN UNCOMMANDED AUTOFEATHER CAUSED BY NR 1 ENGINE TORQUE FLUCTUATIONS. WITH T HE NR 1 PROP FEATHERED AND ENGINE STILL RUNNING AT REDUCED POWER, THE PILOT RETURNED TO BASE. PEC REPLACED. ENGINE RUNS CARRIED OUT. A/C RETURNED TO SERVICE. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P890 2005041800058 20050418 00058 SO 2005 4 18 CA041014005 2 20041011 G 8530 CONNECTING ROD CESSNA 206 U206F 2073333 CE CONT O520 IO520F 17032 SO NR 2 CYLINDER BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) NR 2 CYLINDER REMOVED DUE TO LOW COMPRESSION. NOTED WRIST PIN BEARING BROKEN AND CONNECTING ROD TIGHTER THAN NORMA L ON CRANKSHAFT. AFTER FURTHER INVESTIGATING, FOUND NR 2 MAIN BEARING LOOSE IN BEARING SADDLE AND WAS ABLE TO MOVE FORE AND AFT INTHE CRANKCASE. ENGINE REMOVED AND SENT TO OVERHAUL FACILITY. 1 H 7 1 3O 3 O A4CE E5CE 2005041800059 20050418 00059 CE 2005 4 18 CA041014006 1 20041007 G 2810 121640719 RESERVOIR CESSNA 206 U206E 2073350 CE CONT O520 IO520F 17032 SO FUEL CELL CRACKED W K NONE K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA (CAN) COULD SMELL STRONG FUEL ODOR IN COCKPIT AND ALSO NOTED FUEL STAIN ON BELLY OF AIRCRAFT DURING INSPECTION. SUSPECT ED RESEVOIR QUICK DRAIN LEAKY BUT FURTHER INVESTIGATION REVEALED A 1 INCH CRACK ON FORWARD LOWER WELD SEAM ON RESEVOIR. RESEVOIR REMOVED, REPAIRED AND REINSTALLED. 1 H 7 1 3O 3 O A4CE E5CE 2005041800060 20050418 00060 CE 2005 4 18 CA041014007 1 20041007 G 2810 121640720 RESERVOIR CESSNA 206 U206E 2073350 CE CONT O520 IO520F 17032 SO FUEL CELL DAMAGED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) UPON 1000 HR FUEL SYSTEM INSPECTION AS REQUIRED BY CESSNA, THE FUEL WAS COMPLETELY DRAINED FROM THE AIRCRAFT.UPON REMOVING THE LOWER R/H RESEVOIR QUICK DRAIN,IT WAS REVEALED IT WAS QUITE LOOSE BUT NOT LEAKING. UPON REINSTALLATION OF QUI CK DRAIN VALVE IT COULD NOT BE TORQUED AS THE THREADS WERE COMPLETELY STRIPPED. SUSPECTED QUICK DRAIN WAS OVERTORQUE D ON PREVIOUS REMOVAL/INSTALLATION. RESEVOIR WAS REMOVED, REPAIRED AND REINSTALLED. 1 H 7 1 3O 3 O A4CE E5CE 2005041800061 20050418 00061 CE 2005 4 18 CA041014008 1 20040921 G 3246 D30256 HUB CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160DTM GL PROPELLER CRACKED W K NONE P NO WARNING INDICATION IN INSP/MAINT 1 CA (CAN) DISSASSEMBLY FOR CLEANING / CORROSION / REPAINT FOUND 3 CRACKS IN HUB WEB BY FLANGE BOLT THREADS IN CASTING. INSPE CTION OF OTHER HUB FOUND SIMILAR DAMAGE.INSPECTION WITHOUT PART BEING VERY CLEAN WOULD MAKE IT VERY DIFFICULT TO SEE THE SE CRACKS. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2005041800062 20050418 00062 CE 2005 4 18 CA041015001 1 20041013 G 2430 DOFF10300J ALTERNATOR CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA ENGINE FAILED W O OTHER H ELECT. POWER LOSS-50 PC CR CRUISE 1 CA (CAN) HIGH VOLTAGE LIGHT CAME ON DURING FLIGHT. ALTERNATOR INSPECTED AND FOUND THE BRUSHES WORN TO LIMIT. BRUSHES REPLAC ED. A/C GROUND RUN AND FOUND HIGH VOLTAGE LIGHT REMAINED ON. FUTHER TROUBLESHOOTING FOUND ALTERNATOR WIRE SHORTED TO SHI ELD WIRE. BATTERY CONTACTOR AND STARTER CONTACTOR HAD FAILED, VOLTAGE REGULATER FAILED, AND STARTER WAS NO FULLY DISENGA GING. ALL WIRING INSPECTED AND FOUND NO OTHER FAULTS. BATTERY FOUND WITH NO FAULTS. CONTACTORS, REGULATER, AND ALT WIRE REPLACED. A/C GRD RUN SERVICEABLE. 1 H 7 1 3O 3 O NT 3A12 E274 2005041800063 20050418 00063 EU 2005 4 18 CA041015002 1 20040928 G 6700 LN9038 BOLT BOLKMS 105 BO105S 5626006 EU BEARING SUPPORT MISSING W K NONE F FLT CONT AFFECTED IN INSP/MAINT 1 CA (CAN) PILOT NOTED THAT IT TOOK A MOMENT FOR THE COLLECTIVE PITCH CHANGES TO BECOME EFFECTIVE. WHEN INVESTIGATING THE ENG INEER FOUND APPROXIMATELY 7/16OF PLAY AT THECOLLECTIVE GRIP. FURTHER INVESTIGATION OF THE COLLECTIVE FLIGHT CONTROL SYST EM, REVEALED THAT THE COLLECTIVE PITCH SHAFT ASSEMBLY P/N 105-41221, WAS LOOSE IN T HE BEARING ASSEMBLY P/N 105-41210-18 . ONE OF THE ATTACHING BOLTS P/N LN9038-05010 HAD FALLEN OUT AND THE THREE REMAINING BOLTS REQUIRED THREE COMPLETE TURNS TO TIGHTEN. THE DRAG TORQUE OF THE NUT PLATES WAS SUFFICIENT. THE MISSING BOLT WAS REPLACED AND THE AIRCRAFT WAS RETURN ED TO SERVICE.QUALITY ASSURANCE DEPARTMENT HAS OPENED AN INVESTIGATION OF THIS OCCURRENCE. 1 G 7 2 3U H3EU 2005041800064 20050418 00064 CE 2005 4 18 CA041015003 1 20041012 G 5410 55120416 CAP CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE DUCT WORN W O OTHER W INADEQUATE Q C NR NOT REPORTED 1 CA (CAN) FRESH AIR DUCT PN 6515317-12 FRETTED ON THE OUTBOARD FLANGE OF THE TEE SECTION CAP. 1 L 7 2 4F 4 F A22CE E1NE 2005041800065 20050418 00065 CE 2005 4 18 CA041015004 1 20041015 G 3230 508100352 TORQUE KNEE BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA RT MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING A 8000 CYCLE TORQUE KNEE NDT INSPECTION IT WAS DETECTED THAT THE RT LOWER TORQUE KNEE ATTACH PIN, PN 50-810 035-2 WAS CRACKED IN NUMBER OF PLACES. THE TORQUE KNEE IS POST S/B 32-3116 - IMPROVED STEEL. PRESENTLY THE PIN IS PLACED IN QUARANTINE. THERE IS A FLEET WIDE INSPECTION IN PROGRESS. 1 L 7 2 3T 4 T RT 3A20 E4EA 2005041800066 20050418 00066 EA 2005 4 18 CA041015005 2 20040927 G 7414 1068291218 MAGNETO PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA RT ENGINE CRACKED W A UNSCHED LANDING E VIBRATION/BUFFET CL CLIMB 1 CA L56568A (CAN) RT ENGINE DEVELOPED 'MISSING OR SURGING' IN POWER AT HIGH POWER SETTINGS. RAN FINE AT LOW POWER. AIRCRAFT RETURNED FOR MAINTENANCE. AMO REMOVED MAGNETO AND FOUND DISTRIBUTOR BLOCK CRACKED AND BEARINGROUGH. MAGNETO REPLACED AND GROUND RUN, SERVICEABLE. MAGNETO PN 10-682912-18, SN H259310. 1 L 7 2 3O 3 O A20SO E14EA 2005041800067 20050418 00067 2005 4 18 CA041015006 4 20040923 G 3400 BULB COLLINS BAG JETSTM JETSTM3212 1500217 EU GARRTT TPE331 TPE33110UG 01514 WP ROTOL R333 R333482F12 GL CONTROL HEAD SHORTED W O OTHER B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 CA 14659 (CAN) UPON COMPLETION OF ENG START & TURNING ON AVIONICS IN PREPARATION FOR DEPARTURE ON A CHARTER TRIP, CREW OBSERVED S MOKE COMING FROM THE RT AVIONICS. CREW SHUTDOWN ENGINES & MASTER SWITCH & DEPLANED ALONG WITH PAX. MX RESPONDED & AFTER LOCATING SOURCE OF SMOKE & ATTENDED FUMES, REPLACED NAV CONTROL HEAD SET WITH A SERVICEABLE SET & CHARTERED DISPATCHED. NAV CONTROL HEAD - FACE PLATE LIGHT BULB BURNED OUT. REPAIRED & PROVIDED A MAINTENANCE RELEASE (DATED 24 SEPT 04). MAT CHING UNIT (OTHER 1/2 OF SET)WAS INSPECTED & TESTED & PROVIDED A MAINTENANCE RELEASE. 2 L 7 2 4T 4 T RT BA15CAA E4WE 6 C P61GL 2005041800068 20050418 00068 NE 2005 4 18 CA041015007 2 20041014 G 7230 6A7379 BLADE AIRBUS 320 A320231 3930325 EU IAE V2500 V2500A1 NE COMPRESSOR FAILED W C ABORTED TAKEOFF D INFLIGHT SEPARATION TO TAKEOFF 1 CA 33906 V0314 (CAN) ON TAKE OFF WITH THROTTLES BETWEEN IDLE AND FLEX MCT. LOUD BANG FROM LT ENGINE HEARD IN THE COCKPIT. TAKE OFF ABAN DONED AT 115 KTS. ACRFT RETURNED WITH ENGINE RETARDED TO IDLE. NO UNUSUAL PARAMETERS. BORESCOPE INSPECTION REVEALED ONE FAILED HPC STAGE 4 BLADE WITH RESULTANT IMPACTS TO OTHER STAGE 4 BLADES. 2 L 7 2 4F 4 F RT A28NM E311NE 2005041800069 20050418 00069 GL 2005 4 18 CA041015008 3 20041015 G 6114 D4530 HUB MOONEY M20 M20K 5870220 SW CONT O360 IO360CONT 17025 SO MCAULY 2A34C 2A34C* GL PROPELLER CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 810199 (CAN) PROPELLER RECEIVED FOR 10 YR. O/H. UPON INSPECTION IT WAS FOUND THAT THE HUB, BLADE BEARINGS (C3411),PISTON ROD (B 2345), SPLIT RETAINERS (C3903) AND PISTON (C3418) WERE UNSERVICEABLE DUE TO WEAR AND/OR CORROSION. MANUFACTURERS RECCOME NDED TBO AS PER S/B 137Y IS 2000 HRS OR 72 MONTHS. THIS PROPELLER HAS EXCEEDED THE CALENDAR TIME BY 48 MONTHS. 1 L 7 1 3O 3 O 2A3 E1CE 5 C P3EA 2005041800070 20050418 00070 SO 2005 4 18 CA041017001 2 20041002 G 8500 CRANKCASE CESSNA 185 A185F 2072821 CE CONT O520 IO520D 17032 SO MCAULY 2A34C D2A34C58 GL ENGINE CRACKED W B A EMER. DESCENT UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 CA 175076R (CAN) THE CESSNA 185 WAS RETURNING TO HOME BASE FROM THE HUNTING CAMP, WHEN IN CRUISE,WITH ALL ENGINE PARAMETERS INDICAT ING NORMAL,THE ENGINE STOPPED IN FLIGHT AND T HE SEASONED PILOT WAS ABLE TO LAND WITHOUT INCIDENT. THE ENGINE SUFFERD TW O CRACKS TO THE CRANKCASE HALVES IN THE AREA OF NR 1 AND 2 CYLINDERS. ALL CYLINDERS WERE FOUND INTACT AND UNDAMAGED. ALL CYLINDERS WERE REMOVED AND NEW RINGS INSTALLEDAT 902.0 HRS. SUBJECT ENGINE TO BE SENT TO ANOTHER OVERHAULER FOR ANALYSI S. 1 H 7 1 3O 3 O 3A24 E5CE 5 C P3EA 2005041800071 20050418 00071 EA 2005 4 18 CA041018001 1 20041017 G 5610 601R3303310 WINDSHIELD CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE COCKPIT CRACKED W O OTHER O OTHER AP APPROACH 1 CA (CAN) THE CREW REPORTED ELECTRICAL ARCING FROM THE RT WINDSHIELD DURING APPROACH WHILE THE WINDSHIELD HEAT WAS SELECTED TO LOW . UPON INSPECTION THE WINDSHIELD WAS FOUND CRACKED AND CONSEQUENTLY REPLACED .PLEASE NOTE THE AIRWORTHINESS DIREC TIVE CF-2001-35R1 WAS COMPLIED WITH ON 26 OCTOBER 2002 AND SB601R-56-004 WAS COMPLIED WITH ON APRIL 10 2004 . 2 L 7 2 4F 4 F RT A21EA E15NE 2005041800072 20050418 00072 EA 2005 4 18 CA041018003 1 20041015 G 5311 21531036212 FRAME CNDAIR CL215 CL2151A10 1900320 EA PWA R2800 CA3 52026 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ACRFT IN FOR ITS ANNUAL B-CHECK WHEN A VISUAL INSPECTION OF THE REAR SKI SLOPEAREA REVEALED A CRACK IN THE LT REA R OUTBOARD WING-TO-FUSELAGE FRAME ANGLE AT BL 51.00 FS 434.00.AD CF-1997-07R2 WAS NOT REQUIRED AT THIS TIME BUT THE MX P ERSONAL DECIDED TO DO A QUICK VISUAL INSPECTION ANYWAY. CRACK ORIGINATED AT THE TOP OF BRACKET & CONTINUED PASS THE FIRS T FASTENER AND MAKING ITS WAY TO THE SECOND. THE REPEAT INSPECTION REQUIREMENTS OF THE AD WERE CARRIED OUT ON NOV. 5, 20 02 AT A/F HRS 2163.6 AND WATER DROPS 7516. THE SUBSEQUENT INSPECTION WAS NOT DUE UNTIL A/F HRS 2578.6 OR 9016 WATER DROP S. THE AIRCRAFT NOW HAS AN A/F TIME OF 2331.1 AND WATER DROPS 8147.REPAIRS TO THE AREA WERE CARRIED OUT AS PER THE SRM. 2 H 7 2 4R 4 R RT A14EA E231 2005041800073 20050418 00073 SO 2005 4 18 CA041018004 2 20040930 G 8530 ACE631397 CYLINDER CESSNA 206 U206G 2073356 CE CONT O550 IO550F 17042 SO NR 4 CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 284784R (CAN) DURING A 50 HOUR INSPECTION, NR 4 CYLINDER WAS FOUND TO HAVE ZERO COMPRESSION.CLOSER EXAMINATION FOUND CRACKS EXTE NDING FROM BOTH SPARK PLUG HOSE INTO THE EXHAUST PORT AND CYLINDER HEAD.A FOLLOW-UP ISPECTION INCLUDING COMPRESSON TEST AND SOAP LEAK TEST WILL BE CONDUCTED TO INSURE CONTINUED AIRWORTHINESS. 1 H 7 1 3O 3 O A4CE E3SO 2005041800074 20050418 00074 SO 2005 4 18 CA041018005 2 20041004 G 8530 ACE631397 CYLINDER CESSNA 206 U206G 2073356 CE CONT O550 IO550F 17042 SO NR 5 LEAKING W K NONE O OTHER IN INSP/MAINT 1 CA 284784R (CAN) DURING THE FOLLOW-UP INSPECTION, COMPRESSION WAS FOUND WITHIN LIMITS BUT A SOAP LEAK TEST FOUND NR 5 CYLINDER LEAK ING.THE CYLINDER ASSY WAS REMOVED WITH NO DEFECTS VISIBLE. THE LEAK SEAMS TO BE FROMBETWEEN THE CYLINDER BARREL AND HEAD WHERE THEY SCREW TOGETHER. THERE IS ANOTHER FOLLOW-UP INSPECTION BOOKED. 6 NEW CYLINDERS TO BE INSTALLED IF ANY PROBLEM S FOUND. 1 H 7 1 3O 3 O A4CE E3SO 2005041800075 20050418 00075 NE 2005 4 18 CA041018007 3 20040909 G 6110 582855 HOUSING LKHEED 382 382G 526414U SO ALLSN 501D 501D22A 03006 GL HAMSTD 54H 54H60117 NE PROP VALVE DAMAGED W E ENGINE SHUTDOWN F FLT CONT AFFECTED DE DESCENT 1 CA (CAN) INBOUND, NR 4 PROP RPM DROPPED BELOW LIMIT ACOMPANIED BY RPM FLUCTUATION AND TORQUE ROLL.THE ENGINE WAS SHUTDOWN A S A PRECAUTION. THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE REPLACED THE NR 4 VALVE HOUSING AND AIRCRAFT WAS RETUR NED TO SERVICE. 2 H 7 4 4T 4 T A1SO E282 6 C P906 2005041800076 20050418 00076 NM 2005 4 18 CA041018008 1 20041004 G 2910 LINE BOEING 727 727233 138408A NM PWA JT8 JT8D15 52051 NE HYD SYSTEM LEAKING W D RETURN TO BLOCK K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA (CAN) AFTER START-UP AT PUSH BACK THE PURSER NOTIFIED THE FLT DECK CREW OF FUMES IN THE CABIN. THE PASSENGERS WERE DEPLA NED AND THE AIRCRAFT WAS RETURNED MAINTENAN CE TO IDENTIFY AND DETERMINE THE SOURCE OF THE PROBLEM. MAINTENANCE FOUND A PIN HOLE IN THE TAIL SKID ACTUATOR SUPPLY LINE. THE LINE WAS REPAIRED AND THE AIRCRAFT GROUND CHECKED WITH ENGINES, PACK S AND GASPER OPERATING WITH NO INDICATION PRIOR TO RETURN TO SERVICE 2 L 7 3 4F 4 F RT A3WE E2EA 2005041800077 20050418 00077 EA 2005 4 18 CA041018009 2 20041007 G 7261 PLANETARY GEAR PWA PT6 PT6A28 EA ENGINE FAILED W K NONE O OTHER IN INSP/MAINT 1 CA 40111100 (CAN) ENG REMOVED DUE TO METAL IN OIL. ENG SENT IN FOR INVEST & REPAIR. CUSTOMER DECIDED TO SEND ALL PARTS OF ENG TO OUR AMO FOR REVIEW. SOURCE OF METAL FROM A 2ND STAGE PLANETARY GEAR BEARING SLEEVE FAILURE. BRONZE PARTICLES GENERATED FRO M SLEEVE BEARING BRONZE FACE DURING SEIZURE. SLEEVE SEIZED ONTO THE SHAFT - GEAR OVERCAME RESISTANCE OF GEAR/SLEEVE TIGH T FIT & GEAR STARTED TO TURN AROUND SLEEVE ON SLEEVE OUTSIDE SURFACE. ROTATION GENERATED METAL PARTICLES FROM GEAR BORE AND SLEEVE. ALL OF THE OIL STRAINERS IN BOTH 1ST & 2ND STAGE CARRIERS FOUND TO BE PARTIALLY BLOCKED. SEIZURE RELATED TO OIL STARVATION CAUSED BY THE BLOCKED STRAINERS. 4 T E4EA 2005041800079 20050418 00079 EU 2005 4 18 CA041019001 1 20041010 G 6320 RA13212 BOLT BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL M/R GEARBOX LOOSE W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) THE AIRCRAFT WAS OPERATING AWAY FROM BASE WITHOUT A MAINTENANCE CREW ABOARD. THE FOLLOWING OCCURRENCE WAS REPORTED UPON RETURN TO BASE.AFTER THE LAST FLIGHT OF THE DAY THE PILOT NOTICED A TRANSMISSION OIL LEAK ON THE RIGHT SIDE DRAIN AT THE CROSS TUBE. INVESTIGATION DETERMINED THAT THE BANJO FITTING BOLT ON THE TRANSMISSION OIL PUMP HAD LOST TORQUE EVE N THOUGH IT WAS LOCK WIRED. THE BANJO BOLT WAS TIGHTENED A PART OF A TURN AND LOCK WIRED. THE AIRCRAFT WAS GROUND RUN FO R 20 MINUTES WITH NO LEAKS. THE AIRCRAFT WAS RETURNED TO SERVICE. THE TRANSMISSION HAD BEEN REPLACED TWO MONTHS EARLIER AND HAD ACCUMULATED 50 HOURS OF OPERATION BEFORE THE LEAK APPEARED. 1 G 7 2 3U 3 U H3EU E4CE 2005041800080 20050418 00080 NM 2005 4 18 CA041019002 1 20041012 G 3233 464557 HOSE BFGOODRICH BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA MLG RETRACT RUPTURED W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA (CAN) RT MLG RETRACT ACTUATOR HOSE RUPTURED IN-FLIGHT, AIRCRAFT LANDED WITH NO INCID ENT. LOST ALL HYD FLUID ON NR 2 SYS TEM HOSE REPLACED. RUPTURED RETRACT ACTUATOR FLEX LINE, P/N 46455-7, REPLACED AND GEAR SWINGS CARRIED OUT. A/C RTSRUPT URED HOSE TO BE RETURNED TO BOMBARDIER FOR INVESTIGATION. 2 H 7 2 4T 4 T RT A13NM E00062EN 2005041800081 20050418 00081 CE 2005 4 18 CA041019003 1 20041007 G 7120 265102319 MOUNT CESSNA 208 208B 2073701 CE PWA PT6 PT6A114A 52043 NE MCAULY 3AF34C 3GFR34C703 GL ENGINE CHAFED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AT ENGINE REPLACEMENT, THE CLAMP WAS FOUND TO BE LOOSE AROUND THE ENGINE MOUNT TUBING. THE CLAMP HAD CHAFFED INTO THE TUBE SIGNIFICANTLY. THE MOUNT WAS REMOVED AND SENT FOR REPAIR IAW THE SRM FOR THE C208B. THE CLAMP AND HARDWARE WAS REPLACED AND SECURED. 1 H 7 1 3T 3 T A37CE E4EA 5 C P60GL 2005041800082 20050418 00082 GL 2005 4 18 CA041019004 3 20041019 G 6114 D4190305 HUB CESSNA 337 337G 2075730 CE CONT O360 TSIO360G 17025 SO MCAULY 2AF34C D2AF34C305 GL PROPELLER CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 734518 (CAN) PROP RECEIVED FOR O/H. UPON INSPECTION CORROSION PITS WERE FOUND IN THE PROP MOUNTING FLANGE. THIS DAMAGE WAS TOO DEEP TO BE REMOVED WITHIN MANUFACTURERS SPECIFICATIONS. PROP HAS EXCEEDED THE MANUFCTURERS RECCOMENDED CALENDAR TBO BY 3 1 MONTHS. 1 H 7 2 3O 3 O A6CE E9CE 5 C P5EA 2005041800083 20050418 00083 GL 2005 4 18 CA041019005 3 20041019 G 6114 D7292203 HUB CESSNA 182 182P 2075816 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C203 GL PROPELLER CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 840316 (CAN) PROP RECEIVED FOR 10 YR. CALENDAR O/H. AFTER PAINT REMOVAL FROM HUB CORROSION WAS FOUND ON THE EXTERNAL SURFACES. THIS CORROSION CANNOT BE REMOVED WITHIN THE MANF.'S MINIMUM SPEC'S. THIS PROPELLERHAS EXCEDED THE MANF'S RECOMMENDED CAL ENDAR TBO BY 60 MONTHS. 1 H 7 1 3O 3 O NT TA13 E273 5 C P3EA 2005041800084 20050418 00084 2005 4 18 CA041019006 4 20041018 G 2360 17472 MOUNT PIAGIO P180 P180 6960204 EU PWA PT6 PT6A66 52043 NE STATIC WICK CORRODED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) RUDDER AND AILERON STATIC WICK BASE FOUND LOOSE. PARTS REMOVED CORROSION WAS FOUND ON MATING SURFACE WHICH WAS CLE ANED AND BASES ATTACHED SEALED AND PAINTED. 1 H 7 2 3O 4 T RT A59EU E26NE 2005041800085 20050418 00085 CE 2005 4 18 CA041019007 1 20041008 G 7931 6320622 ROD CESSNA 206 U206G 2073356 CE CONT O550 IO550F 17042 SO OIL GAUGE WRONG PART W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) IMPROPER INSTALLATION OF THE OIL GAUGE ROD TUBE ADAPTER SPIGOT INTO THE CRANKCASE SUCH THAT IT EXTENDS TOO FAR INT O THE CASE ALLOWING THE OIL GAUGE ROD TO PROTRUDE TOO FAR INTO THE OIL SUMP AND CAUSING IT TO MAKE CONTACT WITH THE OIL SUMP. THE CONTACT CAN LEAD TO WEAR, WITH ENGINE VIBRAITON, AND IF PROLONGED COULD EVENTUALLY WEAR COMPLETELY THROUGH THE OIL SUMP RESULTING IN LOSS OF ENGINE OIL WHICH COULD LEAD TO OIL STARVATION AND ENGINE FAILURE.RECOMMENDATION: THE OIL GAUGE ROD, P/N 632062-2, COULD BE DESIGNED SO THAT IT ISONE INCH SHORTER IN OVERALL LENGTH. NOTE: SEVERAL OTHER ENGINE M ODELS COULD BE AFFECTED BY THIS IMPROPER INSTALLATION. 1 H 7 1 3O 3 O A4CE E3SO 2005041800086 20050418 00086 NE 2005 4 18 CA041019009 3 20041004 G 6111 31025751 SHAFT SEAL SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE3311151A 01514 WP MCAULY 4HFR34 4HFR34C652 NE PROP BLADE SEIZED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) PROP SHAFT SEAL WAS FOUND LEAKING.DURING DISASSEMBLY THE SHAFT SEAL WAS FOUND WITH ABNORMAL WEAR AND DETERIATION I N THE SLOTS OF THE CARBON PORTION OF THE SEAL.THE SLOTS WERE WORN HEAVILY AND THE METAL TABS APPEARED TO BE JAMBED INTO THE SIDES OF THE SLOTS. THESE WOULD NORMALLY BE CENTERED WITHIN THE SLOTS. THIS CAUSED THE SEAL TO SEIZE WHICH RESTRIC TED THE FREEDOM OF THE SEAL TO TRAVEL AGAINST THE ROTOR SEAL WHICH CAUSED A MAJOR OIL LEAK. NORMALLY THESE SEALS WILL RU N 7000 HOURS WITHOUT A PROBLEM. 2 L 7 2 4T 4 T RT A8SW E3WE 6 C 3PNE 2005041800087 20050418 00087 2005 4 18 CA041020001 4 20040725 G 3418 C16177AC VANE BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ANGLE OF ATTACK MALFUNCTIONED W C ABORTED TAKEOFF J WARNING INDICATION TO TAKEOFF 1 CA (CAN) SHORTLY AFTER TAKEOFF POWER WAS APPLIED, 'PUSHER SYSTEM FAIL' WAS ANNOUNCED FOR 1-2 SECONDS, AND THEN WENT OFF. TA KEOFF ROLL WAS ABORTED AT APPROXIMATELY 50-60 KNOTS. AOA VANE WAS FOUND HARD TO MOVE WHEN HOT AND IT WAS THEREFORE REPL ACED IN ACC. AMM TASK 27-33-26. 2 H 7 2 4T 4 T RT A13NM E00062EN 2005041800088 20050418 00088 NM 2005 4 18 CA041020002 1 20041016 G 3260 65244809 FITTING BOEING 727 727227 1384078 NM PWA JT8 JT8D9A 52048 NE MLG UPLOCK CRACKED W O OTHER O OTHER NR NOT REPORTED 1 CA 60571 (CAN) DURING ROUTINE MAINTENANCE A CRACK WAS FOUND IN THE LEFT HAND MLG UPLOCK FITTINGIN THE FORWARD RADIUS. NDT CONFIRM ED THE CRACK. FITTING WAS REPLACED AND GEAR RETRACTIONS CARRIED OUT. 2 L 7 3 4F 4 F A3WE E2EA 2005041800089 20050418 00089 EU 2005 4 18 CA041020003 1 20041016 G 3213 C2310961013 STRUT AIRBUS 310 A310304 3930339 EU GE CF6 CF680C2A5 NE NLG DOWNLOCK LACK OF LUBE W O OTHER O OTHER AP APPROACH 1 CA (CAN) ON APPROACH TO AIRPORT, FLIGHT CREW WAS UNABLE TO OBTAIN POSITIVE NOSE LANDING GEAR DOWN LOCK INDICATION EVEN AFTE R SEVERAL CYCLES. A LANDING GEAR GRAVITY EXTENSION WAS CARRIED OUT SUCCESSFULLY.TROUBLE SHOOTING OF THE ELECTRICAL INDIC ATION SYSTEM DID NOT REVEAL ANY FAULTS. A FULL PHYSICAL INSPECTION WAS CARRIED OUT AND GEAR SWING OF NOSE LANDING GEAR. MAINTENANCE WAS UNABLE TO DUPLICATE THE FAULT. NOSE LANDING GEAR LUBRICATION WAS PERFORMED AND THE AIRCRAFT WAS RELEASE FOR RETURN TO SERVICE PENDING SATISFACTO RY TEST FLIGHT. AS PRECAUTIONARY MEASURE FROM TROUBLE SHOOTING AND AIRBUS TFU 3 2-31-24 .002 THE NOSE LANDING GEAR TELESCOPIC STRUT ASSEMBLY WAS REPLACED AS UNIT IS SUSCEPTIBLE TO MOISTURE INGRESS AN 2 L 7 2 4F 4 F RT A35EU E13NE 2005041800090 20050418 00090 NE 2005 4 18 CA041020004 2 20041018 G 7322 8063041 FUEL CONTROL PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL ENGINE OUT OF RIG W O OTHER R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 CA PCE0106 (CAN) WHILE CRUISING AT 25000 THE FLIGHT CREW NOTICED A SMALL SURGE IN POWER, THEN THE ENGINE RETURNED TO THE POWER SETT ING. THIS OCCURRED ONCE MORE ON DESCENT, BUT O NCE AGAIN CLEARED UP. AFTER LANDING AIRCRAFT WAS GROUND RUN AND SURGES IN NG AND TORQUE WERE NOTICED . AIRCRAFT WAS GROUNDED AND FUEL CONTROL WAS REPLACED, THIS CORRECTED THE NG PROBLEM BUT WE STILL HAD TORQUE SURGES WE THEN REPLACED THE PR OP GOV P/N 8210-137 AND ENGINE WAS RIGGED AND GROUND RUN. PROBLEM WAS CO RRECTED. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005041800091 20050418 00091 NE 2005 4 18 CA041020005 2 20041019 G 7314 8256015 PUMP PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL ENGINE FUEL MAKING METAL W K NONE O OTHER IN INSP/MAINT 1 CA PCE0106 (CAN) WHILE AIRCRAFT WAS AT MAINTENCE BASE IT WAS DECIDED TO DO THE FUEL PUMP INLET SCREEN INSPECTION. WHEN THE OUTLET F ILTER WAS REMOVED TO GAIN ACCESS TO THE SCREEN WE FOUND METAL IN THE FILTER AND ALSO LOT OF METAL FILLINGS IN THE FILTE R HOUS ING. OVERHAUL SHOP WAS NOTIFIDED AND NEW PUMP IS BEING SHIPPED. NO METAL WAS FOUND IN AIRFRAME FILTER, INLET SCRE EN ON PUMP OR INLET SCREEN IN FCU. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005041800092 20050418 00092 CE 2005 4 18 CA041020006 1 20041020 G 3243 99121661 SHAFT SEAL CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE HYD BRAKE PWRPK LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) AFTER THE FIRST FLIGHT OF THE DAY THE CREW NOTICED FLUID ON NOSE WHEEL. MORE FLUID WAS FOUND IN THE NOSE WHEEL WEL L. FLUID LEAKAGE WAS TRACED TO THE HYDRAULIC BRAKE POWER PACK SEALS BETWEEN THE PUMP AND THE MOTOR. THE HYDRAULIC BRAKE POWER PACK ASSEMBLY WAS REPLACED AND THE AIRCRAFT WAS RETURNED TO SERVICE. 1 L 7 2 4F 4 F A22CE E1NE 2005041800093 20050418 00093 2005 4 18 CA041020007 4 20041018 G 3140 4055900905 SYMBOL GENERATOR DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE NR 1 PFD FAILED W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA (CAN) AIRCRAFT HAS BEEN DIVERTED TO AN ALTERNATE AIRPORT DUE TO A COMPLETE LOST OF NR 1 PRIMARY FLIGHT DISPLAY AND NAV D ISPLAY. MAINTENANCE FOUND NR 1 SYMBOL GENERATOR AT FAULT, AIRCRAFT DISPATCHED SERVICEABLE FOLLOWING THE REPLACEMENT. 2 L 7 2 4F 4 F RT A6WE E9NE 2005041800094 20050418 00094 NM 2005 4 18 CA041020008 1 20040707 G 7712 304725201 PROBE BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ENG TORQUE FAILED W O OTHER O OTHER DE DESCENT 1 CA (CAN) POWER PLANT CAUTION MESSAGE ON ENGINE DISPLAY DURING DESCENT. A/C COMPLETED AN UNEVENTFUL LANDING. AFTER SUCCESSFU L RESET OF THE SYSTEM WITH TCC CONTACT, ENGINES STARTED. JUST AFTER ENGINE SPOOL-UP WEGOT 'POWERPLANT' ONCE AGAIN. FLIGH T WAS THEN CANCELLED. FAULT CODE 166, QB (P12) SPEED INCONSISTENT, WAS FOUND LOGGED IN THE CENTRAL DIAGNOSTIC SYSTEM ON RT ENGINE.TORQUE PROBE QB WAS CONSEQUENTLY REPLACED. 2 H 7 2 4T 4 T RT A13NM E00062EN 2005041800095 20050418 00095 EA 2005 4 18 CA041020009 2 20041019 G 7200 ENGINE BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA FAILED W G O2 MASK DEPLOYED B SMOKE/FUMES/ODORS/SPARKS DE DESCENT 1 CA FA0106 (CAN) AT TOP-OF-DESCENT (23K FEET) THE BLUISH SMOKE BECAME EVIDENT ON THE FLIGHT DECK AND IN THE CABIN .PILOTS DONNED OX YGEN MASKS, DECLARED AN EMERGENCY AND DIVERTED TO AN ALTERNATE AIRPORT. DURING THE SUBSEQUENT RAPID DESCENT, THE PILOTS REPORTED HEARING A 'BANG' WITH AN ASSOCIATED YAW ALTHOUGH NO SHIFT IN ENGINE PARAMETERS WAS EVIDENT. THE ENGINE WAS NO T SHUTDOWN DURING THE EVENT. 2 H 7 2 4T 4 T RT A13NM E00062EN 2005041800096 20050418 00096 NE 2005 4 18 CA041020010 2 20041011 G 7261 P1010 OIL FILTER BEECH 200 B200 1152922 CE PWA PT6 PT6A42 52043 NE ENGINE OIL CLOGGED W K NONE O OTHER IN INSP/MAINT 1 CA PCE94087 (CAN) ON ROUTINE INSPECTION IT WAS DISCOVERED THAT A PIECE OF THE SCREEN SECTION WAS SEPERATING FROM THE EXTERNAL SECTIO N OF THE FILTER. NOT SURE IF IT IS A MANUFACTURING DEFECT OR IF THE FILTER WAS COMING APART IN USE. 1 L 7 2 4T 4 T A24CE E4EA 2005041800097 20050418 00097 CE 2005 4 18 CA041020011 1 20041019 G 3246 AN36A BOLT CESSNA CESSNA 337 337A 2075704 CE CONT O360 IO360C 17025 SO MCAULY 2AF34C D2AF34C59 GL LT WHEEL MISSING W D RETURN TO BLOCK D B INFLIGHT SEPARATION SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA (CAN) WHILE TAXING TO PARK, THE LEFT WHEEL STARTED TO SMOKE AND THE AIRCRAFT STARTED TO SHAKE. AFTER APPLYING BRAKES EVE RYTHING WENT BACK TO NORMAL. UPON INSPECTION THE TIRE HAD WORN ALMOST THROUGH AND ONE OF THE THREE WHEEL BOLTS WAS MISSI NG. AFTER THE WHEEL WEAS REMOVED IT WAS OBVIOUS WHERE PART OF THE MISSING BOLT HAD TEMPORARILY LODGED ITSELF TO CAUSE TH E WHEEL TO LOCK UP. A NEW TIRE AND BOLT WAS INSTALLED AND AIRCRAFT WAS RETURNED TO SERVICE. IF THE BOLT HAD FALLEN OUT B ECAUSE THE NUT WENT MISSING THERE WOULD HAVE BEEN DAMAGE TO THE WHEEL HALF, BUT THERE WAS NONE. THEREFORE, IT LOOKS LIKE THE BOLT BROKE. WE COULD NOT FIND THE BOLT. 1 H 7 2 3O 3 O A6CE E1CE 5 C P5EA 2005041800098 20050418 00098 NE 2005 4 18 CA041021001 2 20041018 G 7200 POWERPLANT SAAB SF340 340B 7860101 EU GE CT7TP CT75A2 30030 NE ROTOL R389 R3894123F25 NE FAILED W A UNSCHED LANDING X J ENGINE FLAMEOUT WARNING INDICATION DE DESCENT 1 CA 31530 367302 (CAN) ENG FLAMED OUT AT 13,000 FT DURING DESCENT WHEN THEY TRIED TO REAPPLY HIGHER POWER & RESTARTED SUCCESSFULLY AFTER FOLLOWING PROCEDURES. ACRFT LANDED. MX DISPATCHED, EVALUATION CARRIED OUT IAW GE MM. INTERNAL ENG INSPECTED NO FAULT FOU ND, EXTERNAL INSPECT CARRIED OUT NO FAULT FOUND. RUNS CARRIED OUT AT HIGH POWER, AIR VALVE LITE COMING ON MEANING NOT EN OUGH AIRFLOW TO THE ANTI-ICING SYSTEM. AFTER TROUBLESHOOTING FOR THE BLEED AIR VALVE TO BE DEFECTIVE. VALVE REPLACED, DE FECT REPAIRED. THIS ALONE COULD HAVE NOT CAUSED THE FLAME OUT. AFTER DISCUSSION WITH CREW THEY USED QRH PROCEDURE FOR AI R VALVE LIGHT ON, BUT AUTOCOARSEN SWITCH ON AT ALL TIMES 2 L 7 2 4T 4 T RT A52EU E8NE6 6 C P30NE 2005041800099 20050418 00099 2005 4 18 CA041021002 4 20041019 G 2562 BS2173 BATTERY DORNEMARGLN CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL ELT CORRODED W O OTHER H ELECT. POWER LOSS-50 PC NR NOT REPORTED 1 CA 48183 (CAN) BATTERY LEAK CAUSING CORROSION EATING THE CASING AND DESTROYING THE TRANSMITTER. 1 H 7 1 3O 3 O NT 3A19 E223 5 N P50GL 2005041800100 20050418 00100 EU 2005 4 18 CA041021003 1 20040826 G 6123 PUMP FOKKER F27 F27MK50 EU PWA PWA120 PW125B NE ROTOL R352 R3526123F1 GL PROP FEATHERING LEAKING W E ENGINE SHUTDOWN K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA (CAN) DURING CRUISE, THE LOW OIL PRESSURE WARNING WAS ACTIVATED AND THE PILOT ELECTED TO SHUT DOWN THE ENGINE BEFORE PER FORMING AN UNEVENTFUL SINGLE ENGINE LANDING. GROUND MAINTENANCE FOUND AN OIL LEAK AT THE FEATHERING PUMP FROM A DAMAGED O'RING. 2 H 7 2 4T 4 T RT A817 E20NE 6 C P16NG 2005041800101 20050418 00101 EU 2005 4 18 CA041021004 1 20040915 G 6123 PUMP FOKKER F27 F27MK50 EU PWA PWA120 PW125B NE ROTOL R352 R3526123F1 GL PROP FEATHERING LEAKING W E A ENGINE SHUTDOWN UNSCHED LANDING K J FLUID LOSS WARNING INDICATION NR NOT REPORTED 1 CA (CAN) FOLLOWING AN IFSD AND RESULTING EMERGENCY LANDING, GROUND MAINTENANCE FOUND AN OIL LEAK AT THE FEATHERING PUMP ACC OMPANIED BY THE SEIZURE OF THE LOW AND HIGH PRESSURE COMPRESSOR ROTORS. 2 H 7 2 4T 4 T RT A817 E20NE 6 C P16NG 2005041800102 20050418 00102 2005 4 18 CA041021005 4 20041013 G 3425 7926355001 INDICATOR BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA FLT DIRECTOR FAILED W D RETURN TO BLOCK B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA (CAN) AFTER START-UP AND SELECTION OF THE AVIONICS MASTER ON, THE CREW NOTED THAT THE INSIDE OF THE FLIGHT DIRECTOR INDI CATOR, BEHIND THE GLASS FACE, APPEARED TO HAVE SMOKE INSIDE OF THE INSTRUMENT. THE AVIONICS MASTER WAS SELECTED TO OFF A ND THE ENGINES SHUT DOWN. MAINTENANCE WAS CONTACTED AND INSPECTED THE INDICATOR. AN EL ECTRICAL TYPE SMELL WAS PRESENT A T THE UNIT. THE INDICATOR WAS REPLACED AND THE UNSERVICEABLE UNIT HAS BEEN SENT TO THE VENDOR FOR INSPECTION AND OVERHAU L. 1 L 7 2 4T 4 T A24CE E4EA 2005041800103 20050418 00103 NE 2005 4 18 CA041021006 2 20040919 G 7314 6055T19P14 HMU SAAB SF340 SF340A 7850100 EU GE CT7TP CT75A2 30030 NE ROTOL R389 R3894123F26 NE ENGINE FAILED W K NONE L NO TEST IN INSP/MAINT 1 CA (CAN) FOLLOWING A SCHEDULED ENGINE CHANGE AND DURING COMPLETION OF THE GROUND RUN OPERATIONAL CHECKS, THE BOTTOM GOVERNI NG FUNCTION OF THE ENGINE COULD NOT BE ENABLED. THE HMU WAS REPLACED AND RETURNED TO THE MANUFACTURER FOR INSPECTION AND REPAIR. THE SHOP REPORT CONCLUDED THAT A DEFECTIVE LINEAR TRANSDUCER IN THE HMU WAS AT FAULT. 2 L 7 2 4T 4 T RT A52EU E8NE6 6 C P30NE 2005041800104 20050418 00104 NE 2005 4 18 CA041021007 2 20040914 G 7314 6055T19P14 HMU SAAB SF340 SF340A 7850100 EU GE CT7TP CT75A2 30030 NE ROTOL R389 R3894123F26 NE ENGINE FAILED W K NONE L NO TEST IN INSP/MAINT 1 CA 35795 (CAN) DURING COMPLETION OF ENGINE GROUND RUNS AFTER AN ENGINE CHANGE, THE ENGINE BOTTOM GOVERNING FUNCTION COULD NOT BE CONSISTENTLY ENABLED AS REQUIRED BY THE CHECK. IT WOULD INTERMITTENTLY FAULT TO A LOWER THAN SELECTED RPM. THE HMU WAS REPLACED AND SENT TO THE MANUFACTURER FOR INSPECTION AND REPAIR. 2 L 7 2 4T 4 T RT A52EU E8NE6 6 C P30NE 2005041800105 20050418 00105 NM 2005 4 18 CA041021008 1 20041018 G 3310 BV031120333 FIXTURE BOEING 757 757256 1384925 NM RROYCE RB211 RB211535E437 54555 NE COCKPIT LIGHT BURNED W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) BURNING SMELL NOTICED IN FORWARD CABIN AFTER DEPARTURE. CREW ELECTED TO RETURN TO AIRPORT. ON ARRIVAL, MTX NOTICE D CEILING LIGHTING NOT WORKING AT ROW 2DEF FOUND CONNECTOR ON LIGHTING FIXTURE HAD ARCED/BURNED AND EMITTED STRONG ODOUR . FIXTURE REMOVED, INCLUDING BALLAST (PN 05939-3, SN 4515 2 L 7 2 4F 4 F RT A2NM E12EU 2005031400098 20050314 00098 CE 2005 3 14 CA041022001 1 20041019 G 3230 MS166551031 RETAINING RING BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCD4N3 HCD4N3A GL MLG MISSING W O OTHER O OTHER AP APPROACH 1 CA (CAN) AIRCRAFT WAS ON APPROACH AND SELECTED LANDING GEAR DOWN. LANDING GEAR FAILED TO EXTEND. THE FLIGHT CREW THEN SEL ECTED THE EMERGENCY LANDING GEAR EXTENSION SYSTEM. THE LANDING GEAR LOCKED DOWN AND THE AIRCRAFT LANDED SAFELY. UPON I NSPECTION OF THE LANDING GEAR SYSTEM MAINTENANCE FOUND THE RETAINING RING INSTALLED IN THE SHAFT COUPLER MISSING. THIS CAUSED THE COUPLER TO SLIDE TO THE MOTOR SIDE OF THE SPLINED SHAFT, WHICH CAUSED THE MOTOR TO DISENGAGE FROM THE PUMP. 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2005041800106 20050418 00106 2005 4 18 CA041022002 4 20041021 G 2210 6224717004 CONTROL PANEL BOEING 757 75728A 1384976 NM RROYCE RB211 RB211535E437 54555 NE MODE CONTROL FAILED W A UNSCHED LANDING H G ELECT. POWER LOSS-50 PC MULTIPLE FAILURE CR CRUISE 1 CA (CAN) AFTER DEPARTURE YVR ENROUTE LAX, CREW NOTICED NUMBEROUS FAILURES IN AUTOFLIGHT MODE CONTROL PANEL.NOT ABLE TO SELE CT SPECIFIC HEADING. HEADING INDICATIONS ON CAPT/FO EHSI DIFFERENT. UNABLE TO SELECT ALTITUDE, ALSO AUTOPILOT WOULD NOT CONTROL AIRCRAFT TO SELECTED HEADING OR ALTITUDE. CREW ELECTED TO RETURN TO YVR.UPON ARRIVAL YVR, MAINTENANCE REPLACED THE MODE CONTROL PANEL, AIRCRAFT DISPATCHED. NO FURTHER INCIDENT. 2 L 7 2 4F 4 F RT A2NM E12EU 2005041800107 20050418 00107 NE 2005 4 18 CA041022003 2 20040801 G 7250 TURBINE WHEEL SNIAS 350 AS350B 8680801 EU TMECA ARRIEL ARRIEL1B 6OO30 NE ENGINE UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 CA 12736 42704268 (CAN) DURING A SCHEDULED CHECK OF THE SECOND STAGE TURBINE BLADES (T2 ) IAW TURBOMECA ASB 292-72-0807 AND AD2004-047 IT WAS DETERMINE THE BLADE SHIFT HAD FAILED THE CHECK. THE GAS GENERATOR WAS REPLACED 1 G 7 1 3U 3 U H9EU E19EU 2005041800108 20050418 00108 EU 2005 4 18 CA041022004 1 20040909 G 7722 INDICATOR UROCOP EC135 EC135P1 8680990 EU PWA PW206 PW206B 0 NE EGT/TIT FAILED W E ENGINE SHUTDOWN M N OVER TEMP FALSE WARNING NR NOT REPORTED 1 CA (CAN) DURING NORMAL FLIGHT CONDITIONS, ENGINE ITT APPROACHED 900C ACCOMPANIED BY A REDUCTION IN TORQUE ANDN1 AND N2 SPEE DS. THE PILOT REDUCED POWER SETTING TO IDLE AND SUBSEQUENTLY SECURED THE ENGINE IN FLIGHT. AN SINGLE ENGINE LANDING WAS ACCOMPLISHED. SUBSEQUENT ENGINE RUNS AND ASSOCIATED TROUBLESHOOTING WERE UNABLE TO REPRODUCE THE CONDITION. DURING IN VESTIGATION, THE EEC GROUND STRAP WAS FOUND LOOSE. 1 G 7 2 3U 3 U O H88EU E42NE 2005041800109 20050418 00109 EU 2005 4 18 CA041022005 1 20041004 G 6730 AC67244 SERVO SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE HYD SYSTEM FAILED W K NONE F FLT CONT AFFECTED TX TAXI/GRND HDL 1 CA (CAN) PILOT WAS DOING HIS PREFLT HYD TESTS AND THEY FAILED. AFTER TROUBLESHOOTING HYDRAULIC SYSTEM FOUND THAT ONE LATER AL SERVO WAS THE CAUSE OF THIS MOVEMENT EVEN THOUGH DURING OUR TROUBLESHOOTING THE LATERAL SERVOS WERE SWAPPED OVER BUT THE PROBLEM STAYED GOING TO THE RIGHT. REMOVED FAULTY SERVO AND INSTALLED FRESHLY OVERHAULED SERVO. 1 G 7 1 3U 3 U NC H9EU E19EU 2005041800110 20050418 00110 CE 2005 4 18 CA041025001 1 20041020 G 3231 05411066 BELLCRANK CESSNA CESSNA 401 401B 207590E CE CONT O520 TSIO520EB 17040 SO GEAR DOOR UNSERVICEABLE W O OTHER J WARNING INDICATION CL CLIMB 1 CA (CAN) LANDING GEAR IDLER BELCRANK PN 0541106-6 ON NR 2 MAIN LANDING GEAR, GEAR DOOR CONTROL LOBE FOUND SEVERED RESULTING IN GEAR DOOR HANGING DOWN. UPON INSPECTION OF RT LANDING GEAR SYSTEM FOUND A CRACKED WELD ON THE NR 2 TORQUE TUBE ASSEM BLY RESULTING FROM BINDING CONTROL ROD THAT WAS PREVIOUSLY ATTACHED PN 504510-18 AT THE GEAR DOOR CONTROL LOBE 1 L 7 2 3O 3 O A7CE E8CE 2005031400099 20050314 00099 CE 2005 3 14 CA041025002 1 20041014 G 2460 70HF10 DIODE BEECH 200 B200 1152922 CE PWA PT6 PT6A42 52043 NE HARTZL HCE4N HCE4N3 NE DUAL FEED BUSS BURNED W O OTHER F H I FLT CONT AFFECTED ELECT. POWER LOSS-50 PC FLT. ATTITUDE INST. CL CLIMB 1 CA (CAN) EXPERIENCED NR1 DUAL FED BUS FAILURE IN FLT. NR 1 DUAL FEED BUSS EQUIP BECAME DE-ENERGIZED. AC LANDED WITHOUT IN CIDENT. MAINT DISCOVERED BOTH DIODES BURNED OPEN ON NR1 DUAL FEED BUSS SYS. REPLACED DIODES WITH NEW, PERFORMED DUAL B USS CONFORMITY CHECK IAW MM TO CHECK BUSSES NR 1 THRU NR 4. AC CERTIFIED AND RELEASED FOR FLT. SUSPECTED 1 OF 2 DIODES ORIGINALLY FAILED, CAUSING SECOND DIODE TO TAKE REMAINING LOAD, CAUSING ITS LIFE TO BE SHORTENED. IT ALSO APPEARED THA T THESE DIODES HAD BEEN CHANGED IN PAST. SUSPECTED THAT DIODES MAY HAVE BEEN INCORRECTLY INSTALLED, DID NOT APPEAR TO B E VERY SECURE IN DIODE ASSY (50-354308-21). VERY POOR INFO ON CORRECT INSTALLATION OF DIODES. 1 L 7 2 4T 4 T A24CE E4EA 5 C P10NE 2005041800111 20050418 00111 NM 2005 4 18 CA041025003 1 20041025 G 5730 DHC8102 SKIN DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE LT WING CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING A ROUTINE HEAVY MAINTENANCE INSPECTION WIDESPREAD LEVEL ONE CORROSION WASFOUND ON THE UPPER WING SKIN AT TH E MATIN SURFACES OF THE FORWARD AND REAR SPARS. INITIALLY LEVEL ONE CORROSION WAS FOUND JUST AHEAD OF THE REAR SPAR AND JUST AFT OF THE FORWARD SPAR. FURTHER INVESTIGATION THROUGH CUTTING SAMPLES OUT OF THE SKIN, AT BOTH THE FORWARD AND REA R SPARS, REVEALED THAT LEVEL ONE CORROSION WAS ALSO PRESENT AT THE SPAR TO SKIN MATING SURFACE. THE CORROSION THAT WAS F OUND WAS ISOLATED TO THE DRY BAY PORTIONS OF THE WING (STN. YW171.200 PORT TO STA YW171.200 STARBOARD AND OUTBOARD OF ST A. YW405.00 ON BOTH WINGS). CORROSION WAS LIMITEDTO THE SKIN ONLY AND WAS NOT EVIDENT ON THE SPARS. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005020100078 20050201 00078 EU 2005 2 1 CA041025004 1 20040929 G 5310 350A38101891 CROSSBEAM SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THE BI-DIRECTIONAL CROSSBEAM WAS IN FOR NDT INSPECTION IAW AD96-156-071(B)R1. THE NDT AMO FOUND THE CROSSBEAM CRA CKED IN THE CUP OR AS INDICATED IN SB05-00- 28 'R' REGION. 1 G 7 1 3U 3 U H9EU E19EU 2005041800112 20050418 00112 NE 2005 4 18 CA041026001 2 20041022 G 7200 ENGINE DHAV DHC8 DHC8201 2809001 NM PWA 120 PW123D 52152 NE HAMSTD 14SF 14SF23 NE NR 1 MALFUNCTIONED W O OTHER E VIBRATION/BUFFET NR NOT REPORTED 1 CA 18532 AG0049 (CAN) FROM A PILOT REPORT RECTIFICATION, A GROUND RUN OF THE NR 1 ENGINE WAS REQUIRED FOLLOWING A COMPONENT CHANGE. DURI NG THE START CYCLE OF THE GROUND RUN. THE LAME CONDUCTING THE GROUND RUN IDENTIFIED AN ENGINE VIBRATION THROUGH THE FLIG HT DECK CONTROL CONDITION LEVER. NO FLIGHT CREW HAD WRITTEN UP AN ENGINE VIBRATION DEFECT PRIOR TO THIS GROUND RUN. FURT HERMORE WITH THE ENGINE AT IDLE SPEED THE VIBRATION COULD BE INCREASED/DECREASED WITH SOME MANIPULATION OF THE CONDITION LEVER. FOLLOWING EXTENSIVE COLLABORATION WITH THE ENGINE MANUFACTURER AND FOLLOWING SUGGESTED TROUBLESHOOTING, ON ADVIS E FROM THE MANUFACTURER THE ENGINE WAS REMOVED. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005041800113 20050418 00113 NE 2005 4 18 CA041026002 2 20041023 G 7200 ENGINE AGUSTA A109 A109 0260109 EU PWC PW206C PW206C NE NR 1 ENGINE FLUCTUATES W C ABORTED TAKEOFF Y J ENGINE STOPPAGE WARNING INDICATION TO TAKEOFF 1 CA BC0391 (CAN) ON A 'CAT A' TAKE-OFF (DURING THE REVERSING PHASE) THE PILOT REPORTED TORQUE FLUCTUATIONS ON THE NR 1 ENGINE. ALL ENGINE PARAMETER THEN WENT TO ZERO (ENGINE OUT). THE PILOT LOST CONTROL OF THE A/C, ITTURNED LT AND THE TAIL HIT AN OBST ACLE. THE PILOT COMPENSATED BY TURING RIGHT AND THE TAIL HIT THE SAME OBSTACLE AGAIN AFTER WHICH THE A/C FLIPPED ON ITS SIDE.IT WAS ALSO REPORTED THAT THE PILOT HA D DIFFICULTIES STARTING THE NO. 1 ENGINE BEFORE THE FLIGHT. P&WC WILL INVES TIGATE THE INCIDENT AND UPDATE THIS SDR ONCE ROOT CAUSE HAS BEEN ESTABLISHED. 1 G 7 2 3U 3 U H7EU E42NE 2005041800114 20050418 00114 NM 2005 4 18 CA041026003 1 20040928 G 3270 141169 ACTUATOR BOEING 727 727223 1384074 NM PWA JT8 JT8D15A 52051 NE TAIL SKID CRACKED W A UNSCHED LANDING K FLUID LOSS CL CLIMB 1 CA (CAN) DURING CLIMB A SYSTEM HYDRAULIC QUANTITY DROPPED TO 1.5 GALLONS LOW LEVEL LIGHT ILLUMINATED. AIRCRAFT RETURNED TO STATION.TROUBLE SHOOTING REVEALED TAIL SKID ACTUATOR BODY CRACKED.RECTIFICATION: TAIL SKID ACTUATOR REPLACED IN ACCORDAN CE WITH M/M. 2 L 7 3 4F 4 F A3WE E2EA 2005041800115 20050418 00115 NM 2005 4 18 CA041026004 1 20041025 G 2510 1B11071 TUBE DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE SEAT CRACKED W O OTHER O OTHER NR NOT REPORTED 1 CA 29378 070 (CAN) CRACKS FOUND ON BOTH TUBE-WELDED BASE OF CO-PILOT'S SEAT ASSY P/N 1108-3AA. TUBE P/N 1B1107-1 AS PER AMI SEATING S YSTEMS COMPONENT MAINTENANCE MANUAL CHAP 25-11-08 , FIGURE 5 , ITEM 540 ON PAGE 1062. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005041800116 20050418 00116 WP 2005 4 18 CA041026005 1 20041022 G 5270 TARGET DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE DOOR WARNING SYS BENT W C ABORTED TAKEOFF N FALSE WARNING TO TAKEOFF 1 CA (CAN) AIRCRAFT ABORTED TAKE OFF DUE TO FWD CARGO DOOR ANNUNCIATION CAME ON. MAINTENANCE FOUND THE CARGO DOOR PROXIMITY T ARGET BENT. PROX TARGET ADJUSTED AS PER AMM AND AIRCRAFT RELEASED SERVICEABLE. 2 L 7 2 4F 4 F RT A6WE E9NE 2005041800117 20050418 00117 NM 2005 4 18 CA041026006 1 20041025 G 2510 1B11071 TUBE DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE SEAT CRACKED W O OTHER O OTHER NR NOT REPORTED 1 CA 049 (CAN) BOTH WELDED TUBE ASSEMBLIES P/N 1B1107-1FOUND CRACKED IN ROLLER RADIUS AT THE BASE OF THE CAPTAIN'S SEAT ASSY . DE FECTS WERE NOTED DURING ROUTINE INSPECTION PROCESS IN THE SEAT SHOP , WHEN THIS SEAT WAS REMOVED OFF THE AIRCRAFT DURI NG AHEAVY MAINTENANCE CHECK. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005041800118 20050418 00118 NM 2005 4 18 CA041026007 1 20041025 G 2510 1B11071 TUBE DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE SEAT CRACKED W O OTHER O OTHER NR NOT REPORTED 1 CA 32256 068 (CAN) BOTH WELDED TUBE ASSY P/N 1B1107-1 OFF THE PILOT'S SEAT ASSY FOUND CRACKED DURING AN INSPECTION OF THE SEAT IN THE SEAT SHOP DURING A SHOP VISIT WHILE THE AIRCRAFT WAS UNDERGOING A HEAVY MAINTENANCE CHECK. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005041800119 20050418 00119 SO 2005 4 18 CA041026008 2 20041020 G 8530 TIST712ACA CYLINDER HEAD CESSNA 185 A185F 2072821 CE CONT O520 IO520D 17032 SO MCAULY D3A34 D3A34C403 GL NR 3 CYLINDER SEPARATED W C ABORTED TAKEOFF B E SMOKE/FUMES/ODORS/SPARKS VIBRATION/BUFFET AP APPROACH 1 CA 1350622 (CAN) NR 3 ALUMUNUM HEAD SEPERATED AT 3RD FIN ABOVE BARRIER. ALL 6 CYLINDERS REPLACED. CYLINDERS THAT WERE REMOVED SENT BACK TO MFG FOR MATERIAL EXAMINATION. 1 H 7 1 3O 3 O 3A24 E5CE 5 C P47GL 2005041800120 20050418 00120 NE 2005 4 18 CA041026009 2 20041004 G 7314 SEAL CESSNA 425 425 2076018 CE PWA PT6 PT6A112 52043 NE MCAULY 3G34C7 3GFR34C701 GL FUEL PUMP DRIVE LEAKING W K NONE K J FLUID LOSS WARNING INDICATION IN INSP/MAINT 1 CA (CAN) PILOT DISCOVERED EXCESSIVE OIL LEAK AFTER FLIGHT. MAINTENANCE WAS DISPATCHED TO INVESTIGATE.FUEL PUMP OIL SEAL WA S FOUND TO BE DISLODGED FROM ITS CARRIER AND HAD MOVED DOWN THE SHAFT INTO THE ENGINE CASE. 1 L 7 2 3T 3 T RT A7CE E4EA 5 C P60GL 2005041800121 20050418 00121 EU 2005 4 18 CA041026010 1 20041025 G 2121 ETV3454G FAN AIRBUS 320 A320231 3930325 EU IAE V2500 V2500A1 NE E/E BAY FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 CA 36493 (CAN) DURING FLT THE ACRFT HAD BEEN DIVERTED DUE TO FUMES DETECTED IN THE COCKPIT & CABIN. AIRFRAME VIBRATIONS FROM RT W ERE REPORTED IN CONJUNCTION WITH THE FUMES. CAPTAIN HAD SELECTED OFF PACK NR 2 AND ECAM MESSAGE VENT BLOWER FAULT OCCURR ED SIMULTANEOUSLY, FUMES DISSIPATED RAPIDLY & ACRFT LANDED SAFELY. FURTHER INVESTIGATIONS CARRIED OUT BY TECHNICAL STAFF REVEALED THAT THE AVIONICSFAN WAS THE SOURCE OF FUMES AND VIBRATIONS (CIRCUIT BREAKER FOUND POPPED OUT). 2 L 7 2 4F 4 F RT A28NM E311NE 2004120900135 20041209 00135 WP 2004 12 9 CA041026011 1 20041025 G 6320 369D25102SN006 TRANSMISSION HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL MAIN ROTOR CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) SEVERE CORROSION FOUND IN OIL GALLERY BEHIND M/R XMSN UPPER BEARING LINER FOR 369D25149 AND 369D25148 BEARINGS. P ROBLEM INITIALLY INDICATED BY LACK OF FLOW FROM OIL ORFICES. CORROSION FOUND BY REWORK FACILITY DURING LINER REMOVAL, A ND WAS UNDETECTABLE WITHOUT REMOVAL OF LINER. 1 G 7 1 3U 3 U H3WE E4CE 2004123000004 20041230 00004 CE 2004 12 30 CA041026012 1 20041026 G 2720 SHAFT BEECH 95 95B55 1152729 CE CONT O470 IO470L 17026 SO HARTZL HCC2Y BHCC2YF2 GL RUDDER PEDAL BROKEN W K NONE F FLT CONT AFFECTED IN INSP/MAINT 1 CA PILOTS LT RUDDER PEDAL BROKE AT THE UPPER PEDAL SHAFT. THE PEDAL WAS FOUND BROKEN AFTER COMPLETION OF A FLIGHT. RUDDER PEDAL WAS REPLACED. INSPECTION OF THE PEDAL REVEALED WORN SHAFT ATTACHMENT HOLES. 1 L 7 2 3O 3 O RT 3A16 3E1 5 C P920 2004123000005 20041230 00005 SW 2004 12 30 CA041027001 1 20041025 G 6320 206031509005 DRAG PIN BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL GEARBOX YOKE WORN W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA BKW10299 AFT CAST SURFACE OF DRAG PIN ASSY THAT IS PART OF M/R GEARBOX CONTACTED YOKE OF ISOLATION MOUNT. CONTACT DUE TO EXCESSIV E CASTING MATERIAL AFT OF BEARING BORE. COMPONENT SHOP RECEIVED AN ISOLATION MOUNT FOR REPAIR THAT HAD FRETTING/CONTACT MARKS ON YOKE. MARKS WERE CONSISTENT WITH DRAG PIN RUBBING/CONTACTING. BASE THAT ISOLATION MOUNT RECEIVED FROM INFORMED , & DRAG PIN & GEARBOX WERE REMOVED & FORWARDED TO US. WHEN RECEIVED DRAG PIN, WAS APPARENT THAT DRAG PIN BEARING BORE W AS NOT SYMMETRICAL IN CASTING. 1 G 7 1 3U 3 U H2SW E4CE 2005031100022 20050311 00022 NM 2005 3 11 CA041027002 1 20041020 G 5510 4472R170 BRAKE BOEING BOEING 727 727225 1384077 NM PWA JT8 JT8D15A 52051 NE STAB TRIM CONTAMINATED W H DEACTIVATE SYST/CIRCUITS F FLT CONT AFFECTED DE DESCENT 1 CA 6937171 (CAN) DURING DECENT, WHEN LEVELING AT 6000FT CREW EXPERIENCED DIFFICULTY IN CAPTURING ALTITUDE. PROBLEM WAS QUICKLY DETE RMINED TO BE HORIZ STABILIZER TRIM. TRIM WHEEL WAS VERY STIFF TO MOVE BOTH MANUALLY AND ELECTRICALLY WHEN TRIMMING NOSE UP. AC LANDED WITHOUT FURTHER INCIDENT AFTER CARRYING OUT STABILIZER JAM CHECKLIST. MAINT FOUND LARGE QUANTITY OF WATE R IN THE AUX BRAKE SHOE HSG. STABILIZER BRAKE, HIGH SPEED ACTUATOR AND LOW SPEED ACTUATOR REPLACED IAW AMM. STABILIZ ER TRIM TESTED WITHOUT FURTHER DIFFICULTY, AIRCRAFT RETURNED TO SERVICE. IN LITE OF THESE FINDINGS, WE ARE INITIATING A FLEET CAMPAIGN TO INSPECT THE ENTIRE FLEET FOR SIMILAR DEFECTS, AND CORRECT AS NECESSARY. 2 L 7 3 4F 4 F A3WE E2EA 2005041800122 20050418 00122 NM 2005 4 18 CA041027003 1 20041026 G 2913 6617302 PUMP BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA HYD SYSTEM CRACKED W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CL CLIMB 1 CA (CAN) DURING CLIMB, AN AIRCRAFT HAD A HYDRAULIC FAILURE CAUSED BY CRACKED NR 2 ENGINEDRIVEN PUMP. UNSCHEDULED LANDING CO MPLETED. AIRCRAFT WAS CHECKED AFTER REPLACEM ENT OF PUMP, A TESTFLIGHT WAS DONE, BEFORE PUT BACK INTO SERVICE. 2 H 7 2 4T 4 T RT A13NM E00062EN 2005041800123 20050418 00123 WP 2005 4 18 CA041028001 2 20041026 G 7230 TVT10728H3 COMPRESSOR AMD FALC50 FALCON900 2700160 EU GARRTT TFE731 TFE7315BR WP ENGINE FAILED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) PRIOR TO DEPARTURE NOISE AND VIBRATION WAS OBSERVED COMING FROM THE AREA OF THE TURBOFAN. THE AIR CONDITIONING WAS SHUT DOWN AND THE PROBLEM DISAPPEARED. THE TURBOFAN WAS CHANGED AND THE FAULT CLEARED. THE FAILED UNIT EXHIBITED TURBIN E BLADE TIP RUB PROBABLY DUE TO A FAILED BEARING IN THE FAN SHAFT. 2 L 7 3 4F 4 F RT A46EU E6WE 2005031400094 20050314 00094 2005 3 14 CA041029001 4 20041028 G 2562 ELT200 ELT BEECH 99 99 1154002 CE PWA PT6 PT6A28 EA HARTZL HCB3T HCB3TN3 GL CABIN INOPERATIVE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) APPROXIMATELY 3 HOURS AFTER LANDING, ATC INFORMED THE COMPANY THAT THEY HAD A STRONG ELT SIGNAL. AFTER CHECKING A LL AIRCRAFT IT WAS NOTICED THAT THE ELT ON THIS AIRCRAFT WAS ACITVATED. THE SWITCH WAS IN THE ARM POSITION AND THE INDI CATOR LIGHT WAS ON. SEVERAL ATTEMPTS WERE MADE TO RESET THE ELT. THE ELT WAS REMOVED. AS SOON AS IT WAS MOVED IT QUIT TRANSMITTING AND WOULD NOT START AGAIN. REMOVED THE COVER AND FOUND A SUBSTANTIAL AMOUNT OF WATER INSIDE, BOTH AROUND THE BATTERY AND THE SEALED SWITCHES AND BOARDS. THE ELT HAS BEEN SENT FOR REPAIR.THE ELT WAS DUE FOR RECERTIFICATION DE CEMBER 19/04, THE BATTERY WAS DUE FEB/06. 1 L 7 2 3T 4 T A14CE E4EA 6 C P15EA 2005041800124 20050418 00124 EA 2005 4 18 CA041029002 1 20041018 G 7830 SM141038 BEARING CNDAIR CL600 CL600* EA LYC ALF502 ALF502L2 41580 NE THURST REVERSER FAILED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) DURING 600 HRS INSPECTION OF NR 1 ENGINE AME NOTICED THAT THE LT THRUST REVERSER STRUT LOWER ATTACHEMENT WAS CHAFI NG AGAINST BRACE UPPER, AFTER CARRYING OUT AN INVESTIGATION WE NOTICED THAT THE BRACE UPPER BEARING HAD MIGRATED .110 PA RT SENT FOR REPAIR TO BAS. 2 L 7 2 4F 4 F RT A21EA E6NE 2005031400095 20050314 00095 EA 2005 3 14 CA041029003 2 20040910 G 7200 ENGINE EMB 110 EMB110* SO PWA PT6 PT6A34 52043 EA HARTZL HCB3T HCB3TN3 GL FAILED W E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA (CAN) AN OIL PRESSURE FLUCTUATION WAS OBSERVED IN FLIGHT FOLLOWED BY A LOUD NOISE ACCOMPANIED BY A LOSS-OF-GENERATOR AND FIRE INDICATION. THE ENGINE WAS SECURED IN-FIGHT AND THE FIRE WARNING ABATED. A SINGLE-ENGINE LANDING PERFORMED. SUB SEQUENT INSPECTION REVEALED A FRACTURED REDUCTION GEARBOX SUN GEAR, FRACTURED POWER TURBINE AND COMPRESSOR TURBINE BLADE S AND ASSOCIATED CASING DAMAGE. MFG WILL MONITOR THE INVESTIGATION OF THIS EVENT AND WILL AMEND THIS SDR TO REFLECT ROOT CAUSE ONCE IT HAS BEEN ESTABLISHED. 1 L 7 2 4T 4 T RT A21SO E4EA 6 C P15EA 2004121000001 20041210 00001 NE 2004 12 10 CA041029004 2 20041026 G 7200 ENGINE DHAV DHC8 DHC8* NM PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE LEAKING W A UNSCHED LANDING Y J ENGINE STOPPAGE WARNING INDICATION CL CLIMB 1 CA (CAN) ON CLIMB A LOUD BANG WAS HEARD ACCOMPANIED BY YAW AND INDICATIONS OF ENGINE STOPPAGE. AN EMERGENCY WAS DECLARED AN D THE AIRCRAFT RETURNED TO POINT OF DEPARTURE. THE CREW REPORTED THE PROPELLER DID NOT FEATHER ON SHUTDOWN AND ALTERNATE FEATHER PROCEDURES WERE EMPLOYED. AN EXTERNAL OIL LEAK WAS VISIBLE DURING POST FLIGHT INSPECTION. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004122900201 20041229 00201 SW 2004 12 29 CA041029005 1 20041024 G 6230 206040036101 BEARING BELL BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL M/R MAST SPALLED W O OTHER J WARNING INDICATION CR CRUISE 1 CA FAJF56564 THE AIRCRAFT WAS ON A FLIGHT WHEN A TRANSMISSION CHIP LIGHT OCCURRED, APPROPRIATE ACTION WAS TAKEN. THERE WAS FERROUS ME TAL FOUND ON THE TRANSMISSION OIL MONITOR AND TRANSMISSION CHIP DETECTORS. THE TRANSMISSION AND MAST WERE REMOVED FOR I NVESTIGATION. THE M/R MAST ASSEMBLY WAS DISASSEMBLED, THE INNER RACE OF THE MAST BEARING WAS FOUND TO HAVE SPALLED AND WAS CREATING THE FERROUS METAL. NOTE: THE M/R TRANSMISSION WAS ALSO DISASSEMBLED AND NO DISCREPANCY WAS FOUND FOR THE CH IP LIGHT. 1 G 7 1 3U 3 U H2SW E4CE 2004122900202 20041229 00202 SW 2004 12 29 CA041029006 1 20041029 G 7714 2514022A649 TACH GENERATOR RROYCE BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL GEARBOX UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 CA CAG36424 OUT OF THE FOUR MOUNTING PAD EARS, ONE EAR WAS FOUND COMPLETELY BROKEN OFF. 1 G 7 1 3U 3 U H2SW E4CE 2004122900203 20041229 00203 GL 2004 12 29 CA041029007 3 20041029 G 6114 D2483 HUB HARTZL PIPER PA30 PA30 7103002 SO LYC O320 IO320B1A 41508 EA HARTZL HCE2Y HCE2YL2 GL PROPELLER CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA BG3218 PROPELLER REMOVED FROM AIRCRAFT FOR 10 YR O/H. UPON VISUAL INSPECTION OF HUB, CORROSION BEYOND REPAIRABLE LIMITS WAS FO UND IN THE BLADE 'O' RING GROOVES. MANUFACTURERS RECOMMENDED TBO IS 2000 HRS OR 72 MONTHS. THIS PROPELLER HAS EXCEEDED THE CALENDAR TBO BY 48 MONTHS. 1 L 7 2 3O 3 O A1EA 1E12 5 C P9EA 2005020100074 20050201 00074 GL 2005 2 1 CA041029008 3 20041029 G 6114 D2483 HUB PIPER PA30 PA30 7103002 SO LYC O320 IO320B1A 41508 EA HARTZL HCE2Y HCE2YL2 GL PROPELLER CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA BG2075 (CAN) PROPELLER REMOVED FROM AC FOR 10 YR. O/H. UPON VISUAL INSPECTION OF THE HUB CORROSION WAS FOUND ON THE MOUNTING F LANGE AND O-RING GROOVE OF THE REAR HUB HALF. THIS CORROSION IS BEYOND REPAIRABLE LIMITS. MANUFACTURERS RECCOMENDED TBO IS 2000 HOURS OR 72 MONTHS. THIS PROPELLER HAS EXCEDED THE RECOMMENDED CALENDAR TBO BY 48 MONTHS. 1 L 7 2 3O 3 O A1EA 1E12 5 C P9EA 2005041800125 20050418 00125 NE 2005 4 18 CA041029009 2 20041026 G 7200 3038300 ENGINE DHAV DHC8 DHC8311 1386006 EA PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE NR 2 FAILED W O OTHER Y J ENGINE STOPPAGE WARNING INDICATION CL CLIMB 1 CA 28991 TM123112 (CAN) DURING CLIMB AT 11,000 FT FLIGHT CREW HEARD A 'BANG' FOLLOWED BY AIRCRAFT YAW. NR 2 ENGINE FAILED AND WAS SHUT DO WN AND FEATHERED USING ALTERNATE FEATHER. AIRCRAFT RETURNED FOR NORMAL SINGLE ENGINE LANDING AT DEPARTURE AIRPORT. NR 2 ENGINE ASSEMBLY REPLACED. AIRCRAFT RETURNED TO SERVICE. ENGINE RETURNED TO OVERHAUL FACILITY. TEARDOWN REPORT WILL BE FO RWARDED TO TSB WHEN AVAILABLE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005041800126 20050418 00126 NM 2005 4 18 CA041029010 1 20041025 G 2611 3023143 SMOKE DETECTOR DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE CARGO BAY MALFUNCTIONED W O OTHER N FALSE WARNING DE DESCENT 1 CA (CAN) DURING DESCENT , INTERMITTANT BAGGAGE SMOKE WARNING. CREW ELECTED TO DON OXYGEN MASKS AND ADVISE AIRPORT EMERGENCY RESPONSE. UPON ARRIVAL NO EVIDENCE OF SMOKE OR FIRE FOUND. BAGGAGE SMOKE DETECTOR REPLACED. REMOVED UNIT TESTED AS NO F AULT FOUND. AIRCRAFT RETURNED TO SERVICE WITH REPLACEMENT SMOKE DETECTOR. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005041800127 20050418 00127 NE 2005 4 18 CA041031001 2 20041026 G 7314 6078TP04 PUMP CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE ENGINE FUEL LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) DURING SCHEDULED CHECKS ON ENGINE, WE FOUND FUEL LEAK COMING FROM 'MAIN FUEL PUMP INLET PORT BODY' OF RT ENGINE. L EAK WAS DETECTED ACTIVATING THE FUEL BOSST PUMP. LEAK CAN BE DESCRIBED AS FOLLOW: CAPILLARY LEAK, LEAK JET ABOUT 3 INC HES LONG VAPOURIZING AT THE END. PART WAS REPLACED A/C IS BACK IN SERVICE. 2 L 7 2 4F 4 F RT A21EA E15NE 2005031400096 20050314 00096 EA 2005 3 14 CA041031002 1 20041027 G 5610 NP13932211 WINDOW CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE COCKPIT CRACKED W O OTHER O OTHER CR CRUISE 1 CA (CAN) THE PILOT SIDE WINDOW CRACKED WHILE IN CRUISE. THE WINDOW WAS REPLACED IN ACCORDANCE WITH AMM. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2005031400097 20050314 00097 EA 2005 3 14 CA041031003 1 20041025 G 5610 NP1393221 WINDOW CNDAIR CL600 CL6002B19 1900309 EA COCKPIT CRACKED W O OTHER O OTHER AP APPROACH 1 CA 20389 (CAN) THE PILOT SIDE WINDOW CRACK WHILE IN APPROACH. THE WINDOW WAS REPLACED IAW AMM. 2 L 7 2 4F RT A21EA 2004121000002 20041210 00002 NM 2004 12 10 CA041101001 1 20041024 G 3230 ROD END DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE RT MLG ACTUATOR FAILED W O OTHER E VIBRATION/BUFFET AP APPROACH 1 CA DCL12086 (CAN) UPON GEAR DOWN SELECTION ON APPROACH A LOUD THUMP AND THE AIRCRAFT JOLTED. 3 GREEN AND LANDED WITHOUT INCIDENT. UP ON INSPECTION BY MAINTENANCE FOUND THE RT MLG RETRACTION ACTUATOR ROD END BROKEN. RT MLG RETRACTION ACTUATOR REPLACED GE AR SWINGS CARRIED OUT WITH NO FATHER FAULTS FOUND. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004123000010 20041230 00010 CE 2004 12 30 CA041101002 1 20041025 G 2910 2307006101 HOSE LEAR 35 35LEAR 5170600 CE GARRTT TFE731 TFE73122B 01518 WP HYD SYSTEM LOOSE W B EMER. DESCENT K J FLUID LOSS WARNING INDICATION AP APPROACH 1 CA AT CRUISING ALTITUDE, FLIGHT CREW NOTICED A DROP IN MAIN HYDRAULIC PRESSURE. WHEN CREW START TO APPROACH THE HYDRAULIC WAS PRESSURE LOW. LANDING GEAR WERE SELECTED DOWN AND ALL PRESSURE WAS LOST. MAINTENANCE FOUND THE B-FITTING LOOSE ON THE NOSE LANDING GEAR ACTUATOR HYDRAULIC UPPER PORT. FITTING TIGHTENED, GEAR SWING COMPLETED. NO LEAKS FOUND. REFER TO LR35 IPC 32-31-05 FIG 5 ITEM 140-141. 2 L 7 2 4F 4 F A10CE E6WE 2004123000011 20041230 00011 EA 2004 12 30 CA041101004 2 20041020 G 8520 10360BIE CRANKCASE PIPER PA28 PA28R180 7102809 SO LYC O360 IO360B1E 41514 EA HARTZL HCC2Y HCC2YK1 GL ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA L445051A THE ENGINE HAD AN OIL LEAK AT THE LT FRONT OF THE CRANKCASE. IT WAS CLEANED. A CLOSE CHECK FOUND TWO CRACKS LEAVING OI L. THE ENGINE WAS REMOVED AND SENT OUT FOR REPAIRS. 1 L 7 1 3O 3 O 2A13 1E10 5 C P920 2005031100014 20050311 00014 2005 3 11 CA041101005 4 20040907 G 3418 25147A7L1T2 TRANSDUCER CNDAIR CL604 CL604 1900301 EA GE CF34 CF343B1 NE AOA OUT OF LIMITS W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHILE CONDUCTING A LINEARITY CHECK IAW MFG TASK JIC NR 27-35-04-101 (SEE ALSO S/B A604-27-011, REV 1, PART A, B) B OTH LT AND RT AOA TRANSDUCERS WERE FOUND TO BE BEYOND SERVICE LIMITS. BOTH ASSEMBLIES WERE REPLACED WITH IMPROVED TRAN SDUCER ASSEMBLIES, P/N 600-59154-5. 2 L 7 2 4F 4 F RT A21EA E15NE 2005031400090 20050314 00090 EA 2005 3 14 CA041101007 1 20041031 G 2422 DH103024600CS11B INVERTER DHAV DHC8 DHC8311 1386006 EA PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE COCKPIT FAILED W B EMER. DESCENT B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) DURING CRUISE, FLIGHT CREW DETECTED SMOKE IN THE COCKPIT , PRIMARY INVERTER CAUTION LIGHT ILLUMINATED, AIRCRAFT DI D EMERGENCY DESCENT AND DIVERSION TO NEAREST ALTERNATE AIRPORT FOR NORMAL LANDING. SMOKE HAD DISSIPATED PRIOR/ON ARRIVA L. MAINTENANCE INSPECTION FOUND PRIMARY INVERTER UNSERVICEABLE, INVERTER REPLACED. AIRCRAFT RETURNED TO SERVICE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005031400091 20050314 00091 EA 2005 3 14 CA041101008 1 20041020 G 5740 600913563 BRACKET CNDAIR CL604 CL604 1900301 EA GE CF34 CF343B1 NE TRANSMITTER MISINSTALLED W C ABORTED TAKEOFF N FALSE WARNING TO TAKEOFF 1 CA (CAN) DURING TAKEOFF ATTEMPT, THE GREEN TAKE-OFF CONFIGURATION WARNING CAME ON. 2 L 7 2 4F 4 F RT A21EA E15NE 2004121000003 20041210 00003 NE 2004 12 10 CA041101009 2 20041026 G 7200 MS949034 BOLT PWA PT6 PT6A65AR 52043 NE ENGINE FRACTURED W E ENGINE SHUTDOWN K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA (CAN) ENG SHUTDOWN IN FLT DUE TO TORQUE FLUCTS & LOW OIL PRESS. 6 BOLTS USED TO ASSEMBLE 1ST STAGE CARRIER ASSY. 2 OF 6 BOLTS FAILED DURING OPS. 1 BOLT HEAD FOR 1ST STAGE CARRIER ASSY FRACTURED IMMEDIATELY UNDER BOLT HEAD. HEAD OF BOLT LODG ED INTO 1ST STAGE REDUCTION GEAR TRAIN, RESULTING IN DEBRIS & FRACTURING OF 1ST STAGE RING GEAR. DEBRIS IN LAST CHANCE F INGER STRAINER IN RGB, PREVENTING OIL SCAVENGING. RESULTED IN RGB FILLING WITH OIL, & NO OIL BEING RETURNED TO REPERISH OIL TANK. OIL TANK RAN LOW ON OIL CAUSING LOW OIL PRESS. TORQUE FLUCTS RESULT OF DAMAGED RING GEAR & LOW OIL PRESS. 2ND BOLT FRACTURED IN ASSY, BUT STAYED IN ASSY & DIDN`T CAUSE SHUTDOWN. BOLTS WERE RE-INSTALLED DURING OVERHAUL. 4 T E4EA 2004122900196 20041229 00196 NE 2004 12 29 CA041101010 2 20041030 G 7261 304544901 CHIP DETECTOR PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL RGB DAMAGED W O OTHER O OTHER NR NOT REPORTED 1 CA DURING INSPECTION IT WAS NOTICED THAT THE CHIP DETECTOR CONNECTOR WAS SITTING AT AN ANGLE. THE PLUG WAS LOCKWIRED BUT W HEN THE LOCK WIRE WAS REMOVED. THE CONNECTOR WAS LOOSE. WHEN THE CONNECTOR WAS REMOVED, NOTICED THAT THE THREADS ON TH E CHIP DETECTOR WERE DAMAGED AND ONE OF THE PINS WAS BROKEN. THE CHIP DETECTOR WAS REMOVED AND NEW UNIT WAS ORDERED AND INSTALLED. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005020100079 20050201 00079 EU 2005 2 1 CA041102001 1 20041102 G 1430 NAS6605D136 BOLT AIRBUS A330 A330* EU RROYCE RB211 RB211TRENT77 NE RT MLG SHEARED W K NONE O OTHER IN INSP/MAINT 1 CA 13548 (CAN) MSN 419 WAS UNDERGOING A C2 CHECK IN YUL. IN PREP FOR DOING A SEAL CHANGE ON RT MLG MAINT DISCOVERED SM9 PIN MIGR ATED APPROX. 1INCH OUT IN THE IB DIRECTION. GEAR WAS SPLIT,AND IT WAS DISCOVERED THAT THE SM9 PIN RETENTION BOLT (NAS66 05D136) HAD SHEARED AT THE HEAD. THE BOLT RETAINS THE PIN END CAPS. CAMPAIGN NR 9-0066 WAS LAUNCHED ON NOV 1 2004 TO I NSPECT ALL ACFT IN FLEET A330/A340. 2 L 7 2 4F 4 F RT A46NM E39NE 2005032400030 20050324 00030 SW 2005 3 24 CA041102002 1 20041102 G 6330 269A5193001 CARRIAGE HUGHES 269 269C1 8059504 SW LYC O360 HO360C1A 41514 EA M/R TRANSMISSION CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA S0602 DURING A SCHEDULED 4200 HR O/H THE ABOVE DESCRIBED CARRIER WAS FOUND TO HAVE 3 CRACKS AT 3 SEPARATE LOCATIONS IN THE CAR RIER TO COUPLING MOUNTING HOLE LOCATIONS. THESE CRACKS WERE DETECTED DURING FLUORESCENT PENETRANT INSPECTION. FOR THE FUTURE A MIDLIFE INSPECTION MAY BE AN OPTION TO DETECT THESE CRACKS, AS THIS AREA HAS BEEN PRONE TO CRACKS IN THE PAST. 1 G 7 1 3O 3 O O 4H12 E286 2005041800128 20050418 00128 NM 2005 4 18 CA041102003 1 20041118 G 5753 CARRIAGE BOEING 737 737248C 1384415 NM PWA JT8 JT8D9A 52048 NE TE FLAPS CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING COMPONENT REPLACEMENT AT HEAVY CHECK, A TYPICAL CRACK WAS DETECTED AT THE SPINDLE JOURNAL FORWARD END ON FL AP CARRIAGE NR 7. 2 L 7 2 4F 4 F RT A16WE E2EA 2005041800129 20050418 00129 CE 2005 4 18 CA041102004 1 20041123 G 2560 S21994 SEAT BELT CESSNA 206 U206F 2073333 CE CONT O520 IO520F 17032 SO CABIN FAILED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) DURING AN ACCEPTANCE INSPECTION, SEAT BELTS WERE REMOVED FOR 10 YEAR REWEBBING. BELTS WERE REINSTALLED & TESTED. ACRT RETURNED TO SERVICE & WENT ON ITS FIRST CHARTER, FRONT RT PAX WENT TO PLACE HIS SEAT BELT ON AND BELT HAD COME OUT OF REEL ASSY. PILOTS REEL TESTED FURTHER & IT WAS DETERMINED THE POSSIBILITY OF SAME DEFECT HAPPENING EXISTED. AIRCRAFT REMOVED FROM SERVICE. BELTS WERE SENT BACK TO THE VENDER TO INVESTIGATE. DURING THE INVESTIGATION STAGE IT ALSO FOUNDT HAT SOME PILOTS COULD NOT REACH FUEL SELECTOR DEPENDING ON PILOTS SEAT LOCATION.THE VENDER WILL VERIFY BELT LENGTH. ONE MUST REMEMBER TO TEST ALL SEAT LOCATION FOR APPROPERIATE BELT LENGTH TO ENSURE PILOTS ARE ABLE TO REACH FUEL SELECTOR. 1 H 7 1 3O 3 O A4CE E5CE 2005041800130 20050418 00130 2005 4 18 CA041102005 1 20041028 G 1430 J4RF284001E2029 SCREW FUSELAGE SHORT W O OTHER H ELECT. POWER LOSS-50 PC NR NOT REPORTED 1 CA (CAN) TRANSISTOR SHORTED DUE TO WRONG (METAL) SCREWS INSTALLED IN PLACE OF THE NYLON SCREWS P/N JYRF284-001. HISTORY IND ICATES THAT THE EL SHORT CAUSED BY METAL SCREWS CAN PRODUCE SMOKE IN CABIN. PHOTO ATTACHED. 2005041800131 20050418 00131 EA 2005 4 18 CA041102006 1 20041101 G 3411 PITOT LINE DHAV DHC8 DHC8311 1386006 EA PITOT/STATIC SYS OBSTRUCTED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) DURING ACCOMPLISHMENT OF DEHAVILLAND SB 8-34-221,WHICH PROVIDES INSTRUCTIONS TO MODIFY THE ROUTING OF THE STATIC L INES CONNECTION, IT WAS NOTICED DURING THE LEAK CHECK THAT THE MAIN STATIC SOURCE LINE WAS INVERTED WITH THE ALTERNATE S TATIC SOURCE. THIS SB GIVES INTRUCTION TO CONNECT THE NR 3 STATIC SOURCEDIRECTLY TO THE STANDBY ALTIMETER, BYPASSING A S ELECTOR VALVE AND A MANIFOLD. AS A CORRECTIVE ACTION, THE LINE WERE RECONNECTED PROPERLY AND THE SYSTEM WAS CHECKED SERV ICEABLE. 2 H 7 2 4T RT A13NM 2004121000004 20041210 00004 NM 2004 12 10 CA041102007 1 20041018 G 2435 03600923 BEARING LUCAS DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE STARTER GEN FAILED W O OTHER J WARNING INDICATION CR CRUISE 1 CA 13733 119 (CAN) DURING CRUISE NR 2 DC GENERATOR CAUTION LIGHT ILLUMINATED , UNABLE TO RESET. NORMAL LANDING AT INTENDED DESTINATIO N. MAINTENANCE INSPECTION FOUND STARTER DRIVE UNABLE TO ROTATE. STARTER/GEN REPLACED. SHOP TEARDOWN FOUND FAILURE OF C.E , END BEARING. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004122900180 20041229 00180 NM 2004 12 29 CA041102008 1 20040904 G 2435 03600923 BEARING LUCAS DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE STARTER GEN FAILED W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA 27210 694A AIRCRAFT NR 2 DC GENERATOR CAUTION LIGHT ILLUMINATED, CREW ELECTED TO RETURN FOR NORMAL LANDING AT DEPARTURE AIRPORT. M AINTENANCE FOUND NR 2 STARTER GENERATOR END BEARING FAILED CAUSING COOLING FAN TO RUB ON HOUSING. SHOP TEARDOWN FOUND B EARING FAILURE AT ANTI-DRIVE END. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004122900181 20041229 00181 NM 2004 12 29 CA041102009 1 20041020 G 2435 03600923 BEARING LUCAS DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE STARTER GEN FAILED W K NONE J WARNING INDICATION IN INSP/MAINT 1 CA 28684 0322 PRIOR TO TAKEOFF, NR 2 DC GEN HOT CAUTION LIGHT ILLUMINATED. AIRCRAFT RETURNED TO GATE. STARTER/GEN REPLACED. SHOP TE ARDOWN INSPECTION FOUND DRIVE END BEARING FAILED. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004122900182 20041229 00182 NE 2004 12 29 CA041102010 2 20041102 G 7261 9520011653 RECEPTACLE SNIAS 350 AS350B3 8680954 EU TMECA ARRIEL ARRIEL2B NE CHIP DETECTOR LEAKING W O OTHER K FLUID LOSS NR NOT REPORTED 1 CA WHILE CHECKING THE ENG MODULE 05 CHIP PLUG DURING ROUTINE D.I., THE SELF CLOSING VALVE OF RECEPTACLE WAS LEAKING. BY PUS HING THE CHIP PLUG IN AND OUT SEVERAL TIMES, THE VALVE WOULD CLOSE TIGHT, STOPPING LEAK. A NEW RECEPTACLE WAS THEN ORDER ED. DUE TO DELAY IN RECEIVING THE PART, THE ENG WAS OPERATED FOR APPROX 75 HRS BEFORE THE RECEPTACLE WAS REPLACED. UPON REMOVAL OF THE FAULTY RECEPTACLE, IT WAS OBVIOUS THAT TWO WASHERS WERE CAUSING SELF CLOSING VALVE NOT TO CLOSE PROPERLY, ALLOWING IT TO LEAK. THE MANUF WAS CONTACTED AND IT WAS DECIDED TO REMOVE THE ENG FROM SERV UNTIL FURTHER INVEST. A SI MILAR WASHER WAS FOUND IN THE MODULE 01 SCAVENGE OIL STRAINER AT 99.9 HOURS. 1 G 7 1 3U 3 U H9EU E00054EN 2005041800132 20050418 00132 WP 2005 4 18 CA041102011 1 20041029 G 1420 PIN DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE CONNECTOR WRONG PART W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THE PIN 'K' ON THE RECEPTACLE OF THE INDICATOR IS TOO BIG. WHEN THE INDICATOR WAS REMOVED FOR INSPECTION, THE SOCK ET IN THE PLUG (ACFT SIDE)BROKE IN HALF, LEAVING A PORTION OF THE SOCKET ON THE INDICATOR. AFTER INVESTIGATION WE FOUND THE PIN 'K' ON THE INDICATOR WAS TOO BIG, IN A TAPER SHAPE, LIKE A CONE. THE SOCKET INTHE PLUG HAS BEEN REPLACED AND A N EW INDICATOR INSTALLED. NOTE: PART TSN AND TSOARE UNKNOWN 2 L 7 2 4F 4 F RT A6WE E9NE 2005041800133 20050418 00133 GL 2005 4 18 CA041102012 2 20041026 G 7210 ENGINE ALLSN 250C 250C20B 03013 GL MAKING METAL W O OTHER J WARNING INDICATION NR NOT REPORTED 1 CA (CAN) AFTER CLOSE INSP. OF THE BOTTOM CHIP PLUG, IT WAS FOUND TO HAVE A LARGE AMOUNT OF FERROUS METAL ON IT. THE ENGINE WAS REMOVED FROM SERVICE AND SENT TO A REPAIR FACILITY FOR FURTHER INVESTIGATION. 3 U E4CE 2005041800134 20050418 00134 CE 2005 4 18 CA041103001 1 20041102 G 3230 NAS464P538 BOLT CESSNA CESSNA 500 550 2076604 CE PWA 530 PW530A NE UPLOCK HOOK SEIZED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) HYDRAULIC PRESSURE LIGHT AND GEAR UNLOCKED LIGHT REMAINED ON AFTER GEAR RETRACTION. RT MAIN GEAR UPLOCK WAS FOUND TO BE STIFF WHEN RETURNING AT IS ORIGINAL POSITION. BOLT AT THE UPLOCK PIVOT WAS FOUND TO BE SEIZED AND CORRODED. BOLT R EPLACED WITH NEW. 1 L 7 2 4F 4 F A22CE E00053EN 2005041800135 20050418 00135 EA 2005 4 18 CA041103002 1 20041101 G 2410 STATOR CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE ALTERNATOR OPEN W A UNSCHED LANDING O OTHER CL CLIMB 1 CA GJAHN677 (CAN) WHILE IN THE CLIMB, CREW REPORTED AN UNCOMMANDED RT ENGINE OVERSPEED. AIRCRAFT RETURNED TO DEPARTURE STATION. TROU BLESHOOTING TRACED FAULT TO AN OPEN CIRCUIT IN THE RT ENGINE STATOR-ALTERNATOR. STATOR-ALTERNATOR REPLACED. ENGINE OVERS PEED INSPECTIONS COMPLETED SATISFACTORY. IPC REF 73-21-07-01-040A. 2 L 7 2 4F 4 F RT A21EA E15NE 2004121000005 20041210 00005 EA 2004 12 10 CA041103003 2 20041025 G 8530 72877 TAPPET CESSNA 182 R182 2072734 CE LYC O540 O540J3C5 41532 EA MCAULY 2D34C B2D34C214 GL ENGINE CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA L2003640A (CAN) METAL FOUND IN OIL SUCTION SCREEN. AFTER REMOVAL OF NR 1 & 2 CYLINDER FOR INSIDE INVESTIGATION. BOTH HYDRAULIC TAP PET ON THAT CYLINDERS FOUND CORRODED WITH PARTS MISSING ON THE EDGE OF THE BODY. ENGINE REMOVED. FURTHER REPORTS WILL F OLLOW BY THE OVERHAUL SHOP. 1 H 7 1 3O 3 O RT 3A13 E295 5 C P7EA 2004122900186 20041229 00186 SW 2004 12 29 CA041103004 1 20041102 G 3230 2751008018 BELLCRANK SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP MLG WORN W O OTHER J WARNING INDICATION AP APPROACH 1 CA DURING EXTENSION OF MLG, NOTICED RT MLG WOULD NOT EXTEND. NO INTRANSIT OR DOWN & LOCKED IND. CREW ATTEMPTED A VISUAL TO CONFIRM MLG EXTEND BUT COULD NOT SEE IT FROM INSIDE A/C. CREW MANUALLY EXTENDED MLG. MLG PROCEEDED TO COME DOWN & REMAIN ED LOCKED. MX CONTACTED & FLT PERMIT ISSUED FOR FLT BACK TO BASE. MLG REMAINED DOWN & LOCKED FOR REMAINDER OF FLT. MX SW UNG MLG & FOUND RT OB MLG POSITIONING BELLCRANK BEARING RIDING ON THE BELLCRANK DUE TO WEAR IN BELLCRANK TRUNNION PIN BU SHING & PIN CAUSING SIDE TO SIDE 'ROCKING' OF BELLCRANK. MINOR EVIDENCE OF POSITIONING CAM RIDING ON BELLCRANK & NOT BEA RING, CAN BE SEEN ON BELLCRANK. MX REPLACED BELLCRANK & INSP REMAINING MLG COMPONENTS & SWUNG MLG WITH NO PROBLEMS. 2 L 7 2 4T 4 T RT A8SW E4WE 2005021400194 20050214 00194 CE 2005 2 14 CA041103005 1 20041025 G 5210 05170281 PUSHROD CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160CTM GL LT DOOR LATCH BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) LT DOOR WOULD NOT OPEN AND CLOSE PROPERLY. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2005041800136 20050418 00136 NE 2005 4 18 CA041103006 2 20041020 G 7321 312267804 FUEL CONTROL CESSNA 208 208B 2073701 CE PWA PT6 PT6A114A 52043 NE MCAULY 3AF34C 3GFR34C703 GL ENGINE FAILED W E ENGINE SHUTDOWN E J VIBRATION/BUFFET WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) ON ENGINE START UP PRIOR TO DEPARTURE THE ENGINE NG STOPPED ACCELERATING AT 48 PERCENT AND THERE WAS NO RESPONSE T O POWER LEVER MOVEMENT. THE ENGINE RESPONDED TO THE SELECTION OF HIGH IDLE AND THEN IDLED AT THE CORRECT NG OF 52 PERCEN T. POWER LEVER RESPONSE WAS THEN NORMAL. AFTER A SHORT TAXI IT WAS NOTICED THAT IDLE HAD DROPPED TO 48 PERCENT AGAIN AND THERE WAS NO RESPONSE TO POWER LEVER MOVEMENT. THE ENGINE WAS SHUTDOWN. MAINTENANCE COULD NOT REPRODUCE THE DEFECT DURI NG SEVERAL STARTS BUT THE FUEL CONTROL WAS REPLACED AS A PRECAUTION. DURING REMOVAL IT WAS NOTICED THAT BLUE DYE WAS IN EVIDENCE ON THE DRIVE. THE AIRCRAFT HAS FLOWN SEVERAL TIMES SINCE WITH NO PROBLEMS. 1 H 7 1 3T 3 T A37CE E4EA 5 C P60GL 2005041800137 20050418 00137 NM 2005 4 18 CA041103007 1 20041019 G 3234 574295 SELECTOR VALVE DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE MLG FAILED W O OTHER O OTHER AP APPROACH 1 CA (CAN) DURING APPROACH, LANDING GEAR WOULD NOT EXTEND, ALTERNATE MLG EXTENSION USED. TROUBLE SHOOTING REVEALED THAT LDG SELECTOR VALVE EXTENSION SOLENOID COIL WAS OPENED. LDG SELECTOR VALVE WAS REPLACED. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005041800138 20050418 00138 NM 2005 4 18 CA041103008 1 20041103 G 7933 523281 INDICATOR DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE NR 1 ENGINE READS LOW W E ENGINE SHUTDOWN N FALSE WARNING CR CRUISE 1 CA 25384 (CAN) DURING CRUISE NR 1 OIL PRESSURE DROPPED, PRECAUTIONARY SHUTDOWN OF & FEATHER OF NR 1 ENGINE , AIRCRAFT RETURNED TO ORIGINATING AIRPORT. MAINTENANCE INSPECTION FOUND OIL PRESSURE, TEMP INDICATOR AT FAULT . INDICATOR REPLACED. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005041800139 20050418 00139 SW 2005 4 18 CA041103010 1 20041027 G 7120 206064105102 MOUNT BELL 206 206L3 1182108 SW ALLSN 250C 250C30P 03013 GL RT ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING A 100 HR INSPECTION AN AME WAS PERFORMING A VISUAL INSPECTION ON THE ENGINE MOUNTS AND FOUND AN AREA ON THE RT MOUNT THAT LOOKED SUSPICIOUS. UPON FUTHER INVESTIGATION (LIGHT SANDING) IT WAS DETERMINED THAT THERE WERE CRACKS & H OLES IN 2 AREAS OF THE TUBE 180 DEGREES APART. THIS IS THE 2ND CRACKED ENGINE MOUNT WE HAVE FOUND ON 206 L-3'S. 1 G 7 1 3U 3 U H2SW E1GL 2004121000006 20041210 00006 WP 2004 12 10 CA041104001 1 20041102 G 2170 DRAIN CVAC 440 440 2422902 WP ALLSN 501D 501D13D 03004 GL WATER SEPARATOR OBSTRUCTED W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 CA (CAN) ON DEPARTURE, CARGO SMOKE DETECTOR LIGHT CAME ON WITH NO ODOR OR SMOKE IN COCKPIT. EMERGENCY DECLARE AND RETURNED AFTER 10 MINUTES AIR TIME. LIGHT EXTINGUISH DURING TAXI. CARGO CONTAINER AND A/C INSPECTED, NOTHING UNUSUAL DETECTED. PR OBLEM TREATED LIKE A FAULTY DETECTION SYSTEM BY MX PERSONNEL. 1 TEST SWITCH AND 1 SMOKE DETECTOR REPLACE DUE TO SMALL SU SPECTED DISCREPANCY FOUND. A/C RETURN TO SERVICE. AT FOLLOWING DEPARTURE 1 MX PERSON ON BOARD LOOKED IN CABIN BEFORE TAK E-OFF AND SAW WATER VAPOR COMING OUT OF AIR CON SYS, INCREASE THE TEMP AND MIST DISAPPEAR. AFTER ARRIVAL, MX PERSONNEL D ISCOVER THE WATER SEPARATOR DRAIN WAS OBSTRUCTED BY FOD. SYS CLEANED AND A/C RETURN TO SERVICE WITH NO FURTHER REPORT. 2 L 7 2 4R 4 T 6A6 E282 2004122900189 20041229 00189 WP 2004 12 29 CA041104002 1 20041102 G 2612 FIRE DETECTOR DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE ENGINE MALFUNCTIONED W C ABORTED TAKEOFF J WARNING INDICATION TO TAKEOFF 1 CA TAKEOFF REJECTED DUE TO MASTER CAUTION LIGHT ILLUMINATED. MAINTENANCE FOUND BREAKER B1-191 FOR RT ENGINE FIRE LOOP POPP ED. ENGINE FIRE LOOP INSPECTED FOR CONDITION, NO FAULT FOUND. BREAKER RESET AND AIRCRAFT DISPATCHED SERVICEABLE. 2 L 7 2 4F 4 F RT A6WE E9NE 2004122900190 20041229 00190 SW 2004 12 29 CA041104003 1 20041104 G 3220 315435 LEAF SPRING BBAVIA 8 8GCBC 1220803 SW LYC O360 O360C2E 41514 EA MCAULY 1A200 1A200* GL TAIL WHEEL BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA CENTER LEAF SPRING FOUND BROKEN AT ASSY ALIGNMENT DIMPLE. ALL FLEET A/C LEAF SPRINGS WHERE REPLACED APPROX JUNE 2003. T HIS IS THE 4RTH A/C SPRING ASSY FAILURE IN 3 MONTHS. SUSPECT ALL FLEET AIRCRAFT LEAF SPRINGS ARE DEFECTIVE AND SPLAYING /STRAINING TO FAILURE. 1 H 7 1 3O 3 O A21CE E286 5 N P874 2004122900191 20041229 00191 NM 2004 12 29 CA041104004 1 20041104 G 2422 DH103024600 INVERTER DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE ELECTRICAL BURNED W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 CA DURING CLIMB-OUT, FLIGHT CREW IDENTIFIED A BURNING SMELL (NO SMOKE) IN CABIN AND COCKPIT. AIRCRAFT CONDUCTED AN AIR RET URN BACK BATEAUX INVERTER REPORTED TO FLICK ON BRIEFLY. PRECAUTIONARY REPLACEMENT OF AUX INVERTER CARRIED OUT. INVERTE R ASSEMBLY SENT FOR INVESTIGATION AND REPAIR. QUANTITY 3 CAPACITORS REPLACED AND UNIT TESTED SERVICEABLE. INVERTER PN. DH-1030-24-600-CS11B 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005021400195 20050214 00195 EU 2005 2 14 CA041104005 1 20041102 G 3242 16104700 WHEEL BNORM BN2 BN2A 1520204 EU LYC O540 O540E4C5 41532 EA HARTZL HCC2Y HCC2YR2 GL MLG CRACKED W D RETURN TO BLOCK K FLUID LOSS TX TAXI/GRND HDL 1 CA (CAN) CREW FELT LOSS OF BRAKE PRESSURE ON RT SIDE. RETURN TO RAMP. MAINT FOUND NR 3 IB WHEEL HALF BROKEN CAUSING BRAK E UNIT TO DETACH FROM BRAKE DISK. BRAKE UNIT FOUND ON TAXIWAY BY AIRPORT OPS. GIVEN TO TC OUTSIDE OF THEIR SOPS. LOCAL TC OFFICE, RETAINED POSSESSION OF BRAKE UNIT AND WILL NOT RETURN UNIT, DESPITE ENDEAVORS TO RETRIEVE FOR OWNER. THEREFOR E UNABLE TO DETERMINE ORIGINAL CAUSE OF FAILURE WHETHER WHEEL HALF OR BRAKE UNIT FAILED FIRST. 1 H 7 2 3O 3 O A17EU E295 5 C P920 2005041800140 20050418 00140 CE 2005 4 18 CA041104007 1 20041103 G 3251 1158200557 SUPPORT BEECH 99 99 1154002 CE PWA PT6 PT6A28 EA NLG STEERING CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING ROUTINE INSPECTION THE SUPPORT BRACKET FOR THE STEERING IN THE UPPER LT CORNER WAS FOUND CRACKED. 1 L 7 2 3T 4 T A14CE E4EA 2005041800141 20050418 00141 2005 4 18 CA041104008 4 20041104 G 2562 BS2173 BATTERY PACK DORNEMARGLN BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA ELT LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA 12401E (CAN) UPON ROUTINE 12 MONTH INSPECTION OF TH SUBJECT ELT, IT WAS OBSERVED THAT THE BATTERY HAD LEAKED, SHORTED OUT THE E LT MAIN BOARD AND HAD PRODUCED MAJOR AMOUNTS OF BURNING. ELT BATTERY WAS MANUFACTURED ON JUNE/03. BATTERY EXPIRY DATE I S JULY/05. THIS UNIT IS NOW DEEMED BEYOND ECONOMICAL REPAIR.PICTURES ARE ATTACHED. 2 L 7 2 4T 4 T RT A24CE E4EA 2005041800142 20050418 00142 EA 2005 4 18 CA041104009 1 20041026 G 2430 MS3505923 SWITCH DHAV DHC6 DHC6100 2802610 EA PWA PT6 PT6A20 52043 EA GENERATOR FAILED W K NONE H ELECT. POWER LOSS-50 PC IN INSP/MAINT 1 CA (CAN) WHILE TROUBLESHOOTING A RECURRENT DC GENERATION SNAG, THE GENERATOR BUSS-TIE SWITCH WAS FOUND TO BE FAILING INTERM ITTENTLY. THE SWITCH WAS REPLACED AND THE SNAG CLEARED. THIS SWITCH IS NOT A TRACKABLE ITEM AND THERE ARE NO EXISTING R ECORDS OF IT EVER HAVING BEEN CHANGED. TTAF29,120.9TCAF50,033 1 H 7 2 3T 3 T RT A9EA E4EA 2005041800143 20050418 00143 NM 2005 4 18 CA041104010 1 20041025 G 6210 369D21102523 BLADE DOUG 600N 600N 3027377 NM ALLSN 250C 250C47B GL MAIN ROTOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) M/R BLADE FOUND WITH CHORDWISE CRACK AT STA 90.0 DURING ROUTINE 100 HOUR INSPECTION.PILOT THOUGHT HE FELT A SLIGHT CHANGE IN AIRCRAFT VIBRATION LEVELS DURING FLIGHT TO MAINTENANCE FACILITY. THE CRACKEXTENDED 4 INCHES FROM THE TRAILIN G EDGE OFTHE BLADE SKIN TOWARD THE CENTER OF THE BLADE.WE HAVE PICTURES OF THE BLADE THAT CAN BE EMAILED IF REQUIRED.YOU NEED TO CHANGE THE SIZE OF THE MODEL/PN BOX TO ACCOMODATE LARGER PART NUMBERS. THE RIN COUNT ON THIS BLADE WAS 515,664 AT THE TIME OF REMOVAL. 1 G 7 1 3U 3 U NC H3WE E1GL 2004122300040 20041223 00040 EA 2004 12 23 CA041104012 1 20041101 G 5610 NP1393226 WINDOW CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE COCKPIT CRACKED W O OTHER O OTHER CR CRUISE 1 CA RIGHT SIDE COCKPIT WINDOW REPLACED ACCORDING AMM PROCEDURE. 2 L 7 2 4F 4 F RT A21EA E15NE 2004122300041 20041223 00041 WP 2004 12 23 CA041105001 1 20041105 G 5260 591885323 HAND RAIL DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE AIRSTAIR CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA WITH VENTRAL AIR STAIR EXTENDED, BOTH LT AND RT HANDRAIL AFT VERTICAL TUBES ARE CORRODED-RUSTED AT THEIR LOWER END. COR ROSION CAN BE SEEN AS A RING OF RUST POWDER AROUND THE JUNCTION OF THE TUBE INTO THE FITTING ASSEMBLY SUPPORT (P/N 39366 673-501 OR -502). RETAINING BOLT HAS TO BE REMOVE AND THE TUBE PULLED FROM THE FITTING ASSEMBLY SUPPORT FOR A PROPER EV ALUATION OF THE TUBE CONDITION. THESE ARE BELIEVED TO BE THE ORIGINAL TUBES. 2 L 7 2 4F 4 F RT A6WE E9NE 2004122300042 20041223 00042 NE 2004 12 23 CA041105002 2 20041101 G 7314 378200 PUMP BOEING 737 737201 1384454 NM PWA JT8 JT8D9A 52048 NE ENGINE FUEL FAILED W A UNSCHED LANDING X J ENGINE FLAMEOUT WARNING INDICATION CL CLIMB 1 CA 39630 DURING CLIMB, THE NR 2 ENGINE FLAMED OUT. THE AIRCRAFT RETURNED TO THE AIRPORT. MAINTENANCE TROUBLESHOOTING FOUND THAT METERED FUEL WAS NOT BEING DELIVERED TO THE ENGINE, BUT FUEL WAS PRESENT UP TO THE FCU/FUEL PUMP ASSY. THE FCU/FUEL PU MP ASSY WAS REPLACED AND SEVERAL GROUND RUNS WERE CARRIED OUT. THE AIRCRAFT WAS RETURNED TO SERVICE. THE FUEL PUMP APP EARS TO BE BINDING WHEN INSPECTED. THE REMOVED FCU/FUEL PUMP ASSY WAS SENT TO AN APPROVED FACILITY FOR FURTHER INSPECTI ON AND TESTING. 2 L 7 2 4F 4 F A16WE E2EA 2005021400218 20050214 00218 NM 2005 2 14 CA041105003 1 20041104 G 2612 894093 FIRE LOOP BOEING 737 737281 138448P NM PWA JT8 JT8D17 52049 NE NR 1 ENGINE INOPERATIVE W E ENGINE SHUTDOWN N FALSE WARNING AP APPROACH 1 CA (CAN) ENGINE NR 1 FIRE WARNING AT 8000 ASL ON APPROACH. FIRE BOTTLES AND SQUIBS REPLACED IAW MM. NR 1 LOWER FIRE LOOP REPLACED AND CONNECTOR D1098 IAW MM. SYSTEM TESTED SERVICEABLE. 2 L 7 2 4F 4 F A16WE E2EA 2005041800144 20050418 00144 CE 2005 4 18 CA041105004 1 20041104 G 5311 05120111 FRAME CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING A 200 HR INSPECTION FUSLAGE FRAME PN 0512011-1, STA 108.0 WAS FOUND TO HAVE 4 CRACKS APPROXINATLY 1/2 - 1 I NCH IN LENGTH ORIGINATING FROM THE INBOARD FLANGE OF THE FRAME AT EACH OF THE 4 CORNERS. 1 H 7 1 3O 3 O NT 3A12 E274 2005041800145 20050418 00145 GL 2005 4 18 CA041105005 2 20041105 G 7320 FUEL CONTROL LKHEED 188 188C 5262604 SO ALLSN 501D 501D13 03004 GL NR 3 ENGINE FAILED W E A ENGINE SHUTDOWN UNSCHED LANDING E VIBRATION/BUFFET CR CRUISE 1 CA (CAN) ON TEST FLIGHT A/C WAS WEST OF OF THE AIRFIELD IN THE PRACTICE AREA. NR 3 ENGINE WAS SHUTDOWN AND SECURED DUE TO L ACK OF RESPONSE WITH THE POWER LEVER. THE A/C RETURNED TO BASE WITHOUT INCIDENT. FCU IS SUSPECTED. 2 L 7 4 4T 4 T 4A22 E282 2005041800146 20050418 00146 NE 2005 4 18 CA041105006 2 20041029 G 7320 164448620 FUEL CONTROL SNIAS 350 AS350B 8680801 EU TMECA ARRIEL ARRIEL1B 6OO30 NE ENGINE FAILED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) ON P2 CHAMBER INSPECTION AND CLEANING OF FCU. WHEN BELLOWS WERE REMOVED WE FOUNDTHAT THE PIN THAT HOLDS THE METERI NG VALVE IN PLACE WAS BROKEN OFF AND HALF OFTHE PIN WAS FOUND IN THE CHAMBER. 1 G 7 1 3U 3 U H9EU E19EU 2005041800147 20050418 00147 CE 2005 4 18 CA041107001 1 20041026 G 5270 V31 SWITCH BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA PAX DOOR INTERMITTENT W A UNSCHED LANDING N FALSE WARNING CL CLIMB 1 CA (CAN) AFTER TAKE-OFF THE CABIN DOOR WARNING LIGHT ILLUMINATED, WITH THE DOOR REMAININGIN THE CLOSED POSITION. THE AIRCRA FT RETURNED TO BASE FOR LANDING WITHOUT INCID ENT. UPON LANDING AND TAXI TO THE RAMP THE CREW CONFIRMED THAT THE DOOR WA S INDEED IN THE CLOSED AND LOCKED POSITION AS CONFIRMED BY THE OVERCENTER MECHANICAL PLUNGER AND LOCK, AND THE FOUR GREE N VISUAL INDICATORS ON THE DOOR BAYONET LATCHES. MAINTENANCE INSPECTION DETERMINED THAT THE DOOR LATCHING MECHANISM WAS FUNCTIONING NORMAL AND THE FALSE INDICATION WAS CAUSED BY AN INTERMITTENT DOOR WARNING SWITCH. 1 L 7 2 4T 4 T A24CE E4EA 2004122200116 20041222 00116 EU 2004 12 22 CA041108001 1 20041029 G 3210 5321012123 PIN PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL LT MLG SHEARED W O OTHER O OTHER LD LANDING 1 CA (CAN) PINS ON SPECIAL WASHER SHEARED ALLOWING BODY OF HYDRAULIC SWIVEL FITTING TO ROTATE ON GEAR RETRACTION/EXTENSION BR EAKING HYDRAULIC LINE TO THE BRAKES P/N 5324412053. THIS APPEARS TO BE CAUSED BY TO THICK OF A SPACER WASHER P/N 532.10. 12.136 WHICH CAUSES THE ASSEMBLY TO APPLY TO MUCH FORCE TO THE SPECIAL WASHER AND ITS PINS. FOUR THICKNESS'S OF WASHERS ARE AVAILABLE IN THE IPC BUT NO PROCEDURE I S SPELLED OUT IN THE MM FOR THE TECHNICIAN TO HELP HIM/HER DETERMINE IF THE PROPER GAP IS THERE ON ASSEMBLY. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004122900155 20041229 00155 CE 2004 12 29 CA041108003 1 20041025 G 3230 07416011 SPRING CESSNA 182 182G 2072716 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C203 GL LT MLG BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA LEFT HAND MAIN LANDING GEAR SPRING ASSEMBLY BROKE OF AT FUSELAGE WHILE TAXIING FOR FLIGHT. THERE WAS NO VISUAL EVIDENCE OF A PREVIOUS CRACK. THE GEAR LEG WAS SENT TO TRANSPORT SAFETY BOARD TO BE ANALYZED. 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 2004122900156 20041229 00156 NM 2004 12 29 CA041108004 1 20041030 G 2760 BACC13AP3D30 CONTROL CABLE BOEING 737 737210C 1384459 NM PWA JT8 JT8D9A 52048 NE RT WING SPOILER FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA DURING AN 'A' CHECK INSPECTION, FOUND THE CONTROL CABLE FOR NR 7 FLT SPOILER FRAYED, AS A RESULT OF CHAFING THROUGH A FA IRLEAD. CABLE WAS REPLACED, FAIRLEAD RE-POSITIONED, FUNCTION CHECKED. AIRCRAFT RETURNED TO SERVICE. NO OTHER PROBLEMS OR ACTIONS. 2 L 7 2 4F 4 F A16WE E2EA 2005020100081 20050201 00081 CE 2005 2 1 CA041108005 1 20041101 G 5532 07310041 SKIN CESSNA 180 180C 2072608 CE CONT O470 O470L 17026 SO MCAULY 2A34C 2A34C66 GL VERTICAL STAB CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) VERTICAL STABILIZER REMOVED TO ACCESS FUSELAGE SIDE SKIN REPLACEMENT (COSMETIC) WITH STABILIZER ON WORKBENCH, VIS IBLE ACCESS TO INTERNAL STRUCTURE REVEALED CONSIDERABLE SURFACE CORROSION EVERY WHERE INTERNALLY. EXTERNAL UNIT LOOKS F INE. RECOMMEND REMOVAL OF VERTICAL AND HORIZONTAL STABILIZERS ON A REGULAR BASIS. IE. 400 HRS/5 YEARS. 1 H 7 1 3O 3 O 5A6 E273 5 C P3EA 2005041800148 20050418 00148 CE 2005 4 18 CA041108006 1 20040807 G 5753 C145350 MOUNT CESSNA CESSNA 208 208 2073702 CE PWA PT6 PT6A114A 52043 NE MCAULY 3AF34C 3GFR34C703 GL FLAP ACTUATOR LOOSE W D RETURN TO BLOCK F J FLT CONT AFFECTED WARNING INDICATION TX TAXI/GRND HDL 1 CA 747 (CAN) MOUNTING STUD NUTS ON FLAP MOTOR BACKED OFF TO THE POINT WHERE THE DRIVE COUPLING DISENGAGED BETWEEN THE FLAP MOTO R AND THE ACTUATOR. 1 H 7 1 3T 3 T NT A37CE E4EA 5 C P60GL 2005041800149 20050418 00149 2005 4 18 CA041108007 4 20041105 G 2215 15600088 CABLE CESSNA 337 T337G 2075726 CE CONT O360 TSIO360CB 17025 SO MCAULY 2AF34C D2AF34C303 GL AUTOPILOT SYS FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AT INSPECTION THE AUTOPILOT ROLL SERVO BRIDLE CABLE WAS FOUND TO BE FRAYED WHERE IT RUNS OVER IT'S PULLEYS. 1 H 7 2 3O 3 O A6CE E9CE 5 C P5EA 2005041800150 20050418 00150 EU 2005 4 18 CA041108008 1 20041101 G 5523 SD3076011XA BRACKET STBROS SD3 SD360 8100606 EU PWA PT6 PT6A65AR 52043 NE TRIM TAB BALANCE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) BOTH ELEVATOR TRIM TAB MASS BALANCE BRACKETS WERE FOUND CRACKED DURING 9600 HOUR STRUCTURAL INSPECTION. THESE BRAC KETS WERE RECENTLY REPLACED TO COMPLY WITH MAN DATORY S/B SD360-55-20. (REFERENCE AD 009-06-2003) 2 H 7 2 4T 4 T A41EU E4EA 2005041800151 20050418 00151 NM 2005 4 18 CA041108009 1 20041104 G 3230 ISOLATION VALVE BOEING 737 737201 1384454 NM PWA JT8 JT8D9A 52048 NE MLG MALFUNCTIONED W O OTHER J WARNING INDICATION CL CLIMB 1 CA (CAN) ON TAKEOFF, GEAR HANDLE INITIALLY WOULD NOT COME UP AND ASSOCIATED OVERHEAD ISOLATION VALVE ILLUMINATED. AFTER FLA P RETRACTION TOCWS SOUNDED FOR TWO MINUTES, THEN STOPPED AND GEAR CAME UP NORMAL.AIR SAFETY SENSOR REPLACED AND TESTED S ERV. GROUND SPOILER INTERLOCK VALVE CABLE ADJUSTMENT TESTED SERV. GEAR SWINGS CARRIED OUT. AIRCRAFT GEAR OPERATED NORM ALLY. 2 L 7 2 4F 4 F A16WE E2EA 2005041800152 20050418 00152 NM 2005 4 18 CA041108010 1 20041106 G 5330 SKIN BOEING 737 7372Q9 138448M NM PWA JT8 JT8D9A 52048 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) FUSELAGE CRACK FOUND ON OUTER SKIN AT STN 767 STR 18L, 0.875 INCHES LONG. CRACK REPAIRED IAW SRM 53-30-3 FIG 48 SH EET 32 DETAIL X REV.90. TIMES 61643.42 CYCLES 57682. 2 L 7 2 4F 4 F A16WE E2EA 2004122200120 20041222 00120 EU 2004 12 22 CA041108011 1 20041108 G 1420 WIRE HARNESS AIRBUS A330 A330* EU RROYCE RB211 RB211TRENT77 NE LIGHT CHAFED W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA (CAN) FOUND DAMAGE TO 932 HOUSING ASSEMBLY AT 12 AC. THE STOWAGE CLOSET IS LOOSE AT THE TOP. FOUND LCD HARNESS INSIDE CLOSET CHAFED AND SHORTING OUT. DISCONNECTED THE HARNESS AT 6208VC112 (WIRE DIAGRAM). TO FIX THE PROBLEM RED S HOUSING ASSY/ STOWAGE CLOSET REPLACEMENT BEFORE THE HARNESS CAN BE REPAIRED OR REPLACED. 2 L 7 2 4F 4 F RT A46NM E39NE 2004122900175 20041229 00175 EA 2004 12 29 CA041109001 2 20041021 G 8520 CRANKCASE LYC O540 O540E4C5 41532 EA ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA POSSIBLE CRACK FOUND DURING 100 HR INSPECTION. ENGINE REMOVED AND SENT TO AEROTER ENGINES IN HALIFAX. ENGINE SHOP CONF IRMED CRACK BETWEEN NR 2 AND NR 4 CYLINDER ON BOTTOM SIDE. IT ALSO HAD EXCESSIVE FRETTING ON THE CENTER MAINS. 3 O E295 2004122900176 20041229 00176 EU 2004 12 29 CA041109002 1 20041024 G 2140 1379219L401 DUCT BAG JETSTM JETSTM3101 1500215 EU GARRTT TPE331 TPE33110U 01514 WP ROTOL R333 R333482F12 GL CABIN HEAT CONTAMINATED W C H ABORTED TAKEOFF DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS TO TAKEOFF 1 CA AFTER T/O CREW ADJUSTED TEMP CONTROL TO WARM UP CABIN. SHORTLY AFTER CABIN START’S TO FILL WITH SMOKE. TEMP WAS REDUCE D, ATC NOTIFIED OF PROBLEM, QRH DRILL FOLLOWED. SMOKE CLEARED, A/C LANDED BACK IN 4 MM WITHOUT INCIDENT. MX INSPECTION REVEALED, INSULATION ON THE UNDERSIDE OF HEAT DUCT BENEATH FLOOR HAD ABSORBED HYD FLUID FROM A PREVIOUS HYD LEAK. TEMP INCREASE WITHIN DUCTING C CAUSED OIL SOAKED INSULATION TO EMIT A HAZE OR SMOKE CONDITION. HEAT DUCT WAS REPLACED AND F UNCTION TEST SERVICEABLE. 2 L 7 2 4T 4 T RT A21EU E4WE 6 C P61GL 2005021500001 20050215 00001 CE 2005 2 15 CA041109003 1 20041101 G 5610 MS250852BB5 GROUND WIRE PPG BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE WINDSHIELD HEAT BURNED W A UNSCHED LANDING B J SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CR CRUISE 1 CA 03042R6137 (CAN) DURING CRUISE FLT AT FL210, THE FLIGHT CREW DETECTED AND ODOR FOLLOWED BY SMOKE EMANATING FROM THE DASH AREA. THEY DONNED MASKS AND REQUESTED PRIORITY LANDING . THEY RAN THRU THEIR EMERGENCY PROCEDURES AND AFTER THE WINDSHIELD HEAT WA S SELECTED OFF THE SMOKE DISSIPATED. AN UNEVENTFUL LANDING WAS COMPLETED AND AIRCRAFT BROUGHT TO MAINTENANCE. MAINTENA NCE FOUND THAT THE GROUND WIRE HAD CONTACTED THE DASHBOARD EYEBROW AND THE HEAT HAD CAUSED IT TO SMOLDER. THE WIRE WAS REPLACED AND ROUTED TO ENSURE NO CONTACT CAN BE MADE WITH ANYTHING. A FLEETWIDE INSPECTION IS BEING CARRIED OUT AT THIS TIME AND WILL LEAVE SDR OPEN UNTIL TOTAL RESULTS. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2005041800153 20050418 00153 CE 2005 4 18 CA041109004 1 20041003 G 2710 040010741 CONTROL CABLE CESSNA 150 150M 2071830 CE CONT O200 O200A 17020 SO MCAULY 1A102 1A102OCM GL AILERON CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AILERON CONTROL CABLE FOUND CORRODED AT COPILOT FOOT AREA. THIS PROBLEM HAS BEEN NOTICED ON OTHER CESSNA 150. SUSP ECT DIRT FROM SHOES CAUSING CORROSION. TO SEE THE CABLE YOU NEED TO REMOVE COVER (YOKE) AND MOVE AILERON TO TRAVEL LIMIT S. 1 H 7 1 3O 3 O 3A19 E252 5 N P918 2005041800154 20050418 00154 EU 2005 4 18 CA041109005 1 20041109 G 6340 WARNING SYSTEM SNIAS 350 AS350B3 8680954 EU TMECA ARRIEL ARRIEL2B NE LOW ROTOR RPM MALFUNCTIONED W C ABORTED TAKEOFF P NO WARNING INDICATION TO TAKEOFF 1 CA (CAN) WHEN PILOT OR COPILOT TRANSMIT, THE LOW ROTOR RPM AUDIO WARNING & GONG ARE MUTED. THESE INPUTS SHOULD BE UNMUTED W HEN TRANSMITTING. 1 G 7 1 3U 3 U H9EU E00054EN 2005041800155 20050418 00155 SW 2005 4 18 CA041109006 1 20040915 G 6320 206031633105 DRAG PIN BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL MAIN ROTOR UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING INSPECTION THE DRAG LINK BEARING WAS FOUND SMOKING. THIS A NEW STYLE IN WHICH BEARING AND NOT WHOLE ASSEMBL Y IS REPLACED. NEW BEARING INSTALLEDNOTE: THIS STYLE OF BEARING WAS INTRODUCED THROUGHT B206-00-173 TO ELIMINATE THE PRO BLEM WITH THE STAKING COMING LOOSE. SUBJECT BEARING WAS NOT KEPT FOR WARRANTY SUBMISSION. 1 G 7 1 3U 3 U H2SW E4CE 2004121000008 20041210 00008 SW 2004 12 10 CA041109007 1 20040907 G 2810 6895171 CHECK VALVE BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL FUEL SYSTEM UNSERVICEABLE W O OTHER O OTHER TX TAXI/GRND HDL 1 CA (CAN) UPON TROUBLESHOOTING FOR STARTING SNAG, FOUND THAT FUEL WASN'T BEING DELIVERED TO THE FUEL NOZZLE. REPLACED CHECK VALVE. THE REMOVED VALVE WAS FOUND TO HAVE A CRACKING PRESSURE OF APPROXIMATELY 15 PSI. 1 G 7 1 3U 3 U H2SW E4CE 2004122300023 20041223 00023 SW 2004 12 23 CA041109008 1 20040927 G 2897 WIRE SIMMONDS BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA FUEL QTY IND ARCED W O OTHER A FLAME/FIRE CR CRUISE 1 CA 642C (CAN) FUEL QUANTITY REPORTED AS FLUCTUATING. DURING TROUBLESHOOTING PROCESS ONE OF THE WIRES ON THE RT TANK FORWARD FUE L PROBE WAS FOUND ARCING. PROBE REPLACED. 1 G 7 1 4U 4 U H4SW E22EA 2005020100088 20050201 00088 NM 2005 2 1 CA041110001 1 20041108 G 2781 PROXIMITY SENSOR BOEING 737 737200 1384453 NM PWA JT8 JT8D15 52051 NE LE SLAT FAILED W O OTHER J WARNING INDICATION LD LANDING 1 CA (CAN) UPON SELECTION OF FLAPS 15 ON LANDING CHECKLIST THE L/E FLAP TRANSIT REMAINED ILLUMINATED AND THE NR 4 SLAT INDICA TOR WAS SHOWING IN TRANSIT. REPLACED AND ADJUSTED NR 4 SLAT PROX SENSOR IAW MM 27-88-11. NR 4 SLAT FOUND DENTED ON UPPE R SURFACE, REPLACED NR 4 SLAT IAW MM 27-81-21. RII CARRIED OUT. UPON FURTHER INVESTIGATION IT WAS FOUND THAT DAMAGE FR OM A PREVIOUS BIRD STRIKE WAS FOUND TO THE SLAT CURTAINS WHICH CAUSED THE DAMAGE TO THE PROX SENSOR. THIS DAMAGE WAS NOT VISIBLE WITHOUT REMOVING L/E PANELS. 2 L 7 2 4F 4 F A16WE E2EA 2005041800156 20050418 00156 NE 2005 4 18 CA041110002 2 20040911 G 7230 COMPRESSOR WHEEL SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE ENGINE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) MO 2/3 FIRST STAGE WHEEL RUBBING ON THE PLASMA SPRAY IN LINER.. (PLASMA LIFTINGOFF IN TO THE BLADE PATH.) 1 G 7 1 3U 3 U NC H9EU E19EU 2005041800157 20050418 00157 SW 2005 4 18 CA041110003 1 20040729 G 6210 206011016201133 BLADE BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL MAIN ROTOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 14121 (CAN) DURING DI, THE TIP BLOCK WAS FOUND CRACKED ADJACENT TO IMPACT MARK. 1 G 7 1 3U 3 U H2SW E4CE 2005041800158 20050418 00158 CE 2005 4 18 CA041110004 1 20041029 G 5712 042650720 RIB CESSNA 150 150L 2071826 CE CONT O200 O200A 17020 SO RT WING CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 21695 (CAN) THE RIB WAS FOUND CRACKED AROUND ONE OF THE STRENGTHENING DIMPLES OF THE RIB, ABOUT 1.5 INCHES IN LENGTH. A NEW PA RT WAS INSTALLED AS REQUIRED. 1 H 7 1 3O 3 O 3A19 E252 2005031400077 20050314 00077 CE 2005 3 14 CA041110005 1 20041029 G 5753 05232113 FLAP TRACK CESSNA 150 150L 2071826 CE CONT O200 O200A 17020 SO MCAULY 1A101 1A101HCM GL RT WING WORN W K NONE O OTHER IN INSP/MAINT 1 CA 21695 (CAN) ON INSPECTION FLAP TRACK GROOVES WERE FOUND BADLEY WORN. PARTS WERE REPLACED AS REQUIRED. 1 H 7 1 3O 3 O 3A19 E252 5 N P918 2005041900001 20050419 00001 CE 2005 4 19 CA041110006 1 20041029 G 5753 0523113 FLAP TRACK CESSNA 150 150L 2071826 CE CONT O200 O200A 17020 SO LT WING WORN W K NONE O OTHER IN INSP/MAINT 1 CA 21695 (CAN) ON INSPECTION FLAP TRACK GROOVES FOUND BADLEY WORN,PARTS WERE REPLACED AS REQUIRED. 1 H 7 1 3O 3 O 3A19 E252 2004121000009 20041210 00009 CE 2004 12 10 CA041110007 1 20041029 G 5310 04118685 DOOR FRAME CESSNA 150 150L 2071826 CE CONT O200 O200A 17020 SO FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 21695 (CAN) ON INSPECTION FOUND CRACKED AT UPPER FWD RADIUS ABOUT 1.0 INCH IN LENGTH. PART WAS REPLACED AS REQUIRED. 1 H 7 1 3O 3 O 3A19 E252 2004122300024 20041223 00024 EU 2004 12 23 CA041110008 1 20040930 G 6720 350A27118120 PLATE SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE TAILBOOM MISSING W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA DURING AN INSPECTION OF THE CABLE ASSEMBLY, THE BACKING PLATE FOR THE CABLE SUPPORT BEARING AT THE TAIL BOOM/AIRFRAME JU NCTION WAS FOUND TO BE MISSING. AIRCRAFT GROUNDED AND A PLATE INSTALLED. THE MISSING PLATE RESULTED IN EXCESS PLAY IN THE TAILROTOR PEDAL CONTROL. 1 G 7 1 3U 3 U NC H9EU E19EU 2004122300027 20041223 00027 NE 2004 12 23 CA041110009 2 20041108 G 7421 9550175400 IGNITER SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE ENGINE UNSERVICEABLE W O OTHER O OTHER TX TAXI/GRND HDL 1 CA (CAN) WHILE TROUBLESHOOTING A SLOW STARTING ENGINE, THE LT IGNITER PLUG WAS REMOVED FOR INSPECTION. AN OPERATIONAL (SPA RK) CHECK WAS CARRIED OUT WITH NO DEFECTS FOUND. UPON A SECOND LOOK AT THE IGNITER, IT WAS NOTICED THE SEMI CONDUCTOR S URROUNDING THE CENTRAL ELECTRODE WAS EXTENDED 1/16 OF AN INCH AND LOOSE. THE MAINTENANCE LOG SHOWS THE IGNITER WAS INSTA LLED NEW ON SEPT 22 2003 AT AIRFRAME HOURS 11959.5A NEW IGNITER WAS INSTALLED AND A/C RETURNED TO SERVICE. 1 G 7 1 3U 3 U NC H9EU E19EU 2005021500006 20050215 00006 EU 2005 2 15 CA041110010 1 20040820 G 2497 CONNECTOR SNIAS 350 AS350D 8680803 EU LYC LTS101 LTS101600A2 41560 NE BATTERY UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 CA F2103 (CAN) WHEN INSTALLING A REPLACEMENT BATTERY, NOTICED THE TEMP SENSOR WIRING HARNESS DID NOT HAVE A JUMPER WIRE. FURTHER INSPECTION REVEALED THAT THERE WAS NO SHUNT INSTALLED IN THE CONNECTOR. A REVIEW OF THE CHR SHOWED THAT THE ENTRIES WE RE MADE REGARDING THE SHUNT AD AND WIRING HARNESS MOD BUT WERE CROSSED OUT (ENTERED IN ERROR). A WIRE JUMPER WAS INSTAL LED ON THE HARNESS PRIOR TO BATTERY INSTALLATION. 1 G 7 1 3U 3 U H9EU E5NE 2005041900002 20050419 00002 EU 2005 4 19 CA041110011 1 20040722 G 6720 350A33105803 BELLCRANK SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE TAIL ROTOR UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THE BELL CRANK WAS REMOVED TO DETERMINE THE SOURCE OF RADIAL PLAY. UPON REMOVAL OF THE BELLCRANK FROM THE GEARBOX TWO BUSHINGS FELL OUT OF THE BELLCRANK. 1 G 7 1 3U 3 U NC H9EU E19EU 2005041900003 20050419 00003 CE 2005 4 19 CA041110012 1 20041025 G 3222 NAS464P5A42 BOLT CESSNA CESSNA 206 U206C 2073332 CE CONT O520 IO520F 17032 SO NLG STRUT SHEARED W E ENGINE SHUTDOWN D INFLIGHT SEPARATION LD LANDING 1 CA (CAN) BOLT SHEARD ON LANDING CAUSING NOSE GEAR TO PIVOT FORWARD.NOTE - THIS BOLT WAS LAST CHANGED SEPT.9/94 AT 2875.1 T. T. (AIRCRAFT PRESENT T.T. IS 6238.7 HRS) THIS AIRCRAFT HAS OPERATED ON SKIS (SUSPECT THAT BOLT WAS OVERSTRESSED IN THIS CONFIGURATION) THIS BOLT WAS CRACKED PRIOR TO FAILURE AS HALF OF FRACTURE IS BLACK & TOTAL FAILURE IS WHITE. SOME DAMAGE TO AIRFRAME WAS ENCOUNTERED. BOLT WILL BE DELIVERED TOT.C. IN WHITEHORSE. IT SHOULD BE NOTED THAT INSPECTION OF THIS BO LT IS NOT REFE RENCE IN INSPECTION SCHEDULE. 1 H 7 1 3O 3 O A4CE E5CE 2005041900004 20050419 00004 NE 2005 4 19 CA041110013 2 20041109 G 7321 8063005B FUEL CONTROL BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE ENGINE BINDING W K NONE O OTHER IN INSP/MAINT 1 CA PS0157 (CAN) PILOTS REPORTED THAT WHEN LT POWER LEVER WAS ADVANCED, THE LT FUEL CONDITION LEVER WOULD MOVE AFT FROM HIGH IDLE T OWARD LOW IDLE. THIS COULD BE REMEDIED BY SETTING THE FRICTION TO A HIGHER VALUE THAN NORMAL. THE LT ENGINE WAS INSPECTE D BY MAINTENANCE AND EVEN WITH BOTH COCKPIT LEVERS DISCONNECTED FROM THE UNIT, IF YOU MANUALLY MOVED THE INPUT ARM OF TH E FCU, THE FUEL CUTOFF PORTION WOULD ALSO BE AFFECTED. THE BINDING WAS INTERNAL AND INPUTS TOHIGHER POWER LEVER SETTINGS WOULD ALSO MOVE FUEL CUTOFF TOWARDS CUTOFF POSTION. THE FCU WAS REPLACED AND AIRCRAFT GROUND TESTED SERVICABLE. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2005041900005 20050419 00005 2005 4 19 CA041110014 4 20041101 G 3445 F23B22 WIRE LEAR 60 60LEAR 5170707 CE PWA 305 PW305A 52128 NE COMPUTER MISUSED W O OTHER F H FLT CONT AFFECTED ELECT. POWER LOSS-50 PC LD LANDING 1 CA (CAN) DURING A FLT, PILOT REPORTED AILERON AUGMENTATION MODE SYS INOPERATIVE. A LEARJET GPWS/WINDSHEAR SYS INSTALL COMPL ETED ON 09/30/94 REMOVED & A NEW TAWS 8000 SYS UPGRADE INSTALLED ON 05/29/04. FURTHER INVESTIGATION REVEALED THAT DURIN G GPWS/WINDSHIELD UPGRADE TO TAWS 8000, GPWS AUX BOX (E374) HAD BEEN REMOVED AS REQUIRED BY DRAWING WHILE REMAINING WIRE S CAPPED & STOWED & DID NOT TAKE INTO CONSIDERATION USEFULNESS OF WIRES F23B22, TW89A22, F25B22, TW91A22 TO SPOILERON CO MPUTER. A REQUEST FOR ENGINEERING SUPPORT WAS FORWARDED & A REVISED DRAWING 1003421 REV B PROVIDED TO CORRECT ORIGINAL DRAWING AND WIRE OVERSIGHT INCLUDING DATA APPROVAL DOCUMENTED ON 10/22/04. 2 L 7 2 4F 4 F RT A10CE E35NE 2004121000012 20041210 00012 CE 2004 12 10 CA041110015 1 20041101 G 5510 07122071 REINFORCEMENT CESSNA 180 180C 2072608 CE CONT O470 O470L 17026 SO MCAULY 2A34C 2A34C66 GL HORIZONTAL STAB CRACKED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) HORIZONTAL STABILIZER WAS REMOVED TO ACCESS RT FUSELAGE SIDE SKIN REPLACEMENT (COSMETIC) WITH STABILIZER REMOVED V ISIBLE ACCESS TO AFT FUSELAGE STRUCTURE REVEALED A CRACK AT THE LT AFT STABILIZER ATTACH LONGERON PN 0712207-1 - REF. CE SSNA 180-C I.P.C. FIG 35 ITEM 35. NOTE AIRCRAFT HAS BEEN OPERATED ON SKIS AND HANDLING OF THE HORIZONTAL STAB MAY BE A CONTRIBUTING FACTOR. THOUGH NOT CALLED FOR IN THE CESSNA INSPECTION CHECK SHTS, IT WOULD BE PRUDENT TO REMOVE BOTH VERT ICAL AND HORIZONTAL STABILIZERS FOR BETTER VISUAL/INTERNAL INSPECTION ON A REGULAR BASIS. IE. 400 HRS/5 YEARS. 1 H 7 1 3O 3 O 5A6 E273 5 C P3EA 2004122300034 20041223 00034 EU 2004 12 23 CA041110016 1 20041028 G 6730 AC67244 SERVO SNIAS 350 AS350B 8680801 EU TMECA ARRIEL ARRIEL1B 6OO30 NE CYCLIC STICK MALFUNCTIONED W O OTHER O OTHER TX TAXI/GRND HDL 1 CA WHEN HYDRAULIC POWER IS RE-ESTABLISHED AFTER DOING HYDRAULIC ACCUMULATOR PREFLIGHT CHECK, THE CYCLIC STICK WOULD GO HARD LEFT, BUT WAS ABLE TO BE OVERCOME AND WOULD ONLY LAST BRIEFLY. LEFT HAND SERVO WAS REPLACED FOR TROUBLESHOOTING AND PR OBLEM WAS RECTIFIED. ALL FUNCTIONS NORMAL. 1 G 7 1 3U 3 U H9EU E19EU 2004122300035 20041223 00035 EU 2004 12 23 CA041110017 1 20040904 G 2822 P94B12203C PUMP SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE FUEL BOOST UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 CA BOOST PUMP FOUND LEAKING DURING DI. UPON FURTHER INVESTIGATION FOUND PUMP LEAKING INTERNALLY. PUMP REPLACED. 1 G 7 1 3U 3 U H9EU E19EU 2004122300036 20041223 00036 GL 2004 12 23 CA041110018 3 20041110 G 6111 83867 CLAMP SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP HARTZL HCB3T HCB3TN5 GL PROPELLER BLADE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA PROPELLER RECEIVED FOR INSPECTION UNDER AD 88-24-15. DURING ROUTINE VISUAL INSPECTION OF THE BLADE CLAMP ASSEMBLES, A C RACKED WAS DETECTED IN ONE OF THE OUTBOARD CLAMP BOLT HOLES ON S/N EE1910. CLAMP HAS BEEN REMOVED FROM SERVICE AND REPL ACED WITH AN OVERHAULED ASSY. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P15EA 2005020100089 20050201 00089 CE 2005 2 1 CA041110019 1 20041108 G 5751 57150021 SUPPORT BRACKET CESSNA 441 441 2076020 CE GARRTT TPE331 TPE33110 01514 WP MCAULY 3G34C6 3GFR34C601 GL BELLCRANK CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AILERON BELLCRANK SUPPORT BRACKET WAS DISCOVERED TO BE CRACKED. PART WAS REPLACED WITH A NEW BRACKET AND THE AIRCR AFT RETURNED TO SERVICE. 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P54GL 2005041900006 20050419 00006 CE 2005 4 19 CA041112001 1 20041108 G 3230 POWERPACK BEECH 99 99A 1154003 CE PWA PT6 PT6A27 52043 EA RT MLG FAULTY W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) A/C WAS SITTING ON RAMP PARKED, RT MAIN LANDING GEAR COLLAPSED. SUSPECT HYDRAULIC POWER PACK AT FAULT. 1 L 7 2 3T 4 T A14CE E4EA 2005041900007 20050419 00007 EU 2005 4 19 CA041112002 1 20041109 G 2612 D237060 FIRE LOOP BRAERO 748 HS7482A 4231001 EU RROYCE DART DART5342 EU NR 2 ENGINE DAMAGED W E ENGINE SHUTDOWN N FALSE WARNING CR CRUISE 1 CA (CAN) FIRE BELL AND LIGHT ON NR 2 ENGINE CAME ON IN CRUISE. ENGINE NR 2 SHUTDOWN. LANDED WITHOUT INCIDENT. FOUND FIRE L OOP P/N D2370-60 DAMAGED, REPLACED LOOP WITH NEW PART TESTED SERVICEABLEGROUND RUN. NO FAULTS FOUND RETURNED AIRCRAFT TO SERVICE 2 L 7 2 3T 4 T A24EU A196 2005041900008 20050419 00008 NM 2005 4 19 CA041112003 1 20040816 G 3234 574205A SELECTOR DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE MLG MALFUNCTIONED W O OTHER O OTHER AP APPROACH 1 CA (CAN) UNABLE TO EXTEND GEAR DURING APPROACH. THE THREE INDICATIONS LIGHTS REMAINS IN RED AND THE LG SELECTOR HANDLE WAS AMBER. EMERGENCY LANDING GEAR EXTENSION CARRIED OUT.LANDING GEAR SELECTOR VALVE, STRIPREPORT FOUND CORE ASSY. HAD MUSHRO OMED & WAS OUT OF ROUND AT THE TOP. UNIT OVERHAULED. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005041900009 20050419 00009 CE 2005 4 19 CA041112004 1 20041112 G 2913 1153800025 PUMP BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCD4N3 HCD4N3A GL HYD SYS FAILED W O OTHER J WARNING INDICATION CL CLIMB 1 CA 2652 (CAN) ON TAKE OFF, GEAR WOULD NOT RETRACT. NOSE GEAR GREE LIGHT WENT OUT, AND RED INTRANSIT LIGHT REMAINED ON. GEAR WOUL D NOT RETRACT OR EXTEND.PRIOR TO LANDING THE BACKUP EXTENSION SYSTEM WAS USED, AND ALLGEAR INDICATIONS WERE THAT THE GEA R WAS DOWN AND LOCKED. SUBSEQUENT INVESTIGATION REVEALED THAT THE HYDRAULIC PUMP MOTOR WAS UNSERVICEABLE.THE PUMP MOTOR IS A TIME TRACKED ITEM WITH A 1200 HOUR TBO. 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2004121000013 20041210 00013 WP 2004 12 10 CA041112005 1 20041110 G 6310 369D25351SN58 SPRAG CLUTCH HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL MAIN ROTOR BROKEN W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) CLUTCH REMOVED FOR GREASE BEARING REPLACEMENT. UPON INSPECTION 2 SPRAGS FOUND BROKEN. 1 G 7 1 3U 3 U H3WE E4CE 2004122900168 20041229 00168 NE 2004 12 29 CA041115001 2 20041111 G 7200 ENGINE CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE RIGHT MALFUNCTIONED W E ENGINE SHUTDOWN J WARNING INDICATION CR CRUISE 1 CA 12145 807618 DURING CRUISE, THE RT ENG OIL PRESSURE SLOWLY DROPPED BELOW 25 PSI AND OIL TEMPERATURE SLOWLY DROPPED FROM 106 TO 81 DEC C. PERFORMED PRECAUTIONARY SHUTDOWN OF RT ENG. PERFORMED DRY MOTOR AND SERVICED ENGINE OIL. PERFORMED OIL CONSUMPTIO N RUN: 2.5 QTS USED IN 1 HR OIL CONSUMPTION TOO HIGH. ENGINE REPLACED. 2 L 7 2 4F 4 F RT A21EA E15NE 2004122900169 20041229 00169 NE 2004 12 29 CA041115002 3 20041112 G 6111 SFA13MIROADE BLADE DHAV DHC8 DHC8* NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE PROPELLER BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA 29896 8910089347 DETAILS EXTRACTED FROM MAJOR DEFECT REPORT: DAMAGE IN THE FORM OF SLASH TYPE CUTS TO THE DE-ICE BOOT WAS FOUND ON THE RI GHT PROPELLER, NR 3 BLADE, WHICH AS A RESULT REQUIRED THE PROPELLER BLADE TO BE REPLACED. DURING REPLACEMENT OF THE NR 3 BLADE SERIAL NUMBER 851372 ENGINEERS DISCOVERED THAT THE BLADE COLLARS WERE MISSING FROM THE NR 4 BLADE ASSY. SEPARAT ION OF THE BLADE COLLARS IS CURRENTLY UNDER INVESTIGATION BY THE TSB DUE TO A PREVIOUS COLLAR SEPARATION AND IMPACT DAMA GE ON ANOTHER AIRCRAFT. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005031100011 20050311 00011 NE 2005 3 11 CA041115003 2 20041101 G 7321 32447594 FCU CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE ENGINE FAILED W C ABORTED TAKEOFF R J PARTIAL RPM/PWR LOSS WARNING INDICATION TO TAKEOFF 1 CA (CAN) ENGINE START CARRIED OUT NORMAL, AIRCRAFT TAXIED FOR TAKEOFF. POWER SETTINGS WERE SET AND RT ENGINE DID NOT ACCEL ERATE. MAX TURBINE SPEED WAS 56 PERCENT (37 PERCENT FAN) CREW ABORTED TAKE OFF AND RETURNED TO BASE. MAINTENANCE PERFO RMED THE TROUBLESHOOTING PROCEDURES INDICATED IN PWA MM AND DETERMINED FAULT WAS FUEL CONTROL UNIT. FCU 3244759-4 (S/N A58173N) REPLACED AND AIRCRAFT ENGINE RUNS AND RIGGING CARRIED OUT SATISFACTORY. AIRCRAFT RELEASED BACK TO SERVICE NOV . 05. 1 L 7 2 4F 4 F A22CE E1NE 2005020700003 20050207 00003 CE 2005 2 7 CA041115004 1 20041111 G 2434 GENERATOR BEECH 99 99 1154002 CE PWA PT6 PT6A20 52043 EA HARTZL HCB3T HCB3TN3 GL ELECTRICAL INTERMITTENT W A UNSCHED LANDING H ELECT. POWER LOSS-50 PC CL CLIMB 1 CA (CAN) ON CLIMB OUT THE PILOT OBSERVED THAT ONLY ONE GENERATOR WAS ACCEPTING LOAD. DECIDED TO RETURN TO DEPARTURE AERODR OME WITHOUT CARRYING OUT ANY CONFIRMATION CHECKS. A SUBSEQUENT MAINTENANCE INSPECTION DETERMINED THAT AT LIGHT ELECTRIC AL LOADS BOTH GENERATORS DO NOT ALWAYS STAY ON LINE. BOTH GENERATORS WERE CONFIRMED TO BE WORKING. BOTH GENERATOR INDICA TING SYSTEMS WERE CONFIRMED TO BE FUNCTIONAL. 1 L 7 2 3T 3 T A14CE E4EA 6 C P15EA 2005041900010 20050419 00010 2005 4 19 CA041115005 4 20041111 G 3197 WIRE HARNESS CNDAIR CL601 CL6013A 8070802 EA INSTRUMENT PANEL DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) PILOT'S EFIS EADI WIRE BUNDLE CHAFING 12 INCHES FROM CONNECTOR 1P3FH. WIRE BUNDLE CONSISTS OF SEVERAL SHIELDED TWI STED PAIR. SOME WIRE FOUND TO HAVE ABRADED INTO CENTER CONDUCTOR. WIRES FH215D24, FH216D24, 1FH108A24, 1FH109A24, FH230D 24, FH231D24, 1FH116A24, FH117A24, 1FH275A24, AND 1FH276A24 REPAIRED BY SPLICING IAW WM. THERE WERE NO PREVIOUS FAULT IN DICATION, BUT WIRING COMPROMISED TO THE EXTENT THAT FAILURE WAS FORTHCOMING. IT WAS DETERMINED THAT WIRING WAS RUBBING O N EHSI CONNECTOR WHICH IS INSTALLED DIRECTLY BELOW EADI. THERE WAS NO WIRE PROCTION SLEEVE INSTALLED AT THE DAMAGED AREA . CO-PILOTS EADI AND EHSI WIRING INSPECTED AND FOUND ONLY MINOR CHAFING, WITH THE POTENTIAL TO DEGRADE OVER TIME. 2 L 7 2 4F RT A21EA 2005041900011 20050419 00011 EU 2005 4 19 CA041115006 1 20041111 G 2913 704A34310006 HOUSING SNIAS 350 AS350D 8680803 EU LYC LTS101 LTS101600A 41560 NE HYD PUMP DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA 80645856 (CAN) DURING A ROUTINE 100 HRS INSPECTION, IT WAS NOTICED THAT THE HYDRAULIC FILTER WAS CONTAMINATED WITH NON-FERROUS ME TAL SHAVINGS. THE PUMP HOUSING IS MADE OF ALUMINIUM THEREFORE WE SUSPECT THE GEAR ROTORS STARTED TO WEAR THROUGH THE SOF TER HOUSING.THE PUMP WAS REPLACED WITH A NEW ONE AND THE SYSTEM FLUSHED. THE A/C WAS RETURNED TO SERVICE. 1 G 7 1 3U 3 U H9EU E5NE 2004121000014 20041210 00014 SO 2004 12 10 CA041115007 1 20041111 G 3220 4027300 TRUNNION PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA NLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING INSPECTION TWO CRACKS WERE FOUND IN THE UPPER CENTER AREA OF THE TRUNNION. IT APPEARS THAT THE CRACKS ORIG INATED IN A REPAIRED AREA THAT WAS WELDED. THE CRACKS WERE DETECTED VISUALLY. 1 L 7 2 3O 3 O A20SO E14EA 2004122300001 20041223 00001 EA 2004 12 23 CA041115008 2 20041111 G 8530 LW16740 EXHAUST VALVE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA ENGINE ERODED W K NONE O OTHER IN INSP/MAINT 1 CA WHEN THE EXHAUST PIPES WERE REMOVED TO INSPECT THE EXHAUST VALVES, IT WAS FOUND THAT ALL SIX VALVES ON THE ENGINE HAD ER OSION WEAR ON THE STEMS AND THE BACK SIDE OF THE VALVE FACE. THIS IS THE SECOND ENGINE THAT THIS PROBLEM HAS BEEN FOUND ON IN OUR FLEET. 1 L 7 2 3O 3 O A20SO E14EA 2004122300002 20041223 00002 EU 2004 12 23 CA041116001 1 20041105 G 2997 9740926112 RELAY PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL HYDRAULIC SYS FAILED W O OTHER J WARNING INDICATION TO TAKEOFF 1 CA ON TAKEOFF, PILOT SELECTED MLG UP, A HYD CAUTION & WARNING SYS LAMP, MASTER CAUTION & AURAL GONG ACTIVATED. MLG SELECTED DOWN NO CHANGE OBSERVED & MLG SELECTED UP NO CHANGE OBSERVED. HYD C/B PULLED. INDICATION OF A RED NLG LIGHT & GREEN M LG LIGHTS. PILOT FLEW ACFT BACK TO MAIN BASE, WITH MLG DOWN. ON APPROACH, MLG SELECTED DOWN & EMERGENCY GEAR HANDLE WAS USED TO APPLY DOWN PRESSURE & TO CONFIRM THAT THERE WAS HYD PRESS. ALL 3 GREEN MLG LIGHTS ILLUMINATED. ACFT DID A LOW F LY OVER TO CONFIRM DOWN. LANDING UNEVENTFULL. HYD POWER RELAY FOUND FAILED. HYD POWER RELAY REPLACED. MLG RETRACTION & E XTENTION TEST PERFORMED, NO DEFECTS. ACFT RETURNED TO SERVICE. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004122300003 20041223 00003 SW 2004 12 23 CA041116002 1 20041108 G 2910 2781006143 TUBE SWRNGN SA227 SA227AC 8780603 SW MCAULY 4HFR34 4HFR34C652 NE HYD SYSTEM CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA HYDRAULIC FLUID WAS OBSERVED LEAKING FROM BELLY OF AIRCRAFT. FURTHER INSPECTION REVEALED A CRACK IN THE 90 DEGREE BEND SECTION OF THE TUBE. THE LINE WAS REPLACED AND AIRCRAFT RETURNED TO SERVICE. NOTE: THIS LINE IS NOT INCLUDED IN THE LI ST IF LINES REQUIRING A SPECIAL INSPECTION IN ACCORDANCE WITH SB 227-29-005, YET THE LINE DOES PASS THE CRITERIA INCLUDE D IN THE SB. 2 L 7 2 4T RT A8SW 6 C 3PNE 2005021400196 20050214 00196 NE 2005 2 14 CA041116003 2 20041116 G 8520 261280 CRANKSHAFT DHAV DHC2 DHC2* 2800108 EA PWA R985 R985AN14B 52008 NE HAMSTD 22D 22D30 NE ENGINE FAILED W A UNSCHED LANDING O OTHER CR CRUISE 1 CA JP201660 (CAN) CRANKSHAFT FAILED AT THE MALE SPLINE NEAR THE NECKED DOWN AREA NEXT TO THE BUTT FACE IN THE FRONT CRANKSHAFT (P/N 261279). CRANKSHAFT IS BEING HELD FOR POSSIBLE FURTHER INVESTIGATION. 1 H 7 1 3R 3 R A806 5E1 5 C P736 2005031400071 20050314 00071 EA 2005 3 14 CA041116004 1 20040924 G 5510 S203307 HINGE BRACKET FOUND FBA FBA2C 3640102 EA LYC O540 AEIO540L1B5 41532 NE HARTZL HCC3Y HCC3YR GL STABILIZER LOOSE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING COMPLETION OF SGB 55-02R1 STABILIZER ATTACHMENT HINGE BRACKET BOLTS FOUND LOOSE (TURN BY FINGERS). 1 H 7 1 3O 3 O A7EA 1E4 5 C P25EA 2005031400072 20050314 00072 EU 2005 3 14 CA041116005 1 20041104 G 5753 25CF263321A SHAFT BAC BRAERO DH125 BAE125800A 1500285 EU GARRTT TFE731 TFE7315R 01518 WP FLAP VANE WORN W K NONE O OTHER IN INSP/MAINT 1 CA DHB511 (CAN) UPON PERIODIC INSPECTION IT WAS NOTED THAT THERE WAS APPARENT CONTACT BETWEEN THE IB FLAP VANES ON BOTH LT AND RT ASSEMBLIES ONTO THE TORQUE SHAFT AND BEVEL HOUSING ASSY. THIS UNUSUAL CONTACT WAS DEDUCED TO OCCUR DURING FLIGHT LOADS A S THE CLEARANCE BETWEEN THESE ASSEMBLIES AT ITS CLOSEST LOCATION (ABOUT 15 DEGREES OF FLAP DEFLECTION) HAS APPROXIMATELY 0.600' CLEARANCE. EVEN WITH ANY ABNORMAL PLAY CAUSED BY WORN BUSHINGS ON THE ATTACHING HARDWARE OF THE FLAP MECHANISM C OULD NOT PRODUCE THIS KIND OF CONTACT. INVESTIGATION IS ONGOING. 2 L 7 2 4F 4 F RT A3EU E6WE 2005031400073 20050314 00073 EA 2005 3 14 CA041117001 1 20041116 G 5330 SKIN FOUND FBA FBA2C 3640102 EA LYC O540 IO540L1A5 41532 EA HARTZL HCC3Y HCC3YR GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) BELLY SKIN CRACKING AT VARIOUS (MULTIPLE POINTS) RIVETS LOOSENING ON INSPECTION COVER SKIN LAP RIVETS LOOSENING. S USPECTED FROM TURBULENCE CREATED BY PROP INSTALLATION. REPAIRED BY PATCH AND REPLACEMENT OF RIVETS. 1 H 7 1 3O 3 O A7EA 1E4 5 C P25EA 2005031400079 20050314 00079 NM 2005 3 14 CA041117002 1 20041105 G 7933 FRF6E2821P CONNECTOR BOEING 727 727225 1384077 NM PWA JT8 JT8D15A 52051 NE NR 3 ENGINE SHORTED W E J ENGINE SHUTDOWN DUMP FUEL M OVER TEMP CL CLIMB 1 CA (CAN) AT TOP OF CLIMB, THE SECOND OFFICER NOTED AND INFORMED THE CAPTAIN THAT THE NR 3 ENGINE OIL TEMP WAS WELL ABOVE RE DLINE. CREW CARRIED OUT HIGH ENGINE OIL TEMP SUPPORT CHECKLIST WHICH RESULTS IN SHUTTING DOWN THE ENGINE. CREW DUMPED A PPROX. 13,000 LBS OF FUEL AND RETURNED TO DEPARTURE. AIRCRAFT LANDED WITHOUT FURTHER INCIDENT. TROUBLESHOOTING CARRIED O UT BY MAINTENANCE FOUND THE FIREWALL BULKHEAD CONNECTOR SHORTING OUT. AIRCRAFT IS AOG UNTIL REPAIRS AND VERIFICATION ENG INE RUNS CARRIED OUT. 2 L 7 3 4F 4 F A3WE E2EA 2005031100102 20050311 00102 NE 2005 3 11 CA041117003 2 20041015 G 7200 ENGINE PWA PT6 PT6A25 52043 NE FLAMED OUT W A UNSCHED LANDING X J ENGINE FLAMEOUT WARNING INDICATION CR CRUISE 1 CA (CAN) DURING CRUISE (10,000 FT) THE PILOT REPORTED A LOUD NOISE FOLLOWED BY ENGINE FLAMEOUT. AN ATTEMPTED RELIGHT WAS U NSUCCESSFUL AND AN EMERGENCY LANDING WAS PERFORMED. THE ENGINE IS UNDER INVESTIGATION. MFG WILL MONITOR THE PROGRESS AND FINDINGS OF THE INVESTIGATION AND WILL AMEND THIS REPORT TO REFLECT ROOT CAUSE, ONCE ESTABLISHED. 3 T E4EA 2004122300010 20041223 00010 NE 2004 12 23 CA041117004 2 20041115 G 7200 ENGINE CESSNA 560 560XL 2076702 CE PWA 545 PW545A NE FIRE W E A ENGINE SHUTDOWN UNSCHED LANDING A J FLAME/FIRE WARNING INDICATION CL CLIMB 1 CA DB0009 (CAN) SHORTLY AFTER TAKEOFF, THE CREW WERE ADVISED OF SMOKE AND FLAMES EMANATING FROM THE ENGINE. THE ENGINE WAS SECURE D AND AN UNSCHEDULED LANDING WAS PERFORMED AT POINT OF DEPARTURE. P&WC WILL INVESTIGATE THE EVENT AND WILL REVISE THIS REPORT TO REFLECT ROOT CAUSE, ONCE ESTABLISHED. 2 L 7 2 4F 4 F RT A22CE E00059EN 2004122300011 20041223 00011 NE 2004 12 23 CA041117005 2 20041116 G 7200 ENGINE BOEING 737 7372Q9 138448M NM PWA JT8 JT8D9A 52048 NE RIGHT FAILED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA DURING DAILY CHECK, OIL WAS FOUND IN TAILPIPE AND LAST TWO STAGES OF TURBINE SECTION COATED WITH OIL. RT ENGINE SER NR 667210. RT ENGINE REPLACED. ENGINE SER NR ON 667217. TIMES 61700.25 CYCLES 57721. 2 L 7 2 4F 4 F A16WE E2EA 2005020100094 20050201 00094 EU 2005 2 1 CA041117006 1 20041116 G 2910 AC67244 SERVO SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE CHECK VALVE STIFF W K NONE F FLT CONT AFFECTED IN INSP/MAINT 1 CA (CAN) THE PILOT WAS DOING PRE FLIGHT HYDRAULIC TEST IAW FLIGHT MANUAL REQUIREMENTS IAW AWD CF-2003-15R3 AND NOTICED A ST IFFNESS IN THE FLIGHT CONTROLS. THE AIRCRAFT WAS SHUT DOWN. AN ENGINEER WAS NOTIFIED AND STARTED TO TROUBLESHOOT THE PRO BLEM. THIS SERVO WAS REMOVED AND THE DEFECT WAS RESOLVED. THE AIRCRAFT WAS RETURNED TO SERVICE. THIS IS THE INITIAL REP ORT SINCE THE AIRCRAFT IS OUT IN THE FIELD AND REPORTING IS DIFFICULT. THE ENGINEER SUSPECTS THE CHECK VALVE IN THE ACC UMULATOR BLOCK WAS THE PROBLEM. THE AFFECTED SERVO WILL BE IN CITY LATER. 1 G 7 1 3U 3 U H9EU E19EU 2005020100189 20050201 00189 EA 2005 2 1 CA041118001 2 20041026 G 7414 1068291018 MAGNETO PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL ENGINE LOOSE W O OTHER R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 CA (CAN) A RT BREAKER POINT HOLD DOWN SCREW CAME OUT AND CAUSED THE ENGINE TO RUN ROUGH, INTERMITTENTLY. THE MAG WAS REPLA CED AND THE AIRCRAFT RETURNED TO SERVICE. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2005031400064 20050314 00064 NM 2005 3 14 CA041118003 1 20040809 G 5753 MS271113AN3166R WASHER BOEING 727 727221 1384071 NM PWA JT8 JT8D17 52049 NE FLAP TRACK MISSING W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) RT IB AFT MID FLAP (TWO) OB TRACK CARRIAGE ROLLER BOLT TAB WASHERS AND NUTS MISSING. CORRECT HARDWARE INSTALLED, INDEPENDENT CHECK CARRIED OUT. CONTRACTED AMO ADVISED. 2 L 7 3 4F 4 F A3WE E2EA 2005012100173 20050121 00173 SW 2005 1 21 CA041118004 1 20041118 G 5514 3066112 FAIRING AIRTRC AT802 AT802A 0390308 SW PWA PT6 PT6A65AG 52043 NE HARTZL HCB5M HCB5MA3 GL HORIZONTAL STAB MISLOCATED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) DURING ANNUAL INSPECTION THE HORIZONTAL STAB FAIRING SCREW HOLES FOUND TO BE DRILLED THROUGH THE RIVETS ATTCHING T HE SKIN TO THE CLOSING RIBS OF BOTH HORIZONTALSTABS. HOLES WERE LOCATED ON THE LOWER SURFACES ONLY. 7 OF 19 RIVETS WERE DRILL ED ON THE PORT STAB AND 5 OF 19 RIVETS WERE DRILLED ON THE STBD STAB. THE HOLES WERE DRILLED AT TIME OF AIRCRAFT M ANUFACTURE. AIR TRACTOR HAS BEEN NOTIIFIED BY MAINTENANCE PLANNING. 1 L 7 1 3T 4 T NC A19SW E4EA 6 C P44GL 2004122300019 20041223 00019 CE 2004 12 23 CA041119001 1 20041112 G 5711 08113507 SPAR CESSNA 310 310R 2074245 CE CONT O520 IO520M 17032 SO MCAULY 3AF32C 3AF32C87 GL WING CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 12751 WHILE DOING A 100HR INSPECTION ON THE AIRCRAFT, AME'S NOTICED BELLY SKIN ON LOWER RT SIDE WRINKLED. FURTHER INSPECTION REVEALED THAT THE WEB SKIN ON THE REAR OF THE FUSELAGE FRONT SPAR SKIN WAS CRACKED. THE PROTECTIVE TOP CAP OF CARPET WA S REMOVED AND IT WAS DISCOVERED THAT THE UPPER SPAR CARRY THRU WAS BROKEN. AIRCRAFT WAS TAKEN APART AND THE FUSELAGE FR ONT SPAR ASSEMBLY WAS REMOVED AND WILL BE REPLACED. INSPECTION OF THE TECHNICAL RECORDS SHOWED THAT THE AIRCRAFT HAD BE EN DAMAGED AFTER A NOSE GEAR COLLAPSE AND REPAIRED IN 1979. THE SKIN UNDER THE DOOR HAD BEEN REPLACED RIGHT BESIDE THE FUSELAGE FRONT SPAR ASSEMBLY. 1 L 7 2 3O 3 O 3A10 E5CE 5 C P22EA 2004122300020 20041223 00020 SW 2004 12 23 CA041119002 1 20041031 G 7810 LW16620 SEGMENT RKWELL 700 700 7630520 SW LYC O540 TIO540R2AD 41532 EA LT ENG EXHAUST BURNED W K NONE O OTHER IN INSP/MAINT 1 CA L543361A DURING THE INSPECTION OF THE LT ENGINE AFTER IN-FLIGHT STOPPAGE, A HOLE WAS FOUND N AN EXHAUST SEGMENT. DUE TO RESTRICT ED SPACE A HEAT SHROUD THAT CONCEALED THE HOLE COULD NOT BE REMOVED WITHOUT REMOVING THE ENTIRE EXHAUST SYSTEM. THE HOT GASES ESCAPING FROM GROUNDING THE MAG IMMEDIATELY SHUT THE ENGINE DOWN. THE COMPANY INSPECTION PROGRAM HAS BEEN AMENDE D AND NOW REQUIRES THE EXHAUST SYSTEM TO BE REMOVED AND INSPECTED. THIS REQUIRES THE IMMEDIATE INSPECTION AND FOLLOW-UP REMOVAL, INSPECTION EVERY 200 HRS AND TRACKED ON COMPANY INSPECTION SHEETS. 1 L 7 2 3O 3 O A12SW E14EA 2005020100096 20050201 00096 2005 2 1 CA041119003 4 20041119 G 3460 101741111 COMPUTER DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE FMS CONTROLLER FAULTY W A UNSCHED LANDING B H SMOKE/FUMES/ODORS/SPARKS ELECT. POWER LOSS-50 PC CL CLIMB 1 CA (CAN) CREW REPORTED THAT THERE WAS BURNING SMELL AND FOLLOWED SHORTLY BY WISPS OF SMOKE COMING FROM AREA TO THE CAPTAINS SIDE OF CENTER CONSOLE, JUST UNDER HIS INSTRUMENT PANEL. CREW WAS UNABLE TO IDENTIFY SOURCE OF SMOKE, AND CARRIED OUT P ROCEDURES IAW QRH UNIDENTIFIED SMOKE, AND RETURNED TO BASE. CREW CONFIRMED SMOKE STOPPED FOLLOWING QRH PROCEDURES. ENGI NEERING FOUND CIRCUIT BREAKER RNAV 1 ON AVIONICS CB PANEL POPPED LOCATION G4. FMS CONTROLLER/COMPUTER WAS REMOVED, INSP ECTED WITH A STRONG SMELL OF BURNING EMANATING FROM UNIT. WIRING IN GENERAL AREA WAS INSPECTED FOR DAMAGE, AND POWER SUP PLIES AND GROUND VALUES WERE CHECKED FOR PROBLEMS, NONE FOUND. FAULTY FMS UNIT HAS BEEN REMOVED FOR INVESTIGATION. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005020400003 20050204 00003 EU 2005 2 4 CA041119004 1 20041118 G 3222 5322012038 STRUT PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL NLG DIRTY W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) FLT CREW REPORTED THE NLG NOISY WHEN RETRACTED & SCRATCHES WERE SEEN IN THE NOSE WHEEL YOKE. ACFT PLACED ON JACKS & RETRACTION TEST CARRIED OUT. NO DISREPENCIES NOTED. APPEARED NLG OLEO HAD NOT EXTENDED COMPLETELY AFTER TAKEOFF. PRIOR TO RETRACTING MLG, HAD INTERFEERED WITH THE NOSE GEAR DOOR RETRACT MECANISM. STRUT DEFLATED & FOUND TO BE VERY STIFF & COULD NOT BE MOVED UP & DOWN WITH NORMAL HAND PRESSURE. AFTER DISASSEMBLY DIRT FOUND ACCUMULATED UNDER LOWER MICARTA GUI DE BUSHING WITHIN LOWER OLEO RETAINING NUT. ALL PARTS CLEANED & UNIT REASSEMBLED PER MM. UNIT SERVICED & FOUND TO BE FRE E TO MOVE WITH HAND PRESSURE. UNIT PRESSUREIZED & SERVICED PER MM. BINDING OF BUSHING INCREASED WITH COLDER TEMPS. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005020400004 20050204 00004 NE 2005 2 4 CA041119005 1 20041118 G 6320 S613723054001 BEVEL GEAR SKRSKY SKRSKY S61 S61N 8142104 NE GE CT58 CT581401 30011 NE M/R GEARBOX FAILED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA A14K7791120 (CAN) DURING CLIMB OUT THE MAIN GEARBOX CHIP LIGHT ILLUMINATED. AIRCRAFT RETURNED TO SEVICE LANDING.ON INSPECTION, METAL PARTICLES WERE DISCOVERED ON THE CHIP PLUG AND IN THE COARSE SCREEN. THE MGB WAS REMOVED FROM SERVICE. AT DISASSEMBLY O NE TOOTH WAS FOUND MISSING FROM MAIN BEVEL GEAR. OIL/WATER CONTAMINATION WAS ALSO PRESENT. 2 G 7 2 4U 4 U 1H15 1E3 2005031400063 20050314 00063 EU 2005 3 14 CA041119006 1 20041116 G 7921 RK25198A OIL COOLER BRAERO 748 HS7482A 4231001 EU RROYCE DART DART5342 EU ROTOL R4304 R2124304 EU LT ENGINE LEAKING W E ENGINE SHUTDOWN K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA (CAN) ENROUTE, THE LT OIL PRESSURE WARNING LIGHT ILLUMINATED AND OIL PRESSURE WAS SEEN TO DROP. LT ENGINE WAS SHUT DOWN AND A/C LANDED WITHOUT INCIDENT. INVESTIGATION REVEALED LT OIL COOLER WAS LEAKING AND ENGINE OIL CONTENTS WERE LOW. OI L COOLER WAS REPLACED, FILTER AND ENGINE CHECKS WERE CARRIED OUT, A/C RELEASED TO SERVICE. DURING PREVIOUS DAY AC HAD B EEN EXPOSED TO BLIZZARD CONDITIONS WHILE ON GROUND. IT IS BELIEVED THAT SNOW ENTERED OIL COOLER BEFORE ENGINE COVERS CO ULD BE INSTALLED. THIS SNOW MELTED, THEN FROZE INSIDE COOLER MATRIX, CAUSING SOME OF MATRIX TUBES TO CRACK. NEXT DAY, WI TH ENGINE RUNNING, THE ICE MELTED EXPOSING THE MATIX CRACKS, ALLOWING OIL LOSS AND, ULTIMATELY, LOSS OF OIL PRESSURE. 2 L 7 2 3T 4 T A24EU A196 6 C P899 2005020400005 20050204 00005 EU 2005 2 4 CA041119007 1 20041117 G 3246 5006227A WHEEL SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE ROTOL R390 R3904123F27 NE NLG VIBRATION W C ABORTED TAKEOFF E VIBRATION/BUFFET TO TAKEOFF 1 CA (CAN) DEPARTING ON FLT. ON TAKE OFF ROLL NOSEWHEEL SHIMMY AND VIBRATION WAS FELT. THE TAKE OFF WAS ABORTED. MAINTENANCE INSPECTION REVEALED FROZEN GRAVEL AND ICE ON THE INNER RIM OF BOTH NOSEWHEELS. THE NOSE U/C AND SHIMMY DAMPER WAS INSPEC TED, NO DEFECTS WERE FOUND. BOTH NOSEWHEELS WERE CHANGED AND THE A/C RELEASED TO SERVICE. NO SUBSEQUENT VIBRATION WAS RE PORTED. 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P31NE 2004121000016 20041210 00016 WP 2004 12 10 CA041119008 2 20041118 G 7310 30751301 FUEL LINE GARRTT TFE731 TFE7315BR WP ENGINE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING A SCHEDULED OIL PUMP REPLACEMENT SEVERE WEAR WAS FOUND ON THE PRIMARY FUEL MANIFOLD FEED LINE NEAR THE FUEL FLOW TRANSMITTER. THE DAMAGE WAS CAUSED BY CONTACT BETWEEN THE FUEL FLOW TRANSMITTER INLET LINE B-NUT AND THE FEED LIN E DUE TO LACK OF CLEARANCE. MOST OF THE DAMAGE WAS CAUSED BY THE CUTTING ACTION OF THE BNUT AS IT WAS TIGHTENED DURING INSTALLATION OF THE FUEL FLOW TRANSMITTER WHICH HAD BEEN REMOVED 300 HR. EARLIER FOR ENGINE OVERHAUL. TWO OF THE THREE E NGINES ON THE AIRCRAFT HAD SIMILAR DAMAGE. THE DAMAGED LINES WERE REPLACED ON BOTH ENGINES. 4 F E6WE 2004121000068 20041210 00068 EA 2004 12 10 CA041119009 2 20041102 G 7414 S6LN1208 MAGNETO PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2C 41532 EA ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) MAGNETO WAS REMOVED AT ENGINE REMOVAL. MAG WAS SENT IN BECAUSE THE OIL SLINGER RING WAS NOT IN THE GROOVE. TEAR D OWN RESULTED IN THE FOLLOWING FINDINGS, WIRE ROUTING INCORRECT, LEAD WEARING ON COM SCREW, COIL LEAD NOT POSITIONED CORR ECTLY, TUBING MISSING FROM COVER SCREW, EXCESSIVE GREASE LEAKING FROM ROLLER BEARING. IMPROPER GREASE IN BEARING, WRONG WASHERS INSTALLED ON DISTRIBUTOR BLOCK STUDS, DISTRIBUTOR GEAR WASHER WAS WORN ON ID, DISTRIBUTOR BLOCK CRACKED AT ONE OF THE 6 ELECTRODES, VENT SCREEN W AS PAINTED OVER. 1 L 7 2 3O 3 O A20SO E14EA 2004121000069 20041210 00069 SO 2004 12 10 CA041120001 2 20041102 G 8500 ENGINE CESSNA 185 A185F 2072821 CE CONT O520 IO520F 17032 SO MCAULY 3A32C D3A32C90 GL MAKING METAL W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING 200 HR. INSP. THE OIL FILTER WAS CUT OPEN TO LOOK FOR METAL. FILTER ELEMENT WAS WASHED IN VAROSOL AND DRAI NED THROUGH A FILTER TO REVEAL METAL PARTICLES. THE ENGINE SHOP WAS CALLED TO IDENTIFY THE METAL. WE PULLED NR 2 & 4 CY LINDERS TO OBSERVE THE NR 3 CRANKSHAFT BEARING AND FOUND THAT IT WAS ABLE TO BE TURNED IN THE JOURNAL BY HAND. THE ENGIN E WAS IN FINE WORKING ORDER UP TO THIS INSP. THE ENGINE WAS REMOVED AND SENT TO A REPAIR SHOP. 1 H 7 1 3O 3 O 3A24 E5CE 5 C P21EA 2005020100165 20050201 00165 EU 2005 2 1 CA041122002 2 20041114 G 8500 ENGINE DIAMON DA20 DA20A1 2990000 GL ROTAX 912 ROTAX912F3 EU HOFMAN HOV352 HOV352F NE FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) SMOKE ENTERED COCKPIT. PILOT RETURNED TO BASE. ENGINE LOST POWER AND BEGAN TO MISSON FINAL AND WAS SHUT DOWN. 1 L 7 1 3O 3 O NT TA4CH E00051EN 5 C TP5BO 2005020100166 20050201 00166 EA 2005 2 1 CA041122003 2 20041119 G 8530 71973 GASKET CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160CTM GL INTAKE FLANGE SPLIT W K NONE O OTHER IN INSP/MAINT 1 CA L4441827A (CAN) INTAKE FLANGE GASKET SPLIT THROUGH CIRCUMFERENCE RESULTING IN MINOR VACUUM LEAK. THE GASKET MATERIAL IS HARD AND B RITTLE, AND APPEARS TO BE ERODING ON THE INNER EDGE. THIS IS THE FOURTH GASKET FOUND SPLIT IN THE LAST FEW WEEKS. THREE ON THIS ENGINE (1164 HOURS) AND ONE ON ANOTHER AT 700 HOURS. BOTH MGF FACTORY REMANUFACTURES. SUSPECT DEFICIENCY IN MAT ERIAL. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2005020100170 20050201 00170 CE 2005 2 1 CA041122004 1 20041117 G 3244 185F035 TIRE BEECH 100 A100 1152915 CE PWA PT6 PT6A28 EA MCAULY 4HFR34 4HFR34C762 NE MLG BLISTERED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AFTER A PILOT REPORTED THAT THE NR 3 TIRE WAS FLAT, MAINTENANCE REPLACED THE WHEEL ASSY. DURING THE REMOVAL IT WA S NOTICED THAT THE IB SIDEWALL HAD A LARGE BLISTER. IT APPEARS THAT AN AREA (3 INCHES IN DIAMETER) OF THE OUTSIDE LAYER OF RUBBER (.0625 IF AN INCH THICK) WAS DISBONDED FROM THE REST OF THE TIRE, THE AIR PRESSURE CAUSED THIS TO INFLATE CRE ATING A LARGE BLISTER. THIS BLISTER EVENTUALLY RUBBED ON THE BRAKE CALLIPER CAUSING THE BLISTER TO BURST, DEFLATING THE TIRE. 1 L 7 2 3T 4 T A14CE E4EA 6 C 3PNE 2004121000018 20041210 00018 EU 2004 12 10 CA041122005 1 20041120 G 2720 065008617 CONTROL UNIT PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL YAW DAMPER MALFUNCTIONED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) YAW DAMPER INDICATION LAMP WOULD NOT ILLUMINATE ON KMC 321 CONTROL HEAD. 'YD' INDICATION OK ON BOTH EFIS SCREENS. REPLACED WITH SERVICEABLE UNIT. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004121000071 20041210 00071 GL 2004 12 10 CA041122006 2 20041120 G 7230 TURBINE EMB 145 EMB145 3260210 SO ALLSN AE300 AE3007A GL STAGE 3 FAILED W C ABORTED TAKEOFF Y J ENGINE STOPPAGE WARNING INDICATION TO TAKEOFF 1 CA (CAN) ON TAKEOFF ROLL, RT ENGINE PERFORMED AN UNCOMMANDED IN FLIGHT SHUT DOWN AT 80 KNOTS. PRELIMINARY REPORT REVEAL A CRACK TURBINE CASE AND LP STAGE 3 BLADE FAILURE. THE FAN BLADES WORE A HUGE GROOVE IN THE FAN CASE. ENGINE EN ROUTE TO ROLLS ROYCE CANADA FOR FAILURE INVESTIGATION. 2 L 7 2 4F 4 F RT T00011AT TE6CH 2004122200171 20041222 00171 EU 2004 12 22 CA041122007 1 20041120 G 3080 9754421421 ELEMENT ROSEMOUNT PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL VANE HEATER FAILED W K NONE L NO TEST IN INSP/MAINT 1 CA 0425 (CAN) WHILE PERFORMING A CHECK OF THE PROBES HEATING SYSTEM, THE LT VANE HEAT WAS FOUND INOP. AOA ASSY REPLACED, FUNCTIO N TESTS SATISFACTORY. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004122200172 20041222 00172 GL 2004 12 22 CA041122008 2 20041106 G 7230 COMPRESSOR EMB 145 EMB145 3260210 SO ALLSN AE300 AE3007A GL ENGINE DAMAGED W A UNSCHED LANDING D Y INFLIGHT SEPARATION ENGINE STOPPAGE CL CLIMB 1 CA CAE312392 (CAN) UNCOMMANDED IN-FLIGHT SHUTDOWN. IN CLIMB MODE AT 10,000 FT, FLIGHT CREW HEARD A LOUD BANG AND THE NR 1 ENGINE SHU TDOWN. MINOR FINDINGS ON MCD'S. LP WILL ROTATE, HP WILL NOT ROTATE. CMC DOWNLOAD SHOWED HP VIBRATION EXCEEDANCE OF 1. 7 IPS FOR 11SECONDS. FOUND HPC1 IGV DAMAGE AND HPC1 BLADE DAMAGE ON BORESCOPE. NO EVIDENCE OF FOD. ENGINE IN ROUTE FO R INVESTIGATION AT ROLLS-ROYCE CANADA. 2 L 7 2 4F 4 F RT T00011AT TE6CH 2005031100103 20050311 00103 NE 2005 3 11 CA041122009 2 20041118 G 7200 TAY6501510 ENGINE FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE NR 2 VIBRATION W A UNSCHED LANDING E VIBRATION/BUFFET CL CLIMB 1 CA 20192 (CAN) AIRCRAFT ENCOUNTERED HI VIBRATION IN CLIMB ON NR2 ENGINE GAUGE, MFDS MESSAGE ALERT (REF JOURNEY LOG PAGE 031117). UNABLE TO MAINTAIN THRUST. THRUST WAS REDUCED BY .15 TO CLEAR ALERT. AIRCRAFT RETURNED TO BASE. MAINTENANCE TROUBLE SHOT IAW AMM 71-00-00, 811-811A, STEP 101 TO 108. VIBRATION SURVEY WAS C/OUT IAW AMM 71-00-00 AND VIBRATION WAS FELT AT0 .6 IPS. THE NR2 ENGINE WAS REPLACED (P/N OFF: TAY650-15/10, S/N OFF: 17679,P/N ON: TAY650-15/10,S/N ON: 17653) IAW AMM 71-00-00 (REF TASK CARD 71-00-00-400-814-C). 2 L 7 2 4F 4 F RT E25NE 2005020100176 20050201 00176 EU 2005 2 1 CA041122010 1 20041119 G 3260 SK3852 INDICATOR FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE MLG INOPERATIVE W O OTHER P NO WARNING INDICATION AP APPROACH 1 CA (CAN) PILOT DECLARED AN EMERGENCY LANDING BECAUSE HE HAD NO GREEN LIGHT ON HIS LANDING INDICATOR, BUT HAD NO MESSAGE ON MFDU, THAT THE GEAR WAS UNSAFE. NOTE: IN REFERENCE TO THE QRH (QUICK REFERENCE HANDBOOK, ABNORMAL PROCEDURES,6.09 PAGE2, THE FLIGHT CREW WAS NOT REQUIRED TO DECLARE AN EMERGENCY. AIRCRAFT DID 2 FLY BYES TO CONFIRM WITH TOWER AND LANDED WITH NO PROBLEM. MAINTENANCE REPLACED THE LANDING GEAR POSITION INDICATOR IAW 32-61-02. LANDING GEAR EXTENSION/RETRACTION C OMPLETED IAW 32-00-00. 2 L 7 2 4F 4 F RT E25NE 2005020100151 20050201 00151 EA 2005 2 1 CA041122011 2 20041116 G 7322 O-RING BEECH 100 A100 1152915 CE PWA PT6 PT6A28 EA HARTZL HCD4N3 HCD4N3A GL FCU FUEL BOWL DISPLACED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) FUEL LEAK ON LT ENGINE IN FLIGHT. CAUSE BEING, DISPLACED O-RING ON FCU FUEL BOWL. VARIFIED BOWL HAD BEEN TORQUED TO SPECS IAW MM, CHAPTER 73-10-02 FOR ARGO-TECH PUMPS. 1 L 7 2 3T 4 T A14CE E4EA 5 C STC 2005020100177 20050201 00177 NM 2005 2 1 CA041122012 1 20041122 G 3260 858601 PSEU DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE RT MLG INTERMITTENT W A UNSCHED LANDING P NO WARNING INDICATION CL CLIMB 1 CA (CAN) AFTER T/O, RT MLG DOWNLOCK GREEN LIGHT STAYS ON AFTER GEAR UP SELECTION. FLIGHT CREW EXTENDED THE LANDING GEAR AN D LANDED BACK AT BASE. LANDING GEAR INSPECTION CHECKED - OK. PSEU CODES RETRIEVED (53, 55). R/R PSEU. LANDING GEAR TES TED OK. AIRCRAFT RETURNED TO SERVICE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005020100137 20050201 00137 NM 2005 2 1 CA041122013 1 20041118 G 5330 SKIN BOEING 737 737201 1384454 NM PWA JT8 JT8D15 52051 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) A 4 INCH CRACK WAS FOUND ON THE OUTER FUSELAGE SKIN JUST AFT OF THE WING TO BODY FAIRING RT SIDE. CRACK LOCATED O N STR 15R (2) TWO INCHES AFT OF STA.727A. CRACK REPAIRED IAW SRM 53-30-3 FIG48 DETAIL XI TIMES 53851.20 CYCLES 46695. 2 L 7 2 4F 4 F A16WE E2EA 2005020100138 20050201 00138 NE 2005 2 1 CA041122014 2 20041026 G 7200 ENGINE AEROSP ATR72 ATR72 EU PWA PW120 PW124B NE LEFT FAILED W E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA 124496 (CAN) DURING CRUISE, PROPELLER SPEED DECREASED ACCOMPANIED BY MASTER WARNING AND CCAS+LOW ALERTS. THE CREW SECURED THE ENGINE, DECLARED PAN PAN AND COMPLETED A SING LT ENGINE LANDING AT DESTINATION. MFG WILL MONITOR THE INVESTIGATION AND AMEND THIS REPORT TO REFLECT ROOT CAUSE ONCE DETERMINED. 2 H 7 2 4T 4 T RT E2ONE 2004121000019 20041210 00019 EA 2004 12 10 CA041122015 1 20041121 G 2424 51539008C CONTROL UNIT DHAV DHC8 DHC8311 1386006 EA PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE GENERATOR MALFUNCTIONED W O OTHER O OTHER NR NOT REPORTED 1 CA 34748 (CAN) DURING MAINTENANCE SERVICING, ENGINEER FOUND STARTER GENERATOR WARM. AIRCRAFT ENGINE WAS COLD AND NO ATTEMPTED ST ARTS HAD BEEN MADE. MAINTENANCE INSPECTION FOUND FAULT CAUSED BY GENERATOR CONTROL UNIT. DC GENERATOR CONTROL UNIT REP LACED. AIRCRAFT RETURNED TO SERVICE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2004122200176 20041222 00176 NM 2004 12 22 CA041122016 1 20041120 G 5210 852202081007 SEAL DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE PAX DOOR WORN W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) DURING CLIMB, UNABLE TO PRESSURIZE AIRCRAFT TO HIGH DIFFERENTIAL , 'CABIN PRESS' WARNING LIGHT ILLUMINATED. FLIGH T ATTENDANT REPORT LOUD WHISTLING FROM FORWARD EMERG EXIT DOOR. AIRCRAFT RETURNED TO ORIGINATING AIRPORT. MAINTENANCE INSPECTION FOUND FORWARD EMERGENCY EXIT DOOR INFLATABLE SEAL WORN. SEAL REPLACED. AIRCRAFT RETURNED TO SERVICE. (PART IS CONSIDERED AN EXPENDABLE AND TIMES ARE NOT TRACKED) 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005020100065 20050201 00065 CE 2005 2 1 CA041123001 1 20041119 G 2730 NAS427K6 PIN BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA HARTZL HCB3T HCB3TN3 GL ELEVATOR CONTROL MISSING W K NONE F FLT CONT AFFECTED IN INSP/MAINT 1 CA (CAN) THE PRIMARY CABLE FOR THE ELEVATOR CONTROL HAD JUMPED OUT OF THE PULLEY. THE (SPRING PIN) THAT PREVENTS THIS FROM HAPPENING WAS OUT OF POSITION (UNABLE TO STOP THE CABLE FROM LEAVING THE PULLEY). ABRASION OF THE ELEVATOR CABLE AT THE PULLEY AND ON SUPPORTING STRUCTURE A SHORT DISTANCE FROM WHERE THE ELEVATOR CABLE, EMERGES FROM THE PRESSURE VESSEL AS I T TRAVELS AFT TO THE BELLCRANK. 1 L 7 2 3T 4 T RT 3A20 E4EA 6 C P15EA 2004122200177 20041222 00177 NM 2004 12 22 CA041123002 1 20041118 G 3244 DSC428 TIRE DHAV DHC8 DHC8301 1386003 NM TIRE FAILED W C ABORTED TAKEOFF D INFLIGHT SEPARATION TO TAKEOFF 1 CA (CAN) DURING A TAKEOFF, AS THE SPEED INCREASED A MILD VIBRATION WAS FELT WHICH QUICKLY INCREASED. THE VIBRATION WAS PRO BABLY GENERATED BY THE LT OUTBOARD MAIN TIRE FAILING. THE TAKEOFF WAS REJECTED ABOVE 70 KNOTS WITH THE TIRE FINALLY FAI LING BETWEEN 90 TO 100 KNOTS. THE AIRCRAFT WAS ABLE TO ROLL ON THE REMAINING LT INBOARD MAIN TIRE UNTIL IT FAILED AT AB OUT 20 KNOTS. THE AIRCRAFT WAS STOPPED ON THE RUNWAY WITHOUT FURTHER INCIDENT. ENGINEERING ASSESSED THE AIRCRAFT FOR D AMAGE CONFIRMING THAT THE WHEEL ASSEMBLIES ONLY REQUIRED REPLACEMENT. AIRCRAFT WAS RETURNED TO SERVICE WITHOUT FURTHER INCIDENT. GOODYEAR (31X9.75-14 12PLY) 2 H 7 2 4T RT A13NM 2004122200179 20041222 00179 NM 2004 12 22 CA041123003 1 20041123 G 5397 H75C20 WIRE BOEING 767 767375 1385217 NM GE CF6 CF680C2B6F 30025 NE AFT LAV BURNED W H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA FOUND WIRE BUNDLE INSIDE TOILET SHROUD BURNING AND SMOKING, C/B SYST 2 WATERLINE HEATER (LAV LIGHTS) POPPED IN AVIONICS BAY. FURTHER T/S ON WIRING BURNED, FOUND WIRES IDENTIFIED AS H75C20,H75A20, AND H75A20N (GRN) ALL BROKEN FROM SPLICES. ALSO, HEATER TAPE RINSE LINE B8 NEEDS TO BE REPLACED DUE WIRE BROKEN. 2 L 7 2 4F 4 F RT A1NM E13NE 2005020100098 20050201 00098 NM 2005 2 1 CA041123004 1 20041122 G 5240 69222825 HINGE BOEING BOEING 727 727233 138408A NM PWA JT8 JT8D15 52051 NE DOOR HALF DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) HYDRAULIC BAY DOOR SEPARATED FROM AIRCRAFT. AIRCRAFT WAS BEING POSITIONED FROM THE MAIN MAINTENANCE BASE ON THE M ORNING OF NOVEMBER 22, 2004. DURING SERVICE CHECK BY MAINTENANCE, IT WAS NOTICED THAT THE HYDRAULIC BAY DOOR WAS MISSIN G. MAINTENANCE SUSPECT DOOR HINGE FAILURE. THE HYDRAULIC BAY STRUCTURE WAS INSPECTED FOR SECONDARY STRUCTURE DAMAGE. SER VICEABLE DOOR AND DOOR HINGE ASSY WAS INSTALLED AND AIRCRAFT WAS RETURNED TO SERVICE. 2 L 7 3 4F 4 F RT A3WE E2EA 2005041900012 20050419 00012 EU 2005 4 19 CA041123005 1 20041118 G 2910 410100211 PTU AIRBUS A319 A319112 3930323 EU CFMINT CFM565 CFM565B6 13802 NE FUEL PRESSURE LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) AFTER TOW TO GATE, A LEAK WAS NOTICED COMING FROM THE PRESSURE TRANSFER UNIT. UNIT WAS REPLACED BEFORE FLIGHT. 2 L 7 2 4F 4 F RT A28NM E37NE 2005041900013 20050419 00013 NE 2005 4 19 CA041123006 2 20041123 G 7314 1383M68P12 PUMP BOEING 767 767333 1385301 NM GE CF6 CF680C2B6F 30025 NE HP FUEL CONTAMINATED W O OTHER E VIBRATION/BUFFET NR NOT REPORTED 1 CA (CAN) UNABLE TO START NR 2 ENG. DUE FUEL VALVE LT AT PEDESTAL & EICAS MSG FOR 'R FUEL VALVE'. CHECKED 28VDC AT FUEL CUT OFF SW AND PWR AVAILABLE. REPLACED FUEL S/O VALVE SOLENOID, NO FIX. REPLACED HMU, NO FIX. REMOVED FUEL PUMP AND FOUND CONTAMINATED WITH METAL. MPN 9355M33P13 IN (STREAMER CAVITY). 2 L 7 2 4F 4 F RT A1NM E13NE 2005041900014 20050419 00014 CE 2005 4 19 CA041123007 1 20041118 G 2720 0400107150 CONTROL CABLE CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA RUDDER FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) RIGHT RUDDER CABLE FOUND SLIGHTLY FRAYED WHERE IT TRAVELS OVER THE REARMOST PULLEY IN THE AFT FUSELAGE. THERE WER E APPROXIMATELY 8 TO 10 WIRES BROKEN. CABLE WAS REPLACED WITH NEW. 1 H 7 1 3O 3 O NT 3A19 E223 2005012400003 20050124 00003 SW 2005 1 24 CA041123008 1 20040720 G 7500 3017393 LINE PWA PT6T3 BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA P3 AIR BROKEN W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA CPPS61172 (CAN) LINE BROKE. A/C RETURNED TO BASE. LINE WAS REPLACED. A/C WAS RETURNED TO SERVICE. NO FURTHER DEFECTS. 1 G 7 1 4U 4 U H4SW E22EA 2005020100171 20050201 00171 SW 2005 2 1 CA041123009 1 20041124 G 5610 2719442004 WINDSHIELD SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP HARTZL HCE4N HCE4N3 NE COCKPIT BROKEN W O OTHER O OTHER CR CRUISE 1 CA 1250 (CAN) UPON REACHING CRUISING ALTITUDE OF 14, 000 FEET CO-PILOTS HEATED WINDSHIELD SHATTERED. WINDOW REMAINED INTACT AND FLIGHT CREW DEPRESSURIZED AIRPLANE AND FLEW TO A SAFE ALTITUDE. FLIGHT CREW NOTICED A SPARK OR FLASH INSIDE WINDSHEILD PRIOR TO IT SHATTERING, MOST LIKELY RELATED TO WINDSHIELD HEAT SYS. WINDSHEILD HEAT WAS TURNED ON PRIOR TO TAKEOFF. AC WAS CLOSE TO ITS DESTINATION AND CARRIED OUT AN UNEVENTFUL LANDING. MAINT INSPECTED THE WINDOW AND FOUND NOTHING THAT MAY HAVE CAUSED THE FAILURE INCLUDING ANY IMPACT DAMAGE. THE WINDOW AND IT'S TEMPERATURE CONTROLLER HAVE BEEN REPLACED A S A PRECAUTION. THIS WINDOW WAS INSTALLED ON THE AIRCRAFT ON JANUARY 20, 2004 AND HAD A TOTAL TIME OF 1250.5 HOURS. 2 L 7 2 4T 4 T RT A8SW E4WE 5 C P10NE 2005020100172 20050201 00172 SW 2005 2 1 CA041123010 1 20041103 G 2821 BYPASS SWITCH BELL 206 206L 1181522 SW ALLSN 25OC 250C20R GL FILTER ASSY HEAD CORRODED W O OTHER N FALSE WARNING CR CRUISE 1 CA 3755 (CAN) FILTER LIGHT CAME ON UPON LANDING. REMOVED FILTER AND INSPECTED. NO CONTAMINATION FOUND AND TEST LIGHT CIRCUIT. A LIGHT CAME ON AGAIN AND UPON INVESTIGATION, IT WAS FOUND THAT THE SWITCH WAS CORRODED. A NEW FILTER ASSY. WAS INSTAL LED AND TESTED. IT FUNCTIONS CORRECTLY. INCIDENT HAPPENED 35 HOURS AFTER 300 HR INSP, WHICH INCLUDED FILTER CHANGE. 1 G 7 1 3U 3 U H2SW E4CE 2005012400004 20050124 00004 SW 2005 1 24 CA041123011 1 20040712 G 6320 212040054005 CASE BELL BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA M/R GEARBOX BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA ABW270 (CAN) PILOT REPORTED HEARING A LOUD BANG AND THOUGHT PIECES OF THE HELICOPTER FELL FROM THE BELLY. PILOT WAS FLYING VER TICAL REFERENCE WITH A BAMBI BUCKET. UPON IMMEDIATE RETURN TO THE PAD, THE HELL HOLE SIDE INSPECTION PANELS WERE REMOVE D AND THE SUPPORT CASE WAS FOUND BROKEN AT LIFT LINK FITTING. THE TRANSMISSION ASSEMBLY WAS REPLACED. A/C RETURNED TO SERVICE. 1 G 7 1 4U 4 U H4SW E22EA 2005012400005 20050124 00005 SW 2005 1 24 CA041123012 1 20040707 G 2810 FCE53191 FUEL CELL BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA SPLIT W A UNSCHED LANDING J WARNING INDICATION HO HOVERING 1 CA 18044 (CAN) LOW FUEL LIGHT COMING ON WITH 250-300 LBS INDICATED IN LT LOWER FUEL CELL. INVESTIGATION FOUND SPLIT IN FUEL CELL INTERNALLY ACROSS BAFFLE, WHICH ACTED LIKE A ONE WAY VALVE. THIS WOULD PUMP FUEL AWAY FROM BOOST PUMP WHEN A/C IS IN UN USUAL ATTITUDES (HOVER/LONG LINING). 1 G 7 1 4U 4 U H4SW E22EA 2004121000020 20041210 00020 2004 12 10 CA041124001 4 20041119 G 3416 C1621AA02 INDICATOR BOMBDR BD700 BD7001A10 1390006 GL RROYCE BR700 BR700710A220 09500 NE COCKPIT BROKEN W O OTHER O OTHER CR CRUISE 1 CA (CAN) DURING STRAIGHT AND LEVEL FLIGHT, THE ISI (STANDBY ADI) SHUTDOWN AND CAME BACK ONLINE BY ITSELF. THE ISI WAS REPL ACED. 2 L 7 2 4F 4 F RT T00003NY E00061EN 2004122300029 20041223 00029 NM 2004 12 23 CA041124002 1 20040826 G 2742 3993001010 ACTUATOR BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA RT PITCH FEEL MALFUNCTIONED W C ABORTED TAKEOFF O OTHER TO TAKEOFF 1 CA DURING TAKEOFF RUN AT A SPEED BETWEEN 100 AND 120 KIAS, GOT 'ELEVATOR FEEL' FAULT LIGHT ON. TAKEOFF ABORTED, PASSENGERS DEBRIEFED, AND RETURNED TO GATE. THE CENTRAL DIAGNOSTIC SYSTEM (CDS) WAS INTERROGATED AND FCECU FAULT CODES EA AND E9 WERE FOUND LOGGED IN THE FAULT HISTORY, THESE FAULTS INDICATE THAT THE RIGHT PITCH FEEL ACTUATOR IS NOT CORRECTLY TRACKI NG THE COMMAND AND THE MESSAGE WILL SHOW WHEN THE RIGHT PITCH FEEL ACTUATOR OR THE FCECU HAS FAILED. THE RT PITCH FEEL ACTUATOR WAS CONSEQUENTLY REPLACED IN ACC WITH AMM TASK 27-32-11. 2 H 7 2 4T 4 T RT A13NM E00062EN 2004122300030 20041223 00030 EA 2004 12 23 CA041124003 2 20041122 G 7414 M3548 ROTOR SHAFT SLICK 4345 HUGHES 269 269C 4470504 WP LYC O360 HIO360D1A 41514 EA MAGNETO BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA 00072126 (CAN) ON RUN UP MAGNETO CHECK, FOUND LT MAG INOP. LT MAG REMOVED AND INSPECTED, ROTOR GEAR WAS FOUND SEPARATED FROM ROT OR SHAFT. RT MAGNETO WAS INSPECTED IN THE SAME AREA OF LT MAG FAILURE NO DEFECT FOUND. A NEW MAGNETO WAS INSTALLED IN LT POSITION RT MAGNETO REINSTALLED. MAGNETOS TIMED TO ENGINE AIRCRAFT GROUND RUN FUNCTION CHECK-SERVICEABLE. 1 G 7 1 3O 3 O 4H12 1E10 2005020100105 20050201 00105 EU 2005 2 1 CA041124004 1 20041121 G 2740 864401 PROXIMITY SWITCH FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE STAB FAULTY W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA (CAN) AC DIVERTED, AFTER HAVING A HYDR STAB NR 1 FAULT IN FLIGHT (LOST FAULT ON LANDING). MAINT C/OUT A HYDR CONTROL S TABILIZER OPS CHECK IAW AMM 27-42-01, NO FAULT FOUND. ON FOLLOWING FLIGHT, SAME MESSAGE REAPPEARED ON THE MSDS (MULTI F UNCTIONAL DISPLAY SYSTEM) AT THE TOP OF THE DESCENT. MAINT TESTED THE STAB SYSTEM IAW AMM 27-42-01. ALL INDICATIONS FOU ND NORMAL. FUNCTIONAL TEST OF STICKING SWITCH WAS C/OUT IAW AMM 27-42-01-710-054-A03. NO FAULTS FOUND. ON NR 1 ENGIN E START, HYDRAULIC STAB 1 FAULT OCCURRED. MAINT TROUBLESHOOTING CONFIRMED THE NR 1 STAB PROXIMITY SWITCH P/N OFF, 8-64 4-01, S/N OFF, 330- P/N ON, 8-644-01, S/N ON, A2231) AT FAULT AND WAS REPLACED AND TESTED IAW AMM 27-42-01. 2 L 7 2 4F 4 F RT E25NE 2005020100153 20050201 00153 EU 2005 2 1 CA041124005 1 20041123 G 5610 D20543406 WINDSHIELD FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE COCKPIT CRACKED W A UNSCHED LANDING O OTHER CL CLIMB 1 CA (CAN) NOV 23RD 2004, RT FLIGHT OFFICER WINDSHIELD CRACKED IN FLIGHT DURING CLIMB. AIRCRAFT C/OUT AN AIR TURN BACK. MAI NTENANCE REPLACED THE WINDSHIELD (P/NOFF, D20543-406, S/N OFF, 01303H2172 - P/N ON D20543-406, S/N ON 04198H1107) IAW A MM 56-11-00. 2 L 7 2 4F 4 F RT E25NE 2005020100154 20050201 00154 NM 2005 2 1 CA041124006 1 20041123 G 2913 6617302 PUMP BOMBDR DHC8 DHC8402 1390042 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU HYD SYSTEM INOPERATIVE W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CL CLIMB 1 CA (CAN) DURING CLIMB, 10 MIN. AFTER TAKE OFF, CLOSE TO 25 000 FT, PILOT NOTICED NR 2 ENGINE HYD PUMP CAUTION LIGHT FOLLOW ED BY A LOSS OF NR 2 HYD FLUID QTY ON COCKPIT GAUGE. PILOT FOLLOWED Q400 QUICK REF HANDBOOK PROCEDURE NR 12.5. PTU HAS BEEN MANUALLY SELECTED ON WITH NO PRESSURE INCREASE IN NR 2 SYST DUE NO HYD FLUID, PTU SELECTED OFF, NR 2 HYD ISOLATION VALVE SELECTED ON. AC RETURNED AND ALTERNATE LANDING GEAR EXTENSION PROCEDURE USED. NR 2 ENGINE DRIVE HYD PUMP R & R IAW AMM. NR 2 HYD SYS BLEED IAW AMM AND NR 2 HYD SYS SERVICE IAW AMM. AC RETURN TO MAINT BASE. ENGINE DRIVE HYD PUMP D ETAIL FINDING REPORT WILL FOLLOW. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2005012400006 20050124 00006 NE 2005 1 24 CA041124007 1 20041118 G 6210 6117020201 BLADE SKRSKY S61 S61N 8142104 NE GE CT58 CT581401 30011 NE MAIN ROTOR CRACKED W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA (CAN) DURING FLIGHT, THE ROTOR BLADE INTEGRITY MONITOR SYSTEM INDICATED A LEAK IN ONE OF THE MAIN ROTOR BLADES. THE PILO T LANDED THE AIRCRAFT SAFELY AND MAINTENANCE REPLACED THE BLADE AND SENT IT IN FOR INSPECTION. DURING INSPECTION, A LEA K WAS INDICATED UNDER THE CUFF WHICH WAS THEN REMOVED AND A CRACK WAS FOUND BETWEEN BOLT HOLES. THE BLADE IS SCRAP AND AVAILABLE FOR INSPECTION. 2 G 7 2 4U 4 U 1H15 1E3 2005012400007 20050124 00007 CE 2005 1 24 CA041124008 1 20041117 G 5610 5042006936 WINDSHIELD BEECH 100 B100 1152919 CE GARRTT TPE331 TPE3316252B 01514 WP HARTZL HCB4T HCB4TN5 GL COCKPIT BROKEN W B EMER. DESCENT D INFLIGHT SEPARATION CR CRUISE 1 CA (CAN) RT FRONT INNER PANE OF WINDSHIELD SHATTERED IN FLIGHT. 1 L 7 2 4T 4 T A14CE E2WE 6 C P40EA 2005020100155 20050201 00155 SW 2005 2 1 CA041124009 1 20041108 G 6510 327211 DISC PACK BELL 206 206L 1181522 SW ALLSN 25OC 250C20R GL TAIL ROTOR DRIVE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DISC PACK, 1 DISC CRACKED. 1 G 7 1 3U 3 U H2SW E4CE 2005020100109 20050201 00109 NM 2005 2 1 CA041124010 1 20040830 G 2742 3994001009 ACTUATOR BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU ELEV PITCH TRIM FAILED W O OTHER F FLT CONT AFFECTED DE DESCENT 1 CA (CAN) DURING DECENT INBOUND TO BASE, THE PITCH TRIM CAUTION LIGHT CAME ON, QRH PERFORMED AND IT BECAME APPARENT THAT WE HAD A FAILURE OF THE PITCH TRIM. ATC NOTIFIED AND THE APPROACH PLANNED WITH HIGH SPEED FOR AS LONG AS POSSIBLE. DURING SPEED REDUCTION STICK FORCES INCREASED SIGNIFICANTLY AS DESCRIBED IN QRH. STICK FORCES LIGHTENED ON SELECTION OF FLAP 5, AND INCREASED AGAIN WITH SPEED REDUCTION. ALTHOUGH QUITE HEAVY TO HOLD, THE APPROACH AND LANDING WERE PERFORMED WITHOUT PROBLEMS. ELEVATOR PITCH TRIM ACTUATOR WAS REPLACED IAW AMM TASK 27-32-06. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2005020100110 20050201 00110 NE 2005 2 1 CA041124011 2 20041110 G 7260 DRIVE ASSY AEROSP ATR72 ATR72 EU PWA PW120 PW124B NE GEARBOX FRACTURED W O OTHER X J ENGINE FLAMEOUT WARNING INDICATION CR CRUISE 1 CA 124598 (CAN) DURING CRUISE, ENGINE OIL PRESSURE DROPPED TO ZERO FOLLOWED BY AN UNCOMMANDED ENGINE SHUTDOWN. A SINGLE ENGINE LA NDING WAS CARRIED OUT AT DESTINATION. SUBSEQUENT INVESTIGATION HAS EVIDENCED A FRACTURED (ACCESSORY GEARBOX DRIVE) TOWE RSHAFT. PWA WILL INVESTIGATE THE EVENT AND REVISE THIS REPORT TO REFLECT ROOT CAUSE, ONCE DETERMINED. 2 H 7 2 4T 4 T RT E2ONE 2004121000021 20041210 00021 SO 2004 12 10 CA041124012 2 20041122 G 8520 643045 CAMSHAFT CESSNA 303 T303 2073820 CE CONT O520 TSIO520AE 17040 SO MCAULY 3AF32C 3AF32C507 GL ENGINE SHEARED W E A ENGINE SHUTDOWN UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 CA 246120R (CAN) THE ENGINE LOST POWER ON CLIMB-OUT OF CALGARY. THE PILOT FEATHERED THE PROP AND RETURNED TO CALGARY. THE ENGINE W AS GROUND RUN AND THE PROP GOVERNOR WAS FOUND TO BE INOPERATIVE. UPON REMOVAL OF THE GOVERNOR, IT WAS FOUND THAT THE DR IVE P/N 538076 WAS NOT IN INSTALLED POSITION. THE BEVEL GEAR P/N 534655 WAS ALSO MISSING. UPON FURTHER INSPECTION IT W AS FOUND THAT THE CAM SHAFT P/N 643045 HAD SHEARED ALLOWING THE GOVERNOR DRIVE TO FALL OUT OF ITS POSITION AND DROP INTO THE OIL PAN. THE ENGINE HAS BEEN REMOVED AND SENT TO AN ENGINE SHOP FOR TEARDOWN AND REPAIR. A COPY OF THE TEARDOWN R EPORT WILL BE INCLUDED IN THIS SDR WHEN WE RECEIVE IT. 1 L 7 2 3O 3 O A34CE E8CE 5 C P57GL 2004121000048 20041210 00048 NM 2004 12 10 CA041125001 1 20041122 G 5280 65224787 BRACKET BOEING 727 727225 1384077 NM PWA JT8 JT8D9A 52048 NE NLG DOOR BROKEN W D RETURN TO BLOCK O OTHER TX TAXI/GRND HDL 1 CA (CAN) UPON ARRIVAL, MAINTENANCE PERSONEL NOTED THE NOSE LANDING GEAR DOORS HANGING OPEN. FURTHER INSPECTION FOUND THE B RACKET FOR THE DOOR OPERATION ROD BROKEN. SEE IPC 32-30-00-06 ITEM 89. BRACKET AND HARDWARE REPLACED AND GEAR SWINGS C ARRIED OUT, AND A/C RETURNED TO SERVICE. 2 L 7 3 4F 4 F A3WE E2EA 2005020100106 20050201 00106 NM 2005 2 1 CA041125002 1 20041110 G 3260 82410888011 PROXIMITY SENSOR BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU NLG FAULTY W O OTHER N FALSE WARNING DE DESCENT 1 CA (CAN) DURING DECENT TO BASE WITH LANDING GEAR RETRACTED, NOSE (GREEN), NOSE (RED) AND HANDLE (AMBER) LIGHT ILLUMINATED F OR ABOUT 3 MINUTES. EXTENSION, LANDING AND TAXI NORMAL. PSEU FAULT HISTORY INDICATED NGDN1 UNREASONABLE NEAR FAULT. R EPLACED NGDN1 PROXIMITY SENSOR IAW AMM 32-61-06. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2005020100173 20050201 00173 NM 2005 2 1 CA041125003 1 20040903 G 6120 699018002 ECU BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU PROPELLLER FAILED W O OTHER E VIBRATION/BUFFET TX TAXI/GRND HDL 1 CA (CAN) AUTO FEATHER SYSTEM FAILED TO ARMED WHEN TAKE-OFF POWER WAS APPLIED. ABORTED TAKE-OFF. FAULT CODE 794 WAS LOGGED IN THE CENTRAL DIAGNOSTIC SYSTEM (CDS) DURING THE FOLLOWING OVERSPEED GOVERNOR TEST. A FUNCTIONAL TEST OF THE PEC AND C ALIBRATION PROCEDURE WAS THEN PERFORMED IAW AMM TASK 61-20-36-720-801. FAULT CODE 238 REMAINED LOGGED IN THE CDS AS WEL L AS PEC CAUTION LIGHT AND POWERPLANT MESSAGE ON THE ED AND FINALLY THE LT PROPELLER ELECTRONIC CONTROL UNIT (PEC) WAS R EPLACED IAW AMM TASK 61-20-36. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2005020100107 20050201 00107 CE 2005 2 1 CA041125004 1 20041025 G 3213 NAS464P5A42 BOLT CESSNA CESSNA 206 U206C 2073332 CE CONT O520 IO520F 17032 SO MCAULY 3A32C D3A32C* GL NLG STRUT SHEARED W E ENGINE SHUTDOWN D INFLIGHT SEPARATION LD LANDING 1 CA (CAN) BOLT SHEARED ON LANDING CAUSING NOSE GEAR TO PIVOT FORWARD. NOTE: THIS BOLT WAS LAST CHANGED SEPTEMBER 9/94 AT 287 5 I.T.T. (AIRCRAFT PRESENT TT IS 6238.7 HOURS) THIS AIRCRAFT HAS OPERATED ON SKIS (SUSPECT THAT BOLT WAS OVERSTRESSED IN THIS CONFIGURATION). THIS BOLT WAS CRACKED PRIOR TO FAILURE AS HALF OF FRACTURE IS BLACK AND TOTAL FAILURE IS WHITE. S OME DAMAGE TO AIRFRAME WAS ENCOUNTERED. IT SHOULD BE NOTED THAT INSPECTION OF THIS BOLT IS NOT REPLACED IN INSPECTION S CHEDULE. 1 H 7 1 3O 3 O A4CE E5CE 5 C P21EA 2005020100102 20050201 00102 GL 2005 2 1 CA041125005 1 20041123 G 5520 PAF06080P11 BUSHING DIAMON DIAMON DA40 DA40 2990002 GL LYC O360 IO360A1A 41514 EA LT OB ELEVATOR MISSING W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) DURING 100 HOUR INSPECTION, LT OB ELEVATOR BUSHING FOUND MISSING. 1 L 7 1 3O 3 O NT A47CE 1E10 2005020100103 20050201 00103 CE 2005 2 1 CA041126001 1 20041122 G 2752 656014131 CABLE CESSNA 500 560CESSNA 2076750 CE PWA 530 PW535A NE TE FLAPS BROKEN W A UNSCHED LANDING F FLT CONT AFFECTED CL CLIMB 1 CA (CAN) AC DEPARTED, DURING CLIMB THE PILOTS NOTICED THAT THE FLAP INDICATOR DID NOT MATCH FLAP SELECTOR HANDLE. FLAP POS ITION WAS VERIFIED VISUALLY BY CO-PILOT PRIOR TO RETURNING TO BASE. UPON MAINTENANCE INVESTIGATION IT WAS FOUND THAT TH E FWD FLAP FOLLOW-UP CABLE WAS BROKEN AT THE PULLEY SWEDGED BALL. SL560-27-11 (SWEDGED BALL INSPECTION) WAS ACCOMPLISHE D APRIL26/04 AT 573.1 A/F HOURS 411 LDGS. THIS SB WAS NEXT DUE AT 873.1 HRS. AIRCRAFT TT AT FAILURE WAS 846.3 HRS (-26 .8 HRS TO NEXT INSPECTION) THE CABLE WAS REPLACED, RIGGED IAW MM, DUAL INSPECTION C/W AND RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT A22CE E00053EN 2005012400008 20050124 00008 CE 2005 1 24 CA041126003 1 20041125 G 3244 5004913 TIRE LEAR 35 35A 5170602 CE GARRTT TFE731 TFE73122B 01518 WP MLG FAILED W C ABORTED TAKEOFF D INFLIGHT SEPARATION TO TAKEOFF 1 CA (CAN) ON TAKE OFF SOUND WAS HEARD BY THE FLIGHT CREW. THEY ABORTED THE TAKE-OFF. 2 L 7 2 4F 4 F A10CE E6WE 2005020100071 20050201 00071 WP 2005 2 1 CA041126004 2 20041125 G 7310 8945681 LINE SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP MCAULY 4HFR34 4HFR34C652 NE ENGINE FUEL CRACKED W E ENGINE SHUTDOWN K J FLUID LOSS WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) UPON DECENT INTO AIRPORT POWER LEVER STAGGER WAS ENCOUNTERED BY FLIGHT CREW. UPON LANDING AND TAXING THE OIL PRES SURE COULD NOT BE MAINTAINED AND THE FLIGHT CREW SHUT DOWN THE ENGINE. UPON INVESTIGATION THE FUEL FLOW TRANSMITTER LIN E WAS FOUND CRACKED WHICH CAUSED THE ENGINE TO NOT BE ABLE TO MAINTAIN FUEL PRESSURE WHICH CAUSED IT TO SHUTDOWN. THE L INE WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C 3PNE 2005020100095 20050201 00095 EU 2005 2 1 CA041126005 1 20041123 G 2434 9789601091 BRUSH BLOCK PILATS PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL NR 2 GENERATOR WORN W H DEACTIVATE SYST/CIRCUITS J WARNING INDICATION CR CRUISE 1 CA 100446 (CAN) DURING CRUISE FLIGHT, GEN 2 LIGHT CAME ON. PILOT PULLED GEN 2 CIRCUIT BREAKER AND LANDED AT BASE. INVESTIGATION RE VEALED A SLIGHT CONDUCTIVE PATH BETWEEN THE TWO BRUSHES WITH THE BRUSH BLOCK ASSY REMOVED BELIEVED TO BE CAUSED BY BRUSH BLOCK DUST. THE SLIP RING WAS ALSO FOUND TO BE VERY DIRTY. THE SLIP RING WAS CLEANED, A NEW BRUSH BLOCK ASSY INSTALLED AND THE AIRCRAFT RETURNED TO SERVICE. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2004121000049 20041210 00049 EA 2004 12 10 CA041126008 1 20041125 G 2421 31708500 ADAPTER DHAV DHC8 DHC8311 1386006 EA PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE AC GEN PULLED W E ENGINE SHUTDOWN J WARNING INDICATION DE DESCENT 1 CA (CAN) DURING CRUISE, NR1 ENG OIL PRESSURE FLUCTUATED. ON APPROACH NR 1 LOW OIL PX CAUTION LIGHT ILLUMINATED. CREW ELECTE D TO FEATHER & SHUTDOWN NR 1 ENGINE. MAINTENANCE INSPECTION FOUND ENGINE WITH LOW OIL QUANTITY DUE TO OIL LOSS THROUGH P ARTIAL S OPERATION OF NR 1 AC GENERATOR FROM ADAPTOR PLATE. TOP TWO STUDS HAD PULLED OUT OFADAPTOR PLATE, LOWER TWO STUD S AND NUTS STILL INTACT , BUT NUTS SLIGHTLY LOOSE, ALLOWING AC GENERATOR TO BACK OFF FROM ADAPTOR PLATE BY APPROX. 1/4 I NCH AT TOP , STILL IN CONTACT WITH ADAPTOR PLATE AT BOTTOM. AC GENERATOR AND ADAPTER PLATE REPLACED . ADAPTOR PLATE IS C LASSIFIED AS AN EXPENDABLE PART , TIMES NOT TRACKED. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005012400010 20050124 00010 SW 2005 1 24 CA041126009 1 20041125 G 5510 306611306612 COVER AIRTRC AT802 AT802A 0390308 SW PWA PT6 PT6A67A 52043 NE HARTZL HCB5M HCB5MA3 GL HORIZONTAL STAB MISLOCATED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING ANNUAL INSPECTION IT WAS NOTED THAT ON THE LT AND RT HORIZONTAL STABILIZERS, THE HOLES THAT WERE DRILLED FO R THE GAP COVER SCREW HOLES WERE DRILLED THROUGH 2 RIVETS ON THE LT AND RT STABILIZERS ON THE LOWER SURFACES ONLY. THE RIVETS ATTACH THE SKIN TO THE END RIB. REPAIRS WILL BE ACCOMPLISHED PRIOR TO THE AIRCRAFT BEING RETURNED TO SERVICE. 1 L 7 1 3T 4 T NC A19SW E26NE 6 C P44GL 2004121000050 20041210 00050 NM 2004 12 10 CA041126010 1 20041126 G 3213 161T11387 AXLE BFGOODRICH 161T110070 BOEING 767 767375 1385217 NM GE CF6 CF680C2B6 30025 NE RT MLG BROKEN W O OTHER J WARNING INDICATION TO TAKEOFF 1 CA 73707 49091 (CAN) ACFT 684 ON LANDING, DISCOVERED RT ML GEAR AFT AXLE BROKEN, IT SEEMS THAT HAPPEN DURING TAKEOFF IN XXX, BECAUSE FL IGHT CREW REPORT ANTI- SKID LIGHT WAS ON DURING WHOLE FLIGHT. MORE INFO AND PICTURES WILL FOLLOW AS IT BECOME AVAILABLE . 2 L 7 2 4F 4 F RT A1NM E13NE 2005021400219 20050214 00219 EA 2005 2 14 CA041129001 1 20041128 G 5610 NP1393225 WINDOW CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE COCKPIT CRACKED W O OTHER O OTHER AP APPROACH 1 CA (CAN) THE LT SIDE WINDOW CRACKED WHILE IN APPROACH. VSB CSB-NP-139322 WAS PERORMED ON NOV 2003. WINDOW WAS REPLACED IAW AMM. 2 L 7 2 4F 4 F RT A21EA E15NE 2005031100104 20050311 00104 EA 2005 3 11 CA041129002 1 20041123 G 5610 NP1393226 WINDOW CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE COCKPIT CRACKED W O OTHER O OTHER CR CRUISE 1 CA (CAN) THE RT SIDE WINDOW CRACKED WHILE IN CRUISE. A NEW WINDOW WAS INSTALLED AS IAW AMM. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2005031100106 20050311 00106 CE 2005 3 11 CA041129004 1 20041001 G 7921 VALVE CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA MCAULY 1C235 1C235LFA GL OIL COOLER MALFUNCTIONED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) 371 HOURS AFTER OVERHAUL. METAL WAS OBSERVED IN THE OIL FILTER. ENGINE REMOVED, DISMANTLED, AND INSPECTED. CORR OSION FOUND ON RODS AND CRANKSHAFT. ENGINE APPEARED TO HAVE NEVER RUN WARM ENOUGH TO BURN THE WATER OUT OF THE OIL. LA CK OF ANY MARKS ON THE VERNATHERM VALVE CONFIRMS THE VALVE NEVER CLOSED TO ROUTE OIL TO COOLER. AIRCRAFT TEST FLOWN AFT ER REPAIR. OIL TEMP GAUGE READ 160 DEG IN CRUISE. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P12EA 2005031100015 20050311 00015 NE 2005 3 11 CA041129005 2 20041129 G 7314 350880 SHAFT PWA BOEING 767 767233 1385113 NM PWA JT9 JT9D7R4D 52054 NE PUMP SHEARED W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CL CLIMB 1 CA 31526 (CAN) IMMEDIATELY AFTER 500FT, R PRIM PUMP EICAS MSG, STATUS QTY/PX NML. CLIMBING OUT, R QTY DECREASED STEADILY TO ZERO BUT PX NML W/DEMAND PUMP IN AUTO. CKD DEMAND PUMP OFF AND SYS PX WRNG LT DEMAND PUMP AUTO AND RETURNED TO DEPARTURE. F OUND RT EDP LEAKING INTERNALLY, RT EDP RPLD DUE DRIVE SHEARED. PX AND CASE DRAIN FILTERS CONTAMINATED SAME, REPLACED PU RCHASED, PO 19E823411. RT RESERVOIR DRAINED/REFILLED 9 USG, EGR C/OUT LEAK CKD SATISFACTORY. 2 L 7 2 4F 4 F RT A1NM E3NE 2005031100024 20050311 00024 2005 3 11 CA041129006 4 20041129 G 2330 7002061002 MONITOR AIRBUS 330 A330300 EU RROYCE RB211 RB211TRENT77 NE ROW 12 A,B BURNED W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 CA (CAN) APPROX 30 MINUTES AFTER TAKEOFF, PAX IN 12B,C NOTICED A BURNING SMELL IN OVERHEAD BIN. (THERE WAS A BANGING SOUND AT TAKEOFF APPARENTLY) ALSO NOTICED WERE SMALL PUFF OF SMOKE COMING FROM VENT ABOVE THE PAX IN 12 A,C (A COUPLE OF TIME S) SMOKE SMELL WAS CONFIRMED FROM CREW. RETURNED. FOUND VIDEO MONITOR AT SEAT 12 A,C SMELLING OF SMOKE. MONITOR REMOV ED AND CONNECTORS CAPPED. SEE SNAGL1443368, MONITOR REPLACED AND CHECKS OK. 2 L 7 2 4F 4 F RT E39NE 2005031100025 20050311 00025 NM 2005 3 11 CA041129007 1 20041129 G 7312 702101601425 FUEL HEATER BOEING 767 767333 1385301 NM GE CF6 CF680C2* GL LT ENGINE FAILED W O OTHER K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA (CAN) MIDWAY THROUGH THE FLT, THE LT ENG OIL QTY BEGAN TO DECREASE AT THE RATE OF APPROX 1 LITRE EVERY 10 -15 MINUTES. LT ENG THRUST REDUCED OIL QTY STILL DECREASED TO ZERO OIL PRESS AND TEMP REMAINED NORMAL ACTION: REPLACED SERVO FUEL HEA TER IAW MM 73-11-09. 2 L 7 2 4F 4 F RT A1NM E23EA 2004121000022 20041210 00022 NM 2004 12 10 CA041129008 1 20041126 G 3233 651781914 ACTUATOR BOEING 737 737201 1384454 NM PWA JT8 JT8D9A 52048 NE NLG MALFUNCTIONED W A UNSCHED LANDING N FALSE WARNING CL CLIMB 1 CA (CAN) NOSE WHEEL DISAGREEMENT LIGHT REMAINED ON AFTER GEAR SELECTED UP. RETURNED TO FIELD. NOSE GEAR LOCK ACTUATOR REP LACED, AND GEAR SWINGS C/O. CHECKED SERVICEABLE. TIMES- 59932:32 CYCLES- 55882. 2 L 7 2 4F 4 F A16WE E2EA 2005041900015 20050419 00015 NE 2005 4 19 CA041129009 2 20041129 G 7200 ENGINE BOEING 767 767233 1385113 NM PWA JT9 JT9D7R4D 52054 NE LEFT SURGES W O OTHER E VIBRATION/BUFFET CL CLIMB 1 CA (CAN) LOUD BANG AND YAW FELT AT CLIMB THRUST 7000 FT , RETURNED. ADDED MAINTENANCE INFO, LT ENG SURGE DET. MSG91827. LA NDING SMOOTH. 91827.(SIC) ACTION: DFDR CHANGED. REPLACED EVBC IAW MM-75-31-01. ENG. BOROSCOPE CARRIED OUT. NO FAULTS. ENG. TEST 8, 9 AND 10 CARRIED OUT NO FAULTS. CONS. SERVICEABLE. 2 L 7 2 4F 4 F RT A1NM E3NE 2004121000059 20041210 00059 NM 2004 12 10 CA041129010 1 20041128 G 5330 SKIN BOEING 737 737201 1384454 NM PWA JT8 JT8D9A 52048 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) FUSELAGE CRACK FOUND ON OUTER SKIN AT STN. 955.9 - 959.65 BELOW STR. 21L. FUSELAGE CRACK REPAIRED IAW SRM 53-30-3 FIG 48 DETAIL X. TIMES- 64477:16 2 L 7 2 4F 4 F A16WE E2EA 2005020100108 20050201 00108 CE 2005 2 1 CA041129011 1 20041127 G 2752 C3010020211 COUPLING CESSNA CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA MCAULY 1C160 1C160DTM GL ACTUATOR BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) STUDENT AND INSTRUCTOR WERE PERFORMING A WALK AROUND OF THE AIRCRAFT BEFORE GOING FOR A LESSON. STUDENT SELECTED FLAPS DOWN THEY STARTED TO GO DOWN THEN THE FLAPS STOPPED MOVING BUT THE MOTOR KEPT RUNNING. FLAP MOTOR WAS REMOVED AND IT WAS FOUND THAT THE COUPLING BETWEEN THE MOTOR AND THE ACTUATOR HAD BROKEN. NEW COUPLING WAS INSTALLED AND THE FLAPS WORKED CORRECTLY. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2005031400037 20050314 00037 SO 2005 3 14 CA041129012 1 20041109 G 2820 8004804 HOSE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL FUEL SYSTEM CRACKED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) AIRCRAFT ON TRAINING FLIGHT. PILOT REPORTS STRONG FUEL ODOR IN COCKPIT. INVESTIGATION REVEALED LT FUEL PRESSURE F LEXIBLE HOSE TO GAUGE LEAKING FROM UNDER HOSE FITTING SOCKET WHEN FUEL BOOST PUMP TURNED ON. THIS FUEL LEAK WAS A FINE M IST SPRAY. HOSES WERE DRY AND HARDENED DUE TO AGE. REPLACED ALL FLEXIBLE RUBBER HOSES TO LT AND RT GAUGES. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2004121000060 20041210 00060 2004 12 10 CA041129013 4 20041125 G 3418 861DL SENSOR FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE ANGLE OF ATTACK MALFUNCTIONED W C ABORTED TAKEOFF J WARNING INDICATION TO TAKEOFF 1 CA (CAN) NOV 25TH 2004, AIRCRAFT HAD A STALL COMPUTER FAULT, MFDU MESSAGE ON TAKEOFF ROLL. REJECTED THE TAKEOFF AT 90 KTS INDICATED. A DMI (DEFERRED MAINTENANCE ITEM) 14809 WAS RAISED IAW MEL 27-35-3, FOR A STALL WARNING COMPUTER TO BE REPL ACED, IT WAS REPLACED NOV 26TH ALONG WITH AN AOA VANE REPLACED IAW AMM. 2 L 7 2 4F 4 F RT E25NE 2005020100111 20050201 00111 EA 2005 2 1 CA041129014 1 20041129 G 2913 848847 PUMP CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE HYDRAULIC SYS CRACKED W O OTHER K J FLUID LOSS WARNING INDICATION CL CLIMB 1 CA (CAN) FAULT: ON CLIMB OUT MSP, CREW RECEIVED PAX DR HANDLE LATCH MSG, FOLLOWED BY HYD SYS 3 LOW PRESS. MSG FOLLOWED BY PAX DR WARNING MSG. ON AIR RETURN, ON APPROACH FLT, RECEIVED GEAR DISAGREE MSG AND CARRIED OUT MNL EXTENSION. FOUND LIN E LEAKING ON PUMP 3B. FOUND CASE CRACKED ON PUMP 3A. REPLACED BOTH 3A AND 3B HYD. PUMP REPLACED PRESS/RETURN AND CASE D RAIN FILTERS SYS. 3. REPLACED HYD. LINE ON PULSE DAMPENER PUMP 3B. HYD SYST. SERVICED. 2 L 7 2 4F 4 F RT A21EA E15NE 2004121000062 20041210 00062 WP 2004 12 10 CA041129015 1 20041125 G 2410 CSD DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE GENERATOR FAILED W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA (CAN) THE LEFT CSD LOW OIL PRESSURE LIGHT CAME ON IN FLIGHT. CSD DISCONNECTED PER QRH . AIRCRAFT DIVERTED. A DMI (DEFERR ED MAINTENANCE ITEM) 08580 WAS RAISED IAW MEL 24-1-1. MAINTENANCE LATER REPLACED THE CSD AND THE CSD OIL COOLER. 2 L 7 2 4F 4 F RT A6WE E9NE 2005012400015 20050124 00015 SW 2005 1 24 CA041129016 1 20041129 G 1430 AN45A BOLT AIRTRC AT802 AT802A 0390308 SW PWA PT6 PT6A67A 52043 NE HARTZL HCB5M HCB5MA3 GL VERTICAL STAB SHEARED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING ANNUAL INSPECTION THE IB FORWARD AUX FIN ATTACH BOLT WAS FOUND SHEARED AT THE HEAD. IT APPEARS THAT THE FI N WAS INSTALLED WITH A PRE LOAD CAUSING THE BOLT TO FAIL. SUB-CONTRACTOR HAS BEEN NOTIFIED OF THIS OCCURRENCE AND IS CU RRENTLY INVESTIGATING THE REQUIREMENT FOR A SHIM INSTALLATION. THE REMAINING ATTACH BOLTS WILL BE REMOVED FOR NDT INSPE CTION TO ENSURE THE SERVICEABILITY OF THE BOLTS PRIOR TO RE-INSTALLATION. 1 L 7 1 3T 4 T NC A19SW E26NE 6 C P44GL 2004121000063 20041210 00063 GL 2004 12 10 CA041129017 2 20041121 G 7240 6870992C COMBUSTION LINER BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL ENGINE CRACKED W O OTHER J WARNING INDICATION CR CRUISE 1 CA (CAN) THE PILOTS WERE DOING TRAINING, THEY NOTICED AN INCREASE IN TOT. DID A POWER CHECK AND FOUND THAT THE ENGINE WAS BELOW SPEC. AIRCRAFT RETURNED TO BASE AND IT WAS DISCOVERED THAT THE THERE WAS A 1 INCH CRACK THAT FOLLOWED A WELD IN T HE E ARM PIT AREA. NOTE: IN THIS REGION THERE IS A MESHED DOUBLER. 1 G 7 1 3U 3 U H2SW E4CE 2004121000023 20041210 00023 EA 2004 12 10 CA041129018 2 20041126 G 7310 MANIFOLD PWA PT6 PT6A27 52043 EA FUEL SYSTEM MALFUNCTIONED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) AFTER REPLACING A SET OF FUEL MANIFOLD ADAPTERS ON A PT6A-27 ENG, A GROUND RUN WAS CARRIED OUT. THE RESULTING GROU ND RUN SHOWED SIGNS OF FUEL LEAKAGE FROM THE TRANSFER TUBES P/N 3011155.ENGINE PERFORMANCE DATA SHOWED THAT THE T5 TEMPE RATURE AND FUEL FLOW NUMBERS WERE HIGHER THAN BEFORE REPLACEMENT. AFTER FURTHER TROUBLESHOOTING AND GROUND RUNS, THE T5 AND WF REMAINED ABOVE TARGET LIMIT ONDATA PLATE SPEED RUNS. AFTER DOUBLE CHECKING CALIBRATION OF THE T5 TEMPERATURE SYS TEM AND TORQUE INDICATION SYSTEM, ANOTHER SET OF GROUND RUNS WERE CARRIED OUT. THE RESULTS SHOWED CONTINUED HIGH T5 AND HIGHFUEL FLOW.THE ENGINE WAS THENSPLIT AT THE 'C' FLANGE AND A HOT SECTION INSPECTION CARRIED OUT. 4 T E4EA 2005020100072 20050201 00072 CE 2005 2 1 CA041130001 1 20041128 G 2130 CM357024 COUPLER CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE CABIN PRESSURE DISCONNECTED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) COUPLING DISCONNECTED WHEN AIRCRAFT WAS AT FLIGHT LEVEL AND AIRCRAFT AT A OPERATING CABIN PRESSURE ALTITUDE. AIRCR AFT CABIN LOST PRESSURIZATION. 1 L 7 2 4F 4 F A22CE E1NE 2004121000025 20041210 00025 NM 2004 12 10 CA041130002 1 20041117 G 5512 653120043 PANEL BOEING 727 727217 1384061 NM PWA JT8 JT8D17 52049 NE HORIZONTAL STAB SEPARATED W K NONE O OTHER IN INSP/MAINT 1 CA 71148 (CAN) RT HORIZONTAL STABILIZER-TO-FIN SLIDING SEAL SEPARATED FROM AIRCRAFT DURING FLIGHT. DAMAGE WAS ALSO FOUND ON AN A DJACENT COMPOSITE VERTICAL FIN PANEL AND THE LOWER SURFACE OF THE HORIZONTAL STABILIZER, CAUSED BY SEPARATION OF THE SLI DING SEAL FROM THE AIRCRAFT. 2 L 7 3 4F 4 F RT A3WE E2EA 2005031100105 20050311 00105 EA 2005 3 11 CA041130003 1 20041112 G 3222 162005 BEARING MENASCO DHAV DHC7 DHC7102 2802708 EA PWA PT6 PT6A50 52043 EA HAMSTD 24PF 24PF305 GL MLG FAILED W O OTHER O OTHER CL CLIMB 1 CA (CAN) THE AIRCRAFT ON DEPARTURE RETRACT, THE GEAR WOULD NOT RETRACT. POSITION INDICATION LIGHTS REMAINED GREEN AND THE G EAR SELECTOR LEVER WAS ILLUMINATED AND REMAINED SO. NO CIRCUIT BREAKERS WERE TRIPPED ON THE FLIGHT DECK. THE AIRCRAFT LA NDED WITHOUT INCIDENT, THERE WAS NO INJUURY TO PASSENGERS OR FLIGHT CREW. THE AIRCRAFT WAS FERRIED FOR REPAIRS, ALL NOSE AND MAIN WEIGHT SWITCHES WERE CHECKED, ALL WIRING FOR THE LANDING GEAR SYSTEM WAS CHECKED INC WITH MFG WIRING MANUAL 32 -00-00, NO FAULT FOUND. LANDING GEAR RETRACTIONS AND EXTENSIONS CARRIED OUT, FIVE TIMES BUT COULD NOT GET FAULT TO REPEA T ITSELF. DECIDED TO REPLACE ALL MAIN LANDING GEAR WEIGHT SWITCHES, AS A PRECAUTION, P/N 21HE23RB, QTY 4. 2 H 7 4 4T 4 T A20EA E4EA 6 C P1NE 2005020100073 20050201 00073 CE 2005 2 1 CA041130004 1 20041116 G 7931 040031178 LINE CESSNA 150 150L 2071826 CE CONT O200 O200A 17020 SO MCAULY 1A102 1A102OCM GL OIL PRESS WORN W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) THE OIL PRESSURE LINE UNDER THE INSTRUMENT PANEL WAS CHAFED AGAINST THE CABIN HEATER CONTROL CABLE. WE REPLACED T HE PRESSURE LINE AND INSTALLED IT CORRECTLY. 1 H 7 1 3O 3 O 3A19 E252 5 N P918 2004121000026 20041210 00026 GL 2004 12 10 CA041130005 2 20040930 G 7230 230397911 COUPLING RROYCE AGUSTA A109 A109 0260109 EU ALLSN 250C 250C20B 03013 GL COMPRESSOR SHEARED W B EMER. DESCENT W Y M INADEQUATE Q C ENGINE STOPPAGE OVER TEMP CR CRUISE 1 CA CAC39323 (CAN) AFTER FRETTING WEAR OVER PILOT OUTSIDE DIA, THE ADAPTER COUPLING SHEARED IN T (TWO) PARTS. REFERENCES: CEB A-1392 FROM CEB 250-C20 SERIES. 1 G 7 2 3U 3 U H7EU E4CE 2005020100122 20050201 00122 GL 2005 2 1 CA041130006 1 20041113 G 2752 SEAL DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240B 17063 SO SNSNCH W69EK W69EK63 EA FLAP ACTUATOR LOOSE W O OTHER F FLT CONT AFFECTED CL CLIMB 1 CA (CAN)A/C HAD FLAP STUCK FULL DOWN. INSP REVEALED FLAP ACT SEAL HAD COME LOOSE, INTERFERED WITH NR 5 FLAP SWITCH. WILL T AKE ACTUATOR FROM OTHER AC TO USE ON THIS A/C. INSP REVEALED THAT SEAL ON OTHER A/C HAD COME LOOSE TOO, BUT HAD NOT YET CONTACTED SWITCHES, PROCEEDED TO RE-GLUE SEAL IAW INSTRUCTIONS INSTALLED UNIT ON THIS A/C. UNIT WHICH WAS REMOVED FRO M MFB WAS FURTHER INSPECTED, SEAL RE-GLUED, TAB OF NR 5 SWITCH WAS STRAIGHTENED, UNIT INSTALLED IN OTHER A/C, GROUND TES TED SERVICEABLE. 1 L 7 1 3O 3 O NT TA4CH E7SO 5 N TA4CH 2005031400044 20050314 00044 GL 2005 3 14 CA041130007 1 20041113 G 2752 SEAL DIAMON 222750010 DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240B 17063 SO SNSNCH W69EK W69EK63 EA FLAP ACTUATOR LOOSE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AC HAD THE FLAP STUCK FULL DOWN. INSP REVEALED THAT FLAP ACTUATOR SEAL HAD COME LOOSE AND INTERFERED WITH THE NR5 FLAP SWITCH. A/C WAS IN MAINT FOR A TOTALLY UNRELATED DEFECT, TROUBLESHOOTING DECIDED, THAT WE TAKE THE ACTUATOR FROM IT TO USE ON A/C. INSP REVEALED THAT THE SEAL ON A/C HAD COME LOOSE TOO, BUT HAD NOT YET CONTACTED THE SWITCHES AND THEREF ORE WE RE-GLUED SEAL IAW MFG INSTRUCTIONS AND INSTALLED THIS UNIT ON MFB. THEREAFTER UNIT WHICH WAS REMOVED FROM MFB WAS FURTHER INSPECTED, SEAL RE-GLUED AND TAB OF NR5 SWITCH WAS STRAIGHTENED. UNIT INSTALLED IN OTHER A/C AND GROUND TESTED SERVICEABLE. 1 L 7 1 3O 3 O NT TA4CH E7SO 5 N TA4CH 2005041900016 20050419 00016 GL 2005 4 19 CA041130008 1 20041126 G 2752 SEAL DIAMON DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240B 17063 SO SNSNCH W69EK W69EK63 EA FLAP ACTUATOR LOOSE W K NONE O OTHER IN INSP/MAINT 1 CA WITH FLAPS STUCK AT LANDING POSITION DURING WALK AROUND. INSPECTION REVEALED ANOTHER FLAP ACTUATOR SEAL SEPARATION. A/C HAD JUST UNDERGONE A 200 HR INSPECTION AT WHICH TIME SEAL INSPECTED & FOUND TO BE IN PLACE. SEAL AREA IS COVED BY A COM POSITE COVER WHICH IS SOMEWHAT SEE THROUGH BUT DOES NOT ALLOW FOR A PHYSICAL CHECK OF SEAL POSITION ONLY A VISUAL. 1 L 7 1 3O 3 O NT TA4CH E7SO 5 N TA4CH 2005041900017 20050419 00017 NE 2005 4 19 CA041130009 2 20041126 G 7250 RIVET PWA PT6 PT6A67D NE ENGINE SHEARED W O OTHER O OTHER NR NOT REPORTED 1 CA PS114139 A FIELD SERVICE REPRESENTATIVE WAS SERVICING THE POWER SECTION WHEN HE NOTICED A LOOSE NR 3 BEARING COVER. THE LOOSE BE ARING COVER HAD COME INTO CONTACT WITH THE 2ND STAGE PT DISK, RENDERING IT SCRAP. THE BEARING COVER LOCATES IN THE PT S HAFT HOUSING USING 6 LOCATING LUGS (P/N 3030491) AND 6 RIVETS (P/N AN123318). FIVE OF THE 6 RIVETS WERE SHEARED. THE R IVETS HAVE BEEN IN SERVICE FOR AT LEAST 5034 HOURS AND POSSIBLE AS HIGH AS 12757 HOURS. 4 T E26NE 2005020100097 20050201 00097 WP 2005 2 1 CA041130010 1 20041128 G 2611 WARNING LIGHT DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE CABIN SMOKE ILLUMINATED W O OTHER N FALSE WARNING TX TAXI/GRND HDL 1 CA (CAN) TAXIING FOR DEPARTURE, ANNOUNCEMENT TO DIM CABIN LIGHTS, ROWS 10 TO 11 STARTED TO PUSH CALL BUTTONS TO INDICATE SM OKE IN THAT AREA. CREW COULD NOT LOCATE SOURCE OF SMOKE. FLIGHT CREW DECLARED EMERGENCY EVACUATION. MAINT INSPECTED FOL LOWING; CABIN LIGHTING, CEILING PANEL IN FWD AREA WAS LOWERED IN ORDER TO INSPECT CB AND TRANSFORMERS, AISLE CEILING LIG HT (IN FWD AREA) SOCKET AND BALLAST, UPPER SIDEWALL LAMP SOCKETS ROWS 1 TO 12 LT AND RT WERE INSPECTED FOR EVIDENCE OF A RCING. REPLACED 2 BALLASTS AT SEAT ROWS 16L, 18R (AS THEY WERE FOUND INOP, NO SIGNS OF ARCING OR BURNING). INSPECTED CAR GO COMPARTMENTS. RECIRCULATION FAN. APU OIL QUANTITY. APU ENGINE RUN C/OUT. NO FAULTS WERE FOUND. 2 L 7 2 4F 4 F RT A6WE E9NE 2005020100099 20050201 00099 CE 2005 2 1 CA041130011 1 20041122 G 2410 AC2101 CONTROL UNIT CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA MCAULY 1C235 1C235LFA GL ALTERNATOR FAILED W D RETURN TO BLOCK H ELECT. POWER LOSS-50 PC TX TAXI/GRND HDL 1 CA (CAN) ALTERNATOR FIELD C/B TRIPPED WHEN ALTERNATOR TURNED ON. ZERO VOLTS FOUND AT ALT FIELD TERMINAL. REPLACED ALTERNA TOR CONTROL RELAY, NO CHANGE. REPLACED ALTERNATOR CONTROL UNIT, VOLTAGE AT FIELD TERMINAL OF ALTERNATOR. ALTERNATOR FU NCTIONING NORMALLY DURING GROUND RUNUP. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P12EA 2005020100090 20050201 00090 CE 2005 2 1 CA041130012 1 20041129 G 2435 23048018 STARTER GEN BEECH 100 A100 1152915 CE PWA PT6 PT6A28 EA HARTZL HCB4T HCB4TN3 GL LEFT FAILED W H A DEACTIVATE SYST/CIRCUITS UNSCHED LANDING B J SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CR CRUISE 1 CA (CAN) DURING CRUISE FLIGHT AT 12000 FEET THE PILOTS NOTICED THE LT GENERATOR FAIL LIGHT CAME ON. ALSO A PASSENGER INDIC ATED THAT HE NOTICED SPARKS COMING FROM THE ENGINE. THE GENERATOR WAS SELECTED OFF AND AIRCRAFT RETURNED TO BASE FOR INS PECTION. MAINTENANCE INSPECTED THE AIRCRAFT AND NOTICED THAT THE REAR BEARING IN THE STARTER GENERATOR HAD FAILED CAUSI NG IT TO SELF-DESTRUCT. THE GENERATOR WAS REPLACED, ENGINE WAS INSPECTED FOR DAMAGED AND AIRCRAFT WAS RETURNED TO SERVI CE. 1 L 7 2 3T 4 T A14CE E4EA 6 C P40EA 2005020100144 20050201 00144 NE 2005 2 1 CA041201002 1 20041130 G 5314 7620202003101 KEELBEAM SKRSKY S76 S76A 8143006 NE FUSELAGE UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 CA 11167 (CAN) KEELBEAM LOWER CONDUIT IS A BOX SECTION EXTRUSION WHICH RUNS FROM STA 188 TO STA 255. IT IS LOCATED ON FUSELAGE T UBE IN BETWEEN TWO FUEL CELLS. SIX HYDRAULIC TUBES ARE INSTALLED INSIDE CONDUIT AND ARE SECURED IN PLACE BY RUBBER BLOCK S. MOISTURE IS INTRODUCED POSSIBLY THROUGH BLOCKS AND IS RETAINED IN THE EXTRUSION, CAUSING CORROSION, ALMOST TO POINT O F PERFORATION. LT UNCHECKED THIS WOULD RESULT IN FUEL LEAKS FROM INTEGRAL TANKS. THE INTERNAL CORROSION BUILD UP WAS SO SEVERE THAT HYDRAULIC TUBES COULD NOT BE REMOVED BY NORMAL MEANS AND WERE DESTROYED IN REMOVAL. ONCE INITIATED, CORROS ION GROWTH APPEARS TO BE RAPID. RECOMMEND A PERIODIC INSPECTION OF THIS AREA WITH THE YEARLY CALENDAR INSPECTION. 1 G 7 2 3U H1NE 2005020100075 20050201 00075 EU 2005 2 1 CA041201003 1 20041128 G 3211 5531012326 ATTACH BRACKET PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL SUPPORT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING A 100 HOUR INSPECTION, A CRACK WAS FOUND ON THE BRACKET WHICH ATTACHES THE NOSE GEAR ACTUATOR TO THE AIRFRA ME. THE SUPPORT, PN 553.10.12.326 WAS ORDERED AND IS CURRENTLY BEING REPLACED. OTHER AIRCRAFT IN OUR OWN FLEET WERE IN SPECTED AS WELL WITH NO DEFECTS FOUND. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005041900018 20050419 00018 WP 2005 4 19 CA041202001 2 20041201 G 7250 RIVET GARRTT TPE331 TPE33110UA 01514 WP TURBINE WHEEL SEPARATED W K NONE D C INFLIGHT SEPARATION F.O.D. IN INSP/MAINT 1 CA P54214 UPON A REGULARLY SCHEDULED HOT SECTION INSPECTION THE NR 2 TURBINE WHEEL WAS FOUND TO HAVE A RIVET MISSING AT THE BASE O F ONE OF THE TURBINE BLADES. THIS RIVET INSTALLATION IS FOR EXPANSION PURPOSES. THE 3RD STAGE TURBINE AND STATOR ASSY WAS FOUND DAMAGED FROM THIS RIVET AS IT PASSED THROUGH IT AFTER DISLODGING FROM THE NR 2 TURBINE. OUR COMPANY TURBINE S HOP MANAGER HAS WITNESSED THIS SAME PROBLEM SEVERAL TIMES IN THE PAST. 4 T E4WE 2005020100087 20050201 00087 NM 2005 2 1 CA041202002 1 20041202 G 3234 114079016 SELECTOR VALVE AIRBUS A319 A319114 3930350 NM CFMINT CFM56 CFM565A1 NE MLG FAILED W O OTHER J WARNING INDICATION CL CLIMB 1 CA (CAN) FAULT: AFTER T/O AND GEAR UP, NR 1 LGCIU ECAM MSG ON. ALSO DURING A GO-AROUND AFTER GEAR SELECTED UP, MASTER (RED ) WARNING CAME ON WITH MSG. (GEAR DISAGREEMENT) DURING APROX. 10 SEC.ACTION: MLG DOOR SEL VALVE REPLACED IAW MM 32-31-3 4. FUNCTIONAL CHECK CARRIED OUT OK, LEAK CHECK C/OUT SERVICE. 2 L 7 2 4F 4 F RT A28NM E29NE 2005012400026 20050124 00026 CE 2005 1 24 CA041202003 1 20041202 G 2434 66082019 GENERATOR LEAR 35 35LEAR 5170600 CE GARRTT TFE731 TFE73122B 01518 WP RT DC FAILED W B EMER. DESCENT B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) RT DC GENERATOR FAILED. SMOKE NOTICED IN THE CABIN BY PASSENGER. 2 L 7 2 4F 4 F A10CE E6WE 2005012400027 20050124 00027 CE 2005 1 24 CA041202004 1 20041126 G 2710 666000163 CONTROL CABLE CESSNA 560 560XL 2076702 CE PWA 545 PW545A NE LT OB AILERON BROKEN W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) DUE TO THE RISK ASSOCIATED TO BROKEN MAIN CONTROL CABLES, FOLLOWING THE BROKEN RT WING DOWN OB AILERON CABLE P/N 6 660001-62 AT RWS 54 (REF. SDR NR 20031113014), WE DECIDED TO INSPECT THE AILERON WING CABLES MORE FREQUENTLY THAN THE 1 200 HRS REQUIRED BY THE PHASE 61. LT WING UP OB AILERON CABLE P/N 6660001-63 WAS FOUND WORN AT LWS 54 AND LWS 78 WITH B ROKEN STRANDS AT LWS 54 ONLY. THE CABLE WAS ORDERED AOG AND INSTALLED THE CABLE WAS REPLACED ON LAST PHASE 51 INSPECTION (NOW PHASE 61) HAS BEEN NOTIFIED. UNTIL MFG COMES WITH A NEW FREQUENCY INSPECTION WE ARE LOWERING THE INTERVAL INSPECTI ON AT 500 FLIGHT HOURS. 2 L 7 2 4F 4 F RT A22CE E00059EN 2005012400028 20050124 00028 SW 2005 1 24 CA041202005 1 20041202 G 1430 AN6C13A BOLT AIRTRC AT802 AT802A 0390308 SW PWA PT6 PT6A67A 52043 NE HARTZL HCB5M HCB5MA3 GL HORIZONTAL STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING ANNUAL INSPECTION THE HORIZONTAL STABILIZER STRUT ATTACH BOLTS WERE REMOVED FOR INSPECTION. THE LOWER RH BO LT WAS SUSPECTED OF BEING CRACKED. THE BOLT WAS LPI INSPECTED AND THE CRACK WAS VERIFIED. ALL AIRCRAFT IN OUR FLEET WI LL HAVE THE BOLTS INSPECTED USING THE LPI METHOD. WE WILL REPORT ANY FURTHER FINDINGS OF CRACKS. 1 L 7 1 3T 4 T NC A19SW E26NE 6 C P44GL 2005020100017 20050201 00017 EU 2005 2 1 CA041202006 2 20041202 G 7200 ENGINE BRAERO 748 HS7482A 4231001 EU RROYCE DART DART5342 EU ROTOL R4304 R2124304 EU RIGHT FAILED W A UNSCHED LANDING X P ENGINE FLAMEOUT NO WARNING INDICATION CR CRUISE 1 CA (CAN) AC WAS ENROUTE, WHILE IN CRUISE THE AC YAWED TO THE RT AND THE STBD ENGINE SPOOLED DOWN. IN-FLIGHT SHUTDOWN PROCE DURE WAS CARRIED OUT AND THE AC RETURNED, WHERE AN UNEVENTFULL LANDING WAS MADE. UNTIL THE ENGINE SHUT DOWN, OPERATING I NDICATION WERE NORMAL. MAINTENANCE INSPECTION REVEALED HEAVY STEEL CONTAMINATION OF THE OIL FILTERS, INCLUDING A COMPLET E CROWN FROM A GEAR WHEEL. INITIAL INVESTIGATION INDICATES THE PROPELLER GEAR BOX FAILED.THIS ENGINE IS DUE FOR OVERHAUL AND THE ENSUING STRIP REPORT WILL FURNISH A MORE IN DEPTH REPORT. 2 L 7 2 3T 4 T A24EU A196 6 C P899 2005012400029 20050124 00029 EA 2005 1 24 CA041203001 1 20041203 G 2897 WIRE CNDAIR CL215 CL2156B11415 EA PWA PW120 PW123 NE HAMSTD 14SF 14SF* NE LT WING CHAFED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING AN INSPECTION ( B CHECK ), FOUND JUST ABOVE THE PRESSURE REFUELLING LINE, LOCATED ON LT WING W/S 196 (ACCES S PANEL 541-5), AN ELECTRIC WIRE, THAT GOES TO THE FUEL DRAIN SOLENOID VALVE, CHAFED. IT DID CAUSE AN ARCING. 2 H 7 2 4T 4 T RT A14EA E20NE 6 C P7NE 2005020100018 20050201 00018 NM 2005 2 1 CA041203002 1 20041203 G 3251 C24736001 CONTROL VALVE AIRBUS A319 A319114 3930350 NM GE CFM56 CFM565A 13802 NE NLG STEERING INOPERATIVE W O OTHER L NO TEST CR CRUISE 1 CA 33284 19954 (CAN) IN CRUISE, WHEEL NOSE WHEEL STEERING FAULT . TRIED RESET ANTI-SKID /NW STEERING SWNO FIX. NO NW STEERING ON LANDI NG. TOWED TO GATE. TESTED BSCU 1 AND 2 FAULTED NLG STEERING SERVO FTN 6GC. IAW TSM AND AMM REPLACED NLG STEERING SERV O FTN 6GC. OPERATION TEST PERFORMED BSCU 1 AND 2 TESTED, NO FAULTS. 2 L 7 2 4F 4 F RT A28NM E29NE 2005041900019 20050419 00019 SW 2005 4 19 CA041203003 1 20041202 G 2150 35BD219DUM BEARING BELL 412 412 1182202 SW PWA PT6T PT6T3B 52045 NE TRANSMISSION FAILED W A UNSCHED LANDING D INFLIGHT SEPARATION CR CRUISE 1 CA 21 (CAN) IN FLIGHT NOISE WAS HEARD AND SMALL AIRFRAME VIBRATION. A/C LANDED AS PRECAUTION AT AIRPORT. AIRCRAFT INSPECTED AN D PROBLEM NOT DETECTED. COULD NOT DUPLICATE NO ISE OR VIBRATION. A/C FLOWN TO BASE AIRPORT. UPON FURTHER INVESTIGATION B EARING IN SPEED REDUCER FOUND FAILED DAMAGE LIMITED TO BEARING. 1 G 7 2 4U 4 U H4SW E22EA 2005041900020 20050419 00020 EU 2005 4 19 CA041203004 1 20041202 G 2430 U37151 CONTROL UNIT BRAERO 748 HS7482A 4231001 EU RROYCE DART DART5342 EU VOLT PROTECTION FAILED W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 CA (CAN) ON 2/12/04, AT 22:30 THE A/C WAS IN CLIMB OUT OF YYQ. SMOKE AND FUMES WERE NOTED IN THE CABIN, AND SUBSEQUENTLY IN THE COCKPIT. AN UNEVENTFULL LANDING WAS MADE. THERE WERE NO ABNORMAL INSTRUMENT INDICATIONS DURING THIS OCCURRENCE. MAI NTENANCE INVESTIGATION REVEALED THE PORT ALTERNATOR VOLTAGE CONTROL PROTECTION UNIT HAD FAILED. THE UNIT WAS REPLACED AN D SYSTEM CHECKS SHOWED NORMAL OPERATION. WIRING HARNESSES WERE INSPECTED AND NO DETERIORATION WAS FOUND. THE A/C WAS REL EASED TO SERVICE. 2 L 7 2 3T 4 T A24EU A196 2006061200431 20060612 00431 2006 6 12 CA041203005 4 20041019 G 2562 BP1045 BATTERY EBC LAKEAC LAKE 250LAKE 5110322 NE LYC O540 IO540C4B5 41532 EA HARTZL HCE3Y HCE3YR1 GL ELT WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 74739GA UNDER MANUF INSPECTION AND RECERTIFICATION PROCESS, CANADIAN AIR MOTIVE FOUND ILLEGAL AND UNAPPROVED BATTERY PACK INSIDE ELT (NOT EXPIRED CONDITION AUG 2006). AS PER EBC MANDATORY CLASS 1 SERVICE BULLETIN NO.: 8401, ONLY GS21 OR GS51 IS AP PROVED FOR THIS ELT MODEL. THIS SB 8401 IS IN CONFLICT WITH BATTERIES APPROVED BY TRANSPORT CANADA AND INDUSTRY CANADA (AIRWORTHINESS NOTICE NO.: B014 EDITION 5; 28 MARCH 2002). 1 H 7 1 3O 3 O NC 1A13 1E4 5 C P33EA 2005041900021 20050419 00021 NM 2005 4 19 CA041203006 1 20041128 G 5330 SKIN BOEING 737 7372Q9 138448M NM PWA JT8 JT8D9A 52048 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AN OUTER FUSELAGE CRACK WAS FOUND AT STR 16 LT BETWEEN STA 767 & 787 APPROX 2 INCHES LONG. FUSELAGE CRACK REPAIRED IAW SRM 53-30-1 FIG.48 PROCEDURES I, IV & VII. THIS REPAIR IS TIME LIMITED UNTIL 25 FEB. 04. TIMES- 61761:52 CYCLES- 57 769. 2 L 7 2 4F 4 F A16WE E2EA 2005041900022 20050419 00022 EU 2005 4 19 CA041203007 1 20041203 G 6730 LINE SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE SERVO LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) FLUID LEAK AT UPPER HOUSING SPLIT LINE. 1 G 7 1 3U 3 U H9EU E19EU 2005041900023 20050419 00023 NM 2005 4 19 CA041203008 1 20041201 G 3897 WIRE BOEING 737 7372H4 138448C NM PWA JT8 JT8D9A 52048 NE POT WATER TANK ARCED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) THE POTABLE WATER INDICATION BECAME INOPERATIVE AND WAS DEFERRED. TROUBLESHOOTING FOUND WIRES IN THE AREA NEAR THE WATER TANK ON A BELLY STRINGER AT STN 960 TO BE BURNED BY ARCING. WIRES AFFECTED WERE POTABLE WATER INDICATION, R2 DOOR WARNING LIGHT AND LAV DUMP GASKET HEATER. THE AREA WAS WET FROM CONDENSATION WHICH HELPED TO PROMOTE THE ARCING. THE WI RES WERE REPAIRED PER AMM. 2 L 7 2 4F 4 F A16WE E2EA 2005041900024 20050419 00024 NM 2005 4 19 CA041206001 1 20041204 G 2612 10109601 FIRE LOOP BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA NR 2 ENGINE MALFUNCTIONED W E ENGINE SHUTDOWN N FALSE WARNING CR CRUISE 1 CA (CAN) AN AIRCRAFT EXPERIENCED A NR 2 ENGINE FIRE WARNING IN FLT. CREW SHUT ENGINE DOWN AND FIRE WARNING CEASED. FIRE BOT TLES NOT DISCHARGED. A/C LANDED ON NR 1 ENGINE SATISFACTORILY. A/C NOT DIVERTED FROM ORIGINAL DESTINATION. FULL EMERGEN CY DECLARED.INITIAL INSPECTION REVEALS NO FUEL, OIL OR AIR LEAKS AND THERE IS NO PHYSICAL DAMAGE APPARENT. PEC LOOP REM OVED. BOTH ITEMS HAVE A P/N 10-1096-01 WHICH IAW IPC 26-11-03-01 ITEM 30, IS POST SB 84-26-03. A/C HAS COMPLETED ENGINE RUNS WITH BLEED AIR BOTH OFF AND ON, AFTER PEC LOOP REPLACEMENT. ALL IS OPERATING CORRECTLY. AIRCRAFT HAS BEEN SIGNED U P AS SERVICEABLEAND IS BACK INTO SERVICE. 2 H 7 2 4T 4 T RT A13NM E00062EN 2005041900025 20050419 00025 EU 2005 4 19 CA041206002 1 20041206 G 7931 41SG3811 TRANSMITTER AIRBUS A321 A321211 3930370 EU CFMINT CFM56 CFM563B1US GL ENGINE OIL FLUCTUATES W O OTHER N FALSE WARNING CR CRUISE 1 CA (CAN) IN CRUISE WE HAD TO SLOW DOWN OIL PRESS NR 2 FLASHED GREEN 14 PSI. HAD SOME POWER THE PRESSURE FLUCTUATED BETWEEN 18-19 PSI WHEN POWER WAS SELECTED TOWARD IDLE OIL PRESSURE WENT TO 10 PSI (RED). WE KEPT THE POWER UP DURING DECENT AND APPROACH. REPLACED OIL PRESS. TRANSMITTER. OPERATIONAL CHECK CARRIED OUT AT IDLE AND HIGH POWER OIL PRESSURE NORMAL. LEA K CHECK CARRIED OUT, NIL LEAKS. 2 L 7 2 4F 4 F RT A28NM E2GL 2005041900026 20050419 00026 NE 2005 4 19 CA041206003 2 20041202 G 7200 ENGINE BEECH MU300 400A 1155402 CE PWA JT15 JT15D5 52112 NE BOTH MALFUNCTIONED W A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 CA JA03070308 (CAN) AT 15,000 FT IN LEVEL FLIGHT BOTH ENGINES EXPERIENCED A SIMULTANEOUS, UNCOMMAMDED, PARTIAL POWER ROLL-BACK. THE A IRCRAFT DIVERTED TO POINT OF DEPARTURE. SUBSEQUENT GROUND RUNS WERE UNABLE TO DUPLICATE THE EVENT. AIRFRAME CONTROL CA BLES AND ENGINE BOV ACTUATOR RODS WERE FOUND MISRIGGED AND CORRECTED. PWC WILL IN VESTIGATE TO ESTABLISH ROOT CAUSE AND WILL AMEND THIS REPORT TO REFLECT SAME, ONCE AVAILABLE. 2 H 7 2 4F 4 F RT A16SW E25EA 2005041900027 20050419 00027 SO 2005 4 19 CA041206004 1 20041203 G 2410 ALT8421R ALTERNATOR PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA RT ENGINE SEIZED W O OTHER H ELECT. POWER LOSS-50 PC CR CRUISE 1 CA (CAN) ON A FLIGHT, PILOT NOTIED RH ALT OUT LIGHT CAME ON. PILOT CONTINUED FLIGHT AIRPORT. MAINTENANCE THE NEXT MORNING NOTICED THAT THE RT ALTERNATOR BELT HAD BROKEN AND THAT THE ALTERNATOR WAS SEIZED. ALTERNATOR WAS REMOVED AND DISSASSEMB LED FRONT AND REAR BEARINGS WERE DESTROYED AND BRUSH HOLDER WAS DAMAGED. 1 L 7 2 3O 3 O A20SO E14EA 2005041900028 20050419 00028 EA 2005 4 19 CA041206005 1 20041206 G 3246 C6FSM225627 PLATE DHAV DHC6 DHC6300 2802606 EA FUSELAGE MISDRILLED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) MAIN BOLT AND SPIGOT HOLES ARE DRILLED APPROXIMATELY 0.250 INCHES TOO FAR AFT WHICH DOES NOT ALLOW MINIMUM EDGE DI STANCE FOR THE AFT ROW OF RIVETS TO BE MAINTAINED. ONLY PROVIDES 7/32' (0.21875') EDGE DISTANCE FOR A MS20470AD6 RIVET WHEREMINIMUM EDGE IS 3/8' (0.375'). 1 H 7 2 3T RT A9EA 2005041900029 20050419 00029 NE 2005 4 19 CA041206006 2 20041203 G 7200 ENGINE BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE MALFUNCTIONED W O OTHER R J PARTIAL RPM/PWR LOSS WARNING INDICATION AP APPROACH 1 CA 114079 (CAN) ON APPRAOCH THE ENGINE EXPERIENCED A POWER LOSS ACCOMPANIED BY LOW OIL AND FUEL PRESSURE WARNINGS. THE AIRCRAFT LA NDED AT POINT OF DESTINATION. THE EVENT WAS NOT REPRODUCED DURING SUBSEQUENT GROUND AND FLT TESTS. THE FUEL CONTROL UNI T HAS BEEN REPLACED. PWC WILL MONITOR THE INVESTIGATION AND WILL AMEND THIS REPORT TO PROVIDE ROOT CAUSE, ONCE DETERMIN ED. 2 L 7 2 4T 4 T RT A24CE E26NE 2005041900030 20050419 00030 WP 2005 4 19 CA041206007 2 20041201 G 7321 8978015 FUEL CONTROL SWRNGN SA227 SA227* SW GARRTT TPE331 TPE33111U 01514 WP MCAULY 4HFR34 4HFR34C652 NE LT ENGINE MALFUNCTIONED W A UNSCHED LANDING E VIBRATION/BUFFET DE DESCENT 1 CA P44722C (CAN) UPON DESCENT FORM 25,000 FT THROUGH MODERATE TURBULENCE, THE LT ENGINE POWER WOULD NOT RETARD. THE POWER LEVER WAS MOVED FROM FULL POWER TO FLIGHT IDLE AND NO REPSONSE. UPON REACHING 20,000 FT THE ENGINE BECAME RESPONSIVE AGAIN TO PO WER LEVER MOVEMENT. THE AIRCRAFT WAS RUN ON THE GROUND BY MAINTENANCE PERSONNEL AND NO FAULTS COULD BE FOUND. IN DISCU SSION WITH THE MANUFACTURER, MAINTENANCE ELECTED TO REPLACE THE THE P2T2 SENSOR. GROUND RUNS CARRIED OUT ALL WITHIN MAN UFACTURERS PARAMETERS AND AIRCRAFT RETURNED TO SERVICE. SNAG AHS NOT DUPLICATED ITSELF AGAIN. 2 L 7 2 4T 4 T RT A5SW E4WE 6 C 3PNE 2005041200034 20050412 00034 CE 2005 4 12 CA041206008 1 20041130 G 5711 5011002611 SPAR BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL LT WING CRACKED W O OTHER F FLT CONT AFFECTED LD LANDING 1 CA 24431 (CAN) DURING LANDING PHASE AIRCRAFT ROLLED TO LT WHEN APPROACH FLAPS WERE SELECTED. ROLL RESPONSE WAS CORRECTED WITH AIL ERON TRIM INPUT. FURTHER FLAP DEPLOYMENT DID NOT CREATE ANY FURTHER CONTROL DIFFICULTY. MAINTENANCE INSPECTED AIRCRAFT AND DISCOVERED THAT THE RT OUTER FLAP WAS NOT SYMETRICAL TO OTHER FLAPS. THE IB FLAP HANGAR HAD CHANGED POSITIONS DUE TO A CRACK IN THE REAR SPAR WEB AT THE FLAP HANGAR ATTACH POINT. SEVERAL OTHER ANGLES AND BRACKETS WERE ALSO BROKEN. A R EPAIR SCHEME WAS REQUESTED FROM MFG. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2005041900031 20050419 00031 NM 2005 4 19 CA041207001 1 20041207 G 3397 2067081 CONNECTOR DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE LIGHT BURNED W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA (CAN) AN OPERATOR HAS FOUND BURNED PINS ON THE LT SIDEWALL LIGHTING CONNECTOR 3320-P39/J39. DUE TO THE PLUG DAMAGE THEY WILL REPLACE THE CONNECTOR AND THE BURNED PIN OR PINS SHOWING SIGNS OF OVERHEATING. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005041900032 20050419 00032 SW 2005 4 19 CA041207004 1 20041206 G 6320 222040111101 SPLINE BELL BELL 430 430 1182150 SW ALLSN 250C 250C40B 03032 NE TRANSMISSION WORN W K NONE O OTHER IN INSP/MAINT 1 CA A54 (CAN) THE TRANSMISSION WAS IN FOR A HARD LANDING SUDDEN STOPPAGE INSPECTION AND EXCESSIVE WEAR WAS FOUND ON THE INTERNAL SPLINES OF THE GEARSHAFT AS WELL AS ON THE EXTERNAL SPLINES OF THE SUNGEAR.THE WEAR WAS NOT A RESULT OF THE HARD LANDIN G.THIS IS THE SECOND TRANSMISSION IN THE LAST THREE MONTHS THAT HAS HAD THIS SAME PROBLEM. 1 G 7 2 3U 3 U RT H9SW E1GL 2005041900033 20050419 00033 EU 2005 4 19 CA041207005 1 20041202 G 3810 LINE FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE POTABLE WATER LEAKING W A UNSCHED LANDING K FLUID LOSS CL CLIMB 1 CA (CAN) DURING CLIMB, CANNOT PRESSURIZE ACRFT. ACRFT RETURNED TO DEPARTURE AIRPORT. MX FOUND CABIN AIR FILTER FOR OUTFLOW VALVES FULLY ICE COVERED DUE TO POTABLE WATER TANK LINE LEAKING AND DRIPPING OVER FILTER. FILL WATER LINE FITTING AT T HE TANK CONNECTION TIGHTENED & FILTER CLEANED. SYSTEM TESTED AND ACRFT DISPATCHED SERVICEABLE. SAME PROBLEM OCCURRED 2 DAYS LATER (UNABLE TO PRESSURIZE THE AIRCRAFT). THE DRAIN WATER LINE FROM POTABLE WATER TANK FOUND LEAKING & WATER DID CONTAMINATE RT OUTFLOW VALVE, LT SECONDARY OUTFLOW VALVE & OUTLET VALVE FOR AVIONICS COOLING. WATER LINE TIGHTENED & WAT ER TANK PRESSURIZED & CHECKED FOR LEAK. ALL LISTED VALVES REPLACED & AIRCRAFT DISPATCHED SERVICEABLE. 2 L 7 2 4F 4 F RT E25NE 2005041900034 20050419 00034 NM 2005 4 19 CA041208001 1 20041201 G 3350 6104781 BATTERY PACK DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE EMERGENCY LIGHT INOPERATIVE W O OTHER O OTHER NR NOT REPORTED 1 CA 12160 (CAN) EMERGENCY LIGHT BATTERY PACK AT POSITION 3352-P2 WAS REMOVED DUE TO INOPERATIVE E-LIGHTS AT CEILING FIRST THREE PO SITIONS. DURING OVERHAUL OF THE BATTERY PACK IT WAS FOUND THAT THE PACK HAD SHORTED OUT. IT APPEARS THAT DURING THE LA ST CELL REPLACEMENT THE CONNECTION LEADS WERE CUT TO SHORT WHICH PREVENTED THE CORRECT ROUTING OF THE WIRES. WHEN THE P ACK WAS INSTALLED ON THE AIRCRAFT THE WIRES BE CAME PINCHED AND THE PACK SHORTED OUT. THE PACK WAS INSTALLED ON NOVEMBE R 08/04 & REMOVED FROM THE AIRCRAFT ON DECEMBER 01/04. ALTHOUGH THE LAST DEEP CY CLE OCCURRED 140 HOURS PREVIOUS, IT I S UNKNOWN WHEN THE LAST PACK OVERHAUL WITH CELL REPLACEMENT OCCURRED. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005041900035 20050419 00035 CE 2005 4 19 CA041208002 1 20041201 G 7500 12991003363 TUBE BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE BLEED AIR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHILE INSPECTING ONE OF THE FLEETS 1900D AIRCRAFT BLEED AIR TUBE PN 129-910033-63 FOUND TO BE CRACKED ALONG THE WE LD. TIME OF THIS ACRFT 21,691.6 HOURS. A PRECAUTIONARY INSPECTION WAS COMPLETED ON AN OTHER AIRCRAFT TOTAL TIME 6291.9. THE SAME PN TUBE WAS FOUND CRACKED. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2005071200026 20050712 00026 SW 2005 7 12 CA041208003 1 20041206 G 2810 412361639101 FUEL CELL BELL 412 412 1182202 SW LT UPPER CONTAMINATED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) WHILE TROUBLE SHOOTING A FUEL INDICATION PROBLEM, TWO RED PLASTIC PROTECTIVE CAPS WERE FOUND IN THE LT UPPER AFT T ANK. 1 G 7 2 4U H4SW 2005041900036 20050419 00036 EU 2005 4 19 CA041209001 1 20041209 G 5310 STRUCTURE AIRBUS 320 A320211 3930320 EU CFMINT CFM56 CFM565A1 NE FUSELAGE VIBRATION W O OTHER E VIBRATION/BUFFET CR CRUISE 1 CA (CAN) VERT SIGNIFICANT RUMBLE/VIBRATION DURING CLIMB AND CRUISE. A/C ROUTED TO HANGAR FOR INVESTIGATION. NOTE: MORE INF O. WILL FOLLOW AS BECOME AVAIL. 2 L 7 2 4F 4 F RT A28NM E29NE 2005041900037 20050419 00037 NE 2005 4 19 CA041209002 2 20041209 G 7200 ENGINE AIRBUS A321 A321211 3930370 EU CFMINT CFM56 CFM565A3 NE NR 2 MALFUNCTIONED W C ABORTED TAKEOFF R J PARTIAL RPM/PWR LOSS WARNING INDICATION TO TAKEOFF 1 CA 779274 (CAN) THE CREW REJECTED TAKE-OFF AT A SPEED GREATER THAN 100 KNOTS. THE DECISION TO REJECT WAS A RESULT OF A NR 2 ENGIN E ROLL BACK AFTER A N2 OVERSPEED. ACRFT RETURNED TO GATE. A/C OFFLINE FOR INVESTIGATION, DFDR REMOVED FOR READOUT. NOTE : MORE INFO WILL FOLLOW AS BECOME AVAIL. 2 L 7 2 4F 4 F RT A28NM E29NE 2005041900039 20050419 00039 NM 2005 4 19 CA041209004 1 20041207 G 5610 8SC0043014 WINDSHIELD DHAV DHC8 DHC8315 2809010 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE COCKPIT CRACKED W O OTHER O OTHER CL CLIMB 1 CA (CAN) SHORTLY FOLLOWING TAKE-OFF, IN THE CLIMB, AT 9000FT THE CO-PILOT'S WINDSHIELD CRACKED. THE CREW CARRIED OUT APPLIC ABLE PROCEDURES AND LANDED SHORTLY AFTER. THE CO-PILOT'S WINDSHIELD WAS REPLACED AND THE AIRCRAFT WAS RETURNED BACK INTO SERVICE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005041900040 20050419 00040 EU 2005 4 19 CA041209005 1 20041208 G 6730 AC67244 SERVO SNIAS 350 AS350B 8680801 EU TMECA ARRIEL ARRIEL1B 6OO30 NE HYDRAULIC SYS MALFUNCTIONED W O OTHER F FLT CONT AFFECTED TX TAXI/GRND HDL 1 CA (CAN) PILOT REPORTED THAT CYCLIC WAS STIFF WHEN MOVED TO LEFT AND IT WANTED TO MOVE RIGHT WHEN COLLECTIVE LOWERED (NO PR OBLEMS WHEN COLLECTIVE WAS RAISED). LEFT MAIN SERVO WAS CHANGED AND DEFECT WAS CURED. 1 G 7 1 3U 3 U H9EU E19EU 2005041900041 20050419 00041 SW 2005 4 19 CA041209006 1 20041124 G 5720 1701971 STRAP GULSTM 690TP 690A 0141722 SW GARRTT TPE331 TPE33110T WP WING CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING REPLACEMENT OF LOWER SPAR CAP, WE WERE ADVISED THAT AN NEW AD IS PENDING AND WILL BE ISSUED IN JANUARY 2005 TO ADDRESS A CORROSION PROBLEM WITH THE PART NUMBERS. THE STRAPS WERE REMOVED AND EXTENSIVE CORROSION WAS FOUND UNDER T HE STEEL STRAPS ON THE UPPER WING SKIN. THIS IS BEING REPAIRED AS PER TWIN COMMANDER'SINSTRUCTIONS AT A TWIN COMMANDER S ERVICE CENTRE. 1 H 7 2 3T 4 T 2A4 E4WE 2005041900043 20050419 00043 SW 2005 4 19 CA041209007 1 20041125 G 3244 AB3L6 TIRE RKWELL 700 700 7630520 SW LYC O540 TIO540R2AD 41532 EA MLG BLOWN W A UNSCHED LANDING D INFLIGHT SEPARATION CL CLIMB 1 CA (CAN) LT MAIN TIRE WAS REPORTED TO ME AS THE D.M. TO BE FLAT. THE CREW WERE ON TAKEOFF WHEN THERE WAS SHAKING AND AIRCRA FT VEERING TO THE LT. THEY CONTINUED THE TAKEOFF AND MADE A LOW PASS BY THE FSS STATION FOR A VISUAL. IT WAS DETERMINED TO LAND WITH NO PROBLEMS. THE TIRE WAS INSTALLED ON THE ACRFT OCTOBER 13/04 AND HAS ACCUMULATED 162 HOURS. TIRE PRESSUE S ARE CHECKED REGULARLY AND ON THAT PARTICULAR DAY. THE TIRES WERE CHECKED BY ME AND NO NICKS OR DAMAGE WAS NOTED. THIS TIRE PLY LOOKS AS IFIT WAS PULLED AWAY FROM THE STEEL BEAD. 1 L 7 2 3O 3 O A12SW E14EA 2005041900044 20050419 00044 GL 2005 4 19 CA041209008 2 20041119 G 7310 6875632 LINE BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL FUEL CONTROL CRACKED W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION HO HOVERING 1 CA (CAN) WHILE ON A SLING OPERATION, PILOT NOTICED A FLUID LEAKING FROM THE BELLY IN THE CARGO MIRROR. THE AIRCRAFT WAS LAN DED IMMEDIATELY AND IT WAS DISCOVERED THAT FUEL WAS LEAKING FROM A FUEL LINE FITTING. THE ENGINE WAS SHUT DOWN AND THE L INE WAS CHECKED FOR TIGHTNESS AND WITNESS MARK. AS THE LINE WAS FOUND TORQUED SATISFACTORILY, THE LINE WAS REMOVED AND T HE CRACKWAS DISCOVERED. THE LINE HAD BEEN INSTALLED SERVICEABLE.NO LOSS OF POWER OR OTHER OPERATIONAL DISCREPANCIES WERE NOTED WHILE IN FLIGHT. 1 G 7 1 3U 3 U H2SW E4CE 2005041900045 20050419 00045 EU 2005 4 19 CA041209009 1 20040909 G 2497 WIRE BAG JETSTM JETSTM3212 1500217 EU GARRTT TPE331 TPE33110UG 01514 WP ROTOL R333 R333482F12 GL RT WING ROOT CHAFED W A UNSCHED LANDING N FALSE WARNING CL CLIMB 1 CA (CAN) DURING CLIMB, POWER LOSS ON RT ENG AT A FREQ OF 1-2 MINS, A TOTAL OF 4 TIMES. DURING FINAL , LANDING & TAXI TO SHU TDOWN, ENG NORM. CHIP DETECTOR & FILTERS INSPD, NO FAULTS FOUND. FUEL PRESSURE OK. COMPLETE GROUND RUN PERFORMED WITH N O FAULTS. TEST FLT PERFORMED WITH NO FAULTS. PROBLEM REOCCURRED 5 WEEKS LATER. COMPLETE WIRING SYS FOR TORQUE IND SYS IN SPD. CHAFED WIRE FOUND BEHIND TERM BLOCK IN RT WING ROOT. DISASSEMBLED TO EXPOSE WIRE FOR INSP. CHAFED WIRES & CHAFED PA INT ON STRUCT COULD NOT BE SEEN WITH A MAGNIFIER. VOID IN INSULATION FOUND. WIRE REINSULATED & REPOSITIONED. TORQUE IND SYS WORKS WITH MILLIVOLTS (PREAMPLIFIED). SUSPECT MOISTURE PROVIDING A GROUND PATH & TORQUE SYS SEEING AN OVRTORQUE. 2 L 7 2 4T 4 T RT BA15CAA E4WE 6 C P61GL 2005041900046 20050419 00046 EU 2005 4 19 CA041209010 1 20041005 G 2823 39423091 SHUTOFF VALVE BAG JETSTM JETSTM3212 1500217 EU GARRTT TPE331 TPE33110UG 01514 WP ROTOL R333 R333482F12 GL FUEL FAILED W O OTHER O OTHER TX TAXI/GRND HDL 1 CA (CAN) DURING START SEQUENCE THE ENGINE APPEARED TO START NORMALLY UNTIL STARTER DIS-ENGAGED THEN SHUT ITSELF DOWN. TESTI NG FOUND FUEL SHUTOFF VIBRATING LOUDLY WHEN POWER APPLIED WITH ENGINE STOP BUTTON. SUSPECT THE VALVE WAS TRYING TO BE OP EN ANDCLOSED AT THE SAME TIME. REPLACED THE VALVE AND THE ENGINE STARTED AND STOPS NO RMALLY. 2 L 7 2 4T 4 T RT BA15CAA E4WE 6 C P61GL 2005041900047 20050419 00047 2005 4 19 CA041209011 4 20041208 G 6122 210332210316 PILOT VALVE WOODWARD CSU CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 2243677F (CAN) CSU WAS INVOLVED IN A PROP STRIKE THEREFORE OH IS MANDATORY. UPON DISASSY OF CSU IT WAS DISCOVERED THAT THE PILOT VALVE PN 210332 WAS PITTED AND CORRODED ON THE BALL BEARING RACE SURFACE. THE FLYWEIGHT DRIVER PN 210317 AND THE FLYWEIG HT HEAD PN 210316 AND THE FLYWEIGHT DRIVE SPRING PN 192662 WERE CORRODED BEYOND REUSE.THE CORROSION WAS OBSERVED ON THE EXTERNAL SURFACES. THE OVERHAUL WAS COMPLETED USING SERVICEABLE PARTS WHILE THE U/S COMPONETS WERE RETURNED TO OUR CUSTO MER. 2005041900048 20050419 00048 NE 2005 4 19 CA041209012 2 20041201 G 7200 ENGINE PWA PWA120 PW125B NE FLAMED OUT W A UNSCHED LANDING X J ENGINE FLAMEOUT WARNING INDICATION CL CLIMB 1 CA 124246 (CAN) DURING CLIMB THE ENGINE FLAMED OUT. A RELIGHT ATTEMPT WAS UNSUCCESSFUL AND THE AIRCRAFT DIVERTED TO POINT OF DEPA RTURE.P&WC WILL MONITOR THE INVESTIGATION OFTHE EVENT AND SUPPLIMENT THIS REPORT TO REFLECT ROOT CAUASE, ONCE ESTABLISHE D. 4 T E20NE 2005041900049 20050419 00049 NE 2005 4 19 CA041209013 2 20041206 G 7200 ENGINE CESSNA 500 550 2076604 CE PWA 530 PW530A NE MALFUNCTIONED W E ENGINE SHUTDOWN W J INADEQUATE Q C WARNING INDICATION TO TAKEOFF 1 CA DA0260 (CAN) THE ENGINE EXPERIENCED AN UNCOMMANDED ACCELERATION IN FLIGHT AND WAS SHUTDOWN BY THE PILOT DUE TO AN ASSOCIATED IT T INCREASE TOWARDS RED-LINE. AN INFLT RELIGHT CARRIED OUT AND THE INCIDENT REOCCURRED. THE ENGINE WAS AGAIN SHUT DOWN.A SECOND RELIGHT WAS CARRIED OUT AND THE ENGINE RESPONDED NORMALLY TO THROTTLEINPUTS. PWC WILL INVESTIGATE THE EVENT AND WILL SUPPLIMENT THIS REPORT TO IDENTIFY ROOT CAUSE ONCE DETERMINED. 1 L 7 2 4F 4 F A22CE E00053EN 2005041900050 20050419 00050 CE 2005 4 19 CA041209014 1 20041209 G 3233 50820208 ACTUATOR BEECH 100 A100 1152915 CE PWA PT6 PT6A28 EA NLG FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING A ROUTINE ENDPLAY CHECK, THE ACTUATOR S ENDPLAY WAS AT THE MAX ALLOWABLE 0.018 INCH, THESE ACTUATORS HAVE A 7500 CYCLE OVERHAUL REQUIREMENT AND THIS ONE ONLY HAD 1636 CSO. 1 L 7 2 3T 4 T A14CE E4EA 2005041900051 20050419 00051 WP 2005 4 19 CA041209015 1 20041206 G 7714 A5696 WARNING SYSTEM ROBSIN R44 R44 7640120 WP LYC O540 O540F1B5 41532 EA LOW RPM INOPERATIVE W K NONE P NO WARNING INDICATION IN INSP/MAINT 1 CA 083 (CAN) DURING PILOT DAILY INSPECTION, THE LOW RPM WARNING UNIT WAS INOP. TECHNICIAN CONFIRMED THAT SYSTEM WAS DEFECTIVE A FTER TROUBLESHOOTING AND PART HAS BEEN REPLACED AND FOUND SERVICEABLE. 1 G 7 1 3O 3 O H11NM E295 2005041900052 20050419 00052 SW 2005 4 19 CA041210001 1 20041025 G 6220 407010105101 STUD BELL BELL 407 407 1182206 SW ALLSN 250C 250C47B GL HUB ASSY CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA A177 (CAN) ALL EIGHT STUDS (STATIC STOPS) FOUND CRACKED ON INSPECTION. MAINTENANCE CREWS REPORT LOWER STUDS ARE ALWAYS FOUND TO BE CRACKED ANY TIME THEY ARE INSPECTED. PROBLEM IS COMMON THROUGHOUT FLEET OF SEVEN BELL 407 HELICOPTERS. 1 G 7 1 3U 3 U O H2SW E1GL 2005041900053 20050419 00053 EA 2005 4 19 CA041210002 1 20041209 G 2560 6000 LATCH DHAV DHC3 DHC3 2800202 EA PWA PT6 PT6A34 52043 EA CABIN INOPERATIVE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) NEW PART, DISCOVERED AT INSTALLATION. DOES NOT LATCH. THE SPRING WHICH POSITIVELY PUSHES THE LATCH TO THE LOCK POS ITION IS MISSING. 1 H 7 1 3R 4 T A815 E4EA 2005041900054 20050419 00054 SO 2005 4 19 CA041210003 2 20041112 G 8530 538304 PUSHROD CESSNA 207 207A 2073604 CE CONT O520 IO520F 17032 SO EXHAUST BROKEN W A UNSCHED LANDING E VIBRATION/BUFFET CR CRUISE 1 CA 279878R (CAN) AIRCRAFT RETURNED TO XXXX AFTER THE PILOT NOTICED A VIBRATION AND LOSS OF POWER.UPON INSPECTION OF THE ENGINE, FOU ND NR 1 CYCLINDER EXHAUST PUSH ROD WAS BROKEN. PUSH ROD, ROD HOUSING ASSEMBLY & LIFTER WERE REPLACED AND ENGINE RUN & LE AK CHECKED SERVICEABLE. 1 H 7 1 3O 3 O A16CE E5CE 2005041900055 20050419 00055 EA 2005 4 19 CA041210004 1 20041210 G 3242 MS276125 ADAPTER CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE BRAKE FAILED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) AFTER INSTALLING ALL FOUR BRAKES, WE BLED THE SYSTEM. WHILE DOING THE NR 2 BRAKE BLEEDING, THE NR 1 BRAKE BLEED PO RT ADAPTER SHEARED AND BECAUSE OF THE HYDRAULIC PRESSURE THE ADAPTER HIT OUTBOARD MLG DOOR. HYDRAULIC SYSTEM PRESSURE WA S IMMEDIATLY STOPPED. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2005041200035 20050412 00035 SW 2005 4 12 CA041210005 1 20041210 G 5551 30653222 ATTACH FITTING AIRTRC AT802 AT802 0390305 SW PWA PT6 PT6A67A 52043 NE HARTZL HCB5M HCB5MA3 GL HORIZONTAL STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING ANNUAL INSPECTION THE RT HORIZONTAL STABILIZER AUX FIN WAS LOOSE. UPON INVESTIGATION BY MAINTENANCE STAFF I T WAS NOTED THAT THE FORWARD AUX FIN ATTACH PLATE WAS COMPLTELY CRACKED THROUGH AND THE REAR ATTACH PLATE WAS CRACKED ON BOTH SIDES OF THE RADIUS. THE CRACK LENGTHS ON THE REAR PLATE WERE APPROXIMATELY 1INCH AND .3125 INCH IN LENGTH. THE TO TAL WIDTH OF THE PLATE IN THE AREA IS 1.75 INCHES. THE PARTS WILL BE REPLACED PRIOR TO THE AIRCRAFT RETURNING TO SERVIC E. 1 L 7 1 3T 4 T NC A19SW E26NE 6 C P44GL 2005041900057 20050419 00057 CE 2005 4 19 CA041213002 1 20041208 G 3230 131378252CL MASTER LINK BEECH BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL NLG CHAIN DISCONNECTED W O OTHER D J INFLIGHT SEPARATION WARNING INDICATION AP APPROACH 1 CA (CAN) WHEN THE FLT CREW EXTENDED LANDING GEAR FOR LANDING , THEY HEARD STRANGE SOUNDS AND THEY ONLY RECIEVED TWO MAIN LA NDING GEAR LIGHTS. THE NOSE GEAR LIGHT WAS NOT GREEN AND THEY HAD A RED LIGHT ON IN THE HANDLE. THEY LOOKED IN THE NACEL LE MIRROR AND WERE ABLE TO TELL THAT THE NOSE GEAR WAS ONLY HALF WAY EXTENDED.THE CREW DID AN EMERGENCY EXTENSION PROCED URE WITH NO CHANGE. THE AIRCRAFT WAS LANDED IN THIS CONFIGURATION.ON LOOKING AT THE AIRCRAFT IN THE HANGER IT WAS FOUND THAT THE FORWARD NOSE LANDING GEAR CHAIN HAD COME APART AT THE MASTER LINK. THE LINK WAS HALF IN PLACE BUT THE CLIP WAS MISSING. WE DO NOT KNOW IF THE CLIP BROKE OR CAME OFF. THE NOSE GEAR CHAIN AND MASTER LINK WAS NEW 376.1 HOURS AGO. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2006091300287 20060913 00287 2006 9 13 CA041213003 1 20041213 G 1400 TUBE PWA PT6T PT6T3 52045 EA ENGINE WRONG PART W K NONE O OTHER IN INSP/MAINT 1 CA 63225 (CAN) DURING ENGINE VISUAL INSPECTION AT MFG, HAVE IDENTIFIED THAT 2 ITEMS FROM THE FUEL PRESSURE TUBING WERE NOT GENUIN E AND WERE MANUFACTURED BY AN UNKNOWN SOURCE. THOSE 2 ITEMS HAVE NO IDENTIFICATION NUMBERS BUT WERE INSTALLED IN REPLACE MENT OF: FUEL CONNECTOR P/N 3100499-01 CONNECTOR BOLT P/N 3100504-01 BOTH PARTS ARE KEPT IN QUARANTINE FOR 21 DAYS FOR T CCA REVIEW, AFTER WHICH THEY WILL BE DESTROYED. (TC NR 20041213003) 4 U E22EA 2005041900058 20050419 00058 EU 2005 4 19 CA041213005 1 20041204 G 6400 350A33214501 BUSHING SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE T/R PITCH LINK CRACKED W A UNSCHED LANDING F FLT CONT AFFECTED CR CRUISE 1 CA MA1406 (CAN) DURING ROUTINE HYDS OFF TRAINING, TAIL ROTOR INPUTS MADE THROUGH TAIL ROTOR PEDALS WERE NOT BEING TRANSFERRED TO T AIL ROTOR. PILOTS RESELECTED HYDS ON & TAIL ROTOR RESPONDED NORMALLY TO TAIL ROTOR INPUTS. AIRCRAFT RETURNED TO HANGAR F OR INSPECTION. WHEN PITCH LINKS BOLTS WERE LOOSENED ON TAIL ROTOR SPIDER, NOTICED DEFLECTION ON ATTACHMENT FLANGES. WIT H BOLTS LOOSENED, TAIL ROTOR MOVED FREELY WHEN PEDALS ACTUATED (HYDS OFF & ACRFT NOT RUNNING). INSPECTION OF 1 TAIL ROT OR PITCH LINK REVEALED 2 CRACKS THAT WENT COMPLETELY THROUGH BUSHING IN ELASTIMERIC BEARING. WHEN 2 PITCH LINKS REPLACED & TEST PERFORMED, CONCLUDED THAT UNBOOSTED TAIL ROTOR INPUTS RESPONDED NORMALLY. ACRFT RETURNED TO SERVICE. 1 G 7 1 3U 3 U H9EU E19EU 2005041900060 20050419 00060 NE 2005 4 19 CA041214001 2 20041212 G 7532 FITTING BOEING 737 737210C 1384459 NM PWA JT8 JT8D9A 52048 NE NR 2 ENGINE LOOSE W E A ENGINE SHUTDOWN UNSCHED LANDING D INFLIGHT SEPARATION CR CRUISE 1 CA 666056 (CAN) AT TRANSITION TO CRUISE FL 350 AFTER DEPARTURE, THE NR 2 ENGINE APPEARED TO SURGE OR COMPRESSOR STALL. AFTER 2 ATT EMPTS TO REDUCE THROTTLE THE ENGINE WAS SHUTDOWN AND THE AIRCRAFT RETURNED TO POINT OF DEPARTURE. MAINTENANCE FOUND A LE AK AT THE PS4 FITTING AT THE PRESSUE RATIO BLEED CONTROL (PRBC). THE O-RING WAS REPLACED AND THE FITTING RESECURED. AIR CRAFT WAS GROUND CHECKED WITH NO FURTHER PROBLEM AND RETURNED TO SERVICE. 2 L 7 2 4F 4 F A16WE E2EA 2005041900062 20050419 00062 SW 2005 4 19 CA041214002 1 20040713 G 6410 206016201131 BLADE BELL 206 206B 1181511 SW TAIL ROTOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THE BLADE HAS A CHORDWISE CRACK AT BLADE STATION 12.64. THE CRACK IS 2.65 IN. (67.3MM) LONG ON THE DATA PLATE SIDE OF THE BLADE AND 0.4 IN. (10MM) LONG ON THE OTHER SIDE. 1 G 7 1 3U H2SW 2005041900064 20050419 00064 CE 2005 4 19 CA041214003 1 20041118 G 5610 10138402524 WINDSHIELD BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE COCKPIT CRACKED W O OTHER O OTHER CR CRUISE 1 CA (CAN) DURING CRUISE, CREW HEARD A BANG AND NOTICED THE OUTER PANE OF THE RT WINDSHIELD HAD CRACKED. CABIN PRESSURE WAS REDUCED AND THE FLIGHT WASCONTINUED TO DESTINATION. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2005041900067 20050419 00067 NE 2005 4 19 CA041214004 2 20041211 G 7261 7938314506 LINE DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE ENGINE OIL CRACKED W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CL CLIMB 1 CA (CAN) DURING CLIMB, LT ENGINE OIL PRESSURE DROPPED TO 39 PSI. AIRCRAFT LANDED BACK TO DEPARTURE AIRPORT. ON APPROACH, OIL QTY DROPPED TO 5 QTS AND OIL PRESSURE TO35 PSI. MAINTENANCE FOUNDTHE PRESSURE LINE LEAKING BETWEEN THE OIL PRESSURE TRANSMITTER AND THE REDUCER. OIL PRESSURE LINE REPLACED, TESTED AND AIRCRAFT DISPATCHED SERVICEABLE.THE OIL LINE WAS FO UND CRACKED AT THE TUBE FLARE AT THE REDUCER CONNECTION. THE TECHNICIAN FOUND THE FITTING OVER TIGHTENED AND LINE STRES SED DURING THE REMOVAL.IT IS CONCLUDED THAT THE LINE WAS NOT PROPERLY INSTALLED. 2 L 7 2 4F 4 F RT A6WE E9NE 2005041900069 20050419 00069 WP 2005 4 19 CA041214005 2 20041123 G 7250 8657923 BEARING BAG JETSTM JETSTM3212 1500217 EU GARRTT TPE331 TPE33110UG 01514 WP ENGINE LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA P63181C (CAN) OIL WAS FOUND LEAKING FROM THE AFT BEARING COVER, ENOUGH OIL WAS LEAKING WHICH ALLOWED A 4 INCH DIAMETER POOL OF O IL IN THE STUB PIPE.ENGINE TEAR DOWN STRIP REPORT WILL BE SENT IN. 2 L 7 2 4T 4 T RT BA15CAA E4WE 2005041900071 20050419 00071 NE 2005 4 19 CA041214006 2 20041214 G 7497 3957985114 INTERFACE UNIT AIRBUS A321 A321211 3930370 EU CFMINT CFM56 CFM565B4 NE IGNITION SYSTEM MALFUNCTIONED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) ENG 1 IGN 'A' FAULT, ENG 2 IGN 'A' FAULT. 1&2 IGN A C/B POPPED. ENG 1 CTLC/B POPPED. STRONG SMELL OF ELECTRICAL BU RNING. CONNECTOR 473VC SHORTED, CONNECTOR REPLACED. BMC NR 1 DAMAGED, REPLACED PER MM 36-11-34-400. EIU NR 2 CAUSING INT FC PROBLEMS WITH AEVC. EIU NR 2 REPLACED PER M M 73-24-34-500. ENGINE RUN CARRIED OUT AND ALL TESTS OK. 2 L 7 2 4F 4 F RT A28NM E38NE 2005041900075 20050419 00075 NM 2005 4 19 CA041214007 1 20041209 G 7932 10607225 INDICATOR BOEING 727 727260 NM PWA JT8 JT8D17 52049 NE OIL QTY UNRELIABLE W E A ENGINE SHUTDOWN UNSCHED LANDING K N FLUID LOSS FALSE WARNING CL CLIMB 1 CA (CAN) DURING CLIMB ENGINE NR 2 OIL QUANTITY DECREASED RAPIDLY TO ZERO, FOLLOWED BY A RISE IN OIL TEMP. CREW SHUTDOWN TH E ENGINE ANDRETURNED TO AIRPORT. MAINTENANCE CHECKED OIL QTY AND FOUND TANK FULL. MAIN OIL FILTER CHECKED FOR CONTAMINAT ION, NONE FOUND. BEARING TEMP INDICATORS CHECK ED FOUND NORMAL. HIGH POWER ENGINE RUN CARRIED OUT, NO FAULTS FOUND. AIRC RAFT RE TURNED TO SERVICE. FAULT REOCCURRED ON NEXT FLIGHT LEG, HOWEVER, QTY RAPIDLY FLUCTUATED BETWEEN FULL, ZERO AND Q UANTITIES IN BETWEEN. CREW IDENTIFIED THIS AS AN INDICATION PROBLEM AND CONTINUED FLIGHT. MAINTENANCE AT NEXT STATION PL AC ED NR 2 ENGINE OIL QUANTITY SYSTEM ON MEL PART REPLACEMENT SCHEDULED FOR NEXT DAY. 2 L 7 3 4F 4 F RT A3WE E2EA 2005041900078 20050419 00078 2005 4 19 CA041214008 4 20041214 G 3442 6225136201 ANTENNA AIRBUS A340 A340313 EU CFMINT CFM56 CFM565C4 13802 NE WX RADAR DAMAGED W O OTHER D INFLIGHT SEPARATION CL CLIMB 1 CA (CAN) ON ND. SYSTEM RETURNED TO NORMAL BUT GIVEN HISTORY, RETURNED HNL. ANT. COULD BE FELT AND HEARD CLUNKING. REPLACED WX RADAR ANT IAW W/C 34-41-11-000-801-862-050. REPLACED BOTH RADAR T/R UNITS IAW W/C 34-41-313-400. RADAR ANTENNA 34-40- 0247 OFF FTN 639J4G ON FTNRJTR38. NR 1 T/R 34-40-0249 OFF S/N 6050 ON S/N 9J1U NR 2 T/R OFF FTN 76W092 ON S/N 90 DC. 2 L 7 4 4F 4 F RT A197 E37NE 2005041900079 20050419 00079 2005 4 19 CA041214009 4 20041214 G 3442 6225136201 ANTENNA AIRBUS A340 A340313 EU CFMINT CFM56 CFM565C4 13802 NE WX RADAR DAMAGED W O OTHER O OTHER CL CLIMB 1 CA (CAN) ON ND. SYSTEM RETURNED TO NORMAL BUT GIVEN HISTORY, RETURNED HNL. ANTENNA. COULD BE FELT AND HEARD CLUNKING. REPLA CED WX RADAR ANTENNA AS PER W/C 34-41-11-000-801-862-050. REPLD BOTH RADART/R UNITS AS PER W/C 34-41-313-400. RADAR ANT 34-40-0247 OFF FTN 639J4G ON FTNRJTR38. NR 1 T/R 34-40-0249 OFF S/N 6050 ON S/N 9J1U NR 2 T/R OFF FTN 76W092 ON S/N 90DC . 2 L 7 4 4F 4 F RT A197 E37NE 2005041900081 20050419 00081 SO 2005 4 19 CA041215001 1 20041214 G 7810 EXHAUST DUCT EMB 110 EMB110P1 3260122 SO PWA PT6 PT6A34 52043 EA ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 10665 10665 57188 (CAN) DURING ROUTINE MAINTENANCE 2 CRACKS WERE FOUND ON THE STARBOARD ENGINE EXHAUSTDUCT. THE CRACKS WERE LOCATED APPROX IMATELY 1.250 INCHES AFT OF THE REDUCTION GEARBOX MOUNTING FLANGE BETWEEN THE 10 AND 11:30 CLOCK POSITIONS. THE ORIGIN A PPEARED TO BE FROM THE PORT EXHAUST STUB FORWARD ATTACHMENT AREA. THE CRACK LENGTHS WERE .350 AND .613 INCHES WITH A SEP ARATION OF 2.250 INCHES. THE EXHAUST DUCT WASREMOVED AND SENT OUT FOR REPAIR. 1 L 7 2 4T 4 T A21SO E4EA 2005041900082 20050419 00082 CE 2005 4 19 CA041215002 1 20041214 G 7602 AN742D3 CONTROL UNIT CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA MIXTURE LOOSE W A UNSCHED LANDING O OTHER CR CRUISE 1 CA L2107015 (CAN) PILOT WAS IN CRUISE, HE STARTED TO LEAN THE ENGINEWENT PAST LEAN OF PEAK SO HE PUSHED THE MITURE BACK IN BUT THE E NGINE WAS STILL LOSING POWER. HE LANDED IN A FIELD WITHOUT ANY DAMAGE.ENGINEER WENT OUT AND REMOVED THE COWLING AND DISC OVERED THAT THE CLAMP THAT HOLDS THE MIXTURE CABLE TO THE MIXTURE SUPPORT ASSEMBLY WAS LOOSE. CLAMP WAS REPLACED. MIXTUR E WAS MOVED WORKS CORRECTLY. AIRCRAFT WAS FLOWN BACK TO BASE WITHOUT INCIDENT. 1 H 7 1 3O 3 O NT 3A19 E223 2005041900083 20050419 00083 CE 2005 4 19 CA041215003 1 20041213 G 3230 6046H39A RELAY BEECH 95 95B55 1152729 CE CONT O470 IO470L 17026 SO MLG MALFUNCTIONED W O OTHER H ELECT. POWER LOSS-50 PC AP APPROACH 1 CA (CAN) DURING A MISSED APPROACH PILOT INITIATED A TURN TO RETURN FOR A 2ND APPROACH WHEN MLG EXTENDED UNCOMMANDED WITH NO DOWN OR UP INDICATION LIGHTS. PILOT SLOWED ACRFT & CONTINUED TO DESTINATION WITH MLG SELECTED DOWN & CONFIRMED MLG DOWN WITH EMERGENCY GEAR HANDCRANK. MX INSPECTED ACRFT & FOUND MLG DYNAMIC BRAKING RELAY TO BE MALFUNCTIONING. ON INSPECTION OF RELAY, DETERMINED THAT A SPRING OFF OF ONE OF THE CONTACTS HAD BROKEN IN HALF & BROKEN PIECE HAD SHORTED OUT RELAY C AUSING MLG TO EXTEND. RELAY REPLACED & ACRFT TEST FLOWN WITH NO REOCCURANCE. INSTALLATION DATE OF THE RELAY COULD NOT BE FOUND BUT MANUFACTURING DATE 6/77. 1 L 7 2 3O 3 O RT 3A16 3E1 2005041900084 20050419 00084 CE 2005 4 19 CA041215004 1 20041116 G 7714 D11125025 TACHOMETER CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA ENGINE LEAKING W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) TACHOMETER WAS FULL OF OIL. TACH SHAFT SEAL LW14260 AND TACHOMETER REPLACED. TACHOMETER P/N D1-112-5025S/N 17488 1 H 7 1 3O 3 O NT 3A12 E274 2005041900085 20050419 00085 NE 2005 4 19 CA041215005 2 20041206 G 7250 312345201 TURBINE BLADES PWA PW121 PW121 52124 NE ENGINE FAILED W K NONE O OTHER IN INSP/MAINT 1 CA 16038 10372 (CAN) LP TURBINE BLADES WERE INSTALLED NEW DURING THE 1999 OVERHAUL OF ENGINE & HAD ACCUMULATED TSN = 10372.6 HOURS AND CSN = 11948 CYCLES. 41 BLADES WERE ROUTED FOR CREEP INSPECTION. REMAINING BLADES COULD NOT BE INSPECTED DUE TO DAMAGE AB LE TO CONCLUDE THAT THE LP TURBINE BLADES FAILED DUE TO CREEP, RESULTING IN SECONDARY IMPACT DAMAGE TO THE LP STATOR AND DOWNSTREAM GAS PATH COMPONENTS. 4 T E20NE 2005041900086 20050419 00086 EU 2005 4 19 CA041215006 1 20041215 G 2731 Z4244100011 SHAFT ZLIN 242 Z242L 9970204 EU LYC O360 AEIO360A1B6 41514 EA ELEVATOR TRIM SHEARED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING A 100 HR INSPECTION, THE ELEVATOR TRIM CONTROL CABLE DRUM WAS NOTICED TO BE OFFSET ON AN ANGLE. FURTHER IN SPECTION REVEALED THE SHAFT THAT THE DRUM IS ATTACHED TO HAD THE LT END SHEARED OFF.THE LT AND RT ENDS ARE SUPPORTED BY THE LT AND RT INBOARD SEAT RAILS. THE SHAFT IS A HOLLOW STEEL TUBE AND THE SUPPORT IS ALSO STEEL. THE HIGH AMOUNT OFTRI MMING OF THE AIRCRAFT OVER TIME CAUSED THE LT END OF THE TUBE TO BE CUT THROUGH. THIS COULD LEAD TO A STUCK TRIM CONTROL WHICH WOULD MAKE THE AIRCRAFT DIFFICULT TO CONTROL. WE INITIATED AN IMMEDIATE INSPECTION OF ALL OUR Z242L AIRCRAFT TRIM CONTROL SHAFTS. AT THIS TIME WE ARE LUBRICATING THIS AREA OF ROTATION. DURING INSPECTIONS WE WILL BE PAYING CLOSER AT 1 L 7 1 3O 3 O 0 A76EU 1E10 2005041900087 20050419 00087 NE 2005 4 19 CA041215007 2 20041214 G 7310 ENGINE PILATS PC12 PC12 7090550 EU PWA PT6 PT6A67B 52043 NE FAILED W A UNSCHED LANDING D M INFLIGHT SEPARATION OVER TEMP CL CLIMB 1 CA PR0271 (CAN) DURING CLIMB (6000 FT) THE ENGINE EXPERIENCED AN UNCOMMANDED POWER ROLL-BACK ACCOMPANIED BY ITT INCREASE, A LOUD B ANG AND FLAMES EVIDENT FROM THE EXHAUST. THE PILOT SHUT THE ENGINE DOWN IN FLT, DECLARED AN EMERGENCY AND SUBSEQUENTLY L ANDED ON A ROAD. PWC WILL INVESTIGATE THE INCIDENT AND WILL SUPPLEMENT THIS REPORT TO PROVIDE ROOT CAUSE, ONCE DETERMIN ED. 1 L 7 1 3T 4 T RT A78EU E26NE 2005042000001 20050420 00001 EA 2005 4 20 CA041216001 1 20041216 G 3250 C6CF12425 CABLE DHAV DHC6 DHC6300 2802606 EA PWA PT6 PT6A27 52043 EA NLG STEERING MISINSTALLED W K NONE K W FLUID LOSS INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) NOSE WHEEL STEERING CABLE ROUTED INCORRECTLY RESULTING IN ALMOST SAWING THROUGH THE HYDRAULIC HAND PUMP SUCTION LI NE P/N C6H1001-294. 1 H 7 2 3T 4 T RT A9EA E4EA 2005042000002 20050420 00002 EU 2005 4 20 CA041216002 1 20041213 G 3070 CONNECTOR FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE STATIC VENT HEAT BURNED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) FOLLOWING A DISCREPANCY WITH THE LAVATORY DRAINING, MAINTENANCE FOUND THE HEATER ASSY FOR STATIC VENTILATION (REA R DRAIN MAST) NOT WORKING. ONE OF THE 2 CONNECTORS AT THE HEATER WAS FOUND BURNED. THE INSULATION BLANKET AROUND THE H EATER WAS FOUND CARBONIZED. THERE WAS NO SMOKE REPORTED. THE AREA WAS FOUND DRY. THE CAUSE OF THE BURNED CONNECTOR STI LL UNKNOWN. THE AIRCRAFT MANUFACTURER IS INFORMED. THE RESULT OF INSPECTION ON 2 OTHER AIRCRAFT WAS FOUND SATISFACTORY. MORE DETAILS WILL FOLLOW. 2 L 7 2 4F 4 F RT E25NE 2008013100009 20080131 00009 EA 2008 1 31 CA041216003 1 20041216 G 7120 CSP28229 BOLT DHAV DHC6 DHC6300 2802606 EA PWA PT6 PT6A27 52043 EA HARTZL HCB3T HCB3TN3 GL ENG MOUNT SHEARED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AT ENGINE REMOVAL 3 OF THE 4 TOP ENGINE MOUNT BOLTS PN CSP282-29 BOLT FAILED. THE HEADS SHEARED OFF AFTER APPROXIM ATELY 3/1 - 1.25 TURN(S) OF THE BOLT. (TC NR 20041216003) 1 H 7 2 3T 4 T RT A9EA E4EA 6 C P15EA 2008013100010 20080131 00010 EA 2008 1 31 CA041216004 1 20041216 G 7120 CSP28229 BOLT DHAV DHC6 DHC6300 2802606 EA PWA PT6 PT6A27 52043 EA HARTZL HCB3T HCB3TN3 GL ENGINE MOUNT SHEARED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AT ENGINE REMOVAL, ONE OF THE TOP ENGINE MOUNT BOLTS P/N CSP282-29 BOLT FAILED. THE HEADS SHEARED OFF AFTER APPROX IMATELY A .7500 TURN OF THE BOLT. REVIEWED (TC NR 20041216004) 1 H 7 2 3T 4 T RT A9EA E4EA 6 C P15EA 2005042000003 20050420 00003 CE 2005 4 20 CA041216006 1 20041203 G 2740 051010545 CONTROL CABLE CESSNA 172 172N 2072434 CE LYC O320 O320D2J 41508 EA MCAULY 1C160 1C160DTM GL HORIZONTAL STAB FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA 13168 13168 (CAN) CABLE FRAYING AT REAR PULLEY IN HORIZONTAL STABILIZER. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2005042000004 20050420 00004 CE 2005 4 20 CA041216007 1 20041203 G 5312 05123635 BULKHEAD CESSNA 172 172N 2072434 CE LYC O320 O320D2J 41508 EA MCAULY 1C160 1C160DTM GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 13168 13168 (CAN) BULKHEAD FOUND CRACKED AROUND RUDDER TUBE HOLD DOWN CLAMP. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2005042000005 20050420 00005 NM 2005 4 20 CA041216008 1 20041215 G 2751 106131713 TRANSMITTER BOEING BOEING 727 727233 138408A NM PWA JT8 JT8D15 52051 NE LT TE FLAPS STICKING W J A DUMP FUEL UNSCHED LANDING F FLT CONT AFFECTED CL CLIMB 1 CA (CAN) DURING INITIAL CLIMBOUT, FLAPS CYCLED FROM 5 DEG. TO 2 DEG. CREW NOTICED THAT LT OUTBOARD FLAPS WERE INDICATING 5 DEG. & RT OUTBOARD FLAPS WERE INDICATING 3 DEG. CAUSING AN ASSYMETRY SPLIT. CREW HAD TO DUMP FUEL TO LAND WITHIN LANDING WEIGHT. CREW ACCOMPLISHED AN ASSYMETRY FAULT LANDING. LANDING ACCOMPLISHED & ACRFT RETURNED TO RAMP. MX CONFIRMED FLAPS WORKING PROPERLY BUT LT OUTBOARD FLAP INDICATING SYS FAULTY. MX INSPECTED LT OUTBOARD FLAP INDICATION SYS (CABLES, CABL E DRUM, TRANSMITTER) ALL CABLES WERE CLEANED & LUBED. FLAPS CYCLED NUMEROUS TIMES & NO FURTHER FAULTS FOUND. MX SUSPECT FLAP INDICATION TRANSMITTER CABLE HUNG-UP AT THE DRUM ASSY. AS A PRECAUTION, LT OUTBOARD FLAP TRANSMITTER REPLACED. 2 L 7 3 4F 4 F RT A3WE E2EA 2005042000006 20050420 00006 EA 2005 4 20 CA041216009 2 20041214 G 8500 ENGINE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA RIGHT MALFUNCTIONED W E A ENGINE SHUTDOWN UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 CA L11568A (CAN) ON DEPARTURE, THE CREW HAD A POWER LOSS ON THE RT ENGINE, FEATHERED ENGINE AND RETURNED FOR A LANDING. THE ENGINE WAS REPLACED WITH A SERVICEABLE ONE AND THE AIRCRAFT RETURNED TO SERVICE. THE ENGINE SHALL BE OPENED IN OUR ENGINE SHOP IN THE NEAR FUTURE TO DETERMINE THE EXACT CAUSE, SUSPECTED TO BE A PROBLEM IN THE ACCESSORY GEARTRAIN, AT WHICH POINT A CLOSED SDR WILL BE FILED. 1 L 7 2 3O 3 O A20SO E14EA 2005042000007 20050420 00007 CE 2005 4 20 CA041216010 1 20041214 G 8120 470954001 WASTEGATE VALVE CESSNA 182 T182T 2072738 CE LYC O540 TIO540AK1A EA TURBOCHARGER SEIZED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WASTEGATE BUTTERFLY VALVE FOUND SEIZED ON INSPECTION. THIS IS THE SECOND VALVE FOUND SEIZED ON TWO DIFFERENT AIRC RAFT WITH LOW TTSN. 1 H 7 1 3O 3 O NT 3A13 2005042000008 20050420 00008 NE 2005 4 20 CA041216011 2 20041215 G 7261 B-NUT BOEING 737 7377CG 13844FA NM CFMINT CFM567 CFM567B22 13802 NE OIL LINE LOOSE W E A ENGINE SHUTDOWN UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA 891283 (CAN) APPROX 30 MINS AFTER TAKE OFF, CREW NOTED LOSS OF OIL QTY IN NR 2 ENG & DID AN AIR TURNBACK. SEVERAL MINS LATER CR EW NOTED FLUCTUATING OIL PRESSURE IN NR 2 ENG & CARRIED OUT A PRECAUTIONARY SHUTDOWN. MX ISOLATED LEAK TO AN AREA WHICH HAD BEEN DISTURBED BY MX THE PREVIOUS DAY DURING A B-CHECK. AT THAT TIME, COKING HAD BEEN NOTED ON OIL LINES INTERFACE AT REAR TURBINE FRAME & A GASKET REPLACED IN REAR BEARING HOUSING. INVEST IN THIS AREA FOUND TOP FITTING OF OIL SUPPLY L INE LOOSE BY 1 FLAT (60 DEGREES). B-NUT ON THIS TUBE IS RETAINED BY A PIN WHICH TENDS TO ADD DRAG TO TORQUE. 2 L 7 2 4F 4 F RT A16WE E00055EN 2005042000009 20050420 00009 SO 2005 4 20 CA041216012 1 20041216 G 7810 8402917 TANK PIPER PA46 PA46350P 7104602 SO LYC O540 TIO540AE2A 41532 EA FUEL COLLECTOR CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) RIGHT FUEL COLLECTOR TANK WAS LEAKING INSIDE THE WHEEL WELL.FOUND TANK WAS CRACKED ON THE UPPER INBOARD WELD FLANG E. 1 L 7 1 3O 3 O RT A25SO E14EA 2005042000010 20050420 00010 EA 2005 4 20 CA041217001 1 20041216 G 3260 864808 PROXIMITY SENSOR CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE MLG MALFUNCTIONED W A UNSCHED LANDING N FALSE WARNING CL CLIMB 1 CA (CAN) AFTER GEAR UP SELECTION PROX SYS FAULT STATUS MESSAGE APPEARED. THE GEAR WAS RE-CYCLED AND THE MESSAGE PERSISTED . MAINTENANCE CARRIED OUT PSEU BITE CHECK AND FOUND A06 FAIL AND NVRAM FAIL .THE PSEU WAS REPLACED AND THE SYSTEM TESTED SERVICEABLE. 2 L 7 2 4F 4 F RT A21EA E15NE 2005042000011 20050420 00011 EA 2005 4 20 CA041217002 1 20041213 G 3234 555406 SELECTOR VALVE CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE MLG MALFUNCTIONED W O OTHER P NO WARNING INDICATION CL CLIMB 1 CA (CAN) DURING LANDING GEAR EXTENSION, NOSE GEAR TOOK 3-4 TIMES LONGER THAN NORMAL TO EXTEND AND LOCK. MAINTENANCE REPLAC ED THE NOSE LANDING GEAR SELECTOR VALVE AND THE SYSTEM TESTED SERVICEABLE. 2 L 7 2 4F 4 F RT A21EA E15NE 2005042000012 20050420 00012 GL 2005 4 20 CA041217003 1 20041214 G 2752 SEAL DIAMON DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240B 17063 SO SPINE SHAFT LOOSE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) IT WAS NOTICED DURING SCHEDULED INSPECTION THAT THE FLAP ACTUATOR SEAL HAD COME LOOSE ON THE SHAFT. ASSY WAS REMOV ED AND SEAL RE-GLUED IN PLACE AS PER DIAMOND INSTRUCTION, RE-INSTALLED. 1 L 7 1 3O 3 O NT TA4CH E7SO 2005042000013 20050420 00013 EU 2005 4 20 CA041217004 1 20041116 G 5741 HC536H04230 LINK BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE WING TO BODY UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 CA 37986 (CAN) DURING INSPECTIONS CARRIED OUT ON THE ABOVE NOTED ACRFT FOR THE LEASE RETURN, ENGINEERS FOUND WING TO FUSELAGE CO NNECTING LINKS AT REAR SPAR FITTING S, FRAME 29 CORRODED IN THE BORE ON BOTH ENDS OF THE LINKS. BOLTS ASSOCIATED WITH TH E LINKS WERE ALSO CORRODED UNDER THE HEAD AND AROUNDTHE UNDER CUT AREA OF THE THREADED END OF THEBOLT. INITIAL THRESHOL D FOR THESE INSPECTIONS IS AT 24000 FLTS AND THE REPEAT WAS TO BE DONE AT 12000 FLIGHTS THE TWO AIRCRAFT THAT HAVE HAD T HE INSPECTIONS CARRIED OUT ON WERE ON A SAMPLING PROGRAM AND BEING TRACKED ACCORDINGLY.REPLACEMENT PARTS WERE ORDERED AN D ARE INSTALLED ON THE ABOVE NOTED AIRCRAFT. 2 H 7 4 4F 4 F A49EU E6NE 2005042000014 20050420 00014 WP 2005 4 20 CA041217005 1 20041215 G 7711 LG80EI TRANSMITTER DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE LT ENGINE MALFUNCTIONED W O OTHER J WARNING INDICATION CR CRUISE 1 CA (CAN) DURING CRUISE, LT ENGINE EPR DROPPED TO 1.35 FOLLOWED BY AUTO THROTTLE DISCONNECT AND AIRCRAFT DECELERATION. EPR LINE INSPECTED, NO FAULTS FOUND. ENGINE RUN-UP CARRIED OUT AS PER AMM AND ENGINE PARAMETERS FOUND WITHIN LIMIT. THE PR ESSURE TRANSMITTER WAS REPLACED FOR PRECAUTIONARY. NO MALFUNCTION WAS REPORTED ON FOLLOWING FLIGHTS. 2 L 7 2 4F 4 F RT A6WE E9NE 2005042000015 20050420 00015 NE 2005 4 20 CA041217006 2 20041217 G 7310 LINE PWA PT6T PT6T3B 52045 NE ENGINE FUEL WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) DURING ENGINE VISUAL INSPECTION AT PWC, WE HAVE IDENTIFIED THAT 2 ITEMS FROM THE FUEL PRESSURE TUBING WERE NOT GEN UINE AND WERE MANUFACTURED BY AN UNKNOWN SOURCE. THOSE 2 ITEMS HAVE NO IDENTIFICATION NUMBERS BUT WERE INSTALLED IN REPL ACEMENT OF: FUEL CONNECTOR P/N 3100499-01 CONNECTOR BOLT P/N 3100504-01 BOTH PARTS ARE KEPT IN QUARANTINE FOR 21 DAYS FO R TCCA REVIEW, AFTER WHICH THEY WILL BE DESTROYED.NOTE: THIS IS THE 2ND OCCURENCE RECENTLY 4 U E22EA 2005042000016 20050420 00016 2005 4 20 CA041217007 1 20041216 G 1100 3017809 DATA PLATE PWA PT6T PT6T3B 52045 NE ENGINE INCORRECT W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 60263 (CAN) ENG RECEIVED WITH FALSE DATA PLATE (ORIGINAL DATA PLATE FOUND IN ENG LOGBOOK). THE FALSE DATA PLATE ENGRAVED WITH SN 63235 WHILE THE ENGINE INTERNAL COMPONENTS SHOWED THAT ALL THESE COMPONENTS WERE FITTED INTO ENGINE SN 60263. SIMULTA NEOULY, REAL ENGINE SN 63235 WAS IN HOUSE FOR REPAIR WITH ITS REAL DATA PLATE AND THE S/N 63235 ENGRAVED ON IT. 4 U E22EA 2005042000017 20050420 00017 SO 2005 4 20 CA041220001 1 20041220 G 5280 5452810 DOOR PIPER PA31T PA31T 7103124 SO PWA PT6 PT6A28 EA LANDING GEAR CRACKED W O OTHER O OTHER CR CRUISE 1 CA 7820038 (CAN) INFLIGHT, THE CREW NOTICED THAT THE RED GEAR IN TRANSIT LIGHT ILLUMINATED AT SPEEDS ABOVE 210 KNOTS. THE AIRCRAFT LANDED SAFELY AT ITS DESTINATION. UPON INSPECTION, THE INNER SKIN OF THE RIGHT OUTBOARD GEAR DOOR WAS FOUND CRACKED AND BENT INWARDS BY THE AIRFLOW. THE DOOR WAS REPLACED AND SATISFACTORY GEAR SWINGS WERE CARRIED OUT. 1 L 7 2 3T 4 T A8EA E4EA 2005042000018 20050420 00018 CE 2005 4 20 CA041220002 1 20041216 G 3233 SWITCH BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE ACTUATOR NOT CLOSED W O OTHER N FALSE WARNING LD LANDING 1 CA (CAN) DURING LANDING PROCESS, THE CREW NOTED THAT THE NOSE GEAR DOWN GREEN INDICATION WAS NOT ILLUMINATING. MAINTENANCE FOUND THE INTERNAL SWITCH ON THE ACTUATOR WAS NOT CLOSING PROPERLY AND THE ACTUATOR WAS REPLACED. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2005042000019 20050420 00019 CE 2005 4 20 CA041220003 1 20041219 G 3260 MS24171D1 RELAY BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE MLG SHORTED W O OTHER N FALSE WARNING LD LANDING 1 CA (CAN) DURING LANDING PROCESS, GEAR REQUIRED 2 ATTEMPTS FOR EXTENSION. MAINTENANCE FOUND THE LANDING GEAR RELAY, WAS PITT ED INTERNALLY PROVIDING INTERMITTENT CONTACTS.THIS OPERATOR HAS EXPERIENCED NUMEROUS FAILURES AT OR ABOVE 8000 HOURS TSN ON THESE RELAYS. AS A RESULT, THE RELAY WAS HARDTIMED AT 5000 HOURS WITH (TO DATE) GOOD SUCCESS. THIS RELAY FAILED AT A PPROX 3700 HOURS TSN. THEREFORE, THE HARDTIME FOR THIS FLEET SHALL BE ESCALATED TO 3000 HOURS. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2005042000020 20050420 00020 EU 2005 4 20 CA041220004 1 20041214 G 3246 314611 WHEEL PIAGIO P180 P180 6960204 EU PWA PT6 PT6A66 52043 NE MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 1057 (CAN) THE LEFT MAIN TIRE WAS LOOSING AIR. UPON INSPECTION, A CRACK WAS DISCOVERED IN THE LEFT INBOARD WHEEL HALF, AT THE TIRE BEAD AREA. NO INDICATIONS OF HARD LANDING WERE FOUND. THE WHEEL WAS REPLACED WITH AN OVERHAULED UNIT AND THE OLD W HEEL WAS SENT OUT FOR WARRANTY CONSIDERATION. 1 H 7 2 3O 4 T RT A59EU E26NE 2005042000021 20050420 00021 SO 2005 4 20 CA041220005 2 20041207 G 7322 629390A8 METERING VALVE CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO FUEL INJECT SYS LEAKING W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) FUEL METERING UNIT ON TCM I0-520 ENGINE HAD FUEL STAINING LINES AND SCREEN INSPECTED ON FAULTS FOUND. COOLING SHR OUD REMOVED AND SYSTEM WAS PRESSURIZED. SOURCE OF LEAK WAS DETERMINEDTO BE FROM A FILLESTER HEAD SCREW IN THE CENTER OF THE DATA PLATE. SCREW WAS LOCKWIRED AND SEALED WITH TCM LEAD SEAL ON THE LOCKWIRE. LOCKWIRE WAS CUT IT WAS FURTHER DET ERMINED THAT THE SCREW WAS SHEARED OFF. BROKEN SCREW WAS REMOVED, NEW SCREW INSTALLED WITH EXISTING SEAL WASHERS. SYSTE M WAS AGAIN PRESSURE TESTED NO FURTHER FAULTS FOUND. 1 H 7 1 3O 3 O A4CE E5CE 2005042000022 20050420 00022 EA 2005 4 20 CA041220006 2 20041212 G 8530 CYLINDER HEAD CESSNA 172 172RG 2072438 CE LYC O360 O360F1A6 41514 EA MCAULY 2D34C B2D34C220 GL ENGINE SEPARATED W O OTHER D R INFLIGHT SEPARATION PARTIAL RPM/PWR LOSS CR CRUISE 1 CA E2991136A (CAN) HEAD SEPARATION WHILE IN FLIGHT. DISCOVERED WHILE INVESTIGATING A ROUGH RUNNING ENGINE AS REPORTED BY PILOT. 1 H 7 1 3O 3 O 3A17 E286 5 C P7EA 2005042000023 20050420 00023 EA 2005 4 20 CA041221002 2 20041213 G 7240 3029248 COMBUST CHAMBER EMB 110 EMB110* SO PWA PT6 PT6A34 52043 EA HARTZL HCB3T HCB3TN3 GL ENGINE CRACKED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA 057378 (CAN) DURING CLIMB THE ENG EXPERIENCED AN UNCOMMANDED POWER REDUCTION ACCOMPANIED BY AUTO-FEATHER. THE AIRCRAFT DIVERTE D TO POINT OF DEPARTURE. SUBSEQUENT INSPECTION REVEALED A FRACTURED COMBUSTOR SMALL EXIT DUCT AND ASSOCIATED CT BLADE AN D VANE DAMAGE. 1 L 7 2 4T 4 T RT A21SO E4EA 6 C P15EA 2005042000024 20050420 00024 SW 2005 4 20 CA041221003 1 20041210 G 7820 099001050 MUFFLER BBAVIA 7 7GCBC 1220601 SW LYC O320 O320A2D 41508 EA ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AD CF90-03R2 REQUIRES PRESSURE TESTING OF MUFFLERS USED FOR CABIN HEAT. CRACK NOTED AT RT END PLATE ABOVE INLET PO RT, AT OUTER EDGE OF PREVIOUS WELD REPAIR. CRACK WAS NOT INSIDE CABIN HEAT MUFF AREA. 1 H 7 1 3O 3 O NC A759 E274 2005042000025 20050420 00025 CE 2005 4 20 CA041221004 1 20041216 G 5610 PPG1013840257 WINDSHIELD BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE COCKPIT CRACKED W A UNSCHED LANDING O OTHER CL CLIMB 1 CA (CAN) WHILE IN THE CLIMB, PASSING THROUGH 15000 FT THE CAPTAINS WINDSHIELD CRACKED.THE CREW CARRIED OUT THE APPLICABLE F LIGHT MANUAL PROCEDURES AND RETURNED BACKTO AIRPORT. THE AIRCRAFT WAS LATER FERRIED TO THE MAINTENANCE BASE WHERE THE WI NDSHIELD WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2005042000026 20050420 00026 SW 2005 4 20 CA041221005 1 20041214 G 6510 206040339009 BEARING BELL BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL BLOWER ASSY ROUGH W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) DURING BLOWER ASSEMBLY DISSASSEMBLY FOR CLEANING TAIL ROTOR DRIVESHAFT BEARING WAS FOUND TO FEEL ROUGH WHEN ROTATE D. 1 G 7 1 3U 3 U H2SW E4CE 2005042000027 20050420 00027 SW 2005 4 20 CA041221006 1 20041206 G 6510 327211 DISC BELL BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL T/R DRIVE SHAFT CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) ON INSPECTION 4 DISC ASSY WHERE FOUND TO BE CORRODED AND HAD TO BE REPLACED. 1 G 7 1 3U 3 U H2SW E4CE 2005042000028 20050420 00028 EA 2005 4 20 CA041221007 1 20041210 G 5610 WINDOW POST DHAV DHC3 DHC3 2800202 EA COCKPIT CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING AN UNSCHEDULED INSPECTION OF WINDSHIELD POST AT BOTH LT AND RT SIDES SEVERE CORROSION WAS FOUND. THE LT POS T WAS CORRODED THROUGH IN AREAS WITH SEVERE CORROSION ALTHOUGH IT HAD NOT GONE THROUGH.THIS FINDING IS ALSO DESCRIBED IN DEHAVILLAND SB 3/29. 1 H 7 1 3R A815 2005042000029 20050420 00029 NM 2005 4 20 CA041221008 1 20041209 G 2910 DSC252A40272 LINE DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE BRAKE ASSY DAMAGED W O OTHER K FLUID LOSS TX TAXI/GRND HDL 1 CA (CAN) AN OPERATOR EXPERIENCED A HYDRAULIC FLUID LOSS FROM NR 2 SYSTEM ON THEIR A/C DURING TAXI. THE FLUID LOSS WAS DUE T O A LEAK ON THE FLEXIBLE LINE FOR NR 3 BRAKE UNIT. THE LINE PN DSC252A4-0272 (IPC 32-42-00 FIG 17 ITEM 20) WAS FOUND DAM AGE CLOSE TO ONE OF THE END FITTINGS. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005042000030 20050420 00030 CE 2005 4 20 CA041222001 1 20041221 G 3211 LANDING GEAR LEAR 35 35LEAR 5170600 CE GARRTT TFE731 TFE73122B 01518 WP LEFT MALFUNCTIONED W O OTHER N FALSE WARNING DE DESCENT 1 CA (CAN) LT MLG WOULD NOT INDICATE DOWN AND LOCK, ACCOMPANIED BY TWO RED UNSAFE LIGHTS. ALTERNATE GEAR EXTENSION DID NOT SO LVE THE PROBLEM. AIRCRAFT PLACE INSIDE HANGAR FOR A 3 HOURS PERIOD. HYDRAULIC SYSTEM BLED AND GEAR RETRACTIONS CARRIED O UT. UNABLE TO DUPLICATE DEFECT ON GROUND. 2 L 7 2 4F 4 F A10CE E6WE 2005042000031 20050420 00031 EA 2005 4 20 CA041222002 1 20041214 G 5230 C4BM13583 FITTING DHAV DHAV DHC4 DHC4 2800302 EA HINGE ARM CRACKED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) CARGO DOOR PN C4B1024-5. CRACKS FOUND ON AFT LT AND RT HINGE ARM FITTING ASSEMBLY PN C4BM1358-3. THESE CRACKS WERE ON OUTBOARD FLANGE AROUNG TOP AND BOTTOM ATTACH HOLES. 2 H 7 2 4R 1A19 2005042000032 20050420 00032 2005 4 20 CA041222003 4 20041208 G 3497 1835501010001 CONTROL UNIT HONEYWELL CESSNA 500 560CESSNA 2076750 CE COCKPIT DAMAGED W H B DEACTIVATE SYST/CIRCUITS EMER. DESCENT D B H INFLIGHT SEPARATION SMOKE/FUMES/ODORS/SPARKS ELECT. POWER LOSS-50 PC CL CLIMB 1 CA U1195 (CAN) CLIMBING THROUGH FL300 A LOUD BANG OCCURRED FOLLOWED BY ELECTRICAL SMOKE ORIGINATING FROM THE CENTRE PEDESTAL. PRI MARY NAVIGATION FAILED IMMEDIATELY AS THE GNC-XL FMS FAILED. THE FMS WAS ISOLATED ELECTRICALLY AND THE CREW PERFORMED A RAPID DESCENT AND REQUESTED PRIORITY HANDLING. THE AIRCRAFT LANDED WITHOUT FURTHER INCIDENCE. INVESTIGATION ON THE GROUN D REVEALED DAMAGE CONFINED TO THE FMS BOX AND THE UNIT WILL BE SENT TO HONEYWELL FOR FURTHER ANALYSIS. 2 L 7 2 4F RT A22CE 2005042000033 20050420 00033 SO 2005 4 20 CA041222004 2 20041214 G 8500 643207 CRANKCASE CESSNA 414 414 2075908 CE CONT O520 TSIO520N 17040 SO MCAULY 3AF32C 3AF32C505 GL ENGINE CRACKED W K NONE O OTHER NR NOT REPORTED 1 CA 510659 (CAN) THE NR 4 CYLINDER HAD LOW COMPRESSION AND WAS REMOVED FOR REPAIR. WHILE THE CYLINDER WAS REMOVED, A CRACK WAS FOUN D AROUND THE 4 O'CLOCK POSITION CYLINDER ATTACH STUD. THE CRACK WAS ABOUT 1.5 INCHES LONG RADIATING INWARD. THE ENGINE W AS REMOVED FORREPAIR. 1 L 7 2 3O 3 O RT A7CE E8CE 5 C P22EA 2005042000034 20050420 00034 SW 2005 4 20 CA041222005 1 20041217 G 7120 590000 MOUNT MOONEY M20 M20C 5870208 SW LYC O360 O360A1D 41514 EA ENGINE BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING ENGINE OIL AND FILTER CHANGE, VISUAL INSPECTION FOUND THE ENGINE MOUNT P/N 590000, STRUT FORK CRACKED. THE FORK ATTACHES TO THE ENGINE MOUNT BLOCK P/N 590002, AFFIXED TO THE FIREWALL. 1 L 7 1 3O 3 O 2A3 E286 2005042500001 20050425 00001 GL 2005 4 25 CA041222006 2 20041209 G 7250 23038160 TURBINE BELL 206 206L 1181522 SW ALLSN 250C 250C20R2 GL ENGINE FAILED W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA CAT15353 (CAN) CHIP LIGHT AND ENGINE VIBRATION. PRECAUTIONARY LANDING. ON SUBSEQUENT INSPECTION, TURBINE FOUND TO HAVE FAILED. EXHAUST STACKS AND COMBUSTION LINER FOUND CRACKED. REMOVED TURBINE AND INSTALLED SERVICEABLE TURBINE, EXHAUST STACKS AND COMBUSTION LINER. AIRCRAFT INSPECTED, TEST RUN, TEST FLOWN AND CHECKED SERVICEABLE. TURBINE TO QUALIFIED OVERHAU L SHOP. 1 G 7 1 3U 3 U H2SW E4CE 2005042500002 20050425 00002 EU 2005 4 25 CA041222007 1 20041113 G 2612 30011690040012 SENSOR AMD FALC10 FALCON10 2730101 EU GARRTT TFE731 TFE7312 01518 WP LT FIRE LOOP OPEN W K NONE L NO TEST IN INSP/MAINT 1 CA (CAN) DURING PREFLIGHT CHECKS, THE LT ENGINE FIRE WARNING FAILED TO TEST. TROUBLESHOOTING REVEALED A FAILED FIRE LOOP. F IRE LOOP WAS REPLACED WITH NEW PRIOR TO FURTHER FLIGHT. 2 L 7 2 4F 4 F A33EU E6WE 2005042500003 20050425 00003 EU 2005 4 25 CA041222008 1 20041215 G 2842 360930001 AMPLIFIER AMD FALC10 FALCON10 2730101 EU GARRTT TFE731 TFE7312 01518 WP FUEL QTY IND INOPERATIVE W O OTHER N FALSE WARNING CR CRUISE 1 CA (CAN) DURING FLIGHT, THE CREW NOTICED THAT THE RT FUEL QUANTITY GAUGE HAD DROPPED TO ZERO. THE LOW LEVEL LIGHT DID NOT I LLUMINATE, ASSURING THE CREW THAT THIS WAS AN INDICATION PROBLEM ONLY. THE RT QUANTITY AMPLIFIER WAS REPLACED AND THE S YSTEM WAS PROPERLY CALIBRATED PRIOR TO THIS FLIGHT. THE RECENTLY REPLACED AMPLIFIER WAS FOUND TO HAVE FAILED INTERNALLY. 2 L 7 2 4F 4 F A33EU E6WE 2005042500004 20050425 00004 EU 2005 4 25 CA041222009 1 20041210 G 7331 7231602 INDICATOR AMD FALC10 FALCON10 2730101 EU GARRTT TFE731 TFE7312 01518 WP FUEL FLOW FAILED W O OTHER P NO WARNING INDICATION CR CRUISE 1 CA (CAN) DURING CRUISE FLIGHT THE RT FUEL FLOW GAUGE FAILED. GAUGE WAS REPLACED AND SYSTEM TESTED SERVICEABLE. 2 L 7 2 4F 4 F A33EU E6WE 2005042500005 20050425 00005 GL 2005 4 25 CA041222010 3 20041217 G 6111 C4902 NUT CESSNA 185 A185F 2072821 CE CONT O520 IO520D 17032 SO MCAULY 2A34C D2A34C58 GL PROPELLER BLADE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) RETENTION NUT THREAD CRACKED, 3 INCHES IN LENGTH, . DISCOVERED DURING OVERHAUL L.P.I. INSPECTION. 1 H 7 1 3O 3 O 3A24 E5CE 5 C P3EA 2005042500006 20050425 00006 SO 2005 4 25 CA041222011 1 20041201 G 2720 62701154 CONTROL CABLE PIPER PA44 PA44180 7104402 SO RUDDER CHAFED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AFTER REMOVAL OF RUDDER, FOUND MANY STRANDS BROKEN ON LT AFT RUDDER CABLE. THE CABLE CHAFING AT AFT BULKHEAD.THE CABLE WAS REPLACED BY NEW P/N 62701-154. 1 L 7 2 3O A19S0 2005042500007 20050425 00007 SO 2005 4 25 CA041222012 1 20041215 G 1430 AN511A BOLT PIPER PA31 PA31 7103102 SO LYC O540 IO540M1A5 41532 EA STABILIZER MISMANUFACTURED W O OTHER O OTHER NR NOT REPORTED 1 CA (CAN) WHEN REINSTALLING THE HORIZONTAL STAB, (AT THE AFT SPAR ATTACH POINT) USING NEW HARDWARE, IT WAS DISCOVERED THAT THE REQUIRED BOLTS WERE LONGER IN TOTAL LENGTH BY 0.1875 AND SHANK LENGTH BY 0.1875, THAN THE ORIGIONAL BOLTS REMOVED. T HIS CAUSED THE NUTS TO SHANK OUT WHEN TORQUED. IT IS APPARENT THAT THE ENGINEERING SPECIFICATIONS FOR AN AN5-11A BOLT HA VE CHANGED SINCE 1970. THE PARTS LISTING PAGE WAS LAST REVISED MAY 1981. THIS SITUATION IS NOT EASILY NOTICED AS THE NU T END IS ONLY VISIBLE USING A MIRROR SO THE ONLY INDICATION IS BY 'FEEL' OF THE WRENCHES WHEN AT FINAL TORQUE VALUE. IT IS ADVISABLE NOT TO ASSUME THAT A STANDARD PART WILL ALWAYS BE PHYSICALLY THE SAME SIZE AFTER 35 YEARS OF PRODUCT IMPRO 1 L 7 2 3O 3 O A20SO 1E4 2005042500008 20050425 00008 WP 2005 4 25 CA041222014 2 20041209 G 7322 307080022 FUEL CONTROL LEAR 35 35A 5170602 CE GARRTT TFE731 TFE73122B 01518 WP LT ENGINE FAILED W O OTHER X J ENGINE FLAMEOUT WARNING INDICATION DE DESCENT 1 CA (CAN) WHILE ON APPROACH TO DESTINATION AIRPORT, THE LT ENGINE FLAMED OUT. POWER LEVER WAS AT FLIGHT IDLE POSITION. FL AME OUT OCCURRED AS POWER LEVER WAS ADVANCED FROM FLIGHT IDLE. LT ENGINE MAIN FUEL CONTROL REPLACED IAW MANUFACTURERS R ECOMMENDATIONS. 2 L 7 2 4F 4 F A10CE E6WE 2005042500100 20050425 00100 NM 2005 4 25 CA041222015 1 20041221 G 8012 8216003 START VALVE AMD FALC50 FALCON2000 2730170 NM ENGINE FAILED W A UNSCHED LANDING X J ENGINE FLAMEOUT WARNING INDICATION CL CLIMB 1 CA (CAN) THE ENGINE EXPERIENCED AN UNCOMMANDED SHUTDOWN DURING CLIMB AND THE AIRCRAFT DIVERTED TO NEAREST AIRPORT. SUBSEQU ENT INSPECTION REVEALED THE AIRFRAME AIR-START VALVE STUCK IN THE OPEN POSITION AND EVIDENCE OF LOCALIZED OVER HEATING. A (START VALVE FAILED OPEN) EICAS MESSAGE WAS REPORTED. 2 K 7 3 4F RT A50NM 2005042500009 20050425 00009 EA 2005 4 25 CA041222016 2 20041222 G 7421 REM38E SPARK PLUG CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA ENGINE CRACKED W A UNSCHED LANDING E R J VIBRATION/BUFFET PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 CA L2751651A (CAN) NR 1 TOP SPARK PLUG INSULATOR FOUND BROKEN UNDER ELECTRODES. REPLACED NR 1 TOP SPARK PLUG, REMAINING PLUGS FOR LT MAGNETO CLEANED AND FUNCTION TESTED. GROUND RUN CARRIED OUT, LT MAGNETO OPERATION NORMAL. 1 H 7 1 3O 3 O NT 3A12 1E10 2005042500010 20050425 00010 NM 2005 4 25 CA041222017 1 20041220 G 3221 654581945 GUSSET BOEING 737 737201 1384454 NM PWA JT8 JT8D9A 52048 NE NLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING A ROUTINE PHASE 2 CHECK (137.5 HRS.) A 3.5 INCH (THREE AND A HALF INCH) CRACK WAS FOUND ON THE NOSE LANDI NG GEAR GUSSET WHILE CARRYING OUT SERVICE DIFFICULTY ALERT AL-2002-03. RETRACT ACTUATOR SUPPORT FITTING GUSSET REPLACED IAW SRM 51-30-2 FIG II.TIMES. 64641.30 CYCLES. 61588. 2 L 7 2 4F 4 F A16WE E2EA 2008013100011 20080131 00011 2008 1 31 CA041222018 4 20041222 G 2565 PDMC6E101729 ACTUATOR DHAV DHC6 DHC6 2802606 EA SLIDE MISMANUFACTURED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) SLIDE ACTUATOR MANUFACTURED TO INCORRECT LIMITS. SLIDE ACTUATOR WILL NOT FIT ONTO BETA SWITCH BRACKET P/N C6E1060- 3. GROOVE FOR SLIDE ON A C6E1017-29 IS .1300 +/- .0005. GROOVE ON SLIDE FROM J.A.S. PDM C6E1017-29 IS .1200 +/- .0005. TRACK ON BETA SWITCH BRACKET IS .1250. (TC NR 20041222018) 1 H 7 2 3T RT A9EA 2005042500011 20050425 00011 NE 2005 4 25 CA041222019 2 20041220 G 7310 SHUTOFF VALVE PWA 305 PW305B 52128 NE ENGINE FUEL ACTIVATED W A UNSCHED LANDING X B J ENGINE FLAMEOUT SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CL CLIMB 1 CA 305118 (CAN) ON TAXI PRIOR TO TAKEOFF, THE CREW WERE ALERTED TO SMOKE EMINATING FROM THE ENGINE. ON TAKEOFF THE ENGINE EXPERI ENCED AN UNCOMMANDED SHUTDOWN. THE CREW DECLARED AN EMERGENCY AND RETURNED TO POINT OF DEPARTURE. INITIAL INSPECTION R EVEALED THE EMERGENCY FUEL SHUT-OFF VALVE HAD ACTIVATED. PWC WILL INVESTIGATE THE EVENT AND SUPPLIMENT THIS REPORT TO R EFLECT ROOT CAUSE, ONCE DETERMINED. 4 F E35NE 2005042500012 20050425 00012 WP 2005 4 25 CA041222020 1 20041218 G 2140 HEATER CVAC 340 340CVAC 242270A WP ALLSN 501D 501D13D 03004 GL CABIN/COCKPIT MALFUNCTIONED W A UNSCHED LANDING M H G OVER TEMP ELECT. POWER LOSS-50 PC MULTIPLE FAILURE CL CLIMB 1 CA (CAN) ON CLIMB OUT, THE CREW EXPERIENCED MULTIPLE AVIONICS FAILIERS, INCLUDING BOTH COMMS, BOTH NAVS, BOTH TRANSPOND ERS, AN ADF, AND AN RMI. THE A/C RETURNED TO BASE WITHOUT INCIDENT. THE CREW HAD COMMENTED THAT THE COCKPIT WAS VERY WARM PRIOR TO DEPARTURE. MAINTENANCE DISCOVERED THAT SOME ANTENNA CABLES LEADING FROM THE COCKPIT APPEARED TO HAVE BEEN DAMAGED DUE TO OVERHEATING. IT WAS FURTHER FOUND THAT THE HERMAN NELSON USED IN THE PRE-HEATING OF THE A/C HAD A DEFECT IVE THERMOSTAT THAT RESULTED IN UNCONTROLLED FULL HEAT OUTPUT. THE HEATER WAS SENT FOR REPAIR. MAINTENANCE REPLACED 5 A NTENNA COAX CABLES, THE NR 2 COMM TRANSCEIVER, AND THE ADF RECEIVER. THE A/C WAS RETURNED TO SERVICE. 2 L 7 2 4R 4 T 6A6 E282 2005042500013 20050425 00013 NE 2005 4 25 CA041223001 2 20041221 G 7230 COMPRESSOR DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE NR 2 ENGINE DAMAGED W A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 CA 728089 (CAN) A LOUD BANG HEARD ON ROTATION FROM NR 2 ENGINE. POWER WAS REDUCED TO IDLE AND AIRCRAFT LANDED BACK. ENGINE FAN B LADES FOUND DAMAGED. ENGINE REPLACED. THE CAUSE HAS NOT BEEN IDENTIFIED. AWAITING FOR SHOP REPORT. 2 L 7 2 4F 4 F RT A6WE E9NE 2005042500014 20050425 00014 NE 2005 4 25 CA041223003 2 20041223 G 7200 ENGINE CNDAIR CL601 CL6013A 8070802 EA GE CF34 CF343A 30015 NE LEFT MALFUNCTIONED W O OTHER J WARNING INDICATION TO TAKEOFF 1 CA 350131 (CAN) UNCOMMANDDED ACCELERATION ON THE LT ENGINE ON TAKE OFF AROUND + 7 PERCENT ABOVE RETURN TO NORMAL 40 SECONDS LATER. 2 L 7 2 4F 4 F RT A21EA E15NE 2005042500015 20050425 00015 NE 2005 4 25 CA041223004 1 20041215 G 6200 7610708001104 SUPPORT SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30S 03013 GL MAIN ROTOR CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 11010 (CAN) DURING INSPECTION MANDATED BY ASB 76-65-62 SEVERE FRETTING WAS DISCOVERED ON LOWER FAYING SURFACE. SUPPORT ARM HAS BEEN REPLACED AND A/C RETURNED TO SERVICE. 1 G 7 2 3U 3 U H1NE E1GL 2005021400181 20050214 00181 SW 2005 2 14 CA041223005 1 20040821 G 6710 206010355009 PITCH LINK BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL MAIN ROTOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING A SCHEDULED 100-HOUR INSPECTION TWO (2) VERTICAL CRACKS WERE FOUND ON A MAIN ROTOR PITCH LINK. THE CRACKS (APPROX. .180) 1 G 7 1 3U 3 U H2SW E4CE 2005042500016 20050425 00016 EA 2005 4 25 CA041223006 1 20041221 G 5610 NP13932110 WINDSHIELD CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE COCKPIT CRACKED W A UNSCHED LANDING O OTHER CR CRUISE 1 CA (CAN) RT WINDSHIELD CRACKED DURING CRUISE AT FL330. A/C DIVERTED WHERE THE WINDSHIELD WAS REPLACED. 2 L 7 2 4F 4 F RT A21EA E15NE 2005042500017 20050425 00017 EA 2005 4 25 CA041224001 1 20041221 G 5610 NP1393226 WINDSHIELD CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE COCKPIT CRACKED W O OTHER O OTHER AP APPROACH 1 CA (CAN) RECEIVED A REPORT WHICH WE FEEL IS A REPORTABLE EVENT. FLIGHTDECK RT SIDE WINDOW CRACKED DURING APPROACH. WINDOW REPLACED IN MUNICH, AND THEN RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT A21EA E15NE 2005042500018 20050425 00018 EA 2005 4 25 CA041224002 1 20041220 G 2820 T99A38603 EJECTOR CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) OVERNIGHT, APPROX 1200 LBS OF FUEL TRANSFERED INTO THE CENTER TANK. THE FLT HAD REPORTED AN INCREASE OF 120 LBS IN 10 MINUTES, HOWEVER IT WAS NOT DETERMINED IF THE FUEL TRANSFER WAS NOTED ON GROUND OR IN FLT BY THE CREW. MAINTENAN CE FOUND THE LT MAIN EJECTOR CRACKED. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2005042500019 20050425 00019 EA 2005 4 25 CA041224003 1 20041104 G 5312 BULKHEAD CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 26106 (CAN) MAINTENANCE FOUND TWO CRACKS ON THE 'SEMI-PRESSURE BULKHEAD' (FS559) NEAR THE AFT AILERON QUADRANT. REPAIR WAS PE RFORMED IN ACCORDANCE WITH REPAIR ENGINEERING ORDER (REO) 601R-53-41-256. SUBSEQUENTLY CRACKS HAVE BEEN FOUND ON TWO AD DITIONAL A/C: 06-DEC-04. A/C 7025 (25185FH, 20290FC) REO 601R-53-41-263 20-DEC-04. A/C 7004 (27332FH, 21860FC) REO 601 R-53-41-267. 2 L 7 2 4F 4 F RT A21EA E15NE 2005042500020 20050425 00020 EA 2005 4 25 CA041224004 1 20041203 G 5280 CC67010520 DOOR CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE RT MLG SEPARATED W O OTHER D INFLIGHT SEPARATION CL CLIMB 1 CA (CAN) WHILE CLIMBING THRU 16,000 FT, THE FLT CREW HEARD A STRANGE NOISE. ALL COCKPIT INDICATIONS WERE NORMAL. UPON POS T FLT INSPECTION, MAINTENANCE FOUND THE RT MAIN GEAR DOOR MISSING. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2005042500021 20050425 00021 EA 2005 4 25 CA041224005 1 20041120 G 5280 CC67010520 DOOR CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE RT MLG SEPARATED W O OTHER D INFLIGHT SEPARATION CL CLIMB 1 CA (CAN) FOLLOWING DEPARTURE, FLIGHT CREW HEARD A BUMP. POST FLT INSPECTION REVEALED THAT THE RT INBOARD MLG DOOR WAS MIS SING. IN ADDITION IT WAS FOUND THAT THE RT IB FLAP SUFFERED SEVERAL DEEP GOUGES, THE RT PROXIMITY HARNESS CONDUIT WAS D ENTED, THE RT OB MLG DOOR WAS DAMAGED, AND THERE WAS A SCRATCH IN THE BOTTOM OF THE WING ABOVE THE INBOARD MLG DOOR. A NEW DOOR WAS INSTALLED, THE AIRCRAFT WAS REPAIRED AND RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2005042500022 20050425 00022 SW 2005 4 25 CA041224006 1 20041101 G 6410 206016201131 BEARING BELL 206 206L 1181522 SW ALLSN 250C 250C20B 03013 GL T/R BLADE MISALIGNED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) SUBJECT TAIL ROTOR BLADE ASSY WAS REMOVED FROM A/C DUE TO EXCESSIVE T/R VIBRATIONS AT 1.1 IPS. OPERATOR'S OVERHAU L SHOP PERFORMED AN INSPECTION AND AN ALIGNMENT OF SPHERICAL BEARINGS CHECK. IT HAS BEEN DETERMINED THAT THE BEARINGS A LIGNMENT WAS OVER LIMITS (.011 INCH VERSUS .008 INCH MAX ALLOWABLE). THE BLADE WAS REPAIRED BY REMOVING BOTH BEARINGS, REPLACING ONE WORN BEARING IAW BHY-206L-CR & OVERHAUL MANUAL. UPON COMPLETION AN ALIGNMENT CHECK WAS PERFORMED WITH A R ESULT OF .005 INCH. THE BLADE WAS SUBSEQUENTLY RETURNED TO SERVICE WITH NO FURTHER DISCREPANCIES NOTED. 1 G 7 1 3U 3 U H2SW E4CE 2005042500023 20050425 00023 EU 2005 4 25 CA041224009 1 20041223 G 2820 FUEL SYS FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE NR 1 ENGINE MALFUNCTIONED W A UNSCHED LANDING E J VIBRATION/BUFFET WARNING INDICATION CR CRUISE 1 CA (CAN) AFTER DEPARTURE DURING CRUISE, A FUEL UNBALANCE WAS NOTICED AND LEAK SUSPECTED FROM NR 1 ENGINE. ENGINE NR 1 WAS SECURED AND AIRCRAFT LANDED BACK TO DEPARTURE AIRPORT. BOTH ENGINES WERE RAN AND NO LEAK WAS FOUND. THE AUTO FEED SYST EM WAS PUT INOPERATIVE AS PRECAUTION AND AIRCRAFT DISPATCHED AS PER MEL. SAME OCCURRENCE ON THE FOLLOWING FLIGHT.AIRCRA FT STILL UNDER INVESTIGATION. DETAILS WILL FOLLOW. 2 L 7 2 4F 4 F RT E25NE 2005042500024 20050425 00024 SO 2005 4 25 CA041224010 1 20041222 G 7120 8936102 MOUNT PIPER PA44 PA44180 7104402 SO LYC O360 O360A1H 41514 EA LT ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA L346673 (CAN) DURING AN EVENT NR 3 INSPECTION THE LT ENGINE MOUNT WAS FOUND TO BE CRACKED AT THE UPPER RT SUPPORT TUBE AT THE WE LDING POINT WHERE IT MEETS THE RUBBER MOUNT ISCOLATOR WEB. THIS MOUNT HAD PIPER SB 1033 CARRIED OUT AT THE UPPER LT SUP PORT TUBE. 1 L 7 2 3O 3 O A19S0 E286 2005042500025 20050425 00025 EU 2005 4 25 CA041226001 1 20041224 G 6520 770441 MAGNETIC SEAL UROCOP SNIAS 350 AS350B3 8680954 EU TMECA ARRIEL ARRIEL2B NE T/R GEARBOX CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA MA1729 (CAN) UPON LANDING AT DESTINATION AFTER A 40 MINUTE FLIGHT. PILOT CARRIED OUT A WALKAROUND AND NOTICED AN UNUSUAL AMOUN T OF OIL ON TAILBOOM FROM BELOW TAIL ROTOR GEARBOX. OIL LEVEL WAS CHECKED AND WAS FOUND TO BE DOWN A LITTLE BUT STILL I N ACCEPTABLE RANGE LEVEL. UPON EXAMINATION BY AME INPUT SEAL TO GEARBOX WAS COVERED IN OIL. OIL LEVEL WAS DOWN 1/2 OUN CE FOR 4 HOURS OF FLYING. MAGNETIC SEAL WAS REMOVED AND EXAMINED AND IT WAS DETERMINED THAT THE CARBON RING OF THE MAGN ETIC SEAL HAD A DEFECT. WHEN EXAMINED WITH A MAGNIFYING GLASS A TINY DIAGONAL CRACK WAS FOUND ON THE FACE OF THE RING. A NEW MAGNETIC SEAL WAS INSTALLED AND GROUND RUN AND FLIGHT TEST FOLLOWED. NO OIL LEAK EVIDENT AFTER FLIGHT. 1 G 7 1 3U 3 U H9EU E00054EN 2005042500026 20050425 00026 EA 2005 4 25 CA041226002 1 20041221 G 7830 1EN2893 SWITCH CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE THRUST REVERSER DEFECTIVE W E ENGINE SHUTDOWN O OTHER CL CLIMB 1 CA (CAN) RT THRUST REVERSER UNLOCKED MESSAGE IN CLIMB. PROCEDURE ACCORDING QRH PERFORMED. RT ENGINE SHUTDOWN DUE TO THRUS T LEVER/THRUST SPLIT UP TO 9 PERCENT IN LEVEL FLT AT 4000 FT. RT REVERSER FOUND STOWED. DEACTIVATED ACCORDING TO MEL P ROCEDURES. RESISTANCE CHECK OF THE FOLLOWING SWITCHES PERFORMED: S33EZ, S34EZ, S32EZ, PDU FLEX SHAFT LOCK SWITCH AND PDU BRAKE SWITCH. RESISTANCE CHECK PERFORMED. FOUND AT THROTTLE LOCK OUT SWITCH, ONE INTERNAL SWITCH STICKS FROM TIME TO TIME. FOUND AT DEPLOYED SWITCH, WIRING CHAFED AT CARRIER TUBE. THROTTLE LOCKOUT SWITCH (S33EZ) PN 1EN289-3 AND DE PLOYED SWITCH (S32EZ) PN 1EN61-6 REPLACED. 2 L 7 2 4F 4 F RT A21EA E15NE 2005042500027 20050425 00027 WP 2005 4 25 CA041228001 1 20041228 G 6710 D2781 CONTROL SYSTEM ROBSIN R44 R44 7640120 WP LYC O540 O540F1B5 41532 EA GOVERNOR MALFUNCTIONED W H A DEACTIVATE SYST/CIRCUITS UNSCHED LANDING W INADEQUATE Q C CR CRUISE 1 CA L2484140A (CAN) DURING CRUISE THE GOVERNOR WHICH CONTROLS THE ENGINE FROM AN OVERSPEED, MALFUNCTIONED WHICH CAUSED THE ENGINE AND MAIN ROTOR SYSTEMS TO OVERSPEED. DURING THE ENGINE TEARDOWN THE CRANKSHAFT GEAR WAS FOUND DAMAGED. THE CONNECTING ROD BEARINGS WERE ALSO FOUND DAMAGED WITH SLIGHT SPALLING OF THE BEARINGS. THE GOVENOR SYSTEM IS SUSPECTED AND WE ARE IN C ONTACT WITH ROBINSON HELICOPTERS TO DETERMINE WHY THE GOVERNOR DID NOT CONTROL THE OVERSPEED. ROBINSON HELICOPTERS HAVE RELAYED TO US THEY HAVE HAD FURTHER PROBLEMS WITH THE SYSTEM BUT ARE REQUIRING FURTHER INVESTIGATION. WE WILL UPDATE W HEN FURTHER INFORMATION IS AVAILABLE TO US. 1 G 7 1 3O 3 O H11NM E295 2005042500028 20050425 00028 NE 2005 4 25 CA041228002 2 20041205 G 7230 210009021 HOUSING BELL 214 214B1 1182105 SW LYC T55 T5508D 41555 NE COMPRESSOR STRIPPED W K NONE O OTHER IN INSP/MAINT 1 CA LE31939 (CAN) DURING REFUELING BETWEEN HELI-LOGGING CYCLES AME ON SITE ROUTINELY OPENS ENGINE COWLS FOR AN INSPECTION OF ENGINE COMPARTMENT AREA. HE NOTICED AFT ENGINE MOUNT ROD END (BELL PN 214-060-114-001) HAD COMPLETELY PULLED OUT OF ENGINE COM PRESSOR HALF CASTING PN 2-100-090-21. ROD END HAD JAMMED ON AN ANGLE INTO THREADED HOLE PREVENTING FURTHER ENGINE MOVEME NT AND POSSIBLE AIRFRAME DAMAGE. AIRCRAFT IMMEDIATELY SHUTDOWN AND GROUNDED. ENGINE REMOVED FOR REPAIR. IT APPEARS JA M NUT PN 214-060-121-001 WHICH SECURES ROD END INTO ENGINE HAD COME LOOSE SINCE ENGINE INSTALLED 36.6 HOURS PRIOR. THIS ALLOWED MOVEMENT IN THREADS BETWEEN ROD END AND COMPRESSOR HOUSING EVENTUALLY CAUSING THREADS TO FAIL AND THE ROD END T 2 G 7 1 4U 4 U H6SW E4NE 2005042500029 20050425 00029 NM 2005 4 25 CA041229001 1 20041229 G 2752 113T12518 RING GEAR BOEING 767 767233 1385113 NM PWA JT9 JT9D7R4D 52054 NE FLAP ACTUATOR CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) RING WAS FOUND CORRODED AND GEAR BEARING SURFACES WERE PITTED. NR 6 FLAP ACTUATOR HAD CORROSION EMITTING FROM AFT SIDE OF MOUNT FLANGE. REMOVED ACTUATOR AND INVESTIGATED SOURCE. FOUND RING GEAR CORRODED. REACTION RING INSTALLED AND ACTUATOR REINSTALLED PER AMM 27-51-11 AND BAC 5009. 2 L 7 2 4F 4 F RT A1NM E3NE 2005042500030 20050425 00030 NM 2005 4 25 CA041229002 1 20041229 G 3244 32200022 TIRE AIRBUS A319 A319114 3930350 NM NLG FAILED W O OTHER O OTHER TX TAXI/GRND HDL 1 CA (CAN) ON LANDING THERE WAS A NOISE FROM THE NOSE GEAR AND WAS DIFFICULT TO TAXI. ON INSPECTION,BOTH NOSE WHEEL TIRES WER E FLAT. COMPANY SAFETY REG REQ. FDR C/B PULLED. BOTH NOSE WHEELS REPLACED. CONDUIT BRACKET REPAIRED. BURST TIRE INSPECTI ON CARRIED OUT PER AMM 05-51-15. DFDR REPLACED. 2 L 7 2 4F RT A28NM 2005042500031 20050425 00031 EU 2005 4 25 CA041229003 1 20041229 G 2730 COMPUTER AIRBUS 320 A320211 3930320 EU CFMINT CFM56 CFM565A1 NE ELAC NR 2 MALFUNCTIONED W O OTHER F FLT CONT AFFECTED DE DESCENT 1 CA (CAN) F/CTL ELAC 1 PITCH FAULT, F/CTL ELAC 2 PITCH FAULT, F/CTL STAB. JAM, APPEARED ON ECAM. ECAM PROCEDURE COMPLET ED NORMALLY AND A/C REMAINED IN ALTN LAW. RESET ELAC 1 & 2 VIA PUSH BUTTONS AND SYSTEM RESET ITSELF. ELAC NR 2 REPLACED AND TESTED PER AMM. 2 L 7 2 4F 4 F RT A28NM E29NE 2005042500032 20050425 00032 EU 2005 4 25 CA041230001 1 20041214 G 2910 LINE CASA C212 C212CC 2410204 EU HYDRAULIC SYS FAILED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) DISCOVERED SMALL RUBBER PIECES IN HYDRAULIC FILTER. PARTICLES APPEARED TO BE FROM MANUFACTURE OF HOSE ASSEMBLIES, RESEMBLING INTERIOR LINING OF TYPICAL HOSE. REPLACED ALL FLEXIBLE HOSES IN HYDRAULIC SYSTEM AS IT WAS IMPOSSIBLE TO D ETERMINE WHICH HOSE HAD CONTAMINATED THE SYSTEM. WITH NEW HOSES IN PLACE, THE SYSTEM WAS FLUSHED OUT TO REMOVE ANY FUR THER CONTAMINATION AND FILTER WAS REPLACED. THE HOSES HAD EEN IN SERVICE SINCE 2002. 2 H 7 2 4T A43EU 2005042500033 20050425 00033 NM 2005 4 25 CA041230002 1 20041230 G 7500 9639 BLEED AIR SYS BOEING 767 767375 1385217 NM GE CF6 CF680C2B6F 30025 NE RIGHT LEAKING W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA (CAN) R' BLEED DUCT LEAK''EICAS MSG',QRH COMPLETED. LIGHT DUCT LEAK STAYED ON FOR 90 MINUTES, WENT OUT FOR 30 MINUTES, THEN CAME ON AGAIN. NOTICED THAT RT BLEED PRESSURE STAYED AT 5 PSI, NOT ZERO. VISUAL INSPECTION OF PNEUMATIC DUCTS, CLA MPS AND OVERHEAT DETECTION LOOP CARRIED OUT FROM MLG WW TO NR 2 ENG PYLON- NIL FAULTS FOUND. REPLACED DUCT 1 / MLG WW FI RE DETECTION CARD M691- ENGS GROUND RUN. ALL INDICATION AND OPS NORMAL. 2 L 7 2 4F 4 F RT A1NM E13NE 2005042500034 20050425 00034 CE 2005 4 25 CA041230003 1 20041227 G 2121 MOTOR RAYTHN BEECH 100 100BEECH 1152916 CE PWA PT6 PT6A28 EA BLOWER ASSY SEIZED W B EMER. DESCENT B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA 20 (CAN) PILOTS NOTICED SMOKE COMING FROM UNDER THE LT INSTRUMENT PANEL THAT QUICKLY STARTED TO FILL THE COCKPIT. THEY DES CENDED, DEPRESSURIZED AND DECLARED AN EMERGENCY.MAINTENANCE DISCOVERED THAT THE BLOWER MOTOR HAD SEIZED CAUSING THE SMOK E IN THE AIRCRAFT. 1 L 7 2 3T 4 T A14CE E4EA 2005042500035 20050425 00035 EA 2005 4 25 CA041231001 2 20041217 G 8500 ENGINE ROBSIN R44 R44 7640120 WP LYC O540 O540F1B5 41532 EA OVERSPEED W A UNSCHED LANDING J WARNING INDICATION AP APPROACH 1 CA L2455340A (CAN) DURING A TRAINING FLIGHT, THE ENGINE HAD A UNCOMMAMDED OVERSPEED AND A FULL THROTTLE TO IDLE SPEED CONDITION. THE PILOTS RETURNED TO THE AIRPORT WHERE FURTHER INVESTIGATION COULD NOT DUPLICATE THE PROBLEM. THE PILOTS COULD NOT EXPLAIN TO THE REASON WHY THE AIRCRAFT HAD THESE DEFECTS. THEY SAY THEY WERE COMPLETELY UNCOMMANDED. THE AIRCRAFT OVERSPEED WAS ABOVE 109 PERCENT. WE HAVE CONDUCTED AN OVERSPEED INSPECTION IAW LYCOMING SB 369J. NO DAMAGE WAS FOUND AND FURTHER INV ESTIGATION TO THE GOVERNOR SYSTEM IS STILL ON GOING. WE HAVE INSTALLED A NEW GOVERNOR FOR SAFTEY REASONS. WE WILL UPDATE AS SOON AS WE HAVE MORE INFORMATION. 1 G 7 1 3O 3 O H11NM E295 2005042500036 20050425 00036 EU 2005 4 25 CA041231002 1 20041230 G 3810 LINE FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE POTABLE WATER SY BURST W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CL CLIMB 1 CA (CAN) AFTER TAKE OFF, COULD NOT GET AIRCRAFT TO PRESSURIZE. AIRCRAFT LANDED BACK TO DEPARTURE AIRPORT. MAINTENANCE FO UND BOTH PRIMARY AND SECONDARY OUTFLOW VALVES AND OUTFLOW VALVE DRAIN LINE CONTAMINATED WITH ICE. WATER CAME FROM POTAB LE WATER SYSTEM. A WATER LINE BUSTED DUE TO COLD WEATHER AND WATER RESIDUAL WAS THE CAUSE OF CONTAMINATION. BOTH VALVE S AND DRAIN LINE REPLACED 2 L 7 2 4F 4 F RT E25NE 2005042500037 20050425 00037 EU 2005 4 25 CA050103001 1 20041231 G 3222 SLEEVE AIRBUS A319 A319112 3930323 EU AXEL SEIZED W D RETURN TO BLOCK O OTHER TX TAXI/GRND HDL 1 CA L2325 (CAN) THE CREW REPORTED A GRINDING NOISE COMING FROM THE NOSE GEAR. ON INVESTIGATION, MAINTENANCE FOUND THE RIGHT HAND N LG WHEEL INBOARD BEARING ASSY SEIZED ONTO THE AXEL SLEEVE. ATTEMPTS TO FREE THE SLEEVE HAVE BEEN UNSUCCESSFUL AND THE NO SE GEAR STRUT HAD TO BE REPLACED. 2 L 7 2 4F RT A28NM 2005042500041 20050425 00041 WP 2005 4 25 CA050104003 1 20041230 G 7711 INDICATOR DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE NR 2 ENGINE EPR INOPERATIVE W C ABORTED TAKEOFF P NO WARNING INDICATION TO TAKEOFF 1 CA (CAN) AIRCRAFT REJECTED TAKE OFF AT 65 KNOTS, DUE TO NR 2 ENGINE EPR GAUGE BEING INOPERATIVE. MAINTENANCE REMOVED EPR LI NES AND FOUND WATER INU PIPE OF PT7. THE WATER WAS BLOWN OUT AND DRIED. ENGINE RUN CARRIED OUT, SYSTEM FOUND SERVICEABL E. 2 L 7 2 4F 4 F RT A6WE E9NE 2005042500042 20050425 00042 WP 2005 4 25 CA050104004 1 20041230 G 7711 LINE DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE NR 2 ENGINE EPR CONTAMINATED W C ABORTED TAKEOFF O OTHER TO TAKEOFF 1 CA (CAN) AIRCRAFT REJECTED TAKE OFF AT LESS THEN 40 KNOTS, DUE TO NR 2 ENGINE EPR DID NOT RESPOND TO THROTTLE MOVEMENT. MA INTENANCE FOUND WATER IN EPR LINE. MAINTENANCE BLEW AIR AND CLEANEDTHE EPR LINES PT7, PT2 IAW AMM 77-1 1-03, 77-11-04. E NGINE RUN CARRIED OUT, SYSTEM FOUND SERVICEABLE. 2 L 7 2 4F 4 F RT A6WE E9NE 2005021400182 20050214 00182 EU 2005 2 14 CA050104005 1 20041227 G 2910 SD3730311 LINE STBROS SD3 SD360 8100606 EU HYD PRESSURE RUPTURED W L ABORTED APPROACH K J FLUID LOSS WARNING INDICATION AP APPROACH 1 CA (CAN) UPON SELECTING GEAR DOWN DURING APPROACH THE STATED PRESSURE LINE RUPTURED CAUSING HYDRAULIC SYSTEM TO LOSE ALL FL UID. LANDING WAS ABORTED AND AN EMERGENCY WAS DECLARED. GEAR WAS EXTENDED USING EMERGENCY GEAR EXTENSION. AIRCRAFT LANDE D SAFELY AND WAS TAXIED USING DIFFERENTIAL POWER FOR STEERING TO A SAFE LOCATION WHERE PASSENGERS WERE DISEMBARKED. MAIN TENANCE REPLACED LINE, SERVICED HYDRAULIC SYSTEM AND RETURNED AIRCRAFT TO SERVICE. 2 H 7 2 4T A41EU 2005031100027 20050311 00027 2005 3 11 CA050104007 4 20041209 G 3420 7012100825 RMU CESSNA 500 560CESSNA 2076750 CE PWA 530 PW535A NE FAILED W O OTHER H ELECT. POWER LOSS-50 PC CR CRUISE 1 CA (CAN) DISPLAY SCREEN LOST YELLOW AND GREEN COLOR LEAVING ONLY RED AND BLUE. REPLACED RMU WITH EXCHANGE UNIT. NOTE: THI S IS THE SECOND UNIT TO FAIL. THE FIRST FAILED WITH 264 HOURS TSN. 2 L 7 2 4F 4 F RT A22CE E00053EN 2005031100028 20050311 00028 CE 2005 3 11 CA050104008 1 20041126 G 3242 21656 BRAKE ASSY CESSNA 500 560CESSNA 2076750 CE PWA 530 PW535A NE MLG FAILED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) WEEPING OF HYDRAULIC FLUID PAST PISTON PACKINGS, MFG SB 2-1601-32-2 RECOMMENDS INSTALLATION OF OVERSIZE PACKINGS P /N 68-1507 TO REDUCE THE PROBLEM. THESE PACKINGS WERE INSTALLED WHEN THE BRAKES WERE MANUFACTURED. APPROXIMATELY 325 LANDINGS IS NOT VERY GOOD LIFE. 2 L 7 2 4F 4 F RT A22CE E00053EN 2005031100029 20050311 00029 CE 2005 3 11 CA050104009 1 20041031 G 2435 300SG42982 STARTER GEN CESSNA 500 560CESSNA 2076750 CE PWA 530 PW535A NE ENGINE FAILED W K NONE H ELECT. POWER LOSS-50 PC IN INSP/MAINT 1 CA (CAN) GENERATOR FUNCTION OK IN FLIGHT, AFTER SHUTDOWN. ON ENGINE START, ENGINE WOULD NOT ROTATE. FOUND COMMUNTATOR AND BRUSHES DAMAGED BY ARCING. 2 L 7 2 4F 4 F RT A22CE E00053EN 2005031400029 20050314 00029 GL 2005 3 14 CA050104010 2 20041214 G 7532 23053176 BLEED VALVE BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL ENGINE FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) BLEED VALVE WAS INSTALLED AFTER OVERHAUL TO REPLACE A TIME EXPIRED UNIT. SUBSEQUENT POWER CHECK REVEALED HIGH TOT . BLEED VALVE WAS WAS RETURNED TO VENDOR TO CORRECT FAULT. PART WAS INSTALLED AND FAILED A SECOND TIME. PART WAS REPL ACED WITH ANOTHER UNIT, POWER CHECK SATISFACTORY. 1 G 7 1 3U 3 U H2SW E4CE 2005031400054 20050314 00054 EA 2005 3 14 CA050104011 1 20041229 G 5302 S612066120 WEB SKRSKY CARSON S61 S61LSKRSKY EA GE CT58 CT581401 30011 NE TAILBOOM CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA A12324 (CAN) DURING A ROUTINE INSPECTION, A CRACK WAS FOUND ON THE LT FORWARD CORNER OF THE LOWER WEB FITTING. 2 G 7 2 4U 4 U H8EA 1E3 2005031400055 20050314 00055 EA 2005 3 14 CA050105001 2 20041216 G 7414 4371 MAGNETO CESSNA 172 172N 2072434 CE LYC O320 O320D2J 41508 EA MCAULY 1C160 1C160DTM GL ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA RL699239A (CAN) AT 500 HOUR INSPECTION, A 1.5 INCH CRACK WAS NOTICED ON THE MAGNETO COIL ADJACENT TO THE OUTPUT CONNECTOR. MAGNET O REMOVED FROM SERVICE. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2005031400056 20050314 00056 EA 2005 3 14 CA050105002 2 20041221 G 7414 DISTRIBUTOR GEAR LYC ROBSIN R22 R22BETA 7640110 NM LYC O320 O320B2C 41508 EA MAGNETO BROKEN W K NONE O OTHER TX TAXI/GRND HDL 1 CA 919635 (CAN) UNABLE TO START ENGINE. FOUND TWO PLASTIC TEETH MISSING FROM DISTRIBUTOR GEAR. 1 G 7 1 3O 3 O H10WE E274 2005031400051 20050314 00051 NM 2005 3 14 CA050105003 1 20041220 G 2780 CONTROL SYSTEM BOEING BOEING 727 727260 NM PWA JT8 JT8D17 52049 NE SLAT FAILED W J A DUMP FUEL UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA 36135 (CAN) DURING CLIMB FLAPS/SLATS SELECTED UP. FLAPS INDICATED UP, SLAT AMBER REMAINED ON AND AIRCRAFT ROLLED TO THE RT. S ECOND OFFICERS PANEL INDICATED NR6 SLAT STILL IN TRANSIT. FLAPS AND SLATS CYCLED A NUMBER OF TIMES TO NO AVAIL. DECISION TO RETURN WAS MADE, 8000 LBS OF FUEL DUMPED. AC LANDED WITHOUT FURTHER INCIDENT AND WITHOUT DECLARING AN EMERGENCY. MA INT INSPECTED AND TESTED SLATS WITH NO FAULT FOUND ON NR6 SLAT. HOWEVER NR3 KREUGER WAS FAULTED AND REPAIRED. THIS WAS I NCIDENTAL AND WE BELIEVE NOT RELATED TO THE NR6 SLAT PROBLEM. IT IS SUSPECTED THAT NR6 SLAT BECAME ASKEWED INFLIGHT WHI CH COULD NOT BE DUPLICATED ON THE GROUND. AIRCRAFT WAS RELEASED WITH NO FURTHER FAULT ON THE NEXT FLIGHTLEG. 2 L 7 3 4F 4 F RT A3WE E2EA 2005031400052 20050314 00052 EA 2005 3 14 CA050105004 2 20041215 G 8500 ENGINE PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2B 41532 EA HARTZL HCE3Y HCE3YR2A GL LEFT FAILED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA RL194661 (CAN) AFTER TAKEOFF THE LT ENGINE ENCOUNTERED RPM FLUCTUATIONS, THE AIRCRAFT RETURNED TO THE AIRPORT. AFTER SOME DISCUSS ION WITH THE MECHANICS, THE PILOTS DRAINED THE AIRCRAFT AGAIN AND CARRIED OUT A GROUND RUN. EVERYTHING RETURNED TO NORMA L. THE AIRCRAFT DEPARTED RIGHT AFTER THE TANKS WERE FILLED. WHEN THE AIRCRAFT RETURNED TO BASE, WE VERIFIED AND CLEANED ALL THE INJECTORS AND DRAINED THE AIRCRAFT, ALL THE ENGINE FUEL LINES WERE PURGED AS WELL. THERE WAS NO WATER IN THE TA NKS AND NO INJECTORS WERE CLOGGED. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2005031100033 20050311 00033 EA 2005 3 11 CA050105007 2 20041130 G 8520 CAMSHAFT PIPER PA28 PA28R201 7102816 SO LYC O360 IO360C1C6 41514 EA MCAULY 2D34C B2D34C213 GL ENGINE WORN W K NONE O OTHER IN INSP/MAINT 1 CA L2685451A (CAN) AIRCRAFT IS OPERATED BY BUSY FLIGHT TRAINING UNIT NO COMPLAINTS OF ENGINE MALFUNCTIONS HAD BEEN REPORTED. ENGINE W AS RUN UP, FOUND NORMAL, PRIOR TO INSPECTION. OIL SUCTION SCREEN WAS INSPECTED AND FOUND CLEAN. OIL PRESSURE FILTER WA S CUT OPEN AND A SMALL AMOUNT OF STEEL FILINGS WERE FOUND ON FURTHER INVESTIGATION BY REMOVING NR 1 AND 3 CYLINDERS. TH E AFT INTAKE LOBE ON THE CAMSHAFT WAS FOUND TO BE ALMOST NON-EXISTENT. THE ENGINE WAS SENT TO AN OVERHAUL SHOP FOR REPA IRS. 1 L 7 1 3O 3 O 2A13 1E10 5 C P7EA 2005031400060 20050314 00060 NE 2005 3 14 CA050105010 2 20041212 G 7261 CASE DHAV DHC8 DHC8* NM PWA PW120 PW123 NE ENGINE LEAKING W E A ENGINE SHUTDOWN UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA AE0015 (CAN) DURING CRUISE CREW IDENTIFIED LOW OIL PRESSURE. THE ENGINE WAS SHUTDOWN AND THE FLIGHT DIVERTED. INSPECTION REVE ALED LOW ENGINE OIL QUANTITY AND SUBSEQUENT INVESTIGATION FOUND OIL LEAKAGE FROM THE FRONT INLET CASE DRAIN LOCATION. M FG WILL INVESTIGATE THE INCIDENT AND SUPPLEMENT THIS REPORT TO IDENTIFY ROOT CAUSE ONCE DETERMINED. 2 H 7 2 4T 4 T RT A13NM E20NE 2005031400057 20050314 00057 NE 2005 3 14 CA050105011 2 20041224 G 7261 TUBE AEROSP ATR42 ATR42* 8680900 EU PWA PW121 PW121 52124 NE OIL TRANSFER FRACTURED W F E ACTIVATE FIRE EXT. ENGINE SHUTDOWN B J SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CR CRUISE 1 CA 120089 (CAN) DURING CRUISE ENGINE TEMPERATURES INCREASED ACCOMPANIED BY SMOKE AND EXHAUST ODOR IN THE CABIN. THE CREW REDUCED ENGINE POWER. FIRE WARNING INDICATION ACTIVATED 12 MINUTES LATER AND THE CREW CARRIED OUT FIRE SUPPRESSION PROCEDURE AND SHUTDOWN THE ENGINE IN FLIGHT. SUBSEQUENT INSPECTION REVEALED A FRACTURED NR 6 AND NR 7 BEARING OIL TRANSFER TUBE, A B URNED FIRE HARNESS LOOP AND METALLIC DEBRIS ON THE ENGINE CHIP DETECTOR. MFG WILL INVESTIGATE THE EVENT AND WILL SUPPLE MENT THIS REPORT TO PROVIDE ROOT CAUSE ONCE DETERMINED. 2 H 7 2 4T 4 T RT A53EU E20NE 2005031400058 20050314 00058 NE 2005 3 14 CA050105012 2 20041223 G 7532 30B1695 SENSE LINE LEAR 60 60LEAR 5170707 CE PWA 305 PW305A 52128 NE P 2.8 BROKEN W O OTHER D INFLIGHT SEPARATION TO TAKEOFF 1 CA (CAN) CREW REPORTED COMPRESSOR STALL DURING TAKE-OFF. SUBSEQUENT INVESTIGATION REVEALED A BROKEN P2.8 BLEED VALVE (BOV ) SENSE LINE. 2 L 7 2 4F 4 F RT A10CE E35NE 2005031400059 20050314 00059 NM 2005 3 14 CA050105013 1 20041229 G 3233 65404676 ACTUATOR BOEING 727 727233 138408A NM PWA JT8 JT8D15A 52051 NE NLG DOWNLOCK SEPARATED W O OTHER D K J INFLIGHT SEPARATION FLUID LOSS WARNING INDICATION AP APPROACH 1 CA (CAN) ON APPROACH, THE CREW OBSERVED 'A' (HYDRAULIC) SYSTEM DEPLETION. SYSTEM DESELECTED, NORMAL LANDING CARRIED OUT. TH E NOSE LANDING GEAR DOWN LOCK ACTUATOR SEPARATED FROM THE AIRFRAME MOUNT AND HAD DAMAGED THE HYDRAULIC LINES. 2 L 7 3 4F 4 F RT A3WE E2EA 2005041200044 20050412 00044 SO 2005 4 12 CA050106003 1 20041220 G 2913 1213HBG310 PUMP PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2C 41532 EA HARTZL HCE3Y HCE3YR2A GL HYD SYSTEM CRACKED W O OTHER K J FLUID LOSS WARNING INDICATION CL CLIMB 1 CA (CAN) TOOK OFF, ENROUTE, AIRCRAFT WAS ON A BASE RELOCATION FLIGHT. PILOT HAD GEAR IN-TRANSIT LIGHT FOR LONGER THAN NORM AL AFTER GEAR WAS SELECTED UP. RE-SELECTED GEAR DOWN AND LOCKED 3 GREEN. RE-SELECTED GEAR UP AND STILL HAD IN-TRANSIT LIGHT. CONTINUED WITH GEAR HANDLE SELECTED UP AND IN-TRANSIT LIGHT ON. AC LANDED WITHOUT INCIDENT, MAINT DISCOVERED HY DRAULIC OIL UNDER COWL. FURTHER INVESTIGATION REVEALED A CRACKED RT HYDRAULIC PUMP HOUSING. PUMP HAS BEEN CHANGED AND HYDRAULIC SYSTEM INSPECTED, SERVICED AND OPERATED ON THE GROUND, NO ABNORMALITIES NOTED. NOTE: HYDRAULIC PUMP REMOVED DI D NOT HAVE A DATA PLATE ALTHOUGH RECORDS DID INDICATE THAT IT WAS A ZERO TIMED UNIT AT ENGINE CHANGE IN 1998. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2005042500044 20050425 00044 NE 2005 4 25 CA050107001 2 20041128 G 7320 8237006 HMU CESSNA 560 560XL 2076702 CE PWA 545 PW545A NE RT ENGINE FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) RT ENGINE WOULD NOT START. 2 L 7 2 4F 4 F RT A22CE E00059EN 2005042500047 20050425 00047 EA 2005 4 25 CA050107006 2 20041229 G 7200 ENGINE DHAV DHC7 DHC7103 2802710 EA PWA PT6 PT6A50 52043 EA HAMSTD 24PF 24PF305 GL NR 2 FAILED W E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA 19181 PCE86394 (CAN) APPOX 20 MINS INTO FLT, & AT FLT LEVEL 120 ENROUTE TO DIKO FROM DIBK WITH 19 PAX, MASTER CAUTION LIGHT ILLUMINATE D ACCOMPANIED WITH NR 2 ENG LOW OIL PRESSURE LIGHT. NR 2 OIL PRESSURE GAUGE CONFIRMED ACTIVE WARNING LIGHT WITH PRESSUR E INDICATION OF BELOW 75 PSI & DECREASING. ENG SHUTDOWN CARRIED OUT IAW QRH CHKLST. ENG SECURED & FLT DIVERTED TO ABIDJA N. UNITED NATIONS FLT FOLLOWING CENTRE 'AMIGO BASE' INFORMED ON HF FREQUENCY OF SIT & ASKED TO INFORM ALL FORCE NOUVELL E MILITARY GROUND TO AIR SECURITY SURVEILLANCE & DEFENSE SITES INCLUDING FRENCH AIR FORCE OF OUR NEW ROUTING & ALTITUDE & CANCEL OF PREVIOUSLY SCHEDULED AIR TASKING ORDERS. FLT TERMINATED WITHOUT ANY FURTHER INCIDENTS BACK IN ABIDJAN. 2 H 7 4 4T 4 T A20EA E4EA 6 C P1NE 2005042500048 20050425 00048 NM 2005 4 25 CA050107007 1 20041211 G 2913 570717 SHAFT EATON DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE HYD PUMP SHEARED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA 37321 16534 MX459159C (CAN) NR 1 ENG HYD PUMP CAUTION LIGHT ILLUMINATED WITH FLAP RETRACTION ON TAKEOFF. NR 1 SPU TURNED OFF, MAIN PRESSURE DEPLETED TO 0 PSI. FLUID QTY REMAINED STEADY. A/C RETURNED TO YYZ. INPUT SHAFT SHEARED FROM AN INTERNAL FAILURE. PUMP DISMANTLED. INTERNAL DAMAGE FROM 2 BROKEN PISTONS (PN 404783), CAUSING DAMAGE TO OTHER PARTS. (PISTON SHOE PLATE PN 3 96386 & RETAINER PN 405892) ALSO HARDWARE DAMAGE NOTED. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005021400183 20050214 00183 EA 2005 2 14 CA050110001 1 20041229 G 2150 GG67095009 ACM CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE BOTH SEIZED W A UNSCHED LANDING B J SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CL CLIMB 1 CA (CAN) THE AIRCRAFT RETURNED TO FIELD AFTER LAV SMOKE DETECTOR WENT OFF AND VISIBLE SMOKE IN CABIN. AN EMERGENCY WAS DEC LARED AND AN EMERGENCY EVACUATION WAS PERFORMED AFTER LANDING. NOTE: IT WAS REPORTED THAT SOMEONE BROKE BOTH ANKLES DUR ING THE EVACUATION FROM THE OVERWING ESCAPE. BOTH ACMS WERE REPLACED. INVESTIGATION REVEALED THAT ONE ACM WAS ON MMEL AND THE AIRCRAFT WAS OPERATING ON ONE ACM. DURING THE TAKEOFF THAT OTHER ACM LOCKED UP. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2005042000085 20050420 00085 SO 2005 4 20 CA050110004 1 20041208 G 2450 5AMP CIRCUIT BREAKER PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2C 41532 EA HARTZL HCE3Y HCE3YR2A GL ELECTRICAL DAMAGED W A UNSCHED LANDING B H SMOKE/FUMES/ODORS/SPARKS ELECT. POWER LOSS-50 PC CR CRUISE 1 CA 7400992 (CAN) AC WAS RETURNING WHEN RT ALT WENT OFF-LINE, 5 MIN LATER LT ALT SYS WENT OFF-LINE. BATTERY, LT ALT, BOTH VOLT REG, LT OVER-VOLT RELAY, LT VOLT REG CB WERE REPLACED. NO TEST FOR OVER-VOLT RELAY SPECIFIED IN MM, IN ELEC SYS OF MM A 500 HOUR OVER-VOLT RELAY OPS CHECK IS RECOMMENDED, HAS BEEN ADDED TO AC`S TBO SHEET. LT 5 AMP FIELD (VOLTAGE REG) CB. WHE N IT WAS MEASURED AFTERWARDS A VOLTAGE DROP/RESISTANCE WAS NOTED ACROSS IT. WOULD CAUSE VOLT REG TO THINK BUSS VOLTAGE WAS LWR THAN IT ACTUALLY WAS. IN THIS CASE 28.2V WAS MEASURED AT FIELD TERMINAL ON VOLT REG WHILE 30.5V WAS MEASURED AT BUSS. THIS WOULD CAUSE RT ALT SYS TO GO OFF-LINE DUE TO IMBALANCE. LT ALT SYS WOULD CONTINUE IN THIS MANNER. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2005031400032 20050314 00032 EA 2005 3 14 CA050110006 2 20041229 G 7200 ENGINE DHAV DHC7 DHC7100 2802404 EA PWA PT6 PT6A50 52043 EA INOPERATIVE W E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA (CAN) THE ENGINE EXPERIENCED AN OIL PRESSURE LOSS IN CRUISE. THE CREW SHUT THE ENGINE DOWN AND DIVERTED FLIGHT. SUBSEQ UENT INSPECTION REVEALED METALLIC DEBRIS ON THE ENGINE CHIP DETECTOR AND IN THE ENGINE OIL FILTER. MFG WILL MONITOR THE INVESTIGATION OF THIS EVENT AND SUPPLEMENT THIS REPORT TO PROVIDE ROOT CAUSE ONCE DETERMINED. 2 H 7 4 4T 4 T A20EA E4EA 2005031400033 20050314 00033 NE 2005 3 14 CA050110007 2 20041226 G 7200 ENGINE AEROSP ATR72 ATR72 EU PWA PW120 PW127 NE INOPERATIVE W E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) THE CREW REPORTED A LOW OIL PRESSURE WARNING FOLLOWING TAKE-OFF. THE CREW SHUT THE ENGINE DOWN IN FLIGHT AND DIVE RTED TO POINT OF DEPARTURE. MFG WILL INVESTIGATE THE EVENT AND SUPPLEMENT THIS REPORT TO PROVIDE ROOT CAUSE, ONCE DETERM INED. 2 H 7 2 4T 4 T RT E20NE 2005042500051 20050425 00051 EA 2005 4 25 CA050110008 2 20041210 G 7200 ENGINE BEECH 200 B200 1152922 CE PWA PT6 PT6A41 52043 EA NR 1 FAILED W C ABORTED TAKEOFF R J PARTIAL RPM/PWR LOSS WARNING INDICATION TO TAKEOFF 1 CA (CAN) AFTER TAKE-OFF, THE NR 1 ENGINE REPORTEDLY LOST POWER. THE AIRCRAFT SETTLED TO THE GROUND, DEPARTED THE RUNWAY AND WAS CONSUMED BY FIRE. PWC WILL INVESTIGATED THE ENGINE AND WILL SUPPLIMENT THIS REPORT TO PROVIDE ROOT CAUSE, AS AND WH EN DETERMINED. 1 L 7 2 4T 4 T A24CE E4EA 2005031100021 20050311 00021 EA 2005 3 11 CA050117010 2 20041204 G 7200 ENGINE EMB 110 EMB110* SO PWA PT6 PT6A34 52043 EA HARTZL HCB3T HCB3TN3 GL FAILED W O OTHER Y ENGINE STOPPAGE NR NOT REPORTED 1 CA 56857 (CAN) THE ENGINE WAS REPORTED TO HAVE EXPERIENCED AN INFLIGHT SHUTDOWN UNDER UNKNOWN CIRCUMSTANCES. SUBSEQUENT DISASSEM BLY REVEALED A SEIZED COMPRESSOR ROTOR AND METAL DEBRIS IN THE ENGINE OIL FILTER AND CHIP DETECTOR. MFG WILL MONITOR TH E INVESTIGATION OF THIS EVENT AND WILL SUPPLEMENT THIS REPORT TO PROVIDE ROOT CAUSE, AS AND WHEN IT IS DETERMINED. 1 L 7 2 4T 4 T RT A21SO E4EA 6 C P15EA 2005042000089 20050420 00089 EU 2005 4 20 CA050119004 1 20041213 G 5532 350A1402000901 SKIN UROCOP SNIAS 350 AS350B3 8680954 EU TMECA ARRIEL ARRIEL2B NE VERTICAL FIN CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA TB3536 (CAN) CRACK WAS FOUND AT VERTICAL FIN. THIS FIN WAS SENT TO MFG FOR REPAIR. 1 G 7 1 3U 3 U H9EU E00054EN 2005041200005 20050412 00005 NM 2005 4 12 CA050120002 1 20041028 G 5751 65C25920 BALANCE WEIGHT BOEING BOEING 737 737248C 1384415 NM PWA JT8 JT8D9A 52048 NE RT AILERON MISINSTALLED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 92 (CAN) DURING HEAVY MAINTENANCE THE RT AILERON WAS DISCOVERED IN AN IMPROPER CONFIGURATION. THE BALANCE WEIGHT ASSOCIATED WITH A COMPOSITE UNIT WAS FOUND TO BE INSTALLED WHEN THE AILERON WHICH WAS REMOVED FOR REPAINT COULD NOT BE BALANCED AT REINSTALLATION. THE BALANCE WEIGHT IS USED ON 65C25911 COMPOSITE SERIES AILERONS. THE DATE OF INSTALL IS NOT KNOWN. 2 L 7 2 4F 4 F RT A16WE E2EA 2005042500070 20050425 00070 NE 2005 4 25 CA050121005 1 20041125 G 5510 2220021 FITTING CONAER LA4 LA4 5110302 NE LYC O360 O360A1A 41514 EA HARTZL HC92Z HC92ZK8 GL HORIZONTAL STAB CRACKED W O OTHER F FLT CONT AFFECTED IN INSP/MAINT 1 CA (CAN) DURING ANNUAL INSP, IT WAS NOTICED THAT AC DID NOT COMPLY WITH REQUIREMENTS OF AD98-10-12 WITH REF TO SB78 HORIZON TAL STABILIZER INSP AND REWORK. AD98-10-12 WAS SIGNED OUT IN THE TECH RECORDS ON SEPT 1,1998 AT 1683.22 TT. REMOVAL OF F ITTINGS REVEALED P/N 2-2200-21 LT FITTING TO BE CRACKED. HAVE HAD SEVERAL INSTANCES WHERE AD98-10-12 HAD BEEN SIGNED OU T WHILE NOT MEETING THE REQUIREMENTS OF THE AD AND SB. FAILURE OF THE HORIZONTAL STABILIZER FITTINGS IS IMMINENT IF THE SE CRACKS ARE LEFT UNDETECTED. RECOMMEND MAINTAINERS OF LAKE AC REEVALUATE THE REQUIREMENTS OF AD98-10-12 AND SB78 AND M AKE SURE THEIR AC MEETS THESE REQUIREMENTS BY ENSURING THAT SB78 WAS CARRIED OUT CORRECTLY. 1 H 7 1 3O 3 O 1A13 E286 5 C P892 2005042000102 20050420 00102 EU 2005 4 20 CA050124010 1 20041222 G 7830 ENGINE AEROSP ATR72 ATR72 EU PWA PW120 PW124B NE NR 1 MALFUNCTIONED W O OTHER E VIBRATION/BUFFET LD LANDING 1 CA 124446 (CAN) DURING LANDING ROLL, ONE ENGINE DID NOT RESPOND CORRECTLY TO SELECTION OF REVERSE THRUST. AS A RESULT, THE AIRCRAF T DEPARTED THE RUNWAY. VARIOUS ENGINE ACCESSORIES HAVE BEEN REMOVED FOR EVALUATION. MFG WILL MONITOR THE INVESTIGATIO N AND WILL SUPPLEMENT THIS REPORT TO PROVIDE ROOT CAUSE, ONCE ESTABLISHED. 2 H 7 2 4T 4 T RT E2ONE 2005041200021 20050412 00021 SO 2005 4 12 CA050125015 2 20040716 G 8520 PISTON CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO MCAULY D3A34 D3A34C402 GL ENGINE DISINTEGRATED W A UNSCHED LANDING E VIBRATION/BUFFET AP APPROACH 1 CA (CAN) ENGINE HAD 450 HOURS SINCE TOTAL O/H, WAS PERFORMING NORMAL. CYL LEAK TEST WERE MIN. 60/80 AND OIL CONSUMPTION WAS 1 LT-13 HRS. AC WAS IN BASE LEG WITH POWER REDUCED GRADUALLY BACK TO 20 IN., PROP NEAR FINE, MIXTURE NEAR RICH. VIBR ATION STARTED IN ENGINE, IT WAS LOOSING RPM AND POWER. TANKS WERE SWITCHED AND BOOST PUMP ACTIVATED BUT WITH NO RESULTS. GEAR WAS RETRACTED, MORE FLAP ADDED. A CRASH INTO TREES CARRIED OUT ABOUT A MILE SHORT OF RUNWAY. DISCOVERED THAT THE RE WAS A HOLE IN THE CASE NEAR NR 5 CYL. NTSB FINDINGS CONCLUDED THAT NR 5 PISTON DISINTEGRATED, OTHER 5 PISTONS HAD NO RMAL WEAR FOR 450 HRS. NO INDICATION OF ANY PROBLEMS FROM VIBRATION START UNTIL STOPPED IN TREES IS 25 SECONDS. 1 H 7 1 3O 3 O 3A21 E8CE 5 C P47GL 2005021400189 20050214 00189 EA 2005 2 14 CA050126012 1 20041019 G 2435 03600923 BEARING LUCAS DHAV DHC8 DHC8311 1386006 EA PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE STARTER GEN BROKEN W O OTHER J WARNING INDICATION TX TAXI/GRND HDL 1 CA 22546 978 (CAN) DEFECT 422403, STARTED NR 2 DID NOT DISENGAGE AFTER START, QRH WAS FOLLOWED, DC GEN CAUTION LIGHTS REMAINED ON, NO HIGH DISCHARGE BATTERY STARTER GEN SENT TO SHOP. UNIT INSPECTED, CONFIRMED BEARING FAILURE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005042000126 20050420 00126 EA 2005 4 20 CA050128007 1 20041120 G 5753 HINGE BRACKET DHAV DHC6 DHC6200 2802620 EA PWA PT6 PT6A20 52043 EA HARTZL HCB3T HCB3TN3 GL TE FLAP DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) LOOSE RIVETS ATTACHING CENTER FLAP HINGE BRACKET TO IB AND OB PORTIONS OF FORE FLAP ASSY. HIDDEN PROBLEM DOES NOT REALLY SHOW UP UNTILL YOU TAKE THE FLAP OFF. FORE FLAP DISASSEMBLED AND RIVETS REPLACED WITH NEW. 1 H 7 2 3T 3 T RT A9EA E4EA 6 C P15EA 2005061700015 20050617 00015 EU 2005 6 17 CA050207003 1 20041205 G 6730 M02801H003101 PISTON ROD AGUSTA AGUSTA A109 A109E 0260119 EU PWA PW206 PW206B 0 NE ACTUATOR CORRODED W O OTHER K FLUID LOSS NR NOT REPORTED 1 CA 0066 APPARENT CORROSION PITS ON SURFACE OF PISTON ROD LEADING TO SMALL HYDRAULIC LEAKS, DESIGN HAS BEEN CHANGED TO REPLACE AR COR FINISH OF PISTON ROD BY CHROME. NOTE THAT PART NUMBER OF ACTUATOR IS 109-0900-39-103 AND ORIGINAL MANUFACTURER OF A CTUATOR IS MECAER S.P.A. 1 G 7 2 3U 3 U RT H7EU E42NE 2005042500131 20050425 00131 NM 2005 4 25 CA050211008 1 20041219 G 2120 21178041 COMPUTER DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE CABIN PRESSURE MALFUNCTIONED W A UNSCHED LANDING O OTHER CL CLIMB 1 CA 14473 14473 (CAN) ON CLIMB OUT WITH CABIN PRESSURIZATION SET TO AUTO IN BOTH NORMAL AND CAB SET MODE THE RATE OF PRESSURIZATION WAS UNCONTROLLABLE UP TO MAX DIFF.A/C RETURNED TO DEPT AIRPORT. SYSTEM OPERATED SERV IN MANUAL MODE. COMPUTER REPLACED AND F UNCTION CHECKS CARRIED OUT SERV.NO STRIP REPORT FROM REPAIR FACILITY AS OF YET. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005042500157 20050425 00157 SW 2005 4 25 CA050216010 1 20040911 G 6322 HANGER ASSY BELL BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL COOLER BLOWER ROTATED W O OTHER D INFLIGHT SEPARATION CR CRUISE 1 CA SHL017 (CAN) PILOT REPORTED A HIGH FREQUENCY VIBRATION. UPON INVESTIGATION, THE BEARING IN THE FORWARD HANGER ASSEMBLY OF THE OIL COOLER BLOWER WAS FOUND TO BE ROTATING. BLOWER ASSEMBLY REPLACED. 1 G 7 1 3U 3 U H2SW E4CE 2005042500162 20050425 00162 EA 2005 4 25 CA050221002 1 20040920 G 2820 C38214 SEAL DHAV DHC6 DHC6300 2802606 EA FUEL CAP CRACKED W O OTHER K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA 50862 (CAN) DURING FLIGHT FUEL FUMES ENTERED IN THE AIRCRAFT CABIN. AFTER LANDING 3 PAX WERE TAKEN TO THE HOSPITAL DUE TO FEE LING SICK FROM THE FUMES. FUEL CAP WAS SUSPECTED TO BE LEAKING WHICH CAUSED THE FUEL TO ENTER THE CABIN THRU THE PAX DO OR SEAL. FUEL CAP WAS REPLACED. PROBLEM HAS NOT REOCCURED. 1 H 7 2 3T RT A9EA 2005050300115 20050503 00115 SW 2005 5 3 CA050228012 1 20040908 G 6710 D2A201030C BELLCRANK KAMOV KA32 KA32A1 SW AMTR VK1A KLIMOVK1A GL COLLECTIVE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) CRACK DISCOVERED DURING POST FLIGHT INSPECTION. MFG HAS ISSUED A LETTER REGARDING THIS ITEM IN JAN. 2001. MAINTE NANCE CREWS CHECK THIS AREA AT LEAST TWICE DAILY. 1 G 7 2 4U 4 J NC EXPE4J 2005050300038 20050503 00038 SO 2005 5 3 CA050308015 2 20041007 G 8520 654101A7R CRANKCASE CESSNA 206 U206F 2073333 CE CONT O520 IO520F 17032 SO HARTZL HCC3Y PHCC3YF1 GL ENGINE FAILED W K NONE O OTHER IN INSP/MAINT 1 CA 282770R (CAN) CRANKCASE FAILURE (7TH STUD CRANKCASE) AS RESULT OF A RECENT FAILURE. DURING CHANGE ON CYL NR1, SPECIAL ATTENTIO N WAS PAID TO NR2, NR3 INTERMEDIATE BRG SADDLE. INSP CONCLUDED THAT MOVEMENT OF BRGS HAD OCCURRED, TEARDOWN OF ENG WOUL D BE REQUIRED FOR INVESTIGATION. FOUND THAT THERE WAS FRETTING OF CRANKCASE ON NR2, NR3 INTERMEDIATE MN BRG THRU-BOLT P ADS. PINCH FIT IS LOST ON MN BRGS IN THESE POSITIONS, THEY BECOME LOOSE. NOTE: BRGS ON BOTH SIDES OF CRANKCASE WERE MOVI NG IN NR2, NR3 INTERMEDIATE BRG POSITIONS. BRG IS ABLE TO MOVE IN BRG SADDLE (NOT ROTATIONAL). FURTHER OPS WOULD HAVE A LLOWED INCREASED MOVEMENT OF THE BRG, BLOCKING OR RESTRICTING OIL FEED GALLERY IN SADDLE, CAUSE OIL STARVATION. 1 H 7 1 3O 3 O A4CE E5CE 5 C P25EA 2005052300119 20050523 00119 CE 2005 5 23 CA050315007 1 20041110 G 5210 99120754 SEAL CESSNA 500 560CESSNA 2076750 CE PWA 530 PW535A NE PAX DOOR LEAKING W O OTHER O OTHER CL CLIMB 1 CA (CAN) CABIN AIR LEAK PAST CABIN DOOR SEALS IN FLIGHT WITH CABIN DIFFERENTIAL PRESSURE GREATER THAN APPROXIMATELY 7 PSI. BOTH DOOR SEALS REPLACED AND SHIMMED TO GIVE CORRECT GAP BETWEEN DOOR SEAL AND CABIN DOOR FRAME. NOTE: THE GAP WAS INC ORRECTLY SET BY THE AIRCRAFT MANUFACTURER WHEN THE AIRCRAFT WAS BUILT. 2 L 7 2 4F 4 F RT A22CE E00053EN 2005052300088 20050523 00088 2005 5 23 CA050324005 4 20040929 G 3444 9650676008 INVERTER AMD FALC90 FALCON900B 2730171 EU GPWS FAILED W O OTHER O OTHER CR CRUISE 1 CA (CAN) THE GPWS FAILED IN FLIGHT. THE CONNECTOR PLUG ON THE GPWS INVERTER WAS CLEANED OF MOISTURE AND THE SYSTEM WAS TEST ED SERVICEABLE. 2 L 7 3 4F RT 2005052300087 20050523 00087 EU 2005 5 23 CA050324007 1 20040929 G 3020 6911B030100 ANTI-ICE VALVE AMD FALC90 FALCON900B 2730171 EU NR 1 ENGINE FAILED W O OTHER O OTHER DE DESCENT 1 CA (CAN) DURING DESCENT, THE FLIGHT CREW NOTICED THAT THE NR 1 ENGINE ANTI-ICE VALVE WOULD NOT CLOSE UNLESS POWER WAS REDUC ED TO IDLE. THE VALVE WAS REPLACED AND A SATISFACTORY ENGINE RUN WAS CARRIED OUT. 2 L 7 3 4F RT 2005052300086 20050523 00086 CE 2005 5 23 CA050324009 1 20040929 G 3260 65430087 UPLOCK SWITCH CESSNA 560 560XL 2076702 CE NLG FAILED W A UNSCHED LANDING N FALSE WARNING CL CLIMB 1 CA 5026 (CAN) AFTER TAKEOFF, THE LANDING GEAR WOULD NOT RETRACT, THE AIRCRAFT RETURNED TO THE AIRPORT. THE NOSE GEAR UPLOCK SWIT CH WAS FOUND TO BE FAILED. THE SWITCH WAS REPLACED, MULTIPLE SATISFACTORY GEAR SWINGS WERE CARRIED OUT AND THE AIRCRAFT WAS RETURNED TO SERVICE. 2 L 7 2 4F RT A22CE 2005052300065 20050523 00065 2005 5 23 CA050331003 4 20040706 G 3422 7003360941 COMPUTER DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE AHRS UNSERVICEABLE W O H OTHER DEACTIVATE SYST/CIRCUITS I FLT. ATTITUDE INST. CR CRUISE 1 CA (CAN) IN FLIGHT, NR2 HSI TOPPLED AND UNABLE TO RESET. LANDED, REPLACED AHRS WITH SERVICEABLE UNIT, FUNCTION CHECK AND FO UND SERVICABLE. SINCE THE AHRS WAS SENT OUT ON SPEX EXCHANGE WE DIDN'T RECEIVE A STRIP REPORT. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005052300062 20050523 00062 NM 2005 5 23 CA050331004 1 20040712 G 5610 8SC0043013 WINDSHIELD DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE COCKPIT DELAMINATED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) UPON ROUTINE INSPECTION FOUND CAPT WINDSHIELD DELAMINATED BEYOND ALLOWABLE LIMIT IAW MML. WINDSHIELD REPLACED FUN CTION CHECKS CARRIED OUT AND FOUND TO BE SERVICEABLE. WINDSHIELD WAS QUARENTINE SINCE IT IS UNREPAIRABLE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005071200024 20050712 00024 EA 2005 7 12 CA050406006 2 20040404 G 7310 FITTING PIPER PA28 PA28140 7102802 SO LYC O320 O320E2A 41508 EA FUEL LINE LEAKING W C ABORTED TAKEOFF K J FLUID LOSS WARNING INDICATION TO TAKEOFF 1 CA (CAN) ENGINE LOST POWER, SUBSEQUENT INSPECTION REVEALED A LOOSE FITTING ON THE INLET SIDE OF THE MECHANICAL FUEL PUMP CA USING PUMP TO DRAW AIR THUS DEPLETING THE FUEL TO THE CARBURETOR. THE FITTING WAS TIGHTENED AND LOCK FLUID WAS USED ON T HE JAM NUT ONLY, NOT THE FITTING 1 L 7 1 3O 3 O 2A13 E274 2005051900225 20050519 00225 NE 2005 5 19 CA050419002 2 20041125 G 7200 ENGINE REIMS 406 F406 7535723 EU PWA PT6 PT6A112 52043 NE INOPERATIVE W A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 CA 12516 (CAN) DURING TAKEOFF, THE ENGINE EXPERIENCED AN UNCOMMANDED POWER REDUCTION. MFG WILL MONITOR THE INVESTIGATION OF THIS INCIDENT AND WILL ADVISE OF ROOT CAUSE, ONCEESTABLISHED. 1 L 7 2 3T 3 T RT A54EU E4EA 2005071500136 20050715 00136 NM 2005 7 15 CA050519002 1 20040920 G 3240 2661942 HOUSING DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE BRAKE ASSEMBLY OUT OF LIMITS W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING A SCHEDULED OVERHAUL OF THE BRAKE ASSEMBLY, THE ASSEMBLY WAS PRESSURE TESTED, IT WAS THEN THAT IT WAS DISCO VERED THAT ON ONE OF THE PISTON HOUSINGS WAS LEAKING WHEN THE SYSTEM PRESSURE WAS BROUGHT TO THE MAXIMUM RATED PRESSURE. THE UNIT WAS DISASSEMBLED AND SENT FOR NDT, WHERE THEY FOUND THAT THE HOUSING HAD A CRACK IN THE SIDEWALL OF A PISTON. IT WAS DETERMINED THE CRACK WAS BEYOND LIMITS. THE UNIT WAS SCRAPPED. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005071400092 20050714 00092 NE 2005 7 14 CA050615010 1 20041231 G 7920 23001955 HOUSING SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30S 03013 GL ENG OIL BYPASS CRACKED W E A ENGINE SHUTDOWN UNSCHED LANDING K FLUID LOSS CL CLIMB 1 CA (ENGINE OIL FILTER) BYPASS INDICATOR HOUSING CRACKED. 1 G 7 2 3U 3 U H1NE E1GL 2005090600010 20050906 00010 SW 2005 9 6 CA050616006 1 20040611 G 2842 EA4703587 TRANSMITTER BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL FUEL INDICATOR UNSERVICEABLE W K NONE N FALSE WARNING IN INSP/MAINT 1 CA (CAN) FUEL QUANTITY INDICATION FLUCTUATES AT NEAR FULL FUEL LEVELS. UPPER SENDING UNIT REPLACED. THIS INSTALLATION WAS 2 49.9 HOURS. 1 G 7 1 3U 3 U H2SW E4CE 2005090700006 20050907 00006 SW 2005 9 7 CA050616007 1 20040501 G 6330 204030913005 WASHER BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA XMSN MOUNT UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) CONICAL WASHER FOR TRANSMISSION MOUNT BOLT - LT AFT POSITION - FOUND CRACKED. CRACK HAD NOT TRAVELLED COMPETELY TH ROUGH WASHER, IT HAD STARTED AT OUTBOARD EDGE. WASHER REPLACED. 1 G 7 1 4U 4 U H4SW E22EA 2005090600011 20050906 00011 SW 2005 9 6 CA050616008 1 20040727 G 6310 406340104101 SEAL BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL ENG TO XMSN WORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) FORWARD PTO SEAL REMOVED DUE TO OIL TRANSFER FROM ENGINE TO TRANSMISSION. UPON SEAL REMOVAL IT WAS FOUND THE IB S EAL LIP HAD BEEN FOLDED UNDER THE SEAL AT 2 LOCATIONS, APPROXIMATELY 1 INCH EACH. THE TENSION SPRING FROM THE SEAL HAD S TAYED ON THE SEAL, A BARELY DETECTABLE WEAR POINT WAS CREATED AT THIS LOCATION. THIS WEAR POINT IS APPROXIMATELY 0.030 INCH FROM THE RUNNING SURFACE OF THE SEAL. ALSO FOUND AT SEAL REMOVAL WAS TWO OTHER TENSION SPRINGS BEHIND THE SEAL, T HERE WAS NO DETECTABLE DAMAGE NOTED FROM THESE SPRINGS. NEW SEALS INSTALLED FORWARD AND AFT POSITIONS, A/C GROUND RUN, LEAK CHECKED AND RETURNED TO SERVICE. 1 G 7 1 3U 3 U H2SW E4CE 2005090600022 20050906 00022 CE 2005 9 6 CA050802004 1 20040827 G 6120 MS21042L4 NUT BEECH 100 A100 1152915 CE PWA PT6 PT6A28 EA HARTZL HCB4T HCB4TN3 GL LT PROPELLER LOOSE W O OTHER O OTHER CL CLIMB 1 CA (CAN) AFTER TAKE OFF, THE CREW NOTICED THE LT ENGINE TORQUE WAS OVER RED LINE, POWER WAS REDUCED. MAINTENANCE LATER DIS COVERED THAT PART OF THE LOW PITCH ARM WAS BROKEN OFF. IT WAS DETERMINED THAT THE NUT PN MS21042L4 HOLDING THE PIN PN 100-960036-1 HAD BECOME LOOSE AND THIS ALLOWED THE LOW PITCH ARM TO CONTACT THE PROP BULKHEAD AND BREAK OFF. THE POWER SECTION WAS REPLACED FOR LIGHT OVERHAUL. 1 L 7 2 3T 4 T A14CE E4EA 6 C P40EA 2005090600032 20050906 00032 SW 2005 9 6 CA050804002 1 20040629 G 6410 206016201131 BLADE BELL 206 206L3 1182108 SW ALLSN 250C 250C30P 03013 GL TAIL ROTOR DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) UPON PILOT DAILY INSPECTION DAMAGE NOTED TO T/R BLADE ASSY. BLADE ASSY VISUALLY INSPECTED AND FOUND DAMAGED BEYON D ACCEPTABLE LIMITS. BLADE REPLACED. 1 G 7 1 3U 3 U H2SW E1GL 2005110800063 20051108 00063 GL 2005 11 8 CA051003016 1 20041029 G 7810 10351002 EXHAUST HEADER CIRRUS SR SR20 05628AJ GL CONT O360 IO360ES SO HARTZL HCJ2Y BHCJ2YF1 GL ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) NR5 EXHAUST HEADER FOUND CRACKED 75 PERCENT OF THE WAY AROUND JUST BELOW FLANGE WELD. 1 L 7 1 3O 3 O NT A00009CH E1CE 5 C P37EA 2005110800029 20051108 00029 WP 2005 11 8 CA051006001 1 20041027 G 2910 MS2190512D FITTING CVAC 440 440 2422902 WP ALLSN 501D 501D13D 03004 GL HYD LINE CRACKED W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CL CLIMB 1 CA (CAN) AIRCRAFT RETURN TO BLOCK AFTER LOSS OF HYDRAULIC FLUID. AFTER INVESTIGATION MAINTENANCE FOUND FROM LT ENGINE DRIV E HYDRAULIC PUMP PRESSURE LINE AND AC HYDRAULIC PUMP, T-FITTING AT FS 319 CRACKED. THE FITTING WAS REPLACED, SYSTEM REP LENISHED AND LEAK CHECK SERVICEABLE. AIRCRAFT RETURN TO SERVICE. 2 L 7 2 4R 4 T 6A6 E282 2006010500178 20060105 00178 SW 2006 1 5 CA051108009 1 20041120 G 5711 2722136006 FITTING SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP HARTZL HCE4N HCE4N3 NE RT WING CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 43098 (CAN) DURING A ROUTINE PHASE INSPECTION OF THE WING AND CENTER SECTION OF THE AIRCRAFT, SMALL CRACKS WERE FOUND IN THE R T WING AFT SPAR WING TO FUSELAGE ATTACH FITTINGS (PN 27-22136-006 AND 27-22135-006). THE CRACKS WERE FOUND VISUALLY AN D CONFIRMED USING EDDY CURRENT. THE MANUFACTURER WAS CONTACTED FOR A REPAIR AND ANALYSIS AND DETERMINED THE SPAR FITTING S REQUIRED REPLACING. NEW FITTINGS WERE PROCURED AND REPLACED. THE MANUFACTURER DID NOT FEEL IT WAS NECESSARY TO DO A FLEET INSPECTION ON THESE SPAR FITTINGS DUE TO THIS ONE INSTANCE. 2 L 7 2 4T 4 T RT A8SW E4WE 5 C P10NE 2006062200093 20060622 00093 SW 2006 6 22 CA051115006 1 20040705 G 5230 STRUCTURE KAMAN K1200 K1200 05625F6 SW LYC T53 T5317A 41549 NE CARGO DOOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 5059 ON MAINTENANCE SHUTDOWN DURING A NORMAL HELI LOGGING DAY, DURING INSP OF FLIGHT CONTROLS THE APPRENTICE NOTICED SOME SMO KING COMING FROM THE BOTTOM CORNER OF THE STBD OCTAGONAL CARGO DOOR. UPON FURTHER INSP IT WAS DETERMINED TO BE A CRACK. 1 G 7 1 4F 4 U NT TR7BO E17EA 2006062100078 20060621 00078 SW 2006 6 21 CA060117004 1 20041105 G 5511 4300143 SPAR GULSTM 690TP 690D 3970405 SW GARRTT TPE331 TPE3315 01514 WP ROTOL R306 R306382F7 GL HORIZONTAL STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA INSPECTION OF THE AIRCRAFT FOUND THE HORIZONTAL STABILIZER UPPER HORIZONTAL SPAR CRACKED. CRACKED SPAR REMOVED AND NEW PART INSTALLED. 1 H 7 2 3T 4 T 2A4 E4WE 6 C P8EU 2006070500247 20060705 00247 EA 2006 7 5 CA060208010 1 20040507 G 7120 73512562 MOUNT DHAV DHC6 DHC6300 2802606 EA RT ENG BROKEN W E A ENGINE SHUTDOWN UNSCHED LANDING F R J FLT CONT AFFECTED PARTIAL RPM/PWR LOSS WARNING INDICATION TO TAKEOFF 1 CA 38359 (CAN) AFTER LIFT-OFF IT WAS NOTICE A POWER LOSS ON THE RT TORQUE GAUGE. THE WEATHER CONDITIONS WERE VERY BAD THE POWER W AS REDUCED AND THAN THE A/C LANDED 2 MINUTES AWAY. WHEN THE A/C WAS SECURE AND ENGINE SHUT OFF IT WAS NOTICED THAT THE ENGINE MOUNTS ON THE RT ENGINE WERE BROKEN AND THE COWLING OPENED 2 INCH WITH SOME POPPED LATCHES. RT FLIGHT CONTROLS W ERE FOUND DAMAGED. (TC NR 20060208010) 1 H 7 2 3T RT A9EA 2006061900149 20060619 00149 WP 2006 6 19 CA060303015 1 20040530 G 7931 269A4107 INDICATOR HUGHES 269 269C 4470504 WP LYC O360 HIO360D1A 41514 EA OIL PRESSURE FAILED W K NONE O OTHER IN INSP/MAINT 1 CA OIL PRESSURE UNSERVICEABLE. REPLACED CLUSTER ASSEMBLY. 1 G 7 1 3O 3 O 4H12 1E10 2006062300164 20060623 00164 WP 2006 6 23 CA060306009 1 20041111 G 6240 B3201 HORN ROBSIN R44 R44 7640120 WP LYC O540 O540F1B5 41532 EA FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) HORN NOT PRODUCING HORN SOUND. HORN REPLACED. (TC NR 20060306009) 1 G 7 1 3O 3 O H11NM E295 2006061400230 20060614 00230 EA 2006 6 14 CA060418001 1 20040317 G 2730 NAS558P4048 KEY DHAV DHC8 DHC8311 1386006 EA PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE RT ELEVATOR FAILED W K NONE O OTHER IN INSP/MAINT 1 CA ELEVATOR TRIM SCREW JACK ASSEMBLY SPROCKET SPINS WITHOUT ANY MOVEMENT OF SCREWDRIVE. FOUND KEY, P/N NAS558P404-8 TO BE MISSING CAUSING NO ELEVATOR TRIM TO BE AVAILABLE ON RIGHT SIDE. REFERENCE DASH 8/300 IPC 27-38-00; FIGURE 15; ITEM 160. SCREW JACK REPLACED. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006061900225 20060619 00225 NE 2006 6 19 CA060528001 2 20040924 G 7414 B196689RH MAGNETO DHAV DHC2 DHC2MKI 2801830 GL PWA R985 R985AN14B 52008 NE HAMSTD 2D 2D30 NE ENGINE INOPERATIVE W O OTHER O OTHER NR NOT REPORTED 1 CA 500 (CAN) MAGNETO NOT FUNCTIONING PLUS MAGNETO UNSERVICEABLE. (TC NR 20060528001) 1 H 7 1 3R 3 R RC A806 5E1 5 C P206 2004123000064 20041230 00064 2004 12 30 CEVR200400001 4 20041109 G 2561 BATTERY EAAEROMARINE KSE35L8 VEST LIGHT BURST B K NONE O OTHER IN INSP/MAINT 1 GL 03 348838 DURING THE YEARLY INSPECTION OF THE LIFE VEST, THE WATER ACTIVATED BATTERY FOR THE LOCATING LIGHT HAD EXPANDED AND BURST OPEN. THIS MADE THE LIGHT INOPERABLE. ACCORDING TO THE EAM SERVICE INFORMATION SIL-25-104 ,THIS VEST COULD HAVE A INS PECTION INTERVAL OF FIVE YEARS, WHICH MEANT THE LIGHT COULD HAVE BEEN INOPERATIVE FOR FOUR YEARS. REPLACED THIS BATTERY /LIGHT ASSY WITH A DIFFERENT MANUFACTURES BATTERY/LIGHT ASSY. 2005031000034 20050310 00034 2005 3 10 CEVR200400002 4 20041216 G 2561 WABH12 BATTERY EAAEROMARINE KSE35L8 LIFE VEST LIGHT BURST C K NONE O OTHER IN INSP/MAINT 1 GL 03 17767 DURING THE YEARLY INSPECTION OF THE LIFE VEST, THE WATER ACTIVATED BATTERY FOR THE LOCATING LIGHT HAD EXPANDED & BURST O PEN. THIS MADE THE LIGHT INOPERABLE. ACCORDING TO THE E.A.M SERVICE INFORMATION SIL-25-104 ,THIS VEST COULD HAVE A INSPE CTION INTERVAL OF FIVE YEARS, WHICH MEANT THE LIGHT COULD HAVE BEEN INOPERATIVE FOR FOUR YEARS. I HAVE REPLACED THIS BAT TERY/LIGHT ASSY. WITH A DIFFERENT MANUFACTURES BATTERY/LIGHT ASSY. 2005031000035 20050310 00035 2005 3 10 CEVR200400003 4 20041216 G 2561 WABH12 BATTERY EAAEROMARINE KSE35L8 LIFE VEST BULGED C K NONE O OTHER IN INSP/MAINT 1 GL 03 111521 DURING THE YEARLY INSPECTION OF THE LIFE VEST, THE WATER ACTIVATED BATTERY FOR THE LOCATING LIGHT HAD EXPANDED & BURST O PEN. THIS MADE THE LIGHT INOPERABLE. ACCORDING TO THE E.A.M SERVICE INFORMATION SIL-25-104 ,THIS VEST COULD HAVE A INSPE CTION INTERVAL OF FIVE YEARS, WHICH MEANT THE LIGHT COULD HAVE BEEN INOPERATIVE FOR FOUR YEARS. I HAVE REPLACED THIS BAT TERY/LIGHT ASSY. WITH A DIFFERENT MANUFACTURES BATTERY/LIGHT ASSY. 2005031000036 20050310 00036 2005 3 10 CEVR200400004 4 20041216 G 2561 WABH12 BATTERY EAAEROMARINE KSE35L8 LFE VEST BULGED C K NONE O OTHER IN INSP/MAINT 1 GL 03 69775 DURING THE YEARLY INSPECTION OF THE LIFE VEST, THE WATER ACTIVATED BATTERY FOR THE LOCATING LIGHT HAD EXPANDED & BURST O PEN. THIS MADE THE LIGHT INOPERABLE. ACCORDING TO THE E.A.M SERVICE INFORMATION SIL-25-104 ,THIS VEST COULD HAVE A INSPE CTION INTERVAL OF FIVE YEARS, WHICH MEANT THE LIGHT COULD HAVE BEEN INOPERATIVE FOR FOUR YEARS. I HAVE REPLACED THIS BAT TERY/LIGHT ASSY. WITH A DIFFERENT MANUFACTURES BATTERY/LIGHT ASSY. 2005031000037 20050310 00037 2005 3 10 CEVR200400005 4 20041216 G 2561 WABH12 BATTERY EAAEROMARINE KSE35L8 LIFE VEST BULGED C K NONE O OTHER IN INSP/MAINT 1 GL 03 191086 DURING THE YEARLY INSPECTION OF THE LIFE VEST, THE WATER ACTIVATED BATTERY FOR THE LOCATING LIGHT HAD EXPANDED & BURST O PEN. THIS MADE THE LIGHT INOPERABLE. ACCORDING TO THE E.A.M SERVICE INFORMATION SIL-25-104 ,THIS VEST COULD HAVE A INSPE CTION INTERVAL OF FIVE YEARS, WHICH MEANT THE LIGHT COULD HAVE BEEN INOPERATIVE FOR FOUR YEARS. I HAVE REPLACED THIS BAT TERY/LIGHT ASSY. WITH A DIFFERENT MANUFACTURES BATTERY/LIGHT ASSY. 2005031000038 20050310 00038 2005 3 10 CEVR200400006 4 20041216 G 2561 WABH12 BATTERY EAAEROMARINE KSE35L8 LIFE VEST BURST C K NONE O OTHER IN INSP/MAINT 1 GL 03 191455 DURING THE YEARLY INSPECTION OF THE LIFE VEST, THE WATER ACTIVATED BATTERY FOR THE LOCATING LIGHT HAD EXPANDED & BURST O PEN. THIS MADE THE LIGHT INOPERABLE. ACCORDING TO THE E.A.M SERVICE INFORMATION SIL-25-104 ,THIS VEST COULD HAVE A INSPE CTION INTERVAL OF FIVE YEARS, WHICH MEANT THE LIGHT COULD HAVE BEEN INOPERATIVE FOR FOUR YEARS. I HAVE REPLACED THIS BAT TERY/LIGHT ASSY. WITH A DIFFERENT MANUFACTURES BATTERY/LIGHT ASSY. 2005031000039 20050310 00039 2005 3 10 CEVR200400007 4 20041216 G 2561 WABH12 BATTERY EAAEROMARINE KSE35L8 LIFE VEST BULGED C K NONE O OTHER IN INSP/MAINT 1 GL 03 35455 DURING THE YEARLY INSPECTION OF THE LIFE VEST, THE WATER ACTIVATED BATTERY FOR THE LOCATING LIGHT HAD EXPANDED & BURST O PEN. THIS MADE THE LIGHT INOPERABLE. ACCORDING TO THE E.A.M SERVICE INFORMATION SIL-25-104 ,THIS VEST COULD HAVE A INSPE CTION INTERVAL OF FIVE YEARS, WHICH MEANT THE LIGHT COULD HAVE BEEN INOPERATIVE FOR FOUR YEARS. I HAVE REPLACED THIS BAT TERY/LIGHT ASSY. WITH A DIFFERENT MANUFACTURES BATTERY/LIGHT ASSY. 2005031000040 20050310 00040 2005 3 10 CEVR200400008 4 20041216 G 2561 WABH12 BATTERY EAAEROMARINE KSE35L8 LIFE VEST BULGED C K NONE O OTHER IN INSP/MAINT 1 GL 03 35551 DURING THE YEARLY INSPECTION OF THE LIFE VEST, THE WATER ACTIVATED BATTERY FOR THE LOCATING LIGHT HAD EXPANDED & BURST O PEN. THIS MADE THE LIGHT INOPERABLE. ACCORDING TO THE E.A.M SERVICE INFORMATION SIL-25-104 ,THIS VEST COULD HAVE A INSPE CTION INTERVAL OF FIVE YEARS, WHICH MEANT THE LIGHT COULD HAVE BEEN INOPERATIVE FOR FOUR YEARS. I HAVE REPLACED THIS BAT TERY/LIGHT ASSY. WITH A DIFFERENT MANUFACTURES BATTERY/LIGHT ASSY. 2004030100154 20040301 00154 CE 2004 3 1 CGLMK1 1 20040216 G 3097 65280073 CONNECTOR CESSNA 500 550 2076604 CE LE HEAT MISMANUFACTURED B O OTHER O OTHER NR NOT REPORTED 1 NM 09 CGLMK 0100 NEW HEATED LEADING EDGE WAS RECEIVED FROM MFG WITH THE CONNECTOR MIS-WIRED AND WITH ONE DRY CRIMP. 1 L 7 2 4F A22CE 2004083000113 20040830 00113 NE 2004 8 30 CHI2848 2 20040619 G 7230 6010T57G08 BLADE BOEING 107 1072 9420604 EA GE CT58 CT581401 30011 NE COMPRESSOR CRACKED B CHIR O OTHER O OTHER NR NOT REPORTED 1 NM 09 6963 280319A CRACKS AT COMPRESSOR BLADE, LOCK SCREW HOLES, STAGES 3,5,6,7,8,AND 10 SLOTS. THE SUBJECT PARTS HAVE BEEN SUBMITTED TO T HE MFG FOR EVALUATION. 2 G 7 2 4U 4 U 1H16 1E3 2004091400076 20040914 00076 NE 2004 9 14 CHI2849 2 20040619 G 7230 6010T57G08 COMPRESSOR BOEING 107 1072 9420604 EA GE CT58 CT581401 30011 NE ENGINE CRACKED B CHIR O OTHER O OTHER NR NOT REPORTED 1 NM 09 5880 280130A CRACKS AT COMPRESSOR BLADE, LOCK SCREW HOLES, STAGES 3 AND 6. PARTS HAVE BEEN SUBMITTED TO THE MFG FOR EVALUATION. 2 G 7 2 4U 4 U 1H16 1E3 2004022300092 20040223 00092 CE 2004 2 23 CM2R 1 20040108 G 7160 963800295 SEPARATOR BEECH 55 95C55 1152708 CE CONT O520 IO520C 17032 SO ENG AIR INTAKE OBSTRUCTED C K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 15 3367 TE146 810839R OLD ENGINE SEPARATOR WAS CRACKED. ORDERED NEW PART. INSPECTED NEW PART AND COULD NOT BLOW THROUGH IT. THE AIR OUTLET TUBE WAS BLOCKED INTERNALLY. NEW OUT OF BOX FAILURE. IF THIS UNIT WAS INSTALLED ON THE ENGINE IT WOULD HAVE PRESSURIZE D THE CASE AND LEAD TO POSSIBLE ENGINE FAILURE DUE TO ENGINE OIL LOSS. 1 L 7 2 3O 3 O 3A16 E5CE 2005040400102 20050404 00102 WP 2005 4 4 COOSDR040041 1 20040924 G 5343 49568801 FITTING DOUG DC9 DC914 3022034 WP PWA JT8 JT8D5 52046 NE NLG CRACKED B EE4Y K NONE O OTHER IN INSP/MAINT 1 SO 23 700ME 45696 FUSELAGE NOSE LANDING GEAR WHEEL WELL RT SIDE AT Y STA 69.55-X 24 INCH -Z16 INCH FITTING (PN 49568801) WITH CRACK. (K) 2 L 7 2 4F 4 F A6WE E2EA 2005030100057 20050301 00057 WP 2005 3 1 COOSDR040042 1 20041011 G 5313 LONGERON DOUG DC8 DC861F 3021953 WP PWA JT3D JT3D* 52039 NE FUSELAGE CORRODED B K NONE O OTHER IN INSP/MAINT 1 SO 23 41CX 45978 FWD CARGO COMPT AT Y STA 360.0, LONGERON 28R CORRODED. 2 L 7 4 4F 4 F 4A25 1E8 2005030800278 20050308 00278 WP 2005 3 8 COOSDR040044 1 20041015 G 5330 SKIN DOUG DC8 DC871F 302199D WP GE CFM56 CFM562C 13802 NE FUSELAGE CORRODED B EE4Y K NONE O OTHER IN INSP/MAINT 1 SO 23 825BX 45978 LOWER FUSELAGE SKIN WITH CORROSION AT Y-STA 680.0 AND Y-STA 687.0, BETWEEN LONG 31R AND LONG 34R. (K) 2 L 7 4 4F 4 F RT 4A25 E2GL 2005040400112 20050404 00112 WP 2005 4 4 COOSDR040045 1 20041015 G 5340 37502571 FITTING DOUG DC8 DC871F 302199D WP GE CFM56 CFM562C 13802 NE FUSELAGE CRACKED B EE4Y K NONE O OTHER IN INSP/MAINT 1 SO 23 825BX 45978 FWD CARGO COMPARTMENT FROM Y-STA 440 TO Y-STA 460, LONGERON 31R SPLICE FITTING, PN 3750257-1, CRACKED. (K) 2 L 7 4 4F 4 F RT 4A25 E2GL 2005030800277 20050308 00277 WP 2005 3 8 COOSDR040047 1 20041015 G 5330 4643785 SKIN DOUG DC8 DC871F 302199D WP GE CFM56 CFM562C 13802 NE FUSELAGE CRACKED B EE4Y K NONE O OTHER IN INSP/MAINT 1 SO 23 825BX 45978 FWD PASSENGER DOOR HOLD OPEN PAN, PN 4643785, AND FUSELAGE EXTERNAL SKIN CRACKED AT Y-STA 15.000. (K) 2 L 7 4 4F 4 F RT 4A25 E2GL 2005040400111 20050404 00111 WP 2005 4 4 COOSDR040048 1 20041015 G 5320 45976431 FITTING DOUG DC8 DC871F 302199D WP GE CFM56 CFM562C 13802 NE MAIN CABIN CORRODED B EE4Y K NONE O OTHER IN INSP/MAINT 1 SO 23 825BX 45978 MAIN CARGO CABIN, SUPPORT FITTING, PN 4597643-1, CORRODED AT Y-STA 60-X65, Z 0 INCH. (K) 2 L 7 4 4F 4 F RT 4A25 E2GL 2005042500168 20050425 00168 WP 2005 4 25 COOSDR040049 1 20041015 G 5340 FITTING DOUG DC8 DC871F 302199D WP GE CFM56 CFM562C 13802 NE FUSELAGE CRACKED B EE4Y K NONE O OTHER IN INSP/MAINT 1 SO 23 825BK 45978 MAIN CARGO CABIN, FROM Y STA 650 TO Y-STA 680, LONGERON 1 FITTING WITH CRACK. (K) 2 L 7 4 4F 4 F RT 4A25 E2GL 2005031400030 20050314 00030 WP 2005 3 14 COOSDR040051 1 20041025 G 5330 SKIN DOUG DC8 DC871F 302199D WP GE CFM56 CFM562C 13802 NE FUSELAGE CORRODED B EE4Y K NONE O OTHER IN INSP/MAINT 1 SO 23 825BX 45978 LOWER FUSELAGE SKIN WITH CORROSION AT Y STA 622.0, BETWEEN LONG 27L AND LONG 30L. (K) 2 L 7 4 4F 4 F RT 4A25 E2GL 2005040400053 20050404 00053 WP 2005 4 4 COOSDR040052 1 20041026 G 5330 57799293 SKIN DOUG DC8 DC871F 302199D WP GE CFM56 CFM562C 13802 NE FUSELAGE CORRODED B EE4Y K NONE O OTHER IN INSP/MAINT 1 SO 23 825BX 45978 FUSELAGE AFT CENTER SECTION, LOWER PLATING (PN 57799293) CORRODED FROM STA 980 TO STA 1040 BETWEEN LONGERON 35L AND 35R. (K) 2 L 7 4 4F 4 F RT 4A25 E2GL 2005042500167 20050425 00167 WP 2005 4 25 COOSDR040053 1 20041027 G 5755 56551671 SKIN DOUG DC8 DC871F 302199D WP GE CFM56 CFM562C 13802 NE SPOILER DELAMINATED B EE4Y K NONE O OTHER IN INSP/MAINT 1 SO 23 825BX 45978 RT WING, SPOILER PN 56551671, SN 2740 UPPER SKIN DELAMINATED AT STA XRS 218. (K) 2 L 7 4 4F 4 F RT 4A25 E2GL 2004110300118 20041103 00118 CE 2004 11 3 CQN2004F00000 1 20040930 G 5312 24120043 BULKHEAD CESSNA 172 172RG 2072438 CE LYC O360 O360* 41514 EA FUSELAGE CRACKED D O OTHER O OTHER NR NOT REPORTED 1 SW 15 9654B 12955 172RG0947 CRACKS WERE LOCATED AT LT AND RT RELIEF CUTS OF STATION 124.00 UPPER FUSELAGE BULKHEAD. PROBABLE CAUSE FOR LT SIDE IS A UX POWER RECEPTACLE AND RT SIDE COULD BE FROM LANDING STRESSES. 1 H 7 1 3O 3 O 3A17 E286 2004111900034 20041119 00034 CE 2004 11 19 E8I2004F00000 1 20040927 G 3240 388111 CONTROL VALVE RAYTHN 390 390 7150030 CE WILINT FJ44 FJ44 66000 GL EMERGENCY BRAKE INOPERATIVE B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 488RC 576 RB23 PILOT REPORTED NO BRAKING ACTION WITH HARD PEDAL PRESSURE, AIRCRAFT STOPPED ON ROLL-OUT WITH EMERGENCY BRAKING SYSTEM. TROUBLESHOT POWER BRAKE SYSTEM. REPLACED PN 3903843000003 (CRANE-HYDRO AIRE PN 388111) POWER BRAKE/ ANTISKID SYSTEM CON TROL VALVE WITH REPAIRED UNIT IAW MM 32-40-05-401. SYSTEM TESTS IAW MM 32-40-00-501, SATISFACTORY 1 7 2 3F 4 F RT A00010WI E3GL 2004111900035 20041119 00035 CE 2004 11 19 E8I2004F00001 1 20040920 G 2752 3903814020005 ACTUATOR RAYTHN 390 390 7150030 CE WILINT FJ44 FJ44 66000 GL TE FLAP JAMMED B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 488RC RB23 PILOT REPORTED UNABLE TO RETRACT OR EXTEND FLAPS FROM 10 DEGREES EXTENDED POSITION. TROUBLESHOT SYSTEM, FOUND RT IB FLA P IB ACTUATOR JAMMED. REPLACED ACTUATOR WITH NEW PN 3903814020013 ACTUATOR IAW 390 MM 27-50-03-401 AND RIGGED FLAPS AS REQUIRED IAW MM 27-50-00-501. SYSTEM OPERATIONAL, TESTS SATISFACTORY. SUSPECT RELATED TO SUBJECT OF MANDATORY SB 27-36 42/ SAFETY COMMUNIQUE NR 236. 1 7 2 3F 4 F RT A00010WI E3GL 2004083000050 20040830 00050 GL 2004 8 30 EAHR200400001 2 20040819 G 7230 23059598 SCROLL ALLSN ENSTRM F28 ENSTROM480 GL ALLSN 250C 250C20 03013 GL COMPRESSOR CRACKED B K NONE O OTHER IN INSP/MAINT 1 GL 09 723BF 245 49 CAC80964 5047 CAE845063 COMPRESSOR DISCHARGE SCROLL CRACKED AT LOWER RT CUSTOMER BLEED AIR FITTING. 1 G 7 1 3O 3 U NC H1CE E4CE 2004120700154 20041207 00154 GL 2004 12 7 EAHR200400002 1 20040721 G 5400 411004030 TUBE ENSTRM F28 ENSTROM480 GL ALLSN 250C 250C20 03013 GL PYLON BROKEN B A UNSCHED LANDING E VIBRATION/BUFFET NR NOT REPORTED 1 GL 01 480EH 369 74 5046 CAE845090 PYLON TUBE, P/N 4110040-30, BROKEN AT UPPER CLUSTER. 1 G 7 1 3O 3 U NC H1CE E4CE 2004042000015 20040420 00015 CE 2004 4 20 ESPA 1 20040225 G 2120 ODOR LEAR 35 35A 5170602 CE COCKPIT DETECTED H ESPA E ENGINE SHUTDOWN B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 SO 11 568PA 205 SMOKE WAS SUSPECTED IN CABIN. ENTIRE AREA IN SUSPECTED AREA WAS INSPECTED. NO DEFECTS WERE FOUND. PILOT REPORTED LEAD ING EDGE ANTI-ICE WAS INADVERTENTLY LEFT ON POSSIBLE CAUSING THE SMELL OF SMOKE. AIRCRAFT WAS RUN, SYSTEMS WERE OPERATI ONALLY CHECKED AND FOUND TO BE GOOD. 2 L 7 2 4F A10CE 2005102800064 20051028 00064 GL 2005 10 28 EY2R00082166 3 20040819 G 6114 D7292C203 HUB MCAULY CESSNA 182 182 2072702 CE MCAULY 2A34C 2A34C203 GL PROPELLER CORRODED B EY2R O OTHER O OTHER NR NOT REPORTED 1 GL 03 041321 0413212 FOUND HUB CORRODED. 1 H 7 1 3O NT 3A13 5 C P3EA 2005102800051 20051028 00051 GL 2005 10 28 EY2R0072801 3 20040908 G 6114 DO4993 HUB BEECH 200 200BEECH 1152920 CE HARTZL HCD4N3 HCD4N3A GL PROPELLER CORRODED B EY2R O OTHER O OTHER NR NOT REPORTED 1 GL 03 FY2591 FOUND CORROSION ON HUB. 1 L 7 2 4T A24CE 5 C STC 2005102800063 20051028 00063 GL 2005 10 28 EY2R0082166 3 20040819 G 6114 D7292 HUB MCAULY CESSNA 172 172 2072402 CE MCAULY 2A34C 2A34C203 GL PROPELLER CORRODED B EY2R O OTHER O OTHER NR NOT REPORTED 1 GL 03 041321 0413212 FOUND HUB WITH CORROSION. 1 H 7 1 3O NT 3A12 5 C P3EA 2005102800048 20051028 00048 GL 2005 10 28 EY2R0082166A 3 20040819 G 6114 D7292C203 HUB MCAULY CESSNA 182 182 2072702 CE MCAULY 2A34C 2A34C203 GL PROPELLER CORRODED B EY2R O OTHER O OTHER NR NOT REPORTED 1 GL 03 041321 0413212 FOUND CORROSION ON HUB. 1 H 7 1 3O NT 3A13 5 C P3EA 2004071900028 20040719 00028 NE 2004 7 19 F20181 2 20040618 G 7261 COVER AMD FALC20 FALCON 2720302 EU GE CF700 CF7002D2 30010 NE REAR BEARING LEAKING B E A ENGINE SHUTDOWN UNSCHED LANDING K Y J FLUID LOSS ENGINE STOPPAGE WARNING INDICATION CR CRUISE 1 SW 11 5225G 11438 22 181 299G099 ON FLIGHT FROM DEPARTURE AIRPORT TO UNKOWN LOCATION, PILOTS REPORTED THAT ENGINE OIL PRESSURE LIGHT FLICKERD ONCE OR TWI CE THEN CAME ON STEADY. WHEN ENGINE POWER WAS REDUCED, ENGINE SHUTDOWN ON ITS OWN. LANDED. ON INSPECTION BEFORE ENGINE REMOVAL AND REPLACEMENT FOUND NO OIL VISIBLE ON DIPSTICK AND EVIDENCE OF OIL LEAKAGE ON REAR BEARING COVER. NO OTHER IN SPECTIONS PERFORMED . ENGINE SENT TO OVERHAUL FACILITY. 2 L 7 2 4F 4 F A7EU E7EA 2004111900026 20041119 00026 SO 2004 11 19 F692004F00000 1 20040609 G 3231 AN2315A BOLT PIPER PA34 PA34220T 7103420 SO DOOR MISINSTALLED B F69R O OTHER O OTHER NR NOT REPORTED 1 WP 19 ZKJAS 3448010 DURING GROUND TESTING OF THE AIRCRAFT EMERGENCY EXTENSION SYSTEM THE RT A/C FAILED TO EXTEND INVESTIGATION, FOUND THE BO LT ATTACHING THE DOOR TO THE ACTUATING ROD INSTALLED AROUND THE WRONG WAY CAUSING IT TO FOUL ON THE WING SPAR. 1 L 7 2 3O A7SO 2004051200027 20040512 00027 CE 2004 5 12 FBFQA1 1 20040507 G 3610 621456120 BELLOWS CESSNA 650 650 2076802 CE GARRTT TFE731 TFE7313 01518 WP PRECOOLER CRACKED B K NONE O OTHER IN INSP/MAINT 1 GL 09 534H 8587 6500196 P87512 UPON INSPECTION AND PRESSURIZATION CHECKS THE WYE PIPE BELLOWS WAS FOUND TO BE CRACKED. 2 L 7 2 4F 4 F A9NM E6WE 2004051200017 20040512 00017 CE 2004 5 12 FBVXA1 1 20040506 G 2133 LINE CESSNA 500 550 2076604 CE OUTFLOW VALVE CHAFED B O OTHER S AFFECT SYSTEMS NR NOT REPORTED 1 GL 09 627L 1848 5500843 THE ELEVATOR CONTROL CABLE CHAFED THROUGH OUTFLOW VALVE VACUUM EJECTOR LINE CAUSING A (BUMP) IN THE PRESSURIZATION. ALS O CAUSED ERRATIC PRESSURIZATION IN FLIGHT. REPLACED THE LINE AND OPS CHECKED GOOD. 1 L 7 2 4F A22CE 2005012600195 20050126 00195 CE 2005 1 26 FCPR200400020 1 20041119 G 2810 RETAINING RING BEECH 90 E90 1152914 CE FUEL CELL DISLODGED B FCPR O OTHER K J FLUID LOSS WARNING INDICATION NR NOT REPORTED 1 NM 09 3818C 763474 LW196 FUEL CELL RETAINING RING AND CLIP HAD DISLODGED AND MIGRATED TO THE FORWARD SIDE OF THE FUEL CELL, THEN PUNCTURED CELL RESULTING IN A FUEL LEAK. 1 L 7 2 3T 3A20 2005031000058 20050310 00058 CE 2005 3 10 FCPR200500001 1 20041223 G 2140 31A408150 SEAL CESSNA 500 560CESSNA 2076750 CE TAILCONE DISLODGED B E A ENGINE SHUTDOWN UNSCHED LANDING B J SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CR CRUISE 1 NM 09 420DM 2030 90 5600464 CUSTOMER REPOARTS UNUSUAL SMELL FROM TAILCONE. INSPECTED BLEAD AIR LINES. FOUND PERI-SEAL CONNECTING L/H FLOW CONTROL VA LVE TO WINDSHIELD BLEED AIR COUPLING LEAKING AND DISLODGEDALLOWING ENGINE BLEED AIR TO DUMP INTO THE TAIL CONE. 2SAFETY LANYARDSP/N 26A429-17 ARE BROKEN AND AFT PRESSURE BULKHEAD SHOWS SIGNS OF HEAT SCORCHING. WIRE BUNDLE FROM LH ENGINE PYL ON TO AFT PRESSURE BULKHEAD IS DAMAGED CAUSING MULTIBLE SYSTEM TO INDICATE FAILURE. 2 L 7 2 4F RT A22CE 2005031000061 20050310 00061 CE 2005 3 10 FCPR200500002 1 20041220 G 3510 80129310 OXYGEN BOTTLE BEECH 200 B200 1152922 CE RUPTURED B FCPR K NONE O OTHER IN INSP/MAINT 1 NM 09 7250T 5312 694 BB1237 DURING 3 YEAR HYDRO TEST O2 BOTTLE (20 YEARS INSERVICE 3HT 1850) RUPTURED AT OR BELOW 2100 PSI. SIGNIFICANT DAMAGE TO TH E BOTTLE AND PRESSURE TEST TANK OCCURED. NO INJURIES TO TEST PERSONNEL. 1 L 7 2 4T A24CE 2004091400179 20040914 00179 SO 2004 9 14 FSI072304 2 20040723 G 8530 CYLINDER HEAD CESSNA 182 182Q 2072732 CE CONT O470 O470U 17026 SO ENGINE SEPARATED D A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CL CLIMB 1 SO 09 97660 631 18267161 466461 ON CLIMB OUT THE NR 4 CYLINDER HEAD SEPARATED FROM THE BARREL. 1 H 7 1 3O 3 O NT 3A13 E273 2004101500076 20041015 00076 CE 2004 10 15 FTW04LA214 1 20040816 G 2822 S116052 SWITCH CESSNA 188 188CESSNA 2073002 CE CONT O520 TSIO520T 17040 SO MCAULY D3A34 D3A34C402 GL EMER FUEL PUMP DEFECTIVE G UTCG O OTHER S R Y AFFECT SYSTEMS PARTIAL RPM/PWR LOSS ENGINE STOPPAGE AP APPROACH 1 SW 11 9317J 4144 125 T18803794T AIRCRAFT LOST POWER ON LANDING. CRASHED SHORT OF FIELD. DETERMINED (HI-SIDE) OF EMERGENCY FUEL PUMP SWITCH STUCK IN THE HI POSITION. 1 L 7 1 3O 3 O A9CE E8CE 5 C P47GL 2004090800074 20040908 00074 CE 2004 9 8 G5203 1 20040206 G 3230 99102791 CONTROL VALVE CESSNA 441 441 2076020 CE MLG FAILED B K NONE L NO TEST IN INSP/MAINT 1 NM 03 988AE 600 4410175 THIS MLG CONTROL VALVE FOUND TO BE REASON THE MLG FAILED A SCHEDULED EMERGENCY EXTENTION CHECK. FOUND THE RETURN PORT C LOSED WHEN VALVE NOT ENERGIZED, PORT SHOULD BE OPEN IN THIS CONDITION & THIS CAUSED MLG TO HYDRO-LOCK IN UP POSITION. T EAR DOWN REVEALED ON 2ND VALVE NOT ASSEMBLED CORRECTLY, SPOOL WAS INSERTED BACKWARDS RESULTING IN PORTING NOT FUNCTIONIN G. VALVE FAILURE WAS NOT DEFINED DURING TEAR DOWN. VALVE S/N 1152 RETURNED AND FOUND THAT PIN NR 17 IN THE CORE ASSEMB LY BROKEN AT THE TIP. IT IS ASSUMED THAT THIS FAILURE OCCURED DURING THE REQUIRED TEST PROCEEDURE. 1 L 7 2 3T RT A28CE 2004050600036 20040506 00036 SO 2004 5 6 GILALEX404 1 20040409 G 5551 SUPPORT ANGLE AMRGEN AA5 AA5B 3960105 SO FUSELAGE BUCKLED D K NONE O OTHER IN INSP/MAINT 1 WP 07 28478 AA5B0635 AIRCRAFT WAS INSPECTED IAW CE-04-34. BUCKLING WAS FOUND ON BOTH OF THE SUPPORT ANGLES (1 AND 2) JUST BELOW THE HORIZONT AL STAB. MOUNTING BOLTS. SMALL CRACKS FOUND AT THE TOP OF THESE SUPPORT ANGLES. MINOR BUCKLE FOUND AT LT SIDE OF LOWER STIFFENER AT ARROW NUMBER 7. 1 L 7 1 3O A16EA 2004050600034 20040506 00034 SO 2004 5 6 GILALEX404A 1 20040409 G 5551 SUPPORT ANGLE AMRGEN AA5 AA5B 3960105 SO FUSELAGE BUCKLED D K NONE O OTHER IN INSP/MAINT 1 WP 07 28478 AA5B0635 AIRCRAFT WAS INSPECTED IAW SAIB CE-04-34. BUCKLING WAS FOUND ON BOTH OF THE SUPPORT ANGLES JUST BELOW THE HORIZONTAL ST AB. MOUNTING BOLTS. SMALL CRACKS FOUND AT THE TOP OF THESE SUPPORT ANGLES. MINOR BUCKLE FOUND AT LT SIDE OF LOWER STIF FENER AT ARROW NUMBER 7 IN SAIB PICTURE. 1 L 7 1 3O A16EA 2005022200013 20050222 00013 2005 2 22 HE66095154 4 20040524 G 2210 41800847000 ACTUATOR UROCOP EC135 EC135T1 5620026 EU YAW UNRELIABLE B HEEA O OTHER S AFFECT SYSTEMS CR CRUISE 1 SW 03 135CR 1458 0164 CAUSING A YAW ACTUATOR LIGHT, AND AUTOPILOT TO FLY OUT OF TRIM 1 G 7 2 3U H88EU 2005022200015 20050222 00015 EU 2005 2 22 HE66095158 1 20040601 G 6330 L633M2010102 MOUNT UROCOP EC135 EC135T1 5620026 EU M/R GEARBOX UNSERVICEABLE B HEEA O OTHER O OTHER NR NOT REPORTED 1 SW 03 135CR 0164 MAIN ROTOR GEARBOX MOUNT WORN BEYOND LIMITS 1 G 7 2 3U H88EU 2005022200017 20050222 00017 GL 2005 2 22 HEEA095226 2 20040508 G 7200 23004545 ENGINE BELL 206 206L3 1182108 SW ALLSN 250C 250C30P 03013 GL STALLED B HEER A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 SW 03 6748D 16334 51106 COMPRESSOR STALL WHILE HOVERING FOR TAKE OFF. 1 G 7 1 3U 3 U H2SW E1GL 2005031000173 20050310 00173 SW 2005 3 10 HEEA098914 1 20041231 G 3110 1300071 TRANSISTOR BELL 412 412 1182202 SW INSTRUMENT PANEL BURNED OUT B HEEA A UNSCHED LANDING O OTHER CR CRUISE 1 SW 03 2149S 36002 IN CRUISE FLIGHT, NOTED ELECTRICAL BURNING SMELL. RETURNED TO BOOTHVILLE. MAINTENANCE FOUND TRANSISTOR 8Q2 FOR INSTRUM ENT LIGHTS HAD SHORTED AND CAUSED RESISTOR 8R12 TO BURN OUT. REPLACED TRANSISTOR 8Q2, RESISTOR 8R12 AND RHEOSTAT 8R5. 1 G 7 2 4U H4SW 2004101800033 20041018 00033 SO 2004 10 18 HN8R200400001 2 20041005 G 8520 646778 CONNECTING ROD BEECH 95 95B55 1152729 CE CONT O520 IO520C 17032 SO HARTZL HCA3V EHCA3VF2 GL RT ENGINE BENT B K NONE O OTHER IN INSP/MAINT 1 CE 07 2147L 1574 TC1991 215900R FJ437B DURING DIFFERENTIAL COMPRESSION CHECK FOUND NR 6 CYLINDER 20/80. REMOVED CYLINDER AND DISCOVERED THE CONNECTING ROD BEN T. REPLACED THE ENGINE. 1 L 7 2 3O 3 O RT 3A16 E5CE 5 C P6EA 2005021700125 20050217 00125 EU 2005 2 17 I05R098769 1 20040825 G 2910 MA12401 PRESSURE SWITCH AEROSP AS355 AS355* EU HYD SYSTEM FAILED B I05R O OTHER O OTHER NR NOT REPORTED 1 WP 05 970SD 196 3760 PRESSURE SWITCH FAILED IN 3 HRS OF OPERATION. REPLACED PART. 1 G 7 2 3U H11EU 2004092800071 20040928 00071 EU 2004 9 28 I7LA0002725 1 20040805 G 6420 109013105115 TRUNNION AGUSTA A109 A109K2 0260502 EU TMECA ARRIEL ARRIEL1 60030 NE TAIL ROTOR OVERHEATED E I7LA O OTHER O OTHER NR NOT REPORTED 1 NM 07 109RX 149 10016 UPON 25 HOUR INSPECTION, TRUNION SHOWS SIGNS OF EXCESSIVE HEAT, DISCOLORED (BROWN) COATING. ENAMEL PAINT. 1 G 7 2 3U 3 U RT H7EU E19EU 2004092800055 20040928 00055 EU 2004 9 28 I7LA0002736 1 20040820 G 6420 109013105115 TRUNNION AGUSTA A109 A109K2 0260502 EU TMECA ARRIEL ARRIEL1 60030 NE TAIL ROTOR LOOSE E O OTHER O OTHER NR NOT REPORTED 1 NM 07 901HC 10033 UPON DAILY INSPECTION, MECHANIC NOTED EXCESSIVE PLAY IN TAIL ROTOR HUB AT TRUNION AREA. TAIL ROTOR HUB WAS REMOVED FOR INSPECTION A SOFT FACE MALLET WAS REQUIRED TO FREE THE TRUNION FROM TAIL ROTOR GEARBOX OUTPUT SHAFT. REMOVAL OF TRUNION NOTED SIGNS OF EXCESSIVE HEAT DISCOLORATION OF ENAMAL PAINT/ COATING. THE TRUNION BUSHINGS/ RACES WERE LOOSE AND SLIDE .5 WAY OFF TRUNION WITH NO MECHANICAL MEANS. 1 G 7 2 3U 3 U RT H7EU E19EU 2004122200114 20041222 00114 WP 2004 12 22 JV2R200400001 2 20041209 G 7321 21190208000 COMPUTER RKWELL NA265 NA26565 7630107 CE GARRTT TFE731 TFE731* 01518 WP E/E BAY FAILED B JV2R H DEACTIVATE SYST/CIRCUITS J WARNING INDICATION TX TAXI/GRND HDL 1 CE 03 69WU 25 25 46551 DURING MAINTENANCE ENGINE RUN, THE LT COMPUTER FAIL LIGHT ILLUMINATED AT 92 PERCENT AND THE SYSTEM WENT TO MANUAL. THE ENGINE OPERATOR RESET THE SYSTEM PER MANUAL AND PERFORMED A SECOND ENGINE RUN. LEFT COMPUTER FAIL LIGHT ILLUMINATED AT IDLE ON THE SECOND ENGINE RUN AND WENT TO MANUAL. ENGINE OPERATION WAS STOPPED. HONEYWELL WAS CONTACTED. 2 L 7 2 4J 4 F A2WE E6WE 2004123000118 20041230 00118 WP 2004 12 30 JV2R200400003 2 20041209 G 7320 21190208000 EEC RKWELL NA265 NA26565 7630107 CE GARRTT TFE731 TFE731* 01518 WP LT ENGINE DEFECTIVE B JV2R H DEACTIVATE SYST/CIRCUITS O OTHER CL CLIMB 1 CE 03 976SR 46529 OPERATOR REPORTED LEFT DIGITAL ELECTRONIC ENGINE CONTROL COMPUTER FAIL LIGHT ILLUMINATED DURING CLIMB PUTTING THE SYSTEM IN MANUAL. THE OPERATOR REPORTED ATTEMPTING RESET ONE TIME, SYSTEM FAILED AGAIN AND OPERATOR RETURNED TO BASE. HONEYW ELL WAS CONTACTED. 2 L 7 2 4J 4 F A2WE E6WE 2004050300124 20040503 00124 CE 2004 5 3 JV2R20040001 1 20040308 G 3244 TIRE RKWELL NA265 NA26565 7630107 CE MLG SEPARATED B JV2R O OTHER O OTHER NR NOT REPORTED 1 CE 03 47SE 46534 TIRE TREAD SEPARATION FROM TIRE CASING. EACH TIRE REPORTED HAS LESS THAN TWENTY LANDINGS ON IT. THIS PROBLEM REPORTED TO TIRE MFG. SAMPLES OF DISCREPANT UNITS FORWARDED TO MFG FOR EVALUATION. THIS IS THE FIRST OF NINE KNOWN FAILURES OF THESE TIRES. ONE OTHER IS MODEL -65, FOUR ARE ON MILITARY T-39N AIRCRAFT. THREE OTHER AIRCRAFT REPORTED TREAD SEPARATI ONS TO ANOTHER REPAIR STATION WHO FORWARDED THEIR INFORMATION TO MFG. A COPY OF THE MFG CORRECTIVE ACTION REQUEST, NO 6 6 AND THE LETTER REQUESTING AN EVALUATION WILL BE SENT TO MFG AND FSDO WITH THIS REPORT. 2 L 7 2 4J A2WE 2005012100183 20050121 00183 NE 2005 1 21 JYDRMDR04065 1 20041020 G 6410 6516000047101 SPACER SKRSKY SKRSKY S64 CH54B 8142610 NE T/R BLADE CRACKED B JYDR O OTHER O OTHER NR NOT REPORTED 1 NM 09 179AC 65V60735280 64091 PART OF THE OB ROOT END SPACER BLOCK BROKE OFF AND WAS SENT THROUGH THE TIP CAP. THE OB SPACER BLOCK HAS SPLIT AROUND T HE L/E THROUGH BOLT. PRIOR TO DISASSEMBLY THE OB MOST SPACER BLOCK COULD BE SEEN AS MISSING A PORTION THAT IS ABOUT THE SAME SIZE AS THE HOLE IN THE TIP CAP. UPON DISASSEMBLY OF THE ROOT END, IT APPEARS AS IF THE ROOT END SPACER BLOCK WAS NOT PROPERLY FITTED TO THE INSIDE OF THE SPAR. THE L/E OF BLOCK WAS BEARING THE COMPRESSIVE STRESS IMPOSED BY THE TORQ UE SQUEEZE OF THE THROUGH BOLTS. IB SPACER BLOCK FOR THE THROUGH BOLTS IS CRACKED IN THE SAME AREAS THAT THE OTHER BLOC K FAILED. BLOCK WAS NO PROPERLY SHAPED INSIDE OF THE SPAR AND IS SHOWING CONTACT WITH THE SPAR ONLY IN CTR OF BLOCK. 2 G 7 2 4U H6EA 2005012100174 20050121 00174 NE 2005 1 21 JYDRMDR04066 1 20041020 G 6320 SB21511 BEARING SKRSKY S64 S64E 8142604 NE M/R GEARBOX CRACKED B JYDR O OTHER O OTHER NR NOT REPORTED 1 NM 09 CGJZK 1276 A6105 64003 THE AIRCRAFT CREW REPORTED, AFTER PULLING MAX POWER, THAT THE AC JUMPED. AFTER RETURNING TO THE LANDING, THE MECHANICS CHECKED THE CHIP DETECTOR IN THE MAIN GEAR BOX AND FOUND FERROUS METAL. UPON TEARDOWN OF THE GEARBOX IN THE SHOP, DISCO VERED THAT THE INNER RACE OF THE 2ND STAGE INPUT WAS SPALLING AND HAD AN AXIAL CRACK THROUGH THE ENTIRE INNER RACE. DUE TO THE CRACK, THE BEARING LOST ALL PRESS FIT WHICH RESULTED IN THE INNER RACE ROTATING ON INPUT PINION SHAFT. (NM092005 03792) 2 G 7 2 4U H4EA 2005033000124 20050330 00124 NE 2005 3 30 JYDRMDR04069 1 20041206 G 6320 643520017019 HOUSING SKRSKY S64 S64F 8142610 NE PWA JFTD12 JFTD12A5A 52047 NE M/R GEARBOX CRACKED B JYDR K NONE O OTHER IN INSP/MAINT 1 NM 09 159AC 2067 A6148 64084 MGB WAS REMOVED FOR MAIN SHAFT REPLACEMENT AND OVERHAUL. AFTER DISASSEMBLY OF GEAR BOX, THE UPPER HOUSING WAS LOCALLY B LENDED, ETCHED UNDER THE INPUTS AND INSPECTED BY FPI. THE HOUSING WAS REJECTED FOR CRACKS ON THE LT AND RT SIDE. POOR REWELD QUALITY OF CASTING AT MFG. (K) 2 G 7 2 4U 4 U H6EA E15EA 2004121000024 20041210 00024 WP 2004 12 10 KO0R0323 1 20040115 G 5340 37560231N FITTING DOUG DC8 DC863 302198A WP PWA JT3D JT3D7 52039 NE FUSELAGE CORRODED B KO0R O OTHER O OTHER NR NOT REPORTED 1 GL 23 865F 46088 EXTERNAL FUSELAGE SKIN HAS A BULGE AT FS315, LONGERON NR 33R. FOUND DOOR STRUCTURE FITTING CORRODED (FS 315, LONGERON 3 3R). REMOVED AND REPLACED FITTING IAW DC8, SRM 53-2-0, FIG 2D. CORROSION REMOVED IAW DC SRM 51-1-8. 2 L 7 4 4F 4 F 4A25 1E8 2004090800050 20040908 00050 GL 2004 9 8 KRCX0101AA 3 20040827 G 6110 COUNTERWEIGHT CESSNA 337 337F 2075725 CE CONT O360 IO360C 17025 SO MCAULY 2AF34C D2AF34C302 GL PROPELLER DISPLACED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 13 1258M 2191 72 337F01458 5193972C 722959 ON ANNUAL INSPECTION SAW FINE ALUMINUM POWDER ON ONE BLADE SHANK ON REAR PROP. FOUND SPINNER HAD A LARGE BLISTER CAUSED BY PRESSURE FROM WITHIN. WHEN WE REMOVED THE SPINNER WE SAW THE COUNTERWEIGHT FOR THAT BLADE WAS ADVANCED ABOUT 30 DEGRE ES IN THE CRUISE DIRECTION BUT BOTH BLADES WERE IN FULL FLAT PITCH. THE ALUMINUM POWDER CAME FROM THE BALANCE WEIGHT ARM RUBBING THE INSIDE OF THE SPINNER. SENT ENTIRE ASSEMBLY TO THE CRS UF2R211L THAT OVERHAULED IT 72.9 HOURS AGO JAN 2003. THE OWNER OF THAT SHOP CLAIMED THE COUNTER WEIGHT CANNOT REACH THE SPINNER. I HAVE EVIDENCE OTHERWISE. THE CRS CORRECTE D THE LOOSE COUNTERWEIGHT AND ISSUED A YELLOW TAG WITH THE ORIGINAL SPINNER INSTALLED. 1 H 7 2 3O 3 O A6CE E1CE 5 C P5EA 2004112300005 20041123 00005 NM 2004 11 23 L0FR200400012 1 20041118 G 3246 260356116 WHEEL BOEING 747 747200 1384847 NM MLG CRACKED B Q2SA K NONE O OTHER IN INSP/MAINT 1 AL 03 FAILED BOLT HOLES ON OUTER RIM IDENTIFIED PER HONEYWELL COMPONENT MM 32-45-12 EDDY CURRENT PROCEDURES. 2 L 7 4 4F RT A20WE 2005030800180 20050308 00180 NM 2005 3 8 LCQ20052 1 20041221 G 5330 SKIN BOEING 737 737 UTILSYS NM FUSELAGE DENTED B K NONE O OTHER IN INSP/MAINT 1 SW 15 945UA 26684 DENT AT FUSELAGE STA 391, 3 INCHES ABOVE S-17L AT PERIMETER OF EXISTING REPAIR. REF NR 23648 S/O 269001. 2 L 7 2 4F RT A16WE 2004050300160 20040503 00160 SO 2004 5 3 LU4R349M 1 20040316 G 6120 B24521 CYLINDER PIPER PA23 PA23250 7102308 SO LYC O540 IO540* 41532 EA HARTZL HCE2Y HCE2YR2 GL PROPELLER DAMAGED B O OTHER O OTHER NR NOT REPORTED 1 SO 15 BP9634 CYLINDER (PN B-2452-1) SEPARATED FROM PROPELLER ON GROUND RUN. INSPECTION SHOWED THREAD DAMAGE OF CYLINDER. AFTER DISCUS SION WITH MFG, THE LIKELY CAUSE IS DIE TO HIGH PRESSURE FROM GOVERNOR, USUALLY CAUSED BY STICKING PRESSURE RELIEF VALVE. 1 L 7 2 3O 3 O 1A10 1E4 5 C P9EA 2005022200211 20050222 00211 NM 2005 2 22 M0539 1 20040827 G 5302 206030446001 BULKHEAD BELL UNIVAR 108 1083 9230408 NM FRNKLN 6A4165 6A4165* 27025 EA TAILBOOM CRACKED B BXOR O OTHER O OTHER NR NOT REPORTED 1 EA 09 909C 5947 BCJN07208 1083909 DURING ANNUAL INSPECTION, FOUND AFT TAILBOOM BULKHEAD PN 206030446001 CRACKED AT LT BOLT HOLE FOR TAIL ROTOR GEARBOX MOU NT. 1 H 7 1 3O 3 O A767 E238 2004050300182 20040503 00182 CE 2004 5 3 MAFPAPUA 1 20040322 G 2810 S2020 DRAIN CESSNA 206 TU206G 2073357 CE CONT O520 TSIO520M 17040 SO MCAULY D3A34 D3A34C402 GL FUEL SUMP FAILED D O OTHER O OTHER NR NOT REPORTED 1 WP 23 PK-MA U20606231 532210 781860 WHILE INSTALLING THE WING FUEL TANK SUMP DRAIN AT THE MFG RECOMMENDED TORQUE VALUE OF 90 IN-LBS, THE DRAIN ITSELF FAILED , SEPARATING AT THE DRILLED HOLES JUST ABOVE THE FITTING HEAD. 1 H 7 1 3O 3 O A4CE E8CE 5 C P47GL 2004100400089 20041004 00089 SO 2004 10 4 MAGMARTINSEPT 2 20040908 G 7414 103493504 MAGNETO CESSNA 206 TU206* CE CONT O520 TSIO520M 17040 SO ENGINE LOOSE D K NONE O OTHER IN INSP/MAINT 1 WP 23 120 UPON INSPECTION OF THE MAGNETO INTERIOR, FOUND THAT THE (STRIP-FISH PAPER) (P/N 10-349326) HAD COME LOOSE FROM THE SIDE OF THE CASE AND BECOME INGESTED IN THE DRIVE AND DISTRIBUTOR BLOCK GEARS. ADDITIONALLY, THE CARBON BRUSH SHOWED EXCESS IVE SIDE LOAD WEAR. WERE LOOKING FOR A PROBLEM RELATED TO RF NOISE IN THIS MAGNETO. HOLD MFG ACCOUNTABLE FOR ERRORS. BELIEVE WE NEED TO EITHER WORK DIRECTLY WITH MFG PERSONNEL OR THE FAA TO MAKE SURE QUALITY CONTROL ISSUES LIKE THIS ARE NOTICED AND FIXED. 1 H 7 1 3O 3 O A4CE E8CE 2004100400079 20041004 00079 SO 2004 10 4 MAGSENTANI 2 20040908 G 7414 103493504 MAGNETO CESSNA 206 TU206* CE CONT O520 TSIO520M 17040 SO ENGINE LOOSE D K NONE O OTHER IN INSP/MAINT 1 WP 21 120 UPON INSPECTION OF THE MAGNETO INTERIOR, FOUND THAT THE (STRIP-FISH PAPER) (P/N 10-349326) HAD COME LOOSE FROM THE SIDE OF THE CASE AND BECOME INGESTED IN THE DRIVE AND DISTRIBUTOR BLOCK GEARS. ADDITIONALLY, THE CARBON BRUSH SHOWED EXCESSI VE SIDE LOAD WEAR. LOOKING FOR A PROBLEM RELATED TO RF NOISE IN THIS MAGNETO. HOLD MFG ACCOUNTABLE FOR ERRORS. SERIOU SLY BELIEVE WE NEED TO EITHER WORK DIRECTLY WITH MFG PERSONNEL OR THE FAA TO MAKE SURE QUALITY CONTROL ISSUES LIKE THIS ARE NOTICED AND FIXED. 1 H 7 1 3O 3 O A4CE E8CE 2005021500077 20050215 00077 NE 2005 2 15 MDR03032 2 20041002 G 7532 745114 BLEED VALVE JFTD12A5A SKRSKY S64 S64F 8142610 NE PWA JFTD12 JFTD12A5A 52047 NE COMPRESSOR OBSTRUCTED B JYDR O OTHER O OTHER NR NOT REPORTED 1 NM 09 178AC 677806 64097 NR 1 ENG OIL PRESS WAS INDICATING LOWER THAN NR 2 ENG. PRESS INDICATED 45 PSI. ADJUSTED PRESS VALVE TO INCREASE CHECK AT NEXT FLT. NR 1 ENG WAS STARTED, INDICATED NML GROUND IDLE. ACCELERATING TO 70 PERCENT N2, OIL PRESS DROPPED OFF, CA UTION LIGHT ILLUM, PRESS DROPPED TO ZERO. PRESS DID NOT IMPROVE, BOTH ENG WERE SHUT DOWN. SMALL PIECE OF PLASTIC WAS L ODGED IN PRESSURE RELIEF VALVE, HOLDING IT OPEN. PIECE OF PLASTIC WAS BROWN COLORED, ABOUT .1875 X .1250 INCH. OBSTRUC TION WAS A PIECE OF RELIEF VALVE SEAT. VALVE WAS REPLACED, AC RETURNED TO SERVICE. EROSION OF VALVE SEAT CAUSED INITIA L PRESS LOSS. VALVE WAS TIGHTENED TO MATCH PRESS WITH THE NR 2 ENG. SEAT MAY HAVE BEEN DAMAGED BY THIS ADJUSTMENT. 2 G 7 2 4U 4 U H6EA E15EA 2005021500074 20050215 00074 NE 2005 2 15 MDR04060 2 20040802 G 7230 468247001 SPACER SKRSKY S64 S64E 8142604 NE PWA JFTD12 JFTD12A4A 52047 NE COMPRESSOR CRACKED B JYDR O OTHER E VIBRATION/BUFFET NR NOT REPORTED 1 NM 09 CCFRN 1312 1312 64061 COMPRESSOR, SN 672543, CAME INTO THE SHOP AND DURING THE PRELIMINARY TEST RUN, THE VIBES WERE AT 1.7 MILS. WITH THE VIB ES EXCEEDING THE LIMITS, THE COMPRESSOR HAD TO BE DISASSEMBLED FOR BALANCE. DURING THE VISUAL INSPECTION OF THE 3-4 SPA CER, THERE APPEARED TO BE A CRACK AT ONE OF THE FORWARD LIGHTENING HOLES. THE CRACK CONFIRMED VIA EDDY CURRENT AND FPI. RESEARCH OF THE PREVIOUS W/O AND THE PN 468247-001 INDICATE THAT THE SPACER HAD BEEN SHOTPEENED AND SB 6414 WAS COMPLI ED WITH. 2 G 7 2 4U 4 U H4EA E15EA 2004122100164 20041221 00164 NE 2004 12 21 MDR04061 1 20040819 G 6420 6595207526101 BEARING RACE SKRSKY SKRSKY S64 CH54B 8142610 NE TAIL ROTOR HEAD CRACKED B JYDR O OTHER O OTHER NR NOT REPORTED 1 NM 09 159AC 298 A9204 64084 TAIL ROTOR HEAD WAS REMOVED FROM AC DUE TO SUDDEN LEAKAGE FROM TAIL ROTOR GRIP. DISASSEMBLED TAIL ROTOR HEAD AND FOUND THE SHOULDER BOLT INNER RACE CRACKED ON THE BACK SLEEVE AND SPINDLE. CRACK TRAVELS COMPLETELY ACROSS BEARING CONTACT SU RFACE AND COMPLETELY THROUGH INNER RACE TOT HE SHOULDER BOLT CONTACT SURFACE. THE CRACKING OF THE INNER RACE WAS A PROB ABLE CAUSE FOR THE SUDDEN LEAKAGE. NOTE: THIS IS FIRST OCCURRENCE OF THIS TYPE. PART WILL BE SENT OUT FOR ANALYSIS. 2 G 7 2 4U H6EA 2004022500107 20040225 00107 CE 2004 2 25 MYNR748K 1 20040114 G 2710 176703013 CONTROL TUBE CESSNA 177 177 2073704 CE LYC O320 O320* 41508 EA AILERON WORN B MYNR O OTHER O OTHER NR NOT REPORTED 1 GL 11 3231T 2675 17700531 AILERON CONTROL SHAFT, WHERE IT MOUNTS TO FIREWALL BEARING WAS RUSTED AND GROVED BEYOND LIMITS, REPLACED LT AND RT SHAFT S AND BEARINGS. BEARING PN 0760633-1 END. 1 H 7 1 3O 3 O NT A13CE E274 2005031000026 20050310 00026 SW 2005 3 10 N114EL 1 20041215 G 2720 63457003 CONTROL ARM PIPER TMPSON NAVION NAVIOND 6150114 SW CONT O470 O470* 17026 SO ZONE 100 SEPARATED D O OTHER F S FLT CONT AFFECTED AFFECT SYSTEMS CR CRUISE 1 GL 03 114E 2879 NAV416 ON THE RUDDER PEDAL ASSY, THE RUDDER CONTROL ARM ASSEMBLY, TRIM ARM BROKE OFF AT PARENT METAL SURROUNDING THE WELD POINT . PILOT REPORTED LOSS OF RUDDER TRIM INPUT. NO HISTORY OF PART REPLACEMENT. P/N 63457-003. 2879.3 HOURS TOTAL AIRCRAF T TIME. HAND TOW BAR FOR THIS AIRCRAFT WAS FOUND BENT ABOUT 20 DEGREES ABOUT ONE MONTH PRIOR TO LOSS OF RUDDER TRIM INP UT. REPLACEMENT PART WAS INSTALLED AND FUNCTIONAL CHECK FLIGHTS WERE FLOWN WITHOUT DIFFICULTY. 1 L 7 1 3O 3 O A782 E273 2005031000025 20050310 00025 SW 2005 3 10 N114EL1 1 20041215 G 2720 63457003 CONTROL ARM PIPER TMPSON NAVION NAVIOND 6150114 SW CONT O470 O470* 17026 SO RUDDER PEDALS SEPARATED D O OTHER F S FLT CONT AFFECTED AFFECT SYSTEMS CR CRUISE 1 GL 03 114E 2879 NAV416 ON THE RUDDER PEDAL ASSY, THE RUDDER CONTROL ARM ASSEMBLY , TRIM ARM BROKE OFF AT PARENT METAL SUROUNDING THE WELD POINT . PILOT REPORTED LOSS OF RUDDER TRIM INPUT. NO HISTORY OF PART REPLACMENT. P/N 63457-003. 2879.3 HOURS TOTAL AIRCRAFT TIME. HAND TOW BAR FOR THIS AIRCRAFT WAS FOUND BENT ABOUT 20 DEGREES ABOUT ONE MONTH PRIOR TO LOSS OF RUDDER TRIM INPU T. REPLACEMENT PART WAS INSTALLED AND FUNTIONAL CHECK FLIGHTS WERE FLOWN WITHOUT DIFFICULTY. 1 L 7 1 3O 3 O A782 E273 2005031000027 20050310 00027 SO 2005 3 10 N114EL2 1 20041215 G 2720 63457003 CONTROL ARM PIPER PIPER PA32 PA32301 7103207 SO CONT O470 O470* 17026 SO ZONE 100 SEPARATED D O OTHER F S FLT CONT AFFECTED AFFECT SYSTEMS CR CRUISE 1 GL 03 114E 2879 328106096 ON THE RUDDER PEDAL ASSY, THE RUDDER CONTROL ARM ASSY, TRIM ARM BROKE OFF AT PARENT METAL SURROUNDING THE WELD POINT. P ILOT REPORTED LOSS OF RUDDER TRIM INPUT. NO HISTORY OF PART REPLACEMENT. P/N 63457-003. 2879.3 HOURS TOTAL AIRCRAFT TI ME. HAND TOW BAR FOR THIS AIRCRAFT WAS FOUND BENT ABOUT 20 DEGREES ABOUT ONE MONTH PRIOR TO LOSS OF RUDDER TRIM INPUT. REPLACEMENT PART WAS INSTALLED AND FUNCTIONAL CHECK FLIGHTS WERE FLOWN WITHOUT DIFFICULTY. 1 L 7 1 3O 3 O A3SO E273 2004030100039 20040301 00039 SW 2004 3 1 N207RT012804 1 20040128 G 5302 206021103105 BRACKET BELL 206 206L4 1182110 SW TAILBOOM CRACKED E YTRA R AUTOROTATION D INFLIGHT SEPARATION CR CRUISE 1 SW 03 207RT 52207 VERTICAL WINGLET BRACKET CRACKED AND ALLOWED WINGLET TO DETACH IN FLIGHT STRIKING THE TAILROTOR AND CAUSING LOSS OF TAIL ROTOR EFFECTIVENESS. (SW03200405293) 1 G 7 1 3U NC H2SW 2004050600018 20040506 00018 CE 2004 5 6 N736ZX 1 20040311 G 5540 22601145 TORQUE TUBE CESSNA CESSNA 182 182R 2072731 CE RUDDER BAR DETACHED D O OTHER O OTHER NR NOT REPORTED 1 SO 09 736Z 5075 LT RUDDER BAR TORQUE TUBE ASSEMBLY, PN 2260114-5 FAILURE. FAILURE OCCURRED IN FLIGHT RESULTING IN LT SIDE PILOT'S TOTAL LOSS OF LT RUDDER AND STEERING CONTROL. NATURE OF FAILURE; LT OB RUDDER PEDAL SOCKET ON TORQUE TUBE BROKE AWAY FROM THE TORQUE TUBE. THERE IS NO OBVIOUS REASON WHY THIS MIGHT HAVE HAPPENED. THERE ARE NO BENT OR DAMAGED COMPONENTS WITHIN THE SAME SYSTEM, AND THE STEEL TORQUE TUBE HAS ONLY VERY LIGHT INTERNAL CORROSION. 1 L 7 1 3O NT 3A13 2004092300084 20040923 00084 CE 2004 9 23 N827SP1 1 20040809 G 7722 S32778 INDICATOR CESSNA 172 172S 2072439 CE LYC O360 IO360A1A 41514 EA EGT INOPERATIVE D A UNSCHED LANDING O OTHER NR NOT REPORTED 1 SO 19 827SP 25 172S8740 EGT/FUEL FLOW INDICATOR BECAME INOPERATIVE DURING FLIGHT. 1 H 7 1 3O 3 O NT 3A12 1E10 2004102800030 20041028 00030 GL 2004 10 28 NF22004FCCC 1 20040723 G 2497 WIRE CIRRUS SR SR22 2130001 GL CONT O550 IO550* SO ALT OUTPUT CHAFED B NF2R O OTHER O OTHER NR NOT REPORTED 1 GL 03 280L 0154 ALTERNATOR OUTPUT WIRE CHAFED ON THE RT FWD VALVE COVER AND BURNED A .2500 INCH HOLE IN THE VALVE COVER. WIRE AND BAFFL E ABOVE VALVE COVER NEED TO BE SECURED BETTER. SHORTING OF THE WIRE ALSO CAUSED DAMAGE TO COMPONENTS IN THE MCU AND SUB SEQUENT NR 1 ALTERNATOR FAILURE. 1 L 7 1 3O 3 O NT A00009CH E3SO 2004030100124 20040301 00124 SO 2004 3 1 NI1R200400001 1 20040211 G 1430 BOLT PIPER PA44 PA44180 7104402 SO NLG SHEARED B A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 GL 03 554PC 1179 4496073 NOSE GEAR DID NOT RETRACT AFTER TAKE OFF. GEAR HANDLE SELECTED UP INDICATIONS: ALL THREE GREEN LAMPS OUT, GEAR UNSAFE L AMP STAYS ILLUMINATED, HYDRAULIC PUMP MOTOR CYCLES OFF AFTER A NORMAL PERIOD OF TIME. GEAR SELECTED DOWN INDICATIONS: L T AND RT MAIN GEAR DOWN AND LOCKED LAMPS ILLUMINATED, GEAR UNSAFE LAMP ILLUMINATED, THROTTLE AT IDLE, GEAR WARNING HORN SOUNDING OFF. PILOT LANDED THE AIRCRAFT SAFELY. TECHNICIANS FOUND BOLT SHEARED AT THE NOSE GEAR DOWNLOCK TO DRAG LINK ASSY. 1 L 7 2 3O A19S0 2004101300002 20041013 00002 WP 2004 10 13 NM09EDR001 1 20040913 G 6230 369D22014 MAST HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL MAIN ROTOR CORRODED B CHIR K NONE O OTHER IN INSP/MAINT 1 NM 09 502CH 1572 0252D DURING 100 HR INSPECTION, THE MAIN ROTOR DRIVESHAFT WAS REMOVED FOR INSPECTION. THE MECHANIC LOOKED DOWN THE MAST AND FO UND THE PAINT ON THE INSIDE DIAMETER WAS BLISTERED AND PEELING. THE MECHANIC ALSO NOTICED PAINT ON THE TOP OF THE MAIN T RANSMISSION SPLINES. THE MAIN ROTOR MAST WAS REMOVED AND IT WAS NOTICED THAT THE PAINT ON THE BOTTOM FLANGE WAS ALSO PEE LING AND THE INSIDE WAS CORRODING. THE MAIN TRANSMISSION WAS REMOVED FOR CONTAMINATION AND INSPECTED. THE MAIN ROTOR MAS T WAS REPLACED. THE MANUFACTURE WAS NOTIFIED. THE MAST WAS INSTALLED 11-13-2000. 1 G 7 1 3U 3 U H3WE E4CE 2004051200018 20040512 00018 EU 2004 5 12 NP0003 1 20040111 G 2910 MY20751106 LINE AMD FALCON FALCON20 2730103 EU HYD SYSTEM CRACKED C K NONE K FLUID LOSS IN INSP/MAINT 1 SW 04 384K 8878 387 FOUND HYD FLUID DRIPPING OUT OF TAIL OF AC. INSPECTED AFT COMPARTMENT, FOUND HYD FLUID UNDER LT HYD RESERVOIR. FOUND RE SERVOIR MAIN RETURN LINE CRACKED. REMOVED AND REPLACE LINE. FOURTH ALUMINUM LINE REPLACED IN LT HYD SYST IN AFT COMPART MENT. NOTICED THAT THIS LINE IS NOT CLAMPED ANY WHERE BETWEEN END BUT LOOKED LIKE IT SHOULD. CHECKED FOR EXCESS VIBRATI ONS WHEN THE HYD SYST IS RUNNING AND HAVE ONLY FOUND WHAT WOULD BE CONSIDERED NORMAL. HOWEVER, LINES DO VIBRATE EXCESSIV ELY AFTER DISCONNECTING THE HYD CART ON FIRST ENGINE RUN. THERE IS AIR IN SYST THAT HAS TO WORK ITS WAY OUT AND DOES WIT HIN A FEW SECONDS. SUGGESTED THAT A HARDER LOOK AND COME UP WITH A FIX FOR THE OLD, FAILING HYDRAULIC LINES. 2 L 7 2 4F RT A7EU 2004030100126 20040301 00126 GL 2004 3 1 O05R021320044 3 20040213 G 6114 FLANGE CESSNA 172 172 2072402 CE MCAULY 1C160 1C160DTM GL PROP HUB DAMAGED B O OTHER O OTHER NR NOT REPORTED 1 GL 05 CC184 EXCESSIVE DAMAGE TO MOUNTING FLANGE OF PROPELLER HUB. 1 H 7 1 3O NT 3A12 5 N P910 2004030100129 20040301 00129 GL 2004 3 1 O05R200400010 3 20040213 G 6111 FJC7666A BLADE PIPER PA34 PA34200 7103405 SO HARTZL HCC2Y HCC2YK2 GL PROPELLER OUT OF TOLERANCE B O05R K NONE O OTHER IN INSP/MAINT 1 GL 05 AU9346B BLADES WERE FOUND TO BE UNDER MINIMUM DIAMETER AND MINIMUM THICKNESS AT STATION 34. BLADE SERIAL NUMBERS E19818R AND E1 9873R. 1 L 7 2 3O A7SO 5 C P920 2004050300167 20040503 00167 GL 2004 5 3 O05R200400100 3 20040405 G 6111 FJC7666A BLADE PIPER PA34 PA34200 7103405 SO HARTZL HCC2Y HCC2YK2 GL PROPELLER OUT OF TOLERANCE B O OTHER O OTHER NR NOT REPORTED 1 GL 05 9026 2 BLADES REJECTED FOR DIMENSIONS. 1 L 7 2 3O A7SO 5 C P920 2004050300168 20040503 00168 GL 2004 5 3 O05R200400101 3 20040405 G 6111 FJC7666A BLADE PIPER PA34 PA34200 7103405 SO HARTZL HCC2Y HCC2YK2 GL PROPELLER OUT OF TOLERANCE C O OTHER O OTHER NR NOT REPORTED 1 GL 05 9026 2 BLADES REJECTED FOR DIMENSIONS. 1 L 7 2 3O A7SO 5 C P920 2004050300180 20040503 00180 GL 2004 5 3 O05R200400104 3 20040405 G 6111 90DHA16 BLADE PIPER PA28 PA28R200 7102811 SO MCAULY 2D34C B2D34C213 GL PROPELLER SCRATCHED C O OTHER O OTHER NR NOT REPORTED 1 GL 05 1 BLADE REJECTED FOR SCRATCH IN SHOT PEEN. 1 L 7 1 3O 2A13 5 C P7EA 2004050300181 20040503 00181 GL 2004 5 3 O05R200400105 3 20040405 G 6111 T10282DB4R BLADE SWRNGN SA226 SA226T 8780122 SW HARTZL HCB3T HCB3TN5 GL PROPELLER OUT OF TOLERANCE C O OTHER O OTHER NR NOT REPORTED 1 GL 05 1 BLADE REJECTED FOR DIMENSIONS. 2 L 7 2 4T RT A5SW 6 C P15EA 2004050300172 20040503 00172 GL 2004 5 3 O05R200400106 3 20040405 G 6111 T10282DB4R BLADE SWRNGN SA226 SA226T 8780122 SW HARTZL HCB3T HCB3TN5 GL PROPELLER OUT OF TOLERANCE C O OTHER O OTHER NR NOT REPORTED 1 GL 05 1 BLADE REJECTED FOR DIMENSIONS. 2 L 7 2 4T RT A5SW 6 C P15EA 2004050300198 20040503 00198 GL 2004 5 3 O05R200400107 3 20040405 G 6111 T10282DB4R BLADE SWRNGN SA226 SA226T 8780122 SW HARTZL HCB3T HCB3TN5 GL PROPELLER OUT OF TOLERANCE C O OTHER O OTHER NR NOT REPORTED 1 GL 05 1 BLADE REJECTED FOR DIMENSIONS. 2 L 7 2 4T RT A5SW 6 C P15EA 2004050300199 20040503 00199 EA 2004 5 3 O05R200400108 3 20040405 G 6110 72CKS6054 PROPELLER CESSNA 150 152 2071835 CE SNSNCH 72C 72CK EA NR 1 DAMAGED C O OTHER O OTHER NR NOT REPORTED 1 GL 05 1 PROPELLER ASSEMBLY REJECTED FOR IMPACT DAMAGE. 1 H 7 1 3O NT 3A19 5 N P9045 2004050300173 20040503 00173 GL 2004 5 3 O05R200400109 3 20040405 G 6110 1A103TCM6958 PROPELLER CESSNA 150 152 2071835 CE MCAULY 1A103 1A103TCM GL CORRODED C O OTHER O OTHER NR NOT REPORTED 1 GL 05 1 PROPELLER ASSEMBLY REJECTED FOR CORROSION. 1 H 7 1 3O NT 3A19 5 N P50GL 2004050300200 20040503 00200 GL 2004 5 3 O05R200400110 3 20040405 G 6111 82NEA5 BLADE BEECH 58 58 1152740 CE MCAULY 3AF32C 3AF32C512 GL NR 1 PROPELLER DAMAGED C O OTHER O OTHER NR NOT REPORTED 1 GL 05 1 BLADE REJECTED FOR DAMAGE IN SHOT PEEN AREA. 1 L 7 2 3O 3A16 5 C P22EA 2004050700005 20040507 00005 GL 2004 5 7 O05R200400112 3 20040405 G 6111 T10178B3R BLADE BEECH 200 200BEECH 1152920 CE HARTZL HCB3T HCB3TN3 GL PROPELLER OUT OF TOLERANCE C O OTHER O OTHER NR NOT REPORTED 1 GL 05 1 BLADE REJECTED FOR DIMENSIONS. 1 L 7 2 4T A24CE 6 C P15EA 2004050300201 20040503 00201 GL 2004 5 3 O05R200400113 3 20040405 G 6111 T10178B3R BLADE BEECH 200 200BEECH 1152920 CE HARTZL HCB3T HCB3TN3 GL PROPELLER OUT OF TOLERANCE C O OTHER O OTHER NR NOT REPORTED 1 GL 05 6034 1 BLADE REJECTED FOR DIMENSIONS. 1 L 7 2 4T A24CE 6 C P15EA 2004050300170 20040503 00170 GL 2004 5 3 O05R200400114 3 20040405 G 6111 T10178B3R BLADE BEECH 200 200BEECH 1152920 CE HARTZL HCB3T HCB3TN3 GL PROPELLER OUT OF TOLERANCE C O OTHER O OTHER NR NOT REPORTED 1 GL 05 6034 1 BLADE REJECTED FOR DIMENSIONS. 1 L 7 2 4T A24CE 6 C P15EA 2004100400099 20041004 00099 GL 2004 10 4 O05R200400115 3 20040617 G 6114 D22013 HUB PIPER PA32 PA32R300 7103213 SO HARTZL HCC2Y HCC2YK1 GL PROPELLER UNKNOWN C O OTHER O OTHER NR NOT REPORTED 1 GL 05 CH19828E ELIMINATED AD 2001-23-08 COMPLIANCE REQUIREMENT. 1 L 7 1 3O A3SO 5 C P920 2004071200201 20040712 00201 GL 2004 7 12 O05R200400116 3 20040617 G 6114 C701 HUB CESSNA 425 425 2076018 CE MCAULY 3G34C7 3GFR34C701 GL PROPELLER CRACKED C O OTHER O OTHER NR NOT REPORTED 1 GL 05 814730 PROPELLER HUB CRACKED. 1 L 7 2 3T RT A7CE 5 C P60GL 2004092300085 20040923 00085 GL 2004 9 23 O05R200400117 3 20040617 G 6111 93KB0 BLADE CESSNA 425 425 2076018 CE MCAULY 3G34C7 3GFR34C701 GL PROPELLER SCRATCHED C O OTHER O OTHER NR NOT REPORTED 1 GL 05 814730 PROPELLER BLADE HAS A SCRATCH IN SHOTPEEN ON SHANK. 1 L 7 2 3T RT A7CE 5 C P60GL 2004092300095 20040923 00095 GL 2004 9 23 O05R200400118 3 20040617 G 6111 93KB0 BLADE CESSNA 425 425 2076018 CE MCAULY 3G34C7 3GFR34C701 GL PROPELLER SCRATCHED C O OTHER O OTHER NR NOT REPORTED 1 GL 05 814730 SCRATCH IN SHOTPEEN ON SHANK. 1 L 7 2 3T RT A7CE 5 C P60GL 2004120200205 20041202 00205 GL 2004 12 2 O05R200400119 3 20040617 G 6111 93KB0 BLADE CESSNA 425 425 2076018 CE MCAULY 3G34C7 3GFR34C701 GL PROPELLER SCRATCHED C O OTHER O OTHER NR NOT REPORTED 1 GL 05 814730 SCRATCH IN SHOT PEEN ON SHANK. 1 L 7 2 3T RT A7CE 5 C P60GL 2004120200206 20041202 00206 GL 2004 12 2 O05R200400120 3 20040617 G 6111 93KB0 BLADE CESSNA 425 425 2076018 CE MCAULY 3G34C7 3GFR34C701 GL PROPELLER SCRATCHED C K NONE O OTHER IN INSP/MAINT 1 GL 09 814730 SCRATCH IN SHOT PEEN ON SHANK. 1 L 7 2 3T RT A7CE 5 C P60GL 2004120200207 20041202 00207 GL 2004 12 2 O05R200400121 3 20040617 G 6111 93KB0 BLADE CESSNA 425 425 2076018 CE MCAULY 3G34C7 3GFR34C701 GL PROPELLER SCRATCHED C K NONE O OTHER IN INSP/MAINT 1 GL 09 814730 SCRATCH IN SHOT PEEN ON SHANK. 1 L 7 2 3T RT A7CE 5 C P60GL 2004120200208 20041202 00208 GL 2004 12 2 O05R200400122 3 20040617 G 6111 93KB0 BLADE CESSNA 425 425 2076018 CE MCAULY 3G34C7 3GFR34C701 GL PROPELLER SCRATCHED C K NONE O OTHER IN INSP/MAINT 1 GL 09 814730 SCRATCH IN SHOT PEEN ON SHANK. 1 L 7 2 3T RT A7CE 5 C P60GL 2004092300089 20040923 00089 GL 2004 9 23 O05R2004117 3 20040617 G 6111 93KBO BLADE CESSNA 425 425 2076018 CE MCAULY 3G34C7 3GFR34C701 GL PROPELLER SCRATCHED C O OTHER O OTHER NR NOT REPORTED 1 GL 05 814730 SCRATCH IN SHOTPEEN ON SHANK. AMMENDED SERIAL NO IN BOX 5 (D) BF024 1 L 7 2 3T RT A7CE 5 C P60GL 2005042100030 20050421 00030 CE 2005 4 21 PF212LWAA 1 20041223 G 5610 10138402518 WINDSHIELD BEECH 200 B200 1152922 CE COCKPIT CRACKED P B EMER. DESCENT O OTHER CR CRUISE 1 CE 07 212LW BB1420 IN CRUISE FLIGHT AT FL290 IN VMC ON IFR FLIGHT PLAN WITH OAT OF -45C, INNER PANE OF CO-PILOTS WINDSHIELD SHATTERED WITHO UT WARNING. 1 L 7 2 4T A24CE 2005082200091 20050822 00091 2005 8 22 PG9R97674 2 20041013 G 7313 6899001 FUEL NOZZLE ENGINE CRACKED B PG9R O OTHER O OTHER NR NOT REPORTED 1 WP 19 1627 CRACKED SHROUD AND SPRAY BODY, REPLACED. IT IS BEING SUGGESTED THAT THESE NOZZLES BE PRESSURE TESTED (AIR OR LIQUID) PR IOR TO BEING RELEASED FOR SERVICE. IT IS FURHER SUGGESTED THAT QC DEPARTMENT BE INCLUDED IN THIS PROCESS. THESE SUGGES TIONS ARE OF COURSE TO PREVENT LOSS OF VENENUE AND MOST OF ALL, SAFETY. (BN-FSDO) 2005082200090 20050822 00090 GL 2005 8 22 PG9R97676 2 20041013 G 7310 6899001 FUEL NOZZLE CESSNA STC STC206C 1182107 CE ALLSN 250C 250C30P 03013 GL ENGINE CRACKED B PG9R O OTHER O OTHER NR NOT REPORTED 1 WP 19 22425 1412 45743 890233 NOZZLE CRACKED/ REPLACED. (K) 1 H 7 1 3O 3 U NT A4CE E1GL 2005082200087 20050822 00087 GL 2005 8 22 PG9R97678 2 20041013 G 7310 6899001 FUEL NOZZLE BELL 206 206L1 1182107 SW ALLSN 250C 250C30P 03013 GL SHROUD CRACKED B PG9R O OTHER O OTHER NR NOT REPORTED 1 WP 19 1076T 1537 45373 CRACKED SHROUD/ REPLACED. (K) 1 G 7 1 3U 3 U H2SW E1GL 2005082200088 20050822 00088 GL 2005 8 22 PG9R97679 2 20041013 G 7313 6899001 FUEL NOZZLE BELL 206 206L1 1182107 SW ALLSN 250C 250C30P 03013 GL ENGINE CRACKED B PG9R O OTHER O OTHER NR NOT REPORTED 1 WP 19 10761 1397 45381 CRACKED SHROUD AND SPRAY BODY/ REPLACED. (K) 1 G 7 1 3U 3 U H2SW E1GL 2005030200076 20050302 00076 NM 2005 3 2 PG9R97903 1 20041021 G 1410 900D3409526105 LINE DOUG MD900 MD900 3027375 NM PWC PW207 PW207E NE OIL SYSTEM LEAKING B PG9R K NONE O OTHER IN INSP/MAINT 1 WP 19 368PA 90000012 FOUND TO BE LEAKING A SMALL QUANTITY OF OIL/ REPLACED OIL HOSE ASSY. (K) 1 G 7 2 3U 3 U NC H19NM E42NE 2005021700003 20050217 00003 GL 2005 2 17 PG9R97953 2 20041105 G 7313 6899001 FUEL NOZZLE BELL 206 206L1 1182107 SW ALLSN 250C 250C28 03013 GL ENGINE CRACKED B PG9R K NONE O OTHER IN INSP/MAINT 1 WP 19 3895D 1480 45590 FUEL NOZZLE SPRAY SHROUD CRACKED. A NEW MATERIAL SHOULD BE USED FOR THE SPRAY SHROUD. (K) 1 G 7 1 3U 3 U H2SW E1GL 2004091400178 20040914 00178 2004 9 14 QH52004F00000 4 20040514 G 2210 AC66375 HOUSING BBAVIA 7 7AC 2110102 SW SERVO ACTUATOR CRACKED B QH5R O OTHER O OTHER NR NOT REPORTED 1 NM 07 3060 7AC6649 THIS PART WAS TESTED IAW MFG 65-40-03. CRACKED LOCATED AT THE OIL GALLERY. 1 H 7 1 3O A759 2007010800136 20070108 00136 GL 2007 1 8 QKPR06008 1 20040513 G 4930 38828406 FCU HONEYWELL GTCT36150RR DOUG A4D A4D GL APU LEAKING B QKPR O OTHER O OTHER NR NOT REPORTED 1 SO 05 FUEL PRESSURE IN THE DIFFERENTIAL PRESSURE VALVE IS CAUSING SEVERE PITTING INSIDE THE FCU HOUSING. THIS PITTING EVENTUA LLY BECOMES A PIN HOLE IN THE HOUSING. THIS PIN HOLE ALLOWS A STREAM OF FUEL, AT IDLE AND WHEN PRESSURE IS APPLIED, TO EXIT THE FCU. POTENTIALLY, IF THIS PROBLEM IS NOT CORRECTED IT COULD CREATE A FIRE HAZARD. * REMOVE AIRCRAFT INFORMATIO N. 2 L 7 1 4R RT A1GL 2004050600027 20040506 00027 CE 2004 5 6 RAFAR182 1 20040311 G 5540 22601145 TORQUE TUBE CESSNA CESSNA 182 R182 2072734 CE ZONE 100 DETACHED D A UNSCHED LANDING O OTHER CR CRUISE 1 SO 09 736ZX 5075 R18200813 LT RUDDER BAR TORQUE TUBE ASSEMBLY, PN 2260114-5 FAILURE. FAILURE OCCURRED IN FLIGHT RESULTING IN LT SIDE PILOT'S TOTAL LOSS OF LT RUDDER AND STEERING CONTROL. NATURE OF FAILURE; LT OB RUDDER PEDAL SOCKET ON TORQUE TUBE BROKE AWAY FROM THE TORQUE TUBE. THERE IS NO OBVIOUS REASON WHY THIS MIGHT HAVE HAPPENED. THERE ARE NO BENT OR DAMAGED COMPONENTS WITHIN THE SAME SYSTEM, AND THE STEEL TORQUE TUBE HAS ONLY VERY LIGHT INTERNAL CORROSION. 1 H 7 1 3O RT 3A13 2004102600116 20041026 00116 CE 2004 10 26 RO12004F00000 1 20041004 G 2420 BRUSHES CESSNA CESSNA 172 172S 2072439 CE ALTERNATOR MISINSTALLED D O OTHER O OTHER NR NOT REPORTED 1 NM 01 3555L 640 A128904 172S8865 THIS IS THE 3RD OCCURRENCE OF ALTERNATOR FAILURE IN NEW MFG ALTERNATORS. EACH TIME ONE OF THE FIELD BRUSHES WAS FOUND I NSTALLED WITH THE WIRE TOWARD THE SLIP RING (BACKWARDS). THIS IS THE 2ND M AND D REPORT SUBMITTED REGARDING THIS SAME I NCIDENT. NEED TO INFORM MFG OF SITUATION. 1 H 7 1 3O NT 3A12 2004022700083 20040227 00083 SW 2004 2 27 ROSENBERG 1 20040123 G 3240 MILH5606 FLUID MOONEY M20 M20R 5870225 SW CONT O550 IO550* SO BRAKE SYSTEM SOLIDIFIED B K NONE O OTHER IN INSP/MAINT 1 EA 25 108MB 947 290008 DURING ANNUAL INSPECTION IT WAS NOTED THAT THE AIRCRAFT WAS VERY HARD TO TAXI. TOOK HIGH RPM'S TO GET AIRCRAFT TO MOVE A ND PULLED TO THE RIGHT. CHECKED BRAKES. FOUND BRAKE FLUID IN WHEEL CYLINDER HAD TURNED TO CONSISTENCY OF HONEY. OWNER H AD NOT GRIPPED ANY BRAKE PROBLEM ON GRIP LIST, AND WHEN CONTACTED, SAID HE HAD NO PROBLEMS WHEN LAST FLOWN. THE BRAKE PE DALS TOOK VERY HARD FOOT PRESSURE TO PUSH FLUID THROUGH WHEN BLEEDING OUT BAD FLUID. THE AIRCRAFT IS 10 YEARS OLD AND I T IS BELIEVED TO BE ORIGINAL FLUID. 1 L 7 1 3O 3 O RT 2A3 E3SO 2004091400166 20040914 00166 SO 2004 9 14 RX8R2004001 1 20040521 G 1430 AN3H7A BOLT PIPER PIPER PA42 PA42720 7104212 SO PWA PT6 PT6A61 52043 EA HARTZL HCB3T HCB3TN3 GL ZONE 700 SHEARED B RX8R O OTHER O OTHER TX TAXI/GRND HDL 1 SO 15 9142B 425501038 PCE99080 BU16835 WHILE TAXIING AFTER LANDING, THE PILOT DISCOVERED THE AIRCRAFT WOULD NOT TURN TIGHT. AFTER EXAMINATION, IT WAS FOUND TH E (3) AN-3 BOLTS THAT SECURE THE NOSE STEERING LINKAGE TO THE TOP OF THE NOSE LANDING GEAR STRUT HAD SHEARED. FOUR OTHE R AIRCRAFT WERE EXAMINED AND ONE AIRCRAFT WAS FOUND TO HAVE ONE BOLT STRIPPED OUT. WE RECOMMEND THESE BOLTS BE CHECKED O NCE A YEAR FOR TORQUE. 1 L 7 2 4T 4 T A23SO E4EA 6 C P15EA 2004120900111 20041209 00111 SO 2004 12 9 RX8R2004002 1 20041203 G 3213 5768007 STRUT PIPER PA42 PA42720 7104212 SO PWA PT6 PT6A61 52043 EA HARTZL HCB3T HCB3TN3 GL ZONE 700 CRACKED B RX8R O OTHER O OTHER NR NOT REPORTED 1 SO 15 9116Q 6423 65 425501037 PCE99073 BUA27501 RIGHT MAIN LANDING GEAR STRUT CRACKED AT ATTACH POINT TO ACTUATING BRACE. CRACK IS 2.5 INCHES LONG ALONG AFT SIDE OF AF T ATTACH POINT LUG. CRACK IS AT SAME LOCATION THAT GETS INSPECTED IAW PIPER SERVICE BULLETIN 969. AREA WAS INSPECTED P ER SB 65.2 HRS. AGO, USING DYE PENETRANT. THERE WAS NO CRACK AT THAT TIME. 1 L 7 2 4T 4 T A23SO E4EA 6 C P15EA 2004100100069 20041001 00069 SO 2004 10 1 SD92004F00000 1 20040809 G 7120 8936102 MOUNT PIPER PA44 PA44180 7104402 SO RT ENGINE BROKEN D O OTHER O OTHER NR NOT REPORTED 1 SW 15 53395 2918 4496076 ENGINE MOUNT TUBE BROKEN BELOW RT ISOLATOR. DISCOVERED DURING 100 HOUR INSPECTION. 1 L 7 2 3O A19S0 2004072100058 20040721 00058 NE 2004 7 21 SEA04LA125 2 20040715 G 8530 CYLINDER SCWZER G164 G164B 3952802 EA PWA R1340 R134059 52016 NE ENGINE CRACKED G TZKG A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 NM 11 7502Y 696 821B 19771 CYLINDER SEPARATED BETWEEN 2ND AND 3RD HORIZONTAL FINS THROUGH THE SPARK PLUG BOSS. ENGINE LOST POWER AND THE AIRCRAFT NOSED OVER ON EMERGENCY LANDING CAUSING SUBSTANTIAL DAMAGE. THIS CYLINDER HAD BEE OVERHAULED THREE PREVIOUS TIMES. 1 Q 7 1 3R 3 R 1A16 5E2 2004050600035 20040506 00035 CE 2004 5 6 SO1450 1 20040322 G 2710 05232182 ROD CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA AILERONS BENT C C ABORTED TAKEOFF F FLT CONT AFFECTED TX TAXI/GRND HDL 1 SO 05 7275G 1898 20 17280788 L2848551A DURING PREFLIGHT, PILOT FOUND LT AILERON CONTROL ROD BENT AT AILERON SURFACE. AIRCRAFT GROUNDED AND TAKEN TO MAINTENANCE . REMOVED LT AILERON CONTROL ROD AND FOUND IT TO BE BENT APPROXIMATELY 25 DEGREES JUST AFT OF AFT ROD END BEARING. REPLA CED WITH NEW ROD. 1 H 7 1 3O 3 O NT 3A12 1E10 2004071200160 20040712 00160 CE 2004 7 12 SO1550 1 20040610 G 5531 053100695 RIB CESSNA 172 172N 2072434 CE VERTICAL STAB CRACKED D O OTHER E VIBRATION/BUFFET LD LANDING 1 SO 05 1951F 3420 17273041 DURING HIDDEN DAMAGE INSPECTION AFTER BIRDSTRIKE ON VERTICAL STABILIZER LEADING EDGE, FOUND FORMING RIB ASSY CRACKED. RE PLACED WITH NEW PART. 1 H 7 1 3O NT 3A12 2004030300184 20040303 00184 NM 2004 3 3 SROM200400001 1 20040217 G 3397 WIRE BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE EMERGENCY LIGHT DAMAGED C SROM K NONE L NO TEST IN INSP/MAINT 1 AL 03 736BP 6 23465 AFT LEFT EMERGENCY EXIT LIGHT UNDER FA JUMP SEAT INOPERATIVE. REPAIRED WIRE TO LIGHT ASSEMBLY. LIGHT OPS NORMAL WITH E MERGENCY LIGHTS TURNED ON. 2 L 7 2 4F 4 F RT A16WE E2EA 2004030300185 20040303 00185 NM 2004 3 3 SROM200400002 1 20040220 G 5310 655495616 SHEAR TIE BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE FUSELAGE DAMAGED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND ELONGATED HOLE IN SHEAR TIE AT STA 500 BETWEEN STR 16R AND 17R, FORWARD UPPER HOLE. REM OVED DAMAGED SHEAR TIE. FABRICATED AND INSTALLED REPLACEMENT SHEAR TIE IAW B737 SRM 53-10-4. 2 L 7 2 4F 4 F RT A16WE E2EA 2004030400028 20040304 00028 NM 2004 3 4 SROM200400003 1 20040223 G 5310 654652548 SHEAR TIE BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE FUSELAGE DAMAGED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND SHEAR TIE AT STA 380 BETWEEN STR 20R AND 21R HAS HOLES THAT ARE LARGER THEN SRM LIMITS. REMOVED DAMAGED SHEAR TIE, FABRICATED AND INSTALLED REPLACEMENT SHEAR TIE IAW B737 SRM 51-40-3. 2 L 7 2 4F 4 F RT A16WE E2EA 2004030400029 20040304 00029 NM 2004 3 4 SROM200400004 1 20040224 G 5340 6935352U14 STRINGER CLIP BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE FUSELAGE CRACKED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND CRACKED STRINGER CLIP AT STA 639, STR 4L. REMOVED DAMAGED CLIP, ORDERED AND INSTALLED N EW CLIP IAW B737 SRM 51-30-2 2 L 7 2 4F 4 F RT A16WE E2EA 2004030400030 20040304 00030 NM 2004 3 4 SROM200400005 1 20040223 G 5340 6935352U14 STRINGER CLIP BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE FUSELAGE CRACKED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND CRACKED STRINGER CLIP AT STA 639, STR 4R. REMOVED DAMAGED CLIP, ORDERED AND INSTALLED N EW STRINGER CLIP IAW B737 SRM 51-30-2. 2 L 7 2 4F 4 F RT A16WE E2EA 2004030400031 20040304 00031 NM 2004 3 4 SROM200400006 1 20040223 G 5340 6935352U14 STRINGER CLIP BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE FUSELAGE CRACKED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND CRACKED STRINGER CLIP AT STA 616, STA 4L. REMOVED DAMAGED CLIP, ORDERED AND INSTALLED N EW STRINGER CLIP IAW B737 SRM 51-30-2 2 L 7 2 4F 4 F RT A16WE E2EA 2004030400104 20040304 00104 NM 2004 3 4 SROM200400007 1 20040225 G 5311 6546519540 FRAME BOEING 737 737205 1384456 NM APU BAY CORRODED A SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND NON-CPCP CORROSION ON LOWER T-CHORD IN APU CAVITY RT BULKHEAD AT STA 1120-1130. REMOVED DAMAGED T-CHORD, ORDERED AND INSTALLED NEW T-CHORD IAW SRM 51-30-2. 2 L 7 2 4F RT A16WE 2004030400105 20040304 00105 NM 2004 3 4 SROM200400008 1 20040225 G 5310 654654851 SHEAR TIE BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 CRACKED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND AT STA 747 SHEAR TIE CRACKED AT FASTNER HOLE BETWEEN STR 20L AND 21L. REMOVED DAMAGE, F ABRICATED AND INSTALLED REPAIR SHEAR TIE IAW SRM 53-10-4. 2 L 7 2 4F 4 F RT A16WE E2EA 2004030400106 20040304 00106 NM 2004 3 4 SROM200400009 1 20040225 G 5513 654577428 STRINGER BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 ELONGATED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND AFT CARGO PIT STRINGER 20L HAS SEVERAL ELONGATED FASTNER HOLES AND MULTIPLE CRACK INDICA TIONS AROUND HOLES STA 747 TO 887. REMOVED DAMAGE, FABRICATED AND INSTALLED REPAIR STRINGER AND SPLICES IAW SRM 53-10-3 . 2 L 7 2 4F 4 F RT A16WE E2EA 2004030400107 20040304 00107 NM 2004 3 4 SROM200400010 1 20040226 G 5340 69353521 STRINGER CLIP BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 CRACKED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND STRINGER TO FRAME CLIP CRACKED AT STA 495-500, STR 24R. REMOVED DAMAGED STRINGER CLIP, FABRICATED AND INSTALLED REPLACEMENT STRINGER CLIP IAW B737 SRM 51-20-1, 51-30-2. 2 L 7 2 4F 4 F RT A16WE E2EA 2004030400108 20040304 00108 NM 2004 3 4 SROM200400011 1 20040226 G 5330 65479576 SKIN BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 CORRODED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND AFT PIT STA 807 LOWER FORWARD CARGO CUTOUT HAS NON-CPCP CORROSION. REMOVED DAMAGE FABRI CATED AND INSTALLED REPAIR DOUBLER IAW 53-10-1, 51-40-3 AND 51-30-2. 2 L 7 2 4F 4 F RT A16WE E2EA 2004030400109 20040304 00109 NM 2004 3 4 SROM200400012 1 20040226 G 5310 654652510 SHEAR TIE BOEING 737 737205 1384456 NM ZONE 100 OVERSIZED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND SHEAR TIE AT STA 380 BETWEEN STR 19R AND 20R HAS HOLES THAT ARE LARGER THEN SRM LIMITS. REMOVED DAMAGED SHEAR TIE, FABRICATED REPLACEMENT SHEAR TIE IAW SRM 53-10-4. 2 L 7 2 4F RT A16WE 2004030400110 20040304 00110 NM 2004 3 4 SROM200400014 1 20040226 G 5310 693741210 SHEAR TIE BOEING 737 737205 1384456 NM ZONE 200 ELONGATED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND ELONGATED HOLE IN SHEAR TIE AT STA 400 BETWEEN STR 14R AND 15R AT UPPER HOLE. REMOVED D AMAGE, FABRICATED AND INSTALLED REPLACEMENT SHEAR TIE AND REPAIR DOUBLER IAW SRM 53-10-4. 2 L 7 2 4F RT A16WE 2004030400111 20040304 00111 NM 2004 3 4 SROM200400015 1 20040226 G 5313 654577835 STRINGER BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 ELONGATED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND AFT CARGO PIT STRINGER 21R HAC ELONGATED HOLE STA 927. REMOVED DAMAGE, FABRICATED AND I NSTALLED REPAIR FILLER CHANNEL SRM 53-10-3. 2 L 7 2 4F 4 F RT A16WE E2EA 2004042900029 20040429 00029 NM 2004 4 29 SROM200400016 1 20040302 G 5313 6545800124 STRINGER BOEING 737 737205 1384456 NM ZONE 100 CORRODED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND E AND E COMPARTMENT LOWER LOBE INTERIOR HAS CORROSION IN STR 28L BETWEEN STA 316 AND 328 . REMOVED DAMAGED STRINGER CHANNEL, ORDERED AND INSTALLED NEW STRINGER SECTION IAW MFG SRM 51-30-12. CPCP LEVEL 1 FIND ING. 2 L 7 2 4F RT A16WE 2004042900030 20040429 00030 NM 2004 4 29 SROM200400017 1 20040302 G 5342 6549857503 ATTACH FITTING BOEING 737 737205 1384456 NM ZONE 300 GOUGED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 23466 DURING D CHECK INSPECTION FOUND LT HORZ. STAB T/E I/B ATTACH FITTING HAS SMALL GOUGES. BLENDED AREA, REMOVED DAMAGE, FL AP PEENED, TREATED AND PRIMED IAW ASA EA 5510-01186 AND AAR EA 10289. 2 L 7 2 4F RT A16WE 2004042900031 20040429 00031 NM 2004 4 29 SROM200400018 1 20040302 G 5313 654576814 STRINGER BOEING 737 737205 1384456 NM ZONE 100 OVERSIZED I SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND STR 20R BETWEEN STA 360 AND 400 HAS HOLES THAT ARE LARGER THAN SRM LIMITS. REMOVED DAMA GED STRINGER, FABRICATED AND INSTALLED REPLACEMENT STRINGER IAW B737 SRM 51-30-2. 2 L 7 2 4F RT A16WE 2004050600040 20040506 00040 NM 2004 5 6 SROM200400019 1 20040308 G 5330 165457771 SKIN BOEING 737 737205 1384456 NM ZONE 200 DENTED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 1703 23466 DURING D CHECK INSPECTION REQUESTED REMOVAL OF EXTERNAL DOUBLER FROM SKIN STA 970 TO 1016 LT STR 10L TO 14L. RE-EVALUTE D SKIN FOR DAMAGE. REMOVED AND REPLACED SKIN IAW B737 SRM 51-30-2 STA 970 TO 1016 STR 10L TO 14L. 2 L 7 2 4F RT A16WE 2004050600041 20040506 00041 NM 2004 5 6 SROM200400020 1 20040310 G 5313 6935352 STRINGER CLIP BOEING 737 737205 1384456 NM ZONE 100 ELONGATED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND STINGER CLIP STA 495 STR 22R HAS A DAMAGED HOLE. REMOVED DAMAGED CLIP, FABRICATED AND I NSTALLED REPLACEMENT CLIP IAW B737 SRM 51-31-5. 2 L 7 2 4F RT A16WE 2004051300028 20040513 00028 NM 2004 5 13 SROM200400021 1 20040312 G 5313 6545768103 STRINGER BOEING 737 737205 1384456 NM ZONE 100 GOUGED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND STR 19R STA 360 - 440 HAS DAMAGE FROM EXISTING REPAIR (GOUGED). REMOVED DAMAGE STRINGER SECTION, FABRICATED AND INSTALLED REPLACEMENT STRINGER IAW SRM 51-30-5. 2 L 7 2 4F RT A16WE 2004051300029 20040513 00029 NM 2004 5 13 SROM200400022 1 20040314 G 5311 654652353 FRAME BOEING 737 737205 1384456 NM ZONE 200 GOUGED A SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND GOUGES ON FORWARD SIDE OF FRAME STA 1104 BETWEEN 2ND AND 3RD STR UP FROM APU COMPARTMENT RT WEB. REMOVED DAMAGE, FABRICATED AND INSTALLED REPAIR DOUBLER IAW SRM 51-40-3. 2 L 7 2 4F RT A16WE 2004051300030 20040513 00030 NM 2004 5 13 SROM200400023 1 20040314 G 5320 6546585564 WEB BOEING 737 737205 1384456 NM ZONE 100 BENT C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND HORIZONTAL WEB ABOVE APU BENT AT STA 1138. REMOVED DAMAGE, FABRICATED AND INSTALLED REP AIR DOUBLER IAW SRM 51-40-2. 2 L 7 2 4F RT A16WE 2004051300031 20040513 00031 NM 2004 5 13 SROM200400024 1 20040314 G 5330 65457789 SKIN BOEING 737 737205 1384456 NM ZONE 200 OUT OF LIMITS C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND SKIN DOUBLER AT STA 1006 BETWEEN STR 11R AND 12R DOES NOT MEET SRM REQUIREMENTS. REMOVE D SKIN DOUBLER, FABRICATED AND INSTALLED REPLACEMENT SKIN IAW B737 SRM 51-20-1. 2 L 7 2 4F RT A16WE 2004051300032 20040513 00032 NM 2004 5 13 SROM200400025 1 20040314 G 5330 6545771 SKIN BOEING 737 737205 1384456 NM ZONE 100 DENTED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND DENT STA 400 BETWEEN STR 19L & 20L LESS THEN 3 INCHES FROM LAP RIVET AREA IS BEYOND LIMI TS IAW SRM 53-30-1 FIG 1 DETAIL 3. REF SAD LOG 4465763 BEYOND LIMITS DUE TO CHANGE IN SRM WHICH INCLUDED PROXIMITY TO S EAM AND CUTOUT. REMOVED DAMAGE FABRICATED AND INSTALLED REPAIR FILLERS, DOUBLER AND TRIPLER IAW SRM 53-30-3. 2 L 7 2 4F RT A16WE 2004050700008 20040507 00008 NM 2004 5 7 SROM200400027 1 20040315 G 5313 654576822 STRINGER BOEING 737 737205 1384456 NM ZONE 100 BENT C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND STR 24R BENT BETWEEN STA 420 AND 440. REMOVED DAMMAGED SECTION OF STR 24R, FABRICATED A ND INSTALLED REPAIR ANGLE IAW B737 SRM 53-10-3. 2 L 7 2 4F RT A16WE 2004050700009 20040507 00009 NM 2004 5 7 SROM200400028 1 20040315 G 5242 6545830120 SKIN BOEING 737 737205 1384456 NM ZONE 800 CORRODED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 1703 23466 DURING D CHECK INSPECTION EEC DOOR EXTERIOR SKIN HAS LIGHT CORROSION AND BARE METAL. REMOVED DAMAGED SKIN, FABRICATED A ND INSTALLED REPLACEMENT SKIN IAW SRM 51-30-2 AND MFG DRAWING NR 65-45830. 2 L 7 2 4F RT A16WE 2004042900040 20040429 00040 NM 2004 4 29 SROM200400032 1 20040325 G 5511 6553746753 RIB BOEING 737 737205 1384456 NM ZONE 300 CRACKED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND LT HORIZONTAL STABILIZER LOWER SINGLE LEG ATTACH RIB FORWARD OF AFT SPAR, CRACKED. REM OVED RIB, FABRICATED AND INSTALLED REPLACEMENT RIB IAW B737 SRM 51-20-1, 51-30-5. STAB STA 67.54 - 69. 2 L 7 2 4F RT A16WE 2004042900041 20040429 00041 NM 2004 4 29 SROM200400033 1 20040325 G 5330 65C80736834 SKIN BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 DENTED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 1703 23466 DURING D CHECK INSPECTION C/W 069 LOG 4755642 REPLACE SKIN PANEL BS 908 - 1016 STR 20L TO 25L. REMOVED SKIN PANEL, RECE IVED AND INSTALLED NEW SKIN PANEL IAW MFG SRM 51-30-2. 2 L 7 2 4F 4 F RT A16WE E2EA 2004042900042 20040429 00042 NM 2004 4 29 SROM200400034 1 20040328 G 5330 DOUBLER BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 DENTED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 1703 23466 DURING D CHECK INSPECTION FOUND DENT AT STA 338 TO 344 JUST BELOW FWD AIRSTAIR DOOR CUTOUT BEYOND LIMITS IAW SRM 53-30-1 FIG 1 DETAIL 3. REF. SAD LOG 0176053 BEYOND LIMITS DUE TO CHANGES TO SRM INCLUDING PROXIMITY TO CUTOUTS AND SEAMS. RE MOVED DAMAGED DOUBLER, FABRICATED AND INSTALLED REPLACEMENT REPAIR DOUBLER IAW ASA EA 5310-02327 AND AAR 10300. 2 L 7 2 4F 4 F RT A16WE E2EA 2004050300188 20040503 00188 NM 2004 5 3 SROM200400035 1 20040401 G 5330 OO72040400 SKIN BOEING 737 737205 1384456 NM ZONE 100 DENTED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION C/W 061 LOG 4755634 REPLACE SKIN PANEL BS 173 - 259 STR 19R - 24R. REMOVED AND REPLACED SKIN PANEL IAW B737 SRM 51-30-2. SKIN REPLACE TO ELIMINATE PREVIOUS DENT REPAIRS. 2 L 7 2 4F RT A16WE 2004050300189 20040503 00189 NM 2004 5 3 SROM200400036 1 20040401 G 5330 0072040410 SKIN BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 DENTED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION C/W 062 LOG 4753635 REPLACE SKIN PANEL BS 360 - 540 STR 14R - 19R. REMOVED AND REPLACED SKIN PANEL IAW B737 SRM 51-30-2. REPLACED TO ELIMINATE PREVIOUS REPAIRS DUE TO DENTS. 2 L 7 2 4F 4 F RT A16WE E2EA 2004050300190 20040503 00190 NM 2004 5 3 SROM200400037 1 20040401 G 5330 65C80736824 SKIN BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 DENTED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION C/W 063 LOG 4755636 REPLACE SKIN PANEL BS 360 - 540 STR 19R - 25R. REMOVED AND REPLACED SKIN P ANEL IAW B737 SRM 51-30-2. SIN REPLACED TO ELIMINATE PREVIOUS REPAIRS FOR DENTS. 2 L 7 2 4F 4 F RT A16WE E2EA 2004050300191 20040503 00191 NM 2004 5 3 SROM200400038 1 20040401 G 5330 65C3584336 SKIN BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 DENTED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION C/W 064 LOG 4755637 REPLACE SKIN PANEL BS 727 - 968 STR 14R - 20R. REMOVED AND REPLACED SKIN PANEL IAW B737 SRM 51-30-2. PANEL REPLACED TO ELIMINATE PREVIOUS REPAIRS FOR DENTS. 2 L 7 2 4F 4 F RT A16WE E2EA 2004050300192 20040503 00192 NM 2004 5 3 SROM200400039 1 20040401 G 5330 0072040404 SKIN BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 DENTED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION C/W 065 LOG 4755638 REPLACE SKIN PANEL BS 727 - 908 STR 20R - 25R. REMOVED AND REPLACED SKIN PANEL IAW B737 SRM 51-30-2. PANEL REPLACED TO ELIMINATE PREVIOUS REPAIRS DUE TO DENTS. 2 L 7 2 4F 4 F RT A16WE E2EA 2004050300193 20040503 00193 NM 2004 5 3 SROM200400040 1 20040401 G 5330 65C80736850 SKIN BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 DENTED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION C/W 066 LOG 4755639 REPLACED SKIN PANEL MFG 908 STR 20L TO 25L. REMOVED AND REPLACED SKIN IAW MFG SRM 51-30-2. PANEL REPLACED TO ELIMINATE PREVIOUS REPAIRS DUE TO DENTS. 2 L 7 2 4F 4 F RT A16WE E2EA 2004050300194 20040503 00194 NM 2004 5 3 SROM200400041 1 20040401 G 5330 65C36745116 SKIN BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 DENTED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION C/W 067 LOG 4755640 REPLACE SKIN PANEL BS 908 - 1016 STR 20R - 25R. REMOVED AND REPLACED SKIN PANEL IAW B737 SRM 51-30-2. PANEL REPLACED TO ELIMINATE PREVIOUS REPAIRS DUE TO DENTS. 2 L 7 2 4F 4 F RT A16WE E2EA 2004050300195 20040503 00195 NM 2004 5 3 SROM200400042 1 20040401 G 5330 6545800Y135 SKIN BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 DENTED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION C/W LOG 4755645 REPLACE SKIN PANEL BS 178-259 STR 24R - BLO. REMOVED AND REPLACED SKIN PANEL IAW B737 SRM 51-30-2. PANEL REPLACED TO ELIMINATE PREVIOUS REPAIRS DUE TO DENTS. 2 L 7 2 4F 4 F RT A16WE E2EA 2004050300196 20040503 00196 NM 2004 5 3 SROM200400043 1 20040331 G 5743 658276415 SUPPORT BEAM BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE MLG CORRODED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 4514 23466 DURING D CHECK INSPECTION LT MLG SUPPORT BEAM HAS CORROSION IN OB ATTACH HOLE IN BETWEEN BUSHINGS. REMOVED BUSHINGS AND CORROSION. INSPECTED AND INSTALLED REPLACEMENT BUSHINGS IAW MFG EA 5750-01939 AND EA 10537. MINOR REPAIR. 2 L 7 2 4F 4 F RT A16WE E2EA 2004050300197 20040503 00197 NM 2004 5 3 SROM200400044 1 20040331 G 5330 6545775 BEAR STRAP BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE FUSELAGE BROKEN C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION BEAR STRAP HAS A HOLE BROKE FROM EDGE (NO E/D) STA 767, STR 18R. TRIMMED DAMAGE, FABRICATED A ND INSTALLED REPAIR FILLER IAW MFG EA. 5330-01764 AND MFG EA 10311. 2 L 7 2 4F 4 F RT A16WE E2EA 2004050300140 20040503 00140 NM 2004 5 3 SROM200400045 1 20040404 G 5315 65C3453711 FLOORBEAM BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 DAMAGED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION STA 651 FLOORBEAM, BL O REPAIR ANGLE HAS A FASTNER GIVING SHORTED ON P/N 65C34537-11 ANGLE. T RIMMED P/N 65C34537-11 ANGLE, FLAP PEENED, TREATED, PRIMED AND INSTALLED IAW ASA EA 5310-02318 AND AAR EA 10312. 2 L 7 2 4F 4 F RT A16WE E2EA 2004050600030 20040506 00030 NM 2004 5 6 SROM200400046 1 20040405 G 5740 6549488501 FITTING BOEING 737 737205 1384456 NM ZONE 500 CRACKED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 1703 23466 DURING D CHECK INSPECTION COMPLIED WITH EA 10324 AND ASA EA 5720-01237 (LT WING MLG SUPPORT BEAM FITTING INSPECTION AND REPLACEMENT, SB 737-57-1216 REV. 2) REMOVED AND REPLACED LT WING SUPPORT BEAM FITTING IAW ASA EA 5720-01237 AND AAR EA 10324. 2 L 7 2 4F RT A16WE 2004050600031 20040506 00031 NM 2004 5 6 SROM200400047 1 20040405 G 5711 654532414 SPAR BOEING 737 737205 1384456 NM ZONE 600 ELONGATED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 33963 23466 DURING D CHECK RT WING UPPER SPAR AND SPAR WEB HAS ELONGATED HOLES. REAMED HOLES, TRIMMED UPPER FOOTPRINT IAW ASA EA 57 20-01241 AND AAR EA 10336. 2 L 7 2 4F RT A16WE 2004050600032 20040506 00032 NM 2004 5 6 SROM200400048 1 20040405 G 5314 6545866U205 KEELBEAM BOEING 737 737205 1384456 NM FUSELAGE CRACKED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 1703 23466 DURING D CHECK INSPECTION TWO CRACKS FOUND ON KEELBEAM LOWER SKIN BETWEEN STA 660 AND 724 1 EA, 1.G INCH AND 1 EA. 1.25 INCH. REMOVED DAMAGE WEB, INSTALLED NEW WEB IAW B737 SRM 51-30-2. 2 L 7 2 4F RT A16WE 2004050600033 20040506 00033 NM 2004 5 6 SROM200400049 1 20040405 G 5740 6549488502 FITTING BOEING 737 737205 1384456 NM ZONE 600 CRACKED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 1703 23466 DURING D CHECK INSPECTION RT WING REAR SPAR TO MLG SUPPORT BEAM FITTING CRACKED AT IB UPPER CORNER. REMOVED DAMAGED MLG SUPPORT BEAM FITTING AND INSTALLED A NEW MLG SUPPORT BEAM FITTING IAW ASA EA 5720-01238 AND EA 10325. 2 L 7 2 4F RT A16WE 2004050300155 20040503 00155 NM 2004 5 3 SROM200400050 1 20040318 G 5330 6545775 BEAR STRAP BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE ZONE 100 DAMAGED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION, BEAR STRAP HAS A HOLE BROKEN FROM EDGE (NO E/D) AT STA 767 AND STR 18R. REMOVED DAMAGE, FAB RICATED AND INSTALLED REPAIR FILLER IAW ASA EA 5330-01764 AND AAR EA 10311. 2 L 7 2 4F 4 F RT A16WE E2EA 2004050300156 20040503 00156 NM 2004 5 3 SROM200400051 1 20040408 G 5330 654688259 SKIN BOEING 737 737205 1384456 NM PWA JT8 JT8D17 52049 NE FUSELAGE DENTED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 1703 23466 DURING D CHECK INSPECTION DENT IN SKIN STA 1147.5, 8.5 INCHES ABOVE S5. A=2 INCHES Y=.056 A/Y=35.7, BUT DUE TO PROXIM ITY OF CUTOUT FOR HORIZONTAL FITTING IT IS BEYOND LIMITS IAW SRM 53-30-1, FIG 1 NOTE K AND DETAIL 111. COMPLIED WITH HF EC. NO DEFECTS NOTED, COMPLIED WITH IAW ASA EA 5330-01757 AND AAR EA 10285. 2 L 7 2 4F 4 F RT A16WE E2EA 2004051300027 20040513 00027 2004 5 13 SROM200400052 4 20040411 G 2211 COMPUTER BOEING 737 737205 1384456 NM AUTOFLIGHT MALFUNCTIONED C SROM A UNSCHED LANDING O OTHER CL CLIMB 1 AL 03 733PA 23466 DURING POST D-CHECK FERRY FLIGHT, RETURNED TO DEPARTURE DUE TO AUTO PILOT CAPTURE LOC VERY SLUGGISH AND OVERSHOOTS DURIN G CORRECTION. WILL NOT CAPTURE GLIDE SLOPE. ALSO, RADIO ALTIMETER DH LIGHT COMES ON WHEN DH IS SET ABOVE 2500 FT AGL S TARTS INDICATING WHEN PASSING 600 FT, INDICATOR FLICKERS WILDLY UPON READING DH. DURING CLIMB BETWEEN 4000 AND 5000 RAD ALT FLAGG APPEARED BRIEFLY. 2 L 7 2 4F RT A16WE 2004051200019 20040512 00019 NM 2004 5 12 SROM200400053 1 20040410 G 5551 6552857 BUSHING BOEING 737 737205 1384456 NM HORIZONTAL STAB WORN C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33965 23466 DURING D CHECK INSPECTION RT HORIZONTAL STAB CENTER SECTION, AFT CENTER LUG FORWARD BUSHING FITTING WORN. REMOVED DAMAG E, INSTALLED REPAIR BUSHING IAW EA 5510-01191 AND AAR EA 10351. 2 L 7 2 4F RT A16WE 2004051200054 20040512 00054 NM 2004 5 12 SROM200400054 1 20040509 G 3350 20131A BATTERY PACK BOEING 737 737205 1384456 NM EMERGENCY LIGHT DISCHARGED C SROM K NONE L NO TEST IN INSP/MAINT 1 AL 03 736BP 6 23465 DURING PREFLIGHT INSPECTION EMERGENCY LIGHTS AT ROWS 10, 11, 15, 16 AND 18 INOPERATIVE. REPLACED BATTERY PACKS AT STATI ONS 753 LT AND 629 RT. OPS CHECK NORMAL. 2 L 7 2 4F RT A16WE 2005022200181 20050222 00181 NM 2005 2 22 SROM200400055 1 20040620 G 3350 20131A BATTERY PACK BOEING 737 737205 1384456 NM EMERGENCY LIGHT INOPERATIVE C SROM K NONE L NO TEST IN INSP/MAINT 1 AL 03 736BP 6 23465 L2 DOOR EMERGENCY LIGHT INOP. CHANGED OUT BATTERY PACK. OPS CHECKED GOOD. 2 L 7 2 4F RT A16WE 2005022200182 20050222 00182 NM 2005 2 22 SROM200400056 1 20040804 G 3350 30043231 LIGHT BOEING 737 737201 1384454 NM EXTERIOR CORRODED C SROM K NONE L NO TEST IN INSP/MAINT 1 AL 03 245US 3 22751 L2 DOOR EXTERIOR LIGHT INOP. REMOVED AND REPLACED L2 EXTERIOR EMERGENCY LIGHT IAW B737 M/M 33-51-61 - OPS CH'D GOOD. 2 L 7 2 4F A16WE 2004092000053 20040920 00053 NM 2004 9 20 SROM200400057 1 20040905 G 3350 582212 POWER SUPPLY BOEING 737 737205 1384456 NM PWA JT8 JT8D17A 52049 NE EMERGENCY LIGHT INOPERATIVE C SROM K NONE L NO TEST IN INSP/MAINT 1 AL 03 733PA 6 23466 R1 EMERGENCY EXIT SIGN INOPERATIVE. REMOVED AND REPLACED R-1 EMERGENCY EXIT SIGN BATTERY PACK. OPS CK GOOD IAW MM 33-5 1-00. 2 L 7 2 4F 4 F RT A16WE E2EA 2004111000033 20041110 00033 NM 2004 11 10 SROM200400058 1 20041104 G 2821 FUEL FILTER BOEING 737 737201 1384454 NM PWA JT8 JT8D17 52049 NE NR 2 ENGINE ICED C SROM A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 AL 03 245US 22751 DURING CRUISE NR 2 ENGINE FILTER ICING LIGHT CAME ON AND WOULD NOT CLEAR WITH FUEL HEAT. OTHER ENGINE PARAMETERS INDICA TE FUEL HEAT WAS OPERATIVE WITH ENGINE OPERATION NORMAL. UNEVENTFUL RETURN TO DEPARTURE AIRPORT. REMOVED AND REPLACED NR 2 ENGINE MAIN FUEL FILTER IAW WITH , MM 73-11-01 WITH GOOD ENGINE RUN. NOTE: REMOVED FILTER VISUALLY HAD SLIGHT AM OUNT OF DEBRIS PRESENT. 2 L 7 2 4F 4 F A16WE E2EA 2004122200138 20041222 00138 NM 2004 12 22 SROM200400059 1 20041203 G 2821 693733587 MODULE BOEING 737 737201 1384454 NM FUEL SYSTEM MALFUNCTIONED C SROM A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 AL 03 245US 22751 "NR 2 ENG FUEL FILTER ICING LIGHT ILLUMINATED INFLIGHT FL 320. FOLLOWED PROCEDURE LIGHT REMAINED ILLUMINATED. RETURNED TO ANC" THIS WAS A REPEAT WRITE-UP. CONTINUITY CHECK AND INSPECTION OF ALL ACCESSIBLE WIRING NORMAL. REPLACED FUEL M ODULE , (AFTER TESTING BY VENDOR) REPLACED FUEL PRESSURE SWITCH P/N 42D185 WITH NEW UNIT AND REPLACED FUEL PRESSURE SWIT CH CANNON PLUG WITH NEW. OPERATIONAL CHECK FLIGHT CONDUCTED WITH NO FAULTS OBSERVED. AIRCRAFT RETURNED TO SERVICE 12-1 0-04. 2 L 7 2 4F A16WE 2005030800187 20050308 00187 NM 2005 3 8 SROM200400060 1 20041221 G 5210 6990285 SEAL BOEING 737 737205 1384456 NM PAX DOOR TORN C SROM A UNSCHED LANDING O OTHER CL CLIMB 1 AL 03 733PA 814 23466 "AT FL 280 & 6PSID A LOUD HIGH PITCHED NOISE AND VIBRATION AT L1 DOOR. RETURNED TO ANC AND AS A/C DEPRESSURIZED THE NOI SE LESSENED BUT DID NOT GO AWAY" "INSPECTED FWD ENTRY DOOR IAW B737MM 52-11-0. ADJUSTED DOOR STOP PINS AND UPPER GATE DOOR IAW B737 MM 52-11-0, OPERATIONAL CHECK GOOD". DURING GROUND PRESSURIZATION CHECK ORIGINAL PROBLEM WAS DUPLICATED. FURTHER INSPECTION FOUND TEAR IN RUBBER SEAL OF THE HINGE FLAP ASSY LOCATED UNDER THE UPPER HINGE COVER. FURTHER GROUN D PRESSURE CHECK CONFIRMED THIS TO BE THE PROBLEM. REPLACED HINGE FLAP ASSY. 2 L 7 2 4F RT A16WE 2004050700010 20040507 00010 NM 2004 5 7 SROM20040029 1 20040318 G 5330 65457789 SKIN BOEING 737 737205 1384456 NM ZONE 100 DENTED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION DENT AT STA 479, 12 INCHES BELOW CARGO DOOR. EDGE OF DENT LESS THAN 3 INCHES FROM CLOSEST FAS TNERS IN LAP IAW SRM 53-30-1, FIG. 1 DETAIL 3, DENT IS BEYOND LIMITS. REF. SAD LOG NR 4600061. AREA IS NOW BEYOND LIMI TS DUE TO CHANGES IN SRM WHICH INCLUDE PROXIMITY TO CUTOUT, LAP SEAMS AND BUTT SPLICES. REMOVED DAMAGE, FABRICATED AND INSTALLED REPAIR DOUBLERS IAW ASA EA 5330-01766 AND AAR EA. 10304. 2 L 7 2 4F RT A16WE 2004050700011 20040507 00011 NM 2004 5 7 SROM20040030 1 20040318 G 5311 6545800 FRAME BOEING 737 737205 1384456 NM ZONE 100 DAMAGED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 7874 23466 DURING D CHECK INSPECTION FOUND LOSS OF E.D. AT HOLE ON STA 251 FRAME AND W/W LT HAND EDGE STRAP. REMOVED DAMAGED AREA, FABRICATED AND INSTALLED REPAIR FILLER IAW EA 5330-01765 AND E.A. 10340. 2 L 7 2 4F RT A16WE 2004051300036 20040513 00036 NM 2004 5 13 SROM20040031 1 20040323 G 5330 6552988473 SKIN BOEING 737 737205 1384456 NM ZONE 100 DENTED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 733PA 33963 1703 23466 DURING D CHECK INSPECTION C/W 068 LOG 4755641, REPLACE SKIN PANEL BS 908 - 1016, STR 14L - 20L. REMOVED SKIN, INSTALLED NEW SKIN PANEL IAW SRM 51-30-2. REPLACED AT CUSTOMER REQUEST DUE TO DENT. 2 L 7 2 4F RT A16WE 2004101800185 20041018 00185 EU 2004 10 18 SWISSFAA 1 20040805 G 5210 CANOPY PILATS P3 P305 7090101 EU HARTZL HCA3X HCA3X* GL COCKPIT BLOCKED Z O OTHER L NO TEST NR NOT REPORTED 1 SW 99 VARIOUS VARIOUS TO OUR KNOWLEDGE, AT LEAST 11 N-REGISTERED P-3 HAVE BEEN MODIFIED UNDER 337 FIRLD APPROVALS WITH A ONE-PIECE COCKPIT CAN OPY REPLACING THE MULTIPLE SHEET CANOPY INITIALLY INSTALLED. ON AN AIRCRAFT RETURNED TO SWITZERLAND AN UNSAFE CONDITION WAS DISCOVERED. THE EMERGENCY CANOPY JETTISON COULD NOT BE OPERATED SINCE THE MECHANISM WAS BLOCKED BY TWO RIVNUTS INST ALLED TO RETAIN THE NEW CANOPY. WE HAD THE FAULTY INSTALLATION MODIFIED TO MAKE IT WORK. WE LET YOU KNOW OF THIS DEFECT SINCE THERE ARE SOME MORE P-3S OPERATED UNDER FAA REGISTRY THAT MIGHT HAVE THE SAME UNSAFE CONDITION. 1 L 7 1 3O RT 5 C P913 2004051300038 20040513 00038 SO 2004 5 13 T0438 1 20040504 G 1100 DATA PLATE PIPER PA32 PA32R301T 7103220 SO LYC O540 TIO540* 41532 EA ENGINE DEPARTED B K NONE D INFLIGHT SEPARATION IN INSP/MAINT 1 SW 05 424PW 197 197 3257186 RL900561A ENGINE DATA PLATE RIVETS ARE BECOMING LOOSE CAUSING THE DATA PLATE TO SEPARATE FROM ENGINE. WE ARE SEEING THIS ON SEVERA L ENGINES. 1 L 7 1 3O 3 O A3SO E14EA 2004091500090 20040915 00090 EA 2004 9 15 TL9R200400001 1 20040611 G 3246 5010598 WHEEL CNDAIR CL600 CL600* EA ZONE 700 DAMAGED B TL9R K NONE O OTHER TX TAXI/GRND HDL 1 GL 13 REPORTED REMOVAL REASON WAS (BEARING FAILURE). BOTH WHEEL HALVES REJECTED DUE TO BEARING BORE DAMAGE. OPERATOR IS INVE STIGATING THE CAUSE. 2 L 7 2 4F RT A21EA 2004083000089 20040830 00089 EU 2004 8 30 TL9R200400002 1 20040724 G 3242 C20225310 BRAKE AIRBUS 320 A320233 3930329 EU NR 1 BINDING B TL9R K NONE O OTHER IN INSP/MAINT 1 GL 13 THE A320 NR 1 BRAKE WAS REMOVED AS WORN TO LIMITS. THERE WERE NO OPERATIONAL PROBLEMS OR UNUSUAL INDICATIONS LEADING UP TO THE REMOVAL. WHILE ATTEMPTING TO REMOVE THE NR 1 MAIN WHEEL TO FACILITATE REMOVAL OF THE BRAKE, IT WOULD NOT COME OF F AS THE BRAKE WAS JAMMED INTO THE WHEEL. THE WHEEL AND BRAKE WERE REMOVED AS ONE PIECE. BRAKE ROTOR DRIVE BLOCKS WERE DISCOVERED TO HAVE SEPARATED FROM THE ROTOR CAUSING THE WHEEL AND BRAKE TO BE JAMMED AGAINST EACH OTHER. 2 L 7 2 4F RT A28NM 2005022200040 20050222 00040 EU 2005 2 22 TXER095702 1 20040608 G 6320 C632A0201053 GEARBOX UROCOP EC120 EC120B 8680987 EU MAIN ROTOR MAKING METAL B TXER O OTHER O OTHER NR NOT REPORTED 1 SW 09 690WR 1265 1059 MAKING METAL. 1 G 7 2 3U NC R0001RD 2005022200041 20050222 00041 EU 2005 2 22 TXER095703 1 20040608 G 6320 C632A0101052 EPICYCLIC UROCOP EC120 EC120B 8680987 EU M/R GEARBOX MAKING METAL B TXER O OTHER O OTHER CR CRUISE 1 SW 09 690WR 1059 MAIN ROTOR GEARBOX EPICYCLIC MAKING METAL. 1 G 7 2 3U NC R0001RD 2005022200123 20050222 00123 EU 2005 2 22 TXER096384 1 20040713 G 6730 SC5072 SERVO AEROSP AS355 AS355* EU TAIL ROTOR BINDING B TXER O OTHER O OTHER NR NOT REPORTED 1 SW 09 151TA 4090 2601 TAIL ROTOR SERVO IS BINDING. 1 G 7 2 3U H11EU 2004112300003 20041123 00003 EU 2004 11 23 TXER097946 1 20041017 G 6400 365A33354300 FAIRING UROCOP EC155 EC155B 8681000 EU TAIL ROTOR CRACKED B TXER O OTHER O OTHER NR NOT REPORTED 1 SW 09 155EW 376 6660 TAIL ROTOR FAIRING CRACKED. 1 G 7 2 3U H10EU 2004090800028 20040908 00028 SO 2004 9 8 UXCR200400002 1 20040826 G 1410 LW18724 HOSE PIPER PA46 PA46350P 7104602 SO LYC O540 TIO540AE2A 41532 EA HARTZL HCI3Y HCI3YR2 GL FUEL SYSTEM FLAKING B A UNSCHED LANDING E VIBRATION/BUFFET CL CLIMB 1 SW 05 4128K 874 5 4636178 L1005261A HK325A DURING CLIMB TO ALTITUDE, THE ENGINE EXHIBITED A ROUGH RUNNING CONDITION THAT NECESSITATED A REDUCTION IN POWER REQUIRIN G AN UNSCHEDULED LANDING. INSPECTION OF THE ENGINE FUEL INJECTION SYSTEM REVEALED TWO OBSTRUCTED INJECTOR NOZZLES (NR 2 AND NR 4 CYLINDERS). UPON FURTHER INSPECTION, IT WAS DETERMINED THE UPPER DECK AIR MANIFOLD HOSES WERE FLAKING MATERIAL FROM THE INTERNAL WALL SURFACE SUFFICIENT IN SIZE TO OBSTRUCT THE INJECTOR ORIFICE. 1 L 7 1 3O 3 O RT A25SO E14EA 5 C P33EA 2004052500029 20040525 00029 GL 2004 5 25 W592004F00000 3 20040127 G 6110 C4513 SPACER CESSNA 150 A150L 2071828 CE CONT O200 O200A 17020 SO MCAULY 1A102 1A102OCM GL PROPELLER CRACKED B W59R O OTHER O OTHER NR NOT REPORTED 1 WP 07 9903G G13417 A1500456 G13417 PROPELLER SPACER WAS FOUND CRACKED FROM DOWEL PIN HOLES. ONE CRACK PROGRESSED COMPLETELY THROUGH SPACEER, THE SECOND WA S 90 PERCENT THROUGH SPACER. PROPELLER DOWEL PIN HOLES ARE ELONGATED AND OVERSIZE, PROPELLER WAS BENT SEVERELY AT ONE T IME AND IMPROPERY REPAIRED. ANGLES WERE WELL OUT OF SPEC, SOME AS MUCH AS 1 DEGREE. PROPELLER WAS OUT OF BALANCE TRACK AND ANGLES. SUSPECT SEVERE VIBRATION FROM PROPELLER OR PREVIOUS IMPACT DAMAGE CAUSED SPACER TO CRACK. PROPELLER AND S PACER ARE SCRAP. 1 H 7 1 3O 3 O 3A19 E252 5 N P918 2004060100012 20040601 00012 CE 2004 6 1 WK1 1 20040513 G 2121 50041 MOTOR BEECH 200 A200 1152921 CE CABIN FAILED G K7MA H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS TO TAKEOFF 1 WP 11 639B 73 BC67 SHORTLY AFTER TAKEOFF SMOKE WAS OBSERVED IN THE COCKPIT WITH ELECTRICAL ODOR. FORWARD CABIN VENT BLOWER WAS DISABLED AND THE SMOKE CLEARED. VENT BLOWER HAD FAILED INTERNALLY. 1 L 7 2 4T A24CE 2004022700086 20040227 00086 SW 2004 2 27 WYNBRANDT 1 20040202 G 3240 MILH5606 FLUID MOONEY M20 M20K 5870220 SW CONT O360 TSIO360* 17025 SO BRAKE SYS SOLIDIFIED B K NONE O OTHER IN INSP/MAINT 1 EA 25 963PM 2503 251158 DURING A ROUTINE OIL CHANGE IT WAS NOTED THAT THE AIRCRAFT TOOK VERY HIGH RPM TO TAXI. THE BRAKE FLUID IN THE WHEEL CYLI NDER HAD TURNED THE CONSISTENCY OF HONEY. THE FLUID WAS PURGED BY BLEEDING USING PEDALS PRESSURE TO MOVE FLUID OUT. THE BRAKE BLEEDERS HAD TO BE REMOVED TO GET FLUID TO FLOW. THIS IS THE SECOND AIRCRAFT WITHIN THE PAST 2 WEEKS WE HAVE FOUND THIS PROBLEM ON. THE TOTAL TIME ON THIS FLUID IS UNKNOWN, SINCE WE HAVE NOT MAINTAINED IT SINCE NEW AS WE DID THE OTHER AIRCRAFT WITH THE SAME PROBLEM. IT IS BELIEVED TO BE ORIGINAL. 1 L 7 1 3O 3 O 2A3 E9CE 2004030300102 20040303 00102 CE 2004 3 3 YK1R062001 1 20040227 G 4920 GTCP36150W APU RAYTHN DH125 HAWKER800XP 7150012 CE GARRTT TFE731 TFE7313R1H 29001 WP APU BAY FAILED B YK1R H E DEACTIVATE SYST/CIRCUITS ENGINE SHUTDOWN B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 SW 11 653XP 11 11 258653 DURING TAXI, SMOKE RAPIDLY FILLED THE COCKPIT AND THE CABIN. EMERGENCY SHUTDOWN OF ALL SYSTEMS WAS PERFORMED, GROUND EM ERGENCY DECLARED AND AIRCRAFT EVACUATED. IT WAS FOUND DUE TO FAILURE IN THE APU, OIL ENTERED THE BLEED AIR DUCT WHICH C AUSED THE SMOKE. SYSTEM IS IN TROUBLESHOOTING/TEARDOWN PROCESS. 2 L 7 2 4F 4 F RT A3EU E6WE 2004090100083 20040901 00083 NE 2004 9 1 Z1RA096970 1 20040823 G 7601 0177987070 TORQUE BOX SKRSKY S76 S76C 8143008 NE TMECA ARRIEL ARRIEL1S1 60030 NE ENGINE INTERMITTENT C Z1RA O OTHER S AFFECT SYSTEMS NR NOT REPORTED 1 SW 11 760AF 1890 760523 REPLACED TORQUE TRIM CONFORMATION BOX. NO FURTHER DEFECTS 1 G 7 2 3U 3 U NC H1NE E19EU 2005030800001 20050308 00001 2005 3 8 ZN3R200503A 2 20041001 G 7250 384001117 TURBINE WHEEL ENGINE DAMAGED B ZN3R O OTHER O OTHER NR NOT REPORTED 1 WP 07 TURBINE BLADES WERE FOUND VISUALLY VERY "THIN" IN THE TIP AREA AFTER OPERATION.