20030204001702003020400170GL 2003 2 4 00065074 320030114G6111A1851T BEARING BEECH 90 F90 1152909CE PWA PT6 PT6* 52043EA HARTZLHCB4T HCB4TN3 GL PROP BLADE CORRODED B EY2RK NONE O OTHER ININSP/MAINT 1 GL03 EAA1241 CORROSION ON PROPELLER BLADE BEARINGS. 1L72 4T3 T A31CE E2NE 6 CP40EA 20030204001712003020400171GL 2003 2 4 0065077 320030130G6114 HUB CESSNA208 208 2073702CE PWA PT6 PT6* 52043EA MCAULY3AF34C3GFR34C703 GL PROPELLER CORRODED B EY2RK NONE O OTHER ININSP/MAINT 1 GL03 902496 CORROSION ON PROPELLER HUB. 1H71 3T3 TNTA37CE E2NE 5 CP60GL 20030204001722003020400172GL 2003 2 4 0065202 320030120G6114C5152 COUNTERWEIGHT CESSNA208 208 2073702CE PWA PT6 PT6* 52043EA MCAULY3AF34C3GFR34C703 GL CORRODED B EY2RK NONE O OTHER ININSP/MAINT 1 GL03 9611156 CORRISON ON PROPELLER COUNTERWEIGHT. 1H71 3T3 TNTA37CE E2NE 5 CP60GL 20030204001742003020400174 2003 2 4 00665098 420030114G6122F421Z BEARING GOVERNOR CORRODED B EY2RK NONE O OTHER ININSP/MAINT 1 GL03 GOVERNOR HAS CORROSION ON BEARING. 20030409000272003040900027GL 2003 4 9 0074382 320030305G6110CO83867 CLAMP HARTZL PIPER J3 J3C* SO PWA PT6 PT6* 52043EA HARTZLHCB3T HCB3TN3 GL PROPELLER CORRODED B EY2RO OTHER O OTHER NRNOT REPORTED 1 GL03 BUA26954 BUA26954 CORROSION ON CLAMP ASSEMBLY. 1H71 3O3 T ATC660 E2NE 6 CP15EA 20030106000052003010600005CE 2003 1 6 010203 120030103G5510 RIB CESSNA206 U206C 2073332CE CONT O520 IO520F 17032SO MCAULY3A32C D3A32C90 GL HORIZONTAL STAB MISREPAIRED B K NONE W INADEQUATE Q C ININSP/MAINT 1 SW016506R8670 2012 U2060969 818948R 731126 HORIZONTAL STABILIZER WAS REPAIRED AT AIRCRAFT TOTAL TIME OF 6658.5. 6 EACH NEW AND IMPROVED NOSE RIBS WERE INSTALLED AND NUMEROUS RIVETS WERE NOT INSTALLED IN THE REPLACED RIBS. REFERENCE SERVICE NEWSLETTER NR 87-18R1. RIBS THAT WERE DETERMINED TO BE REPLACED ARE AT STATION 14.74 THRU 35.915 LT AND RT OF HORIZONTAL STABILIZER CENTER LINE. 1H71 3O3 O A4CE E5CE 5 CP21EA 20030204001802003020400180EA 2003 2 4 021081 220030109G8520 CRANKCASE PIPER PA60 PA60602P 7106015NM LYC O540 TIO540U2A 41532EA ENGINE CRACKED D EA ENGINE SHUTDOWN UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 SO056902T9831 455 608265046 RL23861A ON 28 DEC 2002, AEROSTAR N6902T LANDED AT OAJ WITH NR 2 (RT) ENGINE SHUTDOWN AND PROPELLERS FEATHERED. THE PILOT STATED THAT DURING FLIGHT, HE NOTICED A DROP IN OIL PRESSURE AND SHUTDOWN THE ENGINE. PRIOR TO SHUTDOWN, THE PILOT STATED THAT ALL OTHER INDICATIONS WERE NORMAL. UPON EXAMINATION OF THE ENGINE, A CRACK WAS FOUND BELOW THE NR 5 CYLINDER EXTENDING FORWARD TO BELOW THE NR 3 CYLINDER MIDWAY. THE LOWER PORTION OF THE CASE WERE THE NR 5 CYLINDER ATTACHED HAD SEPARTATED TO THE POINT WHERE THE LOWER MOUNTING HOLES WERE VISIBLE WITH THE CYLINDER STILL ATTACHED TO THE CASE. INTERNAL DAMAGE IS EXPECTED TO BE FOUND, BUT TO DATE HAS YET TO BE DETERMINED. 1M72 3O3 ORTA17WE E14EA 20030409000282003040900028NM 2003 4 9 021081F 120030325G27106000050507 CONTROL ROD PIPER PA60 PA60602P 7106015NM RT AILERON CORRODED D O OTHER O OTHER NRNOT REPORTED 1 SO056902 2437 RT AILERON PUSH PULL TUBE CORRODED SEVERELY. HOLE WORE THROUGH. LOCATED BEHIND ENGINE. RECOMMEND SPECIAL ATTENTION BE PAID TO THIS AREA DURING INSPECTIONS. 1M72 3O RTA17WE 20030204001892003020400189CE 2003 2 4 030130 120030129G57403910104001 FITTING HELIO H295 H295 4300802CE WING CRACKED B EVGRK NONE O OTHER ININSP/MAINT 1 SO3361JA 1286 UPPER WING ATTACH FITTING IS CRACKED. THE CRACKS APPEAR ON THE FACE OF THE FITTINGS THAT GO AGAINST THE SPAR CARRY THRU. IN SOME CASES THE CRACKS CAN BE DETECTED INSIDE THE BARREL NUT BORE. WE HAVE BEGUN CHECKING SPARE WINGS IN STORAGE AS WELL AS FLIGHT LINE AIRCRAFT. TO DATE WE HAVE FOUND 9 CRACKED FITTINGS. TIMES IN SERVICE RANGE FROM 5087 TO OVER 16,000 HOURS. CRACKS WILL OFTEN RUN PARALLEL TO THE AXIS OF THE BARREL NUT. SOME FITTINGS EXHIBIT A CIRCULAR BRINNELED AREA WHERE THE FITTING CONTACTS THE CARRY THRU. CRACKS CAN APPEAR IN THE CIRCUMFERENCE OF THE IMPRESSION OR RADIATE IN OR OUT FROM THE CIRCUMFERENCE OF THE IMPRESSION. SOMETIMES CORROSION IS PRESENT IN THE CRACK AREA. 1H71 3O 1A8 20030625000032003062500003SO 2003 6 25 03022601 120030227G2810A23D0475 SOLENOID PIPER PA31 PA31 7103102SO LYC O540 TIO540* 41532EA FUEL SYSTEM LEAKING C JIKRO OTHER K FLUID LOSS NRNOT REPORTED 1 WP019132Y257 31178 PILOT REPORTED A FUEL ODOR IN THE COCKPIT ON PREFLIGHT INSPECTION. MAINTENANCE INSPECTED THE COCKPIT AND COMBUSTION HEATER AREA IN THE RIGHT SIDE OF THE THE NOSE SECTION AND FOUND THE HEATER FUEL SHUT OFF SOLENOID LEAKING FUEL FROM THE CASE HOUSING. 1L72 3O3 O A20SO E14EA 20030409000292003040900029EA 2003 4 9 030327 220030327G7414AB357174 POINTS HELIO H295 H295 4300802CE LYC O480 GO480G1D6 41527EA MAGNETO LOOSE B EVGRK NONE O OTHER ININSP/MAINT 1 SO3361JA 232 1286 MAGNETO BREAKER ASSEMBLY HAS LOOSE CAM FOLLOWER. 1H71 3O3 O 1A8 E275 20030611000052003061100005CE 2003 6 11 030520 120030514G57403910104322 ATTACH FITTING HELIO H295 H295 4300802CE LT & RT WING ELONGATED B EVGRK NONE O OTHER ININSP/MAINT 1 SO33PKJAA 1436 REAR SPAR ATTACH FITTING BOLT HOLE IS ENLARGED ON BOTH WINGS. FITTINGS ARE BEING REPLACED. 1H71 3O 1A8 20030611000032003061100003CE 2003 6 11 030521 120030514G57403910104001 FITTING HELIO H295 H295 4300802CE WING CRACKED B EVGRK NONE O OTHER ININSP/MAINT 1 SO33PKJAA 1436 UPPER WING ATTACH FITTINGS ON BOTH WINGS ARE CRACKED. THE CRACKS APPEAR ON THE FACE OF THE LEFT FITTING AND THE INSIDE CORNER OF THE RIGHT FITTING, THE FACES OF WHICH GO AGAINST THE SPAR CARRY THRU. FRETTING IS PRESENT BETWEEN THE FITTING AND SPAR ON THE RIGHT WING. TO DATE WE HAVE FOUND 9 CRACKED FITTINGS OF 30 WINGS INSPECTED. TIMES IN SERVICE RANGE FROM 5087 TO OVER 16,000 HOURS. CRACKS WILL OFTEN RUN PARALLEL TO THE AXIS OF THE BARREL NUT. SOME FITTINGS EXHIBIT A CIRCULAR BRINNELED AREA WHERE THE FITTING CONTACTS THE CARRY THRU. CRACKS CAN APPEAR IN THE CIRCUMFERENCE OF THE IMPRESSION OR RADIATE IN OR OUT FROM THE CIRCUMFERENCE OF THE IMPRESSION. SOMETIMES CORROSION IS PRESENT IN THE CRACK AREA. 1H71 3O 1A8 20030912000752003091200075CE 2003 9 12 030815 120030815G57403910104001 ATTACH FITTING HELIO H295 H295 4300802CE LYC O480 GO480G1D6 41527EA WING CRACKED B EVGRK NONE O OTHER ININSP/MAINT 1 SO3360JA 1240 UPPER WING ATTACH FITTINGS ARE CRACKED. THE CRACKS APPEAR ON THE FACE OF THE FITTINGS THAT GO AGAINST THE SPAR CARRY THRU. IN SOME CASES THE CRACKS CAN BE DETECTED INSIDE THE BARREL NUT BORE. 3 OF THE 4 FITTINGS ON THIS PLANE ARE CRACKED. TIMES IN SERVICE RANGE FROM 5087 TO OVER 16,000 HOURS. CRACKS WILL OFTEN RUN PARALLEL TO THE AXIS OF THE BARREL NUT. SOME FITTINGS EXHIBIT A CIRCULAR BRINNELED AREA WHERE THE FITTING CONTACTS THE CARRY THRU. CRACKS CAN APPEAR IN THE CIRCUMFERENCE OF THE IMPRESSION OR RADIATE IN OR OUT FROM THE CIRCUMFERENCE OF THE IMPRESSION. SOMETIMES CORROSION IS PRESENT IN THE CRACK AREA. 1H71 3O3 O 1A8 E275 20031027001272003102700127CE 2003 10 27 030926A 120030925G2897 WIRE HARNESS CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE BOOST PUMP CHAFED B R8RRK NONE O OTHER ININSP/MAINT 1 WP076763L 5500673 DURING INTERNAL INSPECTION OF THE FUEL BAYS FOUND FUEL PUMP WIRING HARNESSES IN BOTH WINGS WERE DAMAGED BY CHAFFING THROUGH THE WIRING INSULATION. WIRING WAS CHAFFING AGAINST ALUMINUM FUEL LINES AND PUMP BODY INSIDE TANK. CHAFFING CAUSED WEAR BEYOND LIMITS TO ALUMINUM FUEL LINES. 1L72 4F4 F A22CE E1NE 20031027001282003102700128CE 2003 10 27 030926B 120030925G28971C712 WIRE HARNESS CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE FUEL PUMP CHAFED B R8RRK NONE O OTHER ININSP/MAINT 1 WP074614N 5500659 DURING INTERNAL INSPECTION OF THE FUEL BAYS FOUND FUEL PUMP WIRING HARNESSES IN RIGHT WING WAS DAMAGED BY CHAFFING THROUGH THE WIRING INSULATION. WIRING WAS CHAFFING AGAINST ALUMINUM FUEL LINE INSIDE TANK. CHAFFING CAUSED WEAR BEYOND LIMITS TO ALUMINUM FUEL LINE. LEFT WING FUEL PUMP HARNESS HAD BEEN CHAFFING FUEL LINE ALSO. HARNESS DID NOT HAVE DAMAGE BUT FUEL LINE WAS WORN BEYOND LIMITS. 1L72 4F4 F A22CE E1NE 20031027001292003102700129CE 2003 10 27 030926C 120030925G28971C712 WIRE HARNESS CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE FUEL PUMP CHAFED B R8RRK NONE O OTHER ININSP/MAINT 1 WP071200N 5500681 DURING INTERNAL INSPECTION OF THE FUEL BAYS FOUND FUEL PUMP WIRING HARNESSES IN RIGHT WING WAS DAMAGED BY CHAFFING THROUGH THE WIRING INSULATION TO BEAR WIRE. WIRING WAS CHAFFING AGAINST ALUMINUM FUEL LINE INSIDE TANK. CHAFFING CAUSED WEAR BEYOND LIMITS TO ALUMINUM FUEL LINE. LEFT WING FUEL PUMP HARNESS WAS NOT CHAFFING AGAINST ANY STRUCTURE OR TUBING. 1L72 4F4 F A22CE E1NE 20031027001302003102700130CE 2003 10 27 030926D 120030925G28971C712 WIRE HARNESS CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE FUEL PUMP CHAFED B R8RRK NONE O OTHER ININSP/MAINT 1 WP076775C 5500677 DURING INTERNAL INSPECTION OF THE FUEL BAYS FOUND FUEL PUMP WIRING HARNESSES IN RIGHT WING WAS DAMAGED BY CHAFFING THROUGH THE WIRING INSULATION. WIRING WAS CHAFFING AGAINST ALUMINUM FUEL LINE INSIDE TANK. CHAFFING CAUSED WEAR BEYOND LIMITS TO ALUMINUM FUEL LINE. LEFT WING FUEL PUMP HARNESS WAS CHAFFING ON MOTIVE FLOW ALUMINUM FUEL LINE AND BOTH HARNESS AND FUEL LINE WERE DAMAGED. 1L72 4F4 F A22CE E1NE 20030917000182003091700018SO 2003 9 17 031138 120030729G32206330000 CONTROL ARM PIPER PA28 PA28140 7102802SO NLG CRACKED D K NONE O OTHER ININSP/MAINT 1 SO052371T5119 73 287225056 FOUND NWS CONTROL BRACE CRACKED ON LT SIDE. CAUSE DETERMINED TO BE CORROSION ON THE INTERIOR OF THE CONTROL TUBE. UPON INSPECTION OF THE TUBE, FOUND CORROSION ALSO FORMED ON THE RT SIDE OF THE TUBE IN THE SAME LOCATION. ODDLY CORROSION WAS ONLY PRESENT WITHIN A 1 INCH SPACE BETWEEN THE INBOARD WELD OUTWARD. ALSO FOUND THAT EACH SIDE OF THE CONTROL ARM HAD A SLIGHT BEND. RECOMMEND PARTICULAR ATTENTION DURING INSPECTIONS. 1L71 3O 2A13 20030917000192003091700019SO 2003 9 17 031139 120030729G32206330000 CONTROL ARM PIPER PA28 PA28140 7102802SO NLG CRACKED D K NONE O OTHER ININSP/MAINT 1 SO059917W2397 29 2823439 FOUND NWS CONTROL BRACE CRACKED ON LT SIDE. CAUSE DETERMINED TO BE CORROSION ON THE INTERIOR OF THE CONTROL TUBE. UPON INSPECTION OF THE TUBE, FOUND CORROSION FORMED ON THE RT SIDE OF THE TUBE IN THE SAME LOCATION. ODDLY CORROSION WAS ONLY PRESENT WITHIN A 1 INCH SPACE BETWEEN THE INBOARD WELD OUTWARD. ALSO FOUND THAT EACH SIDE OF THE CONTROL ARM HAD A SLIGHT BEND. RECOMMEND PARTICULAR ATTENTION DURING INSPECTIONS. 1L71 3O 2A13 20031230000372003123000037CE 2003 12 30 031311 120031107G3710216CW PUMP CONT CESSNA206 U206A 2073316CE CONT O520 IO520A 17032SO VACUUM SYS WRONG PART B W2ORK NONE O OTHER ININSP/MAINT 1 GL094879F90 20 1110635A U2060579 1110635A DURING PRE-PURCHASE EVALUATION FOUND DRY VACUUM PUMP INSTALLED AT ENGINE OVERHAUL APPROX 90 HOURS AGO. ORIGINAL PUMP WAS WET TYPE. ALL PLUMBING FOR WET PUMP WAS UTILIZED WITH DRY PUMP INSTALLED WITH NON STANDARD FITTINGS. NO APPROVAL FOR INSTALLATION OF DRY PUMP. 1H71 3O3 O A4CE E5CE 20031230000392003123000039 2003 12 30 031311A 420031107G345405700261 BLOCK CESSNA206 U206A 2073316CE ANTENNA MOUNT CRACKED B W2ORK NONE O OTHER ININSP/MAINT 1 GL094879F U2060579 DURING PRE-PURCHASE EVALUATION FOUND VOR ANTENNA ON TOP OF VERTICAL STABILIZER LOOSE. FURTHER INVESTIGATION REVEALED ANTENNA MOUNT BLOCK P/N 0570026-1 CRACKED AND BROKEN IN 2 PIECES. PREVIOUS UNKNOWN PERSON HAD ATTEMPTED REPAIR OF PART WITH EPOXY. 1H71 3O A4CE 20031230000402003123000040CE 2003 12 30 031311B 120031107G781012502591 CLAMP CESSNA206 U206A 2073316CE CONT O520 IO520* 17032SO RT EXHAUST SYS CRACKED B W2ORK NONE O OTHER ININSP/MAINT 1 GL094879F U2060579 DURING PRE-PURCHASE INSPECTION FOUND RT EXHAUST PIPE CLAMP CRACKED AND BROKEN AWAY FROM SUPPORT. 1H71 3O3 O A4CE E5CE 20030321000012003032100001CE 2003 3 21 032031 120030320G27616F3058 RESTRICTOR VALVE RKWELLNA265 NA26565 7630107CE ALIDSGTFE731TFE7313AR WP SPEED BRAKES BYPASSING B O OTHER O OTHER TXTAXI/GRND HDL 1 CE0182CR 2011 46549 MAIN ACCOMPLISHED PREFLT INSP AND THEN PILOTS PROCEEDED TO DO THEIR PREFLT INSP. UPON NORMAL EXTENSION OF SPEED BRAKE PANELS, THEY RETRACTED WITH HIGH SPEED AS THOUGH SWITCHES WERE IN THE "GROUND AUTO DEPLOY" POSITION. DISASSEMBLLY OF RESTRICTOR VALVE SHOWED THAT IT HAD FAILED INTERNALLY EVIDENCED BY PARTIALLY CRUSHED MESH FILTERS AT EACH END AND SEPERATION OF RESTRICTOR FROM CENTER DEVIDER. THIS IS SECOND OCCURANCE ON THIS AIRCRAFT, M&D SUBMITTED AT FIRST OCCURANCE. SUSPECT THAT THIS ASSEMBLY IS NOT SUBSTANTIALLY STRONG ENOUGH TO WITHSTAND INTERNAL PRESSURES. 2L72 4J4 F A2WE E6WE 20030324000022003032400002CE 2003 3 24 032031A 120030320G27606F3058 RESTRICTOR VALVE RKWELLNA265 NA26565 7630107CE ALIDSGTFE731TFE7313AR WP SPOILER BYPASSING B O OTHER F FLT CONT AFFECTED ININSP/MAINT 1 CE0182CR 2011 46549 DURING PREFLT INSP, MAINT CREW NOTED THAT SPOILERS FULLY DEPLOYED IN LESS THAN 1 SECOND WITH SPOILER SWITCHES SET TO "IN-FLT" MODE. NORMAL DEPLOY TIME IN THIS MODE IS 6-10 SECONDS WHEREAS "GROUND AUTO-DEPLOY" MODE FOR LANDING IS LESS THAN ONE SECOND. IN PROCESS OF TROUBLESHOOTING, IT WAS DETERMINED THAT HYD RESTRICTOR IN SPOILER SYS WAS NOT RESTRICTING FLOW IN DEPLOY MODE BUT WILL RESTRICT IN RETRACT MODE. FURTHER INVESTIGATION DETERMINED THAT RESTRICTOR HAD FAILED. IT APPEARS THAT THE INTERNAL FILTER SCREENS IN THE RESTRICTOR DEFORM ALLOWING THE RESTRICTOR AND DIVIDER PLATES TO FLOAT BACK AND FORTH AND DEFORM TO THE POINT THAT RESTRICTOR AND DIVIDER PORTIONS BREAK AWAY FROM THEIR PLATES. 2L72 4J4 F A2WE E6WE 20030902000972003090200097NE 2003 9 2 03IN170035 220030621G8530LW13535 CYLINDER HEAD GULSTM500 500S 0141107SW LYC O540 AEIO540L1B5 41532NE HARTZLHCC3Y HCC3YR2 NE RT ENGINE DEPARTED C E ENGINE SHUTDOWN YEKENGINE STOPPAGE VIBRATION/BUFFET FLUID LOSS CRCRUISE 1 SO17507JP 3262 L1864148 CK959 A/C EXPERIENCED ENG PROBLEMS APPROX 2 MINUTES AFTER INITIATING DESCENT FROM 11,500. PILOT NOTICED VIBRATION, OBSERVED RT ENG FUEL FLOW FLUCTUATING. ENRICHED FUEL MIXTURES AND TURNED ON FUEL PUMPS. VIBR CONTINUED, PILOT MOVED RT THROTTLE BACK, THEN UP TO CONFIRM PROBLEM WAS WITH RT ENG. AT THIS TIME, VIBR WORSENED FOLLOWED BY LOUD THUMP AND LARGE BANG. PASSENGER WITNESSED PARTS FLYING OFF RT ENG. PILOT NOTICED GUAGES FOR RT ENG GO TO ZERO AND THEN FEATHERED, SHUT DOWN ENG, ELECTED TO CONTINUE WHERE HE LANDED SAFELY. INSP REVIELED THAT NR 5 CYL HAD SEPARATED FROM ENG CASE CAUSING DAMAGE TO ENG COWLING AND RT WING LE. CYL DID STAY WITH A/C. ENG HAD 6 NEWLY O/H CYL INSTALLED 10 FLIGHT HOURS EARLIER. 1H72 3O3 O 6A1 1E4 5 CP25EA 20030604000702003060400070 2003 6 4 0411190033585 420030430G34457514060 ANTENNA GULSTMG1159 GIV 3980115SO TCAS MISINSTALLED B K NONE W INADEQUATE Q C ININSP/MAINT 1 SO11768J 1881 1881 1119 FOUND UPPER AND LOWER TCAS ANTENNA NOT INSTALLED IAW THE STRUCTURAL REQUIREMENTS. STC ST01545AT-D INSTALLATION DRAWING SC44 129001 , REV H. 2L72 4F RTA12EA 20030507001592003050700159CE 2003 5 7 0512749 120030419G3320AL1235250 LAMP RAYTHNDH125 HAWKER800XP 7150012CE GARRTTTFE731TFE731* 01518WP CABIN BURNED OUT B K NONE O OTHER ININSP/MAINT 1 EA25828QS 258528 END SOCKET OF CABIN INDIRECT LIGHTING FLUORESCENT LAMP TUBE NOTED AS BURNED/BLISTERED FROM OVERHEATING. THIS CONDITION HAS BEEN NOTED PREVIOUSLY BY AVIONICS PERSONNEL IN OTHER AIRCRAFT. 2L72 4F4 FRTA3EU E6WE 20030917000162003091700016SO 2003 9 17 07280305 220030725G7414653271 MAGNETO HILLERUH12 UH12B 4360110WP CONT O520 IO520N 17032SO HARTZLHCC3Y PHCC3YF1 GL ENGINE OVERHEATED B YD5RO OTHER Y ENGINE STOPPAGE TXTAXI/GRND HDL 1 GL15245C 238 324 357302 THE OWNER/PILOT FOUND DURING GROUND OPERATION THAT THE RIGHT MAGNETO FAILED THE MAGNETO OPERATIONAL CHECK. THE MAGNETO WAS REPLACED AND TESTED NORMAL. TWO DAYS LATER IT WAS DISCOVERED THAT THIS AIRCRAFT HAD A LT MAGNETO FAILURE SEVERAL WEEKS EARLIER. THE RIGHT MAG WAS DISASSEMBLED AND FOUND TO BE PARTIALLY BURNED INSIDE ON THE DISTRIBUTOR GEAR ASSEMBLY. THE FAILED LEFT HAND MAGNETO WAS LOCATED, DISSASSEMBLED AND A SIMILAR CONDITION WAS NOTED, HOWEVER THE DAMAGE WAS NOT AS EXTENSIVE. THE MANUFACTURER WAS CONTACTED. THE SERVICE REP THAT ANSWERED THE PHONE SAID HE HAD SEEN THIS CONDITION BEFORE BUT WE WOULD HAVE TO TALK TO THEIR ENGINEERING DEPARTMENT. WE ARE CURRENTLY AWAITING THEIR RESPONSE. 1G71 3O3 O 6H2 E5CE 5 CP25EA 20030317001642003031700164EU 2003 3 17 073001 120030314G1420MS3126F24 CONNECTOR BRAERODH125 BAE125800A 1500285EU ANGLE OF ATTACK ARCED C H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS APAPPROACH 1 SW11244JM 258138 ANGLE OF ATTACK WILL NOT HEAT: INSPECTED CONNECTOR FS20, AND FOUND BOTH ENDS TO BE BURNT. INSPECTED BREAKER AND FOUND TO BE, 10AMP BREAKER, WHICH WAS TO LARGE FOR 18 GUAGE WIRE. REPLACED CONNECTOR AND ENGINEERING ISSUED A DRAWING TO ACCOMODATE SYSTEM REQUIREMENTS. 2L72 4F RTA3EU 20030922000642003092200064NM 2003 9 22 08010304 120030813G271012537101 BEARING UNIVAR108 1083 9230408NM ZONE 500 LOOSE B YD5RO OTHER O OTHER NRNOT REPORTED 1 GL15747C 940 1083747 LDC873FT AILERON WAS REMOVED FOR OTHER MAINTENANCE. WITH THE AILERON REMOVED IT WAS DISCOVERED THAT THE BEARING MOUNTED IN THE ROLL TRIM MOTOR ASSY. (P/N-12546-001) WAS LOOSE. THIS BEARING IS INSTALLED WITH A LIQUID LOCKING PRODUCT AND SUBJECTED TO A LOAD TEST PRIOR TO INSTALLATION. IT IS NOT KNOWN HOW THIS BEARING COULD HAVE COME LOOSE. IT IS VERY DIFFICULT TO INSPECT THIS INSTALLATION WITH THE AILERON INSTALLED. THIS BEARING SHOULD BE INSTALLED ANY TIME THE LEFT AILERON IS REMOVED. 1H71 3O A767 20030912000462003091200046GL 2003 9 12 0804307 120030804G273014832001 MOTOR CIRRUSSR SR22 2130001GL CONT O520 IO520N 17032SO HARTZLHCC3Y PHCC3YF1 GL PITCH TRIM LOOSE B YD5RO OTHER F FLT CONT AFFECTED TXTAXI/GRND HDL 1 GL151457 169 0547 PILOT NOTED EXCESSIVE FREE PLAY AT ELEVATOR. ELEVATOR WAS ABLE TO BE MOVED WITH LITTLE RESISTANCE APPROX FOUR INCHES (TWO INCHES UP AND TWO INCHES DOWN FROM TRIMMED POSITION)INVESTIGATION REVEALED THAT ARM ON PITCH TRIM MOTOR WAS LOOSE IN RELATIONSHIP TO PITCH TRIM MOTOR SHAFT (ASSY. P/N-14832-001). NEW DESIGN HAS ARM (P/N-14908-001) SECURED TO SHAFT WITH A SINGLE SET SCREW (P/N- 51190-245). IT APPEARS THAT UPON INITAL INSTALLATION IF THE SETSCREW IN THE ARM IS NOT CENTERED CORRECTLY IN SHAFT RECEPTACLE TIGHTENING SETSCREW COULD GIVE AN INDICATION OF BEING "TIGHT" WHEN SETSCREW HAS NOT PENETRATED COMPLETELY DOWN INTO THE SHAFT RECEPTACLE. THIS ARM/SHAFT SHOULD BE CHECKED ANY TIME "FREEPLAY" IS NOTED AT ELEVA1L71 3O3 ONTA00009CHE5CE 5 CP25EA 20040223000302004022300030SO 2004 2 23 1022031237WHR 120031022G52301159SCB2022 DOOR SEAL GULSTM GULSTMG1159 GIV 3980115SO RROYCETAY TAY6118 EU ZONE 800 DEBONDED C K NONE O OTHER ININSP/MAINT 1 GL091904W609 1237 1237 CREW REPORTED THAT WHEN THEY PULLED THE POWER BACK FOR DESCENT, THE CABIN ALTITUDE WOULD CLIMB. INCREASED THE POWER AND THE CABIN WOULD STABILIZE. FOUND THE 1159SCB202-2 BAGGAGE DOOR SEAL BATCH NR 01-0004. UNIT FAILED AT THE MOLD LINE WHERE THE INFLATION TUBE JOINS THE SEAL. APPEARS THAT THE ADHESIVE DID NOT HOLD THE SEAL TOGETHER. THIS IS ONE OF THE NEW SILICON SEALS. THEY DO NOT SEEM TO BE HOLDING UP AS WELL AS THE OLD STYLE SEALS. 2L72 4F4 FRTA12EA E25NE 20040223000292004022300029SO 2004 2 23 102203WHR 120031022G52301159SCB2022 DOOR SEAL GULSTM GULSTMG1159 GIV 3980115SO RROYCETAY TAY6118 EU CARGO DOOR DEBONDED C K NONE O OTHER ININSP/MAINT 1 GL091904W609 1237 1237 CREW REPORTED THAT WHEN THEY PULLED THE POWER BACK FOR DESCENT, THE CABIN ALTITUDE WOULD CLIMB. INCREASED THE POWER AND THE CABIN WOULD STABILIZE. FOUND THE 1159SCB202-2 BAGGAGE DOOR SEAL BATCH NR 01-0004. UNIT FAILED AT THE MOLD LINE WHERE THE INFLATION TUBE JOINS THE SEAL. APPEARS THAT THE ADHESIVE DID NOT HOLD THE SEAL TOGETHER. THIS IS ONE OF THE NEW SILICON SEALS. THEY DO NOT SEEM TO BE HOLDING UP AS WELL AS THE OLD STYLE SEALS. 2L72 4F4 FRTA12EA E25NE 20030805000112003080500011EU 2003 8 5 106476B 120030521G6321C632A2108102 DISC UROCOPEC120 EC120B 8680987EU TMECA ARRIUSARRIUS2B1 NE ROTOR BRAKE FAILED C SC0MO OTHER O OTHER NRNOT REPORTED 1 WP25255SD1068 1102 FOUND DURING 500 HOUR INSPECTION. INSPECTION CHECK WIGH DIAL INDICATOR REQUIRED DISASSEMBLE. SPLINES INSPECTED AND MEASURED WITH PINS. BEYOND LIMITS, PART REJECTED. NOTE: ROTOR BRAKE DISC FREE FLOATS ON THIS SPLINE ASSEMBLY. WEAR STEP ONLY IN AREA DISC RIDES. 1G72 3U3 UNCR0001RD E34NE 20030707002102003070700210EU 2003 7 7 106844B 120030521G6420C642A0402101 STRAP UROCOPEC120 EC120B 8680987EU TMECA ARRIUSARRIUS2B1 NE TAIL ROTOR HEAD DAMAGED C SC0MO OTHER O OTHER NRNOT REPORTED 1 WP25266SD1000 1133 TORSION STRAP ASSY IS USED IN THE TAIL ROTOR ASSY. FOUND DURING 500 HOUR INSPECTION/ DISASSEMBLED FOR INSPECTION. SCORING ON 2 STRAPS. FRETTING ON NUMEROUS STRAPS, SURFACE CORROSION. (ASSEMBLY REJECTED, NEW STRAP ASSEMBLY INSTALLED) 1G72 3U3 UNCR0001RD E34NE 20031113000532003111300053CE 2003 11 13 11032003001 120031003G531224130013 BULKHEAD CESSNA172 172RG 2072438CE LYC O360 O360* 41514EA FUSELAGE CRACKED G K NONE O OTHER ININSP/MAINT 1 AL039390B5460 172RG0810 CRACKS IN LOWER LEFT BULKHEAD UNDER PILOT'S INBOARD RUDDER PEDAL TORQUE TUBE PILLOW BLOCK, ALLOWED ABNORMAL FORWARD/AFT MOVEMENT OF RUDDER PEDAL TORQUE TUBE. REPORTED TO MFG BY TELECON. (AL03200407996) 1H71 3O3 O 3A17 E286 20031113000542003111300054CE 2003 11 13 11032003002 120031003G531224130016 BULKHEAD CESSNA172 172RG 2072438CE FUSELAGE CRACKED M IE8SK NONE O OTHER ININSP/MAINT 1 AL039390B5460 172RG0810 CRACKS IN UPPER LEFT BULKHEAD UNDER PILOT'S INBOARD RUDDER PEDAL TORQE TUBE PILLOW BLOCK, ALLOWED ABNORMAL FORWARD/AFT MOVEMENT OF RUDDER PEDAL TORQE TUBE. REPORTED TO MFG BY TELECON. 1H71 3O 3A17 20031230000152003123000015 2003 12 30 112003 420031120G2562MN1300 BATTERY ACK BEECH 90 65A90 1152908CE PWA PT6 PT6* 52043EA ELT FAILED B EVGRK NONE L NO TEST ININSP/MAINT 1 SO3365JA 0322707 LM34 DURING A FUNCTION TEST OF THE ELT THE UNIT WOULD NOT TEST. ON INVESTIGATION WE FOUND THAT ONE OF THE BATTERIES WAS FAULTY WITH AN (OPEN) CONDITION. WE REPLACED ALL THE BATTERIES AND THE UNIT FUNCTION TESTED PROPERLY. 1L72 3T3 T 3A20 E2NE 20031230000012003123000001SO 2003 12 30 11252003 120031125G32309572402 BRACKET PIPER PA34 PA34200 7103405SO NLG CRACKED G O OTHER O OTHER LDLANDING 1 NE0142309 347450169 NLG COLLAPSED ON LANDING, AFT END OF NOSE GEAR ACTUATOR ATTACHES TO BRACKET. THIS IS RIVETED THRU FIREWALL TO NOSE GEAR MOUNT FITTING. RIVETS WORKED FROM FORWARD/AFT PUSHING MOTION OF NOSE GEAR ACTUATOR, ELONGATING, THEN SHEARING OFF RIVETS. ACTUATOR WENT TO FULLY EXTENDED POSITION, BUT DID NOT CAUSE NOSE GEAR DRAG LINK TO GO TO OVER-CENTER POSITION, AS SHEARED OFF RIVETS PREVENTED IT FROM GETTING GOOD PUSH, AND OVER-CENTER ACTION OCCURING. NOSE GEAR COLLAPSED WHEN WEIGHT OF AC WENT ONTO NON-OVER CENTER DRAG LINK. ELONGATED AND SHEARED OFF SITUATION GOES UNDETECTED AS RIVETS ARE COVERED ON SIDE OF TUNNEL BY MATERIAL GLUED TO TUNNEL WHERE CO-PILOTS LT FOOT WOULD NORMALLY BE. NEED AD 1L72 3O A7SO 20030312000422003031200042EA 2003 3 12 11447 220030220G8550LW13383 BAFFLE PIPER PA32 PA32R301T 7103220SO LYC O540 TIO540A1A 41532EA OIL SUMP CRACKED B K NONE O OTHER ININSP/MAINT 1 EA23398TC501 3257057 L1001761A PN LW13383 SUMP BAFFLE WAS FOUND CRACKED AT THE 6 ATTACHING SCREWS. A FEW OF THE SCREW HOLES WERE COMPLETELY BROKE ALL THE WAY AROUND THE SCREW AND WASHER. 1L71 3O3 O A3SO E14EA 20030218000492003021800049CE 2003 2 18 1206S 120030207G5730 SKIN PANEL CESSNA501 501 2076603CE LT & RT WING CRACKED B WTXRK NONE O OTHER ININSP/MAINT 1 NM03501VP8221 5010261 DURING A PHASE 1-5 DISCOVERED CRACKS IN LT AND RT WING SKIN AT AFT OUTBOARD EDGE OF WHEEL WELL CUT OUT. LT WING CRACK WAS .50 IN. LONG RT WING CRACK WAS 0.40 IN. LONG. REPAIRED IN ACCORDANCE WITH CESSNA REPAIR DEFINITION S-550-0264/02RD DATED NOVEMBER 14, 2000. 1L72 4F A27CE 20030218000502003021800050CE 2003 2 18 1387S 120030214G57402423100002 MOUNT LEAR 35 35A 5170602CE TIP TANK CRACKED B K NONE O OTHER ININSP/MAINT 1 NM07886R 5368 269 DICOVERED DURING INSPECTION FOUND A CRACK IN THE RT TIP TANK MOUNTING FLANGE. REPAIRED PER MFG. DRAWING. 2L72 4F A10CE 20030312000432003031200043CE 2003 3 12 1592S 120030305G5710 STRUCTURE CESSNA441 441 2076020CE LT WING MISREPAIRED B WTXRK NONE O OTHER ININSP/MAINT 1 NM03454EA 4410054 DURING A PHASE 2, 3 & D INSPECTION, IT WAS VISUALLY DISCOVERED UPPER & LOWER RIB CAP STRUCTURE WAS MISSING AT LT WS 128.80 AS WELL AS STRINGER SPLICES WERE NOT ATTACHED TO THE WING SKIN BETWEEN LT WS 120.0 & 148.30 & THE SKIN SPLICE USED WAS THE WRONG MATERIAL THICKNESS. 1L72 3T RTA28CE 20030312000412003031200041 2003 3 12 1A1 420030224G3416066011530101 ALTIMETER SNIAS 350 AS350B2 8680813EU TAILBOOM CONTAMINATED B K NONE O OTHER ININSP/MAINT 1 SW071811F 3430 HYDRAULIC FLUID LEAKING FROM THE TAIL ROTOR CONTROL SERVO ONTO THE RADAR ALTIMETER RECIEVER TRANSMITTER. THE R/T UNIT WAS MOUNTED DIRECTLY UNDER THE TAIL ROTOR CONTROL SERVO WITH NO PROTECTION FROM FLAMABLE FLUID LEAKAGE. 1G71 3U H9EU 20031230000132003123000013NE 2003 12 30 2003006 220031217G7200 ENGINE LEAR 25 25D 5170514CE GE CJ610 CJ6108 30006NE LEFT MALFUNCTIONED E EA ENGINE SHUTDOWN UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CLCLIMB 1 SO11947TC9818 3967 233 240BSCY151A DURING FLT AT APPROXIMATELY 2:00 AM, AIRCRAFT WAS ENROUTE WHEN THE PILOT NOTICED THAT THE LT ENGINE OIL PRESSURE WAS DECREASING. THE PILOT ALSO NOTICED THAT THE LT EGT WAS CLIMBING. THE PILOT ELECTED TO SHUT DOWN THE LT ENGINE AND RETURN AT THIS TIME. NO EMERGENCY WAS DECLARED, AND THE AIRCRAFT LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE HAS BEEN DISPATCHED TO THE AIRCRAFT TO INVESTIGATE AT THIS TIME. 2L72 4J4 J A10CE 1E16 20030311000732003031100073CE 2003 3 11 2003F00113 120030201G574031691 ATTACH FITTING BBAVIA8 8KCAB 2110612CE LYC O360 AEIO360* EA WING STRUT CHAFED D K NONE O OTHER ININSP/MAINT 1 GL13330MS 75095 DURING A ROUTINE SERVICE INTERNAL CUSTOMER REQUESTED THE 1000 HOUR INSPECTION DETAILED IN AIRWORTHY LIMITATIONS OF MM. ON ALL FOUR STRUT ATTACH FITTINGS. BOTH FITTINGS WERE REJECTED ON LEFT WING DUE TO CHAFING ON EDGES WHERE FITTINGS PASS THROUGH LEADING EDGE SKIN. FITTINGS WERE INSTALLED BY ANOTHER AGENCY AT 96 HOUR TT ACCORDING TO AC RECORDS. GREATER ATTENTION TO INTERFERENCE OF SKIN RELIEF WOULD PREVENT THIS. 1H71 3O3 O A21CE 1E10 20030324000352003032400035GL 2003 3 24 2003F00151 320030310G6114D67132C1102 HUB BAG JETSTMJETSTM4112 EU ROTOL R333 R333482F12 GL PROPELLER CRACKED D O OTHER O OTHER NRNOT REPORTED 1 SW99 206953677 922706 RECEIVED PROPELLER FOR OIL LEAK; UPON DISASSEMBLY, FOUND CRACK ON TOP OF HUB AT NR 1 BLADE PORT; CRACK PROPAGATED FROM TOP OF HUB TO NR 1 BLADE SOCKET. 1L72 4T RTA196 6 CP61GL 20030324000952003032400095EU 2003 3 24 2003F00152 120030310G2400450235002 MASTER BOX UROCOPEC135 EC135P1 8680990EU PWA PW206 PW206A NE RIGHT SIDE FAILED D O OTHER B SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 NM02313MS2014 0095 DURING A DEFUELING PROCEDURE WITH THE AIRCRAFT BATTERY DISCONNECTED AND THE GPU CONNECTED. THE BATTERY SWITCH TURNED ON AND AFTER APPROXIMATELY 30 MINUTES INTO THE DEFUELING PROCEDURE THE RIGHT HAND ELECTRICAL MASTER BOX STARTED SMOKING. WE QUICKLY DISCONNECTED ALL ELECTRICAL POWER TO THE AIRCRAFT. THIS OCCURANCE ALSO BLEW AN 8 AMP IN THE BATTERY MASTER BOX AT (F2) LOCATION. 1G72 3U3 UO H88EU E42NE 20030605000192003060500019CE 2003 6 5 2003F00252 120030331G323399120538 ACTUATOR CESSNA500 500CESSNA 2076602CE PWA JT15 JT15D1 52060NE RT MLG FAILED D O OTHER N FALSE WARNING NRNOT REPORTED 1 SW13628BS10586135 5000045 RT MLG ACTUATOR COLLAPSED AND STILL INDICATED DOWN AND LOCKED. 1L72 4F4 F A22CE E1NE 20030919000242003091900024CE 2003 9 19 2003F00513 120030627G27302655221313 BELLCRANK RKWELLNA265 NA26565 7630107CE ELEVATOR CRACKED B O OTHER O OTHER NRNOT REPORTED 1 CE03800M 3840 46541 AFTER FINDING THE LT AFT ELEVATOR BELLCRANK PN 265-5221313 FS457 CRACKED AT LOWER BEARING BOSS AREA ON A DIFFERENT NA 265-65 AIRCRAFT WE PERFORMED INSPECTIONS ON 5 EA. ADDITIONAL NA 265-65 AIRCRAFT THAT WERE IN HOUSE. THIS INSPECTION UNCOVERED A CRACKED BELLCRANK AT THE LOCATION ON THIS AIRCRAFT. RECOMMEND OPERATORS OF NA 265-65 MODEL AIRCRAFT PERFORM A CLOSE VISUAL OR EDDY CURRENT INSPECTION OF THE LOWER BEARING BOSS AREA OF LT BELLCRANK PN 265-5221313 AS SOON AS POSSIBLE. POSSIBLE CAUSE HAS YET TO BE DETERMINED BUT THE HIGH CABLE TENSION AND THE BIAS LOADING OF THE ELEVATOR CABLES MAY BE A CONTRIBUTING FACTOR OR THE POSSIBLE STAKING OF THE BEARING COULD WEAKEN THE AREA AFFECTED. MFG HAS BEEN NOTIFIED. 2L72 4J A2WE 20030919001052003091900105CE 2003 9 19 2003F00515 120030804G3244184F681 TIRE CESSNA525 525 2076601CE WILINTFJ44 FJ44 66000GL MLG LEAKING D O OTHER O OTHER NRNOT REPORTED 1 SO0351GS 293 5250317 SUSPECTED SUDDEN AIR LOSS BETWEEN PRE-FLIGHT INSPECTION AT HOME FBO AND LANDING AT VISITING FBO. APPROX. 1-25 HOURS. 1L72 4F4 FRTA1WI E3GL 20031006000462003100600046SO 2003 10 6 2003F00557 120030827G2140 COMBUSTION LINERJANITROL PIPER PA31T PA31T1 7103126SO PWA PT6 PT6* 52043EA HEATER CRACKED B O OTHER O OTHER NRNOT REPORTED 1 EA0352HL 31T8004023 DURING PRESSURE DECAY TESTS OF ELECTRO SYSTEMS JAN-AERO HEATERS, PN FR10E21-EL, WE HAVE DISCOVERED PRESSURE LEAKS IN THE CERAMIC COATED COMBUSTION TUBES. THIS HAS OCCURED ON 4 SEPARATE OCCATIONS. IT SHOULD BE NOTED THAT THE PERIODIC PRESSURE DECAY TEST REQUIRED BY AD 96-20-07 (DOES NOT APPLY TO) HEATER SERIES B3500 WITH (CERAMIC COATED) COMBUSTION TUBES. ALTHOUGH THE PERIODIC PRESSURE DECAY TEST IS (NOT) REQUIRED BY AD 96-20-07 FOR CERTAIN HEATERS WITH (CERAMIC COATED) COMBUSTION TUBES. MM CONTINUES TO RECOMMEND PERIODIC PRESSURE DECAY TEST OF THE HEATER COMBUSTION TUBES REGARDLESS OF THE HEATER CONFIGURATION. 1L72 3T3 T A8EA E2NE 20030204002152003020400215CE 2003 2 4 2003FA0000019 120030106G5710085150047 BULKHEAD CESSNA402 402B 207590PCE CONT O520 TSIO520* 17040SO RT WING CRACKED D K NONE O OTHER ININSP/MAINT 1 NM08402CA8800 402B0842 INSPECTION IAW AD, A CRACK WAS FOUND IN THE RT ENGINE CANTED BULKHEAD CAP. CRACK WAS LOCATED ON THE INBOARD SIDE OF CAP JUST INSIDE OF INBOARD WING LIP. CRACK WAS APPROXIAMATELY 1.5 INCHES AND RAN CHORD WISE WITH WING. IT WAS LOCATED IN THE AFT OF THE CAP WIDTH. UPON REMOVAL OF CANTED BULKHEAD CAP, FOUND FORWARD CANTED BULKHEAD TO BE CRACKED PERPENDICULAR TO THE CAP CRACK ON THE INBOARD SIDE IN THE BEND OF TOP FLANGE. THIS CRACK WAS ABOUT 1 INCH IN LENGTH. FOUND THAT BOTH AFT AND FORWARD BULKHEAD INBOARD SIDES HAD SEPERATED FROM INBOARD NACELLE WING RIB. FOUND THIS SAME COMBINATION ON LEFT SIDE OF THIS SAME AIRCRAFT AND ON RIGHT SIDE OF ANOTHER. 1L72 3O3 O A7CE E8CE 20030204002182003020400218CE 2003 2 4 2003FA0000020 120030106G5710085150047 BULKHEAD CESSNA402 402B 207590PCE CONT O520 TSIO520* 17040SO ZONE 600 CRACKED D K NONE O OTHER ININSP/MAINT 1 NM08402CA8800 402B0842 WHILE CONDUCTING INSPECTION IAW AD 00-01-16(D)A CRACK WAS FOUND IN THE RIGHT ENGINE CANTED BULKHEAD CAP. CRACK WAS LOCATED ON THE INBOARD SIDE OF CAP JUST INSIDE OF THE INBOARD WING LIP. CRACK WAS APPROXIAMATELY 1.5 INCHES AND RAN CHORD WISE WITH THE WING. IT WAS LOCATED IN THE AFT OF THE CAP WIDTH. UPON REMOVAL OF CANTED BULKHEAD CAP I FOUND THE FORWARD CANTED BULKHEAD TO BE CRACKED PERPENDICULAR TO THE CAP CRACK ON THE INBOARD SIDE IN THE BEND OF THE TOP FLANGE. THIS CRACK WAS ABOUT 1 INCH IN LENGTH. I FOUND ALSO THAT BOTH THE AFT AND FORWARD BULKHEADS INBOARD SIDES HAD SEPERATED FROM THE INBOARD NACELLE WING RIB. 1L72 3O3 O A7CE E8CE 20030204002232003020400223CE 2003 2 4 2003FA0000021 120030106G5710085150047 BULKHEAD CESSNA402 402B 207590PCE CONT O520 TSIO520* 17040SO ZONE 600 CRACKED D K NONE O OTHER ININSP/MAINT 1 NM08402CA8800 402B0842 INSPECTION IAW AD. CRACK WAS FOUND IN RIGHT ENGINE CANTED BULKHEAD CAP. CRACK WAS LOCATED ON INBOARD SIDE OF CAP JUST INSIDE OF INBOARD WING LIP. CRACK WAS APPROXIAMATELY 1.5 INCHES AND RAN CHORD WISE WITH THE WING, IT WAS LOCATED IN THE AFT OF THE CAP WIDTH. UPON REMOVAL OF CANTED BULKHEAD CAP FOUND FORWARD CANTED BULKHEAD TO BE CRACKED PERPENDICULAR TO CAP CRACK ON INBOARD SIDE IN BEND OF TOP FLANGE. CRACK WAS ABOUT 1 INCH IN LENGTH. AFT AND FORWARD BULKHEADS INBOARD SIDES HAD SEPERATED FROM INBOARD NACELLE WING RIB. FOUND THIS SAME COMBINATION ON THE LT SIDE OF THIS SAME AIRCRAFT. 1L72 3O3 O A7CE E8CE 20030204002292003020400229CE 2003 2 4 2003FA0000023 120030106G561010138402521 WINDSHIELD BEECH 200 B200 1152922CE COCKPIT CRACKED D K NONE O OTHER ININSP/MAINT 1 NM11773TP905 905 BB1722 FOUND 3 INCH CRACK ACROSS LOWER,OUTSIDE CORNER OF OUTSIDE GLASS PANEL WITH SOME DELAMINATION EXTENDING 3 INCHES OUT OF SAME CORNER. TECHNICIAN BELIEVES CONTINUAL RETORQING OF WINDSHIELD SCREWS CALLED OUT BY RAYTHEON CAUSED THE CRACK AND INCREASES THE CHANCES OF DELAMINATION. NO OTHER AIRCRAFT THAT HE HAS SERVICED IN HIS 35 YEAR CAREER HAS HAD THIS REQUIREMENT AND HAS REPLACED SEVERAL KING AIR WINDSHIELDS. 1L72 4T A24CE 20030204002352003020400235CE 2003 2 4 2003FA0000025 120030108G27106524113205 AILERON CESSNA500 560CESSNA 2076750CE PWA JT15 JT15D5 52112NE WING JAMMED B A UNSCHED LANDING F FLT CONT AFFECTED CLCLIMB 1 GL27462B 5600016 AILERON TRIM MOVED OVER 10 DEGREES IN FLIGHT WILL JAM, PILOT WILL NOT BE ABLE TO READJUST TO ZERO. 2L72 4F4 FRTA22CE E25EA 20030116001592003011600159WP 2003 1 16 2003FA0000029 120030101G339758643 WIRE HARNESS LKHEED1011 1011* WP CABIN FAULTY G AMTAK NONE L NO TEST ININSP/MAINT 1 GL111641T 293A1238 EGRESS LIGHTING AT GALLEY 72 INCH SEGMENT INOP. REMOVED AND REPLACED TRANSITION CABLE JUMPER 72 INCH BETWEEN SEGMENT AND POWER CABLE. 2L73 4F A23WE 20030204002412003020400241EU 2003 2 4 2003FA0000030 120030110G5753 VANE BRAERODH125 HS125700A 4230170EU RT TE FLAP CRACKED E ILPAK NONE O OTHER ININSP/MAINT 1 CE0312OJC 257065 DURING ROUTINE INSPECTION, IT WAS FOUND THAT THE RT FLAP VANE AT THE NR 2 ATTACH POINT HAD A HAIRLINE CRACK. REPAIR WAS FABRICATED AND INSTALLED IAW SRM. 2L72 4F A3EU 20030204002452003020400245EU 2003 2 4 2003FA0000031 120030110G5753 VANE BRAERODH125 HS125700A 4230170EU RT TE FLAP CRACKED E ILPAK NONE O OTHER ININSP/MAINT 1 CE0312OJC 257065 DURING ROUTINE INSPECTION, IT WAS FOUND THAT THE RT FLAP VANE AT THE NR 2 ATTACH POINT HAD A HAIRLINE CRACK. REPAIR WAS FABRICATED AND INSTALLED IAW SRM. 2L72 4F A3EU 20030204002512003020400251CE 2003 2 4 2003FA0000035 120030115G2700522277577 SKIN CESSNA500 550 2076604CE LT WING CRACKED B K NONE O OTHER ININSP/MAINT 1 SW01 0670 WHILE DOING A DAILY INSPECTION A 1 3/4 INCH CRACK WAS FOUND IN THE LT WING JUST ABOVE THE INBOARD FLAP BELLCRANK. WE OPERATE A FLEET OF 26 550 SERIES AIRCRAFT WITH A LARGE PORTION HAVING A REPAIR TO THE LT OR RT WING AT ONE POINT OR ANOTHER. I HAVE FOUND SEVERAL WHILE WORKING AT A FBO. MANY OF MY FRIENDS ALSO CONFERM THAT THIS IS A COMMON THING TO THE FLEET. TALKING TO THE FACTORY THEY WANT ONE OF THERE ENGINEERS OR A DER TO HELP IN THE FIX. IT SEAMS TO ME THAT IF THIS IS A COMMON THING THEM WHY CAN'T THE MFG. COME UP WITH A SB AND A REPAIR KIT AS WE HAVE SEEN IN THE PAST ON OTHER LESS COSTLY A/C ? 1L72 4F A22CE 20030204002542003020400254CE 2003 2 4 2003FA0000036 120030108G323008421022 BELLCRANK CESSNA310 T310Q 2074244CE MLG BROKEN G O OTHER J WARNING INDICATION LDLANDING 1 SO158108G2075 310Q1047 THE IDLER BELLCRANK FOR THE NOSE GEAR RETRACTION LINKAGE BROKE WHEN THE LANDING GEAR WAS SELECTED TO THE UP POSITION. PILOT WAS UNABLE TO EXTEND THE NOSE GEAR. UPON LANDING THE NOSE GEAR RETRACTED INTO THE WHEEL WELL. INSPECTION REVEALED THAT THE IDLER BELLCRANK BROKE CAUSING THE NOSE GEAR TO BE DISCONNECTED FROM THE GEARBOX. SUSPECT IMPROPER RIGGING OF THE LANDING GEAR CAUSED EXCESSIVE STRESS ON BELLCRANK. MECHANICS NEED TO REMEMBER THAT DUE TO THE DESIGN OF THE LANDING GEAR SYSTEM ON TWIN ENGINE CESSNA'S, ANY ADJUSTMENTS MADE TO ANY OF THE MANY COMPONENTS OF THE LANDING GEAR EFFECTS THE ENTIRE SYSTEM, REQUIRING A COMPLETE RECHECK OF THE LANDING GEAR RIGGING. 1L72 3O 3A10 20030204002552003020400255EA 2003 2 4 2003FA0000039 120030116G5610 WINDSHIELD CNDAIRCL600 CL6002B16 1900305EA GE CF34 CF34* NE COCKPIT CRACKED G A UNSCHED LANDING F FLT CONT AFFECTED CRCRUISE 1 GL11607RP 5184 THE OUTER PLY OF THE PILOT FORWARD WINDSHIELD CRACKED. THE FLIGHT WAS DISCONTINUED. 2L72 4F4 FRTA21EA E15NE 20030204002562003020400256NM 2003 2 4 2003FA0000040 120030121G573044305 DOUBLER LKHEEDP2V P2V7 5260112NM WRIGHTR3350 R3350* 67040EA LT & RT WING CORRODED B BZBRK NONE O OTHER ININSP/MAINT 1 NM04139HP9739 145906 FUEL INTERCONNECT ACCESS PANEL CUT OUT DOUBLER IS CRACKED AT LT AND RT PANEL NUMBERS 53L AND 53R. LT AND RT UPPER CENTER WING BOX BEAM COVERS HAVE MODERATE TO MILD CORROSION ON THE UPPER HAT SECTIONS AND THE SKIN BETWEEN WING STATIONS 84.5 TO 192 LT AND RT. LT AND RT FORWARD UPPER SPAR CAP FROM WING STATION 84.5 TO 192 HAS MILD TO MODERATE CORROSION. LT AND RT REAR UPPER SPAR CAP FROM WING STATION 84.5 TO 192 HAS MILD TO MODERATE CORROSION. 2M72 4R4 RRTA1RM E272 20030204002572003020400257NM 2003 2 4 2003FA0000041 120030121G5711 SPAR CAP LKHEEDP2V P2V7 5260112NM WRIGHTR3350 R3350* 67040EA LT & RT WING CORRODED B BZBRK NONE O OTHER ININSP/MAINT 1 NM04139HP9739 145906 FUEL INTERCONNECT ACCESS PANEL CUT OUT DOUBLER IS CRACKED AT LT AND RT PANEL NUMBERS 53L AND 53R. LT AND RT UPPER CENTER WING BOX BEAM COVERS HAVE MODERATE TO MILD CORROSION ON THE UPPER HAT SECTIONS AND THE SKIN BETWEEN WING STATIONS 84.5 TO 192 LT AND RT. LT AND RT FORWARD UPPER SPAR CAP FROM WING STATION 84.5 TO 192 HAS MILD TO MODERATE CORROSION. LT AND RT REAR UPPER SPAR CAP FROM WING STATION 84.5 TO 192 HAS MILD TO MODERATE CORROSION. 2M72 4R4 RRTA1RM E272 20030203000972003020300097SO 2003 2 3 2003FA0000043 120030109G3260761639 SQUAT SWITCH PIPER PA28 PA28R201 7102816SO LYC O360 IO360A1A 41514EA MLG FAILED G O OTHER O OTHER NRNOT REPORTED 1 NM07850FS194 2844080 JACKED AIRCRAFT TO VERIFY SQUAT SWITCH ADJUSTMENT IAW SRM. SQUAT SWITCH IS SUPPOSE TO ACTUATE WITHIN THE FIRST .250 INCH OF STRUT COMPRESSION FROM FULL EXTENSION. FOUND SQUAT SWITCH TO BE ADJUSTED TO ACTUATE AT .625 INCHES. THIS IS .375 INCHES OUT OF LIMITS. THE TORQUE SEAL ON THE SQUAT SWITCH MOUNTING/ ADJUSTING HARDWARE SHOWS NO EVIDENCE OF BEING DISTURBED. 1L71 3O3 O 2A13 1E10 20030204002582003020400258CE 2003 2 4 2003FA0000047 120030121G531207126153 BULKHEAD CESSNA182 182Q 2072732CE CONT O470 O470* 17026SO FUSELAGE CRACKED C K NONE O OTHER ININSP/MAINT 1 SO09888CH 18266884 SMALL CRACK IN AFT BULKHEAD AT STATION 209. ORIGINATING FROM UNDER THE ATTACH POINT OF RT HORIZONTAL STABILIZER, AT THE UPPER INBOARD CORNER. 1H71 3O3 ONT3A13 E273 20030204002592003020400259CE 2003 2 4 2003FA0000048 120030115G27103652400019 TURNBUCKLE BEECH BEECH 36 36BEECH 1151602CE CONTROL CABLE BROKEN B K NONE O OTHER ININSP/MAINT 1 GL096222V4315 E3 AILERON CABLE TURNBUCKLE FORWARD OF AFT SPAR BROKEN. SAFETY WIRE HOLDING CABLE TOGETHER, FOUND DURING ANNUAL INSPECTION. CABLE HAD BEEN CONTACTING AFT HEAT DUCT. APPEARS TO HAVE INTERNAL CORROSION FROM CONTACT WITH WIRE IN HEAT DUCT. FITTING SHOW NO SIGN OF WEAR OR EXTERNAL CORROSION. 1L71 3O 3A15 20030204002632003020400263SW 2003 2 4 2003FA0000049 120030108G2750191003 VALVE SWRNGNSA226 SA226T 8780122SW GARRTTTPE331TPE331* 01514WP LT TE FLAPS DEFECTIVE B K NONE O OTHER ININSP/MAINT 1 GL27601JT T319 AIRCRAFT ROLLED LT AFTER FLAPS WERE DEPLOYED FOR 30 SECONDS, INTERMITTENLY. FOUND LT LOCK OUT VALVE DEFECTIVE. VALVE WAS GROUND PRESSURE TESTED AND IT FAILED THE TEST. REPLACED LOCK OUT VALVE. THIS PART NEEDS TO BE PUT ON THE REQUIRED OVERHAUL SCHEDULE. 2L72 4T3 TRTA5SW E2WE 20030204002642003020400264 2003 2 4 2003FA0000051 420030110G3416 ENCODER BEECH 58 58 1152740CE CONT O520 IO520* 17032SO COCKPIT OUT OF ADJUST B JG0RO OTHER W INADEQUATE Q C NRNOT REPORTED 1 WP194TG TH335 ENCODER MISSING HIGH ALTITUDE ADJUSTMENT OUT OF THE FACTORY. THE MM REQUIRES YOU TO CALIBRATE THE ENCODER USING HIGH ALTITUDE AND LOW ALTITUDE ADJUSTMENT POTS. 1L72 3O3 O 3A16 E5CE 20030204002652003020400265GL 2003 2 4 2003FA0000052 320030112G6110 NUT MCAULY2A34C D2A34C98 GL PROPELLER CRACKED B UCXRK NONE O OTHER ININSP/MAINT 1 SW15 850 724763 DURING ROUTINE OVERHAUL OF THIS PROPELLER FOUND NR 2 THREAD IN THE NR 2 HUB SOCKET CRACKED. VISUAL/MAGNAFYING GLASS AND CONFIRMED WITH EDDIE CURRENT AND DYE-CHECK NDT. FOUND THE ASSOCIATED BLADE RETENTION NUT CRACKED ON THE NR 2 THREAD AS WELL VIA THE SAME MEANS OF INSPECTION. THESE WERE JUST THE BEGINING OF A MINUTE CRACK AND HAD NOT PROGRESSED TO THE POINT OF THE PROPELLER LEAKING RED DYE OIL YET. COULD HAVE CAUSED A COMPLETE BLADE FAILURE OF THE BLADE LEAVING THE HUB. PHOTO ON FILE. 5 CP3EA 20030204002662003020400266CE 2003 2 4 2003FA0000054 120030113G531207126153 BULKHEAD CESSNA182 182Q 2072732CE CONT O470 O470* 17026SO FUSELAGE CRACKED C K NONE O OTHER ININSP/MAINT 1 SO09888CH 18266884 SMALL CRACK IN AFT FUSELAGE BULKHEAD AT STATION 209. ORIGINATING FROM UNDER THE RIGHT HORIZONTAL STABILIZER UPPER ATTACH POINT. 1H71 3O3 ONT3A13 E273 20030205000022003020500002CE 2003 2 5 2003FA0000055 120030113G531207126153 BULKHEAD CESSNA182 182Q 2072732CE FUSELAGE CRACKED C K NONE O OTHER ININSP/MAINT 1 SO09888CH 18266884 SMALL CRACK IN AFT FUSELAGE BULKHEAD AT STATION 209. ORIGINATING FROM UNDER THE RT HORIZONTAL STABILIZER UPPER ATTACH POINT. 1H71 3O NT3A13 20030205000032003020500003CE 2003 2 5 2003FA0000056 120030123G323012410041 SADDLE CESSNA210 210 2073402CE MLG GEARBOX BROKEN B EG6RK NONE O OTHER ININSP/MAINT 1 GL279422T 57222 COMPLIANCE WITH AD 76-14-07 R2 FOUND LT MAIN GEAR SADDLE BROKEN. 1H71 3O RT3A21 20030203000982003020300098SO 2003 2 3 2003FA0000057 220030109G7414 DISTRIBUTOR BLK CONT O520 IO520BB 17032SO MAGNETO INOPERATIVE B VJ3RK NONE O OTHER ININSP/MAINT 1 WP07 MAGNETO REMOVED FROM ENGINE FOR 500 HOUR INSPECTION IAW MM. DURING INSPECTION FOUND THAT THE CARBON BRUSH HAS EXCESSIVE WEAR. BECAUSE OF THIS EXCESSIVE WEAR IT IS CAUSING CARBON DUST WHICH IS SHORTING OUT MAGNETOS AND CAUSING THEM TO MELT DOWN. BECAUSE THE GEAR IS WORKING SIDE TO SIDE IN BLOCK HOUSING ALLOWING THE BRUSH TO COME IN CONTACT WITH BRUSH HOLDER. REDUCING THE TOLERANCES BETWEEN DISTRIBUTOR BLOCK AND THE GEAR POST WHERE THEY FIT TOGETHER TO HELP PREVENT GEAR FROM ROCKING BACK AND FORTH. 3 O E5CE 20030203000992003020300099SO 2003 2 3 2003FA0000058 220030109G7414 DISTRIBUTOR BLK SLICK CONT O520 IO520BB 17032SO MAGNETO INOPERATIVE C VJ3RK NONE O OTHER ININSP/MAINT 1 WP07 513 02051452 MAGNETO REMOVED FROM ENGINE FOR 500 HOUR INSPECTION IAW MM. DURING INSPECTION FOUND THAT THE CARBON BRUSH HAS EXCESSIVE WEAR. BECAUSE OF THIS EXCESSIVE WEAR IT IS CAUSING CARBON DUST WHICH IS SHORTING OUT MAGNETOS AND CAUSING THEM TO MELT DOWN. BECAUSE THE GEAR IS WORKING SIDE TO SIDE IN BLOCK HOUSING ALLOWING THE BRUSH TO COME IN CONTACT WITH BRUSH HOLDER. C/A: REDUCING THE TOLERANCES BETWEEN DISTRIBUTOR BLOCK AND THE GEAR POST WHERE THEY FIT TOGETHER TO HELP PREVENT GEAR FROM ROCKING BACK AND FORTH. 3 O E5CE 20030203001002003020300100SO 2003 2 3 2003FA0000059 220030110G7414 DISTRIBUTOR BLK SLICK CONT O520 IO520BB 17032SO MAGNETO INOPERATIVE B VJ3RK NONE O OTHER ININSP/MAINT 1 WP07 14 01100458 MAGNETO REMOVED FROM ENGINE FOR 500 HOUR INSPECTION IAW MM. DURING INSPECTION FOUND THAT THE CARBON BRUSH HAS EXCESSIVE WEAR. BECAUSE OF THIS EXCESSIVE WEAR IT IS CAUSING CARBON DUST WHICH IS SHORTING OUT MAGNETOS AND CAUSING THEM TO MELT DOWN. BECAUSE THE GEAR IS WORKING SIDE TO SIDE IN BLOCK HOUSING ALLOWING THE BRUSH TO COME IN CONTACT WITH BRUSH HOLDER. REDUCING THE TOLERANCES BETWEEN DISTRIBUTOR BLOCK AND THE GEAR POST WHERE THEY FIT TOGETHER TO HELP PREVENT GEAR FROM ROCKING BACK AND FORTH. 3 O E5CE 20030203001012003020300101SO 2003 2 3 2003FA0000060 220030110G7414 DISTRIBUTOR BLK CONT O520 IO520BB 17032SO MAGNETO INOPERATIVE B VJ3RK NONE O OTHER ININSP/MAINT 1 WP07 MAGNETO REMOVED FROM ENGINE FOR 500 HOUR INSPECTION IAW MM. DURING INSPECTION FOUND THAT THE CARBON BRUSH HAS EXCESSIVE WEAR. BECAUSE OF THIS EXCESSIVE WEAR IT IS CAUSING CARBON DUST WHICH IS SHORTING OUT MAGNETOS AND CAUSING THEM TO MELT DOWN. BECAUSE THE GEAR IS WORKING SIDE TO SIDE IN BLOCK HOUSING ALLOWING THE BRUSH TO COME IN CONTACT WITH BRUSH HOLDER. REDUCING THE TOLERANCES BETWEEN DISTRIBUTOR BLOCK AND THE GEAR POST WHERE THEY FIT TOGETHER TO HELP PREVENT GEAR FROM ROCKING BACK AND FORTH. 3 O E5CE 20030203001022003020300102SO 2003 2 3 2003FA0000061 220030110G7414 DISTRIBUTOR BLK CONT O520 IO520BB 17032SO MAGNETO INOPERATIVE B VJ3RK NONE O OTHER ININSP/MAINT 1 WP07 468 MAGNETO REMOVED FROM ENGINE FOR 500 HOUR INSPECTION IAW MM. DURING INSPECTION FOUND THAT THE CARBON BRUSH HAS EXCESSIVE WEAR. BECAUSE OF THIS EXCESSIVE WEAR IT IS CAUSING CARBON DUST WHICH IS SHORTING OUT MAGNETOS AND CAUSING THEM TO MELT DOWN. BECAUSE THE GEAR IS WORKING SIDE TO SIDE IN BLOCK HOUSING ALLOWING THE BRUSH TO COME IN CONTACT WITH BRUSH HOLDER. REDUCING THE TOLERANCES BETWEEN DISTRIBUTOR BLOCK AND THE GEAR POST WHERE THEY FIT TOGETHER TO HELP PREVENT GEAR FROM ROCKING BACK AND FORTH. 3 O E5CE 20030203001042003020300104SO 2003 2 3 2003FA0000064 220030108G7414 DISTRIBUTOR BLK SLICK CONT O520 IO520BB 17032SO MAGNETO INOPERATIVE B K NONE O OTHER ININSP/MAINT 1 WP07 01042018 MAGNETO REMOVED FROM ENGINE FOR 500 HOUR INSPECTION IAW MM. DURING INSPECTION FOUND THAT THE CARBON BRUSH HAS EXCESSIVE WEAR. BECAUSE OF THIS EXCESSIVE WEAR IT IS CAUSING CARBON DUST WHICH IS SHORTING OUT MAGNETOS AND CAUSING THEM TO MELT DOWN. BECAUSE THE GEAR IS WORKING SIDE TO SIDE IN BLOCK HOUSING ALLOWING THE BRUSH TO COME IN CONTACT WITH BRUSH HOLDER. REDUCING THE TOLERANCES BETWEEN DISTRIBUTOR BLOCK AND THE GEAR POST WHERE THEY FIT TOGETHER TO HELP PREVENT GEAR FROM ROCKING BACK AND FORTH. 3 O E5CE 20030203001052003020300105SO 2003 2 3 2003FA0000065 220030108G7414 DISTRIBUTOR BLK SLICK CONT O520 IO520BB 17032SO MAGNETO INOPERATIVE B VJ3RK NONE O OTHER ININSP/MAINT 1 WP07 01042019 MAGNETO REMOVED FROM ENGINE FOR 500 HOUR INSPECTION IAW MM. DURING INSPECTION FOUND THAT THE CARBON BRUSH HAS EXCESSIVE WEAR. BECAUSE OF THIS EXCESSIVE WEAR IT IS CAUSING CARBON DUST WHICH IS SHORTING OUT MAGNETOS AND CAUSING THEM TO MELT DOWN. BECAUSE THE GEAR IS WORKING SIDE TO SIDE IN BLOCK HOUSING ALLOWING THE BRUSH TO COME IN CONTACT WITH BRUSH HOLDER. REDUCING THE TOLERANCES BETWEEN DISTRIBUTOR BLOCK AND THE GEAR POST WHERE THEY FIT TOGETHER TO HELP PREVENT GEAR FROM ROCKING BACK AND FORTH. 3 O E5CE 20030203001072003020300107CE 2003 2 3 2003FA0000066 120030103G550035405130 STRUCTURE BEECH 35 35BEECH 1151502CE CONT E185 E18511 17014SO STABILIZER CRACKED D K NONE O OTHER ININSP/MAINT 1 CE0580445 D45 21665D211 CRACK FOUND IN LOWER RT ATTACH BOLT HOLE FROM HOLE CENTER AT THE 2 O`CLOCK POSITION. FOUND DURING INSPECTION FOR AD. CRACK LENGTH .250 INCH. 1L71 3O3 O A777 E246 20030203001092003020300109EU 2003 2 3 2003FA0000068 120030115G6420109013106101 BUSHING AGUSTAA109 A109E 0260119EU T/R HEAD LOOSE B LN3RO OTHER O OTHER NRNOT REPORTED 1 EA0312VW 11074 GRIP BUSHINGS WERE ROTATING INSIDE GRIPS CAUSING SCORING OF HUB. 1G72 3U RTH7EU 20030203001102003020300110EU 2003 2 3 2003FA0000069 120030115G6410109813129101 GRIP AGUSTAA109 A109E 0260119EU BLADE GRIP LOOSE B LN3RO OTHER O OTHER NRNOT REPORTED 1 EA0312VW 366 11074 GRIP BUSHINGS WERE ROTATING INSIDE OF GRIP CAUSING GRIP INSIDE DIAMETER TO WEAR BEYOND LIMITS. 1G72 3U RTH7EU 20030203001122003020300112EA 2003 2 3 2003FA0000070 220030116G7414 BRUSHES SLICK LYC O540 AEIO540D4D5 EA MAGNETO MISSING B VJ3RK NONE O OTHER ININSP/MAINT 1 WP07 01050130 MAGNETO REMOVED FROM ENGINE FOR 500 HOUR INSPECTION IAW MM. DURING INSPECTION FOUND THAT THE CARBON BRUSH WAS MISSING. MFG LOOK AT REDUCING THE TOLERANCES BETWEEN THE DISTRIBUTOR BLOCK AND THE GEAR POST WHERE THEY FIT TOGETHER TO HELP PREVENT GEAR FROM ROCKING BACK AND FORTH. 3 O 1E4 20030203001132003020300113 2003 2 3 2003FA0000071 420030104G2561FV35E3505101 LIFE VEST CABIN FAILED B KQ1RK NONE L NO TEST ININSP/MAINT 1 EA07 LIFE VEST FAILED, MFG RECOMMENDED CELL PRESSURE TEST. DOM: JULY 1990 20030203001162003020300116EA 2003 2 3 2003FA0000073 220030116G7414 DISTRIBUTOR BLK SLICK LYC O540 AEIO540D4A5 41532EA MAGNETO INOPERATIVE B VJ3RK NONE O OTHER ININSP/MAINT 1 WP07 02072354 MAGNETO REMOVED FROM ENGINE FOR 500 HOUR INSPECTION IAW MM. DURING INSPECTION FOUND THAT THE CARBON BRUSH HAS EXCESSIVE WEAR. BECAUSE OF THIS EXCESSIVE WEAR IT IS CAUSING CARBON DUST WHICH IS SHORTING OUT MAGNETOS AND CAUSING THEM TO MELT DOWN. BECAUSE THE GEAR IS WORKING SIDE TO SIDE IN BLOCK HOUSING ALLOWING THE BRUSH TO COME IN CONTACT WITH BRUSH HOLDER. C/A: REDUCING THE TOLERANCES BETWEEN DISTRIBUTOR BLOCK AND THE GEAR POST WHERE THEY FIT TOGETHER TO HELP PREVENT GEAR FROM ROCKING BACK AND FORTH. 3 O 1E4 20030203001182003020300118EA 2003 2 3 2003FA0000074 220030116G7414 DISTRIBUTOR BLK SLICK LYC O540 AEIO540D4D5 EA MAGNETO INOPERATIVE B VJ3RK NONE O OTHER ININSP/MAINT 1 WP07 00072421 MAGNETO REMOVED FROM ENGINE FOR 500 HOUR INSPECTION IAW MM. DURING INSPECTION FOUND THAT THE CARBON BRUSH HAS EXCESSIVE WEAR. BECAUSE OF THIS EXCESSIVE WEAR IT IS CAUSING CARBON DUST WHICH IS SHORTING OUT MAGNETOS AND CAUSING THEM TO MELT DOWN. BECAUSE THE GEAR IS WORKING SIDE TO SIDE IN BLOCK HOUSING ALLOWING THE BRUSH TO COME IN CONTACT WITH BRUSH HOLDER. C/A: REDUCING THE TOLERANCES BETWEEN DISTRIBUTOR BLOCK AND THE GEAR POST WHERE THEY FIT TOGETHER TO HELP PREVENT GEAR FROM ROCKING BACK AND FORTH. 3 O 1E4 20030203001192003020300119EA 2003 2 3 2003FA0000075 220030117G7414 DISTRIBUTOR BLK SLICK LYC O540 AEIO540D4D5 EA MAGNETO INOPERATIVE B VJ3RK NONE O OTHER ININSP/MAINT 1 WP07 00072418 MAGNETO REMOVED FROM ENGINE FOR 500 HOUR INSPECTION IAW MM. DURING INSPECTION FOUND THAT THE CARBON BRUSH WAS RUBBING AND CAUSING CARBON DUST. RECOMMENDATION IS TO HAVE MFG LOOK AT PROCESS OF MANUFACTURING AND LOOK AT REDUCING THE TOLERANCES BETWEEN THE DISTRIBUTOR BLOCK AND THE GEAR POST WHERE THEY FIT TOGETHER TO HELP PREVENT GEAR FROM ROCKING BACK AND FORTH. FURTHER INVESTIGATION BY MFG REQUIRED TO CORRECT PROBLEMS. 3 O 1E4 20030203001292003020300129SW 2003 2 3 2003FA0000082 120030102G7930 WARNING LIGHT BELL 206 206L1 1182107SW ALLSN 250C 250C30 03013GL ENGINE ACTIVATED C A UNSCHED LANDING J WARNING INDICATION NRNOT REPORTED 1 SO094227E6729 6727 45702 ENGINE MAGNETIC PLUG WARNING LIGHT CAME ON DURING FLIGHT. PILOT LANDED AIRCRAFT AND MAINTENANCE WAS NOTIFIED. MECHANIC INSPECTED MAGNETIC PLUGS AND FOUND PASTE ON UPPER ENGINE GEARBOX MAGNETIC CHIP PLUG. MECHANIC CLEANED AND REINSTALLED PLUG PERFORMED MAINTENANCE IAW MM. 1G71 3U3 U H2SW E1GL 20030203001312003020300131EA 2003 2 3 2003FA0000084 220030102G726130216018 HOUSING BEECH 90 C90A 1152911CE PWA PT6 PT6* 52043EA OIL PUMP CRACKED D O OTHER KJ FLUID LOSS WARNING INDICATION NRNOT REPORTED 1 EA03555AL2702 LJ1268 OIL PRESSURE DROPPED IN FLIGHT TO BOTTOM OF GREEN ARC. TROUBLESHOOTING FOUND OIL PUMP HOUSING TO BE CRACKED. 1L72 3T3 TRT3A20 E2NE 20030203001342003020300134SO 2003 2 3 2003FA0000085 220030110G8530628752 CONNECTING ROD BEECH 95 95B55 1152729CE CONT O470 IO470* 17026SO ENGINE BENT C K NONE O OTHER ININSP/MAINT 1 NM095JA 3386 TC942 NR 5 CYLINDER WAS REMOVED FROM RIGHT ENGINE AFTER ROUGH OPERATION AT GROUND RUN UP AND COMPRESSION LOSS. INSPECTION REVEALED BENT I BEAM SECTION OF CONNECTING ROD AND DAMAGE TO SKIRT OF PISTON. FAILURE ANALYSIS DETERMINED CAUSE TO BE HYDROSTATIC LOCK DUE TO OVERPRIMING AT STARTUP. NR 5 CYL OF RT ENGINE, NR 6 CYL OF LT ENGINE ARE MOST LIKELY TO HAVE THIS PROBLEM. INDUCTION SYSTEM BALANCE TUBE NEEDS PROPERLY POSITIONED DRAIN FOR LT AND RT TO PREVENT THIS PROBLEM. 1L72 3O3 ORT3A16 E1CE 20030203001352003020300135SO 2003 2 3 2003FA0000086 220030115G7414103915686 BEARING BEECH 58 58P 1152744CE CONT O520 TSIO520* 17040SO DISTRIBUTOR BLK LOOSE C K NONE O OTHER ININSP/MAINT 1 SW01135Z 189 TJ247 DURING CRUISE POWER SETTING IN FLIGHT. RT ENGINE RPM FLUX 100-200 RPM AND MANIFOLD PRESSURE FLUX 1 INCH TO 2 INCH. DURING GROUND RUN TO TROUBLESHOOT SYSTEM ENGINE RPM WOULD SUDDENLY DROP 200-400 RPM. AT CRUISE SETTING. PERFORMED MAGNETO CHECK. LT MAG FAILED. BEARING IN DISTRIBUTOR BLOCK SPINNING, POSSIBLE DATE CODE ON BLOCK 01/09. 1L72 3O3 O A23CE E8CE 20030203001372003020300137SO 2003 2 3 2003FA0000088 220030114G8530 INTAKE VALVE CESSNA188 T188C 2073012CE CONT O520 TSIO520T 17040SO ENGINE LEAKING D HNJGK NONE O OTHER ININSP/MAINT 1 NM139614K T18803962T 239512R AT 470 HOURS ON REBUILT ENGINE, ALL CYLINDERS WERE REMOVE FOR INTAKE VALVE LEAKAGE. ALL VALVE SEATS WERE EASILY RECONDITIONED, BUT VALVES SHOWED MAJOR IDENTATION AT THE SEAT CONTACT AREA, WITH APPARENT MOVEMENT OF VALVE MATERIAL OUTWARD. 1L71 3O3 O A9CE E8CE 20030203001382003020300138CE 2003 2 3 2003FA0000089 120030107G2730NAS302665170 CONTROL CABLE BEECH 90 C90 1152913CE PWA PT6 PT6* 52043EA ELEVATOR FAILED B TBWRO OTHER O OTHER NRNOT REPORTED 1 SW1590ZH LJ594 ELEVATOR TRIM CABLE FAILED IN FLIGHT WITH NO INCIDENT AT STATION 216. CABLE BROKE AT THE ELEVATOR TRIM SERVO (SERVO: PN 1C4696456). TRIM SERVO HAD BEEN REPLACED ON YEAR PRIOR WITH NO NOTED DEFECTS TO THE TRIM CABLE AT THAT TIME. STC SA1454SW EDO AIRE MITCHELL FLIGHT DIRECTOR AUTO-PILOT SYSTEM WAS INSTALLED APRIL 3, 1972. TIME ON FAILED PART IS 10,034.1 HOURS. SUSPECT CABLE HAD INTERNAL FAILURE OF STRANDS UNABLE TO SEE WHEN INSTALLED ON SERVO. (SW15200304640) 1L72 3T3 T 3A20 E2NE 20030203001392003020300139 2003 2 3 2003FA0000090 420030109G2561CA12P0201 LIFE VEST CABIN FAILED B KQ1RK NONE L NO TEST ININSP/MAINT 1 EA07 INDIVIDUAL FLOAT DEVICE FAILED MFG RECOMMENDED CELL PRESSURE TEST. DOM JUNE 1991. 20030203001402003020300140 2003 2 3 2003FA0000091 420030103G2561CA12P201 LIFE VEST CABIN FAILED B KQ1RK NONE L NO TEST ININSP/MAINT 1 EA07 FLOAT DEVICE FAILED MFG RECOMMENDED CELL PRESSURE IAW 25-60-13. DOM: NOV 1981. 20030204000012003020400001CE 2003 2 4 2003FA0000095 120030103G532004320049 BRACKET CESSNA150 A152 2071836CE LYC O235 O235* 41505EA FUSELAGE CRACKED B LC1RK NONE O OTHER ININSP/MAINT 1 EA078144L4123 A1520833 DURING AN INSPECTION FOR AD (CRACKED NUT PLATES) THE BRACKET WHICH HOLDS THE NUT PLATES WAS FOUND CRACKED ON THE UPPER RIGHT HAND SIDE FROM THE CORNER RELIEF HOLE, INBOARD FOR APPROXIMATELY ONE INCH ALONG THE TOP BEND. THIS CRACK IS DIRECTLY ADJACENT TO AND JUST AFT OF THE UPPER RIGHT NUT PLATE WHICH IS ONE OF THE EIGHT NUT PLATES ADDRESSED IN THE MENTIONED AD, HOWEVER THE AD DOES NOT ADDRESS AN INSPECTION OF THE SUPPORTING STRUCTURE IN ANY MANNER. 1H71 3O3 O 3A19 E223 20030204001522003020400152CE 2003 2 4 2003FA0000096 120030128G323050411081 BEARING RACE CESSNA340 340CESSNA 2076404CE CONT O520 TSIO520NB 17040SO LT MLG CRACKED D K NONE L NO TEST ININSP/MAINT 1 SW055910M3741 643 3400067 DURING INSPECTION IT WAS DISCOVERED THAT LT MLG WOULD NOT RETRACT. GEAR WAS DISASSEMBLED. BEARING INNER RACE WAS FOUND TO BE CRACKED. 1L72 3O3 O 3A25 E8CE 20030204001532003020400153WP 2003 2 4 2003FA0000097 220030124G7314 DRIVE SHAFT GARRTT GARRTTTFE731TFE73122B 01518WP FUEL PUMP STRIPPED C A UNSCHED LANDING XJ ENGINE FLAMEOUT WARNING INDICATION CLCLIMB 1 SW11 MX498409 P89705 LT ENGINE FLAME OUT CLIMBING THROUGH 7,500 FT MSL AT 250 KTS. NO ABNORMAL INDICATIONS PRIOR. UNABLE TO RE-LIGHT. UPON REMOVAL OF FUEL PUMP FROM ENGINE, FOUND SHAFT SPLINES SEPARATED FROM MAIN PUMP SHAFT. REPLACED PUMP WITH OVERHAULED UNIT. 4 F E6WE 20030204001542003020400154EA 2003 2 4 2003FA0000098 220030128G8520 CRANKSHAFT LYC IO360 IO360L2A EA ENGINE DAMAGED H K NONE O OTHER ININSP/MAINT 1 SW15 THIS CRANKSHAFT ALONG WITH FOUR OTHERS OF SAME KIND AND AGE, HAVE EXTREMELY HEAVY GRAINULAR INDICATIONS ON JOURNALS, RADII, FLANGE RADIUS AND SEAL SURFACE WHEN VIEWED UNDER MAGNETIC PARTICLE INSPECTION, WET METHOD. THESE INDICATIONS ARE EXTREMELY RARE WITH CRANKSHAFTS, COMMON ONLY INLIGHT OF SB 549, ALTHOUGH THESE PARTS ARE NOT LISTD IN THE BULLETIN. ONE SUCH CRANKSHAFT HAS BEEN RECERTIFIED BY OEM. 3 O 1E10 20030204001552003020400155EA 2003 2 4 2003FA0000099 220030128G8520 CRANKSHAFT LYC IO360 IO360L2A EA ENGINE DAMAGED H K NONE O OTHER ININSP/MAINT 1 SW15 THIS CRANKSHAFT ALONG WITH FOUR OTHERS OF SAME KIND AND AGE, HAVE EXTREMELY HEAVY GRAINULAR INDICATIONS ON JOURNALS, RADII, FLANGE RADIUS AND SEAL SURFACE WHEN VIEWED UNDER MAGNETIC PARTICLE INSPECTION, WET METHOD. THESE INDICATIONS ARE EXTREMELY RARE WITH CRANKSHAFTS, COMMON ONLY INLIGHT OF SB 549, ALTHOUGH THESE PARTS ARE NOT LISTD IN THE BULLETIN. ONE SUCH CRANKSHAFT HAS BEEN RECERTIFIED BY OEM. 3 O 1E10 20030204001562003020400156SW 2003 2 4 2003FA0000100 120030129G5310206033210 BEAM BELL 206 206L3 1182108SW ALLSN 250C 250C30P 03013GL FUSELAGE ELONGATED B K NONE O OTHER ININSP/MAINT 1 WP07112TV11436 51123 NUMEROUS RIVETS WERE FOUND WORKING LOOSE IN THE BOX BEAM DURING A 100/300/ANNUAL INSPECTION. REQUIRED REPLACEMENT OF 20 EACH CHERRY MAXI-BOLTS, 16 EACH CHERRY MAX RIVETS. DIGITAL PICTURES WERE TAKEN TO FURTHER DESCRIBE. 1G71 3U3 U H2SW E1GL 20030218000522003021800052SO 2003 2 18 2003FA0000103 220030123G7414 DISTRIBUTOR BLK CONT O520 IO520BB 17032SO MAGNETO WORN B VJ3RK NONE O OTHER ININSP/MAINT 1 WP07 502 02040027 MAGNETO REMOVED FROM ENGINE FOR 550 HOUR INSPECTION IAW THE MAINTENANCE MANUAL. DURING INSPECTION FOUND THAT THE CARBON BRUSH WAS RUBBING AND CAUSING CARBON DUST. RECOMMENDATION IS TO HAVE MFG LOOK AT REDUCING THE TOLERANCES BETWEEN THE DISTRIBUTOR BLOCK AND THE GEAR POST WHERE THEY FIT TOGETHER TO HELP PREVENT GEAR FROM ROCKING BACK AND FORTH. 3 O E5CE 20030218000532003021800053SO 2003 2 18 2003FA0000104 220030123G7414 DISTRIBUTOR BLK SLICK CONT O520 IO520BB 17032SO MAGNETO DAMAGED B VJ3RK NONE O OTHER ININSP/MAINT 1 WP07 502 02040023 MAGNETO REMOVED FROM ENGINE FOR 500 HOUR INSPECTION IAW THE MAINTENANCE MANUAL. DURING INSPECTION FOUND THAT THE CARBON BRUSH WAS RUBBING AND CAUSING CARBON DUST. HAVE MFG LOOK AT REDUCING THE TOLERANCES BETWEEN THE DISTRIBUTOR BLOCK AND THE GEAR POST WHERE THEY FIT TOGETHER TO HELP PREVENT GEAR FROM ROCKING BACK AND FORTH. 3 O E5CE 20030218000542003021800054SO 2003 2 18 2003FA0000105 220030122G7414 DISTRIBUTOR BLK SLICK CONT O520 IO520BB 17032SO MAGNETO DAMAGED B VJ3RK NONE O OTHER ININSP/MAINT 1 WP07 501 01071879 MAGNETO REMOVED FROM ENGINE FOR 500 HOUR INSPECTION IAW THE MM. DURING INSPECTION FOUND THAT THE CARBON BRUSH WAS RUBBING AND CAUSING CARBON DUST. HAVE MFG LOOK AT REDUCING THE TOLERANCES BETWEEN THE DISTRIBUTOR BLOCK AND THE GEAR POST WHERE THEY FIT TOGETHER TO HELP PREVENT GEAR FROM ROCKING BACK AND FORTH. 3 O E5CE 20030218000552003021800055GL 2003 2 18 2003FA0000109 220030201G7261R584P205 BOLT GE CF6 CF6* 30020GL BEARING RETAINERMISSING B O OTHER KJ FLUID LOSS WARNING INDICATION NRNOT REPORTED 1 SW99 451304 AIRCRAFT OPERATOR REPORTED A TOTAL LOSS OF OIL PRESSURE AND QUANTITY 20 MINUTES AFTER TAKE OFF FROM LAX. THIS RESULTED IN A IFSD AND AN ATB. INVESTIGATION AT THE ENGINE REPAIR STATION REVEALED THAT ONE OF THE TWELVE RETAINING BOLTS FOR THE NR 7 BEARING WAS MISSING. THE BOLT WAS FOUND IN THE BEARING SCAVENGE LINE. THE BOLT HAD BLOCKED THE PIPE AND CAUSED THE ENGINE TO PUMP ALL OF THE OIL OVERBOARD. 4 F E23EA 20030218000562003021800056EU 2003 2 18 2003FA0000110 120030129G5510453005501 HINGE ISRAEL1124 1124 4500102EU GARRTTTFE731TFE731* 01518WP HORIZONTAL STABCRACKED G K NONE O OTHER ININSP/MAINT 1 SW15400TF4550 279 DURING THE PERFORMANCE OF AD-89-12-08 THE LT OUTBOARD HINGE LUG WAS FOUND CRACKED. CRACK WAS VISUAL TO THE NAKED EYE, MICRO FRACTURES WERE NOTED LAST 200 HOUR INSPECTION BUT WERE NOT DEFINED. SUGGEST THAT CAUSE COULD BE DUE TO EXCESSIVE RADIAL AND AXIAL LOADS TRANSMITTED TO THE HINGE DURING T/R APPLICATIONS. 2M72 4F4 F A2SW E6WE 20030218000572003021800057EU 2003 2 18 2003FA0000111 120030128G5510453005501 HINGE ISRAEL1124 1124 4500102EU GARRTTTFE731TFE731* 01518WP HORIZONTAL STABCRACKED G K NONE O OTHER ININSP/MAINT 1 SW1559PT 5575 202 DURING THE PERFORMING OF AD 89-12-08, THE LT OUTBOARD HINGE LUG WAS FOUND CRACKED. CRACK WAS VISUAL TO THE NAKED EYE. SUGGEST THAT CRACK CAUSE DUE TO EXCESSIVE RADIAL AND AXIAL LOADS TRANSMITTED TO THE HINGE DURING THRUST REVERSE APPLICATIONS AND FLIGHT INTO TURBULENT AIR. THE RADIAL AND AXIAL LOADS CAN BE REDUCED BY ASSURING THAT THE HORIZONTAL STABILIZER SCISSOR SYSTEM IS INSPECTED EACH INSPECTION FOR SCISSOR WEAR AND SCISSOR BUSHING AND PIN WEAR. 2M72 4F4 F A2SW E6WE 20030218000582003021800058 2003 2 18 2003FA0000113 420030116G25622020REVA BATTERY CESSNA182 182S 2072701CE LYC O540 IO540* 41532EA ELT CORRODED B RJURK NONE O OTHER ININSP/MAINT 1 WP19399ME 18280878 SERIES 2000 AND 3000 BATTERY CORRODED FROM GASING BATTERY DISCOLORED SYTRAFOAM CASE, ALSO CAUSED DAMAGED TO ELT PLASTIC COVER. DISCOVERED AT ANNUAL INSPECTION. SUGGEST MORE FREQUENT INSPECTION. 1H71 3O3 ONT3A13 1E4 20030218000652003021800065EU 2003 2 18 2003FA0000114 120030113G282025PF295139A CONDUIT BRAERODH125 HS125700A 4230170EU GARRTTTFE731TFE731* 01518WP FUEL CELL CORRODED G K NONE K FLUID LOSS ININSP/MAINT 1 SO17703TS 257031 CORROSION CAUSES PIN HOLES, FUEL LEAKS INTO CONDUIT AND LEAKS INTO BOOST PUMP WIRES. POSSIBLE EXPLOSION OR FIRE WITH FUEL LEAKING DIRECTLY INTO WIRES. SUGGEST EMERGENCY INSPECTION OF ALL CONDUITS. IN ALL SIMILAR MAKE AND MODELS THE TUBE CORRODES FROM THE INSIDE, WHICH IS NOT PAINTED. 2L72 4F4 F A3EU E6WE 20030218000722003021800072CE 2003 2 18 2003FA0000115 120030127G2752C1444881 CLIP LEAR 45 45LEAR 5170805CE GARRTTTFE731TFE7313 01518WP TE FLAPS BACKED OUT B K NONE O OTHER ININSP/MAINT 1 SO13720CC1372 45072 LEFT FLAP OUTBOARD LOWER ACTUATOR COVER PLATE FOUND DISTORTED AND BENT. UPON INVESTIGATION FOUND CIR-CLIP FOR LOWER GIMBLE PIN MISSING. THIS MISSING CLIP ALLOWED GIMBLE PIN TO DROP DOWN. WHILE PIN WAS BACKING OUT AND DURING FLAP OPERATION DAMAGED OCCURRED TO THE FLAP ACTUATOR COVER PLATE AND FLAP STRUCTURE. REPLACED POWER UNIT-FLAP DRIVE. COMPLETED REPAIRS TO COVER PLATE AND FLAP STRUCTURE PER LEAR INSTRUCTIONS. SUGGEST INSPECTION FOR CIR-CLIPS AT AN INCREASED INTERVAL. 2L72 4F4 FRTT00008WIE6WE 20030218000782003021800078 2003 2 18 2003FA0000121 420030119G6113055032111 BULKHEAD CESSNA172 172S 2072439CE SPINNER CRACKED B IBIRO OTHER O OTHER NRNOT REPORTED 1 EA273537B336 172S8827 SPINNER BULKHEAD CRACKED. 1H71 3O NT3A12 20030218000792003021800079 2003 2 18 2003FA0000122 420030108G611305503671 SPINNER CESSNA172 172S 2072439CE PROPELLER CRACKED B IBIRO OTHER O OTHER NRNOT REPORTED 1 EA27393SP377 172S8290 PROPELLER SPINNER CRACKED. 1H71 3O NT3A12 20030218000812003021800081 2003 2 18 2003FA0000124 420030114G6113055032111 BULKHEAD CESSNA172 172S 2072439CE SPINNER CRACKED B IBIRO OTHER O OTHER NRNOT REPORTED 1 EA27393SP1347 172S8290 SPINNER AFT BULKHEAD, CRACKED. 1H71 3O NT3A12 20030218001192003021800119SO 2003 2 18 2003FA0000131 220030124G7414 DISTRIBUTOR GEARBENDIX MOONEYM20 M20R 5870225SW CONT O550 IO550G 17042SO MAGNETO STRIPPED C HJLAO OTHER O OTHER NRNOT REPORTED 1 SW17326TJ383 D01FA172R 290043 679119 DISTRIBUTOR GEAR, MAGNETO INOPERATIVE ON RUN-UP ON INSPECTION FOUND TEETH SHEARED IN DISTRIBUTOR GEAR-90 DEGREES. 1L71 3O3 ORT2A3 E3SO 20030218001202003021800120SO 2003 2 18 2003FA0000132 220030123G8520 CRANKSHAFT CESSNA210 210 2073402CE CONT O470 IO470E 17026SO ENGINE BROKEN G A UNSCHED LANDING EY VIBRATION/BUFFET ENGINE STOPPAGE NRNOT REPORTED 1 CE016572X 57572 775430E AIRCRAFT MADE EMERGENCY LANDING AFTER ENGINE FAILURE. INVESTIGATION FOUND THAT THE ENGINE CRANKSHAFT HAD BROKEN BETWEEN CYLINDERS TWO AND THREE. 1H71 3O3 ORT3A21 3E1 20030218001222003021800122NM 2003 2 18 2003FA0000134 120030120G2910511531 HOUSING BOEING737 737* NM SHUTTLE VALVE DAMAGED C IU6RO OTHER O OTHER NRNOT REPORTED 1 NM01 5531 PIN HOLE FROM INTERIOR OF UNIT INTO THE INSIDE OF THE MOUNTING LUG HOLE. HIGH PRESSURE ERROSION. (WC/ NR 171602) 2L72 4F RTA16WE 20030218001232003021800123NM 2003 2 18 2003FA0000135 120030128G291065446922 HOUSING BOEING737 737* NM HYD MODULE CRACKED B IU6RO OTHER O OTHER NRNOT REPORTED 1 NM01 80 HOUSING IS CRACKED IN PRIORITY PORT. FATIGUE. MAKE HOUSING FROM DIFFERENT MATERIAL. ( FXS NR 174173) 2L72 4F RTA16WE 20030218001262003021800126NM 2003 2 18 2003FA0000137 120030127G272269356111 SLEEVE BOEING737 737* NM RUDDER PCU GOUGED B IU6RO OTHER O OTHER NRNOT REPORTED 1 NM01 1796AC SLEEVE SURFACE IS GOUGED. SEGEMENT RUBBED ON SLEEVE DURING OPERATION. 2L72 4F RTA16WE 20030218001292003021800129NE 2003 2 18 2003FA0000138 120030127G6210 BLADE SKRSKYS64 S64E 8142604NE MAIN ROTOR DAMAGED B JYDRK NONE O OTHER ININSP/MAINT 1 NM09173AC 64015 ONE OF THE TWO TRAILING EDGE STUDS THAT WAS HOLDING THE TIP END WEIGHT PACKAGE FRACTURED (TRAIL EDGE). THE FRACTURE OCCURED APPROX. 1/4 INCH BELOW THE LOCK RING IN THE BALANCE PLATE ASSY. THIS CAUSED THE LEADING EDGE STUD TO DEFORM, ALLOWING THE WEIGHT PACKAGE TO IMPACT THE TIP CAP. THERE WERE 1.76 LBS. SECURED ON THE TRAILING EDGE STUD. DEFORMATION WAS NOTICED ON THE TIP CAP WHEN THE AIRCRAFT WAS SHUTDOWN. THE CAP WAS REMOVED FOR REPLACEMENT, EXPOSING DAMAGE TP BOTH STUDS AND THE TIP CAP. THE WEIGHT PACKAGE WAS CONTAINED BY THE TIP CAP. THE FLIGHT CREW REPORTED NO VIBRATION. 2G72 4U H4EA 20030218001362003021800136CE 2003 2 18 2003FA0000140 120030113G5540 ATTACH FITTING CESSNA177 177RG 2073709CE LYC O360 IO360A1B6 41514EA RUDDER STOP CRACKED B QLSRO OTHER O OTHER NRNOT REPORTED 1 GL2324DM 9874 177RG0678 FOUND LT RUDDER STOP RIDING OVER HORN AREA. THIS CAUSED DEFLECTION OF HORN ATTACHMENT AND CRACK. STOP BOLTS NOT HITTING HORN SQUARELY, CAUSING HORN TO RIDE UP OR DOWN UNDER STOP BOLT. ASSURE STOP BOLTS HIT HORN SQUARELY. 1H71 3O3 O A20CE 1E10 20030218001382003021800138CE 2003 2 18 2003FA0000141 120030128G323324900022 BUSHING CESSNA172 172RG 2072438CE LYC O360 O360* 41514EA MLG ACTUATOR UNSECURE B CB9TK NONE O OTHER ININSP/MAINT 1 SW155145U984 172RG0258 DURING 100HR INSPECTION, TECHNICIAN FOUND THE LT MLG ACTUATOR CAP BUSHING. UNSEATED AND STICKING OUT OF THE ACTUATOR CAP. DURING RETRACT TEST, IT WAS FOUND THAT THE BUSHING NOW INTERFERED WITH THE BRAKE SWIVEL FITTING. THE CAP WAS REMOVED AND A NEW BUSHING WAS INSTALLED IAW SEB AND SERVICE KIT. ACCOMPLISHMENT INSTRUCTIONS 99.9 HOURS LATER, THE SAME CONDITION WAS FOUND AGAIN, THIS TIME IN BOTH ACTUATOR CAPS. AGAIN, BOTH BUSHINGS WERE REPLACED. IT IS POSSIBLE THAT THE EC1300L ADHESIVE CALLED FOR IN SK172-151 IS NOT COMPATIBLE WITH THE GREASE OR HYDRAULIC FLUID FOUND IN THE ACTUATORS. ALL PARTS WERE THOROUGHLY CLEANED PRIOR TO INSTALLATION. 1H71 3O3 O 3A17 E286 20030218001402003021800140CE 2003 2 18 2003FA0000142 120030128G32332490022 BUSHING CESSNA172 172RG 2072438CE LYC O360 O360* 41514EA MLG ACTUATOR UNSECURE D CB9TK NONE O OTHER ININSP/MAINT 1 SW156220R1091 172RG0120 DURING 100 HOUR INSPECTION, TECHNICIAN FOUND RT MLG ACTUATOR CAP BUSHING, UNSEATED AND STICKING OUT OF THE ACTUATOR CAP. DURING RETRACT TEST, IT WAS FOUND THAT THE BUSHING NOW INTERFERED WITH THE BRAKE SWIVEL FITTING. THE CAP WAS REMOVED AND A NEW BUSHING WAS INSTALLED IAW MFG SEB. THE SAME CONDITION WAS FOUND AGAIN IN THE RT ACTUATOR AND THE BUSHING WAS REPLACED. IT IS POSSIBLE THAT THE EC 1300L ADHESIVE CALLED FOR IN SK172-151 IS NOT COMPATIBLE WITH THE GREASE OR HYDRAULIC FLUID FOUND IN THE ACTUATORS. ALL PARTS ARE CLEANED PRIOR TO INSTALLATION. 1H71 3O3 O 3A17 E286 20030218001412003021800141NM 2003 2 18 2003FA0000145 120030107G29106544947 HOUSING BOEING737 737* NM HYD ACTUATOR CRACKED B IU6RO OTHER O OTHER NRNOT REPORTED 1 NM01 41068 HOUSING CRACKED AROUND THE OUTER DIAMETER OPPOSITE THE SUPPORT MOUNT THROUGH BOLT. 2L72 4F RTA16WE 20030218000442003021800044NE 2003 2 18 2003FA0000150 220030209G7230 COMPRESSOR PWA JT8 JT8D219 52053NE ENGINE FOD B K NONE O OTHER ININSP/MAINT 1 GL23 726974 HIGH PRESSURE COMPESSOR FOD. 4 F E9NE 20030218000452003021800045CE 2003 2 18 2003FA0000152 120030211G3220S217840144 HOSE CESSNA210 T210N 2073456CE NLG RESTRICTED G O OTHER S AFFECT SYSTEMS LDLANDING 1 GL07210AX2483 21063033 THE CESSNA 210 LANDED WITH THE NOSE LANDING GEAR STILL IN THE NOSE WHEEL WELL. UPON TROUBLESHOOTING THE NOSE GEAR HYDRAULC SYSTEM, FOUND ONE OF THE NOSE GEAR ACTUATOR HOSES RESTRICTED AND KINKED. CESSNA SERVICE BULLETIN SEB92-8 RELATES TO THE CHANGING OF CERTIAN LANDING GEAR HOSES ON AFFECTED AIRCRAFT, WITH THIS AIRCRAFT IN THE AFFECTED SERIAL NUMBERS. 1H71 3O 3A21 20030218000462003021800046CE 2003 2 18 2003FA0000153 120030217G3240 LINE RAYTHNDH125 HAWKER800XP 7150012CE BRAKE SYS MISROUTED B K NONE W INADEQUATE Q C ININSP/MAINT 1 SW1151289 258589 DURING INSPECTION OF MLG (LT AND RT) DISCOVERED BRAKE LINES ROUTED INCORRECTLY CAUSING ONE BRAKE LINE TO CHAFE ON THE MAIN TIRE. SHOULD BE ROUTED IAW MAINTENANCE MANUAL 32-40-00-001.CHAFED LINES WERE REPLACED. 2L72 4F RTA3EU 20030218000472003021800047CE 2003 2 18 2003FA0000154 120030217G2597 WIRE RAYTHNDH125 HAWKER800XP 7150012CE ELT CHAFED B K NONE O OTHER ININSP/MAINT 1 SW11664AC 258566 DURING INSPECTION WITH TAIL CONE REMOVED DISCOVERED ELT WIRING HARNESS CHAFING HARD ON AFT SIDE OF NR 2 MAIN OXYGEN BOTTLE. 2L72 4F RTA3EU 20030218000482003021800048 2003 2 18 2003FA0000156 420030217G6122B210776A GOVERNOR AMTR VANS RV8 GL LYC O360 O360A1A 41514EA PROPELLER MALFUNCTIONED C O OTHER O OTHER NRNOT REPORTED 1 SO15468JL673 PROPELLER WOULD CYCLE NORMALLY DURING RUN UP. AFTER TAKE OFF THE PROP WOULD BECOME UNCONTROLLABLE. RMP ONLY CONTROLLABLE BY THROTTLE, NOT PROPELLER CONTROL. REMOVAL AND DISASSEMBLY OF PROP GOVERNOR REVEALED THAT ALLEN SCREW HAD BACKED OUT OF REAR OF UNIT AND WAS CAUGHT BY INTERNAL GASKET SCREEN BETWEEN UNIT AND ACCESSORY HOUSING. THIS WAS A FACTORY NEW UNIT WITH 673 HRS. APPEARS ALLEN SCREW WAS NOT PROPERLY TIGHTENED AT FACTORY. REINSTALLED WITH LOCK TIGHT AND TIGHTENED SECURELY. HAD THERE NOT BEEN GASKET SCREEN IN PLACE, ENGINE DAMAGE OR STOPPAGE COULD OCCUR. 1L71 3O3 ONTEXPA1L71E286 20030218002602003021800260SW 2003 2 18 2003FA0000159 120030130G75008961151 GASKET SWRNGNSA226 SA226TC 8780404SW GARRTTTPE331TPE33110UA 01514WP NR 2 ENGINE RUPTURED G O OTHER O OTHER NRNOT REPORTED 1 NM08158WA TC411 54192 A GASKET RUPTURED BETWEEN THE POWERPLANT AND THE BLEED AIR TUBE. THIS ALLOWED HOT BLEED AIR TO BLOW DIRECTLY ON AN ENGINE FIRE DETECTOR. THE PILOTS, FOLLOWING MFG PROCEDURES, FEATHERED THE ENGINE AND DIVERTED FOR AN UNEVENTFUL LANDING. 2L72 4T4 TRTA8SW E4WE 20030218002612003021800261CE 2003 2 18 2003FA0000160 120030218G2435 BEARING RAYTHNDH125 HAWKER800 7450004CE STARTER GEN FAILED D A UNSCHED LANDING EJ VIBRATION/BUFFET WARNING INDICATION CRCRUISE 1 NM08194JS 695 991105 258251 STARTER-GENERATOR REAR BEARING FAILED. (A) STARTER-GENERATOR SINCE OVERHAUL: 695.9 HOURS. 2L72 4F RTA3EU 20030218002622003021800262CE 2003 2 18 2003FA0000161 120030205G2435 BEARING RAYTHNDH125 HAWKER800 7450004CE GARRTTTFE731TFE731* 01518WP STARTER GEN FAILED D A UNSCHED LANDING EJ VIBRATION/BUFFET WARNING INDICATION CRCRUISE 1 NM08194JS 695 991105 258251 STARTER-GENERATOR REAR BEARING FAILED. (A) STARTER-GENERATOR SINCE OVERHAUL: 695.9 HOURS. 2L72 4F4 FRTA3EU E6WE 20030220000012003022000001EA 2003 2 20 2003FA0000162 120030120G7810C65C11073 EXHAUST PIPE DHAV DHC6 DHC6 2802606EA PWA PT6 PT6A27 52043EA ENGINE CRACKED B A7RRO OTHER O OTHER NRNOT REPORTED 1 SW19 EXHAUST DUCT, CRACK IN BASEMETAL. VIBRATION 1H72 3T4 TRTA9EA E4EA 20030220000032003022000003EU 2003 2 20 2003FA0000168 120030128G3230X030004000000 MANIFOLD GROB 120 G120A 1660208EU MLG INOPERATIVE B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07864AF 85004 DURING FLIGHT THE FLIGHT CREW REPORTED THAT THE LEFT GEAR WAS SLOW TO EXTEND. MAINTENANCE TROUBLESHOT SYSTEM AND FOUND LEFT EXTENSION VALVE BAD. PARTICLES INSIDE OF VALVE WHICH PREVENTED FLUID TO FLOW UNRESTRICTED. 1L71 3O RTA49CE 20030220000042003022000004SO 2003 2 20 2003FA0000169 220030128G7414 BRUSHES SLICK CONT O520 IO520BB 17032SO MAGNETO DIRTY B VJ3RK NONE O OTHER ININSP/MAINT 1 WP07 500 02040024 MAGNETO REMOVED FROM ENGINE FOR 500 HOUR INSPECTION IAW MM. DURING INSPECTION FOUND THAT THE CARBON BRUSH WAS RUBBING AND CAUSING CARBON DUST. 3 O E5CE 20030311000752003031100075CE 2003 3 11 2003FA0000172 120030201G324430620 TIRE CESSNA172 172R 2072401CE LYC O360 IO360A1A 41514EA MLG SPLIT B ODARO OTHER O OTHER NRNOT REPORTED 1 EA219525V 17280315 FOUND SPLIT IN LT MAIN TIRE ON SIDEWALL. RECAP TIRE 6.00 X 6. SPLIT IS APPROX 50 PERCENT RADIUS OF THE SPLIT IS TO CORD. 1H71 3O3 ONT3A12 1E10 20030311000762003031100076 2003 3 11 2003FA0000175 420030124G341610172001999 INDICATOR AMTR VANS RV8A 05608J0GL LYC O360 O360A1A 41514EA ALTIMETER INOPERATIVE D O OTHER O OTHER NRNOT REPORTED 1 WP05751MB RV8A81430 ALTIMETER PURCHASED NEW. MAY 5, 2001 MANUFACTURE DATE. FAILED TO PASS FRICTION PORTION OF PITOT/STATIC/XPDR. BIANNUAL CHECK. MFG CONTACTED AND IS UNAWARE OF ANY PROBLEMS WITH THIS MODEL BUT TECHNICIAN DOING STATIC TEST NOTES SEVERAL LIKE IT HAVE FAILED SAME CHECK EARLY IN THEIR LIFETIMES. INSTALLED IN HANGARED HOMEBUILT. UNIT RETURNED TO MFG FOR EVALUATION. 1L71 3O3 ONCEXPA1L71E286 20030311000772003031100077SO 2003 3 11 2003FA0000176 120030129G2140A23D04 SEAL PIPER PA23 PA23250 7102308SO LYC O540 IO540* 41532EA FUEL REGULATOR LEAKING D K NONE K FLUID LOSS ININSP/MAINT 1 GL09639543519 9771374 277854085 UNIT WAS INSPECTED DURING A 100 HOUR INSPECTION USING S/B. FUEL STAINS WERE FOUND, BAD NO FUEL, AROUND BOTH TOP AND BOTTOM GASKETS. UNIT WAS REMOVED FROM SERVICE. 1L72 3O3 O 1A10 1E4 20030311000782003031100078CE 2003 3 11 2003FA0000178 120030122G5210551905514 MECHANISM CESSNA501 551 2076605CE PWA JT15 JT15D4 52112NE PAX DOOR HANDLE BROKEN D O OTHER O OTHER NRNOT REPORTED 1 EA17322MA3040 5510378 CREW WAS UNABLE TO OPEN THE CABIN DOOR FROM INSIDE. LINE CREW HAD TO USE EXTERNAL HANDLE TO OPEN CABIN DOOR. THE PROBLEM WAS THE INNER DOOR RELEASE LOWER TRIGGER, HAD BROKEN OFF AT THE TOP INNER CORNER AND FALLEN BEHIND THE TRIGGER. CAUSING IT TO JAM AND NOT RELEASE THE DOOR HANDLE. 1L72 4F4 F A27CE E1NE 20030312000472003031200047NE 2003 3 12 2003FA0000181 320030123G61116607132886 BLADE ROTOL R389 R3894123F25 NE PROPELLER CRACKED B MS1RK NONE O OTHER ININSP/MAINT 1 EA27 307186910 DRG172784 PROPELLER RECEIVED FOR OVERHAUL AT TEARDOWN FOUND OUTER SLEEVE WAS CRACKED ON BLADE S/N 1140. CRACK APPROXIMATELY 4 INCHES LONG. BALDE WAS REJECTED FROM FURTHER SERVICE. 6 CP30NE 20030311000802003031100080 2003 3 11 2003FA0000182 420030202G2562AK450 ELT CABIN FAILED B X3DRK NONE L NO TEST ININSP/MAINT 1 NM03 40 INSTALLED NEW AK450 ON 09/01/2001. THE ELT WAS TESTED AND FAILED TO FUNCTION. UNIT SENT TO MFG FOR REPAIRS. 20030311000812003031100081SW 2003 3 11 2003FA0000183 120030218G21507202N BEARING MOONEYM20 M20R 5870225SW CONT O550 IO550G 17042SO AC DRIVE DISINTEGRATED B BGSRO OTHER O OTHER NRNOT REPORTED 1 EA21134MC497 290134 679311 DURING INSTALLATION OF AN AIR/OIL SEPARATOR, REMOVED THE AIR CONDITIONER ACCESSORY DRIVE OFF THE STARTER SHAFT TO INSTALL AN OIL RETURN FITTING FOR THE AIR/OIL SEPARATOR. UPON REMOVAL OF THE ACCESSORY DRIVE HOUSING, PIECES OF THE AIR CONDITIONER DRIVE BEARING FELL OUT OF THE HOUSING, FURTHER EXAMINATION REVEALED TOTAL DISENTIGRATION OF CAGE FOR BALL BEARINGS. 1L71 3O3 ORT2A3 E3SO 20030311000832003031100083CE 2003 3 11 2003FA0000192 120030217G5510083200056 BRACKET CESSNA310 310N 2074234CE STAB HINGE CRACKED D O OTHER O OTHER NRNOT REPORTED 1 WP25721X 8161 310N0061 UNIT WAS MANUFACTURED BY COMBINING TWO SHEETMETAL BRACKETS RIVETED TO A CASTING THAT HOLDS THE OUTBOARD ELEVATOR HINGE BEARING. CRACKING WAS FOUND IN BOTH THE RIGHT AND LEFT HAND ASSEMBLIES ON THE UPPER, INBOARD BEND RADIUS. THIS CAN BE SEEN FROM UNDERNEATH AND LOOKING THRU THE ELEVATOR/STABILIZER GAP. 1L72 3O 3A10 20030311000852003031100085SO 2003 3 11 2003FA0000194 120030212G321378738002 AXLE PIPER PA28 PA28161 7102803SO MLG CRACKED B C85RO OTHER O OTHER NRNOT REPORTED 1 NE012159H13331 287916192 DURING ROUTINE 100 HOUR INSPECTION, BOTH LOWER AXEL STUBS (INNER PORTION OF LOWER STRUT ASSY.) WERE FOUND CRACKED. POSSIBLE JUST NORMAL FATIGUE VS. HARD LANDING DAMAGE. BOTH ARE BELIEVED TO BE ORIGINAL EQUIPMENT. AIRCRAFT IS FLIGHT SCHOOL TRAINING AIRCRAFT. COULD HAVE THOUSANDS OF LANDINGS ON IT. 1L71 3O 2A13 20030311000862003031100086SW 2003 3 11 2003FA0000195 120030220G3710 SHAFT MOONEYM20 M20F 5870214SW LYC O360 IO360A1A 41514EA VACUUM PUMP SHEARED D O OTHER O OTHER NRNOT REPORTED 1 SW099625M 670202 NEW VACUUM PUMP SHAFT SHEARED WITH ONLY 3 HOURS OF OPERATION INSTALLED ON 04/25/2002. BROKE ON 02/19/2003. 1L71 3O3 O 2A3 1E10 20030311000872003031100087CE 2003 3 11 2003FA0000196 120030210G251005142132 CYLINDER CESSNA172 172S 2072439CE SEAT BACK FAILED B O OTHER O OTHER CLCLIMB 1 GL15355221075 172S8846 SHORTLY AFTER ROTATION SEAT BACK FAILED AND WENT TO THE RECLINED POSITION. COMPLETE FAILURE COULD NOT BE DUPLICATED IN THE SHOP BUT SOME SLIPPAGE OF THE LOCKING CYLINDER WAS NOTED. 1H71 3O NT3A12 20030311000882003031100088CE 2003 3 11 2003FA0000197 120030212G3710442CW6 PUMP BEECH 80 65B80 1152812CE LYC O720 IO720* 41546EA RT VACUUM SYS FAILED C O OTHER O OTHER NRNOT REPORTED 1 WP1346MA 239 LD413 VACUUM PUMP FAILED UNDER NORMAL OPERATING CONDITIONS. 1L72 3O3 O 3A20 1E15 20030311000902003031100090SO 2003 3 11 2003FA0000198 120030117G7120MS21919WDG CLAMP PIPER PA28 PA28R201 7102816SO LYC O360 IO360A1A 41514EA ENGINE MOUNT FAILED D O OTHER O OTHER NRNOT REPORTED 1 NE01173ND 2837025 CLAMP PN MS21919WD6 THAT RETAINS THE MIXTURE CONTROL CABLE TO THE ENGINE MOUNT FAILED ALLOWING CABLE TO RESTRICT THE OPERATION OF THE NOSE LANDING GEAR. INSPECT SECURENESS AND ROUTING OF MIXTURE CABLE ON LIKE AIRCRAFT TO PREVERT CABLE FROM RESTRICTING LANDING GEAR TRAVEL. 1L71 3O3 O 2A13 1E10 20030311000922003031100092 2003 3 11 2003FA0000199 420030217G611304500422 SPINNER CESSNA150 150L 2071826CE CONT O200 O200* 17020SO MCAULY1A101 1A101HCM GL PROPELLER DAMAGED B H9QRK NONE O OTHER ININSP/MAINT 1 NM0911418143 15075405 G16376 PROP REMOVED TO FACILITATE REPLACEMENT OF ENG CRANKSHAFT SEAL. REMOVAL OF SPINNER, SEVERE WEAR AND FRETTING OF INNER SURFACE WAS NOTED WHERE FWD BULKHEAD (PN04500503) CONTACTS SPINNER. AFTER REMOVING PROP, PROP MOUNT BOLTS WERE OVERTORQUED, RESULTING IN DEFORMATION OF WASHERS AND BULKHEAD. AFT BULKHEAD (04500465) WAS CRACKED ALMOST ENTIRELY AROUND CIRCUMFERENCE OF BOLT CIRCLE. PROP, AFT BULKHEAD, AND PROPELLER SPACER SHOWED EVIDENCE OF HAVING BEEN PRIED APART WITH A SCREWDRIVER OR SIMILAR INSTRUMENT. MOVEMENT OF CRACKED REAR BULKHEAD HAD CAUSED FRETTING DAMAGE TO AFT FACE OF PROP HUB. REQUIRED REPLACEMENT OF SPINNER, AFT BULKHEAD, AND FORWARD BULKHEAD. PROP WAS REPAIRED AT A CERTIFIED FACILITY. 1H71 3O3 O 3A19 E252 5 NP918 20030311000932003031100093GL 2003 3 11 2003FA0000200 120030103G322011799002B BRACKET CIRRUSSR SR20 05628AJGL CONT IO360 IO360* 17025CE NLG CRACKED D K NONE O OTHER ININSP/MAINT 1 EA13154SD 1197 THE PANT BRACKETS MOVE AND ALLOW THE WHEEL PANT TO MOVE AND CRACK OR COME APART. THE NEW WHEEL PANT BRACKETS COME WITH A BUSHED .2500 INCH HOLE INSTEAD OF THE NR 10 HOLE THAT IS THE SIZE NEEDED FOR THE NR 3 BOLT. WE HAVE BEEN MAKING UP PLASTIC BUSHINGS THAT JUST FIT IN THE HOLES AND TAKE UP THE EXTRA SPACE AND THE NR 3 BOLT FITS INTO. THIS HAS TAKEN CARE OF THE LOOSENESS OF THE BRACKET AND THE WHEEL PANT STAYS IN PLACE. HAVEN'T HAD ANY WHEEL PANTS CRACK OR FALL OFF BEFORE THIS HAS BEEN DONE TO PLANES SERVICED. THIS AC HAD LOST THE BACK HALF OF ITS WHEEL PANT ON LANDING. OWNER HAD REPAIRED WHEEL PANT BEFORE WHEN BACK HALF STARTED TO COME LOOSE. FOUND BRACKETS WOULD ROCK IF YOU TRIED TO MOVE THEM. 1L71 3O3 ONTA00009CHE1CE 20030311000942003031100094SO 2003 3 11 2003FA0000201 220030205G8500653688 CRANKCASE CIRRUSSR SR20 05628AJGL CONT O360 IO360E 17025SO ENGINE CRACKED D K NONE O OTHER ININSP/MAINT 1 EA1396706322 1116 ON AIRCRAFT, BECAUSE OF A CRACK FOUND ON ANOTHER ENGINE, DECIDED TO INSPECT AND FOUND A CRACK ON THE RIGHT FRONT SIDE OF THE ENGINE CASE AT THE ALTERNATOR MOUNTING FLANGE AREA. THE CRACK STARTED ON THE ALTERNATOR REAR MOUNTING CASE THROUGH BOLT. THIS CRACK IS ABOUT 2 INCHES LONG. A REPLACEMENT ENGINE HAS BEEN ORDERED. 1L71 3O3 ONTA00009CHE1CE 20030311000972003031100097SO 2003 3 11 2003FA0000202 220030205G8500653688 CRANKCASE CIRRUSSR SR20 05628AJGL CONT O360 IO360E 17025SO ENGINE CRACKED D K NONE K FLUID LOSS ININSP/MAINT 1 EA13907FS1100 1030 A SLIGHT OIL LEAK COMING FROM THE FRONT RIGHT SECTION OF THE ENGINE WAS FOUND TO BE A CRACKED CASE. REMOVED NR 1 ALTERNATOR AND DYE CHECKED THE AREA. FOUND A 6 INCH CRACK ON THE ALTERNATOR MOUNTING FLANGE STARTING ON THE ALTERNATOR MOUNTING FLANGE THROUGH BOLT. THIS ENGINE WAS REPLACED. 1L71 3O3 ONTA00009CHE1CE 20030311000982003031100098CE 2003 3 11 2003FA0000203 120030301G291367B025 PUMP PIPER PA23 PA23150 7102303CE LYC O320 O320* 41508EA HYD SYSTEM FAILED G O OTHER O OTHER NRNOT REPORTED 1 SO21211CR4456 23358 ONE PRESSURE LINE FAILED IN THE WING BETWEEN PUMP AND THE POWER PACK. AFTER REPLACEMENT OF ALUMINUM LINE THE SYSTEM WAS SERVICED AND TESTED. ON THE TEST HOP THE ENGINE DRIVEN PUMP FAILED AND THE PUMP CASE RUPTURED. THE PUMP WAS REPLACED, THE SYSTEM RESERVICED AND GROUND CHECKS COMPLETED. ON TEST HOP WITH THE SECOND PUMP, THE SAME FAILURE OCCURRED. THE PUMP RUPTURED, THE CASE SPLIT AND AFTER LOSS OF PRESSURE THE GEAR WAS EXTENDED BY HAND PUMP SUCCESSFULLY. THE TWO PUMPS AND THE POWER PACK HAVE BEEN SENT TO REPAIR STATION FOR IRAN. THIS IS ON A 1954 APACHE WITH 4456 HOURS TT. NORMAL CONFIGURATION IS WITH ONE ENGINE DRIVEN HYDRAULIC PUMP ON THE LEFT ENGINE. (EMERGENCY EXTEND BY HAND PUMP OR CO2 BLO DOWN.)1L72 3O3 ORT1A10 E274 20030311000992003031100099EA 2003 3 11 2003FA0000204 220030301G8500 ENGINE LYC O360 O360A4M 41514EA MAKING METAL G NJ1RO OTHER O OTHER NRNOT REPORTED 1 SO21 L2959536A AT JUST FIVE HOURS AFTER MAJOR OVERHAUL, THE FLIGHT CREW REPORTED THAT THE ENGINE MADE NOISE AT LOWER RPMS METAL PARTICLES THAT LOOK LIKE BEARING MATERIAL WERE FOUND IN THE OIL FILTER. AN OIL SAMPLE WAS SENT IN FOR ANALYSIS. 3 O E286 20030311001002003031100100EU 2003 3 11 2003FA0000205 120030301G2897 WIRE CASA C212 C212200 2410304EU GARRTTTPE331TPE331* 01514WP BOOST PUMP CHAFED D UATAO OTHER O OTHER NRNOT REPORTED 1 AL03287MA 287 THE WIRE PROVIDING A NEUTRAL AND POWER TO THE PUMP EXITS/ENTERS PUMP USING A SEALED AN FLARE FITTING CAUSING CHAFING TO OCCUR. 2H72 4T3 TRTA43EU E2WE 20030311001012003031100101CE 2003 3 11 2003FA0000206 120030121G531207126153 BULKHEAD CESSNA182 182Q 2072732CE CONT O470 O470* 17026SO FUSELAGE CRACKED G O OTHER O OTHER NRNOT REPORTED 1 SO09888CH 18266884 SMALL CRACK IN AFT BULKHEAD AT STA 209. ORIGINATING FROM UNDER THE ATTACH POINT OF RIGHT HORIZONTAL STABILIZER, ATHE THE UPPER INBOARD CORNER. 1H71 3O3 ONT3A13 E273 20030311001022003031100102CE 2003 3 11 2003FA0000207 120030217G2434DOFF10300F ALTERNATOR CESSNA172 172H 2072424CE CONT O300 O300D 17022SO ENGINE INOPERATIVE D O OTHER O OTHER NRNOT REPORTED 1 GL133941R 17255441 FAILURE OF THE SHAFT ON AN OVERHAULED ALTERNATOR. THE PILOT REPORTED AN AMMETER DISCHARGED WHILE CONDUCTING A PART 61 INSTRUCTIONAL FLIGHT. A PRECAUTIONARY LANDING WAS MADE AT THE NEAREST AIRPORT. INSPECTION OF THE ELECTRICAL SYSTEM INDICATED A FRACTURE OF THE MAIN SHAFT OF THE GEAR DRIVEN ALTERNATOR, AFT OF THE FRONT SEAL POSSIBLY DUE TO A MANUFACTURING DEFECT. NO OTHER DAMAGE WAS NOTED TO EITHER THE ACCESSORY GEARS OR THE ALTERNATOR ITSELF. PICTURES OF THE FRACTURED SHAFT ARE ENCLOSED. THE UNIT WAS INSTALLED IN DECEMBER 2001 AND ACCUMULATED 328 HOURS. 1H71 3O3 ONT3A12 E253 20030311001122003031100112CE 2003 3 11 2003FA0000208 120030207G5510MS21044N4 NUT ZINAIRCH2000CH2000 9950100CE STAB HINGE BOLT FAILED D Y85SO OTHER O OTHER NRNOT REPORTED 1 SO15668AM 2601008 ON BOTH STABILATOR HINGE BOLTS THE NYLON LOCKNUTS BACKED OFF DUE TO THE NYLON PART OF THE NUT BECOMING DETACHED FROM THE NUT ITSELF. THIS HAPPENED IN APPROXIMATELY 100 HOURS TSN. 1L71 3O NTTA5CH 20030311001132003031100113CE 2003 3 11 2003FA0000209 120030201G5510MS21044N4 NUT ZINAIRCH2000CH2000 9950100CE LYC O235 O235* 41505EA STAB HINGE BOLT FAILED D Y85SO OTHER O OTHER NRNOT REPORTED 1 SO15649AM 100 2601007 ON BOTH STABILATOR HNGE BOLTS THE NYLON LOCKNUTS BACKED OFF DUE TO THE NYLON PART OF THE NUT BECOMING DETACHED FROM THE NUT ITSELF. THIS HAPPENED IN APPROXIMATELY 100 HOURS TSN 1L71 3O3 ONTTA5CH E223 20030313000052003031300005CE 2003 3 13 2003FA0000211 120030110G27301016100195 TORQUE TUBE BEECH 1900 1900C 1154161CE ELEVATOR EXCESS PLAY B K NONE O OTHER ININSP/MAINT 1 SO17 20 FOUND LOOSE RIVETS ON HORN ADAPTER ATTACHED TO LT ELEVATOR TORQUE TUBE PN 1016100195. 2L72 4T RTA24CE 20030313000062003031300006CE 2003 3 13 2003FA0000212 120030304G3230AE1011888G0131 HOSE CESSNA750 750 2076810CE NLG DETERIORATED B A UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION DEDESCENT 1 SW15910QS2620 7500110 AT 19,000 FT, NOSE GEAR TRIED TO EXTEND. HYDRAULIC PRESSURE SLAMMED GEAR BACK UP. WITHIN 30 SECONDS HYDRAULIC QUANITY ON "A" SYSTEM RESERVOIR STARTED DROPPING. AIRCRAFT WAS SLOWED AND NORMAL GEAR EXTENSION WAS MADE. HYDRAULIC QUANITY ON A SYSTEM RESERVOIR WENT TO ZERO. AFTER LANDING A SYSTEM HYDRAULIC QUANITY INDICATED 10 PERCENT. TROUBLE SHOT PROBLEM TO NOSE GEAR EXTEND HOSE LEAKING. REMOVED AND REPLACED HOSE WITH NEW. PERFORMED LANDING GEAR SWING, OPERATIONAL CHECKS, BLED HYDRAULIC SYSTEMS, SERVICED RESERVOIRS, AND LEAK CHECKS. ALL FOUND TO BE SATISFACTORY. RAN ENGINES AND OPERATED HYDRAULIC SYSTEMS ON GROUND ALL FOUND TO BE SATISFACTORY. 2L72 4J RTT00007WI 20030313000072003031300007 2003 3 13 2003FA0000213 420030130G3424PI307 CONNECTOR CESSNA172 172R 2072401CE LYC O360 IO360A1A 41514EA GYRO IMPROPER PART D O OTHER O OTHER NRNOT REPORTED 1 EA07172WG 980990A 17201018 CONNECTOR FROM AIRCRAFT HARNESS TO TURN COORDINATOR HAS IMPROPERLY CRIMPED PINS AND LOOSE BACKSHELL, CAUSING AUTO-PILOT FAILURES AND INCORRECTLY DIAGNOSED FAILURES OF TURN-COORDINATORS. 1H71 3O3 ONT3A12 1E10 20030313000082003031300008SO 2003 3 13 2003FA0000214 220030224G7414K3823 DISTRIBUTOR BLK CONT O520 IO520* 17032SO MAGNETO MISMANUFACTURED B VJ3RK NONE O OTHER ININSP/MAINT 1 WP07 MAGNETO REMOVED FROM ENGINE FOR 500 HOUR INSPECTION IAW THE MAINTENANCE MANUAL. DURING INSPECTION FOUND THAT THE CARBON BRUSH WAS RUBBING AND CAUSING CARBON DUST. RECOMMENDATION IS TO HAVE MANUFACTURE LOOK AT PROCESS OF MANUFACTURING AND LOOK AT REDUCING THE TOLERANCES BETWEEN THE DISTRIBUTOR BLOCK AND THE GEAR POST WHERE THEY FIT TOGETHER TO HELP PREVENT GEAR FROM ROCKING BACK AND FORTH. FURTHER INVESTIGATION BY MFG REQUIRED TO CORRECT PROBLEM. 3 O E5CE 20030313000102003031300010CE 2003 3 13 2003FA0000216 120030307G2621 HARNESS RAYTHNDH125 HAWKER800XP 7150012CE FIRE BOTTLES MISINSTALLED B YK1RK NONE W INADEQUATE Q C ININSP/MAINT 1 SW11 8588 CHECKED THE WIRING OF THE ENG FIRE BOTTLES IN SN 8604 BECAUSE DURING A SCHEDULED INSPECTION OF SN 8588 FOUND SQUIBS TO ENG FIRE BOTTLES MISWIRED. IT WAS DISCOVERED THAT IN THEIR SCENARIO, YOU WOULD SEND FIRE RETARDANT TO THE WRONG ENG (PRESS SHOT FOR LT ENG, AND THE RETARDANT GO TO THE RT ENG). DURING INSPECTION OF 8604 USING MM, IT WAS DISCOVERED CONNECTORS GH2 (ENG 2, SHOT 2) & GJ1 (ENG 2, SHOT 1) WERE REVERSED. RESEARCHING RAC PRINT , IT APPEARS THAT SWITCHES RR & RT HAVE SHOT 1 & SHOT 2 LABELING REVERSED IN THE PRINT. LABELING CONTRADICTS THE PRINT AND THE MM. 8604 WAS TESTED PER MM TO VERIFY THEY WERE CORRECTLY MARKED AND THEN BOTTLES WERE CONNECTED CORRECTLY. 2L72 4F RTA3EU 20030313000112003031300011EU 2003 3 13 2003FA0000217 120030307G262130111102 CARTRIDGE AMD FALC20FALCON200 2730150EU GARRTTATF3 ATF3* 29002WP FIRE BOTTLE DISCHARGED E K NONE L NO TEST ININSP/MAINT 1 SW05200WY6520 2 12116A1 509 FOUND THE "AFT BAGGAGE" FIRE EXTINGUISHER CARTRIDGE DISCHARGED WITHOUT DISPENSING THE FIRE BOTTLE. 2L72 4F4 FRTA7EU E7WE 20030313000142003031300014SO 2003 3 13 2003FA0000220 120030306G24201159SCAV373509 CONVERTER GULSTMG1159 GIV 3980115SO RROYCETAY TAY6118 EU AC SYSTEM INOPERATIVE C D RETURN TO BLOCK HJ ELECT. POWER LOSS-50 PC WARNING INDICATION TXTAXI/GRND HDL 1 EA25317ML690 1446 1802018021 DURING TAXI FROM THE OPERATOR`S HOME BASE AND PRIOR TO A SCHEDULED DEPARTURE, THE RT AC ELECTRICAL SYSTEM FAILED. THE AIRCRAFT RETURNED TO BASE, THE SYSTEM WAS TROUBLESHOT AND THE RT AC CONVERTER WAS FOUND TO BE FAULTY. THE UNIT WAS REPLACED WITH A SERVICABLE PART AND THE AIRCRAFT WAS RETURNED TO AIRWORTHY CONDITION. THIS UNIT HAS PROVEN TO BE VERY UNRELIABLE. SINCE IT'S CONSIDERED TO BE DISPATCH CRITICAL, WE BELIEVE THAT THE FAA AND THE MANUFACTURER NEED TO FULLY INVESTIGATE THIS MATTER. 2L72 4F4 FRTA12EA E25NE 20030313000152003031300015SO 2003 3 13 2003FA0000221 120030122G81209810002004 BELLOWS PIPER PA31 PA31P 7103120SO LYC O541 TIGO541* 41539EA INTERCOOLER CHAFED B MYNRO OTHER YJ ENGINE STOPPAGE WARNING INDICATION APAPPROACH 1 GL116680930 31P7300171 R45762 INSUFFICIENT CLEARANCE, BELLOWS ARE CHAFING THROUGH, CAUSED ENGINE FAILURE ON FINAL APPROACH. PART OF INTER COOLER INSTALLATION, STC NR SA3801NM, 1L72 3O3 O A8EA E19EA 20030313000162003031300016CE 2003 3 13 2003FA0000222 120030303G322012430097 TRUNNION CESSNA210 T210N 2073456CE CONT O520 TSIO520R 17040SO NLG BROKEN B WIWRO OTHER O OTHER TXTAXI/GRND HDL 1 WP0744EC 3686 21063972 517810 NOSE GEAR COLLAPSED DURING TAXI, AFTER LANDING, TOOK PLACE AFT NORMAL LANDING. COLLAR BROKE WHERE TRUNION ATTACHES TO NOSE GEAR BARREL, PREVIOUS CRACK EXISTED. 1H71 3O3 O 3A21 E8CE 20030313000172003031300017CE 2003 3 13 2003FA0000223 120030219G5310954200154748 CHANNEL BEECH 58 58 1152740CE FUSELAGE MISINSTALLED B CGORO OTHER O OTHER NRNOT REPORTED 1 GL033222B221 TH1977 FOUND ROW OF RIVETS MISSING FROM LEFT AND RIGHT CHANNELS, FORWARD END TO ANGLE SPLICE. CHANNELS ARE LOCATED UNDER CABIN FLOOR JUST BEHIND WING AFT SPAR AND SUPPORT FLOOR PANEL. THE RIVETS ATTACH SPLICE ANGLE RUNNING UNDER AFT SPAR TIEING INTO FORWARD CHANNELS. RIVET HOLES WERE PRESENT IN BOTH PIECES IN CORRECT LOCATION. THESE RIVETS ARE PRESENT IN SIMILAR MODELS WITH EARLIER SERIAL NUMBERS. 1L72 3O 3A16 20030312000012003031200001SO 2003 3 12 2003FA0000224 120030218G325063300014 HORN PIPER PIPER PA28 PA28181 7102807SO NLG STEERING BROKEN B A UNSCHED LANDING F FLT CONT AFFECTED CRCRUISE 1 NE03522BC257 2843461 PILOT LANDED AT GON WITH REPORTED LOSS OF RUDDER CONTROL IN FLIGHT. FURTHER INVESTIGATION REVEALED THAT NOSE LANDING GEAR STEERING HORN ASSEMBLY TUBING HAD BROKEN ALLOWING RUDDER CABLES TO SLACK. TUBING IS 3/4 INCH OD STEEL. SUSPECT TOW LIMITS WERE EXCEEDED AND CRACKED STEERING HORN DURING PREVIOUS GROUND HANDLING. LIMIT BOLTS WERE NOT BENT AS USUALLY FOUND WHEN TURN LIMITS HAVE BEEN EXCEEDED. ASSEMBLY RETURNED TO PIPER FOR FURTHER ANALYSIS SINCE IMPROPER HEAT TREATING MAY OF CAUSED FAILURE. 1L71 3O 2A13 20030312000022003031200002SW 2003 3 12 2003FA0000226 120030219G575112341 PUSHROD BBAVIA7 7GCBC 1220601SW AILERON LOOSE B K NONE W INADEQUATE Q C ININSP/MAINT 1 SO01257AC 125799 AILERON RODEND JAM NUTS FOUND LOOSE. HAVE FOUND SIMULAR CONDITION ON PREVIOUS AIRCRAFT NEW FROM FACTORY. 1H71 3O NCA759 20030312000032003031200003EU 2003 3 12 2003FA0000228 120030221G272012CSN022930 RING LET L23 L23 1360308EU RUDDER PEDAL MISSING B O OTHER C F.O.D. CRCRUISE 1 NM03438BA95 029016 RUDDER PEDAL LOST VERTICAL STABILTY AND THE INSTRUCTOR PILOT REPORTED THE PROBLEM TO MAINTENANCE. MAINTENANCE INSPECTED THE AREA AND FOUND THE SAFETY RING,WHICH HOLDS THE RUDDER PEDAL ATTACH SHAFT TO THE FUSELAGE FITTING, MISSING. AN INSPECTION WAS MADE TO FIND THE RING, AND DETERMINED IT WAS NOT IN THE AIRCRAFT. MAINTENANCE QUESTIONED IF IT WAS INSTALLED AT THE FACTORY, WHICH INITIATED A FLEET WIDE ONE TIME INSPECTION. TWO MORE AIRCRAFT WERE FOUND TO BE MISSING THE SAFETY RINGS.THESE ARE NEW AIRCRAFT WITH LESS THAN A HUNDRED HOURS TIME IN SERVICE. 1K00 RCG24EU 20030312000042003031200004EU 2003 3 12 2003FA0000229 120030221G272012CSN022930 RING LET L23 L23 1360308EU RUDDER PEDAL MISSING B O OTHER C F.O.D. CRCRUISE 1 NM03431BA 029013 ONE TIME FLEET INSPECTION REVEALED SAFETY RING MISSING.ONE OF THREE AIRCRAFT BELIEVED TO HAVE NOT HAD INSTALLED AT FACTORY.INSPECTION OF AIRCRAFT DID NOT PRODUCE MISSING PART. 1K00 RCG24EU 20030313000182003031300018EU 2003 3 13 2003FA0000230 120030221G272012CSN022930 RING LET L13 L13ACBLANIK EU RUDDER PEDAL MISSING B O OTHER O OTHER NRNOT REPORTED 1 NM03421BA 028902 ONE TIME FLEET INSPECTION REVEALED SAFETY CLIP MISSING. THIS CLIP HOLDS THE SHAFT THAT ATTACHES THE RUDDER PEDAL TO THE FUSELAGE FITTING.ONE TIME INSPECTION INITIATED DUE TO ANOTHER AIRCRAFT IN FLEET HAVING PEDAL VERTICAL STABILTY DETERIORATE. 1K00 G24EU 20030312000052003031200005CE 2003 3 12 2003FA0000232 120030224G3210 UPLOCK BRACKET BEECH MU300 400BEECH CE MLG SHEARED M K NONE O OTHER ININSP/MAINT 1 GL05 4778 910080 ACFT IN PHASED INSPECTION. WHEN INSPECTORS REMOVED THE AVIONICS RACK TO TORQUE A LOOSE ATTACH FITTING BOLT ON THE RIGHT MLG UPLOCK FITTING, A CHECK WAS MADE OF THE OTHER ATTACH BOLTS. THE BOTTOM FORWARD ATTACH BOLT HEADS WERE FOUND SHEARED OFF. THE BOLT HEADS WERE FOUND ON TOP OF THE GEAR UPLOCK ASSY. THERE WAS EVIDENCE THE BOLTS HAD BEEN SHEARED FOR A LONG TIME. FURTHER EXAMINATION DISCOVERED THE BOLTS WERE PART NUMBER NAS1204-9 AND NOT THE REQUIRED NAS1204-8. 2H72 4F RTA16SW 20030312000062003031200006EA 2003 3 12 2003FA0000234 220030224G732255255 RETAINER PRECISION HA6 PIPER PA44 PA44180 7104402SO LYC O360 O360* 41514EA CARBURETOR MISINSTALLED B O OTHER O OTHER TXTAXI/GRND HDL 1 WP28575ER331 4496151 PILOT COMPLAINED OF STIFF THROTTLE. FOUND THE HA-6 CARBURETOR VERY STIFF. FOUND THE SEAL RETAINERS FOR THE THROTTLE SHAFT, ACCELERATOR ROD AND ECONOMIZER RODS TO BE SEATED TOO DEEPLY CAUSING THE SEALS TO 'GRAB' THE SHAFTS TIGHTLY MAKING THROTTLE ADJUSTMENTS DIFFICULT. MARVEL SHEBLER ADDRESSED THIS PROBLEM IN S/B A2-78 ISSUED JANUARY 1979. HAVE FOUND A TOTAL OF 5 FACTORY NEW CARBS WITH THIS SAME CONDITION 1L72 3O3 O A19S0 E286 20030312000072003031200007SO 2003 3 12 2003FA0000235 220030224G8530538304P030 PUSHROD CONT CONT O520 IO520F 17032SO CYLINDER WORN B K NONE O OTHER ININSP/MAINT 1 WP28 1700 286187R UPON DISASSEMBLING THE ENGINE FOR OVERHAUL IT WAS DISCOVERED THAT THE NR 1 CYLINDER EXHAUST PUSHROD WAS SEVERLY WORN AT A POINT ABOUT 4 INCHES FROM THE ROCKER ARM END. THE WORN AREA WAS SMOOTH, CRESCENT SHAPED, ABOUT 1/2 INCH IN LENGTH, ALMOST PENETRATING THE ENTIRE WALL THICKNESS OF THE PUSHROD. INSPECTION OF THE PUSHROD HOUSING REVEALED A SMALL BUT SHARP DENT ABOUT 1/8 INCH DEEP CORRESPONDING TO AREA OF WEAR ON THE PUSHROD. IT WAS UNABLE TO DETERMINE HOW LONG THE DENT HAD BEEN THERE BUT IMMINENT FAILURE OF THE PUSHROD WAS VERY LIKELY. 3 O E5CE 20030312000082003031200008 2003 3 12 2003FA0000236 420030224G611305503671 SPINNER CESSNA172 172S 2072439CE PROPELLER CRACKED D K NONE O OTHER ININSP/MAINT 1 NM03789EP45 172S8135 DURING PHASE 3 INSPECTION FOUND PROPELLER SPINNER CRACKED AT BLADE CUT OUT ON ONE SIDE. THE PROBLEM IS REOCCURRING, THIS IS THE 5TH SPINNER REPLACEMENT ON THIS AIRCRAFT IN 1928.0 HOURS AND IS A COMMON PROBLEM ON OTHER C-172S AIRCRAFT. CESSNA SERVICE BULLETIN SB02-61-01 WAS ACCOMPLISHED 45.6 HOURS AGO WHICH REQUIRED ELONGATING THE MOUNTING SCREW HOLES TO ACHIEVE A GAP OF LESS THAN 0.03 BETWEEN SPINNER AND AFT BULKHEAD. THE MATERIAL THICKNESS OF THIS P/N SPINNER IS HALF THE THICKNESS OF THE OLDER CESSNA AIRCRAFT SPINNERS AND IS THE REASON FOR THE CRACKING AS IT IS NOT A PROBLEM ON THE OLDER CESSNA AIRCRAFT. 1H71 3O NT3A12 20030312000092003031200009 2003 3 12 2003FA0000237 420030228G343252D189 INDICATOR CESSNA206 206H 2073301CE HSI GLIDESLOPE INOPERATIVE B O OTHER O OTHER APAPPROACH 1 EA213535T 20608151 NEW AIRCRAFT, NEW HSI 345 HRS TTAF. GLIDESLOPE INOPERATIVE, FOUND GLIDESLOPE NEEDLE RESTRAINT (FROM TRANSPORT) STILL IN PLACE. 1H71 3O RTA4CE 20030312000102003031200010SO 2003 3 12 2003FA0000240 120030301G2435MZ4220R STARTER GEN PIPER PA44 PA44180 7104402SO ENGINE MISMARKED B K NONE W INADEQUATE Q C ININSP/MAINT 1 SO15923ER 4496010 THIS STARTER WAS RECEIVED AS AN OVERHAULED UNIT. THE BOX AND FAA FORM 81303 INDICATED A BASIC PART NUMBER PN MZ4220, HOWEVER THE DATA PLATE ON THE STARTER WAS MARKED MZ4222R WHICH ROTATES THE OPPOSITE DIRECTION. 1L72 3O A19S0 20030312000112003031200011 2003 3 12 2003FA0000243 420030301G611305503671 SPINNER CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA MCAULY1A170 1A170E GL PROPELLER CRACKED B K NONE O OTHER ININSP/MAINT 1 SO15448ER830 17280610 L185651A TI046 THE PROP SPINNER ON THE 172 RS SERIES CRACKS VERY FREQUENTLY. THE CRACKS RADIATE FROM THE CUT OUT FOR THE PROP BLADES. 1H71 3O3 ONT3A12 1E10 5 NP857 20030312000122003031200012EA 2003 3 12 2003FA0000244 220030301G8500 ENGINE CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA MCAULY1A170 1A170E GL FLUCTUATES C K NONE O OTHER ININSP/MAINT 1 SO15497ER10816569 17280673 L2013851A TL054 DURING AN INSPECTION THE IDLE WAS FOUND TO BE ABOUT 900 RPM. TYPICALLY THIS IS NOT CONSIDERED TO BE A REPORTABLE EVENT, HOWEVER THIS ENGINE/AIRCRAFT COMBINATION HAS BEEN THE SUBJECT OF AN AIRWORTHINESS DIRECTIVE REGARDING UNSTABLE IDLE/MIXTURE ISSUES. IT IS NOT UNCOMMON FOR THIS SITUATION TO OCCUR NOT ONLY DURING INSPECTION GROUND RUNS, BUT ALSO DURING OPERATION BETWEEN INSPECTIONS. 1H71 3O3 ONT3A12 1E10 5 NP857 20030312000132003031200013CE 2003 3 12 2003FA0000246 120030303G33206900080000 BALLAST BEECH 200 200BEECH 1152920CE CABIN LIGHTS BURNED OUT C H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 GL27616GB BB752 CABIN LIGHT C/B TRIPPED WITH ASSOCIATED ELECTRICAL ODOR IN CABIN. REMOVED ALL FLUORESCENT LIGHT POWER SUPPLIES AND FOUND ONE HAD SHORTED OUT AND HAD BURNED THROUGH POWER SUPPLY BALLAST CASE. CLOSE TO STARTING VELCRO ON FIR THAT HOLDS LIGHT POWER SUPPLY IN PLACE.RECOMMEND PERIODIC INSPECTIONS TO LOOK FOR ANY HOT SPOTS ON BALLASTS. 1L72 4T A24CE 20030312000142003031200014WP 2003 3 12 2003FA0000247 120030304G6410500P3100101 BLADE HUGHES369 369E 4470707WP TAIL ROTOR BROKEN D B EMER. DESCENT F FLT CONT AFFECTED CRCRUISE 1 WP05234RF897 0255E WHILE IN FLIGHT , PILOT EXPERIENCE VIBRATION WITH LOSS OF TAIL ROTOR CONTROL AUTHORITY. AFTER LANDING ,INSPECTION REVEALED THE BLADE PITCH HORN HAD BROKEN INTO TWO PIECES, RENDERING ONE BLADE WITH NO PITCH CONTROL. 1G71 3U H3WE 20030313000192003031300019CE 2003 3 13 2003FA0000249 120030228G5330 SKIN CESSNA182 182T 2072703CE LYC O540 IO540* 41532EA FUSELAGE CRACKED B N9VRO OTHER O OTHER NRNOT REPORTED 1 SO035275726 18281165 BELLY SKIN CRACKED AT NUTPLATE FOR FAIRING AFT OF NOSE GEAR. CAUSED BY VIBRATION OF FAIRING. INCREASE STRUCTURE STRENGTH INSTEAD OF USING .025 2024 USE .032 2024 T-3. 1H71 3O3 ONT3A13 1E4 20030313000202003031300020SO 2003 3 13 2003FA0000250 120030224G33106743604 RHEOSTAT PIPER PA28 PA28R201 7102816SO LYC O360 IO360A1A 41514EA NAV LIGHTS OVERHEATED B BONRO OTHER O OTHER NRNOT REPORTED 1 GL1911562 28R7837194 PILOT REPORTED SMOKE IN THE COCKPIT CLIMBING OUT OR A NIGHT VFR FLIGHT. INSPECTED AIRCRAFT AND FOUND NAV LIGHT / INSTRUMENT LIGHT SWITCH / RHEOSTAT HAD OVERHEATED. ORDERED REPLACMENT SWITCH (PN 587779) AND INSTALLED. OPS CHECKS GOOD. I HAVE SEEN THESE RHEOSTATS GET HOT BEFORE. 1L71 3O3 O 2A13 1E10 20030312000152003031200015EA 2003 3 12 2003FA0000252 220030305G73222520626 VALVE PRECISION CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA FUEL CONTROL SCORED B D RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TXTAXI/GRND HDL 1 SO15416ER592 172S9160 L3042351A THE CREW REPORTED FLUCTUATING IDLE DURING GROUND CHECK. THE CREW RETURNED TO THE RAMP. TYPICALLY THIS IS NOT CONSIDERED TO BE A REPORTABLE EVENT, HOWEVER THIS ENGINE/AIRCRAFT COMBINATION HAS BEEN THE SUBJECT OF AN AIRWORTHINESS DIRECTIVE REGARDING UNSTABLE IDLE/MIXTURE ISSUES. IT IS NOT UNCOMMON FOR THIS SITUATION TO OCCUR NOT ONLY DURING INSPECTION GROUND RUNS, BUT ALSO DURING OPERATION BETWEEN INSPECTIONS. A COMMON SOURCE OF PROBLEMS WITH THIS FUEL CONTROL IS THE MIXTURE VALVE, PN-2520626. THIS VALVE BECOMES SCORED AND THEN INACCURATE IN IT'S FUNCTION. THERE IS A PROCEDURE FOR LAPPING THIS VALVE'S SURFACE. 1H71 3O3 ONT3A12 1E10 20030312000162003031200016 2003 3 12 2003FA0000254 420030210G611305503671 SPINNER CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA PROPELLER CRACKED B K NONE O OTHER ININSP/MAINT 1 SO15433ER424 172S9166 L3045351A THE PROP SPINNER ON THE 172R/S SERIES CRACKS VERY FREQUENTLY. THE CRACKS RADIATE FROM THE CUT OUT FOR THE PROP BLADES. 1H71 3O3 ONT3A12 1E10 20030312000172003031200017 2003 3 12 2003FA0000255 420030210G611305503671 SPINNER CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA PROPELLER CRACKED B K NONE O OTHER ININSP/MAINT 1 SO15433ER424 172S9166 L3045351A THE PROP SPINNER ON THE 172R/S SERIES CRACKS VERY FREQUENTLY. THE CRACKS RADIATE FROM THE CUT OUT FOR THE PROP BLADES. 1H71 3O3 ONT3A12 1E10 20030312000182003031200018EA 2003 3 12 2003FA0000256 220030210G732463B22623 FLOW DIVIDER CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA FUEL SYSTEM STICKING B A UNSCHED LANDING E VIBRATION/BUFFET CRCRUISE 1 SO15409ER475 172S9158 L3045051A DURING CRUISE THE CREW REPORTED AROUGH ENGINE. AFTER INSPECTING APPLICABLE SYSTEMS, THE FUEL FLOW DIVIDER WAS CHANGED AFTER HAVING BEEN FOUND STICKING INTERNALLY. 1H71 3O3 ONT3A12 1E10 20030312000192003031200019EA 2003 3 12 2003FA0000257 220030210G732463B22623 FLOW DIVIDER CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA FUEL SYSTEM STICKING B A UNSCHED LANDING E VIBRATION/BUFFET CRCRUISE 1 SO15409ER475 172S9158 L3045051A DURING CRUISE THE CREW REPORTED AROUGH ENGINE. AFTER INSPECTING APPLICABLE SYSTEMS, THE FUEL FLOW DIVIDER WAS CHANGED AFTER HAVING BEEN FOUND STICKING INTERNALLY. 1H71 3O3 ONT3A12 1E10 20030312000202003031200020EA 2003 3 12 2003FA0000258 220030210G732463B22623 FLOW DIVIDER CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA FUEL SYSTEM STICKING B A UNSCHED LANDING E VIBRATION/BUFFET CRCRUISE 1 SO15409ER475 172S9158 L3045051A DURING CRUISE THE CREW REPORTED A ROUGH ENGINE. AFTER INSPECTING APPLICABLE SYSTEMS, THE FUEL FLOW DIVIDER WAS CHANGED AFTER HAVING BEEN FOUND STICKING INTERNALLY. 1H71 3O3 ONT3A12 1E10 20030312000212003031200021EA 2003 3 12 2003FA0000259 220030205G732225765362 FUEL CONTROL CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA ENGINE OUT OF ADJUST B A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CRCRUISE 1 SO15490ER 1462 17280633 L2786451A THE CREW REPORTED A PARTIAL POWER LOSS DURING STALL RECOVERY. THIS ENGINE/AIRCRAFT COMBINATION HAS BEEN THE SUBJECT OF AN AIRWORTHINESS DIRECTIVE REGARDING UNSTABLE IDLE/MIXTURE ISSUES. IT IS NOT UNCOMMON FOR THIS SITUATION TO OCCUR NOT ONLY DURING INSPECTION GROUND RUNS, BUT ALSO DURING OPERATION BETWEEN INSPECTIONS. THE IDLE SYSTEM ON THIS FUEL CONTROL UNIT HAS ISSUES, WHERE IT REQUIRES CONSIDERABLE ADJUSTING WITHIN A RELATIVELY FEW NUMBER OF OPERATING HOURS. 1H71 3O3 ONT3A12 1E10 20030312000222003031200022EA 2003 3 12 2003FA0000260 220030208G73222520626 VALVE PRECISION RSA5AD1 CESSNA172 172S 2072439CE LYC O360 IO360LYC* 41514EA FUEL CONTROL SCORED B D RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TXTAXI/GRND HDL 1 SO15405ER444 172S9155 L3044751A DURING A PRE TAKE OFF IDLE CHECK THE ENGINE RAN VERY SLOW AND EVENTUALLY QUIT. THE INJECTOR SERVO WAS INSPECTED AND THE INTERNAL IDLE MIXTURE PLATE WAS FOUND TO BE SCORED. THERE IS A PROCEDURE FOR LAPPING THIS VALVE. IT WAS ACCOMPLISHED AND THE IDLE SPEED/MIXTURE WAS ADJUSTED. 1H71 3O3 ONT3A12 1E10 20030312000232003031200023EA 2003 3 12 2003FA0000262 220030218G731325248642 FUEL NOZZLE CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA ENGINE OBSTRUCTED B A UNSCHED LANDING E VIBRATION/BUFFET TOTAKEOFF 1 SO15456ER 17280667 L1562851A ON TAKE OFF THE ENGINE RAN ROUGH. INVESTIGATION SHOWED THAT ONE FUEL INJECTOR NOZZLE WAS FOUND WITH AN IRREGULAR FLOW. IT WAS REPLACED. 1H71 3O3 ONT3A12 1E10 20030312000242003031200024EA 2003 3 12 2003FA0000263 220030219G732225765362 FUEL CONTROL CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA ENGINE FAILED B D RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TXTAXI/GRND HDL 1 SO15420ER 1906 17280634 L2784651A DURING A PRE TAKE OFF IDLE CHECK, THE ENGINE QUIT. THIS ENGINE/FUEL CONTROL SYSTEM IS THE SUBJECT OF AN AIRWORTHINESS DIRECTIVE CONCERNING UNSTABLE IDLE TENDENCIES. 1H71 3O3 ONT3A12 1E10 20030313000232003031300023CE 2003 3 13 2003FA0000264 120030306G5520556555026 ARM CESSNA500 500CESSNA 2076602CE ELEVATOR CRACKED E K NONE O OTHER ININSP/MAINT 1 EA2327SF 13186921 5000064 DURING A PHASE 5 INSPECTION A SMALL CRACK WAS DISCOVERED NEAR THE LT UPPER NUTPLATE ON THE ELEVATOR BOBWEIGHT SUPPORT ARM. AFTER REMOVING THE ASSEMBLY IT WAS DISCOVERED THAT THERE WERE MULTIPLE CRACKS AROUND ALL FOUR NUTPLATES. REPLACED BOTH SUPPORT ARMS. SUSPECT METAL FATIGUE AS CAUSE OF THE CRACKING. SUGGEST THAT THIS ASSEMBLY BE REMOVED AT EACH PHASE 5 INSPECTION TO INSPECT FOR CRACKING. 1L72 4F A22CE 20030312000252003031200025EA 2003 3 12 2003FA0000265 220030219G732225765362 FUEL CONTROL CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA FLUCTUATES B D RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TXTAXI/GRND HDL 1 SO15416ER535 172S9160 L3042351A THE CREW REPORTED A ROUGH IDLE DURING GROUND OPERATION. THIS ENGINE/AIRCRAFT COMBINATION HAS BEEN THE SUBJECT OF AN AIRWORTHINESS DIRECTIVE REGARDING UNSTABLE IDLE/MIXTURE ISSUES. IT IS NOT UNCOMMON FOR THIS SITUATION TO OCCUR NOT ONLY DURING INSPECTION GROUND RUNS, BUT ALSO DURING OPERATION BETWEEN INSPECTIONS. THE IDLE SYSTEM ON THIS FUEL CONTROL UNIT HAS ISSUES, WHERE IT REQUIRES CONSIDERABLE ADJUSTING WITHIN A RELATIVELY FEW NUMBER OF OPERATING HOURS. 1H71 3O3 ONT3A12 1E10 20030313000242003031300024CE 2003 3 13 2003FA0000266 120030212G323024411003 PIVOT CESSNA172 172RG 2072438CE LYC O360 O360* 41514EA MLG CRACKED B WIWRK NONE O OTHER ININSP/MAINT 1 WP076623Z1536 172RG0240 DURING A ROUTINE INSPECTION IT WAS NOTICED BY THE TECHNICIAN THAT THERE WAS A LARGE AMOUNT OF VERY THIN GREASE SEEPING OUT FROM AROUND THE MAIN LANDING GEAR ACTUATOR CAPS ON BOTH THE LEFT AND RIGHT SIDES. THE GEAR ACTUATORS AND PIVOTS WERE FOUND TO BE CRACKED IN THE RADIUS AT THE BOTTOM OF THE GEAR SPLINES. TO PREVENT THIS PROBLEM IT IS SUGGESTED THAT THE MAIN LANDING GEAR 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. AD ON THE MLG PIVOT ASSEMBLIES HAD BEEN COMPLIED WITH. 1H71 3O3 O 3A17 E286 20030312000262003031200026CE 2003 3 12 2003FA0000269 120030227G57530523920 ROLLER CESSNA172 172K 2072430CE LYC O320 O320E2D 41508EA TE FLAP DAMAGED D O OTHER O OTHER DEDESCENT 1 GL23 3641 17258769 L2645527A RT FLAP, INBOARD AFT FLAP ROLLER, FAILED AND BOUND DURING FLAP RETARCTION. THE RT OUTBOARD FLAP END CONTINUED TO RETRACT DEFORMING THE FLAP TO SOME EXTENT. 1H71 3O3 ONT3A12 E274 20030312000272003031200027EA 2003 3 12 2003FA0000270 220030220G731325248642 INJECTOR CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA ENGINE RESTRICTED B A UNSCHED LANDING E VIBRATION/BUFFET CRCRUISE 1 SO15433ER 172S9166 L3045351A DURING CRUISE, THE ENGINE SPUTTERED FOR 1-2 SECONDS. THE AIRCRAFT WAS RETURNED TO HOME BASE. A THOROUGH INSPECTION OF THE ENGINE AND SYSTEMS WAS MADE, AND THE ONLY OBSERVABLE ITEM WAS A FUEL INJECTOR NOZZLE THAT PRODUCED A MINOR IRREGULAR FLOW PATTERN DURING TESTING. THE NOZZLES WERE CLEANED THE AIRCRAFT WAS FLOWN WITH NO OPERATIONAL DEFECTS NOTED. 1H71 3O3 ONT3A12 1E10 20030312000282003031200028EA 2003 3 12 2003FA0000271 220030214G731363B22623 FLOW DIVIDER CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA FUEL SYSTEM STICKING B D RETURN TO BLOCK E VIBRATION/BUFFET TXTAXI/GRND HDL 1 SO15482ER 1467 17280631 L2780951A DURING GROUND OPERATIONS, THE CREW FELT A ROUGH AND UNSTABLE IDLE. AN INSPECTION WAS MADE OFTHE ENGINE AND SYSTEMS. 2 NOZZLES WERE DETERMINED TO HAVE AN IRREGULAR SPRAY PATTERN. AFTER CLEANING, 1 WAS REPLACED. ALSO, THE FUEL FLOW DIVIDER WAS FOUND TO BE STICKING INTERNALLY. IT WAS REPLACED. 1H71 3O3 ONT3A12 1E10 20030312000292003031200029EA 2003 3 12 2003FA0000272 220030217G7421REM40E SPARK PLUG CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA ENGINE FOULED C A UNSCHED LANDING E VIBRATION/BUFFET CRCRUISE 1 SO15437ER483 22 172S8653 L2923351A DURING STALL MANEUVERS, THE ENGINE HESITATED AND RAN ROUGH WHEN POWER WAS BROUGHT TO IDLE. AS ITEMS WERE BEING INSPECTED, THE SPARK PLUGS WERE FOUND WITH HEAVY DEPOSITS. THE PLUGS HAD BEEN CLEANED AND TESTED ABOUT 23 HOURS PREVIOUS TO THE EVENT. TYPICALLY, FOULED SPARK PLUGS ARE NOT A REPORTABLE INCIDENT, BUT THIS ENGINE FUEL CONTROL SYSTEM HAS BEEN THE SUBJECT OF AN AIRWORTHINESS DIRECTIVE REGARDING UNSTABLE IDLE/MIXTURE ISSUES. EVEN THOUGH CONSTANT CHECKING AND ADJUSTMENT OF THE IDLE MIXTURE/SPEED IS ACCOMPLISHED ON THIS ENGINE, IT QUITE OFTEN DEGRADES TO A VERY RICH IDLE, SHORTLY THEREAFTER, THEREBY CAUSING SPARK PLUG AND OTHER PROBLEMS AS DESCRIBED ABOVE. 1H71 3O3 ONT3A12 1E10 20030312000302003031200030EA 2003 3 12 2003FA0000273 220030217G732225765362 FUEL CONTROL CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA ENGINE ERRATIC C D RETURN TO BLOCK O OTHER TXTAXI/GRND HDL 1 SO15406ER 635 172S9156 L3042951A THE CREW REPORTED THAT THEY WERE EXPERIENCING A VERY SLOW IDLE DURING PRE TAKEOFF IDLE CHECK. IT WAS ADJUSTED. THIS ENGINE/FUEL CONTROL COMBINATION HAS BEEN THE SUBJECT OF AN AIRWORTHINESS DIRECTIVE CONCERNING UNSTABLE IDLE AS WELL AS VARIOUS SERVICE BULLETINS ABOUT THE SAME SUBJECT. EVEN WITH CONTINUOUS ADJUSTMENT AND CHECKS, IT IS NOT UNCOMMON TO HAVE MANY WRITE UPS PERTAINING TO HIGH/LOW OR LEAN/RICH IDLE PROBLEMS. 1H71 3O3 ONT3A12 1E10 20030312000312003031200031EA 2003 3 12 2003FA0000274 220030216G732225765362 FUEL CONTROL CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA ENGINE ERRATIC B D RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TXTAXI/GRND HDL 1 SO15405ER 521 172S9155 L3044751A DURING A PRE TAKEOFF IDLE CHECK, THE ENGINE IDLED VERY SLOW AND BEGAN TO QUIT. THIS ENGINE FUEL CONTROL COMBINATION HAS BEEN DIFFICULT TO MAKE MAINTAIN A STABLE IDLE AND REQUIRES A SIGNIFICANT AMOUNT OF BETWEEN INSPECTION ADJUSTMENTS 1H71 3O3 ONT3A12 1E10 20030312000322003031200032EA 2003 3 12 2003FA0000275 220030214G732225765362 FUEL CONTROL CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA ENGINE ERRATIC B D RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TXTAXI/GRND HDL 1 SO15433ER 503 172S9166 L3045351A DURING THE PRE TAKEOFF IDLE CHECK, THE ENGINE QUIT. THE AIRCRAFT WAS RETURNED TO THE RAMP. AS IS OFTEN THE NEE, THE IDLE SPEED AND MIXTURE WERE ADJUSTED. 1H71 3O3 ONT3A12 1E10 20030312000332003031200033 2003 3 12 2003FA0000276 420030214G6113055032111 BULKHEAD CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA SPINNER CRACKED B K NONE O OTHER ININSP/MAINT 1 SO15425ER1011 17280646 RL805651A THE SPINNER AFT BULKHEAD WAS FOUND CRACKED. IT WAS REPLACED WITH A NEW UNIT... 1H71 3O3 ONT3A12 1E10 20030312000342003031200034 2003 3 12 2003FA0000277 420030211G6113055032111 BULKHEAD CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA SPINNER CRACKED B O OTHER O OTHER NRNOT REPORTED 1 SO15408ER965 172S8642 L2779051A AFT SPINNER BULKHEAD WAS FOUND CRACKED, IT WAS REPLACED WITH A NEW PART. 1H71 3O3 ONT3A12 1E10 20030312000352003031200035EA 2003 3 12 2003FA0000281 220030306G732225765362 FUEL CONTROL CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA ENGINE ERRATIC C D RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TXTAXI/GRND HDL 1 SO15497ER 168 17280673 L2013851A DURING A PRE TAKEOFF IDLE CHECK, THE ENGINE RAN EXTREMELY SLOW. IT WAS ADJUSTED. THIS ENGINE/FUEL CONTROL SYSTEM HAS BEEN THE SUBJECT OF AN AIRWORTHINESS DIRECTIVE CONCERNING IDLE ANOMALIES. 1H71 3O3 ONT3A12 1E10 20030312000362003031200036EA 2003 3 12 2003FA0000282 220030306G732225765362 FUEL CONTROL CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA ENGINE ERRATIC B D RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TXTAXI/GRND HDL 1 SO15407ER 401 172S9157 L3045451A DURING A PRE TAKE OFF IDLE CHECK, THE ENGINE IDLED VERY SLOWLY. IT WAS ADJUSTED. THIS ENGINE/FUEL CONTROL SYSTEM HAS BEEN THE SUBJECT OF AN AIRWORTHINESS DIRECTIVE REGARDING ERRATIC IDLE OPERATION. 1H71 3O3 ONT3A12 1E10 20030312000372003031200037 2003 3 12 2003FA0000283 420030307G6113055032110 BULKHEAD CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA MCAULY1A170 1A170* GL SPINNER CRACKED B K NONE W INADEQUATE Q C ININSP/MAINT 1 SO15405ER 172S9155 L3044751A VI23022 DURING INSPECTION, THE REAR SPINNER BULKHEAD WAS FOUND CRACKED. THIS IS A COMMON OCCURANCE WITH THIS PART. 1H71 3O3 ONT3A12 1E10 5 NP857 20030312000382003031200038SO 2003 3 12 2003FA0000284 120030311G2820MS21908D6 ELBOW GULSTMG1159 GIV 3980115SO APU FUEL CRACKED B K NONE K FLUID LOSS ININSP/MAINT 1 GL051PG 1495 1374 DURING POST FLIGHT INSPECTION RESIDUAL FUEL WAS NOTICED IN THE LEFT MAIN WHEEL WELL. WHEN SELECTING MAIN BOOST PUMP ON WITH APU MASTER SWITCH ON, FUEL WAS NOTICED RUNNING OUT OF THE FLEX HOSE ATTACHED TO THE APU FUEL SHUT OFF VALVE. MECHANIC FOUND THE ALUMINUM ELBOW CRACKED. ELBOW WAS REPLACED AND LEAK CHECKED OKAY. PAST EXPERIENCE WITH ANOTHER TYPE AIRCRAFT HAD SIMILAR CRACKS IN ALUMINUM FITTINGS WHEN STAINLESS STEEL LINES WERE CONNECTED TO THEM. A SERVICE BULLETIN WAS ISSUED STATING THAT OVER TORQUE COULD CAUSE THIS CONDITION. NO WORK HAD BEEN DONE IN THIS AREA AND WAS IN THE ORIGINAL PRODUCTION INSTALLATION. 2L72 4F RTA12EA 20030409000092003040900009SW 2003 4 9 2003FA0000285 120030219G6300R47120252003F GRIP BELL 47 47G3B2 1181029SW MAIN ROTOR CRACKED D O OTHER O OTHER NRNOT REPORTED 1 SO09659CD627 6719 EDDY CURRENT SHOWED CRACK IN THREAD AREA OF GRIP. 1G71 3O 2H3 20030409000302003040900030CE 2003 4 9 2003FA0000286 120030228G575355651012 BELLCRANK CESSNA501 501 2076603CE PWA JD15 JT15D1A NE RT IB FLAP CRACKED D O OTHER O OTHER NRNOT REPORTED 1 SO11888MJ8260 5010446 RIGHT FLAP BELLCRANK FOLLOW-UP ROD ARM ATTACH POINT WAS CRACKED ON UPPER AND LOWER ARM. UPON INSPECTION OF OTHER BELLCRANKS; FOUND THAT SPACERS WERE MISSING BETWEEN FOLLOW-UP ROD-END AND BELLCRANK FOLLOW-UP ARM. 1L72 4F4 F A27CE E25EA 20030409000312003040900031CE 2003 4 9 2003FA0000287 120030303G2421X610007 CONTACTOR CESSNA172 172S 2072439CE ALTERNATOR FAILED D O OTHER O OTHER NRNOT REPORTED 1 WP09203KS30 172S8856 CONTACTOR FAILS DURING USE, DUE TO IT BEING A CONTINUOUS DUTY RELAY, WAS INTERMITTENT PRIOR TO FAILURE. (THIS IS FOR THE ALTERNATOR OUTPUT TO THE AIRCRAFT BATTERY BUSS.) 1H71 3O NT3A12 20030409000322003040900032CE 2003 4 9 2003FA0000288 120030314G2810 BAFFLE CESSNA172 172H 2072424CE FUEL TANK BROKEN D K NONE O OTHER ININSP/MAINT 1 SO094977R12028 17256331 DURING VISUAL INSPECTION, FOUND FUEL TANK BAFFLE SPOT WELDS BROKEN LOOSE, ALLOWING BAFFLE TO MOVE AROUND FREELY INSIDE FUEL TANK. CONDITION COULD CAUSE FUEL STARVATION DURING DECENT WITH A LOW FUEL QUANTITY, COULD CAUSE ERRONEOUS FUEL QUANTITY INDICATIONS DUE TO INTERFERENCE WITH TRANSMITTER FLOAT. THE FRONT FACE OF BAFFLE IS APPROX 1 INCH BEHIND FUEL TANK FILLER PORT. DURING REFUELING PROCESS, IF FUEL NOZZLE IS RELAXED, NOZZLE CONTACTS BAFFLE AND APPLIES EXCESSIVE PRESSURE TO BAFFLE EVENTUALLY BREAKING SPOT WELDS LOOSE. DURING THE REFUEL PROCESS, DO NOT INSERT FUEL NOZZLE MORE THAN 3 INCHES INTO THE FUEL TANK. 1H71 3O NT3A12 20030409000332003040900033CE 2003 4 9 2003FA0000289 120030314G2810 BAFFLE CESSNA172 172H 2072424CE CONT O300 O300* 17022SO FUEL CELLS BROKEN D K NONE O OTHER ININSP/MAINT 1 SO094977R12028 56331 DURING VISUAL INSPECTION, FOUND FUEL TANK BAFFLE SPOT WELDS BROKEN LOOSE, ALLOWING BAFFLE TO MOVE AROUND FREELY INSIDE FUEL TANK. THIS CONDITION COULD CAUSE FUEL STARVATION DURING A DECENT WITH A LOW FUEL QUANTITY AND COULD CAUSE ERRONEOUS FUEL QUANTITY INDICATIONS DUE TO INTERFERENCE WITH TRANSMITTER FLOAT. PROBABLE CAUSE: THE FRONT FACE OF THE BAFFLE IS APPROXIMATELY 1 INCH BEHIND FUEL TANK FILLER PORT. DURING THE REFUELING PROCESS, IF THE FUEL NOZZLE IS RELAXED, THE NOZZLE CONTACTS THE BAFFLE AND APPLIES EXCESSIVE PRESSURE TO THE BAFFLE EVENTUALLY BREAKING THE SPOT WELDS LOOSE. DURING THE REFUEL PROCESS, DO NOT INSERT FUEL NOZZLE MORE THAN 3 INCHES INTO THE FUEL TANK. 1H71 3O3 ONT3A12 E253 20030409000342003040900034CE 2003 4 9 2003FA0000290 120030314G2810 BAFFLE CESSNA172 172F 2072414CE CONT O300 O300* 17022SO RT FUEL TANK BROKEN D K NONE O OTHER ININSP/MAINT 1 SO095134F12773 17252909 DURING VISUAL INSPECTION, FOUND FUEL TANK BAFFLE SPOT WELDS BROKEN LOOSE, ALLOWING BAFFLE TO MOVE AROUND FREELY INSIDE FUEL TANK. THIS CONDITION COULD CAUSE FUEL STARVATION DURING A DECENT WITH A LOW FUEL QUANTITY AND COULD CAUSE ERRONEOUS FUEL QUANTITY INDICATIONS DUE TO INTERFERENCE WITH TRANSMITTER FLOAT. PROBABLE CAUSE: THE FRONT FACE OF THE BAFFLE IS APPROXIMATELY 1 INCH BEHIND FUEL TANK FILLER PORT.DURING THE REFUELING PROCESS, IF THE FUEL NOZZLE IS RELAXED, THE NOZZLE CONTACTS THE BAFFLE AND APPLIES EXCESSIVE PRESSURE TO THE BAFFLE EVENTUALLY BREAKING THE SPOT WELDS LOOSE. 1H71 3O3 ONT3A12 E253 20030409000352003040900035CE 2003 4 9 2003FA0000291 120030314G2810 BAFFLE CESSNA172 172F 2072414CE CONT O300 O300* 17022SO RT FUEL TANK BROKEN D K NONE O OTHER ININSP/MAINT 1 SO095203F12886 17253192 DURING VISUAL INSPECTION, FOUND FUEL TANK BAFFLE SPOT WELDS BROKEN LOOSE, ALLOWING BAFFLE TO MOVE AROUND FREELY INSIDE FUEL TANK. COULD CAUSE FUEL STARVATION DURING DECENT WITH A LOW FUEL QUANTITY AND COULD CAUSE ERRONEOUS FUEL QUANTITY INDICATIONS DUE TO INTERFERENCE WITH TRANSMITTER FLOAT. PROBABLE CAUSE: THE FRONT FACE OF THE BAFFLE IS APPROXIMATELY 1 INCH BEHIND FUEL TANK FILLER PORT. DURING REFUELING PROCESS, IF FUEL NOZZLE IS RELAXED, NOZZLE CONTACTS BAFFLE AND APPLIES EXCESSIVE PRESSURE TO BAFFLE EVENTUALLY BREAKING SPOT WELDS LOOSE. PREVENTATIVE MEASURES: DURING THE REFUEL PROCESS, DO NOT INSERT FUEL NOZZLE MORE THAN 3 INCHES INTO THE FUEL TANK. THIS DEFECT WAS FOUND IN 4 OUT OF 8 A/C. 1H71 3O3 ONT3A12 E253 20030409000362003040900036CE 2003 4 9 2003FA0000292 120030314G2810 BAFFLE CESSNA172 R172E 2072413CE CONT IO360 IO360* 17025CE FUEL TANK BROKEN D K NONE O OTHER ININSP/MAINT 1 SO097892N14797 R1720283 DURING VISUAL INSPECTION, FOUND FUEL TANK BAFFLE SPOT WELDS BROKEN LOOSE, ALLOWING BAFFLE TO MOVE AROUND FREELY INSIDE FUEL TANK. THIS CONDITION COULD CAUSE FUEL STARVATION DURING A DECENT WITH A LOW FUEL QUANTITY AND COULD CAUSE ERRONEOUS FUEL QUANTITY INDICATIONS DUE TO INTERFERENCE WITH TRANSMITTER FLOAT. PROBABLE CAUSE: FRONT FACE OF THE BAFFLE IS APPROXIMATELY 1 INCH BEHIND FUEL TANK FILLER PORT.DURING REFUELING PROCESS, IF FUEL NOZZLE IS RELAXED, NOZZLE CONTACTS BAFFLE AND APPLIES EXCESSIVE PRESSURE TO BAFFLE EVENTUALLY BREAKING SPOT WELDS LOOSE. PREVENTATIVE MEASURES: DURING THE REFUEL PROCESS, DO NOT INSERT FUEL NOZZLE MORE THAN 3 INCHES INTO THE FUEL TANK. THIS DEFECT WAS FOUND IN 4 OUT OF 8 A/C. 1H71 3O3 O 3A17 E1CE 20030409000372003040900037SW 2003 4 9 2003FA0000293 120030316G7120590000509 MOUNT MOONEYM20 M20C 5870208SW LYC O360 O360* 41514EA ENGINE BROKEN B NT3RK NONE O OTHER ININSP/MAINT 1 WP27788653432 45 2880 7425 DURING ANNUAL INSPECTION AND AD 75-09-08 COMPLIANCE, FOUND LOWER RT CORNER WELD JUNCTION FULLY BROKEN AND SEPARATED. SB M20-175 & M20-192 HAD NOT BEEN COMPLETED, THAT WAS DESIGNED TO BE PREVENTED BY INSTALLING GUSSET AT THIS CORNER (P/N 590041-1). MOUNT WAS FOR 180 HP ENGINE AND NOT UPGRADED. 1L71 3O3 O 2A3 E286 20030409000382003040900038SW 2003 4 9 2003FA0000294 120030316G7120590000509 MOUNT MOONEYM20 M20C 5870208SW LYC O360 O360A1D 41514EA ENGINE BROKEN B NT3RK NONE O OTHER ININSP/MAINT 1 WP279656M3482 45 2880 6701 DURING CONDUCT OF ANNUAL INSPECTION AND AD 75-09-08 COMPLIANCE, FOUND LOWER RH CORNER WELD JUNCTION FULLY BROKEN AND SEPARATED. SB M20-175 & M20-192 HAD NOT BEEN COMPLETED, THAT WAS DESIGNED TO PREVENT BY INSTALLING GUSSET AT THIS CORNER (P/N 590041-1). MOUNT WAS FOR 180 HP ENGINE AND NOT UPGRADED. 1L71 3O3 O 2A3 E286 20030409000392003040900039SW 2003 4 9 2003FA0000295 120030316G712030505501 MOUNT MOONEYM20 M20K 5870220SW CONT O520 TSIO520NB 17040SO ENGINE BENT B K NONE O OTHER ININSP/MAINT 1 WP271157P448 250647 290820R DURING A SPECIAL INSPECTION, AFTER A PRIOR PROP STRIKE, FOUND THE REAR UPPER CROSSOVER TUBE OFTHE ENGINE MOUNT BENT DOWN. DOWNLOAD BEND. AIRCRAFT MODIFIED IAW STC SA5691NM. REMOVED MOUNT, SENT FOR REPAIR, REINSTALLED MOUNT. 1L71 3O3 O 2A3 E8CE 20030409000402003040900040SW 2003 4 9 2003FA0000296 120030316G712030505501 MOUNT MOONEYM20 M20K 5870220SW CONT O520 TSIO520NB 17040SO ENGINE DAMAGED B NT3RK NONE O OTHER ININSP/MAINT 1 WP271157P448 250647 290820R DURING A SPECIAL INSPECTION, AFTER A PRIOR PROP STRIKE, FOUND THE REAR UPPER CROSSOVER TUBE OFTHE ENGINE MOUNT BENT DOWN. DOWNLOAD BEND. AIRCRAFT MODIFIED PER STC SA5691NM. REMOVED MOUNT, SENT TO MFG. FOR REPAIR, REINSTALLED MOUNT. 1L71 3O3 O 2A3 E8CE 20030409000412003040900041NM 2003 4 9 2003FA0000297 120030317G571241513017R RIB UNIVAR415 A2AALON 0540104NM CONT C90 C90* 17009SO WING CORRODED D K NONE O OTHER ININSP/MAINT 1 SO155638F2529 A238 LIGHT SURFACE CORROSION FOUND IN BOTH STUB WINGS IN CENTER SECTION. BOTTOM SKINS, UNDER SKIN STIFFNERS, A COUPLE SPOTS ON RIBS, AND BETWEEN REAR SPAR AND REAR RIB P/N 415-1307RINSPECTION WAS IN COMPLIANCE WITH AD 2002-26-02. 1L71 3O3 O A787 E252 20030409000422003040900042SW 2003 4 9 2003FA0000299 120030225G3230B10006 COUPLING MOONEYM20 M20C 5870208SW LYC O360 O360* 41514EA MLG MOTOR FAILED D O OTHER O OTHER NRNOT REPORTED 1 EA17111JP 690078 B100-06 RUBBER DRIVE COUPLING BETWEEN LANDING GEAR MOTOR AND TRANSMISSION, ABSORBS SHOCK WHEN LANDING GEAR REACHES ITS LIIT, THIS IS THE ONLY CONNECTION BETWEEN TRANSMISSION AND GEAR LINKAGE, WHEN THIS PART FAILED, YOU CANNOT PERFORM ANY GEAR EXTENSION, ELECTRICALLY OR MECHANICALLY. RECOMMEND TO REPLACE EVERY 200 HOURS TO COINCIDE WITH 200 HOUR TRANSMISSION GEAR BACKLASH INSPECTION AND SB M20-190. 1L71 3O3 O 2A3 E286 20030409000432003040900043SO 2003 4 9 2003FA0000300 120030222G3310GS23614 LIGHT PIPER PA28 PA28236 7102815SO LYC O540 O540* 41532EA CABIN BURNED OUT B SL5RO OTHER O OTHER NRNOT REPORTED 1 NE032332U25 287911298 SPT GLOW STRIPS, INSTALLED CUSTOMER SUPPLIED ELECTROLUMINESCENT LAMPS UNDER INSTRUMENT PANEL GLARE SHIELD, WITHIN 25 HOURS OF AIRCRAFT OPERATION, BOTH LIGHT FAILED. DURING INSPECTION OF THE LAMPS, TURNED POWER ON AND BOTH LAMPS SPARKED AND SMOKE CAME FROM AREA OF PLASTIC CONNECTORS. REMOVED BOTH LAMPS. BOTH FAILED IN SAME LOCATION WINT IN MINUTES AFTER INSTALLATION. SUGGEST THESE LAMPS NOT BE USED OR INSTALLED IN ANY AIRCRAFT UNTIL MFG CAN FIND A BETTER CONNECTOR. 1L71 3O3 O 2A13 E295 20030409000442003040900044EA 2003 4 9 2003FA0000301 220030305G8520IO360A3B6D CRANKCASE MOONEYM20 M20J 5870219SW LYC O360 IO360A3B6 41514EA HARTZLHCC3Y HCC3YR GL NR 2 CYLINDER CRACKED B DINRO OTHER O OTHER NRNOT REPORTED 1 EA131084V 777 241131 L2253851A DY2456A (STC SA4529NM 3 BLADE HARTZELL) AT 777 TSO OF THE ENGINE, THE CRANKCASE WAS FOUND CRACKED THROUGH THE NR 2 CYLINDER MOUNTING PAD AREA AND LEAKING OIL. THE CASE WAS NOT REPAIRABLE. THIS IS THE 2ND TIME THIS AIRCRAFT ENGINE PROPELLER COMBINATION HAS CRACKED A CASE. PREVIOUS TSO WAS ONLY 689. 1L71 3O3 O 2A3 1E10 5 CP25EA 20030409000452003040900045GL 2003 4 9 2003FA0000302 320030305G6110IO360A3B6D CASE MOONEYM20 M20J 5870219SW LYC O360 IO360A3B6 41514EA HARTZLHCC3Y HCC3YR GL PROPELLER CRACKED B DINRO OTHER O OTHER NRNOT REPORTED 1 EA131084V2370 689 241131 L2253851A DY2456A AT 689 HOUR TSO OF ENGINE AND 689 HOURS SINCE REMOVAL OF 2 BLADE PROPELLER AND INSTALLATION OF 3 BLADE PROPELLER IAW STC. CASE CRACKED CAUSING AN OIL LEAK. THE CASE WAS NOT REPAIRABLE. 1L71 3O3 O 2A3 1E10 5 CP25EA 20030409000462003040900046CE 2003 4 9 2003FA0000305 120030319G2822414000103 PUMP BEECH 35 V35 1151538CE CONT O520 GTSIO520* 17032SO INJECTOR SHEARED G C ABORTED TAKEOFF YJ ENGINE STOPPAGE WARNING INDICATION TOTAKEOFF 1 SW179486S2539 D8181 ENGINE QUIT DURING TAKEOFF. THE AIRCRAFT WAS SUBSTANTIALLY DAMAGED. INVESTIGATION REVEALED A SHEARED DRIVE SHAFT FOR THE ENGINE DRIVEN FUEL PUMP (INJECTOR PUMP). DISASSEMBLY REVEALED FOD (A SMALL PIECE OF WIRE) JAMMED IN THE ROTOR/VANE. FURTHER INVESTIGATION OF OTHER COMPONENTS OF THE AIRCRAFT FUEL SYSTEM REVEALED THAT THE LOW PRESSURE FUEL PUMP HAD FAILED INTERNALLY AND FRAGMENTS, INCLUDING PIECES OF THE WIRE-LIKE ROTOR PINS, HAD FLOWED TO THE INJECTOR PUMP. NOTE: THE INJECTOR PUMP HAD RECENTLY BEEN REPAIRED DUE TO FAILURE CAUSED BY DAMAGED VANES/ROTOR. SUBMITTER SURMISES THAT THE LAST INJECTOR FAILURE WAS ALSO DUE TO FOD FROM THE SAME FAILED LOW PRESSURE PUMP. 1L71 3O3 O 3A15 E7CE 20030409000472003040900047CE 2003 4 9 2003FA0000306 120030320G2810 BAFFLE CESSNA172 172F 2072414CE CONT O300 O300* 17022SO FUEL CELLS BROKEN D K NONE O OTHER ININSP/MAINT 1 SO095241F11723 17253322 DURING VISUAL INSPECTION, FOUND FUEL TANK BAFFLE SPOT WELDS BROKEN LOOSE, ALLOWING BAFFLE TO MOVE AROUND FREELY INSIDE FUEL TANK. THIS CONDITION COULD CAUSE FUEL STARVATION DURING A DECENT WITH A LOW FUEL QUANTITY AND COULD CAUSE ERRONEOUS FUEL QUANTITY INDICATIONS DUE TO INTERFERENCE WITH THE TRANSMITTER FLOAT. PROBABLE CAUSE: THE FRONT FACE OF THE BAFFLE IS APPROXIMATELY 1INCH BEHIND THE FUEL TANK FILLER PORT. DURING THE FUELING PROCESS, IF THE FUEL NOZZLE IS RELAXED, THE NOZZLE CONTACTS THE BAFFLE AND APPLIES EXCESSIVE PRESSURE TO THE BAFFLE, EVENTUALLY BREAKING THE SPOT WELDS LOOSE. PREVENTATIVE MEASURES: DURING THE REFUELING PROCESS, DO NOT INSERT THE FUEL NOZZLE MORE THAN 3 INCHES INTO THE FUEL TANK. 1H71 3O3 ONT3A12 E253 20030324000092003032400009EU 2003 3 24 2003FA0000307 120030318G3260803682 PROXIMITY SWITCH AMD FALC50FALCON900 2700160EU GARRTTTFE731TFE731* 01518WP MLG FAILED B A UNSCHED LANDING O OTHER CLCLIMB 1 SW11198FJ29 198 AFTER TAKEOFF WHEN THE GEAR HANDLE WAS PLACED UP ALL THREE GREEN LIGHTS EXTINGUISHED. A LOUD METALLIC GRINDING TYPE NOISE WAS NOTED AFTER SEVERAL SECONDS (10-15) THE NOISE STOPPED AND THE GREEN LIGHT FOR THE NOSE GEAR ILLUMINATED. AT THIS TIME THE GEAR HANDLE WAS UP THE NOSE GEAR INDICATED DOWN, THE LT & RT MAIN GEAR DOORS WERE OPEN. WHEN THE GEAR HANDLE WAS PLACED DOWN NO ACTIVITY WAS NOTED VISUALLY OR NOISE BY THE GEAR, APPROX. 45-75 SECONDS LATER THE LT & RT MAIN GEAR DOWN LOCK GREEN LIGHTS ILLUMINATED AND THE RED DOOR LIGHTS EXTINGUISHED. 2L73 4F4 FRTA46EU E6WE 20030409000482003040900048EA 2003 4 9 2003FA0000308 220030311G73222576532 CARBURETOR PIPER PA28 PA28R201 7102816SO LYC O360 IO360C1C6 41514EA ENGINE SCORED B A UNSCHED LANDING E VIBRATION/BUFFET CRCRUISE 1 SO15701ER1142 2844053 L2995051A THE CREW REPORTED A ROUGH/IRREGULAR SOUND FROM THE ENGINE IN CRUISE. THE CREW RETURNED TO THE RAMP. IT IS NOT UNCOMMON FOR THIS SITUATION TO OCCUR NOT ONLY DURING INSPECTION GROUND RUNS, BUT ALSO DURING OPERATION BETWEEN INSPECTIONS. A COMMON SOURCE OF PROBLEMS WITH THIS FUEL CONTROL IS THE MIXTURE VALVE. THIS VALVE BECOMES SCORED AND THEN INACURATE IN ITS FUNCTION. THERE IS A PROCEDURE FOR LAPPING THIS VALVE SURFACE. 1L71 3O3 O 2A13 1E10 20030409000492003040900049EA 2003 4 9 2003FA0000309 220030314G732225765362 CARBURETOR CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA ENGINE INACCURATE B D RETURN TO BLOCK E VIBRATION/BUFFET TXTAXI/GRND HDL 1 SO15432ER 17280652 L2776751A THE CREW REPORTED A ROUGH IDLE DURING GROUND OPERATION. THIS ENGINE/AIRCRAFT COMBINATION HAS BEEN THE SUBJECT OF AN AD REGARDING UNSTABLE IDLE/MIXTURE ISSUES. IT IS NOT UNCOMMON FOR THIS SITUATION TO OCCUR NOT ONLY DURING INSPECTION GROUND RUNS, BUT ALSO DURING OPERATION BETWEEN INSPECTIONS. THE IDLE SYSTEM ON THIS FUEL CONTROL UNIT HAS ISSUES, WHERE IT REQUIRES CONSIDERABLE ADJUSTING WITHIN A RELATIVELY FEW NUMBER OF OPERATING HOURS. 1H71 3O3 ONT3A12 1E10 20030409000502003040900050EA 2003 4 9 2003FA0000310 220030314G732225765362 CARBURETOR CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA ENGINE INACCURATE C D RETURN TO BLOCK E VIBRATION/BUFFET TXTAXI/GRND HDL 1 SO15420ER 17280634 L2784651A THE CREW REPORTED A ROUGH IDLE DURING GROUND OPERATION. THIS ENGINE/AIRCRAFT COMBINATION HAS BEEN THE SUBJECT OF AN AIRWORTHINESS DIRECTIVE REGARDING UNSTABLE IDLE/MIXTURE ISSUES. IT IS NOT UNCOMMON FOR THIS SITUATION TO OCCUR NOT ONLY DURING INSPECTION GROUND RUNS, BUT ALSO DURING OPERATION BETWEEN INSPECTIONS. THE IDLE SYSTEM ON THIS FUEL CONTROL UNIT HAS ISSUES WHERE IT REQUIRES CONSIDERABLE ADJUSTING WITHIN A RELATIVELY FEW NUMBER OF OPERATING HOURS. 1H71 3O3 ONT3A12 1E10 20030409000512003040900051EA 2003 4 9 2003FA0000311 220030317G732225765362 CARBURETOR CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA ENGINE INACCURATE B D RETURN TO BLOCK E VIBRATION/BUFFET TXTAXI/GRND HDL 1 SO15420ER 17280634 L2784651A THE CREW REPORTED A ROUGH IDLE DURING GROUND OPERATION. THIS ENGINE/AIRCRAFT COMBINATION HAS BEEN THE SUBJECT OF AN AIRWORTHINESS DIRECTIVE REGARDING UNSTABLE IDLE/MIXTURE ISSUES. IT IS NOT UNCOMMON FOR THIS SITUATION TO OCCUR NOT ONLY DURING INSPECTION GROUND RUNS, BUT ALSO DURING OPERATION BETWEEN INSPECTIONS. THE IDLE SYSTEM ON THIS FUEL CONTROL UNIT HAS ISSUES, WHERE IT REQUIRES CONSIDERABLE ADJUSTING WITHIN A RELATIVELY FEW NUMBER OF OPERATING HOURS. 1H71 3O3 ONT3A12 1E10 20030409000522003040900052EA 2003 4 9 2003FA0000312 220030320G732225765362 CARBURETOR CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA ENGINE INACCURATE B D RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TXTAXI/GRND HDL 1 SO15444ER1684 172S8659 L2932851A THE CREW REPORTED A ROUGH ENGINE DURING VARIOUS PHASES OF THE PRE-TAKE OFF RUN UP. AFTER TROUBLESHOOTING AND TESTING, THE FUEL CONTROL, FLOW DIVIDER AND ONE FUEL NOZZLE WERE REPLACED WITH SERVICEABLE PARTS. THIS ENGINE/FUEL CONTROL COMBINATION HAS BEEN THE SUBJECT OF AN AIRWORTHINESS DIRECTIVE. 1H71 3O3 ONT3A12 1E10 20030409000532003040900053EA 2003 4 9 2003FA0000313 220030317G732225765362 CARBURETOR PIPER PA28 PA28R201 7102816SO LYC O360 IO360C1C6 41514EA ENGINE INACCURATE B D RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TXTAXI/GRND HDL 1 SO15703ER 2844057 L3013951A THE CREW REPORTED A ROUGH IDLE DURING GROUND OPERATION. THIS ENGINE/AIRCRAFT COMBINATION HAS BEEN THE SUBJECT OF AN AD REGARDING UNSTABLE IDLE/MIXTURE ISSUES. IT IS NOT UNCOMMON FOR THIS SITUATION TO OCCUR NOT ONLY DURING INSPECTION GROUND RUNS, BUT ALSO DURING OPERATION BETWEEN INSPECTIONS. THE IDLE SYSTEM ON THIS FUEL CONTROL UNIT HAS ISSUES, WHERE IT REQUIRES CONSIDERABLE ADJUSTING WITHIN A RELATIVELY FEW NUMBER OF OPERATING HOURS. 1L71 3O3 O 2A13 1E10 20030409000542003040900054CE 2003 4 9 2003FA0000314 120030320G323010138800511 CONTROL VALVE BEECH 200 B200 1152922CE PWA PT6 PT6* 52043EA INOPERATIVE G A UNSCHED LANDING J WARNING INDICATION LDLANDING 1 SW0136GS 2579 BB1298 DURING APPROACH TO LANDING AT ABQ THE GEAR WOULD NOT EXTEND IN NORMAL OPERATION. LANDING GEAR HYDRAULIC POWER PACK MOTOR WOULD RUN WHEN HANDLE IN DOWN POSITION BUT GEAR WOULD NOT MOVE. EXTENDED GEAR WITH EMERGENCY SYSTEM. INSTALLED NEW SOLENOID VALVE AND GEAR OPERATED NORMALLY. 1L72 4T3 T A24CE E2NE 20030409000552003040900055CE 2003 4 9 2003FA0000315 120030320G324650300010133 WHEEL BEECH 90 E90 1152914CE PWA PT6 PT6* 52043EA MLG BROKEN G D RETURN TO BLOCK O OTHER TXTAXI/GRND HDL 1 SW01676J 9197 LW179 THE INBOARD WHEEL HALF FAILED FROM ONE BOLT HOLE AND THE CRACK WALKED ALL THE WAY AROUND THE WHEEL HALF. THE WHEEL AXLE NUT WAS THE ONLY THING THAT KEPT THE WHEEL ON THE AXLE. THIS HAPPENED DURING TAXI TO TAKEOFF. 1L72 3T3 T 3A20 E2NE 20030324000102003032400010EU 2003 3 24 2003FA0000316 120030318G3260803682 PROXIMITY SWITCH AMD FALC50FALCON900 2700160EU GARRTTTFE731TFE731* 01518WP MLG FAILED B A UNSCHED LANDING N FALSE WARNING CLCLIMB 1 SW11198FJ29 198 AFTER TAKEOFF WHEN THE GEAR HANDLE WAS PLACED UP ALL THREE GREEN LIGHTS EXTINGUISHED. ALOUD METALLIC GRINDING TYPE NOISE WAS NOTED AFTER SEVERAL SECONDS 10-15 THE NOISE STOPPED AND THE GREEN LIGHT FOR THE NOSE GEAR ILLUMINATED. AT THIS TIME THE GEAR HANDLE WAS UP TH NOSE GEAR INDICATED DOWN, THE LT & RT MAIN GEAR DOORS WERE OPEN. WHEN THE GEAR HANDLE WAS PLACED DOWN NO ACTIVITY WAS NOTED VISUALLY OR NOISE BY THE GEAR, APPROX. 45-75 SECONDS LATER THE LT & RT MAIN GEAR DOWN LOCK GREEN LIGHTS ILLUMINATED AND THE RED DOOR LIGHTS EXTINGUISHED. 2L73 4F4 FRTA46EU E6WE 20030409000562003040900056CE 2003 4 9 2003FA0000317 120030321G28100700099108 LINE CESSNA182 182Q 2072732CE CONT O470 O470* 17026SO FUEL SYSTEM CHAFED D O OTHER O OTHER NRNOT REPORTED 1 SO099783212448 18267214 FUEL LINE FROM FUEL SELECTOR VALVE TO FUEL STRAINER. RUDDER PEDALS HAD WORN A DEEP GROOVE IN FUEL LINE. 1H71 3O3 ONT3A13 E273 20030409000572003040900057SO 2003 4 9 2003FA0000318 120030307G273031713 CONTROL CABLE MAULE M5 M5235C 5460135SO LYC O540 O540* 41532EA ELEVATOR WORN D O OTHER O OTHER NRNOT REPORTED 1 CE056170M844 7179C FOUND ELEVATOR DOWN CABLE AT F/W BELCRANK WITH BROKEN STRAND AND WEARING AT POINT OF CONTACT. FOUND WHILE COMPLYING WITH MFG SB NR 64, DURING ANNUAL INSPECTION. REPLACED CABLE WITH NEW PART. 1H71 3O3 O 3A23 E295 20030409000582003040900058GL 2003 4 9 2003FA0000319 120030306G25105049074058013 SEAT BELT CIRRUSSR SR20 05628AJGL COCKPIT INOPERATIVE D O OTHER O OTHER NRNOT REPORTED 1 SO06 THIS ISSUE INVOLVES SEATBELTS INSTALLED ON AIRCRAFT. THE TENSIONER BAR ON LAP BOLT WILL NOT HOLD TENSION ON BELTS ONCE TIGHTENED. BELTS ARE LOOSENING DUE TO VIBRATION IN FLIGHT. THE TENSION BAR IS SMOOTH, SO IT IS NOT HOLDING TENSION. REDESIGN TENSIONER BAR. 1L71 3O NTA00009CH 20030409000592003040900059EA 2003 4 9 2003FA0000320 220030322G732225765362 CARBURETOR CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA ENGINE INACCURATE C D RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TXTAXI/GRND HDL 1 SO15497ER 17280673 L2013851A DURING PRE TAKEOFF GROUND OPERATIONAL CHECK, THE IDLE SPEED WAS ONLY ABOUT 400 RPM. IT WAS ADJUSTED ALONG WITH THE MIXTURE. THIS ENGINE FUEL CONTROL COMBINATION WAS THE SUBJECT OF AN AIRWORTHINESS DIRECTIVE FOR THIS PROBLEM. THE VARIOUS OTHER COMPONENTS OF THIS FUEL CONTROL SYSTEM ALSO HAVE RELIABILITY ISSUES RANGING FROM SCORING OF THE MIXTURE CONTROL PLATES TO IMPROPER MANIFOLD VALVE OPERATION. OFTEN THE INACCURATE OPERATION OF THIS SYSTEM RESULTS IN AN EXTREMELY RICH MIXTURE WHICH CAUSES MANY SPARK PLUG FOULING PROBLEMS. 1H71 3O3 ONT3A12 1E10 20030409000602003040900060CE 2003 4 9 2003FA0000321 120030301G5610101384502522 WINDSHIELD BEECH 200 B200 1152922CE PWA PT6 PT6A60A 52043NE COCKPIT CRACKED D O OTHER O OTHER CRCRUISE 1 NM0963791814 BB1100 CO-PILOT WINDSHIELD CRACKED DURING CRUISE. THIS UNIT WAS INSTALLED ON 01/16/2002 AT 7294.2 TT A/F. CURRENT INSPECTION REQUIREMENT CALLS FOR A WINDSHIELD SCREW TORQUE CHECK EACH 200 HOURS. OUR EXPERIENCE HAS SHOWN THAT SOON AFTER RETORQUEING THE WINDSHIELD WILL FAIL. SUGGEST THAT MFG MODIFY THE RETORQUE REQUIREMENT AT EACH 200 HOUR. 1L72 4T4 T A24CE E4EA 20030409000642003040900064EA 2003 4 9 2003FA0000328 220030310G853070275 CYLINDER HEAD CESSNA172 172P 2072436CE LYC O320 O320D2J 41508EA ENGINE CRACKED D DZXEO OTHER O OTHER NRNOT REPORTED 1 EA2564551 17275577 L1384439A CYLINDER CRACKED IN EXHAUST PORT AREA OF THE HEAD. 1H71 3O3 ONT3A12 E274 20030409000652003040900065EU 2003 4 9 2003FA0000329 120030226G2720 HORN GROB G103 G103A 1660202EU ELEVATOR LOOSE D K NONE O OTHER ININSP/MAINT 1 EA111202Z4500 3615 ON ANNUAL INSPECTION FOUND ELEVATOR HORN LOOSE. HORN IS BOLTED TO TWO INBOARD SOLID RIBS OF ELEVATOR. IT IS NOW BROKEN LOOSE FROM THESE TWO RIBS. THIS IS A VERY SERIOUS CONDITION, NEEDS TO BE CHECKED. THIS AIRCRAFT IS STORED OUTSIDE. 1K00 RCG39EU 20030409000662003040900066EU 2003 4 9 2003FA0000330 120030228G5522 SKIN GROB G103 G103A 1660202EU LT ELEVATOR DELAMINATED D K NONE O OTHER ININSP/MAINT 1 EA111202Z4500 3615 ON ANNUAL INSPECTION, FOUND LEFT ELEVATOR LOWER SKIN DELAMINATED IN TWO PLACES. TOW BLISTERS APPROXIMATELY ONE FOOT LONG. ELEVATOR WAS REMOVED AND SENT OUT FOR REPAIR. 1K00 RCG39EU 20030409000672003040900067EU 2003 4 9 2003FA0000331 120030301G3210 LEG ASSY LET L13 L13BLANIK 1360306EU MLG BROKEN D O OTHER O OTHER NRNOT REPORTED 1 EA11244PT1500 026355 LEG THAT HOLDS MLG FORK ASSEMBLY. HAD STRAIGHT BREAK. APPEARS TO BE FATIGUE FAILURE. MAY HAVE BEEN CAUSED BY TAKING OFF FROM GRASS AT ANGLE TO PAVED RUNWAY AND CONSTANT HITTING OF 2-3 INCHES NEWLY PAVED RUNWAY. RECOMMEND TAKING OFF ON PAVED RUNWAY, HAND PULL GLIDER OVER BUMP. 1K00 G24EU 20030409000682003040900068EA 2003 4 9 2003FA0000332 220030317G8550STD1339 PLUG PIPER PA31 PA31300 7103104SO LYC O540 IO540M1A5 41532EA OIL PUMP BODY UNDERTORQUED B O OTHER W INADEQUATE Q C NRNOT REPORTED 1 SO06411CF60 31339 RL1461648A COMPLIANCE WITH MFG SB 555, OIL PUMP BODY PLUG INSPECTION, BOTH ENGINES CHECKED AND FOUND UNDERTORQUED. RETORQUED IAW SB. RETURNED TO SERVICE WITHOUT INCIDENT. (SHOULD MAKE MANDITORY AD) 1L72 3O3 O A20SO 1E4 20030409000692003040900069EA 2003 4 9 2003FA0000333 220030327G732225765362 CARBURETOR CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA ENGINE INOPERATIVE C D RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TXTAXI/GRND HDL 1 SO15478ER 17280623 L1635851A DURING PRE-TAKEOFF CHECK, THE CREW REDUCED THE THROTTLE TO CHECK THE IDLE SPEED. THE ENGINE WOULD ALMOST QUIT EACH TIME IT WAS ATTEMPTED. THIS ENGINE/FUEL CONTROL COMBINATION REQUIRES SUBSTANTIAL ADJUST FOR A VERY FEW HOURS FLOWN. 1H71 3O3 ONT3A12 1E10 20030409000702003040900070 2003 4 9 2003FA0000334 420030327G611305503671 SPINNER CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA MCAULY1A170 1A170E GL PROPELLER CRACKED C K NONE O OTHER ININSP/MAINT 1 SO15408ER 172S8642 L2779051A UG23005 DURING AN INSPECTION, THE SPINNER WAS FOUND CRACKED. ALL MFG. SERVICE INFORMATION REGARDING THIS PROBLEM HAD BEEN COMPLIED WITH. 1H71 3O3 ONT3A12 1E10 5 NP857 20030409000712003040900071EA 2003 4 9 2003FA0000335 220030327G732225765362 CARBURETOR CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA ENGINE INACCURATE B D RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TXTAXI/GRND HDL 1 SO15404ER 172S9154 L3044651A DURING PRE TAKEOFF IDLE CHECK, THE SPEED WAS ONLY 300-500 RPM. THIS ENGINE/FUEL CONTROL COMBINATION REQUIRES SUBSTANTIAL ADJUSTMENT OVER A FEW HOURS TYPICALLY. 1H71 3O3 ONT3A12 1E10 20030409000722003040900072 2003 4 9 2003FA0000336 420030327G611305503673 SPINNER CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA MCAULY1A170 1A170E GL PROPELLER CRACKED B K NONE O OTHER ININSP/MAINT 1 SO15425ER 17280646 RL805651A TL046 DURING AN INSPECTION, THE SPINNER WAS FOUND CRACKED. 1H71 3O3 ONT3A12 1E10 5 NP857 20030409000732003040900073EA 2003 4 9 2003FA0000337 220030320G732225765362 CARBURETOR CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA ENGINE INACCURATE B D RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TXTAXI/GRND HDL 1 SO15472ER 17280669 L2734251A DURING NORMAL OPERATIONS, THE ENGINE WOULD SPUTTER AND RUN VERY IRREGULARLY AT IDLE. AFTER ROUTINE IDLE SPEED/MIXTURE ADJUSTMENT THE ENGINE RAN PROPERLY. THIS ENGINE/FUEL CONTROL COMBINATION REQUIRES ADJUSTMENT OF THE IDLE SPEED/MIXTURE MORE OFTEN THAN TYPICALLY REQUIRED IN THE GA TYPE AIRCRAFT. 1H71 3O3 ONT3A12 1E10 20030409000752003040900075CE 2003 4 9 2003FA0000339 120030307G3230358100757 BUSHING BEECH P35 P35 1151530CE CONT O470 IO470* 17026SO WORM DRIVESHAFT BROKEN B SNSRO OTHER O OTHER NRNOT REPORTED 1 GL139603Y D7115 THE BUSHINGS AT THE HANDLE END OF THE WORM DRIVE SHAFT WERE SEVERELY WORN AND BROKEN WHICH WOULD ALLOW THE SHAFT TO MOVE BACK AND FORTH AND OVER A PERIOD OF TIME THE LOCKNUT BACKED OFF FAR ENOUGH TO ALLOW THE WORM DRIVE SHAFT TO MOVE BACK AND FORTH A SIGNIFICANT AMOUNT WHICH WOULD CAUSE A BINDING IN THE SECTOR TO WORM GEAR CONTACT AREA. THIS IS WHY THE MOTOR LOCKED UP AND THE EMERGENCY GEAR SYSTEM DID NOT ALLOW THE GEAR TO BE MOVED IN EITHER DIRECTION. 1L71 3O3 ORT3A15 E1CE 20030409000762003040900076EA 2003 4 9 2003FA0000340 220030307G8530LW15318 CYLINDER CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA NR 2 CRACKED B CSLRK NONE O OTHER ININSP/MAINT 1 CE01124FR650 17273814 RL729876T ENGINE DISASSEMBLED DUE TO BIRD STRIKE. FOUND NR 2 CYLINDER BARREL CRACKED AT JOINT OF BARREL AND HEAD. CRACK IS APPROXIMATELY 2 INCHES LONG, LOCATED RADIALLY AROUND BORE. CYLINDER SHOWS EVIDENCE OF LEAKAGE EXTERNALLY IMMEDIATELY BELOW FINNED AREA OF HEAD. SUGGEST CHECKING CYLINDERS FOR LEAKAGE AT INTERSECTION OF BARREL AND HEAD AT REGULAR INSPECTION. 1H71 3O3 ONT3A12 E274 20030409000772003040900077 2003 4 9 2003FA0000341 420030308G2561KS9P01018 LIFE VEST FAILED B KQ1RK NONE L NO TEST ININSP/MAINT 1 EA07 LIFE PRESERVER FAILED. MANUFACTURER RECOMMENDED PSI CELL TEST. DOM:NOV 1980 20030409000782003040900078EU 2003 4 9 2003FA0000342 120030319G3610 SHAFT GROB 120 G120A 1660208EU LYC O540 AEIO540D4D5 EA DRY AIR PUMP DAMAGED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07862AF 85002 L2802448A DURING FLIGHT AIR PRESSURE INDICATED ZERO OUTPUT. MAINTENANCE TECH FOUND BROKEN SHAFT ON DRY AIR PUMP. PROBABLE CAUSE: VIBRATION FROM ENGINE. C/A: MFG TO INVESTIGATE PUTTING STIFFER LORD MOUNTS ON ENGINE FRAME TO REDUCE ENGINE VIBRATION TO OTHER COMPONENTS. 1L71 3O3 ORTA49CE 1E4 20030409000792003040900079EA 2003 4 9 2003FA0000343 220030220G7314 PUMP GROB 120 G120A 1660208EU LYC O540 AEIO540D4D5 EA FUEL SYSTEM FAILED B VJ3RO OTHER J WARNING INDICATION TXTAXI/GRND HDL 1 WP07864AF643 85004 L2826348A DURING GROUND RUN FUEL PRESSURE READINGS WERE HIGH AND UNABLE TO ADJUST PRESSURES. 1L71 3O3 ORTA49CE 1E4 20030409000802003040900080EU 2003 4 9 2003FA0000345 120030320G3230120A9491105AV RELAY GROB 120 G120A 1660208EU MLG DAMAGED B VJ3RK NONE O OTHER ININSP/MAINT 1 WP07867AF395 85007 DURING PROGRESSIVE INSPECTION FOUND BAD RELAY AND DIODES BOARD HAD OPEN ON PC BOARD BETWEEN PC BOARD AND GEAR CONTROL RELAY. 1L71 3O RTA49CE 20030410000012003041000001EU 2003 4 10 2003FA0000346 120030317G3260BAD10500 UPLOCK GROB 120 G120A 1660208EU LYC O540 AEIO540D4D5 EA MLG INOPERATIVE B VJ3RO OTHER J WARNING INDICATION NRNOT REPORTED 1 WP07865AF 85005 L2826448A DURING FLIGHT GEAR ON LT SIDE WOULD NOT RELEASE. FLIGHT CREW HAD TO PREFORM EMERGENCY EXTENSION AND PULL G`S TO RELEASE GEAR. TROUBLE SHOOT SYSTEM AND FOUND LEFT GEAR UPLOCK WOULD NOT RELEASE GEAR. REPLACED UPLOCK ASSY. RIGGING WAS OUT OF LIMIT. PROBABLE CAUSE IS DESIGN OF UPLOCK ASSY INSTALLATION. RECOMMENDATION IS TO C/W SB. 1L71 3O3 ORTA49CE 1E4 20030410000022003041000002EU 2003 4 10 2003FA0000347 120030318G2823120A6229 SELECTOR VALVE GROB 120 G120A 1660208EU FUEL SYSTEM FAILED B VJ3RK NONE O OTHER ININSP/MAINT 1 WP07861AF692 85001 DURING A PROGRESSIVE INSPECTION, TECH FOUND THE FUEL SELECTOR VALVE LOOSE AND HARD TO TURN. PROBABLE CAUSE IS INTERNAL FAILURE. 1L71 3O RTA49CE 20030410000032003041000003EU 2003 4 10 2003FA0000348 120030320G2913X030001B PUMP GROB 120 G120A 1660208EU LYC O540 AEIO540D4D5 EA HYD SYSTEM OVERHEATED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07867AF 85007 THE HYDRAULIC PUMP CIRCUIT BREAKER KEEPS POPPING WHILE PUMP BUILDS UP PRESSURE. NO WARNING LIGHT COMES ON TO INDICATE PUMP IS GETTING HOT. HOWEVER WHEN YOU TOUCH THE PUMP WITH YOUR HAND IT IS HOT. 1L71 3O3 ORTA49CE 1E4 20030410000042003041000004EA 2003 4 10 2003FA0000349 220030401G7414D4LN3000 MAGNETO MOONEYM20 M20J 5870219SW LYC O360 IO360A3B6 41514EA MCAULY2D34C B2D34C214 GL ENGINE LOOSE C A UNSCHED LANDING Y ENGINE STOPPAGE CLCLIMB 1 SO17 1950 180 243306 L2613451A 930320 AIRCRAFT EXPERIENCED ENGINE FAILURE AFTER TAKE-OFF, PILOT LANDED AIRCRAFT WITH MAIN LANDING GEAR RETRACTED. AIRCRAFT RECIEVED CONSIDERABLE DAMAGE FROM LANDING. ENGINE UPPER COWLING REMOVED FOR INVESTIGATION OF ENGINE FAILURE. DURING INSPECTION OF ENGINE FOUND MAGNETO DISENGAGED FROM ACCESSORY CASE, ALL MOUNTING HARDWARE MISSING. REVIEW OF MAINTENANCE LOGBOOKS REVEALED AD 96-12-07 IMPULSE COUPLING INSPECTION COMPLIED 06 APRIL, 2001. MAGNETO HAS 180.1 HRS SINCE LAST INSPECTION. OIL CHANGE COMPLETED 27 JANUARY, 2003. 1L71 3O3 O 2A3 1E10 5 CP7EA 20030410000072003041000007GL 2003 4 10 2003FA0000352 120030301G2731 TAB BLANCA1419 14193 1220406GL CONT O470 IO470* 17026SO ELEVATOR TRIM INOPERATIVE D O OTHER O OTHER NRNOT REPORTED 1 WP07416MB 4225 ELEVATOR TRIM TAB BECAME TIGHT AND HARD TO USE, AND FINALLY IT BECAME INOPERATIVE. IT IS VERY DIFFICULT TO GET TO THIS PROBLEM, SINCE THE PART CONTAINING THE MOVABLE TRIM TAB IS ENCASED IN A TIGHT TUBE AND IT IS ABOVE THE OVERHEAD AND BELOW THE OUTER FABRIC SKIN OF THE AIRPLANE IN THE COCKPIT AREA. 1L71 3O3 O 1A3 E1CE 20030410000082003041000008GL 2003 4 10 2003FA0000353 120030301G2731 TAB BLANCA1419 14193 1220406GL ELEVATOR TRIM INOPERATIVE D O OTHER O OTHER NRNOT REPORTED 1 WP07 ELEVATOR TRIM TAB SYSTEM BECAME DIFFICULT TO OPERATIVE. IT BINDS. IT WAS DETERMINED THAT THE ORIGINAL LUBRICANT HAD CONGEALED IN THE LONG TRIM TAB UNIT, FROM COCKPIT TO TAIL. THIS RESULTED IN AN NONFUNCTIONAL TRIM TAB. THE TRIM IS ENCASED INSIDE A LONG TUBE FROM COCKPIT HANDLE TO TAIL SECTION. IT IS ATTACHED TO AND JUST UNDERNEATH THE UPPER FUSELAGE. EXCESSIVE FRICTION INSIDE THIS TUBE CAUSED THE PROBLEM. LUBRICATE IS THE ANSWER. 1L71 3O 1A3 20030410000122003041000012 2003 4 10 2003FA0000358 420030328G2310 ANTENNA CESSNA500 550 2076604CE PWA 530 PW530A NE VERTICAL STAB SEPARATED E ZESAO OTHER D INFLIGHT SEPARATION NRNOT REPORTED 1 EA03550KL939 5500844 THE HF ANTENNA BROKE OFF DURING FLIGHT, FROM THE VERTICAL STABILIZER TENSION UNIT. THE ANTENNA CABLE SLAPPED AGAINST THE TAILCONE, CHIPPING PAINT. NO STRUCTURAL DAMAGE FOUND. 1L72 4F4 F A22CE E00053EN 20030410000132003041000013CE 2003 4 10 2003FA0000359 120030214G5312 FIREWALL CESSNA172 172R 2072401CE LYC O360 IO360A1A 41514EA FUSELAGE CRACKED B LC1RK NONE O OTHER ININSP/MAINT 1 EA0726499 17280730 DURING A PHASE 1 INSPECTION FOUND A CRACK IN THE FIREWALL AT THE LOWER ROW OF RIVETS ATTACHING THE BATTERY BOX TO THE FIREWALL. UPON REMOVAL OF BOX FOR REPAIR FOUND 2ND CRACK UNDER THE OUTBOARD VERTICAL ROW OF RANGE IN MFG SB FIREWALL INSPECTION. 1H71 3O3 ONT3A12 1E10 20030410000142003041000014CE 2003 4 10 2003FA0000360 120030401G2421E3FF103000AA ALTERNATOR CESSNA210 T210M 2073451CE CONT O520 TSIO520* 17040SO ENGINE SEIZED D E ENGINE SHUTDOWN EB VIBRATION/BUFFET SMOKE/FUMES/ODORS/SPARKS TXTAXI/GRND HDL 1 SO096246B 398 21062721 293993R UPON FIRST START OF THE DAY A LOUD SQUEALING NOISE WAS HEARD ALONG WITH WHITE SMOKE EXITING THE COWL FLAPS AND THE PILOT SHUT DOWN ENGINE. UPON REMOVING THE COWLING IT BECAME OBVIOUS THAT THE ALTERNATOR HAD SEIZED AND THAT THE BELT WAS BADLY BURNED. LATER EXAMINATION BY THE MECHANIC REVEALED THAT A DIODE BLOCK SCREW HAD VIBRATED LOOSE AND WEDGED BETWEEN THE ROTOR AND STATOR AFTER SHUT DOWN FROM THE PREVIOUS DAYS FLIGHT. 1H71 3O3 O 3A21 E8CE 20030410000152003041000015 2003 4 10 2003FA0000361 420030331G2562 BATTERY PACK BEECH 58 58 1152740CE ELT LEAKING B K NONE K FLUID LOSS ININSP/MAINT 1 EA25957PC142 TH2023 DURING 100 HR/ANNUAL INSPECTION ELT TEST, IT WAS NOTED THAT THE ELT CASE WAS CRACKED IN THE BATTERY PORTION AND WHAT APPEARED TO BE CORROSION WAS COMING OUT. THE BATTERY WAS SEPARATED FROM THE ELT. AT LEAST 2 OF THE 6 BATTERIES HAD LEAKED ACID WHICH HAD EATEN INTO THE PLASTIC CASE. THE COMPLETE ELT WAS RETURNED TO THE MANUFACTURE FOR REPAIR. NO DAMAGE WAS DONE TO AIRCRAFT, THE ACID NEVER CAME IN CONTACT WITH AIRFRAME COMPONENTS. THE BATTERY PACK HAD AN EXPIRATION DATE OF JULY 2004, WO NR38555 WHICH WOULD MAKE IT APPROXIMATELY 9 MONTHS OLD. 1L72 3O 3A16 20030410000162003041000016EA 2003 4 10 2003FA0000362 220030331G732225765362 CARBURETOR CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA ENGINE INACCURATE B D RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TXTAXI/GRND HDL 1 SO15418ER 172S8650 L2731951A DURING PRE TAKEOFF RUN, THE IDLE SPEED WOULD DROP TO ABOUT 500 RPM WHEN THE THROTTLE WAS REDUCED TO THE STOP. THIS ENGINE FUEL CONTROL COMBINATION REQUIRES SUBSTANTIAL ADJUSTMENT TO MAINTAIN THE CORRECT IDLE SPEED/MIXTURE. 1H71 3O3 ONT3A12 1E10 20030410000172003041000017CE 2003 4 10 2003FA0000363 120030313G531207126161 BULKHEAD CESSNA182 182L 2072726CE CRACKED B K NONE O OTHER ININSP/MAINT 1 EA21422614078 18258930 THE AFT FUSELAGE BULKHEAD WAS CRACKED IN THE RADIUS AT THE RUDDER STOP ATTACHMENT POINTS. 1H71 3O NT3A13 20030410000182003041000018NE 2003 4 10 2003FA0000364 220030403G732132447687 FUEL CONTROL BEECH 200 B200 1152922CE PWA PT6 PT6A60A 52043NE MALFUNCTIONED G O OTHER O OTHER LDLANDING 1 GL07200EW718 718 BB1163 DURING LANDING ROLLOUT, THE PILOT TRIED TO APPLY REVERSE AND THE AIRCRAFT VEERED OFF INTO THE LEFT GRASSY AREA, AND EVENTUALLY CAME TO REST IN THE WEST SOFT AREA. AN ENGINE RUNUP AFTERWARDS REVEALED A DISCREPANCY IN THE RT ENGINE FUEL CONTROL. IT WAS REPLACED WITH AN OVERHAULED UNIT. THE AIRCRAFT WAS TEST FLOWN SATISFACTORILY. 1L72 4T4 T A24CE E4EA 20030410000192003041000019CE 2003 4 10 2003FA0000365 120030407G21213521000 MOTOR ELECTROMECH 903840311 BEECH 90 C90A 1152911CE PWA PT6 PT6* 52043EA HARTZLHCE4N HCE4N3 NE VENT BLOWER BURNED B O OTHER B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CE05902PL1097 1662 LJ1583 DURING FLIGHT, CREW HAD SMOKE IN THE CABIN. SHUTTING OFF THE VENT BLOWER CLEARED THE SMOKE FORM THE CABIN. AFTER REMOVING THE CABIN VENT BLOWER FROM THE AIRCRAFT INSPECTION OF IT FOUND THE MOTOR LOCKED UP AND THE BRUSHES BURNED UP. 1L72 3T3 TRT3A20 E2NE 5 CP10NE 20030423000012003042300001GL 2003 4 23 2003FA0000366 120030408G2700 ROD END AMTR AVID AVID* 056121ZGL ROTAX 582 582LC 55555CE LIFT STRUT BROKEN Z A UNSCHED LANDING O OTHER CLCLIMB 1 SW99 GFOLD AVID AIRCRAFT LIFT STRUT, THREADED ROD-END FAILURE. THE PILOT OF AN AVID AIRCRAFT LOST CONTROL SHORTLY AFTER TAKE-OFF AND THE AIRCRAFT DESCENDED INTO THE GROUND IN AN UNCOMMANDED LEFT-HAND TURN CAUSING SUBSTANTIAL DAMAGE TO THE AIRFRAME. THE PILOT RECALLS HEARING A SHARP CRACK SHORTLY BEFORE BECOMING AIRBORNE. THE GOVT.AAIB METALLURGIST HAS CONCLUDED THAT THE PORT REAR LIFT STRUT THREADED ROD-END MAY HAVE FAILED BEFORE THE IMPACT. THIS WOULD FIT WITH THE SHARP CRACK NOISE AND THE ROLL TO THE LEFT. THERE WERE NO INDICATIONS OF LONG-TERM FATIGUE OR CORROSION DAMAGE AND THE MATERIAL’S HARDNESS STATE PROVED CORRECT. HOWEVER PRE-ACCIDENT DAMAGE TO THE ROD END CANNOT BE RULED OUT. IN PARTICULAR, THE ROD-END MAY1H71 3 I EXPA1H71EXPA3I 20030428001422003042800142SO 2003 4 28 2003FA0000368 120030408G1430 BOLT PIPER PA28 PA28181 7102807SO LYC O360 O360* 41514EA VERTICAL FIN UNDERTORQUED D K NONE O OTHER ININSP/MAINT 1 SO15137FC3890 8290172 DURING ANNUAL INSPECTION FOUND VERTICAL FIN LOOSE. UPON CHECKING ATTACHMENT HARDWARE, FOUND THE FOUR BOLTS AT THE REAR SPAR TO BE INSUFFICIENTLY TORQUED. THE SINGLE BOLT AT THE FRONT SPAR WAS TIGHT BUT WOULD NOT PREVENT SIDE TO SIDE MOVEMENT OF THE FIN(APPROX. 1/4 TO 1/2 INCH. THERE WAS NO RECORD OF THE VERTICAL FIN BEING REMOVED FOR MAINTENANCE AND THIS MECHANIC CANNOT OFFER ANY EXPLANATIONS AS TO WHY THESE BOLTS WERE NOT TIGHT. ALL THE ATTACHING BOLTS WERE REMOVED, THE AREAS SURROUNDING THE BOLT HOLES INSPECTED FOR CRACKS, NEW HARDWARE INSTALLED AND RETORQUED. 1L71 3O3 O 2A13 E286 20030410002262003041000226SW 2003 4 10 2003FA0000369 120030321G32218644402 SPAR BELL 206 206B 1181511SW NLG CRACKED B K NONE O OTHER ININSP/MAINT 1 SO09345F 3466 2697 FOUND CRACK IN SPAR WEB AT NOSE GEAR SUPPORT AFT ATTACH. BOLT 1G71 3U H2SW 20030414000752003041400075SO 2003 4 14 2003FA0000370 220030411G8530655470A3 CYLINDER BEECH 55 95C55 1152708CE CONT O520 IO520* 17032SO NR 2 & 6 WORN D O OTHER O OTHER NRNOT REPORTED 1 SW09621G 332 TE214 816876R CYLINDERS NR 2 AND 6 HAD LOW COMPRESSION WITH LEAKAGE PAST THE EXHAUST VALVES. REMOVEAL AND TEARDOWN OF THE CYLINDERS REVEALED THE FOLLOWING: CONDITION OF CYLINDER HEAD WAS NORMAL FOR TIME. EXHAUST VALVES EXHIBITED EXTREME WEAR FOR TIME IN SERVICE. CYLINDER BARREL EXHIBITED STEP WEAR IN THE BORE OF .003 INCH, AND PITTING. EXHAUST VALVE GUIDES WERE WORN PAST SERVICE LIMITS. HALF OF THE VALVE SPRINGS WERE OUT OF LIMITS, AND HALF WERE AT SERVICE LIMITS. HAVE BEEN FINDING NUMEROUS EXAMPLES OF FACTORY NEW AND OVERHAULED CYLINDERS THAT FAIL WITH APPROX 300 HOURS SINCE NEW OR OVERHAUL. 1L72 3O3 O 3A16 E5CE 20030429000642003042900064CE 2003 4 29 2003FA0000371 120030326G1430AN724A BOLT CESSNA172 172B 2072406CE CONT O300 O300* 17022SO RT WING MISINSTALLED B AW4RK NONE O OTHER ININSP/MAINT 1 WP116934X1881 17247834 DURING ANNUAL INSPECTION, THE RT DIRECT AILERON CABLE (PN 0510105-72) WAS FOUND TO BE CHAFFING ON THE RT WING AFT ATTACH BOLT THREADS AND NUT. FURTHER INVESTIGATION REVEALED THAT BOTH THE LEFT AND RT AFT WING ATTACH BOLTS WERE INSTALLED BACKWARDS WITH THE THREADS FACING IN THE AFT DIRECTION. THE EXCESSIVE LENGTH OF THE THREADED PORTION AND NUT AFT OF THE WING SPAR CAUSED INTERFERENCE WITH THE RT AILERON CABLE. REPLACED THE AILERON CABLE DUE TO SEVERAL STRANDS BEING CHAFFED EXCESSIVELY. REPLACED BOTH AFT WING ATTACH BOLTS AND HARDWARE. RECORD REVIEW SHOWS THAT A/C HAD BEEN REASSEMBLED (FROM STORAGE) IN MAY OF 2002, AT WHICH TIME AN ANNUAL INSP WAS SIGNED OFF. 1H71 3O3 ONT3A12 E253 20030429000652003042900065CE 2003 4 29 2003FA0000372 120030313G3246 WHEEL CESSNA172 172A 2072404CE CONT O300 O300* 17022SO NLG CORRODED D K NONE O OTHER ININSP/MAINT 1 SW197326T2207 46926 DURING ANNUAL INSP, NOSEWHEEL ASSY WAS REMOVED IN ORDER TO INSPECT THE BEARINGS FOR CONDITION. ONE BEARING CUP WAS FOUND CORRODED. WHEN LW67010 CUP WAS REMOVED FROM WHEEL HALF, TECH DISCOVERED BRG BORE SEVERELY WORN. BEARING CUP HAD BEEN GLUED IN PLACE WITH REDDISH COLORED ADHESIVE COMPOUND, POSSIBLE LOCKTITE. COMPOUND ADHERED TO WHEEL HALF AND BEARING CUP. WITHOUT REMOVING COMPOUND FROM WHEEL HALF, TECH PLACED A CLEAN LW67010 BEARING CUP IN WHEEL HALF. CUP SEATED IN BORE WITH LIGHT HAND PRESSURE AND SPUN FREELY WITH CONSIDERABLE CLEARANCE. A/C OWNER STATED THAT NOSEWHEEL BRGS HAD BEEN REPLACED LAST ANNUAL. GLUEING THE BEARING CUP IN PLACE IS NOT AN APPROVED REPAIR. 1H71 3O3 O 3A12 E253 20030429000822003042900082SO 2003 4 29 2003FA0000373 220030328G8530628488 LIFTER CESSNA210 P210N 2073454CE CONT O520 TSIO520P 17040SO NR 2 CYLINDER SPALLED D O OTHER O OTHER NRNOT REPORTED 1 EA19102KY684 P21000093 278764R REMOVED NR 2 CYL FOR BLOW BY. PULLED LIFTER ASSEMBLY TO INSPECTION CONDITION FOUND EXHAUST LIFTERBODY SPALLING. DISASSEMBLED ENGINE SENT CAM OUT. CAM WAS ALSO BAD, COULD NOT BE RECONDITIONED. 1H71 3O3 O 3A21 E8CE 20030414000642003041400064CE 2003 4 14 2003FA0000375 120030313G532007126161 BULKHEAD CESSNA182 182L 2072726CE AFT FUSELAGE CRACKED B C3VRO OTHER O OTHER NRNOT REPORTED 1 EA21422614078 18258930 THE AFT FUSELAGE BULKHEAD WAS CRACKED IN THE RADIUS AT THE RUDDER STOP ATTACHEMENT POINTS. BLOCK RUDDER WHEN A/C IS TIED DOWN IN WINDY CONDITIONS. 1H71 3O NT3A13 20030423000452003042300045GL 2003 4 23 2003FA0000377 120030321G271012546001 MOTOR CIRRUSSR SR20 05628AJGL CONT IO360 IO360* 17025CE ROLL TRIM DAMAGED B FFGRO OTHER O OTHER NRNOT REPORTED 1 SO33508JS 1170 SHAFTED IN ROLL, TRIM MOTOR ASSEMBLY SHEARED IN FLIGHT, DURING LANDING APPROACH. THE PILOT RETAINED CONTROL AND A SAFE LANDING WAS ACCOMPLISHED. NO FURTHER DAMAGE WAS FOUND DURING INSPECTION OF THE TRIM SYSTEM, AILERON AND LEFT WING. THE CAUSE OF THIS FAILURE IS UNDETERMINED AT THIS TIME. 1L71 3O3 ONTA00009CHE1CE 20030429001232003042900123NE 2003 4 29 2003FA0000379 220030320G7200SAP5999 ROLLER PWA R1340 R1340AN1 52016NE ENGINE FAILED B CP2RO OTHER O OTHER NRNOT REPORTED 1 SW15 P326888 DURING THE OVERHAUL OF THIS ENGINE NEW ROLLERS (PN 5999) WERE INSTALLED. DURING THE TEST RUN OF THE SUBJECT ENGINE ONE OF THE ROLLERS FAILED. AFTER TEAR DOWN, A HARDNESS TEST INSPECTION OF THE ROLLERS WAS CONDUCTED AND IT WAS DETERMINED THE ROLLER THAT FAILED, WAS CONSIDERABLY SOFTER THAN THE REMAINING ROLLERS. (SW15200313699) 3 R 5E2 20030429001242003042900124SO 2003 4 29 2003FA0000380 120030217G57127847504 RIB PIPER PA28 PA28R200 7102811SO LYC O360 IO360C1C 41514EA HARTZLHCC3Y HCC3YR GL LT WING CRACKED B NCLRO OTHER O OTHER NRNOT REPORTED 1 NE01560185506 28R7335334 L1079651A DY4614B THE LT AND RT FORWARD TRUNNION FITTING ASSEMBLIES WERE REMOVED TO COMPLY WITH MFG (FORWARD SIDEBRACE STUD). WHILE THE FITTINGS WERE REMOVED IT WAS NOTICED THAT THE LEFT AND RIGHT WING RIBS MFG (PN 7847504 AND 05) WERE CRACKED AT THE FORWARD OUTBOARD FLANGE OF THE RIBS. THIS FLANGE IS UNDER THE TRUNNION FITTING ASSEMBLY AND CANNOT BE SEEN WITHOUT REMOVAL OF THE TRUNNION FITTING. THIS IS THE THIRD TIME THESE CRACKED RIBS HAVE BEEN FOUND. SUGGEST PERIODIC INSPECTION IN THIS AREA. 1L71 3O3 O 2A13 1E10 5 CP25EA 20030423000552003042300055EA 2003 4 23 2003FA0000381 220030401G8530TB2156011000 LEVER SOCATATB20 TB21 8680697EU LYC O540 TIO540* 41532EA HARTZLHCC3Y HCC3YR GL ENGINE FRETTED D O OTHER E VIBRATION/BUFFET NRNOT REPORTED 1 WP23291GT 2091 L1071061A DY4879B CUSTOMER COMPLAINED OF EXCESSIVE VIBRATION. ATTEMPTS TO BALANCE THE PROP WERE UNSUCCESSFUL. INSPECTION REVEALED THAT THE EXHAUST SUPPORT (LEVER ASSY) SUPPORT BUSHINGS WERE WORN ALLOWING THE METAL PORTION TO CONTACT THE MOUNT TRANSMITTING THE ENGINE VIBRATION TO THE AIRFRAME. 1L71 3O3 ORTA51EU E14EA 5 CP25EA 20030505000552003050500055SW 2003 5 5 2003FA0000382 120030210G1430442615 BOLT GULSTM114 114B O145001SW LYC O540 IO540* 41532EA HORIZONTAL STAB LOOSE B GA5RO OTHER O OTHER NRNOT REPORTED 1 GL056023A1150 14604 DURING 100 HOUR INSPECTION, THE HORIZONTAL STABILIZER WAS FOUND LOOSE. REMOVED DORSAL FIN, RUDDER AND ELEVATORS. FORWARD ATTACH BOLTS FOR HORIZONTAL STABILIZER WERE FOUND LOOSE. 9 RIVETS ON RIGHT HAND AFT VERTICAL SUPPORT ANGLE, (PN 442682 WERE FOUND SHEARED. CHECKED AND REPLACED SHEARED RIVETS. CONTACTED DER FOR REPAIR OF SPAR ATTACH HOLES AND HARDWARE. REPAIRED IAW SR. REPAIR CONSISTED OF GOING TO OVERSIZE HARDWARE FOR FRONT MOUNTING AND INSTALLING SHIM IN DOUBLER PLATE UNDER NUTPLATES. THE FLOATING NUTPLATE USED IN PRODUCTION ARE REPLACED WITH FIXED NUT PLATES. FLOATING NUTPLATES ALLOWED STABILIZER TO MOVE TOO MUCH WITH LOOOSE BOLTS AND ELONGATED HOLES IN STABILIZER. 1L71 3O3 ORTA12SO 1E4 20030423000532003042300053CE 2003 4 23 2003FA0000383 120030401G2510456655 CYLINDER CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA PILOT SEAT INOPERATIVE D O OTHER O OTHER NRNOT REPORTED 1 CE033519U 172S8849 L2962951A PRIOR TO ENGINE START, PILOT COULD NOT GET SEAT BACK TO STAY UPRIGHT. LOCK CYLINDER WILL ALLOW SEAT BACK TO FULLY RECLINE. 1H71 3O3 ONT3A12 1E10 20030507001942003050700194SO 2003 5 7 2003FA0000384 120030314G534067271800 BRACKET PIPER PA28 PA28R201 7102816SO NLG ACTUATOR WORN B UC2RK NONE O OTHER ININSP/MAINT 1 GL195326U1086 2844046 DURING A ROUTINE INSPECTION THE NOSE GEAR ACTUATOR ATTACH BRACKETT WAS FOUND LOOSE. ALL ATTACH RIVETS AND HARDWARE WERE FOUND TO BE WORKING. THE NOSE GEAR ACTUATOR ROD END CLEVIS ATTACH BOLT WAS ALSO FOUND BENT. THE BRACKETT AND CLEVIS BOLT WERE REPLACED. THIS SI THE SECOND SUCH OCCURANCES IN OUR FLEET. RECOMMEND REPLACING THE CLEVIS BOLT EVERY 100 HOUR AND THOROUGHLY INSPECTING THIS AREA AT EACH INSPECTION. THE DEFECTIVE PARTS WERE SENT TO THE MANUFACTURE FOR EVALUATION. 1L71 3O 2A13 20030507001922003050700192CE 2003 5 7 2003FA0000385 120030313G781020179110 EXHAUST PIPE ZINAIRCH2000CH2000 9950100CE LYC O235 O235* 41505EA BEHIND MUFFLER DEFECTIVE B QE5RK NONE O OTHER ININSP/MAINT 1 NM078500Z150 201003 THIS IS THE SECOND REPORT OF FINDING THE ABOVE COMPONENT DEFECTIVE. THEY ARE CRACKING BEHIND THE MUFFLER SHROUD AND CANNOT BE SEEN WITHOUT REMOVAL OF THE SHROUD. THIS ALLOWS EXHAUST GASES TO ENTER THE COCKPIT WHEN THE HEATER IS UTILIZED. THE CRACK LENGTH IS APPROXIMATELY FIVE TO SIX INCHES. A PICTURE OF THE CRACKED AREA WILL BE E-MAILED AS WELL. 1L71 3O3 ONTTA5CH E223 20030507001932003050700193 2003 5 7 2003FA0000386 420030313G3197688381 SWITCH PIPER PA44 PA44180 7104402SO LYC O360 O360* 41514EA INSTRUMENT PANELFAILED B OG5RO OTHER O OTHER NRNOT REPORTED 1 GL21297ND 4496078 PILOT REPORTED COMPLETE ELECTRICAL FAILURE. DURING TROUBLESHOOTING, THE BATTERY WAS FOUND TO HAVE NO CHARGE AND THE RIGHT ENGINE STARTER WAS STILL ENGAGED AT THE BENDIX. FURTHER TROUBLESHOOTING FOUND THE STARTER TOGGLE SWITCH WAS STUCK IN THE ON POSITION FOR THE RIGHT ENGINE CAUSING THE STARTER TO REMAIN ENERGIZED AFTER ENGINE START UNTIL IT SHORTED OUT, DRAINING THE ELECTRICAL SYSTEM TILL FAILURE. 1L72 3O3 O A19S0 E286 20030416002732003041600273EU 2003 4 16 2003FA0000387 120030331G24340120468107 ALTERNATOR GROB 120 G120A 1660208EU LYC O540 AEIO540D4D5 EA ENGINE FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07864AF746 85004 ALTERNATOR FAILED TO PROVIDE ANY OUTPUT WHILE IN USE. SUSPECT INTERNAL FAILURE. 1L71 3O3 ORTA49CE 1E4 20030423000542003042300054SW 2003 4 23 2003FA0000388 120030304G7120206064105102 MOUNT BELL 206 206L1 1182107SW ALLSN 250C 250C28B 03013GL ENGINE MISMANUFACTURED B ALGRO OTHER W INADEQUATE Q C NRNOT REPORTED 1 SW03 WHEN CHECKING FOR FIT, ANGLE OF FITTING NOT CORRECT, WILL NOT FIT RIGHT SIDE. BETTER QUALITY CONTROL PRIOR TO SHIPMENT. 1G71 3U3 U H2SW E1GL 20030423000482003042300048CE 2003 4 23 2003FA0000389 120030414G2720 CONTROL CABLE CESSNA182 R182 2072734CE RUDDER OUT OF RIG G K NONE O OTHER ININSP/MAINT 1 NE01228HP R18201643 WHEN THE RUDDER IS DEFLECTED TO THE FAR RIGHT, THE RIGHT RUDDER CABLE GOES SLACK AND HANGS UP UNDER THE NUT FOR THE ELEVATOR PULLEY CLUSTER LOCATED BY THE FUSELAGE RIGHT SIDE ACCESS PANEL. TO PREVENT THIS A GUARD WAS SUGGESTED TO PREVENT THE CABLE FROM SLIPPING UNDER THE BOLT AND HANGING UP THE CONTROL CABLE. THE CABLE TENSION WAS CHECKED AND DOUBLE CHECKED. THE MECHANIC STATES THAT THIS IS NOT THE FIRST TIME HE HAS SEEN THIS PROBLEM. 1H71 3O RT3A13 20030423000572003042300057SO 2003 4 23 2003FA0000390 120030407G32226705403 TRUNNION PIPER PA44 PA44180 7104402SO LYC O360 O360* 41514EA NOSE STRUT DAMAGED C DF2SC ABORTED TAKEOFF D INFLIGHT SEPARATION TOTAKEOFF 1 SW15355AB 4496093 AIRCRAFT WAS ON TAKEOFF ROLL WHEN AT ABOUT 79 KNOTS PILOT HEARD A LOUD POP AND SAW A PIECE OF NOSE GEAR FLY OFF THE AIRCRAFT. PILOT ABORTED TAKEOFF AND NOTICED A DIFFERENCE IN THE STEERING COMING BACK TO THE RAMP. WHEN CHECKED BY MAINTENANCE, NOTICED THAT THE LOWER REAR SECTION OF THE NOSE TRUNNION ASSEMBLY DETACHED, IT CAUSED THE SHIMMEY DAMPENER SHAFT TO SHEAR AND BENT THE BRACKETS ON THE SHIMMEY DAMPENER BODY. 1L72 3O3 O A19S0 E286 20030423000562003042300056CE 2003 4 23 2003FA0000391 120030331G2510MM201057 LOCK CESSNA172 172R 2072401CE PILOT SEAT MISINSTALLED D O OTHER W INADEQUATE Q C NRNOT REPORTED 1 SW15 17280433 FRONT BOLT HOLE ON THE PILOT LOCK-CYLINDER WAS INSTALLED 90 DEGREES THE WRONG DIRECTION. 1H71 3O NT3A12 20030416002772003041600277EU 2003 4 16 2003FA0000392 120030407G2710120A4125 BEARING GROB 120 G120A 1660208EU LYC O540 AEIO540D4A5 41532EA AILERON LEVER FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07865AF640 85005 DURING PROGRESSIVE INSPECTION OF THE AIRCRAFT THERE WAS A STRANGE SOUND FROM THE AILERON SYSTEM. FURTHER INVESTIGATION REVEALED THAT THE BEARING FROM THE LT AILERON ASSEMBLY WAS COMING APART. PROBABLE CAUSE IS DESIGN OF AILERON LEVER ASSEMBLY. THE ANGLE AND THE AMOUNT OF USE OF THIS SYSTEM. 1L71 3O3 ORTA49CE 1E4 20030507001902003050700190SO 2003 5 7 2003FA0000393 120030205G249779412011 WIRE PIPER PA28 PA28181 7102807SO LYC O360 O360A1D 41514EA ELECTRICAL BURNED B O OTHER O OTHER NRNOT REPORTED 1 EA239105X2408 2890006 AIRCRAFT ALTERNATOR ANNUNCIATOR LIGHT STAYS ON BUT AMMETER SHOWS OUTPUT. FOUND ALTERNATOR POWER WIRE AND ANNUNCIATOR WIRES BURNED AT DIODE ASSEMBLY. REPLACE TERMINAL ENDS AND WIRE. CAUSE UNKNOWN. 1L71 3O3 O 2A13 E286 20030423000412003042300041SO 2003 4 23 2003FA0000402 120030417G57436704212 TRUNNION PIPER PA28 PA28R180 7102809SO LYC O360 IO360A1A 41514EA RT MLG CRACKED B O OTHER O OTHER NRNOT REPORTED 1 EA233811T8066 28R30126 WHILE REBUSHING THE RIGHT MAIN LANDING GEAR, A VERY VISIBLE CRACK WAS FOUND IN THE SUPPORT WEB OF THE AFT TRUNNION FITTING ASSEMBLY. 1L71 3O3 O 2A13 1E10 20030423000422003042300042SO 2003 4 23 2003FA0000403 120030417G57436704212 TRUNNION PIPER PA28 PA28R180 7102809SO LYC O360 IO360A1A 41514EA ZONE 700 CRACKED B O OTHER O OTHER NRNOT REPORTED 1 EA233811T8066 28R30126 WHILE REBUSHING THE RIGHT MAIN LANDING GEAR, A VERY VISIBLE CRACK WAS FOUND IN THE SUPPORT WEB OF THE AFT TRUNNION FITTING ASSEMBLY. 1L71 3O3 O 2A13 1E10 20030428001972003042800197CE 2003 4 28 2003FA0000406 120030410G321124411001 PIVOT ASSY CESSNA172 172RG 2072438CE LYC O360 O360F1A6 41514EA MCAULY2D34C B2D34C220 GL MLG CRACKED D K NONE O OTHER ININSP/MAINT 1 NE016215V2367 172RG0592 L2870136A 807381 FOUND CRACK IN RIGHT MAIN GEAR PIVOT ASSEMBLY AT CASTING SEAM. AIRPLANE SAT FOR 8 YEARS ON THE COAST OF FLORIDA. CORROSION WAS A MAJOR FACTOR IN THIS CRACK. PLANE WAS REPAINTED AND CRACK WAS COVERED. PAINT WAS SPLITTING IN AREA. STRIPPED PAINT AND THE CRACK APPEARED. IT WAS CRACKED ALL THE WAY THROUGH HOUSING DOWN TO GEAR LEG AND EXTENDED IN TOWARDS PIVOT 4 INCHES. 1H71 3O3 O 3A17 E286 5 CP7EA 20030505000542003050500054CE 2003 5 5 2003FA0000408 120030414G2720 CONTROL CABLE CESSNA182 R182 2072734CE LYC O540 O540* 41532EA RUDDER JAMMED C K NONE O OTHER ININSP/MAINT 1 NE01228HP R18201643 WHEN THE RUDDER IS DEFLECTED TO THE FAR RIGHT , THE RIGHT RUDDER CABLE GOES SLACK AND HANGS UP UNDER THE NUT FOR THE ELEVATOR PULLEY CLUSTER LOCATED BY THE FUSELAGE RIGHT SIDE ACCESS PANEL. TO PREVENT THIS A GUARD WAS SUGGESTED TO PREVENT THE CABLE FROM SLIPPING UNDER THE BOLT AND JAMMING THE CONTROL CABLE. THE MECHANIC STATES THAT THIS IS NOT THE FIRST TIME HE HAS SEEN THIS PROBLEM. 1H71 3O3 ORT3A13 E295 20030507001852003050700185EA 2003 5 7 2003FA0000409 220030304G852074309 BEARING PIPER PA32 PA32R301T 7103220SO LYC O540 TIO540S1AD 41532EA ENGINE WORN D O OTHER O OTHER NRNOT REPORTED 1 CE078096Y320 32R8029005 L668561A FOUND BEARING MATERIAL IN OIL SUCTION SCREEN. REMOVED CYLINDERS AND FOUND CYLINDER NR 2 CONNECTING ROD BEARING FAILING BY LAMINATIONS PICKING LOOSE ON INSIDE DIAMETER. THIS IS THE SAME CONDITION FOUND DURING REPLACEMENT OF ROD BEARINGS UNDER MFG SA 59-800 WITH THE SAME MFG DATE CODE. 1L71 3O3 O A3SO E14EA 20030423000492003042300049EA 2003 4 23 2003FA0000410 220030304G8530SL16740A EXHAUST VALVE PIPER PA32 PA32R301T 7103220SO LYC O540 TIO540S1AD 41532EA ENGINE WORN D O OTHER O OTHER NRNOT REPORTED 1 CE078096Y32031 32R8029005 L668561A INVESTIGATED HEAVY OIL CONSUMPTION. UPON DISASSEMBLY, FOUND VALVES EXCESSIVELY WORN. 1L71 3O3 O A3SO E14EA 20030507001892003050700189EA 2003 5 7 2003FA0000411 220030304G8530SL75838 VALVE GUIDE PIPER PA32 PA32R301T 7103220SO LYC O540 TIO540S1AD 41532EA ENGINE WORN D O OTHER O OTHER NRNOT REPORTED 1 CE078096Y320 32R8029005 L668561A INVESTIGATED HEAVY OIL CONSUMPTION. UPON DISASSEMBLY, FOUND VALVE GUIDES EXCESSIVE WORN. 1L71 3O3 O A3SO E14EA 20030423000502003042300050EU 2003 4 23 2003FA0000412 120030321G3520Z00N6039257260 VALVE SOCATATBM TBM700 8682000EU PWA PT6 PT6A6 52043EA HARTZLHCE4N HCE4N3 NE COCKPIT LEAKING D O OTHER O OTHER NRNOT REPORTED 1 NM03700RK72 253 PCEPMOO0130 HH1520 AIRCRAFT ARRIVED WITH AN OXYGEN LEAK. THE ALTIMETRIC VALVE WAS REPLACED. THE REPLACEMENT VALVE ALSO LEAKED. THE THIRD VALVE INSTALLED DIDN`T LEAK IN THE OFF POSITION BUT WHEN THE PASSENGER OXYGEN WAS TURNED ON DEPLOYING THE MASKS THE VALVE LEAKED FROM THE PRESSURE RELIEF VALVE. THIS VALVE IS LOCATED IN THE COCKPIT ABOVE THE HEADLINER IN CLOSE PROXIMITY TO NUMEROUS ELECTRICAL SWITCHES. AN OXYGEN RICH ENVIRONMENT IN THIS LOCATION COULD BE DISASTOROUS. THIS VALVE SHOULD BE RELOCATED TO THE CABIN TO ELEMINATE ANY HAZARDS. 1L71 3T3 TRTA60EU E4EA 5 CP10NE 20030507001802003050700180SO 2003 5 7 2003FA0000413 120030421G326067203000 SPRING PIPER PA28 PA28R180 7102809SO LYC O360 IO360A1A 41514EA DOWNLOCK WORN B O OTHER O OTHER NRNOT REPORTED 1 EA233811T8066 28R30126 DURING AN ANNUAL INSPECTION, IT WAS FOUND THAT BOTH MAIN LANDING GEAR DOWNLOCK SPRINGS WERE WORN 80 PERCENT OF THE WAY THROUGH WHERE THEY CONNECT TO THE LANDING GEAR. 1L71 3O3 O 2A13 1E10 20030507001812003050700181GL 2003 5 7 2003FA0000414 220030414G724023030911 COMBUST CHAMBER BELL 407 407 1182206SW ALLSN 250C 250C47B GL ENGINE CRACKED C O OTHER RJ PARTIAL RPM/PWR LOSS WARNING INDICATION CRCRUISE 1 WP0752AZ 2170 244 53380 OUTER COMBUSTION CAN CRACKED 180 DEGREES AROUND FUEL NOZZLE WELD. PRIOR TO CRACK THE ENGINE WAS RATED AS A +22 MGT. THE ENGINE WAS -6 MGT WHEN CRACK WAS DISCOVERED. THE CRACK IS NOT VISIBLE TO THE PILOT DURING PREFLIGHT. AN INSPECTION MIRROR IS REQUIRED TO SEE THE CRACK. A CATASTROPHIC ENGINE FAILURE WITH A RESULTING FIRE WOULD HAVE OCCURED IF THE CRACK HAD NOT BEEN DETECTED. 1G71 3U3 UO H2SW E1GL 20030423000442003042300044 2003 4 23 2003FA0000415 420030421G611305503671 SPINNER CESSNA CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA PROPELLER CRACKED B K NONE O OTHER ININSP/MAINT 1 SO15409ER737 172S9158 L3045051A PILOT WROTE UP MISSING SCREW. UPON EXAMINATION THE SPNNER AND BULKHEAD WERE FOUND CRACKED. 1H71 3O3 ONT3A12 1E10 20030423000512003042300051EA 2003 4 23 2003FA0000416 220030421G732225765362 FUEL CONTROL CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA ENGINE INACCURATE B D RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TXTAXI/GRND HDL 1 SO15409ER 172S9158 L3045051A DURING PRE TAKEOFF CHECK, THE IDLE WAS TOO LOW TO CONTINUE. THIS ENGINE/FUEL CONTROL COMBINATION REQUIRES SUBSTANTIAL ADJUSTMENT TO MAINTAIN THE CORRECT IDLE. 1H71 3O3 ONT3A12 1E10 20030423000582003042300058EA 2003 4 23 2003FA0000417 220030421G732225765362 FUEL CONTROL CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA ENGINE OUT OF ADJUST B D RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TXTAXI/GRND HDL 1 SO15456ER 17280667 L1562851A DURING GROUND OPERATION, THE CREW NOTICED THE IDLE WAS TOO LOW TO CONTINUE THE FLIGHT. THIS ENGINE/FUEL CONTROL COMBINATION REQUIRES A SIGNIFICANT AMOUNT OF ADJUSTMENT TO MAINTAIN THE CORRECT IDLE MIXTURE AND SPEED. 1H71 3O3 ONT3A12 1E10 20030507001862003050700186SO 2003 5 7 2003FA0000418 120030416G32136531904 HOUSING PIPER PA28 PA28161 7102803SO LYC O320 O320* 41508EA LT MLG STRUT CRACKED G O OTHER O OTHER NRNOT REPORTED 1 CE098341610263 288116160 LT MLG COLLAPSED DURING LANDING ROLLOUT. SUBSEQUENT INVESTIGATION DISCLOSED THAT THE DRAG LINK ATTACH EARS SEPARATED FROM THE STRUT HOUSING. VISUAL INSPECTION SUGGEST THAT A PRE-EXISTING CRACK IN THE OUTBOARD SCISSORS ATTACH POINT INDUCED SEPARATION FROM THE STRUT HOUSING. RECOMMEND VISUAL INSPECTION OF THE MLG STRUT SCISSORS ATTACH POINTS. 1L71 3O3 O 2A13 E274 20030507001532003050700153CE 2003 5 7 2003FA0000419 120030422G5412 STRUCTURE ZINAIRCH2000CH2000 9950100CE LYC O235 O235* 41505EA FIREWALL CRACKED D K NONE O OTHER ININSP/MAINT 1 NE0130ZA 734 100 200030 DURING INSPECTION THE UPPER HORITONTAL (Z) ON THE FIREWALL WAS FOUND CRACKED. THIS IS THE LATER REINFORCED VERSION REV. 4. THE CRACK WAS LOCATED FROM THE HOLE WHERE THE NOSE GEAR STRUT COMES THROUGH TO THE OUTSIDE FORWARD EDGE.THE PLASTIC STOP UNDER THE (Z) WAS ALSO CRACKED. 1L71 3O3 ONTTA5CH E223 20030507001542003050700154CE 2003 5 7 2003FA0000420 120030422G5412 STRUCTURE ZINAIRCH2000CH2000 9950100CE LYC O235 O235* 41505EA FIREWALL CRACKED D K NONE O OTHER ININSP/MAINT 1 NE0130ZA 734 100 200030 DURING INSPECTION THE UPPER HORITONTAL (Z) ON THE FIREWALL WAS FOUND CRACKED. THIS IS THE LATER REINFORCED VERSION REV. 4. THE CRACK WAS LOCATED FROM THE HOLE WHERE THE NOSE GEAR STRUT COMES THROUGH TO THE OUTSIDE FORWARD EDGE.THE PLASTIC STOP UNDER THE (Z) WAS ALSO CRACKED. 1L71 3O3 ONTTA5CH E223 20030507001602003050700160EA 2003 5 7 2003FA0000421 220030422G732225765362 SERVO CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA FUEL INACCURATE B A UNSCHED LANDING RJ PARTIAL RPM/PWR LOSS WARNING INDICATION CRCRUISE 1 SO15483ER 17280632 L2722651A DURING FLIGHT THE CREW REPORTED A ROUGH ENGINE. SUBSEQUENTLY THE FUEL SERVO AND FLOW DEVIDER WERE CHANGED. 1H71 3O3 ONT3A12 1E10 20030506001452003050600145SO 2003 5 6 2003FA0000422 220030407G8530SA631475 PISTON CONT O520 IO520F 17032SO ENGINE BROKEN D O OTHER O OTHER NRNOT REPORTED 1 AL03 1707 286490F NR 2 AND NR 3 CYLINDER PISTON SKIRTS BROKE OFF AND FELL INTO THE OIL SUMP WHILE RUNNING AND CONTAMINATING THE ENGINE WITH METAL. 3 O E5CE 20030506001462003050600146NM 2003 5 6 2003FA0000423 120030325G2910 HOSE AEROVDL29 L29 0564310NM HYD PUMP PRESS CRACKED D O OTHER KJ FLUID LOSS WARNING INDICATION NRNOT REPORTED 1 NE0582674 892830 NOSE LANDING GEAR FAILED TO COMPLETELY EXTEND FOR LANDING. INSPECTION REVEALED HYDRAULIC LEAK NEAR ENGINE COMPARTMENT. FURTHER INVESTIGATION REVEALED THE HOSE WAS CRACKED NEAR THE FITTING WHERE IT ATTACHES TO THE PUMP. 1M71 4U RT1M71EXPA 20030506001472003050600147CE 2003 5 6 2003FA0000424 120030411G531207126161 BULKHEAD CESSNA182 182K 2072724CE CONT O470 O470* 17026SO FUSELAGE CRACKED D O OTHER O OTHER NRNOT REPORTED 1 SO032727Q 18257927 PART WAS FOUND CRACKED DURING INSPECTION REQUIRED BY AD 72-07-09. PART WAS CRACKED AT IT HAND RUDDER CONTROL CABLE HOLE, BETWEEN HOLE AND BULKHEAD FLANGE. PROBABLE CAUSE IS FATIGUE. RECOMMEND THAT CONTROL LOCK IS ALWAYS PUT IN WHEN AIRCRAFT IS STORED OUTSIDE. 1H71 3O3 ONT3A13 E273 20030429001272003042900127EU 2003 4 29 2003FA0000425 120030414G7160F50B258700A2 INTAKE DUCT AMD FALC50FALCON50MYST2730106EU NR 2 ENGINE CRACKED B K NONE O OTHER ININSP/MAINT 1 GL234350M10635 142 DURING 3C INSPECTION FOUND SEVERAL CRACKS IN THE NR 2 ENGINE INTAKE S-DUCT ASSEMBLY. CRACKS WERE AT THE OUTER, UPPER SKIN IN SEVERAL LOCATIONS AROUND THE UPPER ANTI-ICE BLEED AIR DUCTING ON TOP OF THE INTAKE S-DUCT ASSEMBLY. THE ENTIRE S-DUCT ASSEMBLY WAS REPLACED WITH NEW. INITIAL DETERMINATION OF CAUSE OF CRACKS IS SUSPECTED TO BE METAL FATIGUE OVER TIME OF LIFE IN SERVICE. 2L73 4F A46EU 20030429002302003042900230EU 2003 4 29 2003FA0000426 120030414G7160FGFB258702D1 DUCT AMD FALC90FALCON900EX 2730009EU NR 2 ENG INTAKE DAMAGED B O OTHER O OTHER NRNOT REPORTED 1 GL23890FH707 SC271 DURING INSPECTION NOTED PULLED RIVETS AND SPOT WELDS IN THE INTERIOR OF THE FORWARD, NR 2 ENGINE INTAKE S-DUCT ASSEMBLY. FORWARD S-DUCT ASSEMBLY WAS REPLACED WITH NEW. CAUSE OF DEFECTS IS SUSPECTED TO BE OVER PRESSURIZATION OF ANTI-ICE BLEED AIR MANIFOLD LOCATED ON TOP OF THE FORWARD S-DUCT ASSEMBLY. 2L73 4F RTA46EU 20030429002312003042900231SO 2003 4 29 2003FA0000427 120030325G781063726 EXHAUST STACK PIPER PA28 PA28140 7102802SO LYC O320 O320E2A 41508EA NR 4 CYLINDER FAILED G A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CLCLIMB 1 EA133784K 2823729 THE NR 4 CYLINDER EXHAUST RISER PULLED OUT OF THE MUFFLER DURING TAKE-OFF RESULTING IN SMOKE IN THE COCKPIT.INSULATION MELTED AT THE STARTER CONTACTOR AND PLACE WHERE MAIN WIRING HARNESS PASSES THROUGH THE FIRE WALL.NO FAILURE OF THE CLAMP OR HARDWARE WAS NOTED. 1L71 3O3 O 2A13 E274 20030508000072003050800007SO 2003 5 8 2003FA0000428 120030427G24342642997R ALTERNATOR PIPER PA28 PA28RT201 7102818SO LYC O360 IO360C1C6 41514EA ENGINE OVERHEATED P O OTHER HJ ELECT. POWER LOSS-50 PC WARNING INDICATION APAPPROACH 1 EA232218Z 130 28R7918117 A POOR CONNECTION BETWEEN THE OUTPUT STUD AND THE POSITIVE DIODE MOUNTING ASSEMBLY RESULTED IN EXTREME HEATING OF THE STUD AND MOUNTING ASSEMBLY. THIS HEAT ALSO MELTED THE TEFLON OUTPUT STUD INSULATOR AND VAPORIZED THE DIODE LEADS. THE DIODE MOUNTING ASSEMBLY IS HELD IN PLACE ONLY BY THE MOUNTING STUD AND DIODE LEADS. THIS CAUSED THE DIODE MOUNTING ASSEMBLY TO BECOME FREE FLOATING INSIDE THE ALTERNATOR. THIS FAILURE MODE HAS A HIGH POTENTIAL TO CAUSE AN IN-FLIGHT FIRE IN THE ENGINE COMPARTMENT. 1L71 3O3 O 2A13 1E10 20030506001482003050600148CE 2003 5 6 2003FA0000429 120030305G2820S14956 HOSE CESSNA172 172S 2072439CE LYC O360 IO360A1A 41514EA FUEL SYSTEM FAILED B FE4RO OTHER K FLUID LOSS NRNOT REPORTED 1 AL03188VE1867 172S8391 PILOT REPORTED FUEL LEAK AT WING ROOT AREA, RIGHT SIDE OF AIRCRAFT. INSPECTING MECHANIC FOUND THAT WING ROOT FUEL HOSES WERE DETERIORATED CAUSING FUEL LEAKAGE. HOSES LOOKED TO BE ORIGINAL INSTALLATION BUT WERE VACUUM TYPE HOSE. 1H71 3O3 ONT3A12 1E10 20030506001522003050600152SO 2003 5 6 2003FA0000430 220030130G8530EL649358CN CYLINDER CESSNA414 414A 2075907CE CONT O520 TSIO520NB 17040SO RT ENGINE SPLIT D O OTHER O OTHER NRNOT REPORTED 1 CE072690N700 414A0407 519195 STEEL BARREL SPLIT IN A SPIRAL MOTION. CYLINDER SERIAL NR 22597-24. 1L72 3O3 O A7CE E8CE 20030508000272003050800027CE 2003 5 8 2003FA0000433 120030331G81204066109018 TURBOCHARGER CESSNA337 P337H 2075731CE CONT O360 TSIO360CB 17025SO ENGINE MISINSTALLED B WS9RO OTHER W INADEQUATE Q C NRNOT REPORTED 1 NM07 P3370349 311020 TURBOCHARGER UNABLE TO BOOST MANIFOLD PRESSURE. REMOVED TURBOCHARGER AND FOUND EXCESSIVE CLEARANCE BETWEEN T-WHEEL AND HOT SECTION HOUSING. INCORRECT PARTS ASSEMBLED INTO A COMPLETE UNIT. INSPECT PRODUCT PRIOR TO RELEASING TO SERVICE. 1H72 3O3 O A6CE E9CE 20030508001182003050800118SO 2003 5 8 2003FA0000437 120030425G7921B99340413 OIL COOLER PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA ENGINE CRACKED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP074133D 186 2843117 FOUND OIL LEAK ON PRE-FLIGHT INSPECTION BY STUDENT PILOT PRESSURE CHECKED OIL COOLER AND FOUND OIL COOLER LEAKING AT SEAM ON TOP. THIS IS A WEAK AREA ON THE OIL COOLER, COULD BE CAUSED BY VIBRATION AND NOT USING A BACK UP WRENCH WHEN INSTALLING OIL COOLER HOSES. 1L71 3O3 O 2A13 E286 20030509000962003050900096EA 2003 5 9 2003FA0000438 220030430G732225765362 FUEL CONTROL CESSNA172 172R 2072401CE LYC O360 IO360LYC* 41514EA ENGINE INACCURATE B D RETURN TO BLOCK RJ PARTIAL RPM/PWR LOSS WARNING INDICATION TXTAXI/GRND HDL 1 SO15448ER 17280610 L185651A DURING PRE TAKE OFF GROUND CHECK, THE CREW REOPORTED THE IDLE TO BE LOW. IT WAS SUBSEQUENTLY ADJUSTED. THIS ENGINE/FUEL CONTROL COMBINATION REQUIRES SUBSTANTIAL ADJUSTMENT TO MAINTAIN PROPER OPERATION.. 1H71 3O3 ONT3A12 1E10 20030509001052003050900105CE 2003 5 9 2003FA0000439 120030501G5740351150583 FITTING BEECH 90 C90 1152913CE PWA PT6 PT6A21 52043EA HARTZLHCB3T HCB3TN3 GL RT WING DEFORMED B K NONE O OTHER ININSP/MAINT 1 GL21911ND10508806 LJ774 DURING INSPECTION OF THE WING FITTINGS AND BOLTS THE RIGHT REAR WING ATTACH BOLT WAS FOUND TO BE BENT AND THE FITTING WAS DEFORMED. IN THE MFG STRUCTURAL INSPECTION AND REPAIR MANUAL COVERS THE INSTPECTION OF THE BOLTS AND FITTING AREA. THE BOLT AND A CASTING OF THE DEFORMED FITTING WAS SENT TO MFG TECH SUPPORT FOR EVAULATION. TECH RECOMMENED THE FITTING AND BOLT BE REPLACED. 1L72 3T4 T 3A20 E4EA 6 CP15EA 20030509001272003050900127SO 2003 5 9 2003FA0000440 120030424G243668804007 VOLT REGULATOR PIPER PA32 PA32R301T 7103220SO DEFECTIVE B O OTHER O OTHER CRCRUISE 1 GL09902WL 3257075 WHILE UPGRADING VOLTAGE REGULATOR P/N 68804-006 TO P/N 68804-007 IAW MFG SERVICE LETTER 1049 WE HAVE HAD SEVERAL NEW REGULATORS THAT WOULD NOT WORK RIGHT OUT OF THE BOX. IN THIS PARTICULAR INSTANCE THE REGULATOR OPERATIONAL CHECKED NORMAL DURING GROUND RUNS BUT IN FLIGHT CAUSED THE AUTO-PILOT TO FAULT. WE RECCOMEND DOING A THOROUGH JOB OF TESTING AUTO-PILOTS AND AVIONICS WHEN DOING THIS UPGRADE BEYOND THE SCOPE OF NORMAL GROUND CHECKS. 1L71 3O A3SO 20030509001282003050900128 2003 5 9 2003FA0000441 420030430G611305503671 SPINNER CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA MCAULY1A170 1A170* GL PROPELLER CRACKED B K NONE O OTHER ININSP/MAINT 1 SO15407ER 172S9157 L3045451A DURING AN INSPECTION, THE SPINNER WAS FOUND CRACKED. 1H71 3O3 ONT3A12 1E10 5 NP857 20030509001292003050900129EA 2003 5 9 2003FA0000442 220030430G7421 SPARK PLUG CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA ENGINE FOULED B A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CLCLIMB 1 SO15477ER 17280622 RL234451A THE CREW REPORTED THE ENGINE (COUGHED) ON TAKE OFF. COMPLETED AN INSPECTION ON SUSPECT ITEMS. CLEANED, TESTED AND FLOW TESTED ALL NOZZLES, CLEANED AND TESTED SPARK PLUGS. SEVERAL WERE FOUND MARGINALLY FOULED. THIS ENGINE/FUEL CONTROL COMBINATION DOES REQUIRE SUBSTANTIAL ADJUSTMENT TO MAINTAIN PROPER IDLE SPEED/MIXTURE SETTINGS. 1H71 3O3 ONT3A12 1E10 20030604000692003060400069EA 2003 6 4 2003FA0000443 220030430G7322 MANIFOLD CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA FUEL CONTROL INACCURATE B A UNSCHED LANDING E VIBRATION/BUFFET CRCRUISE 1 SO15437ER 85010016 172S8653 L2994351A THE PILOT REPORT A ROUGH ENGINE AT 1,000 FT. DURING SUBSEQUENT INSPECTION AND TROUBLESHOOTING, THE FUEL INJECTOR NOZZLES WERE CLEANED AND TESTED, THE FUEL MANIFOLD WAS REPLACED, AND THE FUEL SERVO WAS REPLACED. 1H71 3O3 ONT3A12 1E10 20030509000752003050900075WP 2003 5 9 2003FA0000444 220030424G7230 SHROUD GARRTTTFE731TFE7314R 01518WP COMPRESSOR FAILED B UO2RO OTHER O OTHER NRNOT REPORTED 1 GL19 5194 P102144 IN-FLIGHT SHUTDOWN. SUSPECT 2ND STAGE LPC ROTOR SHROUD FAILED FROM INITIAL INSPECTION RESULTS. DESTROYED LPC, HPC, HPT, AND LPT. 4 F E6WE 20030509000542003050900054SO 2003 5 9 2003FA0000445 120030501G552065254000 EYEBOLT PIPER PA28 PA28236 7102815SO LYC O540 O540* 41532EA STABILATOR TRIM INCORRECT C O OTHER W INADEQUATE Q C NRNOT REPORTED 1 EA214335M 288411006 PART ON A/C DID NOT FIT BUSHING ASSY. HOLE IN EYEBOLT IS TOO BIG. ORDERED NEW PART AND HOLE WAS THE SAME. API TECH SAID MFG MUST HAVE MADE BAD BATCH OF PARTS W/HOLE ID OF .315 INSTEAD OF CORRECT.286. OUR SUPPLIER (KRN) MEASURED THEIR INVENTORY AND FOUND AN EYEBOLT W/CORRECT DIMENSION. 1L71 3O3 O 2A13 E295 20030509000512003050900051CE 2003 5 9 2003FA0000448 120030313G32469520653 WHEEL CESSNA172 172A 2072404CE CONT O300 O300* 17022SO NLG WORN D O OTHER O OTHER NRNOT REPORTED 1 SW177326T2207 46926 ANNUAL INSPECTION, NOSEWHEEL ASSY WAS REMOVED IN ORDER TO INSPECT BEARINGS FOR CONDITION. ONE BEARING CUP WAS FOUND CORRODED. WHEN LW67010 CUP WAS REMOVED FROM WHEEL HALF, DISCOVERED BEARING BORE SEVERELY WORN. BEARING CUP HAD BEEN GLUED IN PLACE WITH A REDDISH COLORED ADHESIVE COMPOUND. COMPOUND ADHERED TO THE WHEEL HALF AND BEARING CUP. WITHOUT REMOVING COMPOUND FROM WHEEL HALF, TECH PLACED A CLEAN LW67010 BEARING CUP IN THE WHEEL HALF. CUP SEATED IN BORE WITH LIGHT HAND PRESSURE AND SPUN FREELY, CONSIDERABLE CLEARANCE. NOSEWHEEL BEARINGS HAD BEEN REPLACED AT THE LAST ANNUAL. WHEEL HALF DID NOT EXHIBIT A SIMILAR CONDITION, CORROSION IN THE BEARING BORE INDICATES IT WOULD NOT BE LONG IN DEVELOPING. 1H71 3O3 O 3A12 E253 20030509000492003050900049CE 2003 5 9 2003FA0000449 120030325G3243 MASTER CYLINDER CESSNA172 172A 2072404CE CONT O300 O300* 17022SO BRAKE SYSTEM MISOVERHAULED D O OTHER W INADEQUATE Q C NRNOT REPORTED 1 SW177326T 46926 ANNUAL INSP, ACCESS PANELS WERE REMOVED,TO INSPECT BRAKE MASTER CYL, ASSOC FITTINGS. MASTER CYL WERE DISCOVERED TO BE UNAPPROVED PARTS. CYL ASSY RESEMBLED CORRECT PART IN DESIGN, LABEL READ (TRANSMITTING PRESSURE CYLINDEY, TYPE CZD101, NO: 153/200 DATE OF EX-FACTORY: 2000.11 MADE IN CHINA) (MISSPELLING OF (CYLINDEY) NOT A TYPO). UNITS CONTAINED NO PROVISION FOR PARKING BRAKE LEVERS. BRAKE CYL HAD BEEN REPLACED LAST ANNUAL, NO RECORD IN LOGS. BRAKES WERE INOPERABLE, REQUIRED BLEEDING. ATTEMPTED TO SECURE ORIGINAL PARTS FROM IA WHO PERFORMED INSP, BUT UNABLE. SUSPICIOUS OF INSTALLED COMPONENTS, PURCHASED SERVICEABLE UNITS, THESE WERE DISASSEMBLED, INSPECTED, RESEALED, INSTALLED IN PLACE OF CHINESE UNITS. 1H71 3O3 O 3A12 E253 20030509000502003050900050SW 2003 5 9 2003FA0000450 120030501G5280 SKIN MOONEYM20 M20S 5870226SW CONT O550 IO550* SO MCAULY2A34C 2A34C* GL MLG DOOR SEPARATED D O OTHER O OTHER NRNOT REPORTED 1 WP232186J 300047 679473 992960 SKIN ON RIGHT HAND GEAR DOOR SEPARATED FROM THE GEARDOOR FRAME. 1L71 3O3 ORT2A3 E3SO 5 CP3EA 20030605000202003060500020EA 2003 6 5 2003FA0000451 220030307G726126222631 COVER CESSNA208 208B 2073701CE PWA PT6 PT6* 52043EA SUMP CORRODED D O OTHER O OTHER NRNOT REPORTED 1 WP119750B8483 208B0100 UPON REMOVAL OF SUMP COVER, FOUND AFT EDGE CORRODED THROUGH TO PAINT SURFACE DUE TO TRAPPED WATER ERODING CHROMATE PRIMER. SUGGEST REMOVAL OF SUMPS AT 5000-6000 HOUR INTERVALS. 1H71 3T3 T A37CE E2NE 20030605000222003060500022SO 2003 6 5 2003FA0000452 120030501G1100 PLACARD PIPER PA20 PA20 7102002SO LYC O290 O290 41506EA FUSELAGE MISSING B K NONE O OTHER ININSP/MAINT 1 CE014948M 20639 DURING ANNUAL INSPECTION IT WAS DISCOVERED THAT THE ORIGIONAL MFG DATA TAG WAS NOT ON THE AIRCRAFT. USUALLY LOCATED ON THE FLOORBOARD NEAR THE BATTERY BOX. A HANDMADE TAG WAS FOUND RIVETED TO THE FIREWALL. MFG RECORDS INDICATE THAT THE CORRECT FUSELAGE SERIAL NR MATCHES THE LOGBOOK AND HANDMADE TAG. A NEW TAG WILL BE ORDERED FROM MFG AT AN INFLATED PRICE. 1H71 3O3 O 1A4 E229 20030605000182003060500018SO 2003 6 5 2003FA0000453 120030509G2730 CONTROL CABLE PIPER PA25 PA25235 7102504SO LYC O540 O540* 41532EA ELEVATOR FRAYED G O OTHER O OTHER NRNOT REPORTED 1 GL216841Z5503 252512 ELEVATOR UP CABLE FOUND TO HAVE NUMEROUS STRANDS BROKEN WHERE CABLE GOES THROUGH FAIRLEAD IN FUSELAGE AFT TAIL AREA NEAR HORIZONTAL STABILIZER LEADING EDGE / BATTERY AREA. WAS FOUND BY FAA DURING CERTIFICATION OF 137 OPERATOR. 1L71 3O3 O 2A10 E295 20030513000602003051300060CE 2003 5 13 2003FA0000455 120030501G7120121322287 MOUNT BRACKET CESSNA206 T206H 2073303CE LYC O540 TIO540A1A 41532EA ENGINE CRACKED D O OTHER O OTHER NRNOT REPORTED 1 GL25700HW T20608034 L1008661A ENGINE JUST CAME BACK FROM LYCOMING FOR SB553 AND WAS BOLTED ON AIRFRAME. FOUND THE RT REAR LIFTING RING CRACKED 85 PERCENT THROUGH. CRACK HAD GRAY PAINT IN IT. THIS COULD HAVE BROKEN WITH THE ENGINE UP IN THE AIR AND FULL ON SOMEONE OR THE AIRCRAFT. 1H71 3O3 ORTA4CE E14EA 20030513000512003051300051CE 2003 5 13 2003FA0000456 120030331G323399120538 ACTUATOR CESSNA500 500CESSNA 2076602CE PWA JT15 JT15D1 52060NE RT MLG COLLAPSED D O OTHER O OTHER NRNOT REPORTED 1 SO13628BS10586135 5000045 RIGHT MAIN GEAR ACTUATOR COLLAPSED AND STILL INDICATED DOWN AND LOCKED. 1L72 4F4 F A22CE E1NE 20030513000262003051300026SW 2003 5 13 2003FA0000458 120030308G53022703 RING HYNES B2 B2B 1440506SW LYC O360 O360* 41514EA TAILBOOM BLKHD SEPARATED G O OTHER O OTHER NRNOT REPORTED 1 EA032238U 479 DURING ACCIDENT INVESTIGATION, FOUND TOP BULKHEAD RING SEPARATED FROM TAILBOOM PYLON. TAIL ROTOR GEARBOX WAS STILL ATTACHED TO BULKHEAD RING. BULKHEAD RING HAD SEPARATED FROM RIVET FLANGE AT TRANSITION RADIUS DUE TO EXISTING CRACKS ON THE LEFT AND RIGHT SIDES. INSPECTION CAN BE ACCOMPLISHED THROUGH LIGHTENING HOLE OF BULKHEAD. 1G71 3O3 O 2H2 E286 20030513000632003051300063GL 2003 5 13 2003FA0000459 220030415G731323031938 NOZZLE ALLSN 250C 250C20B 03013GL 2ND STG TURBINE DAMAGED B TU3RO OTHER O OTHER NRNOT REPORTED 1 WP07 CAT22870 TURBINE ASSY RECIEVED CUSTOMER REPORTED N1 RUB. INSPECTION REVEALED THE 2ND STAGE NOZZLE DIAPHRAGM TO SEPARATED FROM THE 2ND STAGE NOZZLE DIAPHRAGM TO BE SEPARATED FROM THE NOZZLE ASSEMBLY. BRAZE JOINT FAILED. THIS ALLOW THE NOZZLE TO RUB THE NR 1 AND NR 2 WHEELS. THE WHEELS ARE NOW UNSERVICEABLE. THIS NOZZLE HAS ACCUMULATED 389.4 HOURS SINCE INSTALL. THE TURBINE HAS 693.9 HOURS SINCE OVERHAUL. AT 304.5 HOURS FOLLOWING THE TURBINE OVERHAUL, A LOSS OF POWER WAS EXPERIENCED. THE TURBINE WAS INSPECTED. THE 2ND STAGE NOZZLE WAS IN SIMILAR IF NOT IDENTICAL CONDITION TO THE CURRENT DAMAGED UNIT. THIS NOZZLE HAS ACCUMULATED 389.4 HOURS SINCE INSTALLATION. TURBINE TT: 4192.5, TSO 693, TC 5290, TCSO 700. 3 U E4CE 20030513000312003051300031SO 2003 5 13 2003FA0000461 220030430G8500 ENGINE CIRRUSSR SR20 05628AJGL CONT O360 IO360E 17025SO MALFUNCTIONED D O OTHER O OTHER NRNOT REPORTED 1 GL1561EW 16 16 1302 AIRCRAFT ENGINE DID NOT RESPOND TO FULL THROTTLE DURING ATTEMPTED REJECTED LANDING FOLLOWING ENCOUNTER WITH SEVERE LOW ALTITUDE TURBULENCE. SUBSEQUENT EXAMINATION OF ENGINE AND COMPONENTS REVEALED NO ABNORMALIES. RECOMMEND CAUTIONARY NOTE IN PILOT OPERATING HANDBOOK REGARDING ENGINE POWER RESPONSE DURING TURBULENCE. 1L71 3O3 ONTA00009CHE1CE 20030513000272003051300027SO 2003 5 13 2003FA0000462 120030312G3710 GASKET AIRBORNE PIPER PA32 PA32301T 7103209SO LYC O540 TIO540S1AD 41532EA VACUUM PUMP UNSERVICEABLE D O OTHER O OTHER NRNOT REPORTED 1 WP0981573826 11AP3962 328024004 GASKET FAILED NEAR MOUNTING STUD, ALLOWING OIL UNDER PRESSURE TO EXCAPE OVERBOARD, RESULTING IN LOSS OF OIL PRESSURE AND SUBSEQUENT EMERGENCY OFF AIRPORT LANDING. THE VACUUM PUMP WAS INSTALLED NEW IN DECEMBER 1998 AND HAS BEEN IN SERVICE FOR 826.3 HOURS. THE GASKET WAS FURNISHED NEW WITH THE VACUUM PUMP. MODEL 215CC, S/N 11AP3962. 1L71 3O3 O A3SO E14EA 20030515000012003051500001NM 2003 5 15 2003FA0000463 120030509G3710CH216CW PUMP LANCARLC40 LC40550FG 5150000NM DRY AIR FAILED B O OTHER J WARNING INDICATION CRCRUISE 1 SO05727VP7 40069 DRY AIR VACUMM PUMP SHAFT SHEARD IN FLIGHT AT AROUND 7.0 HRS TOTAL TIME SINCE NEW. THE BACK-UP PUMP MODEL NR CH216CW SERIAL NR C40069 ALSO FAILED BEFORE REACHING DESTINATION WITH A TOTAL AIRFRAME TIME OF 13.0 HRS. 3 PUMPS WERE NEW AND INSTALLED DURING PRODUCTION OF THE AIRCRAFT. 1L71 3O RTA00003SA 20030513000592003051300059CE 2003 5 13 2003FA0000464 120030512G351025F2108 BOOT RAYTHNDH125 HAWKER800XP 7150012CE OXYGEN TANK MISMANUFACTURED B K NONE W INADEQUATE Q C ININSP/MAINT 1 SW11 OXYGEN COVER BOOTS WERE TEARING. UPON INVESTIGATION, FOUND THE BOOTS WERE MADE OF WRONG MATERIAL AND THE MATERIAL DIDN'T HAVE PROPER FLAME RESISTANT TREATMENT. THE BOOTS IN QUESTION WERE MADE BY AER, A COMPANY CONTRACTED BY BRITISH AEROSPACE. BOOTS WE RECEIVE BY PPA (ALSO CONTRACTED BY BRITISH AEROSPACE) ARE ALL GOOD. 2L72 4F RTA3EU 20030514002272003051400227CE 2003 5 14 2003FA0000465 120030430G3230204303112 BELLCRANK CESSNA177 177RG 2073709CE LYC O360 IO360A1B6 41514EA NLG WW FAILED D O OTHER O OTHER NRNOT REPORTED 1 SO06526684355 177RG1241 NOSE GEAR FAILED TO EXTEND ON LANDING SUBSTANTIAL DAMAGE OCCURRED. JACKED AIRCRAFT, CYCLED GEAR TO UP POSITION WITH AFT LG DOORS DISCONNECTED. ON EXTENTION, NOSE GEAR FAILED ONCE AGAIN. MECHANICAL UPLOCK FAILED TO RELEASE. SUSPECT OUT OF ADJUSTMENT. 1H71 3O3 O A20CE 1E10 20030514002312003051400231GL 2003 5 14 2003FA0000466 220030403G723065278 BLADE CESSNA525 525 2076601CE WILINTFJ44 FJ441A GL HP TURBINE DAMAGED D O OTHER O OTHER NRNOT REPORTED 1 EA21349SF1017 RRL0526 5250049 1125 ON TAKEOFF, NOTICE SMALL BIRD PASS OVER NOSE AND LEFT WINDSHIELD, TAKEOFF WAS NORMAL. DURING CLIMBOUT, 14,500 FEET, STARTED TO HEAR A LOUD WHINE AND VIBRATION COMING FROM LEFT ENGINE. DIVERTED AND BROUGHT LEFT ENGINE TO FLIGHT IDLE. DESCENT AND LANDING WAS NORMAL. DURING TAXI IN, SHUTDOWN LEFT ENGINE TO PREVENT POSSIBLE DAMAGE. INITIAL INSPECTION AFTER PILOT REPORTED EVENT. REVEALED EXTENSIVE HP COMPRESSOR AND TURBINE DAMAGE WITH HEAVY OIL CONTAMINATION. CONTINUED OPERATION, WOULD RESULT IN TOTAL CATASTROPHIC FAILURE. 1L72 4F4 FRTA1WI E3GL 20030513001982003051300198SO 2003 5 13 2003FA0000468 220030423G8550626739 COLLAR CONT O520 IO520F 17032SO GOVERNOR OIL MISALIGNED B O OTHER W INADEQUATE Q C ININSP/MAINT 1 WP28 W IN ASSEMBLING A NEW STANDARD GOVERNOR OIL TRANSFER COLLAR TO THE CRANKSHAFT IT WAS FOUND TO BIND ON THE JOURNAL. PRIOR TO DISASSEMBLING THE COLLAR HALVES THE INSIDE DIAMETER WAS NOTED TO BE SMOOTH AND COLLAR TO JOURNAL CLEARANCE WITHIN NEW LIMITS. ONCE THE COLLAR HAD BEEN DISASSEMBLED AND REASSEMBLED A STEP OF APPROXIMATELY .001 INCH WAS FOUND AT THE PARTING SURFACES. INSTALLING THE COLLAR ON THE CRANKSHAFT AND TORQUING IT IN PLACE CAUSED IT TO BIND IN AN INTERFERENCE FIT. IT APPEARS THE TWO HALVES ARE UNDER SOME TORSIONAL STRESS WHICH IS RELIEVED UPON TAKING THEM APART. THIS NOW THE SIXTH CONSECUTIVE COLLAR RECEIVED THAT EXHIBITS THESE CHARACTERISTICS. 3 O E5CE 20030514002292003051400229EA 2003 5 14 2003FA0000469 220030409G741410157123Y GEAR BENDIX PIPER PA22 PA22108 7102204SO LYC O235 O235* 41505EA LEFT MAGNETO WORN D O OTHER O OTHER NRNOT REPORTED 1 CE074860Z1876 763162 228436 THE KEEPER FOR THE MAGNETO TIMING GEAR WAS FOUND LOOSE IN THE MAG CASE. THE KEEPER, TIMING GEAR KEY WAY AND SHAFT KEY WAY SLOT WERE ALL FOUND WORN. THIS WAS A 1961 ENGINE, WITH 1876 HOURS TT. NO RECORD OF MAG MAINTENANCE COULD BE LOCATED. KEY PN 10-907-88-5. 1H71 3O3 O 1A6 E223 20030514002352003051400235SO 2003 5 14 2003FA0000470 120030415G3210402427 BOLT PIPER PA23 PA23250 7102308SO LYC O540 TIO540* 41532EA DRAG LINK SHEARED D O OTHER O OTHER NRNOT REPORTED 1 SO11777RX 274728 LEFT LANDING GEAR COLLAPSED ON LANDING. CENTER BOLT ON LEFT MAIN GEAR DRAG LINK SHEARED AND PULLED LOOSE FROM THE DRAG LINK REMOVING SUPPORT FROM THE LEG. SHAPE OF THE BOLT AFTER SHEARING SUGGEST TREMENDONS LOAD, PROBABLE BAD LANDINGS BOLT WAS TAKEN BY REP FOR TEST. TO PREVENT REOCCURRENCE DEPEND ON WHETHER IT IS A MATERIALS FAILURE OR PILOT ERROR. 1L72 3O3 O 1A10 E14EA 20030514002282003051400228CE 2003 5 14 2003FA0000471 120030513G27100510105364 CONTROL CABLE CESSNA172 172R 2072401CE AILERON CHAFED C K NONE O OTHER ININSP/MAINT 1 SO15472ER 17280669 DURING A ROUTINE INSPECTION, THE LEFT AILERON BALANCE CABLE (P/N 0510105-364) WAS FOUND CHAFING ON A FAIRLEAD LOCATED MIDWAY THROUGH THE FLAP WELL AREA. THE CABLE IS EXTREMELY DIFFICULT TO EXAMINE THOROUGHLY WHILE INSTALLED. A BORESCOPE CAN AID IN VIEWING THE AREA MORE ACCURATELY. THE BEST METHOD IS TO REMOVE THE CABLE AND PERFORM A BENDING TEST ON THE SHINY AREA, WHICH WILL EXPOSE ANY BROKEN WIRES. THIS OPERATOR HAS A FLEET OF APROXIMATELY 60 AIRCRAFT OF THIS MODEL, AND THIS PROBLEM BEGINS TO MANIFEST ITELF AS EARLY AS 1,500 HOURS TIS. 1H71 3O NT3A12 20030514002362003051400236CE 2003 5 14 2003FA0000472 120030513G27100510105365 CONTROL CABLE CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA AILERON CHAFED B K NONE O OTHER ININSP/MAINT 1 SO15441ER 17280660 RL1192151A DURING A ROUTINE INSPECTION, THE RIGHT AILERON BALANCE CABLE (P/N 0510105-365) WAS FOUND CHAFING ON A FAIRLEAD LOCATED MIDWAY THROUGH THE FLAP WELL AREA. THE CABLE IS EXTREMELY DIFFICULT TO EXAMINE THOROUGHLY WHILE INSTALLED. A BORESCOPE CAN AID IN VIEWING THE AREA MORE ACCURATELY. THE BEST METHOD IS TO REMOVE THE CABLE AND PERFORM A BENDING TEST ON THE SHINY AREA, WHICH WILL EXPOSE ANY BROKEN WIRES. THIS OPERATOR HAS A FLEET OF APROXIMATELY 60 AIRCRAFT OF THIS MODEL, AND THIS PROBLEM BEGINS TO MANIFEST ITELF AS EARLY AS 1,500 HOURS TIS. 1H71 3O3 ONT3A12 1E10 20030605000592003060500059CE 2003 6 5 2003FA0000473 120030513G27100510105364 CONTROL CABLE CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA AILERON CHAFED B K NONE O OTHER ININSP/MAINT 1 SO15441ER 17280660 RL1192151A DURING A ROUTINE INSPECTION, THE LEFT AILERON BALANCE CABLE WAS FOUND CHAFING ON A FAIRLEAD LOCATED MIDWAY THROUGH THE FLAP WELL AREA. THE CABLE IS EXTREMELY DIFFICULT TO EXAMINE THOROUGHLY WHILE INSTALLED. A BORESCOPE CAN AID IN VIEWING THE AREA MORE ACCURATELY. THE BEST METHOD IS TO REMOVE THE CABLE AND PERFORM A BENDING TEST ON THE SHINY AREA, WHICH WILL EXPOSE ANY BROKEN WIRES. THIS OPERATOR HAS A FLEET OF APROXIMATELY 60 AIRCRAFT OF THIS MODEL, AND THIS PROBLEM BEGINS TO MANIFEST ITELF AS EARLY AS 1,500 HOURS TIS. 1H71 3O3 ONT3A12 1E10 20030605000602003060500060CE 2003 6 5 2003FA0000474 120030513G27100510105365 CONTROL CABLE CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA AILERON CHAFED C K NONE O OTHER ININSP/MAINT 1 SO15472ER 17280669 L2734251A DURING A ROUTINE INSPECTION, THE RIGHT AILERON BALANCE CABLE WAS FOUND CHAFING ON A FAIRLEAD LOCATED MIDWAY THROUGH THE FLAP WELL AREA. THE CABLE IS EXTREMELY DIFFICULT TO EXAMINE THOROUGHLY WHILE INSTALLED. A BORESCOPE CAN AID IN VIEWING THE AREA MORE ACCURATELY. THE BEST METHOD IS TO REMOVE THE CABLE AND PERFORM A BENDING TEST ON THE SHINY AREA, WHICH WILL EXPOSE ANY BROKEN WIRES. THIS OPERATOR HAS A FLEET OF APROXIMATELY 60 AIRCRAFT OF THIS MODEL, AND THIS PROBLEM BEGINS TO MANIFEST ITELF AS EARLY AS 1,500 HOURS TIS. 1H71 3O3 ONT3A12 1E10 20030605000562003060500056CE 2003 6 5 2003FA0000475 120030513G2730531204423 BRACKET CESSNA340 340A 2076405CE TAIL SECTION BROKEN B O OTHER O OTHER ININSP/MAINT 1 SW15123152223 340A1812 DURING ANNUAL INSPECTION, ELEVATOR CONTROL SYS HAD EXCESSIVE FREE PLAY. FOUND BRACKETS WERE BROKEN. THESE BRACKETS SUPPORT ELEVATOR BELLCRANK IN TAIL SECTION. BOTH BRACKETS WERE MISSING THREE RIVETS EACH ON THE VERTICAL ANGLE THAT ATTACH RESPECTIVE BRACKET TO THEIR FORWARD CHANNEL. BOTH FORWARD TOP & LOWER TABS WERE BROKEN OFF DUE TO THREE RIVETS MISSING ON THE VERTICAL L SECTION. PARTS NEVER WERE DRILLED FOR THE REQUIRED RIVETS FROM FACTORY. IF THE REAR SECTION OF THESE BRACKETS WERE TO BREAK OFF, YOU WOULD LOOSE COMPLETE ELEVATOR CONTROL. THIS A/C WAS MANUFACTURED IN 1984 AND HAS COME THROUGH INSPECTIONS TO DATE WITH THESE RIVETS MISSING. 1L72 3O 3A25 20030605000582003060500058CE 2003 6 5 2003FA0000476 120030513G3233 ARM CESSNA421 421B 2076014CE MLG DOOR ACT BROKEN B O OTHER O OTHER NRNOT REPORTED 1 SW15421KL6551 421B0015 RIGHT GEAR INBOARD DOOR CAME OPEN IN FLIGHT. FOUND THE ACTUATOR ARM BROKE LOOSE AND TURNED ON ITS SHAFT. THIS ALLOW THE GEAR DOOR TO COME OPEN IN FLIGHT. ONLY WARNING IS THE ADDED AIR NOISE. THE ARM IS A PRESS FIT ON THIS PART NUMBER AND HAS BEEN SUPERCEDED BY P/N 5045001-10 WHICH IS WELDED. IF THIS DOOR WERE TO COME OPEN ON TAKE OFF AND THE GEAR WAS RETRACTED IT COULD HANG UP THE GEAR. PILOT FOUND THIS CONDITION AFTER HE LANDED. 1L72 3O A7CE 20030605000612003060500061CE 2003 6 5 2003FA0000477 120030513G27100510105362 CONTROL CABLE CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA AILERON CHAFED C K NONE O OTHER ININSP/MAINT 1 SO15472ER 17280669 L2734251A DURING A ROUTINE INSPECTION, THE RIGHT AILERON BALANCE CABLE (P/N 0510105-362) WAS FOUND CHAFING ON A FAIRLEAD LOCATED MIDWAY THROUGH THE FLAP WELL AREA. THE CABLE IS EXTREMELY DIFFICULT TO EXAMINE THOROUGHLY WHILE INSTALLED. A BORESCOPE CAN AID IN VIEWING THE AREA MORE ACCURATELY. THE BEST METHOD IS TO REMOVE THE CABLE AND PERFORM A BENDING TEST ON THE SHINY AREA, WHICH WILL EXPOSE ANY BROKEN WIRES. THIS OPERATOR HAS A FLEET OF APROXIMATELY 60 AIRCRAFT OF THIS MODEL, AND THIS PROBLEM BEGINS TO MANIFEST ITELF AS EARLY AS 1,500 HOURS TIS. 1H71 3O3 ONT3A12 1E10 20030605000622003060500062CE 2003 6 5 2003FA0000478 120030427G32225322012166 BOLT BEECH 36 A36 1151604CE PWA PT6 PT6* 52043EA NLG SHEARED B K NONE O OTHER ININSP/MAINT 1 CE07429P 294 80 E3356 DURING PILOTS PREFLIGHT, FOUND THE NUT LAYING ON THE GROUND FOR THE LOWER NOSE GEAR BOLT (532.20.12.166). THIS BOLT ATTACHES THE INNER SHOCK STRUT TUBE (LOWER) TO THE NOSE GEAR FORK, AND RETAINES THE INNER SLEEVE PLUG. THE BOLT WAS SHEARED OF FLUSH WITH THE NUT, THERE WERE SIGNS OF EXSISTING CORROSION AT THE FRACTURE LINE. 1L71 3O3 T 3A15 E2NE 20030515000032003051500003CE 2003 5 15 2003FA0000480 120030512G2611153831 FIRE LOOP LEAR 25 25B 5170511CE GE CJ610 CJ610* 30006NE RT ENGINE LOOSE E FA ACTIVATE FIRE EXT. UNSCHED LANDING N FALSE WARNING NRNOT REPORTED 1 SO1123RZ 164 251Y208A FIRE DETECTION LIGHT CAME ON IN FLIGHT. REDUCED ENGINE POWER TO IDLE, AFTER 1 MINUTE SHUT DOWN ENGINE AND EXTIGUISHED BOTH BOTTLES. ONCE ON THE GROUND ENGINE WAS INSPECTED, NO EVIDENCE OF FIRE, FOUND LOOSE CONNECTION ON FIRE LOOP. 2L72 4J4 J A10CE 1E16 20030605000642003060500064EA 2003 6 5 2003FA0000481 220030501G7414 BEARING ELECTROSYS ROBSINR22 R22BETA 7640110NM LYC O320 O320B2C 41508EA MAGNETO FAILED B T22RO OTHER R PARTIAL RPM/PWR LOSS TXTAXI/GRND HDL 1 WP0523617 C090099 2265 ENGINE WAS IN RUN UP/TEST WHEN LEFT HAND MAGNETO FAILED CHECK (DEAD MAG). MAGNETO PROBLEM WAS INVESTIGATED AND THE FOLLOWING CONDITION WAS NOTED. THREE SCREWS WERE MISSING THAT ATTACH THE LOWER AND UPPER MAIN HOUSING. TWO OF THESE SCREWS SEEMED TO HAVE BACKED OUT AND THE THIRD BROKE WHICH LEFT A PORTION OF THE THREADED SCREW REMAINING IN THE LOWER HOUSING. THERE WERE ONLY TWO REMAINING SCREWS SECURING THE TWO HOUSINGS TOGETHER WHICH HAD STARTED TO BACK OUT. ROLLER BEARING FAILED WHICH LED TO LOWER SEAL FAILURE AND DRIVE GEAR DAMAGE DUE TO SHAFT EXCESSIVE PLAY. LOWER MAGNETO HOUSING HAS A TWO INCH CRACK ON THE BOTTOM SIDE LEFT OF PLASTIC INSPECTION PLUG. 1G71 3O3 O H10WE E274 20030605000652003060500065CE 2003 6 5 2003FA0000482 120030203G2460MC012A J-BOX CESSNA172 172R 2072401CE LYC O360 IO360A1A 41514EA FIREWALL LOOSE B Z08RO OTHER O OTHER NRNOT REPORTED 1 CE07465CA3600 17280465 FOUND THE ELECTRICAL JUNCTION BOX (J-BOX) BRACKETS LOOSE. FURTHER INVESTIGATION REVEALED THAT THE 12 RIVETS THAT HOLD THE BRACKETS TO THE BOX WHERE LOOSE AND 6 OF THE 12 RIVETS THE RIVET HEADS WERE POPPING OFF, CRACKED AND FRACTURED (PHOTOS). IF LEFT UNATTENDED THIS COULD CAUSE THE BOX TO COME LOOSE FROM THE BRACKETS AND CAUSE POSSIBLE ELECTRICAL PROBLEMS. ALSO THE RIVET HEADS COMING LOOSE COULD CAUSE ARCING INSIDE THE BOX. WAS ADVISED BY AC MFG TO REPLACE THE B-STYLE RIVETS WITH AD RIVETS. NOTE: IN ORDER TO DO THIS HAD TO DISASSEMBLE THE WHOLE BOX AND COMPONENTS. 1H71 3O3 ONT3A12 1E10 20030527001162003052700116CE 2003 5 27 2003FA0000484 120030409G323312810015 ACTUATOR CESSNA172 172RG 2072438CE LYC O360 O360* 41514EA RT MLG CRACKED B WIWRO OTHER O OTHER NRNOT REPORTED 1 WP079744B 172RG1007 DURING A CHECK RIDE, THE PILOT EXAMINER REPORTED A CLUNKING NOISE AS THE GEAR WAS CYCLED. UPON INSPECTION AND REMOVAL OF THE RIGHT MAIN LANDING GEAR ACTUATOR, IT WAS FOUND TO BE CRACKED ALL THE WAY ACROSS THE LARGE BORE AT THE FORWARD BOLT HOLE. THE SECTOR GEAR AND THE PISTON IN THE ACTUATOR WERE ALSO DAMAGED. MFG SHOULD REDESIGN THE ACTUATOR AND GEAR PIVOT ASSEMBLIES, MAKING IT OUT OF STEEL OR ANOTHER MATERIAL THAT MIGHT STAND UP TO THE REPEATED STRESS THAT IS PUT ON THIS PART. THIS IS AN ONGOING, RECURRING PROBLEM WITH THIS TYPE OF LANDING GEAR. THIS OCCURS ON AVERAGE AROUND 2000 FLIGHT HOURS OR SOONER AND WITHOUT WARNING. SEB 01-2 HAD BEEN COMPLIED WITH AT TIME OF INSTALLATION. 1H71 3O3 O 3A17 E286 20030605000662003060500066CE 2003 6 5 2003FA0000485 120030425G323312810013 ACTUATOR CESSNA172 172RG 2072438CE LYC O360 O360F1A6 41514EA MCAULY2D34C B2D34C220 GL RT MLG CRACKED B Z08RO OTHER O OTHER NRNOT REPORTED 1 CE079865B8128 172RG1061 L2843136A PILOT REPORTED HEARING A LOUD BANG WHEN LAND GEAR WAS RETRACTED. A/C LANDED WITHOUT INCIDENT. INVEST REVEALED MFG PN 1281001-3, RT MAIN GEAR ACTR BODY CRACKED THROUGH (PHOTOS). COMPLIED WITH SEB AT 5741.4 HRS. A/C TT. AD2001-06-06 HAS BEEN COMPLIED WITH. FOUND CRACK STARTING WHERE LANDING GEAR CASTING ATTACHES ONTO SPOT FACE OF BODY. COULD NOT SEE UNLESS ACTUATOR WAS REMOVED. FOUND MFG PN 9882004-1 PISTON AND 9882002-2 SECTOR GEAR SHOWS SIGNS OF GEAR GALLING. SECTOR GEAR WAS REPLACED 4011.0 HOURS PRIOR. ACTUATOR BODY MAY HAVE FAILED DUE TO FATIGUE. INSTALLED NEW ACTUATOR MFG PN 9882015-4 AND SECTOR GEAR AS REQUIRED. TEST RAN LANDING GEAR AND PERFORMED CHECKS AND TESTS, FOUND OK. 1H71 3O3 O 3A17 E286 5 CP7EA 20030527001282003052700128SO 2003 5 27 2003FA0000486 220030506G852065368819 CRANKCASE CIRRUSSR SR20 05628AJGL CONT O360 IO360E 17025SO ENGINE CRACKED D O OTHER O OTHER NRNOT REPORTED 1 EA13198AM305 1105 357275 TWO ONE INCH CRACKS WERE FOUND ON THE FORWARD, RT SIDE OF THE ENGINE CRANKCASE. THE CRACKS ARE LOCATED AROUND THE FRONT ALTERNATOR MOUNTING BRACKET. TOP REAR CASE THROUGH BOLT. THIS IS THE THIRD AIRCRAFT WER ARE DOING AN ENGINE CHANGE ON WITH THIS DISCREPANCY. 1L71 3O3 ONTA00009CHE1CE 20030605000672003060500067SO 2003 6 5 2003FA0000487 120030501G5730 SKIN PIPER PA46 PA46350P 7104602SO LT WING CRACKED B X0FRO OTHER O OTHER NRNOT REPORTED 1 WP079173Z 3476 4622039 DURING ANNUAL INSPECTION, TWO CRACKS WERE FOUND ON THE LOWER LEFT WING SKIN, NEAR THE LOWER SPAR CAP, OUTBOARD OF THE MAIN LANDING GEAR DOOR HINGE. BOTH CRACKS WERE LOCATED NEAR THE DOUBLER, KIT NR 766-210, PREVIOUSLY INSTALLED IAW MFG SB. THIS AIRCRAFT HAS 4324.7 HRS TT AND 3476.3 HRS SINCE THE KIT WAS INSTALLED. INSPECTION SHOWED NO DELAMINATION OF INNER DOUBLERS. RECOMMEND INSPECTING ANNUALLY. 1L71 3O RTA25SO 20030605000752003060500075SO 2003 6 5 2003FA0000488 120030422G2701 YOKE PIPER PA24 PA24250 7102404SO LYC O540 O540* 41532EA COCKCPIT CRACKED D K NONE O OTHER ININSP/MAINT 1 WP288151P3428 243406 DURING ANNUAL INSPECTION, OWNER REQUESTED YOKES BE CHANGED. BOTH YOKES WERE FOUND TO BE CRACKED ON THE LOWER SIDE, THROUGH THE HOLE FOR THE ROLL PIN. THE CONDITION WAS NOT VISIBLE WIGHOUT REMOVING EMBLEM AND YOKE, AS PLASTIC COATING ON YOKE EXTERIOR HAD NOT CRACKED EVEN THOUGH ALUMINUM YOKE BENEATH WAS CRACKED FULLY THROUGH. IF YOKES ARE REMOVED OR EMBLEM IS REMOVED LOOK HARD FOR CRACKS IN LINE WITH ROLL PIN HOLE. 1L71 3O3 O 1A15 E295 20030605000772003060500077SO 2003 6 5 2003FA0000489 120030501G79212071011 OIL COOLER PIPER PA28 PA28181 7102807SO LYC O360 O360A4A 41514EA ENGINE OIL CRACKED B VJ3RO OTHER K FLUID LOSS NRNOT REPORTED 1 WP074133D 2843117 RL202836A AFTER LANDING FLIGHT CREW NOTICED OIL ON SIDE OF AIRCRAFT. MAINTENANCE INVESTIGATED AND FOUND OIL COOLER CRACKED AND LEAKING. CAUSE OF LEAK IS FAILURE OF OIL COOLER AT SEAMS. RECOMMEND TO USE SOLID PIECE OIL COOLER. 1L71 3O3 O 2A13 E286 20030605000802003060500080CE 2003 6 5 2003FA0000490 120030429G7603 THROTTLE CABLE BEECH 33 F33A 1151425CE CONT O520 IO520BB 17032SO FUEL CONTROL JAMMED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP071570A402 CE1333 820456R PILOT REPORTED THROTTLE WAS HARD TO MOVE. ON FURTHER INVESTIGATION FOUND THROTTLE BUTTON WOULD JAM AND NOT RELEASE. THESE CABLES ARE PRETTY RELIABLE, AT THIS TIME, NO PROBLEM, CAUSE OR RECOMMENDATIONS TO PREVENT THIS FROM RECURRING. 1L71 3O3 O 3A15 E5CE 20030605000812003060500081SO 2003 6 5 2003FA0000491 120030505G3610RA215CC PUMP PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA PNEUMATIC SYS BROKEN B VJ3RK NONE O OTHER ININSP/MAINT 1 WP074130W 2843204 L2847836A DURING FLIGHT AIRCREW REPORTED NO AIR PRESSURE. MAINTENANCE INVESTIGATED AND FOUND DRIVE SHAFT ON AIR PUMP HAD SHEARED. PROBABLE CAUSE IS VANES HAD SHEAR AND JAMMED SHAFT CAUSE IT TO SHEAR. NO RECOMMENDATIONS. 1L71 3O3 O 2A13 E286 20030605000822003060500082EA 2003 6 5 2003FA0000492 220030428G7314 SEAL GROB 120 G120A 1660208EU LYC O540 AEIO540D4D5 EA FUEL PUMP LEAKING B VJ3RO OTHER KB FLUID LOSS SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 WP07863AF893 B4377 85003 L2802548A FLIGHT CREW NOTICED ODOR OF FUEL DURING GROUND RUN. TECHNICIAN TROUBLESHOOT FUEL SYSTEM AND NOTICED FUEL STAINS ON FUEL PUMP. SO REPLACED FUEL PUMP. ONCE PUMP REMOVED NOTICED GEAR SPLINE WAS WORN DASTRICALLY. 1L71 3O3 ORTA49CE 1E4 20030611000012003061100001CE 2003 6 11 2003FA0000493 120030505G3610RA216CW PUMP BEECH 33 F33A 1151425CE CONT O520 IO520BB 17032SO PNEUMATIC SYS WORN B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP071556A645 CE1318 820495R DURING GROUND RUN UP OUTPUT OF ENGINE DRIVEN DRY AIR PUMP FAILED TO PUT OUT PROPER PRESSURE AT IDLE RPM. RAN AIRCRAFT UP AND AIR PRESSURE STILL LOW AT HIGHER RPM. TESTED SYSTEM AND FOUND ENGINE DRIVEN AIR PUMP NOT WORKING PROPERLY. BELIEVE DRY AIR PUMP VANES ARE WORN. NO RECOMMENDATIONS. 1L71 3O3 O 3A15 E5CE 20030605000832003060500083CE 2003 6 5 2003FA0000494 120030505G3610RA216CW PUMP BEECH 33 F33A 1151425CE CONT O520 IO520BB 17032SO PNEUMATIC SYS WORN B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP075587K297 CE1392 825812R DURING GROUND RUN UP OUTPUT OF ENGINE DRIVEN DRY AIR PUMP FAILED TO PUT OUT PROPER PRESSURE AT IDLE RPM. RAN AIRCRAFT UP AND AIR PRESSURE STILL LOW AT HIGHTER RPM TESTED SYSTEM AND FOUND ENGINE DRIVEN AIR PUMP NOT WORKING PROPERLY. BELIEVE DRY AIR PUMP VANES ARE WORN. NO RECOMMEDATIONS. 1L71 3O3 O 3A15 E5CE 20030605000842003060500084CE 2003 6 5 2003FA0000495 120030505G3610RA216CW PUMP BEECH 33 F33A 1151425CE CONT O520 IO520BB 17032SO PNEUMATIC SYS WORN B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP078242T CE1610 825836R DURING GROUND RUN UP OUTPUT OF ENGINE DRIVEN DRY AIR PUMP FAILED TO PUT OUT PROPER PRESSURE AT IDLE RPM. RAN AIRCRAFT UP AND AIR PRESSURE STILL LOW AT HIGHT RPM. TESTED SYSTEM AND FOUND ENGINE DRIVEN AIR PUMP NO WORKING PROPERLY. BELIEVE DRY AIR PUMP VANES ARE WORN. HAVE NO RECOMMENDATIONS. 1L71 3O3 O 3A15 E5CE 20030605000852003060500085CE 2003 6 5 2003FA0000496 120030505G3610RA216CW PUMP BEECH 33 F33A 1151425CE CONT O520 IO520BB 17032SO PNEUMATIC SYS WORN B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP075609S414 CE1454 825756R DURING GROUND RUN UP OUTPUT OF ENGINE DRIVEN DRY AIR PUMP FAILED TO PUT OUT PROPER PRESSURE AT IDLE RPM. RAN AIRCRAFT UP AND AIR PRESSURE STILL LOW AT HIGHER RPM. TESTED SYSTEM AND FOUND ENGINE DRIVEN AIR PUMP NO WORKING PROPERLY. BELIEVE DRY AIR PUMP VANES ARE WORN. NO RECOMMENDATIONS. 1L71 3O3 O 3A15 E5CE 20030605000862003060500086EU 2003 6 5 2003FA0000497 120030503G3230X03004B VALVE GROB 120 G120A 1660208EU MLG MANIFOLD INOPERATIVE B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07864AF802 85004 PILOT REPORTED GEAR WAS SLOWLY TO EXTEND, OVER 1 MINUTE. AFTER PULLING 3 G`S AT 150 KNOTS GEAR FINALLY EXTENDED DOWN AND LOCKED. ON FURTHER INVESTIGATION WE FOUND NO PROBABLE CAUSE OR RECOMMENDATIONS TO PREVENT THIS FROM RECURRING. 1L71 3O RTA49CE 20030605001022003060500102SO 2003 6 5 2003FA0000498 120030414G27206010532 SPRING PIPER PA20 PA20 7102002SO LYC O360 O360* 41514EA RUDDER RETURN FAILED D D RETURN TO BLOCK O OTHER TXTAXI/GRND HDL 1 EA034948M903 20639 DURING TAXI TO POSITION FOR TAKEOFF, THE RIGHT RUDDER RETURN SPRING FAILED AT THE ATTACHMENT HOOK TO THE CABLE BELLCRACK. THE PILOT HEARD A NOISE BUT DID NOT REALIZE THE SPRING HAD FAILED UNTIL LATE IN THE ROLLOUT. THE FLIGHT CYCLE WAS COMPLETED WITHOUT EVENT. ABOVE NORMAL RIGHT RUDDER PRESSURE WAS REQUIRED TO CORRECT YAW. PART FAILURE APPEARS TO BE THE RESULT OF FATIGUE. 1H71 3O3 O 1A4 E286 20030606000022003060600002EA 2003 6 6 2003FA0000499 220030417G73103011158 LOCK PLATE PWA PT6 PT6A34 52043EA FUEL MANIFOLD DISTORTED G O OTHER O OTHER NRNOT REPORTED 1 SW17 6921 PCE14125 LOCKPLATE WAS DISTORTED AND FAILED TO RETAIN FUEL TRANSFER TUBE IN THE FUEL MANIFOLD ADAPTER. RESULTING, FUEL LEAK CAUSE POWER LOSS/ EMERGENCY LANDING/ CRASH. RECOMMEND LOCKPLATES ARE INSPECTED FOR PROPER SEATING IN TRANSFER TUBES AT 100 HOUR ANNUAL INSPECTIONS. 4 T E4EA 20030605001052003060500105EA 2003 6 5 2003FA0000500 220030403G73142B663FR PUMP PIPER PA31 PA31350 7103110SO LYC O540 TIO540* 41532EA FUEL SYSTEM LEAKING D K NONE K FLUID LOSS ININSP/MAINT 1 SO054093W 2402 318152176 UPON INSPECTION OF THE ELECTRIC FUEL PUMP, HAD DISCOVERED FUEL STAINS AROUND THE TOP AND BOTTOM OF THE MOTOR HOUSING. 1L72 3O3 O A20SO E14EA 20030605000792003060500079NE 2003 6 5 2003FA0000501 220030514G7250775404 BLADE PWA JT8 JT8D217 52053NE TURBINE SECTION CRACKED B T48RK NONE O OTHER ININSP/MAINT 1 GL09 5935 5935 708409 T4 BLADE PART NUMBER 775404 KNIFE EDGES AXIAL CRACKS. (APPROXIMATELY 40 PERCENT) 4 F E9NE 20030605001642003060500164SO 2003 6 5 2003FA0000502 220030501G8530653816A7BP CYLINDER CONT O200 O200A 17020SO ROCKER SHAFTS GALLED D O OTHER O OTHER NRNOT REPORTED 1 WP25 10518A ENGINE INSPECTED AFTER APPROXIMATELY 70 HOURS OF OPERATION ON NEW MFG ASSY. GALLING HAD OCCURED ON THE ROCKERSHAFTS. THE MFG HAD MODIFIED THE AGE OLD DESIGN TO INCLUDE LOCKING THE ROCKER SHAFT IN PLACE WITH A SET SCREW. THE SHAFT, BEING UNABLE TO FLOAT AND ROTATE FOR PROPER OILING AND WEAR, GALLED. RECOMMEND ALLOWING THE ROCKER SHAFT TO FLOAT AS IT WAS ORIGINALLY DESIGNED TO DO. OTHER PROBLEMS ENCOUNTERED WITH THESE ASSEMBLIES INCLUDE THE BLACK CARBON/ GRAPHITE COATINGS ON THE PISTONS FLAKING OFF AND CAUSING A POTENTIALLY BLOCKED OIL SCREEN AND SUBSEQUENT ENGINE FAILURE. 3 O E252 20030605001652003060500165CE 2003 6 5 2003FA0000503 120030410G712005510231 MOUNT CESSNA172 172P 2072436CE LYC O360 O360A4M 41514EA ENGINE DAMAGED D O OTHER O OTHER NRNOT REPORTED 1 EA03965737262 970 17276088 L865336A ENGINE MOUNT WAS REMOVED FOR INSPECTION FOLLOWING PROPELLER STRIKE WITH AIRCRAFT. AEROSPACE WELDING REPORTED MOUNT WAS PUSHED UP ON LOWER SECTION AND PUSHED IN ON RIGHT SIDE. AT REMOVAL MOUNT AWAS DIFFICULT TO REMOVE FORM ATTACHMENT BOLTS. AFTER PROPELLER STRIKE ENGINE MOUNT SHOULD BE REMOVED FOR INSPECTION. 1H71 3O3 ONT3A12 E286 20030605001682003060500168CE 2003 6 5 2003FA0000506 120030416G321307436214 STRUT CESSNA182 182S 2072701CE PWA PT6 PT6A11 52043NE MLG DEFECTIVE B QU5RO OTHER O OTHER NRNOT REPORTED 1 NM07603TC 18280712 THE DIAMETER OF THE OLOE TUBE IS .0012 INCHES SMALLER THAN THE BORE OF THE FORK. THE FORK WAS HELD ON ONLY BY THE NR5 BOLT. THE OLEO TUBE HAS AN UNUSUAL WEAR PATTERN OF CIRCUMFERENTIAL WEAR AND RIDGES. IT IS BELIEVED THAT THIS OLEO WAS DEFECTIVE FROM THE MANUFACTURER. IT IS RECOMMENDED IXISTING AIRCRAFT BE INSPECTED FOR THIS CONDITION. THE IMPROPER FIT OF THE TUBE TO THE FORK WILL EVENTUALLY CAUSE EXCESSIVE WEAR ON THE FORK AND POSSIBLE NLG FAILURE. 1H71 3O3 TNT3A13 E4EA 20030606000092003060600009CE 2003 6 6 2003FA0000507 120030508G2434632018 DRIVE GEAR CESSNA335 335 2075601CE CONT O520 TSIO520EB 17040SO ALTERNATOR INOPERATIVE B WDARO OTHER O OTHER NRNOT REPORTED 1 SO09918AA 972 3350048 815072R REPORTED ALTERNATOR INOPERATIVE. UPON REMOVAL OF ALTERNATOR FOUND ALTERNATOR DRIVE GEAR TO BE DESTROYED. REMOVED AND INSPECTED OIL FILTER. FOUND SIGNIFICANT AMOUNTS OF METAL. 1L72 3O3 O 3A25 E8CE 20030606000122003060600012 2003 6 6 2003FA0000508 420030426G2561KS9P0101HC2 LIFE VEST CABIN FAILED B KQ1RO OTHER L NO TEST NRNOT REPORTED 1 EA07 LIFE VEST FAILED MFG RECOMMEND CELL PRESSURE TEST IAW 25-60-1 DOM: JANUARY 1981. 20030606000132003060600013 2003 6 6 2003FA0000509 420030428G25616A12P0201101 LIFE VEST CABIN FAILED B KQ1RO OTHER L NO TEST NRNOT REPORTED 1 EA07 INDIVIDUAL FLOAT DEVICE FAILED MFG RECOMMENDED CELL PRESSURE TEST IAW 25-60-13. DOM: OCT 1983. 20030527001242003052700124 2003 5 27 2003FA0000510 420030428G25616A12P0201101 LIFE VEST CABIN FAILED B KQ1RK NONE L NO TEST ININSP/MAINT 1 EA07 INDIVIDUAL FLOAT DEVICE FAILED. MFG RECOMMENDED CELL PRESSURE TEST IAW 25-60-13. DOM: OCT 1983. 20030527001212003052700121NM 2003 5 27 2003FA0000511 120030425G6220A1581 BEARING ROBSINR22 R22BETA 7640110NM LYC O320 O320* 41508EA SPINDLE ROUGH B GJORO OTHER O OTHER NRNOT REPORTED 1 NM018051M464 1168 ROTORCRAFT EXPERIENCED UNUSUAL VIBRATION. REMOVED MAIN ROTOR BLADES FOUND UPON VISUAL (BY FEEL) SPINDLE BEARINGS WERE ROUGH AND BRINELD. FACTORY STATES THIS IS CAUSED BY MAIN ROTOR OVERSPEEDS. IF AIRCRAFT/ROTORCAFT EXPERIENCES UNUSUAL VIBRATION TO CHECK SPINDLE BEARINGS FOR CONDITION. 1G71 3O3 O H10WE E274 20030606000352003060600035CE 2003 6 6 2003FA0000512 120030424G8012S1991A1 SOLENOID CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA MCAULY1C160 1C160DTM GL STARTER INOPERATIVE D O OTHER O OTHER NRNOT REPORTED 1 WP27737BC 17269283 L205976 731046 FOURTH INCIDENT INVOLVING THIS SAME STARTER SOLENOID INTAILING SHORTING OUT INTERNAL WINDING CAUSING STARTER TO MALFUNCTION. THE FORMER THREE OCCASIONS, THE STARTER FAILED TO ROTATE (SOLENOID STUCK IN THE OPEN POSITION) ON THIS OCCASION, STARTER TURNED AS SOON AS THE MASTER WAS TURNED ON ( SOLENOID STUCK IN CLOSED POSITION). ON THIS OCCASION, THE BATTERY WAS NOT FULLY CHARGED AND CAUSED A HIGH CURRENT DRAW TO THE STARTER. A DICECTEDED SOLENOID REVELED SHORTED WINDINGS. THIS SWITCH WAS IN OPERATION NOT MORE THAN 6 MONTHS. 1H71 3O3 ONT3A12 E274 5 NP910 20030606000422003060600042EA 2003 6 6 2003FA0000514 220030430G8530LW15861 LIFTER BEECH 60 B60 1153605CE LYC O541 TIO541* 41536EA CYLINDERS CORRODED D O OTHER O OTHER NRNOT REPORTED 1 SW051WA 51 P423 L135159 LIFTERS PITTED AND MUSHROOMED. 1L72 3O3 O A12CE E10EA 20030606000522003060600052SO 2003 6 6 2003FA0000515 120030312G3710 GASKET PIPER PA32 PA32301T 7103209SO LYC O540 TIO540S1AD 41532EA VACUUM PUMP FAILED D O OTHER O OTHER NRNOT REPORTED 1 WP0981573826 11AP3962 328024004 GASKET FAILED NEAR MOUNTING STUD, ALLOWING OIL UNDER PRESSURE TO ESCAPE OVERBOARD, RESULTING IN LOSS OF OIL PRESSURE AND SUBSEQUENT EMERGENCY OFF AIRPORT LANDING. THE VACUUM PUMP WAS INSTALLED NEW IN DECEMBER 1998 AND HAS BEEN IN SERVICE FOR 826.3 HOURS. THE GASKET WAS FURNISHED NEW WITH THE VACUUM PUMP. 1L71 3O3 O A3SO E14EA 20030605001622003060500162SW 2003 6 5 2003FA0000517 120030512G3220540017509 TRUSS MOONEYM20 M20R 5870225SW CONT O550 IO550* SO NLG BROKEN B O OTHER O OTHER TXTAXI/GRND HDL 1 SW159169E119 290149 A/C RECEIVED STRUCTURAL DAMAGE DURING LANDING. (THE RECORDS SHOW A NEW 540017-509 (TRUSS ASSY, NOSE GEAR, UPPER, RETRACT) WAS INSTALLED IN A/C AT THE TIME OF REPAIR.) AT TOTAL TIME 211.1 A/C WAS TAKEN OUT OF SERVICE TO REPAIR STRUCTURAL PROBLEMS THAT CAUSED SLOWER THAN NORMAL FLIGHT. ON THIRD TEST FLIGHT AFTER REPAIRS, NOSE GEAR COLLAPSED AT END OF LANDING ROLLOUT. INSP OF NOSE GEAR SHOWED WELDED TRUSS ASSEMBLY HAD FAILED. TRUSS ASSY IS 4130-TUBE WELDED STRUCTURE THAT IS HEAT TREATED AFTER ASSY. TWO ATTACH POINTS FOR RETRACT RODS; EACH POINT HAS TWO 4130 0.50 OD X 0.035 WALL TUBES THAT TIE IT TO WELDED ASSY. BOTH RETRACT ROD ATTACH POINTS FAILED JUST ABOVE THE WELDS THAT TIE THE TUBES TO THE ASSY. 1L71 3O3 ORT2A3 E3SO 20030605001142003060500114EA 2003 6 5 2003FA0000518 220030516G7322CF30766 FLOAT MARVELSCHEBX PIPER PA28 PA28151 7102805SO LYC O320 O320E3D 41508EA CARBURETOR FAILED G A UNSCHED LANDING Y ENGINE STOPPAGE CLCLIMB 1 SO0343266 75106625 287415460 L3777227A UPON TAKEOFF ENGINE QUIT. UNSCHEDULED LANDING, AIRCRAFT DAMAGE WAS HEAVY. INPSECTION OF CARBURETOR MA4SP, PART NUMBER 10-5217, SERIAL NUMBER 75-10-6625-CFA02043, FLOAT PART NUMBER CF-30-766, FLOAT SERIAL DATE 11-01. FLOAT SANK IN BOWL DO TO FLOATS SPLITTING AT SEAMS. NO AD NOTED ON THESE FLOATS. 1L71 3O3 O 2A13 E274 20030605001192003060500119CE 2003 6 5 2003FA0000519 120030508G5751 STRUCTURE CESSNA425 425 2076018CE PWA PT6 PT6* 52043EA AILERON DEBONDED B O OTHER W INADEQUATE Q C ININSP/MAINT 1 SW15788JL 881 4250202 THE AILERON IS AN ALL ALUMINUM BONDED ASSEMBLY. THE AILERON WAS REPAIRED BY REPLACING THE AFT SKIN, USING DER APPROVED DATA AND WAS RETURNED TO SERVICE 11-15-2002. ON 05-08-2003 A BOND LINE SEPARATION WAS DISCOVERED ON A SKIN EDGE. REVIEW OF THE REPAIR PROCESS INDICATES THAT AN EXCESSIVE AMOUNT OF TIME ELAPSED BETWEEN SKIN ETCH AND PRIMER APPLICATION. OXIDATION OF THE ALUMINUM SKIN RESULTED IN POOR ADHESION OF THE SKIN TO THE STRUCTURE. REPAIR PROCESSES WERE REVIEWED TO INSURE THAT ALL CORE REPAIR PARTS ARE BROUGHT TO A STABLE CONDITION IF THEY ARE NOT GOING TO BE USED IMMEDIATELY. 1L72 3T3 TRTA7CE E2NE 20030611000022003061100002CE 2003 6 11 2003FA0000520 120030409G2710451350393 LINKAGE BEECH 58 58 1152740CE CONT O550 IO550* SO LT WING AILERON OUT OF ADJUST D K NONE O OTHER ININSP/MAINT 1 EA231066H TH1766 DURING ANNUAL INSPECTION, FOUND THE AILERON TRIM TAB LINKAGE RUBBING ON LEADING EDGE OF AILERON. UPON INVESTIGATION AND CONVERSING WITH MFG TECH, FOUND THE TRIM TAB LINKAGE ARM (PN 451350393) WAS INSTALLED 180 DEGREES OUT, WITH THE SHORT END HOOKED TO THE ACTUATOR LINKAGE, AND THE TRIM TAB LINKAGE ATTACHED TO THE LONG END. LINKAGE ARM WAS REINSTALLED IN PROPER ORIENTATION DISCREPENCY WAS CLEARED. 1L72 3O3 O 3A16 E3SO 20030611000042003061100004EA 2003 6 11 2003FA0000521 220030328G8550 FILTER GRTLKS2T1 2T1A2 3910101NM LYC O360 AEIO360B1G6 41514EA ENGINE OIL DAMAGED D O OTHER W INADEQUATE Q C NRNOT REPORTED 1 GL256018L1485 1 0711 L1304351A UPON INSTALL, OIL FILTER SCREEN WAS REMOVED TO DRAIN OIL, WAS FOUND, INSTALLED IMPROPER, WAS CRUSHED ON ONE END. OIL FILTER BASE ASSY WAS REMOVED TO AID IN INSTALL OF AN OIL LINE, GASKET WAS FOUND INSTALLED BACKWARDS, PARTIAL BLOCKAGE OF OIL PORTS. INSTALLED FUEL SERVO, AND FOUND ARMS (MIXTURE AND THROTTLE) WERE DIFFERENT FROM ONES WE SENT, AND THROWS WERE DIFFERENT (NEITHER ARM INSTALLED ALLOWED STOP TO STOP MOVEMENT), ARMS HAD TO BE REPLACED. AFTER FINAL INSTALL, READY FOR START, BUT WOULD NOT. TROUBLESHOOTING REVEALED FUEL MANIFOLD PLUNGER WAS STUCK CLOSED, WOULD NOT OPEN TO FUEL PRESSURE. ONCE PLUNGER WAS RELEASED ENG WAS GROUND RUN AND SET UP. ONE HOUR FLIGHT WAS MADE BEFORE THE PLUNGER SEIZED AGAIN.1Q71 3O3 O A18EA 1E10 20030611000072003061100007CE 2003 6 11 2003FA0000522 120030501G281012000655 FUEL CELL CESSNA182 182H 2072718CE CONT O470 O470* 17026SO LEFT WING LEAKING D O OTHER O OTHER NRNOT REPORTED 1 GL251970X 18256070 FLOATS AND FUEL CELLS. RECEIVED NEW MFG LEFT WING FUEL CELL, MFG DATE 3/03. INSTALLED IN AIRCRAFT, FILLED WITH 1000LL AVGAS, DISCOVERED FUEL LEAK, RETURNED FUEL CELL TO MFG, FFC DISCOVERED MFG LT REAR BOTTOM CHANNEL LEAK DEFECT. FFC REPAIRED DEFECT AND RETURNED FUEL CELL. 1H71 3O3 ONT3A13 E273 20030527001232003052700123EA 2003 5 27 2003FA0000523 220030521G8530 CYLINDER HEAD CESSNA172 172P 2072436CE LYC O320 IO320* 41508EA ENGINE CRACKED D K NONE O OTHER ININSP/MAINT 1 EA25645511494 17275577 L1355539A CYLINDER HEAD FOUND CRACKED FROM UPPER TO LOWER SPARK PLUG HOLES. BEING FOWARDED FOR MECHANIC AS FAX NUMBER DOES NOT WORK AT AFS-640. POC J. SHAPIRO 201-556-6600 EXT 230. 1H71 3O3 ONT3A12 1E12 20030606001012003060600101EA 2003 6 6 2003FA0000525 220030521G8520STD1211 PLUG LYC CESSNA172 172S 2072439CE LYC O360 O360* 41514EA CAMSHAFT LOOSE B A UNSCHED LANDING K FLUID LOSS CLCLIMB 1 WP03518ER1401 172S8922 L2992451A WHILE PRACTICING TOUCH AND GOES, THE INSTRUCTOR NOTICED A THIN FILM OF OIL ON THE WINDSHIELD. IT QUICKLY GOT WORSE. MADE EMERGENCY LANDING. MAINTENANCE DISCOVERED THE CRANKSHAFT PLUG HAD COME LOOSE. OIL LEVEL WAS AT 4.5 QTS. REPLACED CRANK PLUG, CHECKED ENGINE BREATHER LINES (CLEAR), CLEANED AIRCRAFT, SERVICED OIL AND PUT AIRCRAFT BACK INTO SERVICE. MFG CONTACTED AND INFORMED OF THE INCIDENT. 1H71 3O3 ONT3A12 E286 20030611000092003061100009 2003 6 11 2003FA0000527 420030327G25624530421366 ELT RAYTHNDH125 HAWKER800XP 7150012CE GARRTTTFE731TFE731* 01518WP CABIN INOPERATIVE D O OTHER O OTHER NRNOT REPORTED 1 NM08327LJ 258490 ELT (PN 02195 MODEL 110-406) IS TRIGGERED ON WHENEVER AIRCRAFT IS WASHED, DEICED OR IN HEAVY STANDING RAIN, ELT IS MOUNTED AT FRAME 25, INSIDE THE TAIL CONE FAIRING ABOVE THE DATUM LINE. POSSIBLE WATER ENTRY AREA IS THROUGH THE RUDDER SHAFT AS IT PASSES THROUGH THE TAIL CONE FAIRING. MM ATA23 PROVIDES NO SPECIAL INSTRUCTIONS FOR SEALING DURING INSTALLATION. DOCUMENT NR 570-5012 PARA 3.8 DTD 6/4/01 PROVIDES INSTRUCTION FOR SEALING THE CONNECTOR BUT NOT THE CONTAINER. UNIT WAS NEVER MENT TO BE SEALED UNIT. POSSIBLE REPAIR WOULD BE TO INSTALL A COVER FOR THE ELT. 2L72 4F4 FRTA3EU E6WE 20030611000112003061100011SW 2003 6 11 2003FA0000528 120030408G5754 SKIN MOONEYM20 M20C 5870208SW LYC O360 O360* 41514EA RT WING OB LE CORRODED D O OTHER O OTHER NRNOT REPORTED 1 SW0952RM 1852 A/C RT WING OB LE SKIN WAS SLIGHTLY DAMAGED DURING TAXING. ACCOMPLISHED REPAIR OF LE AND A/C RETURNED SERVICE. IN COURSE OF INSP, FOUND EXTENSIVE CORROSION ON RT WING SPAR CAP STIFFNER BEHIND COPILOTS SEAT. CORROSION WAS SO EXTENSIVE THAT SPAR CAP STIFFNER WAS 90 PERCENT CORRODED THROUGH. REMOVED ALL WING PANELS THAT WERE INSTALLED WITH COUNTERSUNK CHERRY MAX RIVETS. CORROSION ON SPAR CAP OB OF FUEL TANK THAT COULD HAVE BEEN FOUND HAD COVERS BEEN ATTACHED WITH SCREWS AND EASILY REMOVABLE AND BEEN REQUIRED INSPECTION POINTS DURING ANNUAL INSPECTION. CHERRY MAX RIVETS IN COUNTERSUNK HOLES ARE NEXT TO IMPOSSIBLE TO DRILL. PINS COULD NOT BE PUNCHED OUT OR GROUND OFF TO ALLOW RIVET TO BE DRILLED. 1L71 3O3 O 2A3 E286 20030611000122003061100012NM 2003 6 11 2003FA0000529 120030414G5714 SKIN LKHEEDP3A P3A 5260103NM WING BOX CRACKED B K NONE O OTHER ININSP/MAINT 1 WP25925AU 151361 DURING ANNUAL (SPECIAL) INSPECTION CRACKS IN THE WING CENTER BOX PLANK NR 1 AND NR 3 WERE FOUND EMITTING FROM THE INTERNAL WEEP HOLES LOCATED NTHE INTERNAL PLANK RISERS. CRACK IN NR 1 PLANK, RT SIDE WAS ABOUT 3 INCHES LONG AND A 1 INCH CRACK IN SAME PLANK ON LEFT SIDE ABOUT 3 INCHES LONG. ALL CRACKS RUN FORWARD AND AFT. FATIGUE OR HARD LANDING ARE SUSPECTED. 2L74 4T RTA32NM 20030611000142003061100014CE 2003 6 11 2003FA0000530 120030515G3710442CW PUMP CESSNA402 402C 207590RCE CONT O520 TSIO520VB 17040SO NR 1 ENG VACUUM INOPERATIVE B NE5RO OTHER O OTHER NRNOT REPORTED 1 GL13635MA 75 402C0634 VACUUM PUMP INOPERATIVE, OVERHAULED ON 1-15-03. 1L72 3O3 O A7CE E8CE 20030611000152003061100015CE 2003 6 11 2003FA0000531 120030515G3710442CW PUMP CESSNA402 402C 207590RCE CONT O520 TSIO520VB 17040SO NR 2 ENG VACUUM INOPERATIVE B NE5RO OTHER O OTHER NRNOT REPORTED 1 GL13635MA 63 402C0634 VACUUM PUMP INOPERATIVE, OVERHAULED ON 1-15-03. 1L72 3O3 O A7CE E8CE 20030611000132003061100013SO 2003 6 11 2003FA0000533 120030522G275082905002 BELLCRANK PIPER PA46 PA46350P 7104602SO LYC O540 TIO540* 41532EA TE FLAP BROKEN D O OTHER F FLT CONT AFFECTED LDLANDING 1 NE02120FW631 4636134 PILOT REPORTED THAT THE AIRCRAFT ROLLED LEFT WHEN THE FLAPS WERE EXTENDED FOR LANDING REQUIRING SIGNIFICANT RIGHT AILERON INPUT TO COUNTERACT THIS FORCE. PILOT RETRACTED THE FLAPS AND NOTED THE LT FLAP REMAINED DOWN APPOXIMATELY 10 DEGREES. PILOT COMPLETED A NORMAL LANDING. INVESTIGATION REVEALED THAT THE LEFT FLAP BELLCRANK WAS TWISTED IN TWO AT ITS MIDPOINT. BELLCRANK WAS IN COMPLIANCE WITH MFG SB 1062 AND DID NOT BREAK AT A WELD. INSPECTION OF THE RT SIDE REVEALED THAT THE PAINT WAS BROKEN IN A TWISTING DIRECTION BUT THE BELLCRANK HAD NOT SEPARATED (YET). BOTH BELLCRANKS WERE REPLACED WITH NEW PARTS. FLAP RIGGING WAS CHECKED AND FOUND OK WITH NO BINDING IN EITHER DIRECTION NOTED. 1L71 3O3 ORTA25SO E14EA 20030611001162003061100116EU 2003 6 11 2003FA0000535 120030512G2710 BEARING GROB 120 G120A 1660208EU AILERON LEVER FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07862AF897 85002 DURING INSPECTION OF AIRCRAFT, FOUND BEARING TO BE FAILING. RETAINING CLIP AND SEAL WERE BEING FORCED OUT OF BEARING. PROBABLE CAUSE IS A DESIGN FLAW IN THE CONTROL SYSTEM WHICH ALLOWS THE CONTROL ROD DEFLECTION TO EXCEED THE DESIGN LIMIT OF BEARING. RECOMMEND DESIGN CHANGE OR REPLACE BEARING WITH ONE THAT HAS BETTER LIMITS AND LOAD HANDLING CAPABILITIES. 1L71 3O RTA49CE 20030611001172003061100117EU 2003 6 11 2003FA0000536 120030512G2710 BEARING GROB 120 G120A 1660208EU AILERON LEVER FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07863AF902 85003 DURING INSPECTION OF AIRCRAFT, FOUND BEARING TO BE FAILING. RETAINING CLIP AND SEAL WERE BEING FORCED OUT OF BEARING. PROBABLE CAUSE IS A DESIGN FLAW IN THE CONTROL SYSTEM WHICH ALLOWS THE CONTROL ROD DEFLECTION TO EXCEED THE DESIGN LIMIT OF THE BEARING. 1L71 3O RTA49CE 20030611001182003061100118EU 2003 6 11 2003FA0000537 120030512G2700 BEARING GROB 120 G120A 1660208EU AILERON CONTROL FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07864AF802 85004 DURING INSPECTION OF AIRCRAFT, FOUND BEARING TO BE FAILING. RETAING CLIP AND SEAL WERE BEING FORCED OUT OF BEARING. PROBABLE CAUSE IS A DESIGN FLAW IN THE CONTROL SYSTEM WHICH ALLOWS THE CONTROL ROD DEFLECTION TO EXCEED THE DESIGN LIMIT OF THE BEARING. RECOMMEND A DESIGN CHANGE OR REPLACE BEARING WITH ONE THAT HAS BETTER LIMITS AND LOAD HANDLING CAPABILITIES. 1L71 3O RTA49CE 20030611001192003061100119EU 2003 6 11 2003FA0000538 120030512G2710 BEARING GROB 120 G120A 1660208EU AILERON CONTROL FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07861AF841 85001 DURING INSPECTION OF AIRCRAFT, FOUND BEARING TO BE FAILING. RETAINING CLIP AND SEAL WERE BEING FORCED OUT OF BEARING. PROBABLE CAUSE IS A DESIGN FLAW IN THE CONTROL SYSTEM WHICH ALLOWS THE CONTROL ROD DEFLECTION TO EXCEED THE DESIGN LIMIT OF THE BEARING. RECOMMEND A DESIGN CHANGE OR REPLACE BEARING WITH ONE THAT HAS BETTER LIMITS AND LOAD HANDLING CAPABILITIES. 1L71 3O RTA49CE 20030611001202003061100120CE 2003 6 11 2003FA0000539 120030506G3710RA216CW PUMP BEECH 33 F33A 1151425CE PNEUMATIC WORN B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP078173C501 CE1541 DURING GROUND RUN UP OUTPUT OF ENGINE DRIVEN DRY AIR PUMP FAILED TO PUT OUT PROPER PRESSURE AT IDLE RPM. RAN AIRCRAFT UP AND AIR PRESSURE STILL LOW AT HIGHTER RPM. TESTED SYSTEM AND FOUND ENGINE DRIVEN AIR PUMP NOT WORKING PROPERLY. BELIEVE DRY AIR PUMP VANES ARE WORN. HAVE NO RECOMMENDATION AT THIS TIME. 1L71 3O 3A15 20030611001212003061100121EU 2003 6 11 2003FA0000540 120030512G2710 BEARING GROB 120 G120A 1660208EU AILERON LEVER FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07865AF723 85005 DURING INSPECTION OF AIRCRAFT, FOUND BEARING TO BE FAILING. RETAINING CLIP AND SEAL WERE BEING FORCED OUT OF BEARING. PROBABLE CAUSE IS A DESIGN FLAW IN THE CONTROL SYSTEM WHICH ALLOWS THE CONTROL ROD DEFLECTION TO EXCEED THE DESIGN LIMIT OF THE BEARING. RECOMMEND A DESIGN CHANGE OR REPLACE BEARING WITH ONE THAT HAS BETTER LIMITS AND LOAD HANDLING CAPABILITIES. 1L71 3O RTA49CE 20030611001222003061100122EU 2003 6 11 2003FA0000541 120030512G2710 BEARING GROB 120 G120A 1660208EU AILERON LEVER FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07867AF459 85007 DURING INSPECTION OF AIRCRAFT, FOUND BEARING TO BE FAILING. RETAINING CLIP AND SEAL WERE BEING FORCED OUT OF BEARING. PROBABLE CAUSE IS A DESIGN FLAW IN THE CONTROL SYSTEM WHICH ALLOWS THE CONTROL ROD DEFLECTION TO EXCEED THE DESIGN LIMIT OF THE BEARING. RECOMMEND A DESIGN CHANGE OR REPLACE BEARING WITH ONE THAT HAS BETTER LIMITS AND LOAD HANDLING CAPABILITIES. 1L71 3O RTA49CE 20030611001232003061100123EU 2003 6 11 2003FA0000542 120030512G2710 BEARING GROB 120 G120A 1660208EU AILERON LEVER FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07861AF841 85001 DURING INSPECTION OF AIRCRAFT, FOUND BEARING TO BE FAILING. RETAINING CLIP AND SEAL WERE BEING FORCED OUT OF BEARING. PROBABLE CAUSE IS A DESIGN FLAW IN CONTROL SYSTEM WHICH ALLOWS THE CONTROL ROD DEFLECTION TO EXCEED THE DESIGN LIMIT OF THE BEARING. RECOMMEND A DESIGN CHANGE OR REPLACE BEARING WITH ONE THAT HAS BETTER LIMITS AND LOAD HANDLING CAPABILITIES. 1L71 3O RTA49CE 20030611001242003061100124EU 2003 6 11 2003FA0000543 120030512G2710 BEARING GROB 120 G120A 1660208EU AILERON LEVER FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07864AF802 85004 DURING INSPECTION OF AIRCRAFT, FOUND BEARING TO BE FAILING. RETAINING CLIP AND SEAL WERE BEING FORCED OUT OF BEARING. PROBABLE CAUSE IS A DESIGN FLAW IN THE CONTROL SYSTEM WHICH ALLOWS THE CONTROL ROD DEFLECTION TO EXCEED THE DESIGN LIMIT OF THE BEARING. RECOMMEND A DESIGN CHANGE OR REPLACE BEARING WITH ONE THAT HAS BETTER LIMITS AND LOAD HANDLING CAPABILITIES. 1L71 3O RTA49CE 20030611001252003061100125EU 2003 6 11 2003FA0000544 120030512G2710 BEARING GROB 120 G120A 1660208EU AILERON LEVER FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07864AF802 85004 DURING INSPECTION OF AIRCRAFT, FOUND BEARING TO BE FAILING. RETAINING CLIP AND SEAL WERE BEING FORCED OUT OF BEARING. PROBABLE CAUSE IS A DESIGN FLAW IN THE CONTROL SYSTEM WHICH ALLOWS THE CONTROL ROD DEFLECTION TO EXCEED THE DESIGN LIMIT OF THE BEARING. RECOMMEND A DESIGN CHANGE OR REPLACE BEARING WITH ONE THAT HAS BETTER LIMITS AND LOAD HANDLING CAPABILITIES. 1L71 3O RTA49CE 20030611001262003061100126EU 2003 6 11 2003FA0000545 120030512G2730 BEARING GROB 120 G120A 1660208EU ELEVATOR LEVER FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07863AF902 85003 DURING INSPECTION OF AIRCRAFT, FOUND BEARING TO BE FAILING. RETAINING CLIP AND SEAL WERE BEING FORCED OUT OF BEARING. PROBABLE CAUSE IS A DESIGN FLAW IN THE CONTROL SYSTEM WHICH ALLOWS THE CONTROL ROD DEFLECTION TO EXCEED THE DESIGN LIMIT OF THE BEARING. RECOMMEND A DESIGN CHANGE OR REPLACE BEARING WITH ONE THAT HAS BETTER LIMITS AND LOAD HANDLING CAPABILITIES. 1L71 3O RTA49CE 20030611001282003061100128EU 2003 6 11 2003FA0000546 120030512G2710 BEARING GROB 120 G120A 1660208EU AILERON LEVER FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07862AF897 85002 DURING INSPECTION OF AIRCRAFT, FOUND BEARING TO BE FAILING. RETAINING CLIP AND SEAL WERE BEING FORCED OUT OF BEARING. PROBABLE CAUSE IS A DESIGN FLAW IN THE CONTROL SYSTEM WHICH ALLOWS THE CONTROL ROD DEFLECTION TO EXCEED THE DESIGN LIMIT OF THE BEARING. RECOMMEND A DESIGN CHANGE OR REPLACE BEARING WITH ONE THAT HAS BETTER LIMITS AND LOAD HANDLING CAPABILITIES. 1L71 3O RTA49CE 20030611001292003061100129EU 2003 6 11 2003FA0000547 120030512G2730 BEARING GROB 120 G120A 1660208EU ELEVATOR LEVER FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07862AF897 85002 DURING INSPECTION OF AIRCRAFT, FOUND BEARING TO BE FAILING. RETAINING CLIP AND SEAL WERE BEING FORCED OUT OF BEARING. PROBABLE CAUSE IS A DESIGN FLAW IN THE CONTROL SYSTEM WHICH ALLOWS THE CONTROL ROD DEFLECTION TO EXCEED THE DESIGN LIMIT OF THE BEARING. RECOMMEND A DESIGN CHANGE OR REPLACE BEARING WITH ONE THAT HAS BETTER LIMITS AND LOAD HANDLING CAPABILITIES. 1L71 3O RTA49CE 20030611001302003061100130EU 2003 6 11 2003FA0000548 120030512G2710 BEARING GROB 120 G120A 1660208EU AILERON LEVER FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07867AF459 85007 DURING INSPECTION FO AIRCRAFT, FOUND BEARING TO BE FAILING. RETAINING CLIP AND SEAL WERE BEING FORCED OUT OF BEARING. PROBABLE CAUSE IS A DESIGN FLAW IN THE CONTROL SYSTEM WHICH ALLOWS THE CONTROL ROD DEFLECTION TO EXCEED THE DESIGN LIMIT OF THE BEARING. RECOMMEND A DESIGN CHANGE OR REPLACE BEARING WITH ONE THAT HAS BETTER LIMITS AND LOAD HANDLING CAPABILITIES. 1L71 3O RTA49CE 20030624001032003062400103EU 2003 6 24 2003FA0000549 120030512G2720 BEARING GROB 120 G120A 1660208EU RUDDER FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07864AF802 85004 DURING INSPECTION OF AIRCRAFT, FOUND BEARING TO BE FAILING. RETAIN CLIP AND SEAL WERE BEING FORCED OUT OF BEARING. 1L71 3O RTA49CE 20030624001042003062400104EU 2003 6 24 2003FA0000550 120030512G2720 BEARING GROB 120 G120A 1660208EU RUDDER FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07865AF723 85005 DURING INSPECTION OF AIRCRAFT, FOUND BEARING TO BE FAILING. RETAINING CLIP AND SEAL WERE BEING FORCED OUT OF BEARING. 1L71 3O RTA49CE 20030624001072003062400107EU 2003 6 24 2003FA0000551 120030512G2720 BEARING GROB 120 G120A 1660208EU RUDDER FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07865AF723 85005 DURING INSPECTION OF AIRCRAFT, FOUND BEARING TO BE FAILING. RETAINING CLIP AND SEAL WERE BEING FORCED OUT OF BEARING. PROBABLE CAUSE IS A DESIGN FLAW IN THE CONTROL SYSTEM WHICH ALLOWS THE CONTROL SYSTEM WHICH ALLOWS HE CONTROL ROD DEFLECTION TO EXCEED THE DESIGN LIMIT OF THE BEARING. RECOMMEND A DESIGN CHANGE OR REPLACE BEARING WITH ONE THAT HAS BETTER LIMITS AND LOAD HANDLING CAPABILITIES. 1L71 3O RTA49CE 20030624001082003062400108EU 2003 6 24 2003FA0000552 120030512G2710 BEARING GROB 120 G120A 1660208EU ELEVATOR FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07865AF723 85005 DURING INSPECTION OF AIRCRAFT, FOUND BEARING TO BE FAILING. RETAINING CLIP AND SEAL WERE BEING FORCED OUR OF BEARING. 1L71 3O RTA49CE 20030624001092003062400109EU 2003 6 24 2003FA0000553 120030512G2710 BEARING GROB 120 G120A 1660208EU AILERON FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07867AF459 85007 DURING INSPECTION OF AIRCRAFT, FOUND BEARING TO BE FAILING. RETAINING CLIP AND SEAL WERE BEING FORCED OUT OF BEARING. 1L71 3O RTA49CE 20030624001102003062400110EU 2003 6 24 2003FA0000554 120030512G2710 BEARING GROB 120 G120A 1660208EU AILERON SYS FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07867AF459 85007 DURING INSPECTION OF AIRCRAFT, FOUND BEARING TO BE FAILING. RETAINING CLIP AND SEAL WERE BEING FORCED OUT OF BEARING. 1L71 3O RTA49CE 20030624001132003062400113EU 2003 6 24 2003FA0000555 120030512G2710 BEARING GROB 120 G120A 1660208EU AILERON FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07865AF723 85005 DURING INSPECTION OF AIRCRAFT, FOUND BEARING TO BE FAILING. RETAINING CLIP AND SEAL WERE BEING FORCED OUT OF BEARING. 1L71 3O RTA49CE 20030625000012003062500001EU 2003 6 25 2003FA0000557 120030512G2710 BEARING GROB 120 G120A 1660208EU CONTROL SYSTEM FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07862AF897 85002 DURING INSPECTION OF AIRCRAFT, FOUND BEARING TO BE FAILING. RETAINING CLIP AND SEAL WERE BEING FORCED OUT OF BEARING. 1L71 3O RTA49CE 20030805000012003080500001EU 2003 8 5 2003FA0000558 120030512G2710 BEARING GROB 120 G120A 1660208EU LEVER ASSY FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07863AF902 85003 DURING INSPECTION OF AIRCRAFT, FOUND BEARING TO BE FAILING. RETAINING CLIP AND SEAL WERE BEING FORCED OUT OF BEARING. PROBABLE CAUSE IS A DESIGN FLAW IN THE CONTROL SYSTEM WHICH ALLOWS THE CONTROL ROD DEFLECTION TO EXCEED THE DESIGN LIMIT OF THE BEARING. 1L71 3O RTA49CE 20030625000022003062500002EU 2003 6 25 2003FA0000559 120030512G2710 BEARING GROB 120 G120A 1660208EU CONTROL SYSTEM FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07867AF459 85007 DURING INSPECTION OF AIRCRAFT, FOUND BEARING TO BE FAILING. RETAINING CLIP AND SEAL WERE BEING FORCED OUT OF BEARING. 1L71 3O RTA49CE 20030625000092003062500009SW 2003 6 25 2003FA0000560 120030519G6220406310405101 BEARING BELL 407 407 1182206SW ALLSN 250C 250C47B GL M/R PITCH LINK LOOSE D O OTHER O OTHER NRNOT REPORTED 1 EA1357HK 836 53404 PILOT FOUND UPPER END OF BEARING ASSEMBLY LOOSE ON PRE-FLIGHT. UPON INSPECTION BY MECHANIC FOUND THE RUBBER AROUND UPPER BEARING CRACKED AND BEARING CRACKED AND BEARING HOUSING HAD AXIAL PLAY. 1G71 3U3 UO H2SW E1GL 20030625000102003062500010SW 2003 6 25 2003FA0000561 120030519G8011SM20ACD300A21 RELAY BELL 407 407 1182206SW ALLSN 250C 250C47B GL STARTER FAILED D O OTHER O OTHER NRNOT REPORTED 1 EA1357HK 888 53404 PILOT REPORTED START LIGHT WOULD NOT COME ON AND AIRCRAFT WAS UNABLE TO BE STARTED. TALKED TO PRODUCT SUPPORT AT MFG, STATED SOME 1K1 RELAYS WITHOUT A T STAMPED ON BOTTOM HAD A HIGH FAIL RATE. REPLACED RELAY WITH NEW RELAY STAMPED WITH T. 1G71 3U3 UO H2SW E1GL 20030625000212003062500021 2003 6 25 2003FA0000563 420030516G2562AK450 ELT CABIN FAILED D O OTHER O OTHER NRNOT REPORTED 1 NM08 ELT FAILED FUNCTIONAL TESTS REQUIRED BY FAR 91.207. NEW BATTERIES WERE USED FOR TEST. UNIT PERFORMED OK AT LAST 100 HOUR INSPECTION. NO KNOWN DAMAGE HISTORY. 20030625000232003062500023CE 2003 6 25 2003FA0000564 120030325G212126193873 FAN LEAR 35 31A 5170531CE GARRTTTFE731TFE731* 01518WP CABIN SEIZED D O OTHER O OTHER NRNOT REPORTED 1 GL25 078 CABIN/ CREW FAN PHYSICALLY LOCKED UP CAUSING BURNING ODOR AND SMOKE IN CABIN. CB POPED AND RESET ONCE. IN THE FUTURE CREW/ CABIN FROM CB POPS RECOMMEND NOT RESETTING IN FLIGHT AS THIS IS NOT A REQUIRED FOR FLIGHT ITEM. 2L72 4F4 FRTA10CE E6WE 20030625000292003062500029CE 2003 6 25 2003FA0000565 120030501G531207126161 BULKHEAD CESSNA182 182N 2072730CE CONT O470 O470* 17026SO FUSELAGE CRACKED D O OTHER O OTHER NRNOT REPORTED 1 AL059VP 4246 18260376 TIME SINCE LAST AD REQUIRED INSPECTION 901.8. ORIGINALLY INSPECTED ON 9/19/74 WITH 1246 TT, FOUND OK. REINSPECTED AT 1502 AND 2334.58 TT AND FOUND, OK. ALSO INSPECTED AT 3345.1 AND FOUND AIRWORTHY. CURRENT INSPECTION REVEALED TWO SMALL CRACKS .1250 AND .2500 INCH AT TOP OF RUDDER CABLE CUT-OUT AND FLANGE. FIN SPAR BOLTS WERE TIGHT. DYE PEN INSPECTION OF FIN SPAR ATTACH FITTINGS REVEALED NO OTHER DAMAGE. REPLACED BULKHEAD WITH SERVICEABLE ASSEMBLY. GASSER BANNER TOW HITCH WAS INSTALLED IAW STC SA-220-50 ON 8/14/73 TT 757.0 ON THE AFT BULKHEAD TAIL SKID BOLT. TIME OF REMOVAL IS UNKNOWN. AD 72-07-09. (AL05200300898) 1H71 3O3 ONT3A13 E273 20030625000242003062500024CE 2003 6 25 2003FA0000567 120030528G3210 HOUSING CESSNA172 172RG 2072438CE LYC O360 O360F1A6 41514EA ACTUATOR CRACKED B A UNSCHED LANDING K FLUID LOSS CRCRUISE 1 GL0720SU 7164 4 1485 172RG0323 L2977836A PILOT REPORTED HEARING LOUD POP. LT MLG WAS HANGING OUT OF WHEEL WELL. PUTTING GEAR SELECTOR IN DOWN POSITION, RT MAIN AND NLG EXTEND FULLY. LT WAS STILL HANGING LOOSE. ATTEMPT TO PUMP DOWN LT WITH EMERGENCY PUMP WAS UNSUCCESSFUL. A/C WAS PUT INTO HANGAR AND GEAR INSPECTED. INSP REVEALED LT MAIN GEAR ACT HAD CRACKED THROUGH FWD MOUNTING BOLT HOLE. CRACK CAUSED PINION GEAR TO SEPERATE FROM RACK GEAR. THESE SEEM TO BE CRACKING AFTER COMPLING WITH AD AND MFG SB. ACT, S/N 5349 WAS FOUND CRACKED IN SAME LOCATION. ACT S/N 5384 WAS FOUND CRACKED IN SAME LOCATION. SEEMS NEW BUSHINGS THAT ARE INSTALLED AS PART OF SB MAY BE CAUSING SOME ADDED STRESS TO ACTUATORS. 1H71 3O3 O 3A17 E286 20030611001272003061100127GL 2003 6 11 2003FA0000568 120030527G792110281A OIL COOLER CIRRUSSR SR22 2130001GL CONT O550 IO550N 17042SO ENGINE OIL CRACKED C O OTHER O OTHER NRNOT REPORTED 1 CE033YH 111 0239 686282 OIL COOLER CRACKED AT OUTBOARD FLANGE, AT BAFFLING MOUNT. THIS IS THE TENTH OIL COOLER ON A/C THAT OUR REPAIR STATION HAS SEEN WITH A CRACKED OIL COOLER IN THE EXACT SAME LOCATION. MFG HAS AN OPTIONAL SB22-71-03 BAFFLE MODIFICATION THAT SUGGESTS THAT THE BAFFLE BE MODIFIED TO PREVENT THIS PROBLEM. MY SUGGESTION IS THAT THIS SB BE MANDATORY AND/OR TIED TO AN AD TO PREVENT THE OIL COOLER FROM CRACKING AND CAUSING A POSSIBLE OIL LEAK. 1L71 3O3 ONTA00009CHE3SO 20030624001062003062400106SO 2003 6 24 2003FA0000569 120030525G24977U1055502 WIRE PIPER PA12 PA12 7101202SO LYC O145 O145* 41501EA SNSNCH74D 74DM EA TAIL BRACE BROKEN D A UNSCHED LANDING E VIBRATION/BUFFET CLCLIMB 1 WP09 613 122657 L3564127A LEFT UPPER TAIL BRACE WIRE BROKE ABOUT ONE HALF IT'S LENGTH, DURING CLIMB. 1H71 3O3 O A780 TC199 5 NP88614 20030630000452003063000045EA 2003 6 30 2003FA0000570 220030510G741410682016 DISTRIBUTOR GEARBENDIX D6LN3000 PIPER PA32 PA32RT300T 7103216SO LYC O540 TIO540S1AD 41532EA MAGNETO BROKEN D O OTHER O OTHER NRNOT REPORTED 1 WP17 331 331 J319703GR 32R7987027 L587361A DISTRIBUTOR GEAR ON RIGHT MAGNETO, FAILED. 1L71 3O3 O A3SO E14EA 20030708001102003070800110SO 2003 7 8 2003FA0000572 220030516G7414 DISTRIBUTOR BLK SLICK BEECH 33 F33A 1151425CE CONT O520 IO520BB 17032SO MAGNETO SHORTED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP076311Z496 01120306 CE997 MAGNETO REMOVED FROM ENGINE FOR 500 HOUR INSP IAW THE MM. REMOVED THE REAR COVER OF MAGNETO AND FOUND A CARBON DUSTS POWER ON THE CAP AND AROUND THE COIL. DIST BLOCK K3823 WAS BURNED AWAY AND EVIDENCE OF SHORTING TO THE COIL. PROBABLE CAUSE IS THE MANUFACTURER OF THE DIST BLOCK BEARING. MFG IS AWARE PROBLEM AND HAS CORRECTED. HOWEVER WHAT ABOUT ALL THE MAGNETOS THAT HAVE NOT HAD THE BLOCKS REPLACED OR MADE IT TO THE 500 HOUR INSPECTION. WE RECOMMEND THAT ANYONE WITH SLICK MAGNETOS MFG IN THE YEAR 1999-2001 HAVE THE DIST BLOCKS REPLACED TO PREVENT POSSIBLE FAILURE. 1L71 3O3 O 3A15 E5CE 20030805000062003080500006CE 2003 8 5 2003FA0000573 120030517G3710 MOTOR BEECH 33 F33A 1151425CE VACUUM PUMP INOPERATIVE B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP078101C CE1538 PILOT REPORTED STANDBY INSTRUMENT AIR PRESSURE INOPERATIVE. ON FURTHER INVESTIGATION FOUND STAND BY VACUUM PUMP DRIVE MOTOR FAILED. RECOMMEND OPERATING SYSTEM AT EACH PHASE INSPECTION. 1L71 3O 3A15 20030805000072003080500007SO 2003 8 5 2003FA0000574 120030515G7921F017641 OIL COOLER PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA ENGINE CRACKED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP074144P68 2843121 RL3909136A FOUND OIL LEAK ON PREFLIGHT INSPECTION BY STUDENT PILOT. PRESSURE CHECKED OIL COOLER LEAKING AT SEAM ON TOP. THIS IS A WEAK AREA ON THE OIL COOLER, COULD BE CAUSED BY VIBRATION AND NOT USING A BACK UP WRENCH WHEN INSTALLING OIL COOLER HOSES. RECOMMEND FINDING A REPLACEMENT THAT IS MORE DURABLE. 1L71 3O3 O 2A13 E286 20030707002092003070700209EU 2003 7 7 2003FA0000576 120030520G2121C209690B1 FAN SAAB SF340 SF340A 7850100EU CABIN INOPERATIVE B JGVRO OTHER O OTHER NRNOT REPORTED 1 WP05 FAN RETURNED FOR REPAIR, THE FAN WAS TESTED UPON ARRIVAL AND FAILED TO OPERATE. WHEN FAN WAS DISASSEMBLED, THIS ARMATURE ASSY WAS FOUND TO BE NOT OF MFG DESIGN. THE WINDINGS IN THE STATOR ASSY ARE NOT OF MFG DESIGN, THE MOTOR HOUSING HAS BEEN MODIFIED NOT TO MFG SPECIFICATIONS, THE FAN HOUSING HAS BEEN AND MODIFIED NOT TO MFG SPECS. MFG OVERHAUL MANUAL DOES NOT ALLOW FOR RE-WINDING OF THE STATOR ASSY OR THE MODIFICATIONS OR REPLACEMENT OF PARTS OTHER THAN LISTED. NOTE: REPAIR STATES FAN REPAIRED AND CERTIFIED IAW MFG COMPONENT MM. 2L72 4T RTA52EU 20030707001962003070700196SO 2003 7 7 2003FA0000579 220030416G741410400309 IMPULSE COUPLING BEECH 95 95B55 1152729CE CONT O470 IO470L 17026SO MAGNETO FAILED D O OTHER O OTHER NRNOT REPORTED 1 SO0672TK TC2267 272983R RT ENGINE WOULD NOT DEVELOP FULL POWER. FOUND MAGS TIMED TO 10 DEGREES ATC. REMOVED RT AND LT MAGS, FOUND IMPULSE COUPLER SPRINGS 10-51324 BROKEN ON BOTH MAGS. NO REASON FOUND FOR FAILURE. INSTALLED 2 NEW IMPULSE COUPLERS. 1L72 3O3 ORT3A16 3E1 20030805000152003080500015CE 2003 8 5 2003FA0000580 120030512G801299103971 RELAY CESSNA402 402C 207590RCE CONT O520 TSIO520* 17040SO LT STAB WING FAILED D O OTHER O OTHER NRNOT REPORTED 1 NE022748Y 402C0248 AIRCRAFT LOST ELECTRICAL POWER, AIRCRAFT LANDED WITHOUT INCIDENT. MECHANIC FOUND RT STARTER RELAY FAILED IN ON POSITION. MECHANIC CHANGED THE RELAY, RT STARTER AND AIRCRAFT BATTERY, THEN RETURNED AIRCRAFT TO SERVICE. 1L72 3O3 O A7CE E8CE 20030805000162003080500016 2003 8 5 2003FA0000581 420030506G3457GNS530 GPS CESSNA177 177RG 2073709CE COCKPIT FAILED B RH6RO OTHER O OTHER NRNOT REPORTED 1 NE018248G300 177RG0148 GPS SCREEN WENT TOTALLY BLANK. UNIT STILL RECEIVING AND TRANSMITTING COMMUNICATION DATA. SCREEN FAILED 2-3 MINUTES AFTER POWER UP. REPORTED THAT HIGH VOLTAGE TRANSFORMER FAILED UNDER IFR FLIGHT COULD BE FATAL. 1H71 3O A20CE 20030805000172003080500017CE 2003 8 5 2003FA0000582 120030319G270005131661 CONTROL WHEEL CESSNA182 182E 2072712CE CONT O470 O470* 17026SO COCKPIT FAILED D O OTHER O OTHER NRNOT REPORTED 1 NM022996Y4667 18253996 PILOT SIDE CONTROL WHEEL FAILURE ON LANDING FLAIR. BRAKE ON TOP LT CORNER WHERE THE HAND GRIP MEETS THE MAIN CROSS SPOKE. THE BRAKE IS CLEAN AND SHOWS NO SIGN OF CRACKING BEFORE THE FAILURE OCCURED. 1H71 3O3 ONT3A13 E273 20030805000182003080500018CE 2003 8 5 2003FA0000583 120030505G7931040010629 LINE CESSNA140 140 2071602CE CONT O200 O200* 17020SO OIL PRESS IND CORRODED D O OTHER K FLUID LOSS NRNOT REPORTED 1 NE05730173861 10222 THE OIL INDICATOR LINE WAS WORN COMPLETELY THROUGH. THE CIRCUMSTANCES UNDER WHICH IT OCCURED, WAS DURING FLIGHT. PROBABLE CAUSE: OLD AND CORRODED. RECOMMENDATION TO PREVENT RECURRENCE: CLOSER INSPECTIONS OF ENGINE, AND ENGINE PARTS/ COMPONENTS. 1H71 3O3 ONCA768 E252 20030805000212003080500021CE 2003 8 5 2003FA0000584 120030513G2701S20103 BEARING CESSNA206 U206G 2073356CE YOKE GUIDE WORN D O OTHER O OTHER NRNOT REPORTED 1 NM08729 U20606151 WHILE INSPECTING THE AIRCRAFT, THE PILOTS YOKE TUBE WAS OBSERVED TO HAVE BEEN WORN DUE TO CHAFFING ON THE UNDERSIDE. THE COATING ON THE YOKE GUIDE ROLLER BEARINGS HAD WORN OFF AND THE TUBE HAD WORN ABOUT .3333 OF THICKNESS OF THE TUBE. IN ADDITION TO THE GUIDE BEARINGS THE YOKE TUBE PN 1260142-14 WAS REPLACED. RECOMMEND INSPECTION OF THE BEARINGS TO PREVENT MORE COSTLY PARTS REPLACEMENT. 1H71 3O A4CE 20030805000242003080500024CE 2003 8 5 2003FA0000585 120030510G5520AN414 BOLT CESSNA340 340A 2076405CE ELEVATOR PIVOT BENT B CTURO OTHER O OTHER NRNOT REPORTED 1 GL2198585 340A0046 DURING INSPECTION DISCOVERED ELEVATOR PIVOT BOLT TO BE BENT. REMOVED AND REPLACED BOLT WITH NEW AN4-14. CAUSE COULD BE ATTRIBUTED TO GUST LOCK NOT BEING INSTALLED AND ELEVATOR MOVEMENTS WHILE AIRCRAFT ARE PARKED ON THE RAMP. 1L72 3O 3A25 20030805000282003080500028SO 2003 8 5 2003FA0000586 220030326G7414K3823 DISTRIBUTOR GEAR CESSNA210 P210N 2073454CE CONT O520 TSIO520P 17040SO MAGNETO DAMAGED D O OTHER O OTHER NRNOT REPORTED 1 NE0282DF 450 94100168 P21000276 513403 THIS PRESSURIZED MAGNETO WAS REMOVED AND DISASSEMBLED FOR THE 500 HOUR INSPECTION. ALL OF THE INTERNAL HARDWARE WAS FOUND RUSTED. THE DISTRIBUTOR GEAR, DRIVEGEAR AND DISTRIBUTOR BLOCK WAS FOUND COVERED IN A FILM AND NOTICEABLY SOFTER THAN NEW EXAMPLES. THIS IS A RESULT OF MOISTURE IONIZATION. RECORDS CONFIRM THAT THE MOISTURE FILTER IN THE PRESSURIZATION LINE HAD BEEN REPLACED REGULARLY. AD 88-25-04 ADDRESSES THIS PROBLEM IN EARLIER SERIES MAGNETOS. SHOULD INCLUDE 6300 SERIES PRESSURIZED MAGNETOS. 1H71 3O3 O 3A21 E8CE 20030805000292003080500029SO 2003 8 5 2003FA0000587 220030326G7414K3823 DISTRIBUTOR GEAR CESSNA210 P210N 2073454CE CONT O520 TSIO520P 17040SO MAGNETO FAILED D O OTHER O OTHER NRNOT REPORTED 1 NE0282DF 95030099 P21000276 513403 THIS PRESSURIZED MAGNETO WAS REMOVED AND DISASSEMBLED FOR THE 500 HOUR INSPECTION. ALL THE INTERNAL HARDWARE WAS FOUND RUSTED. THE DISTRIBUTOR GEAR, DRIVE GEAR AND DISTRIBUTOR BLOCK WAS FOUND COVERED IN A FILM AND NOTICEABLY SOFTER THAN NEW EXAMPLES. THIS IS A RESULT OF MOISTURE IONIZATION. RECORDS CONFIRM THAT THE MOISTURE FILTER IN THE PRESSURIZATION LINE HAD BEEN REPLACED REGULARLY AD 88-25-04 ADDRESSES THIS PROBLEM IN EARLIER SERIES MAGNETOS. SHOULD BE AMENDED TO INCLUDE 6300 SERIES, PRESSURIZED MAGNETOS. 1H71 3O3 O 3A21 E8CE 20030805000132003080500013CE 2003 8 5 2003FA0000588 120030603G324613889 BEARING CAGE CESSNA172 172 2072402CE CONT O300 O300* 17022SO MLG WHEEL DETERIORATED D O OTHER O OTHER NRNOT REPORTED 1 WP097145T35 46745 MAIN LANDING GEAR WHEEL BEARING CUPS SHOW SIGNS OF FAILURE BY PITTING. THIS APPLIES TO BOTH INNER AND OUTER CONES ON TWO (2) MAIN LANDING GEAR WHEELS FOR A TOTAL OF FOUR (4) FAILURES. 1H71 3O3 ONT3A12 E253 20030805000122003080500012CE 2003 8 5 2003FA0000589 120030603G324613836 BEARING RACE CESSNA172 172 2072402CE CONT O300 O300* 17022SO MLG WHEEL WORN D O OTHER O OTHER NRNOT REPORTED 1 WP097145T35 46745 MAIN LANDING GEAR WHEEL BEARING CUPS SHOWS SIGNS OF FAILURE BY SCUFFING. THIS APPLIES TO BOTH INNER AND OUTER CUPS ON TWO (2) MAIN LANDING GEAR WHEELS FOR A TOTAL OF FOUR (4) FAILURES. 1H71 3O3 ONT3A12 E253 20030606000012003060600001EU 2003 6 6 2003FA0000590 120030501G5523 WASHER AIMM AIMM AMT200AMT200S EU TRIM ASSY COCKED B O OTHER WF INADEQUATE Q C FLT CONT AFFECTED CRCRUISE 1 NM03147XS62 DURING POST INSPECTION FLIGHT, PILOT WAS UNABLE TO MOVE ELEVATOR CONTROL FULL AFT.ELEVATOR CONTROL APPEARED TO BE PARTIALLY JAMBED. AFTER SEVERAL PULLS FULL MOVEMENT WAS ESTABLISHED AND A SAFE LANDING COMPLETED.MAINTENANCE DISCOVERED A WASHER ON THE TRIM SYSTEM IN FRONT OF TRIM GUIDE PN 55302/3 APPERENTLY JAMMED IN FLIGHT ON BOLT AT FORWARD END OF ROD PN 55301.A FLEET WIDE INSPECTION OF ACADEMY AMT-200S REVEALED THREE BOLTS INSTALLED WITH THE HEADS DOWN AND NINE WITH HEADS UP. THE AIRCRAFT WITH THE HEADS DOWN APPEAR TO CAUSE NO CONFLICT. RECOMMEND CONTACTING XIMANGO USA FOR GUIDANCE ON FIX. 1L71 3I NCTG0004A 20030805000302003080500030 2003 8 5 2003FA0000591 420030506G2561KS9P0101 LIFE VEST CABIN FAILED B O OTHER L NO TEST NRNOT REPORTED 1 EA07 LIFE VEST FAILED, MFG RECOMMENDED CELL PRESSURE TEST IAW 25-60-1. DOM JANUARY 1983 20030805000312003080500031 2003 8 5 2003FA0000592 420030519G2561KS9P0101 LIFE VEST EMERGENCY EQUIP FAILED B KQ1RO OTHER L NO TEST NRNOT REPORTED 1 EA07 LIFE VEST FAILED. MFG RECOMMENDED CELL PRESSURE TEST IAW 25-60-1. DOM: JANUARY 1983 20030805000322003080500032 2003 8 5 2003FA0000593 420030524G2561KS9P0101 LIFE VEST EMERGENCY EQUIP FAILED B KQ1RO OTHER L NO TEST NRNOT REPORTED 1 EA07 LIFE VEST FAILED. MFG RECOMMENDED CELL PRESSURE TEST IAW MANUAL 25-60-1. DOM: MAY 1980 20030805000362003080500036EA 2003 8 5 2003FA0000594 220030523G853005K23038 CYLINDER CESSNA150 152 2071835CE LYC O235 O235N2C 41505EA ENGINE WORN D O OTHER O OTHER NRNOT REPORTED 1 SW1995563137 15285926 RL22756915 WITH 137 HOURS ON THIS ENGINE THE OIL CONSUMPTION WENT UP. ON INSPECTION OF THE ENGINE, OIL WAS FOUND ON NR 1 AND NR 3 CYLINDER SPARK PLUGS. ALL FOUR CYLINDERS WERE REMOVED AND THE OIL CONTROL RINGS WERE FOUND BROKEN ON CYL NR 1 AND NR 3. THE CYLINDER WALLS WERE BADLY WORN AND A WEAR STEP COULD BE FELT AT THE BOTTOM TRAVEL OF THE PISTON. THE WEAR WAS WORSE IN NR 1 AND NR 3 CYLINDER. BUT WAS PRESENT ON ALL FOUR CYLINDERS. THIS IS THE THIRD ENGINE IN FLEET FOUND IN THIS CONDITION IN THE PAST TWO WEEKS. SINCE ALL CYLINDERS WERE MFG IN THE SAME TIME FRAME IT SEEMS THAT IT MIGHT BE A BAD BATCH OF CYLINDERS FROM THE FACTORY. THIS ENGINE WAS REBUILT ON 2/21/03. 1H71 3O3 ONT3A19 E223 20030805000442003080500044EA 2003 8 5 2003FA0000595 220030523G8530O5K23038 CYLINDER CESSNA150 152 2071835CE LYC O235 O235N2C 41505EA ENGINE WORN D O OTHER O OTHER NRNOT REPORTED 1 SW1995564 15285927 L1454115 ENG WAS REMOVED AT 353.2 HRS SMOH AND WAS SENT BACK TO MFG FOR REPAIR DUE TO METAL IN THE OIL. AT 779.5 HRS METAL WAS FOUND IN OIL SYS. WE REPLACED ALL FOUR CYLINDERS AND CONNECTING ROD ASSY. GROUND RUN AND TEST FLIGHT CHECKED GOOD. AT 981.6 HRS TSO AND 202.1 HRS REPLACED CYLINDERS ASSY, OIL CONSUMPTION INCRESSED. WHEN SPARK PLUGS WERE CHECKED, OIL WAS FOUND ON NR 1 AND NR 4 SPARK PLUGS. REMOVED NR 1 CYLINDER AND FOUND OIL CONTROL RING BROKEN AND CYLINDER WALL BADLY WORN AND WEAR STEP COULD BE FELT AT BOTTOM TRAVEL OF PISTON. REMOVED THE NR 4 CYLINDER AND FOUND TO BE WORN BUT NO BROKEN RING. ALL CYLINDERS WERE MFG IN SAME TIME FRAME. IT SEEMS THAT IT MIGHT BE A BAD BATCH OF CYLINDERS FROM FACTORY. 1H71 3O3 ONT3A19 E223 20030805000452003080500045EA 2003 8 5 2003FA0000596 220030523G853005K23038 CYLINDER CESSNA150 152 2071835CE LYC O235 O235N2C 41505EA ENGINE WORN D O OTHER O OTHER NRNOT REPORTED 1 SW19956045237 490 15285935 PROBLEM WITH HIGH OIL TEMP ON TEST FLIGHT. AT 280.3 OIL CONSUMPTION INCREASED AND ENG STARTED RUNNING ROUGH, WHEN CHECKING SPARK PLUGS FOUND OIL ON NR 3 CYL PLUG. REMOVED NR 3 CYLINDER FOUND OIL CONTROL RING BROKEN, METAL IN OIL SYS. ON 12/27/02 REPLACED ALL 4 CYLINDERS AND CONNECTING ROD ASSY. GROUND RUN AND TEST FLIGHT CKD GOOD. AT 490.7 HRS SMOH AND 210.4 HRS SINCE WE REPLACED CYL ASSY, OIL CONSUMPTION INCRESSED. WHEN SPARK PLUGS WERE CHECKED, OIL WAS FOUND ON NR 3 SPARK PLUG. REMOVED NR 3 CYL, FOUND OIL CONTROL RING BROKEN AND CYL WALL BADLY WORN AND WEAR STEP COULD BE FELT AT BOTTOM TRAVEL OF PISTON. REMOVED OTHER CYL AND FOUND THEM ALL TO BE BADLY WORN. ALL CYL WERE MFG IN SAME TIME FRAME. 1H71 3O3 ONT3A19 E223 20030805000462003080500046 2003 8 5 2003FA0000598 420030515G3424 CONNECTOR CESSNA182 T182T CE LYC O540 TIO540* 41532EA IMPROPER B O OTHER O OTHER NRNOT REPORTED 1 EA07529PT 2101299 T18208119 THE CONNECTOR FROM AIRCRAFT HARNESS THAT MATS TO THE TURN COORDINATOR HAS IMPROPERLY CRIMPED PINS. THIS FAULTY CONNECTION CAUSES AUTOPILOT WING ROCKING AND CAN CAUSE UNDESIRABLE ROLL RATES DURING CLIMBS. 1H71 3O3 ONT3A13 E14EA 20030805000482003080500048NM 2003 8 5 2003FA0000599 120030415G2170NAS5213215 SLEEVE ISRAEL1125 1125 NM GARRTTTFE731TFE731* 01518WP WATER SEPARATOR LEAKING D O OTHER O OTHER NRNOT REPORTED 1 WP23255AL2190 32583 0075 CLAMP ATTACHING SLEEVE TO WATER SEPERATOR WORKED LOOSE CAUSING SLEEVE TO LEAK AT 5.0 PSI. CREW NOTED LOSS OF COLD AIR FLOW AND INABILITY TO MAINTAIN CABIN PRESSURE IN FULL COLD. PRESSURIZATION WORKED NORMALLY WITH CABIN TEMPS SETTINGS ABOVE FULL COLD. CLAMP MAY HAVE BEEN STRESSED BY REPEATED OVER LIGHTENING. MFG SPECIFIES 20-25 INCH POUNDS TORQUE. 2L72 4F4 FRTA16NM E6WE 20030805000502003080500050SW 2003 8 5 2003FA0000600 120030102G6320 SCAVENGE PUMP BELL 206 206L3 1182108SW ALLSN 250C 250C30 03013GL GEARBOX INOPERATIVE C A UNSCHED LANDING J WARNING INDICATION NRNOT REPORTED 1 SO093893U5989 51020 DURING BUCKET SLING TRAINING, AIRCRAFT STARTED SMOKING. PILOT PERFORMED PRECAUTIONARY LANDING AND OVERTORQUED AIRCRAFT. MAINTENANCE WAS NOTIFIED AND DISPATCHED TO RETRIEVE AIRCRAFT FROM LOCATION. AIRCRAFT ENGINE WAS INSPECTED AND FOUND THAT THE NR 8 SCAVENGE PUMP WAS NOT FUNCTIONING. GEARBOX WAS REPLACED AND OVERTORQUE INSPECTION WAS PERFORMED. AIRCRAFT WAS THEN RETURNED TO SERVICE. 1G71 3U3 U H2SW E1GL 20030805000512003080500051SW 2003 8 5 2003FA0000601 120030102G243523081018 STARTER GEN BELL 206 206L1 1182107SW ALLSN 250C 250C* GL ENGINE INOPERATIVE B V9MRA UNSCHED LANDING O OTHER NRNOT REPORTED 1 SO0938885502 45726 GENERATOR FAILED PILOT PERFORMED CAUTIONARY LANDING. MECHANIC INSPECTED AND REPLACED AIRCRAFT BATTERY AND STARTER GENERATOR. AIRCRAFT WAS THEN RETURNED TO SERVICE. 1G71 3U3 U H2SW E4CE 20030606000632003060600063EA 2003 6 6 2003FA0000602 220030520G7414 IMPULSE COUPLINGSLICK PIPER PA25 PA25235 7102504SO LYC O540 O540B2B5 41532EA MAGNETO FAILED C O OTHER O OTHER NRNOT REPORTED 1 GL09 442 00120999 FAILURE OF SLICK 6351, S/N 00120999, MAGNETO. INSTALLATION DATE 7/15/01; TIME IN SERVICE SINCE NEW - 442 HRS. INSTALLED ON PIPER PAWNEE PA-25-235 AIRCRAFT; LYC O-540-B2B5 (I BELIEVE). IT WAS 235 HP. MODEL. FAILURE DATE 5/19/03. THE NOTED MAGNETO FAILED DURING OPERATION, RESULTING IN DISTRUCTION OF THE MAGNETO MOUNT SYSTEM, INGESTION OF METAL COMPONENTS INTO THE ENGINE, DEFORMING OF THE MAG DRIVE GEAR SHAFT, MISCELLANEOUS OTHER MECHANICAL DAMAGE, AND THE DISPLACEMENT OF THE MAG, RESULTING IN LOSS OF OIL FROM THE ENGINE. THE MAG. APPARENTLY FAILED JUST PRIOR TO TAKE-OFF (MAG COMPONENTS WERE FOUND ON THE RUNWAY). THE PILOT NOTED THE ROUGH RUNNING OF THE ENGINE AND RETURNED TO THE AIRPORT AFTER A SHORT FLIGHT. 1L71 3O3 O 2A10 E295 20030805000522003080500052SO 2003 8 5 2003FA0000603 120030520G32431035 MASTER CYLINDER MAULE MX7 MX7235 5460180SO LYC O540 IO540* 41532EA PARK BRAKE LEVERINOPERATIVE G O OTHER O OTHER NRNOT REPORTED 1 NM13114MK1175 10022C SPRING AROUND MASTER CYLINDER SHAFT HUNG UP TO BURR AND DID NOT EXTEND TO HOLD THE PARKING BRAKE LEVER DOWN AGAINST TOP OF CYLINDER. PREVENTING APPLICATION OF PARKING BARKE BY NATURAL MOTION OF RUDDER PEDAL IN FLIGHT. BRAKE LOCKED DURING FLIGHT UNKNOWN TO PRIOR. 1H71 3O3 ONC3A23 1E4 20030805000532003080500053WP 2003 8 5 2003FA0000604 120030406G2840A5211 TRANSMITTER ROBSINR22 R22 7640102WP LYC O320 O320* 41508EA LOW FUEL INOPERATIVE D O OTHER O OTHER NRNOT REPORTED 1 SW179071K1798 0194 LOW FUEL WARNING SYSTEM WAS INOPERATIVE: WARNING LIGHT DOES NOT ILLUMINATE WHEN FUEL IS EMPTY. INVESTIGATION REVEALED SYSTEM COMPONENTS OPERATIVE SATISFACTORY, BUT A (BUTT CONNECTOR) REPAIR HAD BEEN MADE ON THE WIRE FROM CIRCUIT BREAKER TO SYSTEM AT AN UNKNOWN DATE BY AN UNKNOWN PERSON; REPAIR WAS NOT CRIMPED PROPERLY AND WIRE INSIDE INSULATION WAS SEVERED, PREVENTING LIGHT FROM ILLUMINATING. CONDITION COULD NOT BE DETECTED DURING PREFLIGHT BECAUSE THIS SN AIRCRAFT DOES NOT HAVE A (PRESS TO TEST) SWITCH FOR THIS SYSTEM, UNLIKE LATER MODELS WHICH DO HAVE THIS TEST SWITCH. IN COMBINATION WITH INACCURATE FUEL IDICATION SYSTEM, THIS IS A DANGEROUS SITUATION. 1G71 3O3 O H10WE E274 20030805000542003080500054WP 2003 8 5 2003FA0000605 120030406G2840624600473 INDICATOR ROBSINR22 R22 7640102WP LYC O320 O320* 41508EA FUEL SYSTEM INACCURATE D O OTHER O OTHER NRNOT REPORTED 1 SW179071K1798 0194 FUEL INDICATION SYSTEM INACCURATE: GAUGE READS .1875 FULL WHEN TANK IS EMPTY. REPLACED TRANSMITTER WITH OVERHAULED UNIT AND PROBLEM REMAINED THE SAME. ACCURACY OF SYSTEM SHOULD BE VERIFIED AT EACH ANNUAL OR 100 HOUR INSPECTION. 1G71 3O3 O H10WE E274 20030805000552003080500055CE 2003 8 5 2003FA0000606 120030428G272107612101 SPROCKET CESSNA206 T206H 2073303CE LYC O540 TIO540* 41532EA TRIM WHEEL WORN B YGJRO OTHER O OTHER NRNOT REPORTED 1 GL174218U788 T20608035 RUDDER TRIM SYST DID NOT SEEM TO BE RESPONDING TO INDICATED TRIM INPUT. INSP OF RUDDER TRIM SYS, IT WAS DISCOVERED THAT TRIM WHEEL SPROCKETS, PN 07612101 WERE NOT SHIMMED CORRECTLY TO ALLOW FOR PROPER ENGAGEMENT OF GEAR TEETH. TWO SPROCKETS ENGAGE AT 90 DEGREES TO EACH OTHER AND WERE BARELY MAKING CONTACT. AS INCREASING TRIM LOAD WAS APPLIED SPROCKETS WOULD SLIP INDUCING AN UNKNOWN ERROR INTO TRIM INDICATOR. SLIPPAGE HAD CAUSED NOTCHES TO WEAR SPROCKET TEETH ALLOWING ADDITIONAL SLIPPAGE TO OCCUR WHEN DECREASINGLY LESS TRIM INPUT FORCES WERE APPLIED. TRIM SYSTEM WAS NOT PROPERLY SHIMMED DURING MFG. PN 0761210-1 SPROCKETS WERE REPLACED AND SHIMMED FOR PROPER ENGAGEMENT. 1H71 3O3 ORTA4CE E14EA 20030708000462003070800046CE 2003 7 8 2003FA0000607 120030421G550017320345 ARM CESSNA177 177 2073704CE LYC O320 O320* 41508EA GUST LOCK INOPERATIVE D O OTHER O OTHER NRNOT REPORTED 1 EA172895X 17700295 WITH GUST LOCK INSTALLED BALANCE ARM LOCKED ON DOWN STOP WHILE A/C WAS TIED DOWN IN GUSTY WIND CONDITIONS. 1H71 3O3 ONTA13CE E274 20030826000942003082600094CE 2003 8 26 2003FA0000608 120030601G2720 CONTROL CABLE CESSNA182 R182 2072734CE LYC O540 O540* 41532EA RUDDER LOOSE D O OTHER F FLT CONT AFFECTED UKUNKNOWN 1 NE01228HP R18201643 WHEN RUDDER IS DEFLECTED TO THE FAR RIGHT, THE RIGHT RUDDER CABLE GOES SLACK AND HANGS UP UNDER THE NUT FOR THE ELEVATOR PULLEY CLUSTER LOCATED BY THE FUSELAGE RIGHT SIDE ACCESS PANEL. TO PREVENT THIS, INSTALLED A SECOND NUT ON THE BOLT AND INSTALLED AN AN4-15 BOLT INTO THE OTHER END OF THE SECOND NUT. THIS WAS ASSEMBLED AND TORQUED USING LOCKTITE. 1H71 3O3 ORT3A13 E295 20030826000962003082600096CE 2003 8 26 2003FA0000609 120030523G32464087A WHEEL BEECH 58 58 1152740CE CONT O520 IO520* 17032SO NLG SEPARATED B CTURK NONE O OTHER TXTAXI/GRND HDL 1 GL2158LF TH237 WHILE AIRCRAFT OWNER WAS TAXING AIRCRAFT, NOSE WHEEL BEAD SEAT AREA SEPARATED. PROBABLE CAUSE COULD BE ATTRIBUTED TO A PREVIOUS HARD LANDING OR A DEFECT IN THE PART AT TIME OF MFG. TO PREVENT FUTURE OCCURANCES AT TIRE REPLACEMENT MORE DILLIGENT INSPECTION OF THE BEAD SEAT AREA. 1L72 3O3 O 3A16 E5CE 20030805000472003080500047CE 2003 8 5 2003FA0000610 120030605G1430S26061 MOUNT CESSNA172 172S 2072439CE WIRE HARNESS DEBONDED D K NONE O OTHER ININSP/MAINT 1 NM03567JW1752 172S8187 ON THE NEW C-172 R AND S AIRCRAFT, THE WIRING UNDER THE CABIN FLOOR IS ATTACHED WITH TIE WRAPS TO ADHESIVE BACKED NYLON MOUNTS P/N S2606-1, THAT ARE ADHEARED TO THE AIRCRAFT SKIN. DURING PHASE 3 INSPECTION ON THIS AIRCRAFT WITH 1752.3 HOURS, FOUR MOUNTS WERE UNATTACHED, THE ADHESIVE DEBONDED ALLOWING THE WIRING TO BE UNSECURE. AT STATION 65.33 THE REAR SEAT INTERCOMM WIRES WERE CHAFING ON THE TRIM CABLES. THE UNSECURED NYLON MOUNTS WERE REPLACED WITH ADEL CLAMPS SECURED WITH SCREWS AND NUTS. NYLON ADHESIVE BACKED MOUNTS SHOULD NEVER HAVE BEEN CERTIFIED TO SECURE AIRCRAFT WIRING WITHOUT THE USE OF ATTACH SCREWS. ON OTHER AIRCRAFT, FINDING THE S2606-1 MOUNTS DEBONDING FROM THE AIRCRAFT SKIN. 1H71 3O NT3A12 20030805000492003080500049SO 2003 8 5 2003FA0000611 120030605G271062701123 CONTROL CABLE PIPER PA28 PA28R201 7102816SO AILERON FRAYED B K NONE O OTHER ININSP/MAINT 1 SO15772FT2048 95 2844029 BROKEN STRANDS ON LEFT BALANCE CABLE WAS FOUND DURING NORMAL MAINTENANCE. CABLE HAS BROKEN STRANDS AT POINT WHERE CABLE WAS INBOARD PULLEY AT WING ROOT. PULLEYS SHOW NO SIGN OF WEAR AND TURN FREELY. THE TOTAL TIME ON THESE CABLES WERE FROM 1049 TO 2058. PROBABLE CAUSE BAD CABLES. 1L71 3O 2A13 20030826001052003082600105CE 2003 8 26 2003FA0000612 120030521G214070121 MUFFLER BEECH 36 A36 1151604CE CONT O550 IO550* SO HEATER BULGED B CGORK NONE O OTHER ININSP/MAINT 1 GL0348GE 597 E3215 HEATER MUFFLER ASSY FAILED 500 HR PRESSURE TEST PERFORMED IAW MM. UPON DISASSEMBLY, FOUND LARGE BULGES IN EXTERIOR OF MAIN BARREL OF MUFFLER, TOWARDS ONE END. FAILURE MODE UNDETERMINED, POSSIBLY CAUSED BY OVERHEATING. RECOMMEND THAT PERSONS INSPECTING SERIES AIRCRAFT ADHERE TO MFG AIRCRAFTS RECOMMENDED DETAILED INSPECTION SCHEDULE IN ORDER TO REMOVE FAILING UNITS BEFORE POSSIBLY CAUSING CARBON MONOXIDE IN CABIN OR ENGINE COMPARTMENT FIRES. 1L71 3O3 O 3A15 E3SO 20030826001132003082600113EA 2003 8 26 2003FA0000613 220030506G7322 THROTTLE PLATE CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA CARBURETOR WORN D K NONE K FLUID LOSS NRNOT REPORTED 1 GL17738YH CK34866 17270338 L514276 CARBURETOR WAS LEAKING FROM ACCELERATOR PUMP SHAFT SEAL. IN ADDITION TO PUMP SHAFT SEAL, UNIT WAS INSPECTED AND WAS ALSO NOTED THAT THROTTLE SHAFT AND BUSHINGS WERE WORN BEYOND LIMITS. INSTALLED THIS CARBURETOR BACK IN OUR CUSTOMERS PLANE, TEST FLEW WITH NO PROBLEMS. JUST A COUPLE OF WEEKS LATER, CUSTOMER WAS MAKING APPROACH. HAD PULLED THROTTLE BACK TO IDLE A LITTLE EARLY AND DECIDED TO PUSH THROTTLE CABLE FROM THROTTLE ARM TO SEE IF PROBLEM COULD BE IN THE CABLE. IT WAS NOT, ARM ON CARBURETOR WOULD NOT MOVE. THROTTLE PLATE MAY HAVE COME LOOSE AND CAUSE A BINDING SITUATION. ONE SCREW ON PLATE WAS SLIGHTLY LOOSE, BUT EVEN WITH PLATE REMOVED THERE WAS BINDING. SENT CARBURETOR BACK FOR REWORK. 1H71 3O3 ONT3A12 E274 20030826001142003082600114CE 2003 8 26 2003FA0000614 120030317G57309914218 ACCESS PANEL CESSNA525 525 2076601CE WING TANK LEAKING B FCPRK NONE K FLUID LOSS ININSP/MAINT 1 NM09177RE2509 5250030 FUEL BAY ACCESS PANELS CAUSE A FUEL LEAK WHEN INSTALLED AS SPARES REPLACEMENT. AT ALL FASTENER HOLES ON EACH DOUBLER THERE IS PROTRUSION CAUSED BY THE OLD PANELS DESIGNED WITH A MILLED AREA ON BACK SIDE OF COUNTER SUNK FASTENER HOLES. WHEN ORIGINAL PANEL SCREWS ARE TIGHTENED IN ANCHOR NUTS HAVE PULLED DOUBLER MATERIAL INTO THE MILLED AREA OF ACCESS PANELS LEAVING DIMPLE LIKE PROTRUSION UP TO DEPTH OF THE MILLED AREA. BUT WHEN YOU HAVE TO INSTALL NEW ACCESS PANELS NOT HAVING A MILLED AREA BECAUSE THE OLDER ONES ARE NO LONGER AVAILABLE YOU END UP WITH A FUEL LEAK DUE TO THE PROTRUSION HOLDING THE NEW FLAT PANELS AWAY FROM THE FLAT SURFACE OF THE DOUBLER. 1L72 4F RTA1WI 20030707001412003070700141EU 2003 7 7 2003FA0000615 120030429G5320MY2023723 STRIP AMD FALC20FALCON20C5 2730107EU GARRTTTFE731TFE731* 01518WP CENTER WING MISALIGNED B JGVRO OTHER O OTHER NRNOT REPORTED 1 CE0920UA 11348 91 NOTICED FUEL LEAKING FROM LT SIDE OF CENTER WING AREA. DETERMINED ORIGIN OF LEAKAGE TO BE TWO OF THE BOLTS THAT SECURE REMOVABLE CENTER PLANK. WHILE REMOVING SEALANT FROM HEAD OF BOLT 19, FROM LT SIDE, ALONG FRONT ROW OF PLANK FASTENERS, FOUND THAT BOLT WAS NOT PROPERLY SECURED, WOULD NOT TIGHTEN AT ALL. REMOVED BOLT 19 FROM CENTER PLANK. BORESCOPE INSPECTION REVEALED THE NUTPLATE GANG STRIP WAS OUT OF POSITION. FOUND ADJACENT BOLT 18, WAS NOT SECURED TO NUTPLATE GANG STRIP EITHER. GANG STRIP SHIFTED DURING PLANK REINSTALLATION. THESE TWO BOLTS ARE ONLY FASTENERS AFFECTED BY IMPROPER POSITION OF THIS GANG STRIP. BOLTS APPEAR TO HAVE BEEN INSTALLED WITH SEALANT ON SHANK AND OVER THE HEAD AS INSTRUCTED. 2L72 4F4 FRTA7EU E6WE 20030826001772003082600177SO 2003 8 26 2003FA0000616 120030430G3340MP1600 CIRCUIT BREAKER PIPER PA38 PA38112 7103812SO LYC O235 O235* 41505EA ANTI COLL LIGHT DEFECTIVE B YJ5RO OTHER O OTHER NRNOT REPORTED 1 NM054267E6500 3878A0515 CHANGED 2 CIRCUIT BREAKERS. PN 454707 HIGH VOLTAGE DROP AND WOULD NOT TRIP AT 200 PERCENT RATING. PN 454706 HIGH VOLTAGE DROP AND TERMINALS WERE HOT ENOUGH TO BLISTER A FINGER AFTER 5 MINUTES OF OPERATION. 1L71 3O3 O A18SO E223 20030708000622003070800062SO 2003 7 8 2003FA0000617 120030318G32307954312 BOLT PIPER PA28 PA28180 7102808SO TORQUE LINK BROKEN D O OTHER O OTHER NRNOT REPORTED 1 AL0544681 287405274 CENTER TORQUE LOCK BOLT BROKE ON TAKE OFF WHICH CAUSED THE LANDING GEAR TO FALL OFF AIRCRAFT. THE BOLT WAS AN OLD STYLE BOLT THAT IS STEPPED DOWN AT THE THREADS TO .5000. A FIX WOULD BE TO HAVE THE NEW STYLE HEAVY DUTY BOLT WHICH IS .7500 INSTALLED IN THE TORQUE LINK. 1L71 3O 2A13 20030707000742003070700074NM 2003 7 7 2003FA0000618 120030610G571213017R RIB UNIVAR415 415C 0420302NM CONT C85 C8512F 17008SO WING CORRODED D K NONE O OTHER ININSP/MAINT 1 GL15147VX 3832 AD 2002-26-02 ADMENDMENT 39-12987, MFG SERVICE BULLETIN NR 31. METHOD 1, INSPECTION HOLES IN WING CENTER SECTION. INSPECTED FRONT AND REAR SPARS...NO EVIDENCE OF CORROSION. DISCOVERED CORRODED RIB, RIGHT SIDE TRAILING EDGE WING WALK BOX. REMOVED AND REPLACED RIB WITH NEW MANUFACTURED. CLEANED LIGHT CORROSION FROM TRAILING EDGE WING WALK OUTER SKINS, TREATED AREA WITH ZINC CHROMATE. TREATED WING CENTER SECTION WITH CORROSION INHIBITOR. 1L71 3O3 O A718 E233 20030826001112003082600111 2003 8 26 2003FA0000619 420030610G2562BS2190 BATTERY ELT LEAKING G K NONE O OTHER ININSP/MAINT 1 AL01 TWO CELLS LEAKED. DESTROYED PRINTED CIRCUIT BOARD IN ELT. DISCOVERED DURING BIENNIAL REPLACEMENT. 20030826001102003082600110NM 2003 8 26 2003FA0000620 120030610G571213017R RIB UNIVAR415 415C 0420302NM WING CORRODED D K NONE O OTHER ININSP/MAINT 1 SW09 3832 AD NO. 2001-CE-45-4D WING CENTER SECTION INSPECTION FOR CORROSION. SERVICE BULLETIN NO.31 USED METHOD 1, INSPECTION HOLES IN WING WALK. INSPECTED FRONT AND REAR SPARS. NO EVIDENCE OF CORROSION. FOUND CORRODED WING WALK TRAILING EDGE RIB, RIGHT SIDE. REMOVED AND REPLACED THIS RIB WITH NEW MANUFACTURED PART. CLEANED LIGHT CORROSION FROM TRAILING EDGE WINGWALK OUTER SKINS, TREATED AREA WITH ZINC CHROMATE. TREATED WING CENTER SECTION WITH CORROSION INHIBITOR. 1L71 3O A718 20030826001072003082600107SO 2003 8 26 2003FA0000621 220030609G8530AEC631397STA CYLINDER BEECH 36 A36 1151604CE CONT O550 IO550B SO ENGINE CRACKED D K NONE O OTHER NRNOT REPORTED 1 CE077252T79 E2261 6/1/02 SIX NEW ECI CYLINDER ASSY AEC631397STA INSTALLED. 11/15/02 NR 4 CYL CRACKED AFTER 171 HOURS OF SERVICE AND DAMAGED NR 2 CYL, BOTH OF WHICH WERE REPLACED. 2/20/03 NR 2 CYL CRACKED AFTER 79 HOURS OF SERVICE. 4/4/03 NR 4 CYL CRACKED AFTER 99 HOURS OF SERVICE. 6/5/03 FOUND NR 2 PISTON RING LAND AREA CRACKED AND DAMAGED SKIRT, CLOSER EXAMINATION REVEALED THE PISTON HAD NOT RECEIVED SOME MACHINING OPERATIONS AND THE SKIRT HAD CONTACTED THE CONNECTING ROD OF AN ADJACENT CYLINDER. 1L71 3O3 O 3A15 E3SO 20030827000342003082700034GL 2003 8 27 2003FA0000622 120030309G32333435640101 ACTUATOR AMTR GAIR GLASAIRIII 05691HKGL LYC O540 IO540* 41532EA NLG SEPARATED G O OTHER O OTHER NRNOT REPORTED 1 WP07307SH1044 3061 ACTUATOR PISTON SEPARATED AT THE ROD END BEARING THREADED AREA. MFG SB NR 109 DATED 1-1092 RECOMMENDED INSTALLATION OF A THREADED REINFORCEMENT BARREL (PN 523-5627-001) BE INSTALLED TO REPLACE TO ORIGINAL BEARING JAM NUT. THIS SB HAD BEEN INSTALLED AT THE TIME OF THIS INCIDENT. 1L71 3O3 ORTEXPA1L711E4 20030827000672003082700067CE 2003 8 27 2003FA0000623 120030529G273112600744 ACTUATOR CESSNA414 414A 2075907CE ELEVATOR TRIM FAILED B CWNRK NONE O OTHER ININSP/MAINT 1 WP09XEEBC 414A0009 NEWLY OVERHAUL ELEVATOR TRIM ACTUATOR LITERALLY FELL APART AFTER INSTALL DURING TRIM OP`S CHECKS. GROOVE PIN PN .0937 X .325 TYPE 3 FELL OUT OF ROLL CHAIN SPROCKET PN 0310332. GROOVE PIN HOLES WORN IN SPROCKET AND ACTUATOR CAUSING FAILURE. SUSPECT FAULTY OVERHAUL PROCEDURES. 1L72 3O A7CE 20030902000402003090200040SO 2003 9 2 2003FA0000625 220030506G8530655469A7 PISTON CONT O520 IO520* 17032SO CYLINDER IMPROPER PART B BSYRO OTHER O OTHER NRNOT REPORTED 1 GL07 EACH CYLINDER KIT CONTAINS PISTON (PN 654850) ON PISTON BOX IS CORRECT. THE ACTUAL PISTON IN BOX IS (PN 654840), WHICH IS LOW COMPRESSION PISTON FOR TSIO520 SERIES. 3 O E5CE 20030826001762003082600176GL 2003 8 26 2003FA0000626 220030509G725023055438 NOZZLE ALLSN 250C 250C30S 03013GL ENGINE CRACKED B YKERK NONE O OTHER ININSP/MAINT 1 EA17 613 CAT90072 CAE890607S RECEIVED THE ENGINE FOR REPAIR DUE TO HIGH OIL TEMPERATURE. DURING INSPECTION OF THE PARTS FOUND THE WELD ON 1 OF THE 5 TURBINE NOZZLE DIAPHRAGM RETAINING KEYS WAS CRACKED THROUGH THE CNETER FOR ALMOST ITS ENTIRE LENGTH. 3 U E1GL 20030827000582003082700058CE 2003 8 27 2003FA0000627 120030616G5511 SPAR CESSNA172 172P 2072436CE HORIZ STAB CRACKED B K NONE O OTHER ININSP/MAINT 1 GL07522502300 17274460 FOUND HORIZIONAL STABILIZER SPAR CRACKED AROUND CENTER LIGHTING HOLE 1H71 3O NT3A12 20030617002282003061700228NM 2003 6 17 2003FA0000628 120030501G5270 ANNUNCIATOR ISRAEL1125 1125 NM GARRTTTFE731TFE7313 01518WP CABIN DOOR FALSE INDICATIONC A UNSCHED LANDING N FALSE WARNING CLCLIMB 1 SO14455SH4902 9612729 MAIN CABIN DOOR OPENED ON CLIMB OUT. INSIDE DOOR LEVER HAD NOT BEEN PLACED IN SECONDARY LATCH. THE ANNUNCIATOR PANEL LIGHT HAD EXTINGUISHED INDICATING DOOR WAS SECURE. GULFSTREAM AEROSPACE HAS DETERMINED THAT ANNUNCIATOR LIGHT MAY BE EXTINGUISHED WHILE DOOR LEVER HAS NOT BEEN PLACED IN SECONDARY LATCH. 2L72 4F4 FRTA16NM E6WE 20030827000282003082700028SO 2003 8 27 2003FA0000629 220030606G8530SA631475 PISTON CONT O520 IO520F 17032SO ENGINE BROKEN B O3ORO OTHER O OTHER NRNOT REPORTED 1 AL03 1490 818805R DISMANTELD ENGINE DUE TO METAL CONTAMINATION. FOUND NR 2 PISTON SKIRT ON BOTTOM SIDE BROKEN. 3 O E5CE 20030827000292003082700029SO 2003 8 27 2003FA0000630 220030530G8530SA631475 PISTON CONT O520 IO520D 17032SO ENGINE BROKEN B O3ORO OTHER O OTHER NRNOT REPORTED 1 AL03 1594579D DISMANTLED ENGINE DUE TO METAL CONTAMINATION FOUND NR 2 PISTON SKIRT BROKEN ON BOTTOM SIDE. 3 O E5CE 20030708000272003070800027CE 2003 7 8 2003FA0000631 120030528G37101H525 CHECK VALVE CESSNA182 182S 2072701CE LYC O540 IO540* 41532EA VACCUM PUMP LOOSE B SL5RO OTHER O OTHER NRNOT REPORTED 1 NE03157RD411 18280646 PILOT REPORTED RIGHT VACUUM PUMP WARNING LIGHT WAS ON. DURING TROUBLESHOOTING, DISCONNECTED HOSE FROM RIGHT SIDE OF CHECK VALVE MANIFOLD TO CONNECT TEST KIT AND DISCOVERED TWO MISSING RIVETS, TWO RIVETS ABOUT TO FALL OUT AND TWO LOOSE RIVETS ALL ON THE RIGHT SIDE OF CHECK VALVE ALLOWING VACUUM AIR TO LEK OUT BETWEEN, THE VALVE DIAPHRAM. PROBABLE CAUSE IS VIBRATION FROM ENGINE , ACTING ON HOSE CONNECTED THIS END, CANNOT SEE AT THIS TIME, ANY OTHER ROUTING OF HOSE. 1H71 3O3 ONT3A13 1E4 20030708000292003070800029EA 2003 7 8 2003FA0000633 220030529G73226390217 CONTROL CABLE PIPER PA28 PA28180 7102808SO LYC O360 O360A4A 41514EA CARBURETOR BROKEN D O OTHER O OTHER NRNOT REPORTED 1 SO011599R 283845 1045536A CONTROL CABLE BROKE, ONE INCH FROM CARBURETOR IN FLIGHT. CARBURETOR WENT TO IDLE CUT-OFF. 1L71 3O3 O 2A13 E286 20030828000012003082800001SO 2003 8 28 2003FA0000638 120030611G281012J3648A COUPLING GULSTMG1159 GIV 3980115SO LT WING MISMANUFACTURED C O OTHER K FLUID LOSS TXTAXI/GRND HDL 1 NM09941AM66 1499 LEFT WING NACA VENT PORTING FUEL ONTO GROUND AND DURING CLIMB WHEN OVER 11000 LB OF FUEL PUT INTO WING. EVENTUALLY FOUND MISSING O-RING P/N MS29513-337 IN OUTBOARD VENT COUPLING P/N 12J36-48A. THIS WAS REPLACED BY MFG TECHNICIANS AT OPERATOR'S FACILITY. FUNCTIONALLY CHECKED WITH WING FULLY LOADED WITH FUEL. IT WAS OBVIOUS THAT THIS WAS CAUSED BY THE AIRFRAME MANUFACTURER AND WAS NOT PROPERLY TESTED. 2L72 4F RTA12EA 20030827000682003082700068EA 2003 8 27 2003FA0000639 220030618G732225765362 FUEL CONTROL CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA ENGINE OUT OF ADJUST B D RETURN TO BLOCK E VIBRATION/BUFFET TXTAXI/GRND HDL 1 SO15405ER 172S9155 L3044751A DURING A PRE TAKEOFF ENGINE CHECK, THE ENGINE WAS IDLING AT APPROXIMATELY 1000 RPM, AND WAS ROUGH. THE FUEL CONTROL WAS ADJUSTED... 1H71 3O3 ONT3A12 1E10 20030827000692003082700069EA 2003 8 27 2003FA0000640 220030525G732225765362 FUEL CONTROL CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA ENGINE OUT OF ADJUST B D RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TXTAXI/GRND HDL 1 SO15418ER 172S8650 L2731951A DURING A PRETAKEOFF IDLE CHECK, THE IDLE WAS FOUND TOO LOW AND ROUGH. THE FUEL CONTROL WAS ADJUSTD AND THE IDLE SPEED AND MIXURE CONFIRMED CORRECT.. 1H71 3O3 ONT3A12 1E10 20030827000702003082700070EA 2003 8 27 2003FA0000641 220030618G732225765362 FUEL CONTROL CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA ENGINE OUT OF ADJUST B K NONE R PARTIAL RPM/PWR LOSS ININSP/MAINT 1 SO15412ER 172S8643 L2819151A DURING A RUNUP FOR A MAINTENANCE CHECK, THE IDLE RPM AS FOUND VERY LOW. IT WAS ADJUSTED AND CHECKED. THIS IS A PROBLEM WITH THIS FUEL CONTROL ENGINE COMBINATION THAT OCCURS REGULARLY. 1H71 3O3 ONT3A12 1E10 20030827000742003082700074CE 2003 8 27 2003FA0000642 120030616G5511 SPAR CESSNA172 172P 2072436CE HORIZ STAB CRACKED C K NONE O OTHER ININSP/MAINT 1 GL07100SU14628 17275001 FOUND HORIZONTAL STABILIZER SPAR CRACKED AROUND CENTER LIGHTING HOLE. 1H71 3O NT3A12 20030828000042003082800004SO 2003 8 28 2003FA0000644 120030618G612083930700 ROD END PIPER PA28 PA28R201 7102816SO LYC O360 IO360C1C6 41514EA PROP GOVERNOR WORN B O OTHER R PARTIAL RPM/PWR LOSS TOTAKEOFF 1 SO15708ER1079 2844067 L3023651A DURING THE FLIGHT, ON TAKEOFF, THE ENGINE RPM WAS NOT CONSISTENT. INSPECTION OF THE PROPELLER GOVERNOR CABLE ROD END, REVEALED EXCESSIVE WEAR AT THE CONNECTION BETWEEN THE SPHERICAL BALL AND THE SOCKET IT SNAPS INTO. 1L71 3O3 O 2A13 1E10 20030827000652003082700065EA 2003 8 27 2003FA0000645 220030514G732225765362 FUEL CONTROL CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA ENGINE ERRATIC B D RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TXTAXI/GRND HDL 1 SO15439ER 172S8935 L2996851A DURING THE PRE TAKEOFF IDLE CHECK, THE IDLE RPM WAS FOUND VERY LOW. IT WAS ADJUSTED. THE IDLE MIXTURE/SPEED, ON THIS SERVO, IS VERY ERRATIC AND UNSTABLE WITHIN A VERY FEW NUMBER OF HOURS/DAYS. 1H71 3O3 ONT3A12 1E10 20030827000632003082700063EA 2003 8 27 2003FA0000646 220030516G732225765362 FUEL CONTROL CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA ENGINE ERRATIC C D RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TXTAXI/GRND HDL 1 SO15501ER 172S8947 L2996051A DURING THE PRE TAKEOFF IDLE CHECK, THE IDLE RPM WAS FOUND VERY LOW. IT WAS ADJUSTED. THE IDLE MIXTURE/SPEED, ON THIS SERVO, IS VERY ERRATIC AND UNSTABLE WITHIN A VERY FEW NUMBER OF HOURS/DAYS. 1H71 3O3 ONT3A12 1E10 20030827000642003082700064EA 2003 8 27 2003FA0000647 220030519G732225765362 FUEL CONTROL CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA ENGINE ERRATIC B D RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TXTAXI/GRND HDL 1 SO15498ER 17280674 DURING THE PRE TAKEOFF IDLE CHECK, THE IDLE RPM WAS FOUND VERY LOW. IT WAS ADJUSTED. THE IDLE MIXTURE/SPEED, ON THIS SERVO, IS VERY ERRATIC AND UNSTABLE WITHIN A VERY FEW NUMBER OF HOURS/DAYS. 1H71 3O3 ONT3A12 1E10 20030902000372003090200037WP 2003 9 2 2003FA0000648 220030613G720031030351 BEARING ALIDSG GRUMANSA16 G64 EA GARRTTTPE331TPE3312201A WP TORQUE SENSOR DISINTEGRATED G A UNSCHED LANDING XJ ENGINE FLAMEOUT WARNING INDICATION LDLANDING 1 NM093629E687 2R2957 744B P26058 ENGINE SHUT DOWN IN FLIGHT, AIRCRAFT LANDED IN A FIELD SUFFERED SUBSTANTIAL DAMAGE. AN ENGINE TEARDOWN WAS CONDUCTED, THE TORQUE SENSOR GEAR BEARING HAD FAILED, THE BEARING HAD COME APART BITS AND PIECES OF THE CAGE AND BALLS WERE FOUND IN THE BOTTOM OF THE GEAR BOX. VERY LITTLE EVIDENCE OF HEAT, OUTER RACES WERE STILL SHINY. 2H72 4R4 T EXPA2H72E3WE 20030902000362003090200036NM 2003 9 2 2003FA0000649 120030501G5270 ANNUNCIATOR ISRAEL ISRAEL1125 1125 NM GARRTTTFE731TFE7313 01518WP DOOR LATCH FALSE INDICATIONC A UNSCHED LANDING N FALSE WARNING CLCLIMB 1 SO14 4902 017 9612729 MAIN CABIN DOOR OPENED ON CLIMB OUT. INSIDE DOOR LEVER HAD NOT BEEN PLACED IN SECONDARY LATCH. THE ANNUNCIATOR PANEL LIGHT HAD EXTINGUISHED INDICATING DOOR WAS SECURE. MFG HAS DETERMINED THAT ANNUNCIATOR LIGHT MAY BE EXTINGUISHED WHILE DOOR LEVER HAS NOT BEEN PLACED IN SECONDARY LATCH. 2L72 4F4 FRTA16NM E6WE 20030902000482003090200048SW 2003 9 2 2003FA0000650 120030530G325035021505 VALVE SWRNGNSA227 SA227AC 8780603SW NLG STEERING FAILED D C ABORTED TAKEOFF O OTHER TOTAKEOFF 1 GL03387PH AC531 DURING THE TAKEOFF ROLL, WHILE INDICATING 40 KIAS, THE PILOT DISARMED THE NOSEWHEEL STEERING IAW THE AFM. UPON APPROACHING 95 KIAS THE AIRCRAFT BEGAN TO STEER LEFT. THE PILOT PUT IN RIGHT RUDDER AND RIGHT BRAKE WITH NO EFFECT. THE TAKE OFF WAS ABORTED BUT THE AIRCRAFT CONTINUED LEFT DEPARTING THE RUNWAY AND CONTINUING TO TURN LEFT UNTIL IT CAME TO A STOP. UPON INVESTIGATION IT WAS DISCOVERED THAT THE ARMING VALVE HAD ALLOWED HYDRAULIC PRESSURE TO ENTER THE STEERING MANIFOLD AND PASS THROUGH THE SERVO VALVE TO THE LEFT CYLINDER OF THE ACTUATOR. 2L72 4T RTA8SW 20030902000512003090200051SO 2003 9 2 2003FA0000651 120030522G271062701143 CONTROL CABLE PIPER PA44 PA44180 7104402SO LYC O360 O360* 41514EA AILERONS BROKEN B ECQRO OTHER O OTHER NRNOT REPORTED 1 SO15880FT2256 4496033 BOTH LT AND RT FORWARD AILERON CABLES HAVE BROKEN WIRES. AT SPOT WHERE CABLE RIDES ON INBOARD PULLEY, NEAR WING ROOT. PULLEY TURNS FREELY. FOUND ON ROUTINE MAINTENANCE. PROBABLE CAUSE MISALIGNED PULLEY FROM FACTORY. 1L72 3O3 O A19S0 E286 20030902000522003090200052SO 2003 9 2 2003FA0000652 120030505G275062701185 CONTROL CABLE PIPER PA44 PA44180 7104402SO LYC O360 O360* 41514EA TE FLAP BROKEN B OG5RO OTHER O OTHER NRNOT REPORTED 1 GL21295ND2861 4496030 DURING SCHEDULED INSPECTION FLAP OPERATION WAS FOUND TO BE DIFFICULT. FURTHER INSPECTION FOUND FLAP CABLE HAD 4 OF 7 STRANDS BROKEN AT WHERE THE CABLE ENTERS THE TURNBUCKLE TERMINAL. NO ABNORMAL SWAGING WAS NOTED ON TERMINAL. 1L72 3O3 O A19S0 E286 20030707000982003070700098EU 2003 7 7 2003FA0000653 120030623G5280 DOOR ISRAEL1125 ASTRASPX 4500205EU RT MLG OUT OF RIG B A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 GL15420CE 139 RED INTRANSIT LIGHT STAYED ON AFTER SELECTING GEAR UP. RIGGED RT MLG INBOARD DOOR AND RIGGED RT AND LT OUTBOARD. MLG DOORS IAW MM 32-10-07. FUNCTIONAL CHECKED GOOD. 2L72 4F RTA16NM 20030827000732003082700073CE 2003 8 27 2003FA0000654 120030618G2910651710539 LINE CESSNA500 550 2076604CE PWA 530 PW530A NE HYD SYSTEM CRACKED D O OTHER K FLUID LOSS NRNOT REPORTED 1 GL09121L 1491 5500896 AIRCRAFT CAME BACK FROM A TRIP LEAKING HYDRAULIC FLUID FROM THE NOSE GEAR AREA. FOUND LINE PN 6517105-39 CRACKED AND LEAKING HYDRAULIC FLUID. 1L72 4F4 F A22CE E00053EN 20030827000302003082700030SO 2003 8 27 2003FA0000655 220030603G8530 INTAKE VALVE CONT O470 O470* 17026SO ENGINE CRACKED D O OTHER O OTHER NRNOT REPORTED 1 EA03 ENGINE 561.58 SMOH, NR 5 INTAKE VALVE, CRACK IN STEM .1875 INCH FROM TOP END. COMPLETELY AROUND. TELEDYNE TECH REP SAID IT WAS NORMAL. STELLITE TIP WELDED INTO STEM. OTHER VALVES IN ENGINE SHOW SIGNS OF CRACK STARTING. CLYINDERS WERE FACTORY NEW AT OVERHAUL. 3 O E273 20030708000432003070800043CE 2003 7 8 2003FA0000656 120030602G32971SF13 WIRE CESSNA402 402B 207590PCE CONT O520 TSIO520E 17040SO DOWNLOCK SWITCH BROKEN D O OTHER O OTHER NRNOT REPORTED 1 WP135403M 402B0003 812629R DURING INSPECTION OF THE GEAR, FOUND WIRE SPLICE BROKEN. 1L72 3O3 O A7CE E8CE 20030827000602003082700060CE 2003 8 27 2003FA0000658 120030625G2510161102127 CABLE CESSNA172 172R 2072401CE LYC O360 IO360A1A 41514EA PILOT SEAT BROKEN D K NONE O OTHER ININSP/MAINT 1 GL232083F410 17280671 PILOT SEAT WOULD NOT MOVE FORWARD OR AFT WHEN MOVING SEAT LOCK CONTROL. INSPECTION FOUND OUTBOARD PIN NOT DISENGANGING FROM SEAT RAIL. FURTHER DISASSEMBLY FOUND THE CABLE BROKEN INTERNALLY JUST ABOVE PIN RETURN SPRING. (PREVIOUS MDR DATED 6/25/03 SHOWED INCORRECT P/N OF MC194-24) 1H71 3O3 ONT3A12 1E10 20030827000362003082700036CE 2003 8 27 2003FA0000659 120030620G2497321060 TERMINAL BEECH 36 A36 1151604CE BATTERY BROKEN G O OTHER O OTHER LDLANDING 1 NM04307641272 E2382 AIRCRAFT BATTERY POSTIVE CABLE TERMINAL BROKE AT THE BATTERY POST CONNECTOR IN FLIGHT. ALL ELECTRICAL POWER WAS DISCONNECTED FROM AIRCRAFT. 1L71 3O 3A15 20030827000722003082700072CE 2003 8 27 2003FA0000660 120030617G531207126172 BULKHEAD CESSNA182 182G 2072716CE CONT O470 O470* 17026SO FUSELAGE CRACKED B VUXRK NONE O OTHER ININSP/MAINT 1 WP212157R5187 18255357 THIS DEFECT WAS FOUND AS A RESULT OF INSPECTION REQUIRED BY AD. THIS PART WAS REPLACED AT THIS TIME JUNE 17, 2003. TT 5187.97. THIS REPORT REQUIRED BY AD PART (I). 1H71 3O3 ONT3A13 E273 20030828000022003082800002CE 2003 8 28 2003FA0000661 120030623G3234711701 SELECTOR VALVE RKWELLNA265 NA26540 6402608CE PWA JT12 JT12A6A 52042NE LT MLG FAILED D O OTHER J WARNING INDICATION CLCLIMB 1 SW1343W 28215 MAIN LANDING GEAR DOOR SELECTOR VALVE FAILED CAUSING MAIN GEAR FAIRING DOORS TO REMAIN OPEN. THE LANDING GEAR UN-SAFE LIGHT REMAINED ON WITH GEAR UP. WITH MAIN DOOR SELECTOR VALVE FAILED, HYDRAULIC PRESSURE WAS NOT SUPPLIED TO THE NOSE STEERING SYSTEM. POSSIBLE CAUSE OF VALVE FAILURE MAY BE ATTRIBUTED TO THE AGE OF THE VALVE AND THE LIGHT FLIGHT SCHEDULE OF THE AIRCRAFT. 2L72 4J4 J A2WE 1E9 20030827000402003082700040CE 2003 8 27 2003FA0000662 120030529G3233HH55 ROD END BEECH 35 F35 1151514CE CONT E225 E225* 17015SO NLG ACTUATOR FAILED D O OTHER O OTHER NRNOT REPORTED 1 WP253363C5151 D4030 NOSE LANDING GEAR RETRACT/ EXTEND ROD END (PN HH55) FAILED, ALLOWING THE NOSE GEAR TO MOVE OVER CENTER AND COLLAPSE. 1L71 3O3 O A777 E267 20030902000652003090200065SO 2003 9 2 2003FA0000663 120030514G32200615400 CLIP PIPER PA22 PA22160 7102214SO LYC O320 O320A1A 41508EA TAIL SPRING BENT D O OTHER O OTHER TXTAXI/GRND HDL 1 GL258714D 225895 ON ROLLOUT AFTER LANDING AC GROUND LOOPED TO RIGHT. FOUND LEFT TAILSPRING ATTACH CLIP EARS OPENED UP. STEERING CHAIN DISCONNECTED. PILOT STATED NO SHIMMY. 1H71 3O3 O 1A6 E274 20030827000622003082700062EA 2003 8 27 2003FA0000664 220030604G8520 STUD CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA NR 2 CYLINDER BROKEN D O OTHER O OTHER NRNOT REPORTED 1 GL17122FR 17273927 L805476T TWO 38-13 STUDS BROKEN N NR 2 CYLINDER TOP. 1940 HOURS SMOH. 1H71 3O3 ONT3A12 E274 20030828000032003082800003GL 2003 8 28 2003FA0000665 120030615G1430 BOLT AMTR VANS RV8 GL LYC O360 IO360B1B 41514EA HARTZLHCC2Y HCC2YK1 GL RT MLG SHEARED G K NONE O OTHER TXTAXI/GRND HDL 1 SO05 111 111 RV-8, N9868K, LANDED AND BEGAN ROLLOUT WHEN THE RIGHT MAIN LANDING GEAR ASSEMBLY DEPARTED AIRCRAFT. INVESTIGATION REVEALED THE RIGHT MAIN LANDING GEAR LEG ATTACH BOLT SHEARED/BROKE. FAILED LANDING GEAR PARTS HAVE BEEN SENT FOR ANALYSIS. 1L71 3O3 ONTEXPA1L711E10 5 CP920 20030902000632003090200063CE 2003 9 2 2003FA0000668 120030411G2434DOFF10300B ALTERNATOR CESSNA206 206CESSNA 2073302CE CONT O520 IO520* 17032SO ENGINE DAMAGED D O OTHER O OTHER CRCRUISE 1 SW05 6 ALTERNATOR FAN BLADES CAME OFF. 1H71 3O3 O A4CE E5CE 20030902000692003090200069EU 2003 9 2 2003FA0000669 120030630G324250032804 BRAKE ASSY AMD FALC50FALCON50MYST2730106EU MLG VIBRATION B DXSRO OTHER E VIBRATION/BUFFET LDLANDING 1 GL154351M 90 THE BRAKE ASSEMBLY WAS REMOVED AFTER 5 LANDINGS AND .7 FLIGHT HOURS DUE TO A VIBRATION WHEN THE BRAKES WERE APPLIED. THE ASSEMBLY FAILED BENCH CHECK, THE GRIP AND TUBE ASSEMBLIES FAILED TO RELEASE THE BRAKE DISK. 2L73 4F A46EU 20030902000702003090200070EU 2003 9 2 2003FA0000670 120030630G324250032804 BRAKE ASSY AMD FALC50FALCON50MYST2730106EU MLG OUT OF TOLERANCEB DWURO OTHER E VIBRATION/BUFFET LDLANDING 1 EA114351M 90 THE BRAKE ASSEMBLY WAS REMOVED AFTER 5 LANDINGS AND .7 FLIGHT HOURS DUE TO A VIBRATION WHEN THE BRAKES WERE APPLIED. THE ASSEMBLY FAILED A BENCH CHECK, THE GRIP AND TUBE ASSEMBLIES FAILED TO RELEASE THE BRAKE DISK. 2L73 4F A46EU 20030827000322003082700032EU 2003 8 27 2003FA0000671 120030630G324250032804 BRAKE ASSY AMD FALC50FALCON50MYST2730106EU MLG OUT OF TOLERANCEB O OTHER E VIBRATION/BUFFET LDLANDING 1 GL154351M 90 BRAKE ASSEMBLY WAS REPLACED AND AFTER 5 LANDINGS IT WAS REMOVED AND BENCH CHECKED DUE TO A WHEEL VIBRATION. THE ASSEMBLY FAILED THE BENCH CHECK. THE GAP CLEARANCE WAS TWO NARROW. THE GRIP AND TUBE ASSEMBLIES FAILED TO RELEASE THE BRAKE ASSEMBLY 2L73 4F A46EU 20030827000332003082700033EU 2003 8 27 2003FA0000672 120030630G324250032804 BRAKE ASSY AMD FALC50FALCON50MYST2730106EU MLG OUT OF TOLERANCEB O OTHER E VIBRATION/BUFFET LDLANDING 1 GL154351M 90 THE BRAKE ASSEMBLY WAS REMOVED AFTER 5 LANDINGS AND .7 FLIGHT HOURS DUE TO A VIBRATION WHEN THE BRAKES WERE APPLIED. THE ASSEMBLY FAILED A BENCH CHEC THE GRIP AND TUBE ASSEMBLIES FAILED TO RELEASE THE BRAKE DISK. 2L73 4F A46EU 20030902000782003090200078EA 2003 9 2 2003FA0000673 220030604G8530AEL6510212 CYLINDER PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA ENGINE CRACKED D O OTHER O OTHER NRNOT REPORTED 1 GL17 CRACKED FROM TOP SPARK PLUG HOLE AROUND OUT SIDE EX SEAT TO BOTTOM SPARK PLUG HOLE. 1L71 3O3 O 2A13 E286 20030708000072003070800007EA 2003 7 8 2003FA0000674 220030605G8530AEL6510241 CYLINDER PIPER PA28 PA28161 7102803SO LYC O320 O320* 41508EA ENGINE CRACKED D O OTHER O OTHER NRNOT REPORTED 1 GL174328D996 288416019 L1346239A CYLINDER CRACKED FROM TOP SPARK PLUG HOLE AROUND OUTSIDE EX SEAT TO BOTTOM SPARK PLUG HOLE. 1L71 3O3 O 2A13 E274 20030902000792003090200079EA 2003 9 2 2003FA0000675 220030604G8530 CYLINDER HEAD PIPER PA28 PA28161 7102803SO LYC O320 O320D3G 41508EA ENGINE CRACKED C O OTHER O OTHER NRNOT REPORTED 1 GL174328D1958 288416019 L810539A CYLINDER CRACKED FROM HEAD OF COMBUSTION CHAMBER EX SIDE OUT TO COOLING RING. 1L71 3O3 O 2A13 E274 20030902000802003090200080EA 2003 9 2 2003FA0000676 220030605G8530AEL6510241 CYLINDER HEAD PIPER PA28 PA28161 7102803SO LYC O320 O320D3G 41508EA ENGINE CRACKED D O OTHER O OTHER NRNOT REPORTED 1 GL17 CRACKED FROM TOP SPARK PLUG HOLE AROUND OUTSIDE EX SEAT TO BOTTOM SPARK PLUG. 1L71 3O3 O 2A13 E274 20030902000812003090200081EA 2003 9 2 2003FA0000677 220030605G8530AEL6570241 CYLINDER HEAD PIPER PA28 PA28161 7102803SO LYC O320 O320D3G 41508EA ENGINE CRACKED D O OTHER O OTHER NRNOT REPORTED 1 GL174379V1829 288516010 L1346239A CYLINDER CRACKED FROM TOP SPARK PLUG HOLE AROUND OUTSIDE OF EXHAUST SEAT TO BOTTOM SPARK PLUG HOLE. 1L71 3O3 O 2A13 E274 20030902000822003090200082EA 2003 9 2 2003FA0000678 220030605G8530AEL6510241 CYLINDER HEAD PIPER PA28 PA28161 7102803SO LYC O320 O320D3G 41508EA ENGINE CRACKED D O OTHER O OTHER NRNOT REPORTED 1 GL174379V569 288516010 CYLINDER CRACKED FROM TOP SPARK PLUG HOLE AROUND OUTSIDE EX SEAT TO BOTTOM SPARK PLUG HOLE. 1L71 3O3 O 2A13 E274 20030902000832003090200083EA 2003 9 2 2003FA0000679 220030604G8530AEL6510241 CYLINDER HEAD PIPER PA28 PA28161 7102803SO LYC O320 O320D3G 41508EA ENGINE CRACKED D O OTHER O OTHER NRNOT REPORTED 1 GL17 CRACKED FROM TOP SPARK PLUG HOLE AROUND OUTSIDE EXHAUST SEAT TO BOTTOM SPARK PLUG HOLE. 1L71 3O3 O 2A13 E274 20030902000852003090200085EU 2003 9 2 2003FA0000680 120030530G2720N7799233627 TURNBUCKLE SOCATATBM TBM700 8682000EU PWA PT6 PT6A64 EA RUDDER CONTROL UNSAFETIED B K NONE O OTHER ININSP/MAINT 1 WP23459MA97 259 PCEPM0138 DURING THE FIRST ONE HUNDRED HOUR INSPECTION OF THIS AIRCRAFT THE AFT TURNBUCKLE FOR THE RUDDER SYSTEM, AS VIEWED THROUGH ACCESS DOOR 311, HAD FIVE THREADS EXPOSED ON LOWER END AND FOUR THREADS EXPOSED ON UPPER END. BOTH ENDS WERE SAFETIED WITH CLIPS. CLOSE INSPECTION ON ALL TURNBUCKLES BOTH FOR EXPOSED THREADS AND PROPER SAFETIES DURING FIRST 100 HOUR INSPECTION. 1L71 3T4 TRTA60EU E4EA 20030902000942003090200094SW 2003 9 2 2003FA0000681 120030612G321331600 AXLE BBAVIA7 7GCAA 21101N8SW LYC O320 O320* 41508EA LT MLG BROKEN D OF1RO OTHER O OTHER NRNOT REPORTED 1 EA1792LB 2800 26273 STEEL AXLE BROKE AT WELD WHILE MOVING A/C BY HAND. NO HARD LANDINGS REPORTED. 1H71 3O3 O A759 E274 20030902000952003090200095SO 2003 9 2 2003FA0000682 120030618G27506378209 LEVER PIPER PA28 PA28161 7102803SO LYC O320 O320* 41508EA FLAP LEVER WORN B O OTHER O OTHER NRNOT REPORTED 1 EA23382907352 287716239 INSPECTION OF FLAP SYSTEM DURING ANNUAL FOUND FLAP LEVEL HANDLE ATTACH BOLT HOLE WORN. AD96-10-03 HAD BEEN PREVIOUSLY ACCOMPLISHED IAW SB 965. NEEDED NEW REPLACEMENT HANDLE, BUSHING AND BOLT. 1L71 3O3 O 2A13 E274 20030902001012003090200101SO 2003 9 2 2003FA0000683 120030619G71206711961 MOUNT PIPER PA28 PA28RT201 7102818SO RT ENGINE CRACKED D O OTHER O OTHER NRNOT REPORTED 1 EA038364N10325 28R8118060 ENGINE MOUNT TUBE CRACKED AT TOP RIGHT ENGINE ATTACH BELOW MOUNT CUSHION. FOUND CRACK ON 100 HOUR INSPECTION. 1L71 3O 2A13 20030902001022003090200102EA 2003 9 2 2003FA0000684 320030622G6111 STRIP PIPER J3 J3C* SO SNSNCHW72 W72GK EA PROPELLER LE SEPARATED D O OTHER O OTHER NRNOT REPORTED 1 GL25CFSOR 900 T7159 AT CRUISE, PORTION OF PROP LEADING EDGE STRIP SEPARATED FROM PROP. EMERGENCY LANDING ON LAKE ERIE SHORE. PROP OVERHAULED IN 1974. APPROX 40 HOURS SINCE LAST ANNUAL INSPECTION. 1H71 3O ATC660 5 NP170 20030902001092003090200109SW 2003 9 2 2003FA0000685 120030505G6120B24573 FORK MOONEYM20 M20C 5870208SW LYC O360 O360A1A 41514EA HARTZLHCC2Y HCC2YK1 GL PITCH CHANGE CRACKED B IX4RO OTHER O OTHER NRNOT REPORTED 1 SO09 12000200 PITCH CHANGE FORK WAS CRACKED, POSSIBLY DUE TO EXCESSIVE ENGINE VIBRATION. PROPELLER HAD 200 HOURS SINCE LAST OVERHAUL. CUSTOMER WAS ADVISED TO HAVE PROPELLER, DYNAMICALLY BALANCED TO AVOID ANY FURTHER DAMAGE TO PROPELLER ASSEMBLY. 1L71 3O3 O 2A3 E286 5 CP920 20030902001082003090200108GL 2003 9 2 2003FA0000686 120030703G27202055450300 SUPPORT BRACKET DIAMONDA20 DA20C1 2990001GL RUDDER HINGE CRACKED D K NONE O OTHER ININSP/MAINT 1 NM03932AF180 C0198 LOWER RUDDER HINGE/SUPPORT BRACKET CRACKED AT THE LOWER WELD. 1L71 3O NTTA4CH 20030902001552003090200155NM 2003 9 2 2003FA0000688 120030625G6710A4372 PIN ROBSINR22 R22BETA 7640110NM LYC O320 O320* 41508EA FLT CONTROLS BROKEN B GJORO OTHER O OTHER NRNOT REPORTED 1 NM018051M508 1168 DURING OTHER MAINTENANCE INSPECTION REVEALED COLLECTIVE JACK SHAFT MOVED FORE AND AFT. AFTER FURTHER INSPECTION, FOUND TAB PIN A437-2 BROKEN BETWEEN MOUNTING HOLE AND RODE END THRU HOLE. UNKNOWN CAUSE. 1G71 3O3 O H10WE E274 20030902001572003090200157SO 2003 9 2 2003FA0000689 120030603G3297 WIRE PIPER PA34 PA34200T 7103406SO DOWNLOCK SWITCH BROKEN D O OTHER O OTHER NRNOT REPORTED 1 SO11147FL4731 348170047 WIRE BROKEN OFF OF SWITCH (N/C) SHORTED TO GROUND, POPPED GEAR CONTROL CIRCUIT BREAKER. INSULATION ON WIRE (SPAGETTI) VERY BRITTLE AND WOULD NOT BEND WITH THE GEAR MOVEMENT AND BROKEN WIRE AT SOLDER CONNECTOR ON SWITCH. LANDING GEAR NEEDS TO BE REWIRED IN ALL THREE GEAR WELLS. 1L72 3O A7SO 20030902001592003090200159EU 2003 9 2 2003FA0000690 120030620G55101100211 FITTING AEROSPSA316 SA315B 8680615EU HORIZONTAL STAB BROKEN D O OTHER O OTHER NRNOT REPORTED 1 WP2858000448 2639 RIGHT HAND AFT (T) FITTING BROKEN. THIS FITTING IS ONE OF FOUR THAT ATTACHES THE HORIZONTAL STABILIZER TO THE TAILBOOM. NO ABNORMAL VIBRATIONS. CAUSE UNKNOWN, NEW UNPROVEN MODIFICATIONS. AT 448 HOURS TT THIS STABILIZER HAS THE HIGHEST TIME ON THIS STC. SUGGEST DAILY INSPECTION, CHANGE MATERIAL FROM ALUMINUM TO STEEL. 1G71 4U H1IN 20030902001612003090200161SW 2003 9 2 2003FA0000691 120030527G571152625263 SPAR BBAVIA7 7ECA 21101NNSW LYC O235 O235* 41505EA WING CRACKED D O OTHER O OTHER NRNOT REPORTED 1 WP256346N2086 470 CRACK UNDER PLYWOOD PLATE, BOTH CRACKS FLOW THE GRAIN. 1H71 3O3 O A759 E223 20030902001622003090200162CE 2003 9 2 2003FA0000692 120030620G270126134401 BEARING CESSNA208 208 2073702CE CONROL COLLUMN CORRODED B EL6RO OTHER O OTHER NRNOT REPORTED 1 EA23 ROD ASSY PN 2613440-1 LOCATED CENTER FLOOR FORWARD BY PEDESTAL FORWARD BEARING NOTED, CORRODED AND WORN TO HAVE EXCESSIVE PLAY. BEARING HAS GREASE FITTING BUT HARD TO GAIN ACCESS TO, ALSO NOTED, EXCESSIVE WATER ACCUMULATING IN THIS AREAS AND NO DRAIN HOLES NOTED. SUGGEST DRILLING HOLES AND INCREASE LUBE AND INSPECTION OF BEARING AS THIS CONTROL ROD IS THE MAIN CONNECTION BETWEEN CONTROL YOKE AND ELEVATOR CABLE BELLCRANK. 1H71 3T NTA37CE 20030902001642003090200164GL 2003 9 2 2003FA0000693 320030622G6111FL76664Q BLADE CONAERLA4 LA4200 5110310NE HARTZLHCC2Y HCC2YK1 GL PROPELLER BROKEN B ME4RO OTHER O OTHER NRNOT REPORTED 1 SO194GS 738 CH18101 DURING NORMAL OPERATION, A PORTION OF BLADE TIP (P-TIP) BROKE OFF. 1H71 3O 1A13 5 CP920 20030902001652003090200165EA 2003 9 2 2003FA0000694 220030529G7414SLICK4345 MAGNETO SCWZER269 269D 8059501EA LYC O360 HIO360D1A 41514EA ENGINE FAILED C O OTHER O OTHER NRNOT REPORTED 1 GL23103WP5 S1573 L2539051A MAGNETO WAS REPLACED ON 5-27-03 WITH THIS MAGNETO. ON 5-28-03, WHILE PERFORMING MAGNETO CHECK, LEFT MAGNETO WAS DEAD. VERIFIED BY REMOING PRIMARY LEAD. CHECKED NEXT DAY AND STILL WAS NOT FUNCTION ING. REMOVED AND REPLACED MAGNETO. 1G71 3U3 O0 4H12 1E10 20030902001662003090200166EA 2003 9 2 2003FA0000695 220030531G741467542 BEARING CAGE PIPER PA25 PA25235 7102504SO LYC O540 O540B2C5 41532EA IMPULSE COUPLINGDISINTEGRATED D O OTHER O OTHER NRNOT REPORTED 1 SO039827P 257556146 L2280840A DURING MAINTENANCE ACTION, FOUND LT IMPULSE COUPLING MAG GEAR ROLLER BEARING CAGE, PN LYC 67542 DISINTEGRATED AND DEPOSITED IN OIL SUMP. BOTH SIDES OF ROLLER CAGE CAME LOOSE AND ROLLER BALLS BUNCHED UP INSIDE BEARING RACES. ADDITIONAL STRESS OF IMPULSE MAGNETO MAY CONTRIBUTE TO DEFECT. RT MAG ROLLER BEARING, OK. 1L71 3O3 O 2A10 E295 20030902001672003090200167EA 2003 9 2 2003FA0000696 220030531G741467542 BEARING CAGE PIPER PA25 PA25235 7102504SO LYC O540 O540B2C5 41532EA IMPULSE COUPLINGDISINTEGRATED D O OTHER O OTHER NRNOT REPORTED 1 SO039883P974 257556211 L1736940A DURING MAINTENANCE ACTION, FOUND LT IMPULSE COUPLING MAG GEAR ROLLER BEARING CAGE, PN LYC 67452 DISINTEGRATED AND DEPOSITED IN OIL SUMP. BOTH SIDES OF ROLLER CAGE CAME LOOSE AND ROLLER BALLS BUNCHED UP INSIDE BEARING RACES. ADDITIONAL STRESS OF IMPULSE MAG MAY CONTRIBUTE TO DEFECT. RT MAG ROLLER BEARING, OK. 1L71 3O3 O 2A10 E295 20030902001722003090200172CE 2003 9 2 2003FA0000697 120030701G323312805042 ACTUATOR CESSNA210 210L 2073448CE MLG FAILED D O OTHER O OTHER LDLANDING 1 CE03210PY2242 21060117 SHORTLY AFTER TAKEOFF AND PRIOR TO PERFROMING TOUCH AND GO`S, IT WAS NOTED THAT LANDING GEARS WERE NOT SAFELY DOWN AND LOCKED. MLG'S WERE VISUALLY NOT EXTENDING PASSED FREE HANGING POSITION. SEVERAL PROCEDURES AND ATTEMPTS WERE MADE OVER THE FOLLOWING THREE FLIGHT HOURS WITH NO SUCCESS. AIRCRAFT LANDED GEAR UP ON RUNWAY WITH NO FIRE, INJURIES AND SUSTAINING ONLY MINOR DAMAGES. UPON INSPECTION, IT WAS FOUND THAT MLG UPLOCK ACTUATOR PN 1280504-2 FAILED. WHEN SELECTING EXTEND POSITION, IT WOULD UNLOCK THE MLG'S BUT RESTRICT PRESSURE TO FLOW THROUGH IT TO EXTEND THE MLG ACTUATORS. AIRCRAFT WAS JUST OUT OF ANNUAL INSPECTION WHERE THE RETRACTION SYSTEM AND EMERGENCY EXTENSION SYSTEM WAS INSPECTED FREE OF DEFECTS. 1H71 3O 3A21 20030902001762003090200176NM 2003 9 2 2003FA0000698 120030713G5712 RIB UNIVAR415 415* NM RT WING CORRODED D K NONE O OTHER ININSP/MAINT 1 SW053595H 4220 LIGHT CORROSION FOUND ON CENTER RIB IN RT SIDE OF WING WALK WAY BETWEEN 2ND, 3RD AND 4TH LITING HOLES. WHILE INSPECTING THE CENTER SECTION IAW AD AND SB NR 31-R1 IAW METHOD NR 3 OF THE AD AND SB. THE CORROSION WAS REMOVED AND AFFECTED AREAS TREATED IAW AC 43-4A CHAP. 6 PARA. 640, PARA. 641. AND SB.31-R1. NO OTHER COROSION WAS FOUND. 1L71 3O A718 20030902001702003090200170GL 2003 9 2 2003FA0000700 120030711G7810DC00015B EXHAUST PIPE DIAMONDA20 DA20C1 2990001GL CONT O240 IO240B 17063SO SNSNCHW69EK W69EK63 EA ENGINE CRACKED C K NONE O OTHER ININSP/MAINT 1 NM03 233 C0196 806396 EXHAUST STACK FLANGE CRACKED. 1L71 3O3 ONTTA4CH E7SO 5 NTA4CH 20030903000172003090300017SO 2003 9 3 2003FA0000701 120030702G2720 TORQUE TUBE PIPER PA31T PA31T 7103124SO PWA PT6 PT6A60A 52043NE RUDDER CORRODED B O OTHER O OTHER NRNOT REPORTED 1 GL252FJ 5512 31T7620050 FOUND RUDDER TORQUE TUBE WITH CORROSION ON TUBE AND SURROUNDING ALUMINUM RIB. FOUND DURING INSPECTION IAW SB1105. PROBABLE CAUSE IS DISSIMILAR METAL CORROSION. CLOSERER INSPECTION DURING EVENT 1 INSPECTIONS. REPAIRS REQUIRED REPLACEMENT OF THE TORQUE TUBE AND TWO RIBS. 1L72 3T4 T A8EA E4EA 20030903000182003090300018SO 2003 9 3 2003FA0000702 120030620G1430 BOLT PIPER PA28 PA28161 7102803SO LYC O320 O320* 41508EA RT MLG STRUT SHEARED D O OTHER O OTHER NRNOT REPORTED 1 WP238209E10109 288316027 BYSTANDER POINTED OUT TO PILOT THAT RT MLG HAD FOLDED BACKWARDS. UPON INVESTIGATION IT WAS FOUND THAT ALL 4 STRUT CYLINDER ATTACH BOLTS WERE SHEARED OR MISSING AT THE LOWER SPAR FLANGE ATTACH POINT. AT 100 HR INSPECTION, CONDUCTED 86 HOURS PREVIOUSLY, ALL BOLTS WERE PRESENT AND GEAR DID NOT MOVE WHEN SHAKEN. IT IS SUGGESTED THAT ALL MLG GEAR ATTACH BOLTS BE WRENCH CHECKED FOR PROPER TIGHTNESS AT EACH 100 HOUR INSPECTION. 1L71 3O3 O 2A13 E274 20030903000152003090300015CE 2003 9 3 2003FA0000703 120030715G323051412044 SUPPORT CESSNA421 421C 2076016CE MLG BROKEN B K NONE O OTHER ININSP/MAINT 1 SO25885863907 421C0644 THE TAB ON THE SUPPORT BROKE OFF ALLOWING THE RT MAIN LANDING GEAR UPLOCK PIVOT BLOCK TO MISSALIGN. THIS COULD RESULT IN THE LANDING GEAR NOT LOCKING UP OR NOT RELEASING WHEN DOWN WAS SELECTED. 1L72 3O A7CE 20030903000022003090300002SO 2003 9 3 2003FA0000704 120030714G284138230002 FLOAT PIPER PA32 PA32RT300 7103215SO LYC O540 IO540* 41532EA FUEL QTY WORN D K NONE C F.O.D. ININSP/MAINT 1 SO11316423623 32R7885114 FUEL QUANTITY FLOAT P/N 38230-002. COMPOSITE FLOAT HAS BEEN HITTING THE UPPER BODY OF THE ASSY WHEN IN A FULL CONDITION AND HAS WORN .2500 INCH GROOVE ON ONE SIDE OF FLOAT AND .1875 INCH GROOVE ON THE OTHER SIDE. GAUGE STILL OPERATED, BUT PARTICLES OF THE COMPOSITE FLOAT MADE IT'S WAY TO THE FUEL SCREEN. PART NEEDS MECHANICAL STOP TO PREVENT CONTACT WITH UPPER BODY. HAVE DIGITAL PICTURES OF FLOAT. 1L71 3O3 O A3SO 1E4 20030903000132003090300013EA 2003 9 3 2003FA0000705 220030414G7414 POINTS CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA MAGNETO WORN D QYIRA UNSCHED LANDING Y ENGINE STOPPAGE CRCRUISE 1 NM019892J 3120253 17273952 L493276T ENGINE STOPPAGE DUE TO ABNORMALLY HIGH WEAR TO THE LIFTING BLOCKS OF THE CONTACT POINTS OF BOTH THE LT AND RT SIDES OF A COMMON MAGNETO. BOTH CONTACT POINTS WERE REMOVED AND INSPECTED FOR BOGUS PARTS; REINSTALLED, LUBRICATED, RE-GAPPED AND TIMED. THE AIRCRAFT WAS RETURNED TO SERVICE AFTER GROUND RUN. THE MAGNETO HAS 115.5 HOURS SINCE RETURN TO SERVICE. MAGNETO WAS PREVIOUSLY SENT BACK FOR THE SAME ABNORMAL WEAR AFTER 225.6 HOURS IN SERVICE. 1H71 3O3 ONT3A12 E274 20030903000362003090300036SO 2003 9 3 2003FA0000707 120030701G32227642603 BRACE PIPER PA28 PA28R200 7102811SO NLG DRAG BRACE CRACKED D O OTHER O OTHER NRNOT REPORTED 1 NM018991E6500 28R7635220 DURING 100 HR INSPECTION, DISCOVERED 1.5 INCH LONG CRACK IN RT LEG OF NOSE LANDING GEAR DRAG BRACE, 1 INCH FORWARD OF ACTUATOR ATTACH POINT. AREA IS HIDDEN FROM VIEW BY DOWNLOCK SWITCH ASSY. CRACK WAS CLOSED TIGHT AND UNDETECTABLE WHEN GEAR WAS EXTENDED DOWN. WHEN GEAR WAS RAISED, ACTUATOR PRESSURE CAUSED CRADT TO OPEN .030-.040 INCH. (IF MECH HAD NOT BEEN REPLACING DOWNLOCK SWITCH, COULD HAVE POSSIBLY NOT DISCOVERED CRACK.) DOWNLOCK SWITCH HAD A (HOME MADE) STRIKER PLATE AND SWITCH WAS OUT OF ADJUSTMENT. THIS MAY HAVE LED TO EXCESSIVE STRESS OVER A PERIOD OF TIME, AT THE ACTUATOR ATTACH POINT. 1L71 3O 2A13 20030903000392003090300039CE 2003 9 3 2003FA0000708 120030701G29104532403475005 LINE LEAR 45 45LEAR 5170805CE BRAKE LINE CHAFED D O OTHER O OTHER NRNOT REPORTED 1 SO11397AT1194 105 LINE CHAFED ON TOP OF SPOILER SHUTOFF VALVE CAUSING HYDRAULIC LEAK. REPLACE LINE AND BLED BRAKE SYSTEM. TIME ON PART: 1194.9 HOURS AND 1099 LANDINGS. INSTALLED CLAMPS WITH SPACING DISTANCE TO PREVENT RECURRANCE. MAY NEED TO INSTALL ADDITIONAL CLAMPS TO ENSURE THIS WOULD NOT HAPPEN AGAIN. NOTE: STAINLESS STEEL LINE. 2L72 4F RTT00008WI 20030903000402003090300040CE 2003 9 3 2003FA0000709 120030325G323398820152 ACTUATOR CESSNA182 R182 2072734CE LYC O540 O540* 41532EA RT MLG CRACKED B E5WRO OTHER O OTHER NRNOT REPORTED 1 GL214873S R18201440 CRACK INDICATIONS IN THE 2.28 INCH BORE. CRACK FOUND WHILE INSPECTING ACTUATOR IAW SB 01-2 REV 1. RIGHT MAIN GEAR. 1H71 3O3 ORT3A13 E295 20030903000432003090300043NE 2003 9 3 2003FA0000710 220030701G7200414302017 HOUSING LYC LTS101LTS101750B1 41560NE ENGINE CLOGGED B C7GRO OTHER O OTHER NRNOT REPORTED 1 SO13 LE45876 NEWLY OVERHAULED COMBUSTOR HOUSING INSTALLED ON ENGINE LE-45876, DURING REPAIR. WHILE ASSEMBLING THE ENGINE, A HIGH AND UNACCEPTABLE DELTA (P) WAS CONFIRMED, WHICH INDICATED CLOGGED OIL PASSAGE AT THE NR 2 AND NR 3 BEARING BORE AREA. FURTHER INVESTIGATION CONFIRMED THE PROBLEM. REPAIR WORK AT VENDOR HAS BEEN HALTED PENDING FURTHER REVIEW AND SUCCESSFUL PROCESS AUDITS. NOTE: NO NONCONFORMING PARTS HAVE BEEN RELEASED TO SERVICE BY THIS FACILITY. 3 U E5NE10 20030903000442003090300044 2003 9 3 2003FA0000711 420030701G8300408112017 GEAR LYC LTS101LTS101600A 41560NE ACCESSORY G/B WORN B C7GRO OTHER O OTHER NRNOT REPORTED 1 SO13 LE43133 NEW PART INSTALLED ON ENGINE LE-43133 DURING REPAIR. WHILE INVESTIGATING THE CAUSE OF AGB VIBRATION, IT WAS NOTED THAT THE OUTPUT GEAR MENTIONED IN BLOCK 5 HAD ABNORMAL WEAR FOR A NEW PART. THE GEAR IN QUESTION WAS REMOVED FROM THE ENGINE AND RETURNED TO THE OEM FOR EVALUATION/ INVESTIGATION. IT HAS BEEN DETERMINED THAT THIS PART WAS NOT MANUFACTURED CORRECTLY. AS OF 06/30/03 THERE IS A RECALL IN PROCESS BY THE MANUFACTURER OF THIS PART. 3 U E5NE 20030903000542003090300054EU 2003 9 3 2003FA0000712 120030716G2510A780596L SEAT LET L23 L23 1360308EU OPTIONAL WEIGHT MISMANUFACTURED B K NONE W INADEQUATE Q C ININSP/MAINT 1 NM03437BA100 029015 THE WEIGHTED SEATS HAVE A HANDLE WELDED ON THE LEFT REAR CORNER. WITH THE SEAT BELT FASTENED IT IS POSSIBLE TO LIMIT FULL LEFT RUDDER TRAVEL DUE TO THE RUDDER PEDAL JAMMING THE SEAT BELT ATTACH TAB BETWEEN THE PEDAL AND THE HANDLE. IT ONLY HAPPENS WITH THE OPTIONAL WEIGHTED SEAT IN THE FRONT INSTALLED. 1K00 RCG24EU 20030903000512003090300051 2003 9 3 2003FA0000713 420030715G3418XE4N024 RELAY GULSTMGV GULFSTREAMGV3980116SO STALL WARNING INOPERATIVE B K NONE L NO TEST ININSP/MAINT 1 GL09524AC250 686 NR 1 STICK SHAKER WOULD NOT TEST. FOUND INOPERATIVE RELAY, LOCATION NO. 018K2AN2.(GULFSTREAM P/N GAR835NR1.) 2L72 4F RTA12EA 20030912000312003091200031 2003 9 12 2003FA0000714 420030715G6122 GOVERNOR PIPER PA31 PA31325 7103105SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2 GL PROPELLER INOPERATIVE D O OTHER O OTHER NRNOT REPORTED 1 EA033539S200 317912119 PILOT REPORTED, WENT THRU SEVERE TURBULANCE AND LOST GOVERNOR CONTROL. ENGINE WENT TO 2575 RPM. TROUBLESHOT UNIT, COULD NOT DUPLICATE, OPERATED AND CHECKED WITH PROP TACH. OPENED ON GROUND. 1L72 3O3 O A20SO E14EA 5 CP33EA 20030916000552003091600055EU 2003 9 16 2003FA0000715 120030708G5751120A1152 HINGE GROB 120 G120A 1660208EU RT AILERON FAILED B VJ3RK NONE O OTHER ININSP/MAINT 1 WP07861AF946 85001 DURING 50 HR INSPECTION THE TECH FOUND THE RETAINING CLIP COMING OUT OF BEARING. 1L71 3O RTA49CE 20030912001342003091200134CE 2003 9 12 2003FA0000716 120030726G3610RA216CW PUMP BEECH 33 F33A 1151425CE CONT O520 IO520BB 17032SO DRY AIR WORN B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP075521A465 CE1338 825825R AVIONICS PERSONNEL FOUND INSTRUMENT AIR PRESSURE LOW ON GROUND RUN UP. ON FURTHER INVESTIGATION FOUND VANES WORN ON PUMP. RECOMMEND PUTTING DIFFERENT TYPE OF VANES IN PUMP TO LAST LONGER. 1L71 3O3 O 3A15 E5CE 20030912001372003091200137EU 2003 9 12 2003FA0000717 120030606G3230X030004000000 MANIFOLD GROB 120 G120A 1660208EU FLOW CONTROL INOPERATIVE B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07867AF549 85007 DURING FLIGHT THE FLIGHT CREW REPORTED THAT THE LEFT GEAR WAS SLOW TO EXTEND. MAINTENANCE PERSONNEL TROUBLESHOT SYSTEM AND FOUND LEFT EXTENSION VALVE BAD. PROBABLE CAUSE IS BELIEVED PARTICIALS INSIDE OF VALVE WHICH PREVENTED FLUID TO FLOW UNRESTRICTED. 1L71 3O RTA49CE 20030912001402003091200140EU 2003 9 12 2003FA0000718 120030608G29100332204204 RELAY GROB 120 G120A 1660208EU HYD SYSTEM SHORTED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07865AF 85005 WHILE PERFORMING GEAR CHECK, THE HYDRAULIC PRESSURE WOULD NOT BUILD UP. FOUND RELAY SHORTED OUT. RECOMMEND INSTALLING AN INLINE FUSE IN THE SYSTEM. WHEN THIS RELAY FAILS, THE RELAY AND DIODES BOARD ALSO FAILS. 1L71 3O RTA49CE 20030912000242003091200024CE 2003 9 12 2003FA0000719 120030620G3610216CW PUMP BEECH 33 F33A 1151425CE CONT O520 IO520BB 17032SO PNEUMATIC SYS FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP071570A401 CE1333 820456R AIR PUMP FAILED TO PROVIDE AIR PRESSURE. RECOMMEND DIFFERENT VANES OR BETTER MATERIAL. 1L71 3O3 O 3A15 E5CE 20030912001452003091200145CE 2003 9 12 2003FA0000720 120030708G3610RA216CW PUMP BEECH 33 F33A 1151425CE CONT O520 IO520BB 17032SO PNEUMATIC SYS FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP078252T313 CE1545 INSTRUMENT AIR PRESSURE BELOW LIMITS AT LOWER RPM. GYRO WARNING LIGHT ON AT 1100 RPM. LOW VOLUME FROM AIR PUMP. 1L71 3O3 O 3A15 E5CE 20030915000202003091500020CE 2003 9 15 2003FA0000721 120030624G3230SM50D7 RELAY BEECH 33 F33A 1151425CE MLG FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP075582X304 CE1353 DURING 50 HOUR INSPECTION OF LANDING GEAR, GEAR FAILED TO EXTEND (2) TIMES. UPON TROUBLESHOOTING GEAR SYSTEM FOUND DYNAMIC RELAY PN SM50D7 WAS BAD. REPLACED DYNAMIC RELAY AND CYCLED GEAR SEVERAL TIMES OPERATIONAL OF GEAR CHECKED GOOD. 1L71 3O 3A15 20030915000142003091500014EU 2003 9 15 2003FA0000722 120030618G3234 LIGHT GROB 120 G120A 1660208EU GEAR HANDLE INTERMITTENT B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07867AF 85007 PILOT REPORTED RT GEAR LIGHT INOPERATIVE IN FLIGHT, AFTER TOUCH DOWN GEAR INDICATOR LIGHT CAME ON. ON FURTHER INVESTIGATION WE BELIEVE WE HAD AN INTERMITTENT LIGHT INSIDE THE GEAR HANDLE, AFTER FOUR GEAR CYCLES THE LIGHT QUIT WORKING. 1L71 3O RTA49CE 20030915000162003091500016CE 2003 9 15 2003FA0000723 120030617G575012527Y6331 CONTROL CABLE BEECH 33 F33A 1151425CE LT FLAP BROKEN B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP075581T CE1350 PILOT REPORTED WHEN SETTING FLAP SELECTOR TO 15 DEGREES, INDICATOR STAYED A (0), RIGHT FLAP EXTENDED TO 30 DEGREES AND LEFT FLAP STAYED IN THE UP POSITION AND CIRCUIT BREAKER POPPED. ON FURTHER INVESTIGATION FOUND THAT FLAP CABLE WAS BROKEN WERE IT CONNECTS TO THE FLAP MOTOR. 1L71 3O 3A15 20030912001482003091200148CE 2003 9 12 2003FA0000724 120030617G33400107900790 POWER SUPPLY BEECH 33 F33A 1151425CE TAIL STROBE INOPERATIVE B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP078268T CE1547 TAIL STROBE WAS FOUND INOPERATIVE BY THE MECHANIC PERFORMING THE PHASE INSPECTION. ON FURTHER INVESTIGATION FOUND THE POWER SUPPLY INOPERATIVE. TIME SINCE REPAIRED 2295. 1L71 3O 3A15 20030916000562003091600056CE 2003 9 16 2003FA0000725 120030619G3297SM50D7 RELAY BEECH 33 F33A 1151425CE MLG FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP075581T649 CE1350 PILOT REPORTED GEAR FAILED TO RETRACT DURING FLIGHT. TROUBLESHOOT SYSTEM, BELIEVE RELAY FAILED INTERNALLY. RECOMMEND FINDING A BETTER RELAY. 1L71 3O 3A15 20030916000572003091600057EU 2003 9 16 2003FA0000726 120030619G3234 HANDLE GROB 120 G120A 1660208EU MLG INTERMITTENT B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07862AF 85002 PILOT REPORTED LT GEAR LIGHT FLICKERED IN FLIGHT. ON FURTHER INVESTIGATION WE BELIEVE WE HAD AN INTERMITTENT LIGHT INSIDE THE GEAR HANDLE. NO PROBABLE CAUSE OR RECOMMENDATION TO PREVENT THIS FROM RECURRING. 1L71 3O RTA49CE 20030912001002003091200100CE 2003 9 12 2003FA0000727 120030618G3610RA216CW PUMP BEECH 33 F33A 1151425CE CONT O520 IO520BB 17032SO DRY AIR INOPERATIVE B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP078268T CE1547 825913R PUMP OUTPUT DECREASED AS ENGINE WARMED UP UNTIL IT BECAME UNACCEPTABLE AT LOWER RPM. AT 1000 RPM PRESSURE DROPPED BELOW 3 INCHES ON INDICATOR. TESTED AIR SYSTEM FOR LEAKS AND FOUND NONE. CHECKED REGULATOR AND MANIFOLD VALVE, REPLACED BOTH THE SYSTEM STILL FAILED TO MAINTAIN PROPER PRESSURE. SO REPLACED ENGINE DRIVEN AIR PUMP AND SYSTEM PASSED. 1L71 3O3 O 3A15 E5CE 20030912001012003091200101SO 2003 9 12 2003FA0000728 120030604G792120710A OIL COOLER PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA ENGINE CRACKED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP074144P 2843121 RL3909136A FOUND OIL LEAK DURING PREFLIGHT BY STUDENT PILOT. PRESSURE CHECKED OIL COOLER AND FOUND OIL LEAK AT TOP SEAM. THIS IS A WEAK AREA ON THE COOLER. MAY BE CAUSED BY VIBRATION OR IMPROPER INSTALLATION METHODS. 1L71 3O3 O 2A13 E286 20030912001022003091200102SO 2003 9 12 2003FA0000729 120030604G792120710A OIL COOLER PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA ENGINE CRACKED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP074142Q1601 2843207 RL3705736A FOUND OIL LEAK DURING PREFLIGHT BY STUDENT PILOT. PRESSURE CHECKED OIL COOLER AND FOUND OIL LEAK AT TOP SEAM. THIS IS A WEAK AREA ON THE COOLER. MAY BE CAUSED BY VIBRATION OR IMPROPER INSTALLATION METHODS. REPLACEMENT WITH BETTER COOLER. 1L71 3O3 O 2A13 E286 20030916000582003091600058EU 2003 9 16 2003FA0000730 120030604G3610 SHAFT GROB 120 G120A 1660208EU LYC O540 AEIO540D4D5 EA DRY AIR PUMP SHEARED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07865AF T35829H 85005 L2826448A DURING FLIGHT, THE INSTRUMENT VACUUM SYSTEM FAILED. THE AIRCRAFT RETURNED TO MAINTENANCE AND AN INSPECTION OF THE SYSTEM REVEALED THAT THE ROTOR SHAFT HAD SHEARED. PROBABLE CAUSE MAY BE THE ENGINE MOUNTS USED ARE TOO SOFT AND ALLOW THE ENGINE TO VIBRATE TOO MUCH AND THIS CAUSES THE PUMP SHAFT TO SHEAR. RECOMMEND ALTERNATIVE DRY AIR PUMP OR ALTERNATIVE ENGINE LOAD MOUNTS. 1L71 3O3 ORTA49CE 1E4 20030916000592003091600059EU 2003 9 16 2003FA0000731 120030613G7722 PROBE GROB 120 G120A 1660208EU LYC O540 AEIO540D4A5 41532EA EXHAUST EGT FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07862AF941 85002 L2802448A ON GROUND RUN-UP EGT INDICATOR FLUCTUATED 25 DEGREES. ON FURTHER INVESTIGATION FOUND CARBON ON END OF PROBE. 1L71 3O3 ORTA49CE 1E4 20030916000602003091600060CE 2003 9 16 2003FA0000732 120030612G3297SM50D7 RELAY BEECH 33 F33A 1151425CE MLG STICKING B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP075587K446 CE1392 RELAY FAILED TO FUNCTION ON THREE SEPARATE OCCASIONS CAUSING LANDING GEAR NOT TO EXTEND, PROBABLE CAUSE IS STICKING SOLENOID. RELAY IS SCHEDULED FOR CHANGE EVERY 900 HOURS. RECOMMEND CHANGING TO AN IMPROVED DESIGN RELAY. 1L71 3O 3A15 20030916000612003091600061CE 2003 9 16 2003FA0000733 120030613G284210238901211 TRANSDUCER BEECH 33 F33A 1151425CE CONT O520 IO520* 17032SO FUEL QTY INTERMITTENT B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP078173C CE1541 825840R PILOT REPORTED GAUGE FLUCTUATED FOR A SHORT TIME THEN WENT TO (0) FOR 15 MINUTES. AFTER THAT GAUGE INDICATED NORMAL FUEL FLOW, DUE TO HIGH TIME PART. 1L71 3O3 O 3A15 E5CE 20030916000622003091600062CE 2003 9 16 2003FA0000734 120030616G3297SM50D7 RELAY BEECH 33 F33A 1151425CE MLG FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP075519A657 CE1337 PILOT REPORTED GEAR FAILED TO RETRACT DURING FLIGHT. TROUBLESHOT SYSTEM, BELIEVE RELAY FAILED INTERNALLY. 1L71 3O 3A15 20030915000312003091500031CE 2003 9 15 2003FA0000735 120030616G3230SM50D7 RELAY BEECH 33 F33A 1151425CE MLG FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP078251C32 CE1543 PILOT REPORTED GEAR FAILED TO EXTEND DURING FLIGHT. TROUBLESHOT SYSTEM, BELIEVE RELAY FAILED INTERNALLY. RECOMMEND FINDING A BETTER RELAY. 1L71 3O 3A15 20030915000102003091500010CE 2003 9 15 2003FA0000736 120030616G3234MS25125E3 SELECTOR BEECH 33 F33A 1151425CE MLG INTERMITTENT B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP078251C CE1543 PILOT REPORTED GEAR SWITCH DOES NOT LOWER GEAR AT TIMES, MUST BE FIRMLY PUSHED DOWN. 1L71 3O 3A15 20030912000252003091200025SO 2003 9 12 2003FA0000737 120030521G2597 WIRE PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA OVERHEAD PANEL BURNED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP074149Y3990 2843128 RL1412936A THE WIRING, CONNECTOR AND PINS IN THE PANEL ASSY OVERHEAD SWITCHES ARE MELTED AND SHORTED OUT. THE CONNECTOR IS P5 AND THE WIRES ARE L1B20, L1D20, AND L3B18 WHICH GOES TO THE LANDING LIGHT SWITCH, NAV. LIGHTS SWITCH, AND THE STROBE SWITCH. BELIEVED THE CAUSE IS HIGHTER RESISTANCE WAS CREATED AND WITH THE AMOUNT OF CONTINUOUS CURRENT FLOW CREATED ENOUGH HEAT TO MELT THE CONNECTORS AND BURNED THE PINS. ECOMMENDATION IS TO US A HIGHTER AMP CONNECTOR AND PINS. 1L71 3O3 O 2A13 E286 20030912000262003091200026SO 2003 9 12 2003FA0000738 220030530G7322 SHAFT BEECH 33 F33A 1151425CE CONT O520 IO520BB 17032SO FUEL CONTROL BINDING B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP075581T6 CE1350 820457R PILOT REPORTED HIGH CHT AND OIL TEMP IN FLIGHT. RAN AIRCRAFT AND FOUND ENGINE RUNNING LEAN, ATTEMPTED TO SET THE MIXTURE BUT WE WERE UNABLE TO. WHEN DISCONNECTING MIXTURE CONTROL CABLE FROM FUEL CONTRO AND MOVING THE SHAFT ON FUEL CONTROL BY HAND, FOUND IT ROUGH AND BINDING. 1L71 3O3 O 3A15 E5CE 20030916000632003091600063CE 2003 9 16 2003FA0000739 120030529G7430 IGNITION SWITCH BEECH 33 F33A 1151425CE CABIN INTERMITTENT B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP075582X CE1353 PILOT REPORTED NO DROP IN RPM WHILE PERFORMING MAGNETO CHECK ON GROUND RUN UP. WHILE JIGLING THE KEY AROUND, THE PILOT THEN NOTICED A DROP IN RPM. MAGNETO SWITCH IS CHECKED BEFORE TAKEOFF BY PILOTS FOR PROPER OPERATION AND AT EACH 50 HOUR INSPECTION MY MAINTENANCE. 1L71 3O 3A15 20030915000322003091500032SO 2003 9 15 2003FA0000740 120030523G7921 OIL COOLER PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA ENGINE CRACKED B VJ3RK NONE K FLUID LOSS ININSP/MAINT 1 WP074130W507 2843204 L2847836A FOUND OIL LEAK ON PREEFLIGHT INSPECTION BY STUDENT PILOT. PRESSURE CHECKED OIL COOLER AND FOUND OIL COOLER LEAKING AT SEM ON TOP. THIS IS A WEAK AREA ON THE OIL COOLER, COULD BE CAUSED BY VIBRATION AND NOT USING A BACK UP WRENCH WHEN INSTALLING OIL COOLER HOSES. RECOMMEND FINDING A REPLACEMENT THAT IS MORE DURABLE. 1L71 3O3 O 2A13 E286 20030912000272003091200027CE 2003 9 12 2003FA0000741 120030605G2121152320212 MOTOR BEECH 33 F33A 1151425CE VENT BLOWER INOPERATIVE B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP075587K CE1392 DURING FLIGHT, VENT BLOWER BECAME INOPERATIVE. TESTED SYSTEM ON GROUND AND FOUND VENT BLOWER ASSEMBLY MOTOR WAS BURNED OUT. SUSPECT CAUSE IS CONTINUOUS USE OF VENT BLOWER DURING FLIGHT. RECOMMEND INSTALLING AN INTERMITTENT SWITCH TO SHUT OFF VENT BLOWER WHEN LANDING GEAR IS CYCLED UP. 1L71 3O 3A15 20030916000642003091600064CE 2003 9 16 2003FA0000742 120030609G3610RA216CW PUMP BEECH 33 F33A 1151425CE CONT O520 IO520BB 17032SO DRY AIR WORN B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP075585Y594 CE1389 AVIONICS PERSONNEL FOUND INSTRUMENT AIR PRESSURE LOW ON GROUND RUN UP. ON FURTHER INVESTIGATION FOUND VANES WORN ON PUMP. RECOMMEND PUTTING DIFFERENT TYPE OF VANES IN PUMP TO LAST LONGER. 1L71 3O3 O 3A15 E5CE 20030916000652003091600065SO 2003 9 16 2003FA0000743 120030606G2435MHB4016 STARTER PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA ENGINE FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP074132D1249 2843234 RL3707736A PILOT REPORTED AIRCRAFT IS HARD TO START. ON FURTHER INVESTIGATION FOUND STARTER WAS BAD. NO RECOMMENDATION AT THIS TIME BECAUSE STARTER WAS HIGH TIME. 1L71 3O3 O 2A13 E286 20030916000662003091600066 2003 9 16 2003FA0000744 420030605G2562ELT1104 CASE BEECH 33 F33A 1151425CE CONT O520 IO520BB 17032SO ELT CORRODED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP078101C2747 CE1538 825785R DURING A REPLACEMENT OF THE ELT BATTERY FOR TIME CHANGE TECHNICIAN FOUND CORROSION INSIDE BATTERY CASE. PROBABLE CAUSE IS THE HEAT. 1L71 3O3 O 3A15 E5CE 20030916000672003091600067SO 2003 9 16 2003FA0000745 120030605G79212071011 OIL COOLER PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA ENGINE CRACKED B VJ3RO OTHER K FLUID LOSS NRNOT REPORTED 1 WP074130W 15 2843204 L2847836A DURING A MAINTENANCE INSPECTION OF THIS AIRCRAFT, THE OIL COOLER WAS FOUND TO BE CRACKED AROUND THE MOUNTING BOLT HOLES AND LEAKING FROM THE SEAM IN THAT AREA. PROBABLE CAUSE IS VIBRATION. RECOMMEND USING A SOLID PIECE OIL COOLER. 1L71 3O3 O 2A13 E286 20030916000682003091600068CE 2003 9 16 2003FA0000746 120030605G3297SM50D7 RELAY BEECH 33 F33A 1151425CE CONT O520 IO520BB 17032SO MLG STICKING B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP038251C CE1543 825822R DURING FLIGHT, PILOT SELECTED GEAR UP. THE GEAR REMAINED IN THE DOWN AND LOCKED POSITION. TROUBLESHOT SYSTEM AND FOUND THE DYNAMIC RELAY WAS STICKING. PROBABLE CAUSE IS THE POINTS NOT RELEASING. RECOMMEND THAT A DIFFERENT STYLE RELAY BE USED. 1L71 3O3 O 3A15 E5CE 20030916000692003091600069SO 2003 9 16 2003FA0000747 120030530G7921 OIL COOLER PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA ENGINE CRACKED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP074161Z219 2843129 RL3133236A WHILE PERFORMING MAINTENANCE ON AIRCAFT, MECHANIC DISCOVERED OIL LEAK COMING FROM THE AREA OF THE OIL COOLER. PERFORMING PRESSURE CHECK ON OIL COOLER AND FOUND OIL COOLER LEAKING AT SEAM ON TOP. THIS IS A WEAK AREA ON THE OIL COOLER, COULD BE CAUSED BY VIBRATION. 1L71 3O3 O 2A13 E286 20030916000702003091600070SO 2003 9 16 2003FA0000748 120030630G2434 ALTERNATOR PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA ENGINE BROKEN B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP074175V665 2843126 RL1179636A WHILE PERFORMING PHASE INSPECTION ON ENGINE, FOUND EAR BROKEN ON ALTERNATOR. NEED TO MAKE SURE ALTERNATOR IS SHIM MED IN THIS AREA SO THERE IS NO STRESS ON THE EARS. 1L71 3O3 O 2A13 E286 20030915000332003091500033SO 2003 9 15 2003FA0000749 120030604G2434 DIODE PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA ALTERNATOR FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP074144P22 D023784 2843121 RL39091 PILOT REPORTED ALTERNATOR INOPERATIVE. LIGHT STAYED ON AND AMP METER SHOWED 28 AMPS. UPON FURTHER INVESTIGATION, IT WAS FOUND THAT A DIODE HAD FAILED INSIDE THE ALTERNATOR. 1L71 3O3 O 2A13 E286 20030916000712003091600071EU 2003 9 16 2003FA0000750 120030513G2711G1204105 ACTUATOR GROB 120 G120A 1660208EU LYC O540 AEIO540D4D5 EA AILERON TRIM FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07867AF459 85007 RL2451848A DURING FLIGHT, TRIM WOULD NOT STOP AND CONTINUED TO MOVE TO THE LEFT. PROBABLE CAUSE IS INTERNAL COMPONENT FAILURE IN THE AILERON TRIM ACTUATOR UNIT. 1L71 3O3 ORTA49CE 1E4 20030912000152003091200015SO 2003 9 12 2003FA0000751 220030529G73226299022 FUEL CONTROL BEECH 33 F33A 1151425CE CONT O520 IO520BB 17032SO ENGINE FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP075581T6 CE1350 820457R WAS UNABLE TO SET IDLE MIXTURE AND TOP END WAS RUNNING LEAN. PROBABLE CAUSE IS INTERNAL FAILURE ON FUEL CONTROL. FEELS AS IF BRASS IS GALLING. 1L71 3O3 O 3A15 E5CE 20030912000282003091200028SO 2003 9 12 2003FA0000752 120030603G3610RA215CC PUMP PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA PNEUMATIC SYS WORN B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP074133D250 2843117 RL202836A DURING GROUND RUN, ENGINE DRIVEN DRY AIR PUMP FAILED TO PUT OUT PROPER PRESSURE AT IDLE RPM. RAN AIRCRAFT UP AND AIR PRESSURE STILL LOW AT HIGHER RPM. 1L71 3O3 O 2A13 E286 20030912000292003091200029SO 2003 9 12 2003FA0000753 120030603G3610RA215CC PUMP PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA DRY AIR FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP074175V 2843126 RL1179636A DURING GROUND RUN, ENGINE DRIVEN DRY AIR PUMP FAILED TO PUT OUT PROPER PRESSURE AT IDLE RPM. RAN AIRCRAFT UP AND AIR PRESSURE STILL LOW AT HIGHER RPM. PROBABLE CAUSE IS HEAT AND VANES WEARING ON THIS DRY AIR PUMP. 1L71 3O3 O 2A13 E286 20030912001502003091200150NE 2003 9 12 2003FA0000754 320030714G6110 PROPELLER GULSTM500 500S 0141107SW LYC O540 TIO540* 41532EA HARTZLHCC3Y HCC3YR2 NE INOPERATIVE B R2JRO OTHER O OTHER NRNOT REPORTED 1 EA2147RF 3261 FC8468 PROPELLER ASSY, AIRCRAFT CREW REPORTED RT PROPELLER GOES TO FEATHER ON TAXI WITH HOT OIL. ENGINE AND PROP GOVERNOR CHANGED. PROPELLER SWAPPED. PROBLEM FOUND TO BE PROPELLER AIR CHARGE PROCEDURE WAS CHANGED IAW MFG LS. C/W THIS SL FIXED PROBLEM . 1H72 3O3 O 6A1 E14EA 5 CP25EA 20030917000232003091700023GL 2003 9 17 2003FA0000756 320030711G6110 BEARING MCAULY2A34C 2A34C50 GL PROPELLER FAILED B N5PRO OTHER O OTHER NRNOT REPORTED 1 SW01 170 710327 PROPELLER LOCKED INTO LOW PITCH TWICE. REMOVED NR 2 BLADE TO INSPECT NR 1 BLADE BUTT. FOUND SEVERAL BALL BEARINGS PRESSED INTO SIDE OF INNER HUB WALL AND FERRULE. BEARING RACE BROKEN, WITH SEVERAL SMALL PIECES IN BOTTOM OF HUB. PROPELLER, HUB HAD BEEN SERVICED WITH AUTOMATIC TRANSMISSION FLUID, NOT RED DYE OIL. PROP WAS OVERHAULED 9/25/95. 5 CP3EA 20030912000222003091200022SO 2003 9 12 2003FA0000757 120030710G53113039205 FRAME PIPER PA23 PA23250 7102308SO LYC O540 TIO540* 41532EA FUSELAGE CORRODED D O OTHER O OTHER NRNOT REPORTED 1 GL2554770 277554078 FRAME HAS SEVERE RUST PITTING ON FRAME TUBING BOTTOM LEFT AND RIGHT SIDES FORWARD OF WELDED CLUSTER. PITTING AREA APPROXIMATELY 1 INCH LONG ALL AROUND TUBING. CAUSE UNKNOWN, HOWEVER THIS IS INBOARD AND AFT OF FLAP AREA. NOTED CONDITION WHEN FLOOR REMOVED FOR ANNUAL AND AD 2008-09-13 FLAP TO TUBING REPAIR NEEDED. THIS AREA SHOULD BE CHECKED ON OTHER AIRCRAFT. 1L72 3O3 O 1A10 E14EA 20030917000252003091700025EA 2003 9 17 2003FA0000758 220030710G8500A6422 SHAFT ROBSINR22 R22BETA 7640110NM LYC O360 O360J2A 41514EA ENGINE FAN DEFECTIVE C A UNSCHED LANDING MJ OVER TEMP WARNING INDICATION HOHOVERING 1 SO35122YB413 3309 L3842936A FANSHAFT SHEARED, WHILE AIRCRAFT WAS IN A HOVER, CAUSING THE COOLING FAN TO DROP INTO THE SCROLL. CAUSE UNKNOWN, BUT BELIEVED TO HAVE STARTED WITH A CRACK CAUSED BY A MANUFACTURING DEFECT. 1G71 3O3 O H10WE E286 20030912000952003091200095 2003 9 12 2003FA0000759 420030404G2564 VALVE LIFE RAFT IMPROPER PART D RU3AO OTHER O OTHER NRNOT REPORTED 1 SW15 WHILE CONDUCTING PART 135 TRAINING OF LIFE RAFT DEPLOYMENT USING A SWITLIK FOUR-MAN LIFE RAFT, THE RAFT FAILED TO INFLATE. IT WAS DISCOVERED THAT .020 STAINLESS STEEL SAFETY WIRE, INSTALLED ON THE BOTTLE VALVE, PREVENTED INFLATION OF THE RAFT. THE VALVE SHOUD HAVE BEEN SAFETIED WITH .020 SOFT COPPER SAFETY WIRE. INVESTIGATION FOUND THAT BOTTLE HAD RECENTLY BEEN RECHARGED. WE IMMEDIATELY BEGAN INSPECTING THE REST OF THE FOUR-MAN RAFTS IN OUR FLEET AND HAVE FOUND 6 BOTTLE VALVES THUS FAR WITH .020 STAINLESS STEEL SAFETY WIRE INSTALLED. 20030912001302003091200130NE 2003 9 12 2003FA0000760 220030603G72502A0847 SEAL IAE V2500 V2500A1 NE NR 4 BEARING CORRODED B KB1RO OTHER O OTHER NRNOT REPORTED 1 NE03 PART RECEIVED FROM REPAIR STATION FOR FPI IAW IAE V2500A1A5 (REV 53) AND V2500D5 (REV 35), ATA 72-43-20, TASK 70-23-02-230-501. PART REJECTED AT FPI FOR HOLES AND PITS ON INNER GROVE. 4 F E311NE 20030917000362003091700036NE 2003 9 17 2003FA0000761 220030423G8530 CYLINDER PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2B NE ENGINE SEPARATED D A UNSCHED LANDING RJ PARTIAL RPM/PWR LOSS WARNING INDICATION CLCLIMB 1 WP014107Q5657 51 318253008 LT ENGINE FAILED DURING CLIMBOUT AT 1500 FEET AGL, 3 MILES FROM TAKE OFF. INSPECTION REVEALED NR 2 CYLINDER SEPARATED FROM CASE, A LARGE SECTION OF THE CASE WAS BROKEN OFF AT THE NR 2 POSITION AND THE CONNECTING ROD WAS SEPARATED FROM THE CRANKSHAFT. 1L72 3O3 O A20SO E14EA 20030917000382003091700038CE 2003 9 17 2003FA0000762 120030616G213113035616 CONTROLLER CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE CABIN PRESSURE MISWIRED B MNGRO OTHER O OTHER NRNOT REPORTED 1 SW05312NC 5500290 PX CONTROLLER REPLACED DUE TO INTERNAL FAILURE AFTER REPLACEMENT PILOT COMPLAINED ABOUT A 6000+ FOOT PER MINUTE CABIN CLIMB RATE AND THAT THE CONTROLLER BACK LIGHTING CAME ON WHEN THROTTLES WERE REDUCED BELOW 90 PERCENT. INSPECTION OF THE SYSTEM REVEALED THAT THE REPLACEMENT CONTROLLER WAS MISS-WIRED AT OVERHAUL. REPLACED THE CONTROLLER NO FURTHER PROBLEMS REPORTED. (SW05200308828) 1L72 4F4 F A22CE E1NE 20030915000182003091500018CE 2003 9 15 2003FA0000763 120030709G3240 B-NUT CESSNA206 T206H 2073303CE BRAKE LINE CRACKED D O OTHER O OTHER NRNOT REPORTED 1 EA212456Q25 T20608273 WHILE PERFORMING SB 03-53-02, FOUND 5 EA (B NUTS) CRACKED, DUE TO OVERTORQUE ON BRAKE LINES. SEG ATTACHED IPC PAGES AND LOCATION OF DAMAGED (B NUTS) NUMERED 1 THRU 5. AC TT 0025.1. LEFT AND RIGHT BRAKES. 1H71 3O RTA4CE 20030918000772003091800077CE 2003 9 18 2003FA0000765 120030718G3610RA216CW PUMP BEECH 33 F33A 1151425CE CONT O520 IO520BB 17032SO PNUEMATIC SYS WORN B VJ3RK NONE O OTHER ININSP/MAINT 1 WP075540P387 CE1335 825826R INSTRUMENT AIR SYSTEM INDICATED LOW OUTPUT ON GAUGE. UPON FURTHER INVESTIGATION OF PNUEMATIC SYSTEM FOUND INSTRUMENT AIR PUMP VANES WHERE WORN. PROBABLE CAUSE IS A COMBINATION OF ENGINE HEAT AND CARBON VANE HARDNESS. 1L71 3O3 O 3A15 E5CE 20030918000782003091800078SO 2003 9 18 2003FA0000766 120030715G792120710A OIL COOLER PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA ENGINE CRACKED B VJ3RO OTHER KJ FLUID LOSS WARNING INDICATION NRNOT REPORTED 1 WP074142Q47 2843207 RL3705736A FOUND OIL LEAK DURING 50 HOUR INSPECTION. FOUND COOLER TO BE CRACKED. RECOMMEND CHANGING TO A SOLID CAN COOLER. 1L71 3O3 O 2A13 E286 20030912000912003091200091CE 2003 9 12 2003FA0000767 120030715G3610RA216CW PUMP BEECH 33 F33A 1151425CE DRY AIR INOPERATIVE B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP078242T256 CE1610 FLIGHT CREW REPORTED THAT GYRO WOULD NOT ERECT AT LOW RPM. DISCOVERED LOW INSTRUMENT AIR PRESSURE. REPLACED AIR PUMP AND SYSTEM OPS CHECKED NORMAL. NO RECOMMENDATION AT THIS TIME. 1L71 3O 3A15 20030918000792003091800079 2003 9 18 2003FA0000768 420030801G6113D7309 SPINNER PIPER PA34 PA34200T 7103406SO CONT O360 TSIO360GB 17025SO RT ENG PROPELLERCRACKED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 SO03644AC194 3449261 PROPELLER SPINNER BULKHEAD, CRACKED. 1L72 3O3 O A7SO E9CE 20030910000652003091000065CE 2003 9 10 2003FA0000770 120030730G3710B906 HOSE CESSNA182 R182 2072734CE LYC O540 O540J3C5 41532EA MCAULY3D32C B3D32C407 GL VACUUM INLET ROTTED D O OTHER O OTHER NRNOT REPORTED 1 SO016201T1302 1302 R18201938 L2358040A 821894 VACUUM SUPPLY LINE (MFG PART NO S 5202-10) LINES FROM THE INLET FILTER TO THE INSTRUMENTS (EASTMAN HY---ON B906 REDI- PLASTICE LINE FELL APART WHEN TOUCHED. THIS AIRCRAFT IS AN ORIGINAL INSTALLATION AND THE SECOND WITH THIS PLASTIC INSTALLED. 1H71 3O3 ORT3A13 E295 5 CEXPP5C 20030910000762003091000076EU 2003 9 10 2003FA0000771 120030718G1410312301901 LINE STBROSSD3 SD360300 EU PWA PT6 PT6A67R 52043NE HARTZLHCA6A HCA6A3A NE LT ENG BLEED AIRBROKEN B E ENGINE SHUTDOWN Y ENGINE STOPPAGE CRCRUISE 1 SO17 227884896 160032 GP35 AIRCRAFT WAS CROSSING THE NORTH ATLANTIC BETWEEN GREENLAND AND ICELAND AND ONCE THEY REACHED CRUSING ALTITUDE THE LEFT ENGINE SHUT DOWN. THEY STARTED LOSING ALTITUDE AND WENT INTO ICELAND. THE LEFT ENGINE BLEED AIRLINE PART NR 3123019-01 HAS BROKEN AT THE MOUNTING POINT AT THE BOTTOM OF THE COMPRESSOR CASE. THIS LINE TAKES COMPRESSOR AIR FROM COMPRESSOR TO THE BLEED AIR FILTER THEN ON TO THE FCU. THE LOSS OF P3 AIR TO THE FCU CAUSED THE ENGINE TO ROLL BACK TO MIN FLOW AND THEN SHUT DOWN. WAS N-360CC NOW G-BNYI 2H72 4T4 TRTA41EU E26NE 6 CP14NE 20030912001492003091200149NE 2003 9 12 2003FA0000772 220030724G7230410126004 DIFFUSER LYC LTS101LTS101600A3 41560NE BLEED HOLE MISOVERHAULED B C7GRK NONE O OTHER ININSP/MAINT 1 SO13 LE43198 DIFFUSER 4-101-260-04 (SN 0062A / C301849) WAS OVERHAULED, TRACKING NR C301849-1 DATED 02/26/2003. RECEIVED DIFFUSER FROM CUSTOMER FOR INSTALLATION IN THEIR ENGINE. UPON INSPECTION, DISCOVERED THAT PART WAS MISSING P3 AIR BLEED HOLE. ADDITIONAL DIMENSIONAL INSPECTIONS WERE PERFORMED, FOUND AT LEAST THREE DIMENSIONS TO BE OUT OF B/P REQUIREMENTS. PART WAS INSPECTED, OVERHAULED IAW DER ROUTING NR AMT-1926/98-25. IN SEPTEMBER OF 2000 A SUSPECT UNAPPROVED PART WAS FILED WITH FAA BY THIS REPAIR STATION, REF. FAA SUP CASE FILE NO. 2001-00016. ON 23 APRIL 2001, WAS NOTIFIED THAT CASE WAS INVESTIGATED AND WAS CLOSED. UNDERSTANDING WAS THAT DER REPAIR WAS RESCINDED. 3 U E5NE 20030915000262003091500026CE 2003 9 15 2003FA0000774 120030731G32301015801881 LINE BEECH 300 300BEECH 1152930CE HYD SYSTEM MISMANUFACTURED B K NONE K FLUID LOSS ININSP/MAINT 1 SW07 3318 FL65 STAINLESS STEEL HYD RETURN LINE TO THE HYD POWER PACK CAME APART AT THE POINT WHERE THE FITTING IS SWEDGED ONTO THE TUBING. THIS LINE APPERARS TO NOT HAVE BEEN SWEDGED. 2L72 4T A24CE 20030918000662003091800066CE 2003 9 18 2003FA0000775 120030731G323398820152 ACTUATOR CESSNA172 172RG 2072438CE MLG CRACKED D A UNSCHED LANDING FJ FLT CONT AFFECTED WARNING INDICATION NRNOT REPORTED 1 WP059592B13641 172RG0905 AFTER TAKE OFF TOWER REPORTED RIGHT MAIN GEAR NOT FULLY RETRACTING. AFTER A NONEVENTFULL LANDING I INSPECTED THE MAIN LANDING GEAR ACTUATORS AND FOUND THE RIGHT ACTUATOR TO BE SEVERLY CRACKED AND THE LEFT ACTUATOR TO HAVE HAIRLINE CRACKS. A FERRY PERMIT WAS FILED WHERE THEY WERE REPLACED THE FOLLOWING DAY. ACCORDING TO THE NTSB THIS AIRCRAFT HAD A SIMILAR FAILURE OF THE RIGHT MAIN GEAR ACTUATOR IN 1992 WHERE IT GEARED UP IN CHICAGO. THE TOTAL CYCLES ARE UNKNOWN, BUT THE PROGRAM WANTED ME TO ENTER IT. 1H71 3O 3A17 20030917001122003091700112CE 2003 9 17 2003FA0000777 120030731G2720 TORQUE TUBE BBAVIA11 11AC 0191102CE RUDDER PEDAL SEPARATED G O OTHER F FLT CONT AFFECTED LDLANDING 1 GL2386233 11AC37 DURING ACCIDENT INVESTIGATION, FOUND BRACKET ATTACHED TO RUDDER PEDAL TORQUE TUBE FOR ATTACHMENT OF LT RUDDER CABLE SEPARATED FROM TORQUE TUBE. BRACKET APPEARED TO HAVE SMALL CRACK AT REAR, APPROXIMATELY 1 INCH BELOW CABLE ATTACHMENT HOLE, AND DURING ACCIDENT, IT APPEARS THAT EXCESSIVE FORCE ON THE RUDDER PEDALS CAUSED THIS BRACKET TO TWIST AND SEPARATE. BECAUSE OF THIS FAILURE, PILOT WAS UNABLE TO RECOVER FROM GROUND LOOP. 1H71 3O A761 20030918000972003091800097SO 2003 9 18 2003FA0000778 120030718G5340795530100 FITTING PIPER PA28 PA28181 7102807SO LYC O360 O360A1D 41514EA COCKPIT CORRODED D O OTHER O OTHER NRNOT REPORTED 1 NE029088Q261 2890002 DURING AN ANNUAL INSPECTION REMOVED TRIM FROM LEFT AND RIGHT WINDSHIELD POSTS. FOUND FOAM INSULATION IN CONTACT WITH STEEL FITTINGS. PN 79553-00 AND 7955301. FITTINGS AND ATTACHING AN3 BOLTS WERE CORRODED. THIS IS THE SECOND INSTANCE OF THIS CONDITION SEVERAL TIMES BEFORE. RECOMMEND REMOVAL OF INSULATION. TREATMENT AND REMOVAL OF CORROSION. REPLACE AFFECTED HARDWARE. APPLY ZINC CHORATE AND DINATROL AV-8 CORROSION PREVENTATIVE. 1L71 3O3 O 2A13 E286 20030918001032003091800103SW 2003 9 18 2003FA0000779 120030624G5730 FABRIC BBAVIA7 7GCAA 21101N8SW LYC O320 O320* 41508EA BOTH WINGS ROTTED D O OTHER O OTHER NRNOT REPORTED 1 EA178642V 31375 WING FABRIC WAS FOUND TO BE ROTTED ALONG THE EDGE OF THE STRAIGHT EDGED FIBREGLASS SURFACE TAPE ON A TWO YEAR OLD FACTORY COVERED WING. THE PAINT PPG SYSTEM DELTA, SHOWS CRACKS ALONG THE EDGES OF ALL SURFACE TAPES ON THE TOP OF BOTH WINGS IN THE PROP ARC. THE BAY THAT ACTUALLY FAILED SHOWED A BROWN STAIN ALONG ITS LENGTH. AIRCRAFT IS NORMALLY HANGARED. 1H71 3O3 O A759 E274 20030918001052003091800105SW 2003 9 18 2003FA0000780 120030717G323310203 SPRING MOONEYM20 M20R 5870225SW CONT O550 IO550* SO MLG ACTUATOR BROKEN G O OTHER O OTHER NRNOT REPORTED 1 NE03557RM37 290210 PILOT WAS UNABLE TO LOWER LANDING GEAR INVESTIGATION REVEALED THAT THE SUBJECT SPRING HAD A BROKEN TANG. RESULTING FAILURE OF LANDING GEAR ACTUATOR. MOONEY SB M20-279C WAS COMPLETED 37 HOURS AGO. 1L71 3O3 ORT2A3 E3SO 20030918001062003091800106SO 2003 9 18 2003FA0000781 120030722G5340795530001 FITTING PIPER PA28 PA28181 7102807SO LYC O360 O360* 41514EA COCKPIT CORRODED D O OTHER O OTHER NRNOT REPORTED 1 NE02820853800 288290132 DURING AN ANNUAL INSPECTION, REMOVED TRIM FROM LEFT AND RIGHT WINDSHIELD POSTS. FOUND FOAM INSULATION IN CONTACT WITH STEEL FITTINGS (PN 7955300 AND 7955301). FITTINGS AND ATTACHING BOLTS (AN3) WERE RUSTED. HAVE FOUND SEVERAL A/C WITH THIS PROBLEM. RECOMMEND REMOVAL OF FOAM INSULATION TREATMENT AND REMOVAL OF CORROSION. REPLACE AFFECTED HARDWARE. APPLY ZINC CHROMATE AND DINATROL AV8 CORROSION PREVENTATIVE. 1L71 3O3 O 2A13 E286 20030918001072003091800107SO 2003 9 18 2003FA0000782 120030710G716086245036 AIR BOX PIPER PA44 PA44180 7104402SO LYC O360 O360* 41514EA RT CARBURETTOR CRACKED B OG5RO OTHER O OTHER NRNOT REPORTED 1 GL21326ND125 4496173 DURING SCHEDULED INSPECTION, RT ENGINE CARB AIRBOX WAS FOUND TO BE CRACKED ADJACENT TO 3 OF THE 4 CARB MOUNTING HOLES. RESEARCH OF FLEET MECHANIC RECORDS INDICATE THIS IS THE SECOND AIRBOX IN 2 WEEKS TO BE FOUND CRACKED IN THE SAME AREA. 1L72 3O3 O A19S0 E286 20030918001092003091800109SO 2003 9 18 2003FA0000783 120030701G2710NAS649816S BARREL PIPER PA18 PA18150 7101828SO LYC O320 O320A2B 41508EA TURNBUCKLE DAMAGED D O OTHER O OTHER NRNOT REPORTED 1 AL0154182 187609043 L4435127A UPON INSPECTION FOUND TURN BARREL THAT HAS GROOVE FOR CLIPS SPLIT LOCATION UPPER RT ALIRON TURNBUCKLE ONLY FOUND THESE STYLE TURN BARRELS THAT DONT REQUIRE SAFETY WIRE ON LATER AIRCRAFT. FOUND THIS BEFORE AND COULD CAUSE LOSS OF AILRON CONTROL IF BROKEN. 1H71 3O3 O 1A2 E274 20030912000982003091200098 2003 9 12 2003FA0000784 420030613G2562465510 ELT MOONEYM20 M20J 5870219SW LYC O360 IO360A1A 41514EA CABIN INOPERATIVE D O OTHER O OTHER NRNOT REPORTED 1 NM02201QX 240367 NEW ELT WAS INOPERATIVE. RETURNED TO SUPPLIER. 1L71 3O3 O 2A3 1E10 20030918001112003091800111SO 2003 9 18 2003FA0000785 120030708G2701410046 SCREW PIPER PA28 PA28181 7102807SO LYC O360 O360A1D 41514EA CONTROL WHEEL LOOSE B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP074141U 2843125 DURING FLEET-WIDE INSPECTION, FOUND SCREW THAT ATTACHES CONTROL WHEEL TO CONTROL SHAFT LOOSE. RECOMMEND DIFFERENT METHOD OF ATTACHMENT OR THE USE OF A LOCKING/ SAFETY DEVICE. 1L71 3O3 O 2A13 E286 20030912000992003091200099SO 2003 9 12 2003FA0000786 120030709G2701MS24694S59 SCREW PIPER PIPER PA28 PA28R201 7102816SO LYC O360 IO360C1C6 41514EA CNTRL WHEEL YOKEUNDERSIZE B FQARO OTHER O OTHER NRNOT REPORTED 1 WP07289PA1464 2844065 THE SCREW THAT HOLDS THE CONTROL WHEEL TO THE YOKE WAS FOUND TO BE BACKED OUT ON THE PILOTS WHEEL BY A .2500 TURN. WHEN THE SCREW BACKS OUT ENOUGH, IT FALLS OUT ALLOWING THE WHEEL TO ROTATE FREELY AROUND THE YOKE. THIS RESULTS IN NO FLIGHT CONTROL INPUT. PROBABLE CAUSE OF THE SCREW BACKING OUT IS THAT THE SCREW IS TOO SHORT. THE MS24964-S59 SCREW IS 1.0937 INCH LONG WITH ONLY HALF A THREAD SHOWING THROUGHT THE NUTPLATE. 1L71 3O3 O 2A13 1E10 20030918001122003091800112SO 2003 9 18 2003FA0000787 120030709G2701MS24694S59 SCREW PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA CONTROL WHEEL BACKED OUT B FQARO OTHER O OTHER NRNOT REPORTED 1 WP07430PA2602 2843488 L3222236A THE SCREW THAT HOLDS THE CONTROL WHEEL TO THE YOKE WAS FOUND TO BE BACKED OUT ON THE PILOTS WHEEL BY A .2500 TURN. WHEN THE SCREW BACKS OUT ENOUGH, IT FALLS OUT ALLOWING THE WHEEL TO ROTATE FREELY AROUND THE YOKE. THIS RESULTS IN NO FLIGHT CONTROL INPUT. PROBABLE CAUSE OF THE SCREW BACKING OUT IS THAT THE SCREW IS TOO SHORT. THE MS24964S59 SCREW IS 1.0937 INCH LONG WITH ONLY HALF A THREAD SHOWING THROUGH THE NUTPLATE. 1L71 3O3 O 2A13 E286 20030918001132003091800113SO 2003 9 18 2003FA0000788 120030709G2701MS24694S59 SCREW PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA CONTROL WHEEL BACKED OUT B FQARO OTHER O OTHER NRNOT REPORTED 1 WP07428PA2398 2843476 RL2983936A THE SCREW THAT HOLDS THE CONTROL WHEEL TO THE YOKE WAS FOUND TO BE BACKED OUT ON THE PILOTS WHEEL BY A .2500 TURN. WHEN THE SCREW BACKS OUT ENOUGH, IT FALLS OUT ALLOWING THE WHEEL TO ROTATE FREELY AROUND THE YOKE. THIS RESULTS IN NO FLIGHT CONTROL INPUT. PROBABLE CAUSE OF THE SCREW BACKING OUT IS THAT THE SCREW IS TO SHORT. THE MS24964-S59 SCREW IS 1.0937 INCH LONG WITH ONLY HALF A THREAD SHOWING THROUGH THE NUTPLATE. 1L71 3O3 O 2A13 E286 20030918001142003091800114SO 2003 9 18 2003FA0000789 120030709G2701MS24694S59 SCREW PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA CONTROL WHEEL BACKED OUT B FQARO OTHER O OTHER NRNOT REPORTED 1 WP07429PA2543 2843487 L2939636A THE SCREW THAT HOLDS THE CONTROL WHEEL TO THE YOKE WAS FOUND TO BE BACKED OUT ON THE PILOTS WHEEL BY A .2500 TURN. WHEN THE SCREW BACKS OUT ENOUGH, IT FALLS OUT ALLOWING THE WHEEL TO ROTATE FREELY AROUND THE YOKE. THIS RESULTS IN NO FLIGHT CONTROL INPUT. PROBABLE CAUSE OF THE SCREW BACKING OUT IS THAT THE SCREW IS TOO SHORT. THE MS24964S59 SCREW IS 1.0937 INCH LONG WITH ONLY HALF A THREAD SHOWING THROUGH THE NUTPLATE. 1L71 3O3 O 2A13 E286 20030918001162003091800116SO 2003 9 18 2003FA0000790 120030709G2701MS24694S59 SCREW PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA CONTROL WHEEL BACKED OUT B FQARO OTHER O OTHER NRNOT REPORTED 1 WP07928PA3508 2843298 L2939636A THE SCREW THAT HOLDS THE CONTROL WHEEL TO THE YOKE WAS FOUND TO BE BACKED OUT ON THE PILOTS WHEEL BY A .2500 TURN. WHEN THE SCREW BACKS OUT ENOUGH, IT FALLS OUT ALLOWING THE WHEEL TO ROTATE FREELY AROUND THE YOKE. THIS RESULTS IN NO FLIGHT CONTROL INPUT. PROBABLE CAUSE OF THE SCREW BACKING OUT IS THAT THE SCREW IS TOO SHORT. THE MS24964-S59 SCREW IS 1.0937 INCH LONG WITH ONLY HALF A THREAD SHOWING THROUGH THE NUTPLATE. 1L71 3O3 O 2A13 E286 20030918001172003091800117SO 2003 9 18 2003FA0000791 120030709G2701MS24694S59 SCREW PIPER PA44 PA44180 7104402SO LYC O360 O360A4M 41514EA SNSNCH76E 76EM8S5 EA CONTROL YOKE BACKED OUT B FQARO OTHER O OTHER NRNOT REPORTED 1 WP07433PA2234 4496063 L3831536A 34792K THE SCREW THAT HOLDS THE CONTROL WHEEL TO THE YOKE WAS FOUND TO BE BACKED OUT ON THE PILOTS WHEEL BY A .2500 TURN. WHEN THE SCREW BACKS OUT ENOUGH, IT FALLS OUT ALLOWING THE WHEEL TO ROTATE FREELY AROUND THE YOKE. THIS RESULTS IN NO FLIGHT CONTROL INPUT. PROBABLE CAUSE OF THE SCREW BACKING OUT IS THAT THE SCREW IS TOO SHORT. THE MS24964S59 SCREW IS 1.0937 INCH LONG WITH ONLY HALF A THREAD SHOWING THROUGH THE NUTPLATE. 1L72 3O3 O A19S0 E286 5 NP4EA 20030918001182003091800118SO 2003 9 18 2003FA0000792 120030709G2701MS24694S59 SCREW PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA SNSNCH76E 76E* EA CONTROL WHEEL BACKED OUT B FQARO OTHER O OTHER NRNOT REPORTED 1 WP07917PA3613 2843306 33416K THE SCREW THAT HOLDS THE CONTROL WHEEL TO THE YOKE WAS FOUND TO BE BACKED OUT ON BOTH THE PILOT AND COPILOTS WHEEL BY A .2500 TURN. WHNE THE SCREWS BACKS OUT ENOUGH, IT FALLS OUT ALLOWING THE WHEEL TO ROTATE FREELY AROUND THE YOKE. THIS RESULTS IN NO FLIGHT CONTROL INPUT. PROBABLE CAUSE OF THE SCREW BACKING OUT IS THAT THE SCREW IS TOO SHORT. THE MS24964-S59 SCREW IS 1.0937 INCH LONG WITH ONLY HALF A THREAD SHOWING THROUGH THE NUTPLATE. 1L71 3O3 O 2A13 E286 5 NP4EA4 20030915000152003091500015SO 2003 9 15 2003FA0000793 120030709G2701MS24694S59 SCREW PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA SNSNCH76E 76EM8 EA CONTROL COLLUMN BACKED OUT B FQARO OTHER O OTHER NRNOT REPORTED 1 WP07445PA2134 2843500 L3833436A 34946K THE SCREW THAT HOLDS THE CONTROL WHEEL TO THE YOKE WAS FOUND TO BE BACKED OUT ON BOTH THE PILOT AND CO-PILOTS WHEEL BY A .2500 TURN. WHEN THE SCREW BACKS OUT ENOUGH, IT FALLS OUT ALLOWING THE WHEEL TO ROTATE FREELY AROUND THE YOKE. THIS RESULTS IN NO FLIGHT CONTROL INPUT. PROBABLE CAUSE IS THA THE SCREW IS TOO SHORT. THE MS24964S59 SCREW IS 1.0937 INCH LONG WITH ONLY HALF A THREAD SHOWING THROUGH THE NUTPLATE. 1L71 3O3 O 2A13 E286 5 NP4EA 20030918001192003091800119SO 2003 9 18 2003FA0000794 120030709G2701MS24694S59 SCREW PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA SNSNCH76E 76E* EA CONTROL WHEEL BACKED OUT B FQARO OTHER O OTHER NRNOT REPORTED 1 WP07288PA1802 2843502 L2840236A 34879K THE SCREW THAT HOLDS THE CONTROL WHEEL TO THE YOKE BACKS OUT ON BOTH THE PILOT AND COPILOTS WHEEL. WHEN THE SCREW BACKS OUT ENOUGH, IT FALLS OUT ALLOWING THE WHEEL TO ROTATE FREELY AROUND THE YOKE. THIS RESULTS IN NO FLIGHT CONTROL INPUT. THIS INCIDENT HAPPENED ON THIS AIRCRAFT PILOT SIDE CONTROL WHEEL FORCING THE PILOT TO MAKE AN EMERGENCY LANDING ON A DIRT ROAD. AFTER LANDING, THE RIGHT WING IMPACTED A TREE CAUSING SEVERE DAMAGE TO THE WING AND FUSELAGE. PROBABLE CAUSE OF THE SCREW BACKING OUT IS THAT THE SCREW IS TOO SHORT. THE MS24964S59 SCREW IS 1.0937 INCH LONG WITH ONLY HALF A THREAD SHOWING THROUGH THE NUTPLATE. ADDITIONALLY, THE LOCKING FEATURE OF THE NUTPLATE HAD FAILED. 1L71 3O3 O 2A13 E286 5 NP4EA4 20030918001202003091800120SO 2003 9 18 2003FA0000795 120030708G2701410046 SCREW PIPER PA28 PA28181 7102807SO LYC O360 O360C1F 41514EA CONTROL WHEEL LOOSE B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP074188T 2843124 DURING FLEET-WIDE INSPECTION, FOUND SCREW THAT ATTACHES CONTROL WHEEL TO CONTROL SHAFT LOOSE. RECOMMEND DIFFERENT METHOD OF ATTACHMENT OR THE USE OF A LOCKING/SAFETY DEVICE. 1L71 3O3 O 2A13 E286 20030918001212003091800121SO 2003 9 18 2003FA0000796 120030708G2701410046 SCREW PIPER PA28 PA28181 7102807SO CONTROL WHEEL LOOSE B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP074133D 2843117 DURING FLEET-WIDE INSPECTION, FOUND SCREW THAT ATTACHES CONTROL WHEEL TO CONTROL SHAFT LOOSE. RECOMMEND DIFFERENT METHOD OF ATTACHMENT OR THE USE OF A LOCKING/SAFETY DEVICE. 1L71 3O 2A13 20030918001222003091800122SO 2003 9 18 2003FA0000797 120030708G2701410046 SCREW PIPER PA28 PA28181 7102807SO LYC O360 IO360A1A 41514EA CONTROL WHEEL LOOSE B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP074163W 2843127 DURING FLEET-WIDE INSPECTION, FOUND SCREW THAT ATTACHES CONTROL WHEEL TO CONTROL SHAFT LOOSE. RECOMMEND DIFFERENT METHOD OF ATTACHMENT OR THE USE OF A LOCKING/SAFETY DEVICE. 1L71 3O3 O 2A13 1E10 20030912000332003091200033CE 2003 9 12 2003FA0000798 120030403G1430A251392 BOLT CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA PROP IMPROPER PART D O OTHER O OTHER NRNOT REPORTED 1 NM03397SP2371 172S8294 RL657951A THE PROPELLER MOUNTING BOLTS ON NEW AC MODEL SEEM TO BE TOO SHORT. THEY DO NOT EXTRUDE AT ALL THRU THE CRANKSHAFT PRESSED THREADED BUSHINGS. USUALLY THE THREADS WILL EXTRUDE 2-3 THREADS THRU THE BUSHING. RECOMMENDATION IS TO HAVE A LONGER BOLT INSTALLED SO THE THREADS EXTRUDE ALL THE WAY THRU THE CRANKSHAFT BUSHINGS AT LEAST 3 THREADS. 1H71 3O3 ONT3A12 1E10 20030918001252003091800125SO 2003 9 18 2003FA0000799 120030623G3213 AXLE PIPER PA25 PA25260 7102508SO LYC O540 O540G1A5 41532EA MCAULY1A200 1A200FA GL MLG FATIGUED D CDMRO OTHER O OTHER NRNOT REPORTED 1 EA178502L5800 254916 L1290040 99999 AIRCRAFT LANDED ON SOFT FIELD WITH A LANDING WEIGHT OF 2850 LB. THE MAX. CERTIFIED GROSS WT 2900 LB. AFTER TOUCH DOWN, APPROX 200FT DOWN THE RUNWAY. THE RIGHT MAIN AXLE FAILED. THE AXLE WAS NOT ORIGINAL EQUIPMENT, LANDING GEAR UNDER STC SA441SW. THE AXLE WAS MACHINED FROM A SOLID PIECE OF ALUMINUM. THE BRAKE OCCURED AT THE TRANSITION OF THE AXLE TO THE MOUNTING FLANGE. RECOMMENDATIONS: AVOID LANDING AT OR NEAR GROSS WEIGHT. INSPECT ALL REMAINING AXLES OF THIS TYPE PRIOR TO FURTHER FLIGHT. CENTER BORE THE ALUMINUM SOLID AXLES AND INSERT A STEEL TUBE. REPLACE ALL SOLID ALUMINUM AXLES WITH STEEL TYPE. (EA17200307288) 1L71 3O3 O 2A10 E295 5 NP874 20030912000162003091200016NE 2003 9 12 2003FA0000800 320030310G6111K6523A24 BLADE NAMER F51 F51D 6402309WP PCKARDV1650 V1650* 49001SO HAMSTD24D 24D50 NE PROPELLER CRACKED B K NONE O OTHER ININSP/MAINT 1 WP238677E 4474865 154011 UPON REMOVING FAIRINGS ON BLADE, CORROSION WAS UNDER FAIRING. PROPELLER CAME FOR AD LONGITUDINAL CRACKS FOUND ON CAMBER AND FACE SIDE BLADE FAIRING. FAIRING WAS ORIGINALLY INSTALLED IN 1940'S. NEED TO REPLACE THEM. 1L71 4V4 V EXPA1L71EXP4V 6 CP784 20030912001512003091200151NE 2003 9 12 2003FA0000802 320030310G6111K6523A24 BLADE HAMSTD NAMER F51 F51D 6402309WP PCKARDV1650 V1650* 49001SO HAMSTD24D 24D50 NE PROPELLER CRACKED B K NONE O OTHER ININSP/MAINT 1 WP238677E 154011 4474865 154011 UPON REMVING FAIRINGS ON BLADE, CORROSION WAS UNDER FAIRING. PROPELLER CAME FOR A.D. LONGITUDINAL CRACKS FOUND ON CAMBER AND FACE SIDE BLADE FAIRING. FAIRING WAS ORIGINALLY INSTALLED IN 1940'S, NEED TO REPLACE THEM. 1L71 4V4 V EXPA1L71EXP4V 6 CP784 20030915000212003091500021GL 2003 9 15 2003FA0000803 120030615G5510PN81611 BRACE AVIAT A1 A1A 2210405GL LYC O360 O360* 41514EA HARTZLHCC2Y HCC2YK1 GL HORIZONAL STAB SHEARED C O OTHER O OTHER NRNOT REPORTED 1 GL15190BA 1447 L3654536A CH33048 PREFLT INSPECTION FOUND THE TERMINAL HOLDING THE LT FORWARD TAIL BRACE TO THE HORIZONTAL STABILIZER TO BE SHEARED OFF. 1H71 3O3 ONCA22NM E286 5 CP920 20030915000282003091500028SO 2003 9 15 2003FA0000804 120030806G7100LW18506 FLYWHEEL PIPER PA44 PA44180 7104402SO STARTER BROKEN B K NONE O OTHER ININSP/MAINT 1 WP07577ER899 4496153 FLYWHEEL ASSEMBLY AFT BELT GROOVE FLANGE BROKEN. FLANGE WEB AREA VERY THIN. 1L72 3O A19S0 20030917000482003091700048CE 2003 9 17 2003FA0000806 120030731G275055651754CR CONTROL CABLE CESSNA500 560CESSNA 2076750CE TE FLAP OUT OF RIG B K NONE O OTHER ININSP/MAINT 1 GL09374QS2400 2400 560475 DURING INSP FLAP PRESELECT CABLE P/N: 5565175-4CR, LOCATED IN COCKPIT CTR PEDESTAL, WAS FOUND BROKEN IN HALF AT SWEDGED BALL END. DURING INSTALLATION OF NEW CABLE IT WAS NOTED THAT NEW CABLE COULD NOT BE RIGGED EXACTLY IAW MM DUE TO LOCATION OF PRESWEDGED BALL ON CABLE. RIGGING SYSTEM IAW MM IS SUCH THAT A PRELOAD EXISTS ON CABLE AT SWEDGED BALL END WHENEVER FLAPS ARE RETRACTED TO ZERO DEGREES. TRYING TO RIG OUT PROBLEM WITH CABLE TURNBUCKLES IS NOT POSSIBLE. CONTACTED MFG AND DISCUSSED SITUATION. SUSPECT THAT CABLE PRESWEDGED BALL IS BEING INSTALLED IN WRONG SPOT ON CABLE. ALL NEW CABLES HAVE THE BALL SWEDGED IN SAME SPOT ACCORDING TO THE MFG. 2L72 4F RTA22CE 20030917000112003091700011SO 2003 9 17 2003FA0000807 120030728G32971159SCAV3856 WIRE HARNESS GULSTMG1159 GIV 3980115SO MLG DAMAGED C K NONE O OTHER ININSP/MAINT 1 NM09941AM114 1499 IN TRYING TO FIT BUSHING, P/N 1159LM20156, TO INSTALL MAIN GEAR JACK ADAPTER, IT WAS FOUND THAT THE PORTION OF THE 1159SCAV385-6 WIRE HARNESS FOR THE NR 4 WHEEL SPEED SENSOR IN TRAILING LINK OF RIGHT HAND LANDING GEAR WAS DAMAGED SUCH THAT BOTH CONDUCTORS ONLY HAD A FEW STRANDS OF WIRE EACH ALLOWING CIRCUIT TO BE COMPLETE. SUSPECT THAT DAMAGE WAS CAUSED PREVIOUSLY AT SERVICE CENTER. HARNESS WAS REPLACED WITH NEW COMPONENT. 2L72 4F RTA12EA 20030918001002003091800100NE 2003 9 18 2003FA0000808 320030310G6111K6523A24 BLADE NAMER F51 F51D 6402309WP PCKARDV1650 V1650* 49001SO HAMSTD24D 24D50 NE PROPELLER CRACKED B O OTHER O OTHER ININSP/MAINT 1 WP238677E 4474865 154011 UPON REMOVING FAIRINGS ON BLADE, CORROSION WAS UNDERFAIRING. PROPELLER CAME FOR AD. LONGITUDINAL CRACKS FOUND ON CAMBER AND FACE SIDE BLADE FAIRING. FAIRING WAS ORIGINALLY INSTALLED IN 1940'S. NEED TO REPLACE THEM. 1L71 4V4 V EXPA1L71EXP4V 6 CP784 20030917001212003091700121SO 2003 9 17 2003FA0000809 220030801G85306524517 CYLINDER CONT O550 IO550N 17042SO ENGINE OUT OF TOLERANCEB K NONE O OTHER ININSP/MAINT 1 SO09 25 686263 DURING ENGINE ASSEMBLY AFTER LIGHTING STRIKE INSPECTION IN ACCORDANCE WITH TCM SB M88-9 FOUND ALL CYLINDERS TO HAVE EXCESSIVE DRY LIFTER CLEARANCE. MANUFACTURERS SPECIFICATION IS .060 TO .200 INCH., ALL CYLINDER ALL VALVES EXCEEDED .200 INCH CLEARANCE. 3 O E3SO 20030917001172003091700117CE 2003 9 17 2003FA0000810 120030731G2770256CF145 GUST LOCK RAYTHNDH125 HAWKER800XP 7150012CE RUDDER MISSING C K NONE O OTHER ININSP/MAINT 1 SW11 258525 RUDDER GUST LOCK WAS MISSING FROM AIRCRAFT. 2L72 4F RTA3EU 20030919000192003091900019CE 2003 9 19 2003FA0000812 120030701G3246130909B177 BOLT BEECH B300 B300 1159232CE BUSHING SEIZED C O OTHER W INADEQUATE Q C NRNOT REPORTED 1 SO13434BW FL109 DURING INSPECTION FOUND BOLT ON NOSE WHEEL DRAG LEG SEIZED IN BUSHING AS THE RESULT OF IMPROPER LUBRICATION. THIS SEEMS TO BE DUE TO A RESENT LUBE POINT DESIGN CHANGE. THE OLD BOLT WAS HOLLOW ALLOWING GREASE TO BE DELIVERED TO THE INNER BUSHING. THE NEW BOLT IS SOLED WITH THE LUBE POINTS ONLY ON OUTER BUSHINGS. 2L72 4T RTA24CE 20030919000202003091900020CE 2003 9 19 2003FA0000813 120030701G3246130909B177 BOLT BEECH B300 B300 1159232CE BUSHING SEIZED D O OTHER W INADEQUATE Q C NRNOT REPORTED 1 SO13583AT FL258 DURING INSPECTION FOUND BOLT ON NOSE WHEEL DRAG LEG SEIZED IN BUSHING AS THE RESULT OF IMPROPER LUBRICATION. THIS SEEMS TO BE DUE TO A RESENT LUBE POINT DESIGN CHANGE. THE OLD BOLT WAS HOLLOW ALLOWING GREASE TO BE DELIVERED TO THE INNER BUSHING. THE NEW BOLT IS SOLID WITH THE LUBE POINTS ONLY ON OUTER BUSHINGS. 2L72 4T RTA24CE 20030919000212003091900021CE 2003 9 19 2003FA0000814 120030701G273011452403725 CONTROL CABLE BEECH 1900 1900D 1154162CE ELEVATOR TRIM BROKEN D O OTHER O OTHER NRNOT REPORTED 1 SO1361HA UE175 DURING A GROUND OPERATIONAL CHECK, THE ELEVATOR TRIM CABLE BROKE. THE PART HAD 7208.0 FLIGHT HOURS AND COMPLIED WITH AD 2003-03-18 AND SAFETY COMMUNIQUE NR 216 ON 02/17/03. 2L72 4T RTA24CE 20030919000232003091900023SW 2003 9 19 2003FA0000815 120030717G7921407340339101 BEARING BELL 407 407 1182206SW ALLSN 250C 250C47B GL COOLER FAN FAILED B O OTHER O OTHER NRNOT REPORTED 1 WP23702WP296 53543 THIS WAS THE REAR OIL COOLER FAN SHAFT BEARING. THIS IS PART OF THE TAIL ROTOR DRIVE SYSTEM FOR THIS AIRCRAFT. THE BEARING SUFFERED A COMPLETE FAILURE. BEARING BALLS WERE FOUND ON THE AIRCRAFT OIL COOLER DECK AREA ALONG WITH PIECES OF BEARING CAGE. ONE BALL FROM THE BEARING WAS FOUND LODGED IN THE OIL COOLER IMPELLAR. THIS CONDITION WAS FOUND ON A ROUTINE MAINTENANCE INSPECTION AT AC TOTAL TIME 296.3. JULY 17, 2003. VERY LITTLE GREASE WAS FOUND ON THESE BEARING PIECES AND THE REMAINING RACES. THE PROBABLE CAUSE WAS LACK OF LUBRICATION INTERVAL OR REPLACEMENT OF THIS BEARING WITH A BEARING OF A DIFFERENT DESIGN, ABLE TO WITHSTAND THE HEAT GENERATED IN THIS AREA AND STILL RETAIN ITS LUBRICATION. 1G71 3U3 UO H2SW E1GL 20030918001392003091800139CE 2003 9 18 2003FA0000816 120030808G2910S3183E1 LINE CESSNA560 560XL 2076702CE HYD SYSTEM CHAFED B K NONE O OTHER ININSP/MAINT 1 GL09637QS2608 5605137 LT FLAP RETRACTION HYDRAULIC LINE, RT AND LT EMERGENCY BRAKE PNEUMATIC LINES CHAFING ON PILLOW BLOCK CLAMPS. 2L72 4F RTA22CE 20030919000092003091900009SO 2003 9 19 2003FA0000817 120030808G716086245836 AIR BOX PIPER PA44 PA44180 7104402SO CARBURETOR BROKEN B O OTHER R PARTIAL RPM/PWR LOSS NRNOT REPORTED 1 WP28572ER333 4496148 PILOT REPORTED SURGING ENGINE AND LOSS OF POWER IN FLIGHT. MECHANIC FOUND DUCT ON CARB AIRBOX FROM INDUCTION FILTER COMPLETELY BROKEN OFF. PARTIALLY BLOCKING INTAKE. REPLACED COMPLETE ASSY. 1L72 3O A19S0 20030918001012003091800101EA 2003 9 18 2003FA0000819 220030731G7310LW120980180 LINE CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA MCAULY1C235 1C235LFA GL FUEL SYSTEM CHAFED D K NONE O OTHER ININSP/MAINT 1 EA152370F2370 50 17280618 L2778551A RE012 NR 2 CYLINDER FUEL INJECTOR LINE RUBBING ON CYLINDER COOLING FIN, CAUSING A DEEP CUT IN OUTER WALL OF FUEL INJECTOR LINE, LEADING TO POSSIBLE ENGINE FIRE. 1H71 3O3 ONT3A12 1E10 5 NP12EA 20030918001402003091800140CE 2003 9 18 2003FA0000820 120030808G2520 SEAT CESSNA172 172M 2072418CE CABIN DAMAGED D O OTHER O OTHER NRNOT REPORTED 1 NM0112577 17262088 NUMEROUS ROLL PINS IN THE PILOT AND PASSENGER SEAT FRAME (TUBULAR) ASSEMBLIES ARE BACKING OUT, ALSO FOUND NUMEROUS ROLL PINS THE EXACT LENGHT AS THE DIAMETER OF THE FRAME. THEREFORE WHEN THE PIN STARTS BACKING OUT THE PIN BENDS INSIDE THE FRAME AND BREAKS, FOUND TWO PINS IN THIS CONDITION.. 1H71 3O NT3A12 20030912000302003091200030SO 2003 9 12 2003FA0000821 120030801G25973507201 CONNECTOR PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA OVERHEAD PANEL BURNED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP074163W3825 2843127 RL3705636A DURING MAINTENANCE ON AIRCRAFT TECHNICIAN FOUND CONNECTOR P5 PINS 5 AND 6 SHOWS SIGNS OF OVERHEATING AND DISCOLORING OF CONNECTOR AND PINS. THESE PINS GO TO THE NAVIGATION LIGHTS. PROBABLE CAUSE OF OVERHEATING IS CURRENT DRAW EXCEEDING DESIGN OF CONNECTORS AND PINS. RECOMMENDATION IS TO INSTALL HIGHER PERFORMANCE CONNECTORS AND PINS. 1L71 3O3 O 2A13 E286 20030912001292003091200129SO 2003 9 12 2003FA0000822 220030730G8500631427220 VALVE BEECH 33 F33A 1151425CE CONT O520 IO520BB 17032SO MANIFOLD FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP075581T93 CE1350 820457R FLIGHT CREW REPORTED THAT THE ENGINE WOULD NOT SHUT DOWN WHEN IDLE CUT OFF WAS SELECTED. PROBABLE CAUSE IS INTERNAL FAILURE, DEBRIS, FAILED DIAPHRAGM. NO RECOMMENDATIONS AT THIS TIME. 1L71 3O3 O 3A15 E5CE 20030915000302003091500030NM 2003 9 15 2003FA0000823 120030729G3213400053501 STRUT PIPER PA60 PA60601 7106010NM LYC O540 IO540S1A5 41532EA MLG BROKEN E TZRAO OTHER O OTHER LDLANDING 1 SW05600TE6973 610146077 TORQUE LINK ATTACH POINT ON THE RIGHT STRUT BROKE AT LANDING. THIS ALLOWED THE RIGHT MLG TIRE TO ROTATE AND PULL THE AIRCRAFT OFF THE RUNWAY. THE RESULTING SIDE LOAD ON THE MLG CAUSED THE OVER CENTER LINK PN 400084-001, AND THE STRUT CYLINDER 400054-001, TO BREAK. ALSO, BOTH RIGHT SIDE MLG DOOR WERE DAMAGED ALONG WITH THE RIGHT FLAP. THE CUFF FOR ATTACHING THE TORQUE LINKS TO THE STRUT IS INSTALLED BY THE SWEAT METHOD. IN THIS CASE, THE CUFF WAS BROKEN AT THE ATTACH POINT FOR THE SCISSORS LINK FOR SOME TIME AND NOT NOTICED DUE TO COVERAGE OF PAINT. IT TOOK A FEW LANDINGS FOR THE SWEAT ATTACHMENT TO BREAK LOOSE. THE DISBONDING WAS EVIDENT BY THE DISCOLOR OF THE SWEAT SEALED AREA ON THE CUFF AND THE STRUT. 1M72 3O3 ORTA17WE 1E4 20030919000352003091900035NM 2003 9 19 2003FA0000824 120030811G5730 SKIN UNIVAR415 A2ALON 0540102NM CENTER WING CORRODED D O OTHER O OTHER NRNOT REPORTED 1 NM106620W A110 WHILE COMPLYING WITH AD NR 2002-26-02 ON THE WING CENTER SECTION OF THIS ERCOUPE WE FOUND SEVERAL SPOTS THAT WERE WELL BEYOND LIGHT CORROSION AND HAD PROGRESSED INTO THE EXFOLIATION STAGE. WE ENDED UP REMOVING THE BOTTOM SKIN ON THE RIGHT WALKWAY TO REPLACE 2 STIFFENERS BEHIND THE RIGHT REAR AUX SPAR. AND REPLACED ANOTHER 9 STIFFENERS IN THE CENTER SECTION WING WALK AREAS. ALL AREAS CLEANED UP, AND ARE PRIMED AND TREATED FOR CORROSION AFTER PARTS REPLACEMENT. 1L71 3O A787 20030917000322003091700032EU 2003 9 17 2003FA0000826 120030729G6710ASNA013735E2 BEARING UROCOP SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE CYCLIC CONTROL ROUGH D O OTHER O OTHER NRNOT REPORTED 1 GL0772HP 2663 2717 9277 CYCLIC CONTROLS PIVOT ON THIS BEARING DURING PITCH INPUTS. BEARING WAS (CATCHING) OR (RATCHETING) CAUSING DIFFICULTY CONTROLLING AIRCRAFT IN PITCH. 1G71 3U3 U H9EU E19EU 20030912001032003091200103CE 2003 9 12 2003FA0000827 120030328G7910BJ1000A13DO DRAIN BEECH 55 95A55 1152704CE CONT O470 IO470* 17026SO VALVE BODY FAILED C O OTHER O OTHER NRNOT REPORTED 1 CE0920JW TC258 QUICK DRAIN FAILED, CAUSING TOTAL LOSS OF ENGINE OIL. AFTER SHUTDOWN OF ENGINE, BROKEN OFF PART WAS FOUND. AFTER REMOVING OIL PAN, ENGINE OIL WAS CHECKED AT TIME OF OIL LOSS AND HAD 4 QUARTS REMAINING, BUT WAS STILL DRAINING. 1L72 3O3 O 3A16 E1CE 20030912000442003091200044EA 2003 9 12 2003FA0000828 220030709G8520 CONNECTING ROD CESSNA150 152 2071835CE LYC O235 O235N2C 41505EA ENGINE BROKEN G O OTHER O OTHER NRNOT REPORTED 1 EA17152AW 715 15285977 L937915 AIRCRAFT MADE EMERGENCY LANDING. NR 3 CONNECTING ROD BROKE, CAUSING A HOLE TO BE PUNCHED IN THE CRANKCASE AND DESTROYING THE CAM FOLLOWER AREA. CAUSE OF FAILURE HAS NOT BEEN DETERMINED. 1H71 3O3 ONT3A19 E223 20030919001042003091900104WP 2003 9 19 2003FA0000829 220030801G7210310286529 GEARBOX AYRES S2 S2RG10 0970217SO GARRTTTPE331TPE331* 01514WP PROPELLER FAILED G A UNSCHED LANDING JX WARNING INDICATION ENGINE FLAMEOUT NRNOT REPORTED 1 GL153299A5361 G10117 ENGINE LOW OIL PRESSURE LIGHT ILLUMINATED, FOLLOWED BY ENGINE FAILURE AND PROPELLER FEATHER. SUBSEQUENT EXAMINATION FOUND SIGNIFICANT QUANTITIES OF FERROUS METAL IN GEARBOX OIL SCREEN, LOW OIL QUANTITY AND FEROUS METAL IN ENGINE OIL TANK. 1L71 3T3 TNCA4SW E2WE 20030910000832003091000083CE 2003 9 10 2003FA0000831 220030707G85306524201048 BOLT CIRRUSSR SR20 05628AJGL CONT IO360 IO360* 17025CE NR 2 & 3 CYL SHEARED D K NONE O OTHER ININSP/MAINT 1 NM01365DP1009 1062 WHILE PERFORMING A COMPRESSION CHECK ON THE CYLINDER FOR THE 100 HOUR INSPECTION, HAPPENED TO LOOK AT THE CYLINDER BOLTS AND NOTICED ONE OF THE NUTS WAS MISSING ON THE TOP FORWARD THRU BOLT ON THE NR 2 CYLINDER. LOOKED AROUND ON THE BAFFLING AND FOUND THE OTHER PIECE OF THE BOLT WITH THE NUT STILL ATTACHED. WENT OVER TO THE NR 3 CYLINDER TO LOOK AND FOUND THAT THE NUT WAS MISSING ON THE THRU BOLT AFTER LOOKING AROUND THE AREA, FOUND THE NUT ON THE CYLINDER BAFFLE. AFTER LOOKING AT THE NUT AND THE THRU BOLT, IT APPEARS THAT THE THRU BOLT WAS OVERTORQUED AT THE FACTORY. HAD TO REPLACE BOTH UPPER AND LOWER THRU BOLTS. 1L71 3O3 ONTA00009CHE1CE 20030915000192003091500019EA 2003 9 15 2003FA0000834 220030808G8530 VALVE GUIDE ROBSINR44 R44 7640120WP LYC O540 O540F1B5 41532EA CYLINDER DAMAGED G O OTHER O OTHER NRNOT REPORTED 1 EA17442EK550 1146 L2599740A CYLINDER ASSY LOCATED AT NR 5 POSITION. EXHAUST VALVE STUCK, UPON REMOVAL OF THE CYLINDER FROM THE ENGINE. THE INTAKE VALVE LIFTER WAS ALSO FOUND TO BE DAMAGED (SHATTERED). 1G71 3O3 O H11NM E295 20030922000112003092200011SO 2003 9 22 2003FA0000835 120030728G2797W20994304 WIRE PIPER PA24 PA24 7102402SO LYC O360 O360* 41514EA LT AILERON FRAYED D O OTHER O OTHER NRNOT REPORTED 1 GL055863P 24946 L135236 REPLACED W2094304, DUE TO 4 FRAYED WIRES. FOUND AT ANNUAL. LOCATION , BEHIND LEFT GEAR WELL COVER WHERE CABLE COMES INTO WING. 1L71 3O3 O 1A15 E286 20030922000122003092200012GL 2003 9 22 2003FA0000836 120030801G5210MS16562224 PIN CIRRUSSR SR20 05628AJGL CONT IO360 IO360* 17025CE CREW DOOR SHEARED D O OTHER O OTHER NRNOT REPORTED 1 EA23823AC116 1201 COPILOTS DOOR WOULD NOT OPEN FROM INSIDE. OUTSIDE HANDLE WORKED OK. UPON DISASSEMBLY, THE PIN (CROSS PIN) FOR THE PILOTS WAS FOUND SHEARED. SAFETY HAZARED EVIDENT. REPLACED PIN FROM PN MS16562-224. NO FURTHER MALFUNCTIONS AT THIS TIME. 1L71 3O3 ONTA00009CHE1CE 20030915000242003091500024CE 2003 9 15 2003FA0000837 120030809G33401520010 POWER SUPPLY CESSNA172 172N 2072434CE LYC O320 O320* 41508EA STROBE MALFUNCTIONED B UVJRO OTHER O OTHER NRNOT REPORTED 1 EA23737XS 17269759 THIS UNIT WAS PURCHASED TO REPLACE AN EXISTING FACTORY UNIT. UPON INSTALLATION IT WAS TESTED AND DETERMINED TO BE MALFUNCTIONING, FLASHES ARE SPACED APPROXIMATELY 10 SECONDS APART. MARKINGS ON THE DATA TAG OF THE POWER UNIT ARE UNCLEAR AS TO THE VOLTAGE. THE TAG INDICATES 12-14 VOLTS. THE PART UMBER IS LISTED AS CAPABLE OF 12 V OR 24 V. 1H71 3O3 ONT3A12 E274 20030922000132003092200013EA 2003 9 22 2003FA0000838 220030813G8520LW18840 CAMSHAFT MOONEYM20 M20J 5870219SW LYC O360 IO360A3B6 41514EA ENGINE SPALLED B PP4RO OTHER O OTHER NRNOT REPORTED 1 SO05205N 998 243030 L1843151A FOUND EVIDENCE OF SEVERE SPALLING ON SEVERAL CAM LOBES. ENGINE HAS 998.37 HOURS SINCE OVERHAUL. CAM WAS REGROUND AT OVERHAUL. 1L71 3O3 O 2A3 1E10 20030922000482003092200048 2003 9 22 2003FA0000839 420030812G2562E01 ELT CIRRUSSR SR20 05628AJGL LYC O360 IO360A1A 41514EA CABIN FALSE ACTIVATIONB O OTHER O OTHER NRNOT REPORTED 1 GL03213CD 1111 WHEN COMM 2 TRANSMITS IT ACTIVATES ELT WHICH THEN NEEDS TO BE MANUALLY SHUT OFF. ELT HAS BEEN EXCHANGED, NO HELP. PROXIMITY OF NR 2 COMM ANTENNA (BOTTOM REAR MOUNT) MAY BE CAUSE OF PROBLEM. 1L71 3O3 ONTA00009CH1E10 20030922000502003092200050CE 2003 9 22 2003FA0000840 120030801G3244021350 TIRE MTSBSIMU2 MU2B36 5780412CE RT MLG FAILED B TUPRO OTHER O OTHER LDLANDING 1 NM09500PJ 668 UPON LANDING, THE TIRE DISINTEGRATED. ASSURE THE TIRE WAS FLAT ON LANDING, DUE TO RUNWAY FOD ON TAKEOFF. 1H72 3T RTA10SW 20030922000512003092200051SO 2003 9 22 2003FA0000841 220030803G8530 CYLINDER HEAD CESSNA414 414A 2075907CE CONT O520 TSIO520NB 17040SO ENGINE SEPARATED D O OTHER RJ PARTIAL RPM/PWR LOSS WARNING INDICATION CRCRUISE 1 NE012618L 414A0284 244785R CYLINDER HEAD SEPARATED FROM THE BARREL IN CRUISE FLIGHT. LIMIT THE USE OF CHROMED CYLINDERS TO NON TURBOCHARGED ENGINES. 1L72 3O3 O A7CE E8CE 20030922000832003092200083EA 2003 9 22 2003FA0000843 220030811G8520 CASE HALF PIPER PA32 PA32300 7103212SO LYC O540 IO540K1A5 41532EA ENGINE LEAKING D O OTHER O OTHER NRNOT REPORTED 1 SO054053W 3240075 L411948 DURING ENGINE ANNUAL INSPECTION, FOUND 3 EA CYLINDER MOUNT THROUGH BOLTS LEAKING. SUSPECT FRETTING CORROSION BETWEEN CASE HALVES. ENGINE REMOVED FOR REPAIR. 1L71 3O3 O A3SO 1E4 20030922000842003092200084SO 2003 9 22 2003FA0000844 120030811G5730 SKIN PIPER PA32 PA32300 7103212SO LYC O540 TIO540* 41532EA FUSELAGE CRACKED D O OTHER O OTHER NRNOT REPORTED 1 SO054053W3396 3240075 DURING ANNUAL INSPECTION, FOUND LEFT WING INBOARD FORWARD SKIN AT ROOT WITH SPIDER CRACKS IN 2 AREAS. ALSO FOUND WALKWAY SURFACE MUSHY, SUSPECT INTERNAL DAMAGE. SUSPECT CRACKS CAUSED BY OVERSTRESS OF WINGS DURING FLIGHT. REPAIR- IN WORK. 1L71 3O3 O A3SO E14EA 20030922000852003092200085SO 2003 9 22 2003FA0000845 120030811G5730 SKIN PIPER PA32 PA32300 7103212SO LYC O540 TIO540* 41532EA WING CRACKED D O OTHER O OTHER NRNOT REPORTED 1 SO054053W 3240075 DURING ANNUAL INSPECTION, FOUND 20 STRESS CRACKS ON TOP OF BOTH WINGS ALONG BOTH LONGITUDINAL STRINGERS AFT OF MAIN SPAR. CRACKS RANGE FROM .250 INCH TO .750 INCH IN LENGTH, AND PROPOGATE ENTIRE LENGTH OF WINGS. SUSPECT CRACKS CAUSED BY OVER-STRESS OF AIRCRAFT DURING FLIGHT. REPAIR IS IN-WORK. 1L71 3O3 O A3SO E14EA 20030922000872003092200087EU 2003 9 22 2003FA0000846 120030812G6210L621M1010054 BLADE UROCOPEC135 EC135P1 8680990EU PWA PW206 PW206A NE MAIN ROTOR CRACKED G O OTHER O OTHER NRNOT REPORTED 1 NM13312MS2304 0129 CRACKS FOUND IN BOTH MAIN ROTOR BLADES IN THE AREA OF THE CONTROL CUFF/ FLEXBEAM VIEWED FROM THE INSPECTION AND DRAIN HOLES. FLEXING BLADES UP AND DOWN YOU CAN SEE THE CRACK OPEN AND CLOSE. ALSO YOU CAN HEAR AN AUDIBLE CLICKING SOUND. 1G72 3U3 UO H88EU E42NE 20030922000892003092200089SO 2003 9 22 2003FA0000847 120030814G5711 SPAR CAP PIPER PA28 PA28180 7102808SO LYC O360 O360* 41514EA RT WING BLISTERED G GH3TO OTHER O OTHER NRNOT REPORTED 1 WP239753J 283868 ON INSPECTION, LARGE BLISTER WAS OBSERVED ON RIGHT WING, OB OF WING TANK FROM WING STA 95 TO STA 108. AREA OF BLISTER WAS APPROX 10 INCHES X 15 INCHES X 3 INCHES. SMALL BLISTER WAS ALSO OBSERVED IB OF FUEL TANK BETWEEN WING STA 55 TO 65. RIVETS WERE DRILLED OUT OF WING PNL OB OF FUEL TANK, PANEL WAS PULLED BACK. FUEL TANK WAS REMOVED FROM RT WING. ON INSP, SEVERE CORROSION, WHICH APPEARED TO BE INTERGRANULAR, WAS SEEN IN TOP CAP OF WING SPAR BETWEEN WING STA 97 TO 108. AREA WAS APPR 10 INCHES IN LENGTH, COVERED ENTIRE WIDTH OF SPAR CAP. SPAR ABOUT .045 MATERIAL REMAINING IN SPAR CAP AREA. LESS CORROSION FOUND BETWEEN WING STATIONS 50 TO 52, 57 TO 63 AND 76 TO 84. (WP23200307722) 1L71 3O3 O 2A13 E286 20030922000912003092200091EA 2003 9 22 2003FA0000848 220030811G8520LW11754 CAMSHAFT MOONEYM20 M20F 5870214SW LYC O360 IO360A1A 41514EA ENGINE SPALLED B PP4RO OTHER O OTHER NRNOT REPORTED 1 SO053534H 750 221437 CAMSHAFT, FOUND EVIDENCE OF SEVERE SPALLING ON SEVERAL CAM LOBES. ENGINE HAD APPROX 750 HOURS ON A FACTORY OVERHAUL. 1L71 3O3 O 2A3 1E10 20030912000972003091200097NM 2003 9 12 2003FA0000849 120030806G2820 FUEL LINE UNIVAR415 415C 0420302NM CONT A75 C7512F 17005SO NACELLE WRONG PART D O OTHER O OTHER NRNOT REPORTED 1 SO132149H239 2772 DURING AN ANNUAL INSPECTION THE FUEL HOSES THAT ARE ROUTED FROM THE RT SIDE OF FIREWALL TO FUEL PUMP HAD BEEN SEVERLY EXPOSED TO HEAT FROM RT EXHAUST STACK CAUSING ONE HOSE TO BUBBLE UP. THESE HOSES DID NOT HAVE FIRE SLEEVE ON THEM. THIS IS AN INFLIGHT FIRE HAZARD. 1L71 3O3 O A718 E233 20030922001132003092200113EU 2003 9 22 2003FA0000850 120030811G2710 BEARING GROB 120 G120A 1660208EU LYC O540 AEIO540D4D5 EA LT AILERON BULGED B VJ3RK NONE O OTHER ININSP/MAINT 1 WP07865AF904 85005 L2826448A DURING SPECIAL INSPECTION OF THE AIRCRAFT REVEALED THAT THE BEARING ON THE LT AILERON LEVER ASSY IS SHOWING SIGNS OF BULGING . PROBABLE CAUSE IS DESIGN OF LEVER ASSY. THE AMOUNT OF USE OF THIS SYSTEM. REDESIGN OR REPLACE BEARING OF A HIGHER QUALITY. 1L71 3O3 ORTA49CE 1E4 20030922001152003092200115SO 2003 9 22 2003FA0000851 220030806G73206314272A13M VALVE BEECH 33 F33A 1151425CE CONT O520 IO520BB 17032SO MANIFOLD FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP075581T 77 CE1350 820457R FLIGHT CREW REPORTED THAT THE ENGINE WOULD NOT SHUT DOWN WHEN IDLE CUT OFF WAS SELECTED. PROBABLE CAUSE IS INTERNAL FAILURE, DEBRIS, FAILED DIAPHRAGM. 1L71 3O3 O 3A15 E5CE 20030922001162003092200116SO 2003 9 22 2003FA0000852 120030701G571167070003 SPAR PIPER PA28 PA28R200 7102811SO LYC O360 IO360A1A 41514EA WINGS CRACKED B BX4RO OTHER O OTHER NRNOT REPORTED 1 NM03751536703 28R7635271 DURING REPAIRS TO BOTH WINGS FOR DAMAGED RIBS AT WING STA B9.24. FOUND THE RT MAIN SPAR CRACKED AT WEB TO LOWER SPAR CAP JUNCTION UNDER THE MAIN GEAR TRUSS BRACKET(PN95642-5P). THE HORIZONTAL CRACK IS APPROX 1.5 INCH LONG, ABOUT .25 INCH OF THE CRACK IS PAST THE OUTBOARD END OF THE TRUSS BRACKET. THE LOWER MOUNT HOLES IN THE SPAR CAP FOR THE TRUSS BARACKET ARE SLIGHTLY ELONGATED. TRUSS BRACKET IS UNDAMAGED WITH .6250 IN STUD, REF AD 97-01-01R1 39-10864, 10-22-98. 1L71 3O3 O 2A13 1E10 20030922001172003092200117CE 2003 9 22 2003FA0000853 120030804G555304310093 ATTACH FITTING CESSNA150 152 2071835CE LYC O235 O235* 41505EA VERTICAL STAB CRACKED D O OTHER O OTHER NRNOT REPORTED 1 GL275364H 15284093 ON ANNUAL INSPECTION FOUND LEFT VERTICAL FIN ATTACH POINT OUTBOARD EAR BROKEN OFF. ALSO FOUND A STEEL TAPERED SHIM (.018 TO .065) UNDER THE RIGHT THREE OF THE FOUR AFT FIN ATTACH FITTING BOLTS. TECH SUPPORT FOUND NO REF TO ANY SUCH PART. REMOVED SHIM AND REPLACED FIN ATTACH FITTING WITH SERVICABLE USED. 1H71 3O3 ONT3A19 E223 20030922001182003092200118CE 2003 9 22 2003FA0000854 120030722G2820 FUEL SYS BEECH 58 58 1152740CE CONT O520 IO520* 17032SO CELL CONTAMINATED B SNARO OTHER O OTHER NRNOT REPORTED 1 NE0586BR TH1072 AIRCRAFT HAS CONTAMINANT IN FUEL SYSTEM, A WHITE GEL/PASTE SUBSTANCE THAT IS CAPABLE OF PASSING THROUGH SCREENS AND CAN CLOG SMALL ORIFICES SUCH AS FLOW DIVIDER BORES. RT ENGINE FAILED ON GROUND AS A RESULT OF FLOW DIVIDER BLOCKAGE, CONTAMINANT IS IN ENTIRE FUEL SYSTEM. 1L72 3O3 O 3A16 E5CE 20030922001192003092200119CE 2003 9 22 2003FA0000855 120030804G2510504516403 INERTIA REEL CESSNA172 172R 2072401CE LYC O360 IO360A1A 41514EA REAR SEAT BELT FAILED B UIVRO OTHER O OTHER NRNOT REPORTED 1 EA2124547 17280796 IT HAS BEEN FOUND THAT THE REAR SEAT BELT LOWER IN REELS WILL NOT PROPERLY RETRACT UNLESS THE BELTS ARE MANUALLLY INSERTED/FED INTO THE REEL ASSY. ADDITIONALLY UNLESS THE BELTS ARE FULLY RETRACTED FIRST, THEY WILL NOT EXTEND. 50 PERCENT OF THE TIME, FACTORY NEW PART EXIBIT SAME PROBLEM. 1H71 3O3 ONT3A12 1E10 20030922001202003092200120CE 2003 9 22 2003FA0000856 120030721G61201317651F ROD END BEECH 36 A36 1151604CE CONT O550 IO550* SO PROP CONTROL WORN B AWKRO OTHER O OTHER NRNOT REPORTED 1 WP25536W 220 E3458 AIRCRAFT WAS IN FOR ITS FIRST ANNUAL INSPECTION SINCE NEW. FOUND FORWARD PROP CONTROL ROD END WORN BEYOND SERVICEABLE LIMITS. PART MAY HAVE MFG DEFECT. 1L71 3O3 O 3A15 E3SO 20030912000522003091200052CE 2003 9 12 2003FA0000857 120030721G61201317651F ROD END BEECH 36 B36TC 1151609CE CONT O520 TSIO520* 17040SO BEECH 278 278* CE PROP CONTROL WORN B AWKRO OTHER O OTHER NRNOT REPORTED 1 WP2536PV 236 EA695 AIRCRAFT WAS IN FOR ITS FIRST ANNUAL INSPECTION SINCE NEW. FOUND FORWARD PROP CONTROL ROD END WORN BEYOND SERVICEABLE LIMITS. PART MAY HAVE A MFG DEFECT. 1L71 3O3 O 3A15 E8CE 5 CP882 20030912000542003091200054SO 2003 9 12 2003FA0000858 120030107G3220NAS464P427 BOLT PIPER PA44 PA44180 7104402SO LYC O360 O360* 41514EA NLG DRAG LINK BROKEN B KRTRO OTHER O OTHER LDLANDING 1 SO092088K5942 447995175 UPON TOUCH DOWN OF THE NOSE GEAR DURING LANDING THE NOSE GEAR COLLAPSED RESULTING IN DAMAGE TO THE NOSE OF THE AIRCRAFT, BOTH ENGINES AND BOTH PROPELLERS. AFTER EXAMINATION OF THE NOSE GEAR IT WAS NOTED THAT THE CENTER DRAG LINK BOLT WAS SHEARED IN THE CENTER AND THE DOWN LOCK HOOK WAS BROKEN IN HALF. NOSE LANDING GEAR DOWN LOCK BUSHING REPLACEMENT. 1L72 3O3 O A19S0 E286 20030912000112003091200011CE 2003 9 12 2003FA0000859 120030815G2140D83A28 HEATER BEECH 95 95B55 1152729CE CONT O470 IO470* 17026SO CABIN CRACKED D O OTHER O OTHER NRNOT REPORTED 1 NM01 TC1541 HEATER COMBUSTION TUBE CRACKED SEVERELY IN MULTIPLE LOCATIONS WHICH LIKELY INDICATES THAT CRACKS HAVE EXISTED FOR SOME TIME.BIG PROBLEM IS THAT THERE IS NO REQUIRED PRESSURE DECAY TEST FOR THESE HEATERS. PRESSURE DECAY TESTING SUCH AS REQUIRED FOR OTHER HEATER MODELS IAW AD 96-20-07 IS PROBABLY MOST EFFICIENT METHOD OF DETERMINING CONDITION OF COMBUSTION TUBE. 1L72 3O3 ORT3A16 E1CE 20030912000122003091200012GL 2003 9 12 2003FA0000860 120030813G7603A155055 THROTTLE CABLE DIAMONDA20 DA20C1 2990001GL CONT O240 IO240B 17063SO SNSNCHW69EK W69EK63 EA ENGINE BROKEN D A UNSCHED LANDING O OTHER CRCRUISE 1 NM03922AF320 C0179 THROTTLE CABLE BROKE IN FLIGHT AT FULL POWER. 1L71 3O3 ONTTA4CH E7SO 5 NTA4CH 20030912000172003091200017EA 2003 9 12 2003FA0000861 220030818G8550LW14789 DIPSTICK LYC O360 O360A1G 41514EA OIL SYSTEM CHAFED D O OTHER O OTHER NRNOT REPORTED 1 WP153724 2600 426 L948136A OIL LEVEL INDICATOR (DIP STICK) ROD BECAME LOOSE IN HOUSING (THREADED CAP) THAT HOLDS ROD IN PLACE. THIS OCCURED WHERE ROD FITS INTO SCREW-IN PART OF DIP STICK CAP. THIS ALLOWED ROD TO MOVE IN AN ARC OVER 1INCH IN TRAVEL OVER A RANGE OF 360 DEGREES (AS MEASURED AT END OF ROD OPPOSITE SCREW-IN CAP) ALLOWING ROD TO RUB AND CHAFE WHERE ROD ENTERS ENGINE CRANKCASE. WHEN MEASURED ROD HAD CHAFED DOWN .030 INCH. MAIN CONCERN WOULD BE THAT ROD WOULD BREAK AT CHAFE POINT OR ROLL PIN WOULD WEAR AND ALLOW ROD TO FALL INTO ENGINE CASE. UPON CHECKING OIL FILTER AND OIL SUCTION SCREEN, NO LARGE AMOUNTS OF METAL WERE FOUND. DIP STICK LW-14789 WAS REPLACED ALONG WITH ENGINE OIL AND FILTER TO CORRECT THIS CONDITION. 3 O E286 20030912000182003091200018CE 2003 9 12 2003FA0000862 120030821G5730501201869 PANEL BEECH 300 B300C 1152933CE WING DEPARTED B O OTHER D INFLIGHT SEPARATION NRNOT REPORTED 1 SW07 VARIOUS WING BOLT PANEL DEPARTED AIRCRAFT WHILE IN FLIGHT. THIS IS THE THIRD OCCURANCE ON THREE DIFFERENT AC IN APPROXIMATELY ONE MONTH. INSPECTION REVEALED THE THE SPRING TAB HAD FAILED. RECOMMEND CLOSE INSPECTION OF THIS PANEL AT EACH PHASE INSPECTION. 2L72 4T RTA24CE 20030923000052003092300005SO 2003 9 23 2003FA0000863 120030812G2752HSBG7S4 BEARING LKHEED1329 132925 5263125SO GARRTTTFE731TFE731* 01518WP FLAP ACTUATOR CRACKED D O OTHER O OTHER NRNOT REPORTED 1 SO01701JH8343 5230 DURING NORMAL FLAP ACTUATOR INSPECTION, FLAP SUPPORTS AT FLAP STA 19.405 WERE FOUND TO NOT ACCEPT GREASE TO THE BEARINGS FOR THE FLAP SUPPORT HINGE, CLOSER INSPECTION ALSO REVEALED THAT THE BEARING BALL HAD CRACKED ACROSS THE LUBRICATION HOLE. TWO BEARINGS WERE FOUND IN THIS CONDITION. BEARINGS WERE REMOVED, LUBE PASSAGE CLEARED AND NEW BEARINGS WERE INSTALLED. 2L74 4F4 F 2A1SO E6WE 20030922000012003092200001EU 2003 9 22 2003FA0000864 120030819G3411 STATIC LINE PILATSPC12 PC1245 7090551EU COCKPIT SEPARATED B O OTHER O OTHER NRNOT REPORTED 1 NM03487PC 487 AT CRUISE ALTITUDE, STATIC SYSTEM LINE UNDER CABIN FLOOR BETWEEN FRAMES 32 AND 33 SEPARATED, INTRODUCING PRESSURIZED CABIN AIR INTO THE STATIC SYSTEM, DAMAGING PILOT AIRSPEED INDICATOR AND PILOT VERTICAL SPEED INDICATOR. THE STATIC LINE INVOLVED PULLED OUT OF A TEE FITTING IN THE SYSTEM. SUSPECTED CAUSE IS THAT THE STATIC SYSTEM LINES ARE BEING CUT TOO SHORT AT THE AIRCRAFT FACTORY, CAUSING UNDUE STRESS WHEN AIRCRAFT IS SUBJECTED TO PRESSURIZATION. THIS DEFECT HAS BEEN NOTED ON ANOTHER AIRCRAFT OF SAME TYPE AT THIS REPAIR STATION. 1L71 3T RTA78EU 20030919000772003091900077SO 2003 9 19 2003FA0000865 120030813G716086245034 AIR BOX PIPER PA44 PA44180 7104402SO ENGINE CRACKED B K NONE O OTHER ININSP/MAINT 1 WP28572ER349 4496148 ENGINE AIRBOX CRACKED IN THE FLANGE AREA WHERE THE CARB HEAT CABLE ATTACH BRACKET IS ATTACHED TO THE AIRBOX ASSEMBLY WITH TWO RIVETS. THIS IS A CONSTANTLY CRACKING AREA ON THE AIRBOX. MFG IS WELL AWARE OF THE PROBLEM AND HAS BROUGHT OUT AN (IMPROVED) ASSEMBLY P/N 86245-836 WHICH IS SUPPOSED TO SOLVE THE PROBLEM. 1L72 3O A19S0 20030922000022003092200002EU 2003 9 22 2003FA0000866 120030819G3411 STATIC LINE PILATSPC12 PC1245 7090551EU COCKPIT SEPARATED B O OTHER O OTHER NRNOT REPORTED 1 SO11487PC 487 AT CRUISE ALTITUDE, STATIC SYSTEM LINE UNDER CABIN FLOOR BETWEEN FRAMES 32 AND 33 SEPARATED, INTRODUCING PRESSURIZED CABIN AIR INTO THE STATIC SYSTEM, DAMAGING PILOT AIRSPEED INDICATOR AND PILOT VERTICAL SPEED INDICATOR. THE STATIC LINE INVOLVED PULLED OUT OF A TEE FITTING IN THE SYSTEM. SUSPECTED CAUSE IS THAT THE STATIC SYSTEM LINES ARE BEING CUT TOO SHORT AT THE AIRCRAFT FACTORY, CAUSING UNDUE STRESS WHEN AIRCRAFT IS SUBJECTED TO PRESSURIZATION. THIS DEFECT HAS BEEN NOTED ON ANOTHER AIRCRAFT OF SAME TYPE AT THIS REPAIR STATION. 1L71 3T RTA78EU 20030924000792003092400079GL 2003 9 24 2003FA0000867 120030826G5346 ATTACH BOLT CIRRUSSR SR22 2130001GL CONT O550 IO550N 17042SO FIREWALL IMPROPER PART B K NONE W INADEQUATE Q C ININSP/MAINT 1 GL13940CD 0259 FOUND LOWER ENGINE MOUNT TO FIREWALL BOLTS LOOSE. BOTH LOWER BOLTS WERE TO LONG AND GRIP LENGTH TO LONG. REPLACED BOTH BOLTS WITH PROPER SIZE AND TORQUED TO SPECS. 1L71 3O3 ONTA00009CHE3SO 20030912000452003091200045EU 2003 9 12 2003FA0000868 120030730G6720AC66375 HOUSING SNIAS 350 AS350BA 8680817EU TAIL ROTOR SERVOCRACKED B QH5RO OTHER O OTHER NRNOT REPORTED 1 NM071430 TAIL ROTOR SERVO BODY, CRACKED IN LOWER FLANGE AREA. 1G71 3U NCH9EU 20030912000932003091200093 2003 9 12 2003FA0000869 420030730G2210AC66375 HOUSING GULSTMGV GULFSTREAMGV3980116SO SERVO CRACKED B QH5RO OTHER O OTHER NRNOT REPORTED 1 NM071540 580 SERVO BODY, CRACK IN LOWER FLANGE AREA. 2L72 4F RTA12EA 20030912000962003091200096CE 2003 9 12 2003FA0000870 120030611G32460723120 TIRE CESSNA150 152 2071835CE NLG DAMAGED B O OTHER O OTHER NRNOT REPORTED 1 GL1794778258 15285785 PILOT NOTICED A LARGE BUMP ON SIDEWALL OF TIRE. UPON INVESTIGATION THE TUBE WAS FOUND TO BE IN GOOD CONDITION BUT TIRE SIDEWALL WAS VERY SOFT, ALLOWING THE TUBE TO PUSH OUTWARD. NO OTHER DEFECTS WERE EVIDENT AND TIRE NEVER LOST AIR PRESSURE. NO HARD LANDINGS WERE REPORTED. TIRE REMOVED FROM SERVICE. 1H71 3O NT3A19 20030915000132003091500013EU 2003 9 15 2003FA0000872 120030814G5540LN90898E4 BEARING GROB 120 G120A 1660208EU LYC O540 AEIO540D4D5 EA RUDDER HINGE FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07862AF1073 85002 L2802448A DURING PRE-FLIGHT INSPECTION, FLIGHT CREW REPORTED A NOISE FROM THE RUDDER. INSPECTION OF THE RUDDER SYSTEM REVEALED A FAILED BEARING IN THE BEARING SUPPORT OF THE LOWER RUDDER HINGE. THE OUTER CASE OF THE BEARING HAD TWO PIECES BROKEN OFF AND MISSING. BEARING WAS RETURNED TO MANUFACTURER FOR INVESTIGATION. RECOMMEND REPLACEMENT OF BEARINGS WITH BETTER QUALITY BEARINGS. 1L71 3O3 ORTA49CE 1E4 20030926000072003092600007GL 2003 9 26 2003FA0000873 220030802G753223053176 BLEED VALVE HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL ENGINE INOPERATIVE B EOORO OTHER MJ OVER TEMP WARNING INDICATION NRNOT REPORTED 1 AL03511SB710 1090592D CAE834299 HIGH TOT - BLEED VALVE POPPET BUSHING SLOPPY IN THE HOUSING. REPLACED UNIT. 1G71 3U3 U H3WE E4CE 20030926000142003092600014WP 2003 9 26 2003FA0000874 120030726G324636902900069 SKID HUGHES369 369D 4470706WP ALLSN 250C 250C* GL MLG CORRODED B EOORO OTHER O OTHER NRNOT REPORTED 1 AL03511SB 1090592D FOUND EXTENSIVE CORROSION AND LOOSE HARDWARE ON SKID TUBE ASSEMBLIES. 1G71 3U3 U H3WE E4CE 20030912000142003091200014 2003 9 12 2003FA0000875 420030818G2561KSD35PO723107 LIFE VEST EMERGENCY EQUIP FAILED B KQ1RO OTHER O OTHER NRNOT REPORTED 1 EA07 LIFE VEST FAILED. MFG RECOMMENDED CELL PRESSURE TEST. DOM: JULY 1987 20030926000162003092600016 2003 9 26 2003FA0000876 420030825G2300GMA340 AUDIO PANEL AMRGENAG5B AG5B 3990100SO LYC O360 O360* 41514EA COCKPIT MISWIRED B HI1RO OTHER W INADEQUATE Q C NRNOT REPORTED 1 NE05934TE 10213 UPON HAVING AN AUDIO PANEL PARTIAL FAILURE, THE PILOT NOTED THAT THE EMERGENCY MODE DID NOT OPERATE. THE UNIT HAD MODE 4 INSTALLED. IN TROUBLESHOOTING, IT WAS DETERMNED THAT THE MONO HEADSET JACKS WERE WIRED TO THE RIGHT STEREO OUTPUT INSTEAD OF THE LEFT AS SHOWN IN THE GM4340 INSTALL MANUAL. 1L71 3O3 ONT1L71 E286 20030926000192003092600019SW 2003 9 26 2003FA0000878 120030819G7910206061505115 OIL TANK BELL 407 407 1182206SW CRACKED C O OTHER O OTHER NRNOT REPORTED 1 WP07 53275 TANK CRACKED IN BODY NEAR VENT, ALSO APPEARS TO BE CRACKED IN APPROX OF FORMED NECK BELLOW WELD. 1G71 3U O H2SW 20030910000772003091000077SO 2003 9 10 2003FA0000879 120030821G2197475213 WIRE PIPER PA31 PA31350 7103110SO BLOWER MOTOR BURNED OUT E A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CE0333JR 5694 318052097 DURING CRUISE FLIGHT, ODOR OF SMOKE WAS NOTED COMING FROM FORWARD COMPARTMENT. DIVERTED TO NEAREST LANDING LOCATION. LANDED WITHOUT INCIDENT. IT WAS NOTED THAT THE AIR CONDITIONING VENT BLOWER CB WAS TRIPPED. NO FURTHER SMELL OR SMOKE WAS NOTED, LANDING WAS STILL EXECUTED. UPON INSPECTION, IT WAS NOTED THAT THE RT VENT BLOWER MOTOR WIRING WAS DAMAGED AT POINT WHERE WIRES GO THROUGH TO THE INTERNAL MOTOR. THERE WAS NO GROMMET OR PROTECTIVE COVERING OVER WIRING TO PREVENT IT FROM CHAFING TO BRONZE BUSHING SURROUNDING IT. SHORT CIRCUIT TO GROUND TRIPPED BREAKER AND ISOLATED THE FAULT. REPLACEMENT MOTOR PN 475-213 IS IMPROVED TO HAVE A NON METALLIC GROMMET SURROUNDING WIRING THAT GOES THROUGH TO MOTOR. 1L72 3O A20SO 20030910000782003091000078WP 2003 9 10 2003FA0000881 220030826G7320211800260 EEC AMD FALC20FALCONF 2720306EU GARRTTTFE731TFE7315BR WP NR 2 ENGINE DEFECTIVE C D RETURN TO BLOCK XJ ENGINE FLAMEOUT WARNING INDICATION TXTAXI/GRND HDL 1 NM09312K 4890 324 103149 DURING TAXI, NR 2 ENG EXPERIENCED AN UN-COMMANDED ENG SHUTDOWN. CREW OBSERVED THE ENG COMPUTER 2 CB (201E2) HAD TRIPPED. POWER LEVER WAS PUT IN CUT-OFF, A/C RETURNED TO RAMP. INSP OF NR 2 ENG INTAKE AND EXHAUST AREAS WAS NORMAL. MAINT TROUBLESHOOTING REVEALED NR 2 DIGITAL ELECTRONIC ENGINE CONTROL (DEEC) TO BE DEFECTIVE. CB COULD NOT BE RESET; IN ADDITION THE DEFECTIVE DEEC CAUSED EMERGENCY BATTERY (93E2) CIRCUIT BREAKER TO OPEN. THE DEFECTIVE PART WAS REPLACED WITH A SERVICEABLE UNIT, CIRCUIT BREAKERS WERE RESET AND DEEC WAS ADJUSTED / TESTED IAW MFG SPECIFICATIONS AND AC WAS RETURNED TO SERVICE. ABOVE MALFUNCTION SHOULD HAVE CAUSED ENG TO TRANSFER TO MANUAL MODE AND NOT CAUSED AN ENGINE SHUTDOWN. 2L72 4F4 F A7EU E6WE 20030912000232003091200023CE 2003 9 12 2003FA0000882 120030519G5797 WIRE CESSNA500 560CESSNA 2076750CE RT TE FLAP WORN B O OTHER O OTHER NRNOT REPORTED 1 GL2549NS 5600116 NAV LIGHT CIRCUIT BREAKER POPPED. TROUBLESHOT, FOUND WIRES IN RIGHT FLAP AREA HAD WORN THROUGH PROTECTIVE SLEEVE AND WIRE INSULATION. FOUND BARE SPOTS ON OTHER WIRES IN SAME AREA. RECOMMEND THAT THESE AREA BE INSPECTED CLOSELY FOR INSULATION SLEEVE BEING WORN THROUGH. 2L72 4F RTA22CE 20030910000702003091000070CE 2003 9 10 2003FA0000883 120030905G54106621280103 PANEL CESSNA560 560XL 2076702CE HEATSHIELD CRACKED B K NONE O OTHER ININSP/MAINT 1 CE09676QS2044 5605176 DURING INSPECTION FOUND RT WING, INBOARD LEADING EDGE BLEED AIR TUBE HEATSHIELD PANEL LOWER MOUNT FLANGE CRACKED APPROXIMATELY HALF WAY LENGTHWISE. THIS IS THE THIRD C-560XL THAT WE HAVE FOUND THIS CONDITION ON. REPLACED THE PANEL WITH NEW. 2L72 4F RTA22CE 20030912000212003091200021CE 2003 9 12 2003FA0000884 120030903G5540 BUSHING BBAVIA8 8KCAB 2110612CE RUDDER LOOSE B K NONE O OTHER ININSP/MAINT 1 WP07330MS838 75095 RIGHT FORWARD RUDDER ATTACH BUSHING COTTER PIN HEAD WORN OFF BY CYCLIC CONTACT WITH FLOORBOARD. PIVOT BUSHING WAS FOUND MORE THAN HALF WAY OUT OF RUDDER ATTACH POINT. 1H71 3O A21CE 20030912000322003091200032SW 2003 9 12 2003FA0000885 120030903G5411 CLAMP FRCHLDSA227 SA227CC 3377522SW ENGINE TRUSS BROKEN D O OTHER O OTHER NRNOT REPORTED 1 SW05 ON AIRCRAFT ENGINE TRUSS ADEL CLAMPS FROM 3 O'CLOCK POSITION TO 9 O'CLOCK ARE SEVERLY BRITTLE AND ARE BREAKING, AND CORRODING THE ASSEMBLY DUE TO THE HIGH HEAT BEING GENERATED FROM THE ENGINE. 2L72 4T RTA18SW 20030912000192003091200019NE 2003 9 12 2003FA0000887 220030908G7320109063064103 ATTACH FITTING AGUSTAA109 A109E 0260119EU PWA PW206 PW206B 0 NE FUEL CONTROL LOOSE D O OTHER O OTHER NRNOT REPORTED 1 SO156VZ 796 150 11099 ENGINE FUEL CONTROL LINKAGE ATTACHING NUT HAS BACKED OUT. THIS HAS ACCURED FIVE TIMES IN THE PAST, ON DIFFERENT AIRFRAMES OPERATED. THE RESULT OF THE NUT BACKING OFF THE FUEL CONTROL ACTUATING SHAFT CAUSED A LOSS OF MANUAL CONTROL VIA THE POWER LEVER IN COCKPIT. THE A109E POWER CONTROL SYSTEM IS ONE OF A REDUNDENT NATURE , SO NO LOSS OF POWER WAS EXPERIENCED IN FLIGHT. THESE AIRCRAFT ARE NOT OPERATED IN CIVILIAN CATAGORY, AND THIS DISCREPENCY IS OF AN ISOLATED NATURE, WHICH HAS BEEN CORRECTED USING UPDATED INSPECTION METHODS LOCALLY. 1G72 3U3 URTH7EU E42NE 20030915000172003091500017CE 2003 9 15 2003FA0000888 120030908G2710626010625 CONTROL CABLE CESSNA650 650 2076802CE RT AILERON BROKEN B PAZRO OTHER F FLT CONT AFFECTED CRCRUISE 1 CE03651EJ4708 59 6500241 RT AILERON OUTBOARD FORWARD CABLE WAS FOUND BROKEN AT OUTBOARD PULLEY LOCATION. PILOT NOTICED AIRCRAFT ROLLING TO RIGHT. LOOKED OUT WINDOW AND FOUND RT AILERON DEFLECTED UP APPROXIMATELY 2 INCHES FROM NEUTRAL POSITION. AIRCRAFT LANDED WITHOUT INCIDENT. UPON VISUAL INSPECTION ON GROUND BY MECHANIC, FOUND RT AILERON CABLE BROKEN. INSPECTED PULLEYS AND SURROUNDING STRUCTURE AND FOUND SATISFACTORY. CABLE WAS REPLACED WITH A NEW CABLE AND RIGGED IAW MAINTENANCE MANUAL. 2L72 4F A9NM 20030929000042003092900004EA 2003 9 29 2003FA0000890 220030521G8500 ENGINE ROBSINR44 R44 7640120WP LYC O540 O540F1B5 41532EA MAKING METAL B O OTHER O OTHER NRNOT REPORTED 1 GL09244HP556 0427 L2516940A DURING SCHEDULED INSPECTION FOR PART 135 OPERATOR, FOUND OIL FILTER CONTAMINATED WITH METAL PARTICLES. METAL WAS IDENTIFIED AS PROBABLE FROM CAMSHAFT. ENGINE REMOVED AND SENT TO MFG FOR REPAIR. MFG FOUND CAMSHAFT AND LIFTERS FAILED. ENGINE REPAIRED BY MFG AND RETURNED. 1G71 3O3 O H11NM E295 20030930000502003093000050SW 2003 9 30 2003FA0000892 120030806G3233 NUT MOONEYM20 M20G 5870316SW LYC O360 O360* 41514EA ACTUATOR FAILED G O OTHER O OTHER NRNOT REPORTED 1 EA213680N 680034 FAILURE TO SECURE JAM NUT ALLOWED ACTUATOR TO UNTHREAD FROM ROD END BEARING. THIS CAUSED OUT OF RIG CONDITION OF LANDING GEAR AND INABILITY TO EXTEND GEAR TO DOWN AND LOCKED POSITION VIA NORMAL OR EMERGENCY. 1L71 3O3 O 2A3 E286 20030912001362003091200136GL 2003 9 12 2003FA0000893 320030811G614026060141RX INDICATOR CESSNA208 208B 2073701CE PWA PT6 PT6A45 52043EA MCAULY3AF34C3GFR34C703 GL PROP TACH MALFUNCTIONED B RF1RO OTHER O OTHER NRNOT REPORTED 1 SW0164BP 7226 208B0604 PROPELLER RPM GAUGE INDICATED 300 RPM OVER REDLINE DURING FLIGHT. PILOT PERFORMED PRECAUTIONARY LANDING AT FIELD OTHER THAN PLANNED. FURTHER INVESTIGATION OF ENGINE AND SYSTEM: NOR TORQUE FLUCTUATUON, NO ITT FLUCTUATION, NO N FLUCTUATION, INDICATOR FAILURE ONLY. REPLACED INDICATOR. OPS CHECKED GOOD. 1H71 3T4 T A37CE E4EA 5 CP60GL 20030930000532003093000053CE 2003 9 30 2003FA0000894 120030721G3230AN51588 SCREW BEECH 55 9555 1152702CE CONT O470 IO470* 17026SO MLG BRACE ASSY BROKEN G O OTHER O OTHER NRNOT REPORTED 1 GL15517DC6350 TC1029 SCREW BROKEN, ALLOWING TRUNNION PIN TO BACK OUT. RETRACT BRACE BECAME LOOSE ALLOWING DOWN AND LOCK TO (UNLATCH). WHEN THAT HAPPENED THE RT MAIN GEAR COLLAPSED (ON ROLL OUT) AND DAMAGED THE RIGHT FLAT, WING TIP, AND BRAKE ASSEMBLY. PROPELLER STRUCK THE GROUND AS WELL. (GK15200314901) 1L72 3O3 O 3A16 E1CE 20030930000542003093000054CE 2003 9 30 2003FA0000895 120030714G27010513167200 CONTROL WHEEL CESSNA210 210C 2073412CE CONT O470 IO470* 17026SO COCKPIT BROKEN D O OTHER O OTHER NRNOT REPORTED 1 NM019794X 21058094 05131682 CONTROL WHEEL BROKE ON LT TOP .7500 INCH FROM CORNER ON LIFT OFF VX ON PILOTS SIDE. THIS IS THE OLD SQUARE CONTOL WHEEL AND IS ORIGINAL PART, 40 YEARS OLD. BROKEN CONTROL WHEEL SHATTERED, PUSH TO TALK SWITCH FASTENED TO CONTROL AT SAME LOCATION. CONTROL WHEEL IS WHITE PLASTIC WITH BLACK PLASTIC COATING OVER ALL SURFACES. 1H71 3O3 O 3A21 E1CE 20030930000552003093000055NM 2003 9 30 2003FA0000896 120030809G572013034 BRACKET UNIVAR415 415C 0420302NM CONT C85 C8512 17008SO MCAULY1A90 1A90CF GL LT WING CORRODED D O OTHER O OTHER NRNOT REPORTED 1 SW19870553970 228 208512 8374 REMOVED AND REPLACED (2) ANGLE BRACKETS IN LT WING WALKWAY THAT WERE ATTACHED TO THE RIB. THESE WERE FOUND CORRODED DURING THE INSTALLATION OF INSPECTION PANELS BEING INSTALLED TO COMPLY WITH AD 02-26-02. IT APPEARED WATER HAD BECOME TRAPPED INSIDE TRAILING EDGE OF WALKBOX AND CORROSION HAD SET IN. THE RIB WAS NOT AFFECTED. AIRCRAFT NEEDS SMALL DRAIN HOLE IN THIS AREA FOR DRAINAGE. 1L71 3O3 O A718 E233 5 NP842 20030930000622003093000062SW 2003 9 30 2003FA0000897 120030702G3230143331853 BRACE TMPSONNAVIONNAVIONG 6150120SW CONT O470 IO470* 17026SO MLG CRACKED G O OTHER O OTHER NRNOT REPORTED 1 GL172418T2671 NAV42418 BRACE WAS FOUND TO HAVE TWO CRACKED OUT WELD JUST BELOW UPPER WRIST. THE FIRST CRACK PROCEEDED 150 DEGREES AROUND THE WELD AND THE SECOND 150 DEGREES ON THE OPPOSITE SIDE. THE TWO CRACKS DO NOT MERGE. THE CRACKS WERE FOUND DURING ANNUAL INSPECTION WITH THE NAKED EYE, A DYE PENTRATE INSPECTION CONFIRMED THE INITIAL FINDING. UNIT WAS REMOVED FROM SERVICE. 1L71 3O3 O A782 E1CE 20030930000642003093000064CE 2003 9 30 2003FA0000898 120030828G2910551701055 LINE CESSNA501 501 2076603CE HYD SYSTEM CORRODED B X6URO OTHER KJ FLUID LOSS WARNING INDICATION NRNOT REPORTED 1 SW1553BB 6650 5010146 DURING GEAR RETRACTION AND GEAR EXTENSION, HYDRAULIC FLUID LEAKED UNDER PRESSURE. FOUND THIS LINE CORRODED SO BADLY THAT A HOLE HAD BEEN FORMED IN THE LINE. THE CORROSION WAS DUE TO PREVIOUS ROUTING OF AIR CONDITIONING DUCT TY-WRAPPED TO THE FOUR LANDING GEAR HYDRAULIC LINES. CONDENSATION INSIDE THE DUCT AND THE DUCT WIRE SPIRAL OF THE DUCT MAKING CONTACT WITH THE HYDRAULIC LINES CREATED THIS SEVERE CORROSION AND HYDRAULIC LINE FAILURE. ALL FOUR (4) LANDING GEAR HYDRAULIC LINES WERE REPLACED DUE TO CORROSION. THIS IS AN INSTALLATION PROBLEM WITH THE FREON AIR CONDITIONING SYSTEM. 1L72 4F A27CE 20030930000652003093000065CE 2003 9 30 2003FA0000899 120030707G2820631293 ELBOW CESSNA421 421C 2076016CE CONT O520 GTSIO520L 17032SO LT ENGINE BROKEN C DYVSO OTHER KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 NM072655B271 421C0698 277163R AT CRUISE, PILOT NOTICED A BLUE FUEL STAIN STREAMING BACK FROM THE LEFT ENGINE COOLING LOUVRES. FOUND BROKEN 90 DEGREE ELBOW FITTING ON FUEL MANIFOLD VALVE INLET WAS BROKEN DUE TO VIBRATION OF ENGINE. 1L72 3O3 O A7CE E7CE 20030930000662003093000066GL 2003 9 30 2003FA0000900 320030812G6114C514C HUB MCAULY3AF32C3AF32C* GL PROPELLER CRACKED B F3PRO OTHER O OTHER NRNOT REPORTED 1 SW15 1400 891104 891104 CRACK FOUND WITH ZYGLO INSPECTION DURING PROP OVERHAUL. 5 CP22EA 20030930000672003093000067 2003 9 30 2003FA0000901 420030818G2562E01 ELT PIPER PA32 PA32300 7103212SO LYC O540 IO540* 41532EA CABIN FAILED G K NONE O OTHER ININSP/MAINT 1 EA056373C 327840081 DURING AN ACCIDENT INVESTIGATION THAT DESTROYED THIS AIRCRAFT. IT WAS NOTED THAT THE ELT DID NOT ACTIVATE THE ELT WAS FOUND IN THE ARMED SWITCH POSITION. THIS AIRCRAFT HIT SEVERAL TREES AND IMPACTED THE GROUND VERY HARD. 1L71 3O3 O A3SO 1E4 20030930000702003093000070CE 2003 9 30 2003FA0000902 120030711G7820C1560200101 MUFFLER CESSNA172 172RG 2072438CE LYC O360 O360F1A6 41514EA MCAULY2D34C B2D34C220 GL ENGINE EXHAUST CRACKED B K NONE O OTHER ININSP/MAINT 1 GL179515B1185 172RG0846 L2769436A 851376 WHILE INSPECTING MUFFLER AND SHROUD IAW AD 83-14-04, A CRACK WAS FOUND AROUND A WELD ON THE AFT END OF THE CAN. 1H71 3O3 O 3A17 E286 5 CP7EA 20030930000732003093000073EU 2003 9 30 2003FA0000903 120030814G6510N651G10V1021 BEARING AGUSTAA109 A119 0261102EU PWA PT6 PT6* 52043EA T/R DRIVE DISLODGED D EH1RK NONE O OTHER ININSP/MAINT 1 EA13172P 41 14027 DURING INSPECTION TAIL ROTOR DRIVE SHAFT BEARING WAS FOUND WITH SEAL AND RETAINING RING DISLODGED FROM BEARING. THIS BEARING IS CHECKED BY FLIGHT CREW. THIS IS THE SECOND BEARING REPLACED IN 72.1 HOURS. 1G72 3U3 T H7EU E2NE 20030930000742003093000074WP 2003 9 30 2003FA0000904 120030808G2560C6284 BUCKLE ROBSINR44 R44 7640120WP LYC O540 O540* 41532EA PAX SEAT BELT CRACKED B QC0RO OTHER O OTHER NRNOT REPORTED 1 SO177085U1695 0607 THE LT REAR PASSENGER SEAT BELT BUCKLE ASSY WAS INSPECTED DURING A 100 HOUR INSPECTION AND WAS FOUND TO BE CRACKED. THE CRACK HAD DEVELOPED IN THE STAINLESS STEEL STRAP AT THE BUCKLE TO STRAP RIVIT ATTACH POINTS. THIS STRAP IS FORMED IN A HORSESHOE SHAPE AROUND THE BUCKLE WITH TWO RIVETS ATTACHED TO ONLY ONE SIDE OF THE STRAP. THIS ALLOWS MORE FLEXING OF THE BUCKLE DURING NORMAL OPERATION AND SUBSEQUENT CRACKING OF THE STRAP. THIS AREA IS HIDDEN BY A PLASTIC COVER AND MUST BE INSPECTED CLOSELY, AS THIS IS NOT THE FIRST BUCKLE OF THIS TYPE TO HAVE BEEN FOUND CRACKED. 1G71 3O3 O H11NM E295 20030926000982003092600098CE 2003 9 26 2003FA0000905 120030902G521066113598 PUSHROD CESSNA560 560XL 2076702CE PAX DOOR CHAFED B K NONE O OTHER ININSP/MAINT 1 GL07 5227 5605227 DURING A ROUTINE INSPECTION OF THE MAIN ENTRY DOOR, IT WAS DISCOVERED THAT THE DOOR OPENING / CLOSING PUSHROD WAS RUBBING AGAINST THE CUT OUT IN THE DOOR STRUCTURE. 2L72 4F RTA22CE 20030912000102003091200010EU 2003 9 12 2003FA0000908 120030910G2810 FUEL TANK ISRAEL1125 ASTRASPX 4500205EU CENTER LEAKING B K NONE K FLUID LOSS ININSP/MAINT 1 CE09302TS1394 108 FUEL LEAKING INTO THE AIRCRAFT CABIN FROM THE AIRCRAFT CENTER TANK DUE TO IMPROPER INTERNAL AND EXTERNAL SEALING AT MANUFACTURE. THE FUEL TANK FASTENERS APPEAR TO HAVE BEEN INSTALLED WITHOUT ADEQUATE SEALING. RECOMMEND ACO NOTIFICATION AS THIS HAS BEEN AN HISTORICAL PROBLEM WITH THE ASTRA SPX. CONDITIONS SUGGEST THAT THE SEALANT MATERIAL IS EFFECTIVE, HOWEVER, THERE APPEARS TO BE A PROBLEM IN THE APPLICATION OF THE SEALANT AND QUALITY CONTROL. THE FUEL TANK SEALANT WAS REMOVED, THE AREA CLEANED, AND RESEALED. 2L72 4F RTA16NM 20030912000132003091200013CE 2003 9 12 2003FA0000909 120030911G32468A080002074 CONTROL CABLE WIPLINEINC CESSNA208 208 2073702CE WATER RUDDER MISINSTALLED B K NONE W INADEQUATE Q C ININSP/MAINT 1 GL09912DS104 20800361 DURING A SCHEDULED INSPECTION FOUND THE LEFT WATER RUDDER CABLE IN EMPENNAGE WAS OFF ITS PULLEY AND CUTTING INTO THE PULLEY BRACKET. THE PULLEY SAFETY PIN HAD BEEN INSTALLED IN THE BRACKETT WHILE THE CABLE WAS NOT ON THE PULLEY AT THE TIME OF THE FLOAT INSTALLATION. REPLACED THE BAD BRACKET AND INSTALLED A NEW CABLE, THEN FOUND THAT THE RIGHT WATER RUDDER CABLE WAS MANUFACTURED TOO LONG TO COMPENSATE FOR THE INCORRECT ROUTING OF THE LEFT CABLE. CUT THE RIGHT CABLE TO PROPER LENGTH AND INSTALLED A NEW CABLE END AND RIGGED WATER RUDDERS. ALL WORK WAS PERFORMED IAW INSTRUCTION MANUALS AND DISCUSSIONS WITH MFG TECH SERVICE PEOPLE. 1H71 3T NTA37CE 20030912000352003091200035EA 2003 9 12 2003FA0000910 220030910G7261 SPRING DHAV DHC6 DHC6300 2802606EA PWA PT6 PT6A27 52043EA HARTZLHCB3T HCB3T* GL LT ENG OIL CAP BACKED OUT B E ENGINE SHUTDOWN K FLUID LOSS CLCLIMB 1 SW01 206101348 429 PCE40881 OIL CAP WAS NOT FULLY ENGAGED IN OIL TANK CAUSING LOSS OF APPROX 6 QUARTS OIL DURING CLIMB OUT. DISCOVERED OIL CAP UNLATCH ASSIST SPRING HAD DISENGAGED FROM HOLE IN CAP LATCH BAR. THIS ALLOWED OIL CAP LOCKING TAB TO LOCK WITHOUT OIL CAP FULLY ENGAGED IN OIL TANK. INSPECTED SIX ENGINES AND FOUND TWO CAPS WITH THIS SPRING AND FOUR WITH A SPRING DESIGN WHICH WAS BENT OVER DURING MFG TO PREVENT DISENGAGEMENT. NO OIL CAP PN CHANGE OR SB FOUND FOR CHANGE. REPLACED BOTH OIL CAPS. 1H72 3T4 TRTA9EA E4EA 6 CP15EA 20031002000682003100200068CE 2003 10 2 2003FA0000911 120030909G5711052309608 SPAR CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA MCAULY1C235 1C235LFA GL RT WING CRACKED D K NONE O OTHER ININSP/MAINT 1 GL113517S1075 17281083 L2997251A VB48036 DURING MAINTENANCE OF THE AIRCRAFT IN WHICH THE RIGHT FUEL TANK WAS OPENED UP, A CRACK WAS FOUND IN THE AFT SPAR. THE CRACK EXTENDS FROM WS 33.0 TO 34.375 AND IS APPROX 1.375 INCHES LONG. THE CRACK IS LOCATED IN THE UPPER BEND RADIUS OF THE AFT SPAR. 1H71 3O3 ONT3A12 1E10 5 NP12EA 20030912000942003091200094EU 2003 9 12 2003FA0000912 120030814G2910723552387 LINE ISRAEL1124 1124 4500102EU GARRTTTFE731TFE731* 01518WP LT BRAKE CORRODED D O OTHER O OTHER NRNOT REPORTED 1 EA17809JC11864 298 BRAKE LINE IS MADE FROM -4 ALUMINUM LINE. CRACK STARTS .2500 INCH FROM FLARED END, AND RUNS APPROX. .3750 INCH LONG LENGTH OF LINE. PROBABLE CAUSE IS FATIGUE OR LINE STRESSED, OR CORROSION. 2M72 4F4 F A2SW E6WE 20030915000122003091500012EA 2003 9 15 2003FA0000913 220030801G853014187 EXHAUST VALVE STOLAMRC3 RC3 3080203NM FRNKLN6A82156A8215* 27030EA NR 4 CYLINDER MISSING G O OTHER O OTHER NRNOT REPORTED 1 GL156201K 397 23433 DURING CRUISE ENGINE STARTED RUNNING. ROUGH AND LOST POWER. AIRCRAFT MADE EMERGENCY LANDING IN CORN FIELD. FOUND EXHAUST VALVE NR 4 ENGINE CYLINDER MISSING AND HOLE IN PISTON HEAD. (.5 INCH X 2.5 INCH) HOLE. 1H71 3O3 ORCA769 E242 20031002001672003100200167CE 2003 10 2 2003FA0000914 120030825G53205142003491 BRACE CESSNA414 414A 2075907CE CONT O520 TSIO520* 17040SO FUSELAGE CRACKED B E5WRO OTHER O OTHER NRNOT REPORTED 1 GL216631C 414A0038 CRACK LIKE INDICATION WHICH EXCEEDS 0.020 INCH IAW MEB 91.11 REV 1 (02/24/03) CRACK LIKE INDICATION DETECT BY EDDY CURRENT INSPECTION. 1L72 3O3 O A7CE E8CE 20031002001692003100200169GL 2003 10 2 2003FA0000915 320030825G614026060141RX INDICATOR CESSNA208 208B 2073701CE PWA PT6 PT6A45 52043EA HARTZLH3B3M HCB3M GL PROPELLER FAILED B RF1RO OTHER O OTHER NRNOT REPORTED 1 SW0164BP 7226 208B0604 PROPELLER RPM INDICATED 300 RPM HIGH DURING FLIGHT. PILOT PERFORMED PRECAUTIONARY LANDING. NO OTHER PERIMETER FLUCTUATIONS. REPLACED INDICATOR WITH NEW PART. OPERATIONAL CHECK GOOD. 1H71 3T4 T A37CE E4EA 5 CP9NE 20030915000042003091500004NE 2003 9 15 2003FA0000916 220030818G726110585J HEATER BEECH 200 B200 1152922CE PWA PT6 PT6A42 52043NE ENGINE OIL CRACKED D O OTHER K FLUID LOSS NRNOT REPORTED 1 NM01706TA BB1656 PCEPJ0276 TROUBLESHOT NR 2 ENGINE OIL LEAK. FOUND A HAIRLINE CRACK NEAR UPPER INBOARD WELD OF PARTS MAIN BODY. LOCATED JUST UNDER WELD AND APPROX .7500 INCH IN LENGTH. 1L72 4T4 T A24CE E4EA 20030915000022003091500002EU 2003 9 15 2003FA0000917 120030806G2710258CW2011A CONTROL CABLE BRAERODH125 BAE125800A 1500285EU AILERON MISMANUFACTURED B UO2RO OTHER W INADEQUATE Q C NRNOT REPORTED 1 GL19110MH NA0425 NEW CABLE WAS .5 INCH TOO SHORT. 2L72 4F RTA3EU 20030915000052003091500005NE 2003 9 15 2003FA0000918 120030819G6320MS8005J060E000 HOSE SKRSKYS61 S61N 8142104NE GE CT58 CT58* 30011GL M/R GEARBOX CRACKED D O OTHER K FLUID LOSS NRNOT REPORTED 1 WP13265F 61492 AIRCRAFT WAS ENROUTE FOR REDEPLOYMENT OF FIREFIGHTING CREWS. AIRCRAFT DEVELOPED A LARGE OIL LEAK AND MADE A PRECAUTIONARY LANDING. AIRCRAFT SUSTAINED NO DAMAGE AND OCCUPANTS WERE NOT INJURED. INVESTIGATION FOUND A MAIN TRANSMISSION OIL LINE HAD RUPTURED AT THE POINT WHERE THE STEEL BRAIDED LINE IS SWAGED TO THE COUPLING. 2G72 4U4 U 1H15 1E3 20030915000062003091500006SO 2003 9 15 2003FA0000919 120030818G57531642400 HORN PIPER PA23 PA23250 7102308SO LYC O540 IO540C4B5 41532EA LT FLAP CORRODED B O OTHER O OTHER NRNOT REPORTED 1 NE01273AD6154 274806 DURING COMPLIANCE OF AD, THE FLAP TUBE WAS FOUND NOT TO PASS. A NEW STEEL TUBE WS ORDERED AND IN THE REPLACEMENT PROCEDURE THE LEFT BELLCRANK (PN 16424-00) WAS FOUND TO HAVE RUST INSIDE. USING AN AWL TO PUSH ON THE RUSTED AREAS, IT COLLAPSED THE WALLS. WATER HAD COLLECTED IN THE AREA BETWEEN THE WALLS AND ROTTED THE STEEL. NO DRAIN HOLES ARE LOCATED IN THAT AREA. THE AD DOES NOT CALL FOR AN INSPECTION OF THIS PART. 1L72 3O3 O 1A10 1E4 20030915000082003091500008SO 2003 9 15 2003FA0000920 120030822G24973507201 CONNECTOR PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA OVERHEAD PANEL BURNED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP074181M 2843120 RL3909036A DURING INSTALLATION RYAN TCAD 9900 BX SERIES WE FOUND PLUG P5 HAS SEVERAL PINS AND WIRE COATING BURNED AND MELTED. PROBABLE CAUSE IS OVER CURRENT DRAW OF LANDING LIGHT AND NAV. LIGHT SYSTEM CAUSING HIGH RESISTANCE WHICH GENERATED ENOUGH HEAT TO MELT THE PLUG AND WIRES. RECOMMENDATION IS TO INSTALL HIGHER CAPACITY PINS TO CARRY THE LOAD OF THE CURRENT. 1L71 3O3 O 2A13 E286 20031002001772003100200177SO 2003 10 2 2003FA0000921 120030825G24973507201 CONNECTOR PIPER PA28 PA28181 7102807SO INSTRUMENT PANELBURNED B VJ3RO OTHER MB OVER TEMP SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 WP074133K4029 2843205 DURING INSTALLATION OF RYAN TCAD 9900 BX SERIES WE FOUND PLUG P5 HAS SEVERAL PINS AND WIRE COATING BURNED AND MELTED. PROBABLE CAUSE IS OVER CURRENT DRAW OF LANDING LIGHT AND NAV. LIGHT SYSTEM CAUSING HIGH RESISTANCE WHICH GENERATED ENGOUGH HEAT TO MELT THE PLUG AND WIRES. RECOMMENDATION IS TO INSTALL HIGHER CAPACITY PINS TO CARRY THE LOAD OF THE CURRENT. 1L71 3O 2A13 20031002001782003100200178SO 2003 10 2 2003FA0000922 120030825G24973507201 CONNECTOR PIPER PA28 PA28181 7102807SO INSTRUMENT PANELBURNED B VJ3RO OTHER B SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 WP074130W4136 2843204 DURING INSTALLATION OF RYAN TCAD 9900 BX SERIES. WE FOUND PLUG P5 HAS SEVERAL PINS AND WIRE COATING BURNED AND MELTED. PROBABLE CAUSE IS OVER CURRENT DRAW OF LANDING LIGHT AND NAV LIGHT SYSTEM CAUSING HIGH RESISTANCE WHICH GENERATED ENOUGH HEAT TO MELT THE PLUG AND WIRES. RECOMMEND IS TO INSTALL HIGHER CAPACITY PINS TO CARRY THE LOAD OF THE CURRENT. 1L71 3O 2A13 20030915000092003091500009SO 2003 9 15 2003FA0000923 120030825G24973507201 CONNECTOR PIPER PA28 PA28181 7102807SO OVERHEAD PANEL BURNED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP074161Z4145 2843129 DURING INSTALLATION OF RYAN TCAD 9900 BX SERIES WE FOUND PLUG P5 HAS SEVERAL PINS AND WIRE COATING BURNED AND MELTED. PROBABLE CAUSE IS OVER CURRENT DRAW OF LANDING LIGHT AND NAV. LIGHT SYSTEM CAUSING HIGH RESISTANCE WHICH GENERATED ENOUGH HEAT TO MELT THE PLUG AND WIRES. RECOMMENDATION IS TO INSTALL HIGHT CAPACITY PINS TO CARRY THE LOAD OF THE CURRENT. 1L71 3O 2A13 20030915000032003091500003SO 2003 9 15 2003FA0000924 120030825G24973507201 CONNECTOR PIPER PA28 PA28181 7102807SO OVERHEAD PANEL BURNED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP074149Y3990 2843128 DURING INSTALLATION OF TCAD 9900 BX SERIES, FOUND PLUG P5 HAS SEVERAL PINS AND WIRE COATING BURNED AND MELTED. PROBABLE CAUSE IS OVER CURRENT DRAW OF LANDING LIGHT AND NAV LIGHT SYSTEM CAUSING HIGH RESISTANCE WHICH GENERATED ENOUGH HEAT TO MELT THE PLUG AND WIRES. RECOMMENDATION IS TO INSTALL HIGHER CAPACITY PINS TO CARRY THE LOAD OF THE CURRENT. 1L71 3O 2A13 20030915000232003091500023SO 2003 9 15 2003FA0000925 120030825G24973507201 CONNECTOR PIPER PA28 PA28181 7102807SO OVERHEAD PANEL BURNED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP074175V4567 2843126 DURING INSTALLATION OF RYAN TCAD 9900 BX SERIES, FOUND PLUG P5 HAS SEVERAL PINS AND WIRE COATING BURNED AND MELTED. PROBABLE CAUSE IS OVER CURRENT DRAW OF LANDING LIGHT AND NAV. LIGHT SYSTEM CAUSING HIGH RESISTANCE WHICH GENERATED ENOUGH HEAT TO MELT THE PLUG AND WIRES. RECOMMENDATION IS TO INSTALL HIGHER CAPACITY PINS TO CARRY THE LOAD OF THE CURRENT. 1L71 3O 2A13 20031002001792003100200179SO 2003 10 2 2003FA0000926 120030826G24973507201 CONNECTOR PIPER PA28 PA28181 7102807SO COCKPIT BURNED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP079294Q4440 2843122 DURING INSTALLATION OF RYAN TCAD 9900 BX SERIES, FOUND PLUG P5 HAS SEVERAL PINS AND WIRE COATING BURNED AND MELTED. PROBABLE CAUSE IS OVER CURRENT DRAW OF LANDING LIGHT AND NAV. LIGHT SYSTEM CAUSING HIGH RESISTANCE WHICH GENERATED ENOUGH HEAT TO MELT THE PLUG AND WIRES. RECOMMENDATION IS TO INSTALL HIGHER CAPACITY PINS TO CARRY THE LOAD OF THE CURRENT. 1L71 3O 2A13 20030915000072003091500007SO 2003 9 15 2003FA0000928 120030825G24973507201 CONNECTOR PIPER PA28 PA28181 7102807SO OVERHEAD PANEL BURNED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP074122F4919 2843118 DURING INSTALLATION OF RYAN TCAD 9900 BX SERIES, WE FOUND PLUG P5 HAS SEVERAL PINS AND WIRE COATING BURNED AND MELTED. PROBABLE CAUSE IS OVER CURRENT DRAW OF LANDING LIGHT AND NAV. LIGHT SYSTEM CAUSING HIGH RESISTANCE WHICH GENERATED ENOUGH HEAT TO MELT THE PLUG AND WIRES. RECOMMENDATION IS TO INSTALL HIGHER CAPACITY PINS TO CARRY THE LOAD OF THE CURRENT. 1L71 3O 2A13 20030915000012003091500001SO 2003 9 15 2003FA0000929 220030913G741410885431 CAM BENDIX S6LN21 CONT O300 O300D 17022SO MAGNETO CRACKED D K NONE O OTHER ININSP/MAINT 1 EA254960R DURING ANNUAL INSPECTION MAGNETO WAS REMOVED FOR 500 HR INSPECTION. FOUND MAGNETO CAM PART NR 10-88543-1 TO BE CRACKED AND UNSERVICEABLE. MAGNETO WAS FUNCTIONING NORMALY DURING ENGINE RUN UP PRIOR TO ANNUAL INSPECTION. CRACK WAS NOT VISIBLE UNTILL THE MAGNETO CASE WAS DISASSEMBLED. MAGNETO HAD RECIEVED 1000 HOUR OVERHAUL APPROXIMATELY 480 HOURS PRIOR. 3 O E253 20030915000222003091500022SO 2003 9 15 2003FA0000931 220030912G7421URHB32E SPARK PLUG CESSNA340 340A 2076405CE CONT O520 TSIO520NB 17040SO ENGINE SEPARATED D A UNSCHED LANDING EDRVIBRATION/BUFFET INFLIGHT SEPARATION PARTIAL RPM/PWR LOSS APAPPROACH 1 EA256827Z151 340A1222 509811 PILOT REPORTED ENGINE ROUGHNESS ON APPROACH AND LOSS OF RIGHT ENGINE NR 3 CYLINDER EGT INDICATION. AIRCRAFT LANDED WITH OUT INCIDENT. INSPECTION REVEALED NR 3 CYLINDER LOWER SPARK PLUG HAD SEPERATED INTO TWO PIECES BETWEEN THE GASKET SURFACE AND THE WRENCH HEX ALOWING THE CENTER ELECTRODE TO BE EJECTED FROM THE SPARK PLUG. THE COWLING SUFFERED MINOR FLAME DAMAGE. 1L72 3O3 O 3A25 E8CE 20031006000472003100600047CE 2003 10 6 2003FA0000932 120030902G2432RG380E40B BATTERY BEECH 200 200BEECH 1152920CE PWA PT6 PT6* 52043EA MASTER WRONG PART B E81RO OTHER W INADEQUATE Q C NRNOT REPORTED 1 GL03355TW290 BB521 NOTED SEALED LEAD-ACID BATTERY INSTALLED IN AIRCRAFT DURING A SCHEDULED PHASE CHECK. ONLY DOCUMENTATION IN AIRCRAFT RECORDS SHOWED THAT G6381E UNSEALED TYPE LEAD ACID BATTERY SHOULD BE INSTALLED IAW STC SA1016SO. PREVIOUS OPERATOR HAD (SWAPPED OUT) BATTERIES AT SOME POINT AND SUBSEQUENT MAINTENANCE CENTERS HAD ASSUMED BATTERY WAS A VALID INSTALLATION. SECOND SUCH INSTALLATION FOUND RECENTLY. TECHNICIANS AND REPAIR STATIONS NEED TO VERIFY LEAD ACID BATTERY IS VALID FOR THE STC INSTALLED IN THE AIRCRAFT. MULTIPLE LEAD-ACID BATTERY STC`S HAVE BEEN ISSUED, HOWEVER MANY REQUIRE THE USE OF ONE SPECIFIC MANUFACTURERS PART NUMBER BATTERY. 1L72 4T3 T A24CE E2NE 20031006000482003100600048CE 2003 10 6 2003FA0000933 120030902G2497D34A22 WIRE BEECH 200 200BEECH 1152920CE PWA PT6 PT6* 52043EA P330 CONNECTOR MISLOCATED B E81RO OTHER O OTHER NRNOT REPORTED 1 GL03355TW 1025 BB521 CABIN ALTITUDE WARNING SYSTEM FAILED INITIAL TEST IAW NEW 12 MONTH INSPECTION REQUIREMENT OF MM, CHAPTER 5. DURING SUBSEQUENT TROUBLESHOOTING, FOUND WIRE D34A22 CONNECTED TO NC TERMINAL OF ALTITUDE SWITCH S117 INSTEAD OF C TERMINAL AS SHOWN IN WDM 21-30-01 P.3. EVIDENCE WIRING IN AREA DISTURBED PREVIOUSLY DURING AVIONICS MODIFICATIONS OR INTERIOR REFURBISHMENT. 1L72 4T3 T A24CE E2NE 20031006000852003100600085 2003 10 6 2003FA0000934 420030916G2210131819TCAC420 GUIDE BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE ELEVATOR BROKEN C K NONE O OTHER ININSP/MAINT 1 SO0561HA UE175 WHILE CHECKING ELEVATOR TRIM WE FOUND INTERMITENT BINDING OF ELEVATOR TRIM WHEN MANUALLY OPERATING TO NOSE DOWN DIRECTION. BINDING WAS OF SUCH THAT IT WOULD MOMENTARILY HANG BEFORE RELEASING. IT OCCURED AT PRETY MUCH THE SAME POSITION EACH TIME, (WHEN MOVING FROM 6 TO 3 ON THE ELEVATOR TRIM WHEEL). HEARD POPPING IN FLOOR UNDER SEAT 8A. REMOVED SEAT AND FLOOR PANELS AND FOUND ELEVATOR TRIM CABLE TURN BARREL HANGING UP ON THE ABOVE REFERENCED GUIDE TUBE. REMOVED AND REPLACED GUIDE TUBE RESET CABLE TENSIONS AND SAFTIED TURN BARREL. OPERATIONALLY CHECKED SATISFACTORY. 2L72 4T4 TRTA24CE E26NE 20031006000252003100600025CE 2003 10 6 2003FA0000935 120030915G771426060131 TACHOMETER CESSNA208 208B 2073701CE PWA PT6 PT6A114A 52043NE MCAULY3AF34C3GFR34C703 GL COCKPIT DAMAGED D O OTHER O OTHER CRCRUISE 1 WP231232X71 208B0989 TENTHS POINTER FELL OFF OF ENGINE COMPRESSOR RPM TACHOMETER INDICATOR. 1H71 3T3 T A37CE E4EA 5 CP60GL 20031003000912003100300091CE 2003 10 3 2003FA0000936 120030915G5210071100159 HINGE PIN CESSNA CESSNA172 172R 2072401CE PAX DOOR SHEARED D A UNSCHED LANDING D INFLIGHT SEPARATION CRCRUISE 1 NE0524783515 17281029 DOOR HELD IN PLACE BY LOWER HINGE, DOOR STOP SPRING, & PASSENGER. INSP REVEALED UPPER HINGE PIN OF RT CABIN DOOR WAS SHEARED COMPLETELY. LWR HINGE PIN (P/N 0517019-12) WAS FOUND TO BE BENT, BROKEN, AND PARTIALLY INSTALLED. LOWER HINGE & ADJACENT STRUCTURE WAS BENT & BROKEN. RT CABIN DOOR WINDOW SEPARATED FROM DOOR IN FLT & WAS LOST. RT FUSELAGE WAS DAMAGED BEHIND AFT DOOR FRAME, AS RESULT OF CONTACT WITH DOOR OR WINDOW. HINGE PIN MATERIAL OF SHEARED UPPER HINGE PIN HAS BRASS COLOR. HINGE PIN MATERIAL OF BENT LOWER HINGE PIN HAS SILVER COLOR. UPPER HINGE PIN ON LT CABIN DOOR SHOWS SOME MINOR WEAR, METHOD OF INSTALLATION PREVENTS DISASSEMBLY FOR INSP. PIN MUST BE REPLACED AFTER REMOVAL. 1H71 3O NT3A12 20031006000092003100600009CE 2003 10 6 2003FA0000937 120030915G2820260010148 VENT LINE CESSNA208 208B 2073701CE PWA PT6 PT6A114A 52043NE MCAULY3AF34C3GFR34C703 GL FUEL SYSTEM CHAFED D O OTHER O OTHER NRNOT REPORTED 1 WP23PKMPS4398 208B0656 THIS AIRCRAFT IS EQUIPPED WITH OPTIONAL INBOARD FUEL FILLER CAPS. THE FUEL FILLER CAP ADAPTER ASSY. (P/N C156005-0105) HAS A SPRING LOADED FLAPPER WHICH IS DEPRESSED BY THE FUEL DISPENSING NOZZLE WHILE FILLING THE TANK. THE FLAPPER HAS BEEN HITTING ON THE (P/N 2600101-48) VENT LINE ASSY INSIDE THE TANK BAY AND HAS WORN THE VENT LINE APPROXIMATELY HALF WAY THROUGH ITS DIAMETER. DEFECT WAS DISCOVERED BECAUSE FUEL FILLER ADAPTER WAS REMOVED FOR MAINTENANCE. 1H71 3T3 T A37CE E4EA 5 CP60GL 20031009000992003100900099SO 2003 10 9 2003FA0000939 120030917G2434 ATTACH FITTING PRESTOLITE PIPER PA28 PA28R201T 7102813SO CONT O360 TSIO360FB 17025SO ALTERNATOR CRACKED D O OTHER O OTHER NRNOT REPORTED 1 SO111996 80 C111046 28R7703425 UNKNOWN COMPONENT WAS CRACKED IN THREE PLACES, THIS IS IN THE DRIVE ATTACHMENT BASE. (JUST FORWARD OF THE ATTACHMENT PLATE), ON THE WEB THAT SECURES THE ALTERNATOR. OWNER SAID THAT HE HAD REPLACED THE ALTERNATOR 7 MONTHS AGO FOR THE SAME PROBLEM, CRACKED JUST AFT OF THE BASE PLATE APPROX. TIME 80 HOURS. ALTERNATOR RETURNED TO MFG. BELIEVE THAT PROBLEM IS A UNBALANCE PROBLEM. THE WAY THE ALTERNATOR IS MOUNTED SHOWS THAT IT IS NOT A OVER TORQUE ISSUE. 1L71 3O3 O 2A13 E9CE 20031014000152003101400015SO 2003 10 14 2003FA0000940 120030918G2434 BEARING PIPER PA18 PA18 7101802SO LYC O320 O320* 41508EA ALTERNATOR OVERHEATED B O OTHER M OVER TEMP NRNOT REPORTED 1 GL03 D071908 ALTERNATOR HARD TO ROTATE DUE TO NON-DRIVE END BEARING BEING PRESSED INTO HOUSING TOO FAR. BEARING COVER FOUND (BLUED) DUE TOO EXCCESIVE HEAT. DRIVE PULLEY HARD TO ROTATE BY HAND. NOTE: 0 TIME SINCE OVERHAUL! 1H71 3O3 O 1A2 E274 20031010000722003101000072SO 2003 10 10 2003FA0000942 120030820G1430 NUT PIPER PA28 PA28180 7102808SO LYC O360 O360* 41514EA CIRCUIT BREAKER LOOSE B V2ARO OTHER O OTHER NRNOT REPORTED 1 AL039387J 283488 INSTRUMENT NUT CAME OFF VSI AND SHORTED FROM AM/FM RADIO CASE TO TOP TERMINAL OF CIRCUIT BREAKER FOR THE TURN BANK INDICATOR, CAUSING WIRE FROM BUS TO CIRCUIT BREAKER TO BURN. CHECK ALL INSTRUMENTS FOR MISSING SCREW AND REMOVE AM/FM RADIO FROM AIRCRAFT. 1L71 3O3 O 2A13 E286 20031010000732003101000073NE 2003 10 10 2003FA0000943 220030816G8530 CYLINDER SCWZERG164 G164A 3952704EA PWA R1340 R1340AN1 52016NE ENGINE CRACKED C O OTHER O OTHER NRNOT REPORTED 1 SW9948395816 1628 21888 FOUND ALUMINUM CHIPS IN SCREEN. INTERNAL ENGINE INSPECTION REVEALED A 5 INCH LONG CRACK IN THE NR 5 CYLINDER SKIRT. 1Q71 3R3 R 1A16 5E2 20031010000752003101000075 2003 10 10 2003FA0000944 420030627G6122A3496 SPRING HARTZLHCB5M HCB5MP3 GL FEATHERING BROKEN B ME4RO OTHER O OTHER NRNOT REPORTED 1 SO19 EV820 FEATHERING SPRING FOUND BROKEN INSIDE DURING DISASSEMBLY FOR OVERHAUL. 6 CP44GL 20031010000812003101000081SO 2003 10 10 2003FA0000945 220030718G7414 BRUSHES CONT O520 IO520* 17032SO MAGNETO WORN B CY4RO OTHER O OTHER NRNOT REPORTED 1 AL03 1092 00102120 MAGNETO HAS SEVERE BRUSH WEAR. 3 O E5CE 20031014000332003101400033 2003 10 14 2003FA0000951 420030903G3418S16722 STALL WARNING CESSNA177 177RG 2073709CE LT WING MALFUNCTIONED B CRJRO OTHER O OTHER NRNOT REPORTED 1 CE01353732557 177RG1049 STALL WARNING SYSTEM FUNCTION TEST AT ANNUAL INSPECTION WAS CORRECT. SYSTEM WOULD NOT OPERATE WHEN PITOT HEAT WAS SWITCHED ON. REMOVED STALL SWITCH AND CLEANED CORROSION FROM GROUND. BOTH STALL WARNING AND PITOT HEAT WOULD OPERATE CORRECTLY THEN. PREVIOUSLY, THE STALL WARNING SYSTEM WOULD FIND A GROUND THROUGH THE PITOT HEATER VIA THE STALL WARNING HEATER. WHEN THE PITOT HEAT WAS TURNED ON, THE STALL WARNING WOULD NOT GROUND. 1H71 3O A20CE 20031022000982003102200098 2003 10 22 2003FA0000952 420030902G2561KSE35LP0723E105PLIFE VEST CELL FAILED B KQ1RO OTHER L NO TEST NRNOT REPORTED 1 EA07 LIFE VEST FAILED, MFG RECOMMENDED CELL PRESSURE TEST IAW 25-60-12. DOM: JUNE 1998 20031022001042003102200104SO 2003 10 22 2003FA0000953 120030910G792120710AR OIL COOLER PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA ENGINE CRACKED B VJ3RK NONE K FLUID LOSS ININSP/MAINT 1 WP074142Q 2843207 RL3705736A DURING PREFLIGHT INSPECTION PILOT FOUND SIGNS OF AN OIL LEAK. THE MAINTENANCE TECHNICIAN FOUND OIL LEAK ON OIL COOLER. PERFORMED PRESSURE CHECK ON OIL COOLER AND FOUND BOTTOM FLANGE CRACKED. THIS IS A WEAK ARA ON THE OIL COOLER. RECOMMEND FINDING A REPLACEMENT THAT IS MORE DURABLE. 1L71 3O3 O 2A13 E286 20031022001052003102200105CE 2003 10 22 2003FA0000954 120030910G733310238901011 TRANSDUCER BEECH 33 F33A 1151425CE CONT O520 IO520BB 17032SO FUEL SYSTEM FAILED B VJ3RO OTHER J WARNING INDICATION NRNOT REPORTED 1 WP075585Y146 CE1389 825837R FUEL FLOW WENT TO ZERO INDICATION IN FLT. TESTS SHOWED THAT HERTZ FLUCTUATED AND READ LOWER THAN PUBLISHED SPECIFICATIONS. SUSPECT INTERNAL FAILURE, PERHAPS IMPELLER IS STICKING. NOT RECOMMENDATIONS AT THIS TIME. 1L71 3O3 O 3A15 E5CE 20031022001062003102200106SO 2003 10 22 2003FA0000955 120030909G792120710AR OIL COOLER PIPER PA28 PA28181 7102807SO LYC O360 O360A4A 41514EA ENGINE CRACKED B VJ3RK NONE K FLUID LOSS ININSP/MAINT 1 WP074142Q3699 52 2843207 RL3705736 DURING A MAINTENANCE INSPECTION OF THIS AIRCRAFT, THE OIL COOLER WAS FOUND TO BE CRACKED AROUND THE MOUNTING BOLT HOLES AND LEAKING FROM THE SEAM IN THAT AREA. PROBABLE CAUSE IS VIBRATION. RECOMMEND USING A SOLID PIECE OIL COOLER. 1L71 3O3 O 2A13 E286 20031022001072003102200107CE 2003 10 22 2003FA0000956 120030912G733310238901211 TRANSDUCER BEECH 33 F33A 1151425CE CONT O520 IO520BB 17032SO FUEL SYSTEM INTERMITTENT B VJ3RC ABORTED TAKEOFF J WARNING INDICATION TOTAKEOFF 1 WP078252T12 CE1545 825834R DURING TAKE OFF POWER PILOT REPORTED THAT FUEL FLOW INDUCTION WENT TO 12GPH. UPON TROUBLESHOOTING OF THE FUEL SYSTEM MAINTENANCE TECHNICIAN FOUND FUEL FLOW TRANSDUCER WAS INTERMITTENT. NO RECOMMEND AT THIS TIME. 1L71 3O3 O 3A15 E5CE 20031021002782003102100278EU 2003 10 21 2003FA0000957 120030922G5743A720390L FAIRING LET L23 L23 1360308EU WING-TIP CRACKED B O OTHER O OTHER LDLANDING 1 NM03438BA 029016 RADIAL CRACKS ARE BEING FOUND FLEETWIDE ON WING-TIP FAIRINGS.THERE HAVE BEEN NO COMPLETE FAILURES AT THIS TIME. FACTORY ADVISES WING TIPS ARE DESIGNED TO FAIL ON SIDE LOADS TO PREVENT MAJOR DAMAGE TO WING SPAR. 1K00 RCG24EU 20031021003012003102100301CE 2003 10 21 2003FA0000958 120030922G21501015552117 CLUTCH BEECH 200 B200 1152922CE AIR CON COMPRESSBROKEN B O OTHER O OTHER NRNOT REPORTED 1 NM036124A58 03120305ICT BB1824 AIR CONDITIONING COMPRESSOR CLUTCH ASSY HAD FAILED AFTER 58.0 HOURS OF AIRCRAFT OPERATION. APPEARS THAT THE ELECTRIC CLUTCH ASSY HAD BEEN ACTIVATED CONTINOUSLY AND OPERATED WHENEVER THE ENGINE WAS OPERATING. 1L72 4T A24CE 20031022000772003102200077EA 2003 10 22 2003FA0000959 220030923G8530 CYLINDER PIPER PA34 PA34200 7103405SO LYC O360 IO360C1E6 41514EA HARTZLHCC2Y HCC2YK2 GL LT ENGINE SEPARATED G E ENGINE SHUTDOWN O OTHER DEDESCENT 1 GL23439CT 627 347250177 L884151A AU2637 THE AIRCRAFT WAS PREPARING FOR LANDING AT ARB, PILOT REDUCED POWER. WITHOUT WARNING, LEFT ENGINE FWD OUTBOARD CYLINDER SEPARATED FROM ENGINE, WAS HELD ON BY FUEL LINES AND IGNITION HARNESS. OUTBOARD UPPER ENGINE COWLING, PISTON AND ROD DEPARTED AIRCRAFT. LT WING LEADING EDGE AND FUEL TANK WERE PUNCTURED, CAUSING LOSS OF FUEL. LT HORIZONTAL STABILIZER LEADING EDGE WAS DAMAGED, POSSIBLY FROM DEPARTING COWLING. PILOT SECURED ENGINE, MADE EMERGENCY LANDING. NO INJURIES. 1L72 3O3 O A7SO 1E10 5 CP920 20031023000152003102300015CE 2003 10 23 2003FA0000960 120030905G7921LW10025 OIL COOLER BEECH 60 B60 1153605CE LYC O541 TIO541* 41536EA ENGINE CRACKED D O OTHER O OTHER NRNOT REPORTED 1 GL25 WE HAVE FOUND 3 OIL COOLERS IN THE PAST YEAR ON THESE AC WITH IDENTICAL CRACKS ON THE DIAGONAL SUPPORT BARS AT THE INBOARD WELD. THIS LEADS TO SEPARATION OF ONE END OF THE BAR. CAUSE OF THE CRACKS ARE NOT OBVIOUS. WE ARE ALSO AWARE OF 2 OTHER AC THAT HAVE EXPERIENCED IN-FLIGHT OIL COOLER FAILURES IN THE PAST YEAR. WE DO NOT HAVE ENOUGH INFO ON PART TIMES OR MAINTENANCE TO FIND A COMMON LINK. 1L72 3O3 O A12CE E10EA 20031023000162003102300016NE 2003 10 23 2003FA0000961 220030905G852040350 CRANKSHAFT BOEING75 A75 1380108CE PWA R985 R985AN14B 52008NE ENGINE FRACTURED B CP2RO OTHER O OTHER NRNOT REPORTED 1 SW15806RB10026 754000 JP206277 THE CRANKSHAFT APPEARS TO HAVE FRACTURED AT THE CRANK PIN. SEPARATING THE CRANK PIN AND ROD ASSEMBLY FROM THE PROPELLER SHAFT. THE AIRCRAFT WAS IN THE PROCESS OF BEING FERRIED CROSS COUNTRY. THE AIRCRAFT IS USED FOR AEROBATIC PERFORMANCES. (SW15200318971) 1Q71 3R3 R A743 5E1 20031023000172003102300017SO 2003 10 23 2003FA0000962 220030829G8530646612 EXHAUST VALVE UNIVAR415 415C 0420302NM CONT A75 C7512 17005SO NR 2 CYLINDER SEPARATED G O OTHER O OTHER NRNOT REPORTED 1 WP073182H 3807 3962612 THE FACE OF THE NR 2 CYL EXHAUST VALVE SEPARATED FROM THE STEM OF THE VALVE. SUBSEQUENT DAMAGE TO THE POSTON AND CYLINDER WAS SUBSTANTIAL. THIS FAILURE OCCURRED WHILE IN CRUISE FLIGHT. 1L71 3O3 O A718 E233 20031023000182003102300018SW 2003 10 23 2003FA0000963 120030807G5302206032409001 FITTING BELL 206 206L3 1182108SW ALLSN 250C 250C30 03013GL TAILBOOM CRACKED D O OTHER O OTHER NRNOT REPORTED 1 WP01999AH 51046 DURING A ROUTINE INSPECTION THE UPPER LEFT HAND TAIL BOOM ATTACH FITTING WAS FOUND TO HAVE A CRACK EMANATING FROM THE FASTENER HOLES WHICH ATTACH THE FITTING TO THE ADJACENT STRUCTURE. 1G71 3U3 U H2SW E1GL 20031023000212003102300021SW 2003 10 23 2003FA0000964 120030909G561033036710 WINDOW GULSTM690TP 690A 0141722SW GARRTTTPE331TPE331* 01514WP COCKPIT CRACKED D O OTHER O OTHER NRNOT REPORTED 1 SW09208CL 11297 OPERATOR COMPLAINED OF PRESSURIZATION PROBLEM. DURING CABIN PUMP UP, A LEAK WAS DISCOVERED AT THE RT PICTURE WINDOW. THE WINDOWS OUTER PANEL WAS FOUND TO BE CRACKED. THE CRACK LENGTH WAS DETERMINED TO BE 18 INCHES. THE CRACK WAS LOCATED AT THE UPPER FASTENER HOLES. 1H72 3T3 T 2A4 E2WE 20031023000222003102300022CE 2003 10 23 2003FA0000965 120030823G25207145416 SEAT FRAME BBAVIA7 7KCAB 21101P3CE LYC O320 IO320* 41508EA CABIN BROKEN G O OTHER O OTHER NRNOT REPORTED 1 SW058730V2808 52675 2 SEAT BACK SUPPORT STRAPS BROKE ON HARD LANDING (G-METER REUD 9G) UPPER STRAP WAS A NEW BREAK AT WELD CENTER STRAP BROKE AT REPAIR WELD FROM PREVIOUS BREAK. CFI IN REAR SEAT SUSTAINED MINOR BACK INJURY, AIRCRAFT LT MAIN GEAR COLLAPSED RESULTING IN PROP STRIKE. 3-G NEGATIVE READ ON G METER IS BELIEVED TO OCCURRED WHEN AIRCRAFT SLID ON NOSE FOR 100+ FT ON ASPHALT RUNWAY. ALUMINUM SHEET FOR BACK SUPPORT MIGHT ALLOW BETTER LOAD DISTRIBUTION IN LIEU OF STEEL STRAPS. 1H71 3O3 O A759 1E12 20031023000242003102300024SO 2003 10 23 2003FA0000966 220030910G8530SA629340 ROD BOLT CESSNA310 310R 2074245CE CONT O520 TSIO520BB 17040SO ENGINE DAMAGED B ZSNRO OTHER O OTHER NRNOT REPORTED 1 SW052636P 310R1649 INSTALLED (1) NEW ROD BOLT, SA 629340 LOT NR 578901, ALONG WITH NEW NUT NR SA 628109. NUT WOULD NOT REACH SPEC. TORQUE. NUT WAS REMOVED TO REVEAL THREADS, DAMAGED. 1L72 3O3 O 3A10 E8CE 20031023000252003102300025CE 2003 10 23 2003FA0000967 120030822G272052000083 CONTROL CABLE CESSNA402 402C 207590RCE CONT O520 TSIO520* 17040SO RUDDER CONTROL BROKEN G O OTHER O OTHER NRNOT REPORTED 1 SW01775RC8143 402C0311 LEFT RUDDER CABLE HAD CHAFED THROUGH ON THE FLEXIBLE BRAKE MASTER CYLINDER LINE. ROUTING OF THE BRAKE LINE OVER THE RUDDER CABLE PULLEY CAUSED THE CABLE TO FAIL BEFORE THE BRAKE FLEX LINE FAILED. ACCESS TO EFFECTED AREA IMPOSSIBLE DUE TO LACK OF WORKING AREA. 1L72 3O3 O A7CE E8CE 20031023000482003102300048CE 2003 10 23 2003FA0000969 120030908G32400500118126 LINE CESSNA172 172P 2072436CE LYC O320 O320* 41508EA RT MLG BRAKE FAILED D O OTHER KJ FLUID LOSS WARNING INDICATION TXTAXI/GRND HDL 1 AL0363541 17275449 DURING LANDING ROLLOUT, RT MAIN BRAKE LINE FAILED CAUSING LOSS OF BRAKE PRESSURE. INSPECTION DETERMINED THAT BRAKE LINE HAD BEEN CHAFING ON FAIRING ASSEMBLY AND SIDEWALL OF RIGID LINE HAD FAILED. SUGGEST MORE FREQUENT INSPECTIONS AND MORE ATTENTION TO CLEARANCES BETWEEN FAIRING AND BRAKE LINE. 1H71 3O3 ONT3A12 E274 20031023000472003102300047SO 2003 10 23 2003FA0000970 120030924G3230 BOLT PIPER PA32 PA32R301 7103218SO RT MLG BROKEN D O OTHER E VIBRATION/BUFFET TXTAXI/GRND HDL 1 GL059203R 3213044 WHILE PERFORMING A NON RELATED MAINTENANCE GROUND RUN, ON THE TAXI BACK TO THE HANGER A VIBRATION OCCURED FROM THE RT MAIN LANDING GEAR. AFTER SHUT DOWN AN INSPECTION OF THE RT MAIN GEAR ASSEMBLY FOUND THE BOLT (PN 691308) HOLDING THE TWO TORQUE LINKS TOGETHER WAS BROKEN. THE BOLT HALVES WERE FROZEN INTO THE LINK AND WOULD NOT TURN, DUE TO INADEQUATE LUBRICATION. AFTER REMOVAL, THE BOLT WAS INSPECTED AND FOUND TO RUSTED OVER HALF WAY ACROSS THE DIAMETER OF THE BOLT. THE BOLT TIME SINCE NEW WAS 1530.7 HOURS. 1L71 3O A3SO 20031023000842003102300084CE 2003 10 23 2003FA0000972 120030822G7810654892 CROSSOVER TUBE BEECH 58 58P 1152744CE CONT O520 TSIO520WB 17040SO RIGHT CHAFED C O OTHER O OTHER NRNOT REPORTED 1 NM07153Z 1186 TJ322 274467R DURING A PHASE INSPECTION, THE LEFT CROSSOVER TUBE WAS POUND CHAFED BY THE ENGINE MOUNT TRUSS (PN 102-910026-131). THE CHAFING WAS APPROXIMATELY HALFWAY THROUGH THE WALL THICKNESS. WE HAVE A SPECIAL INSPECTION TO CHECK THE HEATSHIELD FOR CHATING IN THIS SAME AREA, OTHERWISE THIS WOULD HAVE PROBABLY BEEN MISSED DUE TO ITS INACCESSIBILITY BEHIND THE INDUCTION FILTER HOUSING, THE PART WILL BE REPLACED TO SEE IF A DIFFERENT TUBE HAS THE SAME PROBLEM. OTHER AIRCRAFT IN THE FLEET WERE CHECKED WITHOUT DEFECTS NOTED.(K) 1L72 3O3 O A23CE E8CE 20031027000102003102700010EA 2003 10 27 2003FA0000973 120030106G64201885 BALL SCWZER269 269D 8059501EA LYC O360 HIO360* 41514EA T/R ZERC FITTINGMISSING B OG5RO OTHER O OTHER NRNOT REPORTED 1 GL212086F1011 S1754 AFTER ENGAGEMENT OF ROTOR SYSTEM, TAIL ROTOR DID NOT MOVE. INVESTIGATION FOUND BALL MISSING OUT OF ZERC, ALLOWING GREASE TO ESCAPE ALLOWING BUMPER TO WEAR ALLOWING SHAFT TO DECOUPLE. 1G71 3U3 O0 4H12 1E10 20031027000132003102700013SO 2003 10 27 2003FA0000974 120030718G575186396004 RIB PIPER J3 PA11 7101102SO LYC O360 O360* 41514EA AILERON CRACKED D O OTHER O OTHER NRNOT REPORTED 1 WP092163N6775 447995222 DURING INSPECTION OF LT AILERON, FOUND ALL THREE AILERON ATTACH POINT RIBS CRACKED ADJACENT TO MOUNTING BELL CRANKS. 1H71 3O3 O A691 E286 20031027000032003102700003CE 2003 10 27 2003FA0000975 120030925G7603C805975 THROTTLE CABLE CESSNA500 560CESSNA 2076750CE DAMAGED B O OTHER O OTHER NRNOT REPORTED 1 SW99 THROTTLE CABLES FREEZING BETWEEN 6000 AND 8000 HOURS. FWD P/NC80597-5 AND AFT P/N7-42346-1 2L72 4F RTA22CE 20031023000742003102300074SO 2003 10 23 2003FA0000976 220030915G7421URHB32E SPARK PLUG CESSNA421 421B 2076014CE CONT O520 GTSIO520H 17032SO ENGINE CRACKED D K NONE O OTHER ININSP/MAINT 1 EA25421GC177 421B0926 231527R DURING ROUTINE 100 HR INSPECTION 4 SPARK PLUGS ON RIGHT ENGINE FOUND TO HAVE CRACKS IN THE PLUG BODY BETWEEN THE GASKET SURFACE AND THE WRENCH HEX. 1L72 3O3 O A7CE E7CE 20031027000322003102700032SO 2003 10 27 2003FA0000977 220030823G853024122 BUSHING CESSNA150 150G 2071816CE CONT O200 O200A 17020SO ROCKER ARMS WORN D K NONE O OTHER ININSP/MAINT 1 CE072698J10 10 15065698 635456A EIGHT ROCKER ARM BUSHINGS SHOWED INDICATIONS OF EXCESSIVE WEAR. THE PROBLEM WAS INDICATED AT THE FIRST OIL CHANGE (10 HOURS) AFTER ENGINE OVERHAUL AS BRONZE PARTICLES IN THE OIL FILTER. THE OVERHAULED ROCKER ARMS WERE INSTALLED IN NEW MFG CYLINDERS P/N 653816 WHICH INCLUDED NEW ROCKER SHAFTS P/N 654375. THE ROCKER ARMS WERE REMOVED AND BUSHING CLEARANCE MEASURED. THE CLEARANCES VARIED FROM .005 TO .010. MANUFACTURER'S O/H MANUAL STATES NEW CLEARANCE AS .001 TO .0025 AND THE SERVICE LIMIT AS .004. 1H71 3O3 O 3A19 E252 20031027000142003102700014SO 2003 10 27 2003FA0000978 120030925G32206338300 LINK ASSY PIPER PA28 PA28180 7102808SO LYC O360 O360* 41514EA MLG CRACKED D K NONE O OTHER ININSP/MAINT 1 SO139426J3068 283537 THE PROBLEM EXISTS WITH PN 6338300.THE ONLY DIFFERENCE WITH THE TWO PARTS IS THAT THERE IS A STIFFENER INSTALL IN THE 6541300. THE STIFFENER INSTALL PREVENTS THE COLLAPES OF THE BUMPER MOUNT WHICH IN TURN SPREDS THE LINK SIDE CHANNELS WHICH THEN CAUSES THE LINK TO CRACK. THIS IS WHAT HAPPENED TO THE 6338300 ON ACFT 283537. I FEEL THAT THE 6338300 SHOULD BE EITHER RECALLED, OR MODIFIED TO A 6541300,OR AT LEAST INSPECTED TO SEE IF THIS FAILURE EXISTS IN THE FIELD. FAILURE OF THIS LINK IS A LIFE THREATENING CONDITION. 1L71 3O3 O 2A13 E286 20031028000012003102800001SO 2003 10 28 2003FA0000981 220030929G8520655004 CONNECTING ROD CONT O520 TSIO520P 17040SO ENGINE NICKED B K NONE O OTHER ININSP/MAINT 1 SO09 130 130 278874 DURING ENGINE INSPECTION FOR DEBRIS IN OIL FILTER FOUND NUMBER 3 CONNECTING ROD CAP TO HAVE DEEP NICK OR GOUGE. 3 O E8CE 20031029001362003102900136CE 2003 10 29 2003FA0000982 120030909G8010643109 CLUTCH SPRING CESSNA210 210L 2073448CE CONT O520 IO520* 17032SO STARTER ADAPTER BROKEN D O OTHER O OTHER NRNOT REPORTED 1 SO1559299 3102 21060199 295269R CLUTCH SPRING, BROKEN. 1H71 3O3 O 3A21 E5CE 20031030000032003103000003SW 2003 10 30 2003FA0000983 120030912G63302060325095 DRAG PIN BELL 206 OH58A 1181579SW TRANSMISSION CRACKED B E5WRO OTHER O OTHER NRNOT REPORTED 1 GL211082M 7221309 CRACK-LIKE INDICATION ON OUTER SIDE AND EDGE OF BORE. CRACK-LIKE INDICATION DETECTED BY FLUORESCENT MT. 1G71 3U H2SW 20031001000612003100100061CE 2003 10 1 2003FA0000984 120030929G32301VA20 SAFETY SWITCH CESSNA401 401 207590CCE CONT O520 TSIO520BE 17040SO MCAULY3AF32C3AF32C* GL MLG DEFECTIVE E A UNSCHED LANDING S AFFECT SYSTEMS CLCLIMB 1 SW05401TE 4010180 LANDING GERA WOULD NOT RETRACT AFTER TAKE OFF DUE TO A DEFECTIVE GEAR SAFETY SWITCH. 1L72 3O3 O A7CE E8CE 5 CP22EA 20031001000822003100100082SO 2003 10 1 2003FA0000987 120030930G2597 WIRE NARCO PIPER PA32 PA32RT301 7103222SO ELT BATTERY CORRODED D K NONE O OTHER ININSP/MAINT 1 GL03 116 3257233 C/W FAR 91.207D INSPECTION FOUND ELT INOP. OPENED ELT TO REPLACE BATTERY ASSEMBLY FOUND POWER WIRE CORRODED OFF CELL. OTHER CELLS SHOW SIGNS OF CORROSION 1L71 3O A3SO 20031030000112003103000011EU 2003 10 30 2003FA0000991 120030918G8012945UN01Q4AF8A SWITCH UROCOPEC155 EC155B 8681000EU TMECA ARRIELARRIEL1 60030NE START FAILED B QC0RO OTHER O OTHER NRNOT REPORTED 1 SO17155WH513 6563 DURING A TEST RUN FOLLOWING AN ENGINE CHANGE OF THE NR 1 ENGINE, THE NR 1 ENGINE FAILED TO RETURN TO IDLE WHEN THE NR 1 START SWITCH WAS BROUGHT FROM FLIGHT TO IDLE POSITION. SUBSEQUENT TROUBLE-SHOOTING FOUND THAT THE SWITCH WOULD ALSO FAIL FROM IDLE TO FLIGHT POSITIONS. THIS CONDITION, IF NOT REALIZED BY THE FLIGHT CREW, COULD RESULT IN AN UNDERPOWERED SINGLE ENGINE TAKE-OFF. THIS IS NOT THE FIRST FAILURE OF THIS TYPE WITH THIS SWITCH. 1G72 3U3 U H10EU E19EU 20031030000152003103000015CE 2003 10 30 2003FA0000992 120030805G324326820011 MASTER CYLINDER CESSNA208 208B 2073701CE PWA PT6 PT6* 52043EA RT BRAKE DAMAGED C O OTHER O OTHER NRNOT REPORTED 1 WP119750B8641 1989 208B0100 RT BRAKE DRAGGING DUE TO FLUID NOT RETURNING TO RESERVOIR WHEN BRAKE WAS RELEASED, CAUSED BY OVERHEATED BRAKE CALIPER AND SUBSEQUENT BRAKE FIRE AND TIRE DAMAGE DURING LONG TAXI PERIOD. RECOMMEND MASTER CYLINDERS BE OVERHAULED AT 1000 HOUR INTERVALS. 1H71 3T3 T A37CE E2NE 20031030000672003103000067SO 2003 10 30 2003FA0000993 120030418G1430 FASTENER PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA VERTICAL STAB UNDERTORQUED B UW4RO OTHER O OTHER NRNOT REPORTED 1 SO15134FC4092 288290169 L3032436A AIRCRAFT OWNER REQURESTED THAT WE CHECK TORQUE ON BOLTS SECURING VERTICAL FIN TO TAILCONE BULKHEAD. FOUND ALL VERTICAL FIN ATTACH HARDWARE UNDER TORQUED. INSPECTED HARDWARE AND MOUNTING HOLES. FOUND NOT PERFECT. REINSTALLED BOLTS AND TORQUED TO MFG SPECIFICATIONS. 1L71 3O3 O 2A13 E286 20031030000682003103000068EA 2003 10 30 2003FA0000995 120030826G6320269A510351 SHAFT SCWZER269 269D 8059501EA M/R TRANSMISSIONWORN B BS2RO OTHER O OTHER NRNOT REPORTED 1 SW17277DT S0028 0028 OPERATOR NOTICED CLUNK NOISE WHILE ROTATING DRIVE SYSTEM ON PREFLIGHT. NOISE WAS FROM THE M/R TRANS. DISASSEMBLY OF BOLT DRIVE SYSTEM REVEALED A LOOSE UPPER PULLEY STACK UP DUG TO LOOSE AFT PINION NUT WITH ALL THE ASSOCIATING FRETTING DAMAGE OF UPER PULLEY HUB AND BEARINGS. M/R TRANS WAS REMOVED AND DISASSEMBLED. PINION SHAFT BEARING RETAINER NUT WAS FOUND TO BE LOOSE AND THE OUTER PINION BEARINGS INNER RACE HAD BEGAN SPINNING ON THE PINION SHAFT JOURNAL. THE UPPER PULLEY AFT PINION NUT HAS HISTORY OF LOOSENING AND IS CHECKED AT 100 HOR INTERVALS BUT THIS ONE HAD BEEN COMING LOOSE TOO SOON (80 HRS FROM LAST TORQUE) FIRST OCCUR ON THE PINION SHAFT BRG NUT PROBLEM. 1G71 3U 0 4H12 20031030000992003103000099SO 2003 10 30 2003FA0000997 120030902G323067665857002 CONTROL CABLE PIPER PA28 PA28R180 7102809SO LYC O360 IO360A1A 41514EA FIREWALL MALFUNCTIONED D O OTHER O OTHER NRNOT REPORTED 1 EA217527J 28R30898 ALTERNATE AIR CABLE WRAPPED AROUND NOSE GEAR WHEN RETRACTED AFTER TAKE-OFF. ROUTING OF CABLE BOTTOM RIGHT OF FIREWALL UP AND AROUND GEAR INDENTATION ON FIREWALL. IF CABLE COMES LOOSE IT WILL WRAP AROUND NOSEWHEEL TIRE. REROUTING OF CABLE ABOVE NOSE GEAR TO AIR BOX AND MOUNT WITH MS-21919 CLAMPS WILL ELIMINATE THIS FROM HAPPENING. I WOULD SUGGEST PULLING REPORTS ON REPETITIVE PROBLEMS AND ALSO HAVING MFG ISSUE SERVICE BULLETIN ON ALTERNATE ROUTING OF THE CABLE, AWAY FROM THE GEAR WELL. I WOULD APPRECIATE BEING KEPT INFORMED OF FUTURE ACTION. 1L71 3O3 O 2A13 1E10 20031003000892003100300089SO 2003 10 3 2003FA0001004 120030926G493060277 BUTTON HAMLTN EMB 135 EMB135ER 3260203SO FILTER MODULE CRACKED C OY0RO OTHER O OTHER NRNOT REPORTED 1 WP01 INDICATOR BUTTON FAILURE OCCURED ON THREE UNITS AND CRACKS CLEARLY EVIDENT ON TWO OTHERS IN SAME AREA OF BREAKAGE. ONCE BROKEN, A SECTION OF THE BUTTON CAN TRAVEL BEYOND THE SEALED AREA OF THE HOUSING AND HAS THE CAPABILITY OF ALLOWING A FUEL LEAK OF UP TO 1.5 GALLONS PER MINUTE. ENGINEERING ANALYSIS INDICATES A LOW CYCLE FATIGUE SITUATION (FATIGUE CRACKS VISIBLE WITH A MICROSCOPE EXAM AT 7-30X). CEP PERFORMED A FEA SIMULATING THE BUTTON RESTRAINED IN THE CAP HOUSING WHICH SHOWS THE FAILURE TO BE IN THE LOW CYCLE FATIGUE REGION FOR 7075-T6 ALUMINUM. FUEL FILTER MODULE, PN 60500 & PN 4951960 / SN`S: C0072, C0213, C0383, C0390, C0528 2L72 4F RTT00011AT 20031103000592003110300059SO 2003 11 3 2003FA0001005 220030905G8550 ADAPTER BEECH 33 35C33 1151408CE CONT O470 IO470N 17026SO OIL FILTER WORN D O OTHER K FLUID LOSS NRNOT REPORTED 1 GL17866P CD1023 ENGINE DEVELOPED OIL LEAK, FOUND THIS ADAPTER LEAKING AT THREADS, LOCKING NUT SAFETY WAS INTACT, TORQUE DOPE WAS INTACT. ALL REQUIREMENTS OF AD 96-12-22 WERE MET AS PREVIOUSLY INSPECTED 18 HOURS BEFORE FAILURE. 1L71 3O3 O 3A15 3E1 20031103000662003110300066EA 2003 11 3 2003FA0001006 220030829G8520LW117725 CRANKSHAFT PIPER PA60 PA60601P 7106012NM LYC O540 IO540* 41532EA ENGINE BROKEN B MW2RO OTHER O OTHER NRNOT REPORTED 1 GL17442AF1173 343 61P063779632 CRANK BROKE ON NR 4 AND NR 6 CHEEK. 1M72 3O3 ORTA17WE 1E4 20031103000682003110300068EA 2003 11 3 2003FA0001007 220030808G853038135015 STUD PIPER PA34 PA34200 7103405SO LYC O360 IO360C1E6 41514EA ENGINE CYLINDER BROKEN B MW2RO OTHER O OTHER NRNOT REPORTED 1 GL171039U 700 347250024 L819451A CYL STUDS BROKEN. CYL BACKED OFF ENGINE. 1L72 3O3 O A7SO 1E10 20031103000692003110300069SO 2003 11 3 2003FA0001008 120030926G2821 BUTTON EMB 145 EMB145ER 3260211SO FUEL FILTER FAILED B OY0RO OTHER O OTHER NRNOT REPORTED 1 WP01 C0072 INDICATOR BUTTON FAILURE OCCURRED (DETAIL PART BROKE IN HALF) ON THREE UNITS AND CRACKS CLEARLY EVIDENT ON TWO OTHERS IN SAME AREA OF BREAKAGE. ONCE BROKEN, A SECTION OF THE BUTTON CAN TRAVEL BEYOND THE SEALED AREA OF THE HOUSING AND HAS THE CAPABILITY OF ALLOWING A FUEL LEAK OF UP TO 1.5 GALLONS PER MINUTE. ENGINEERING ANALYSIS INDICATES A LOW CYCLE FATIGUE SITUATION (FATIGUE CRACKS VISIBLE W/MICROSCOPE EXAMIN AT 7-30 POWER). CEP PERFORMED A (FEA) SIMULATING THE BUTTON RESTRAINED IN THE CAP HOUSING WHICH SHOWS THE FAILURE TO BE IN THE LOW CYCLE FATIGUE REGION FOR 7075-T6 ALUMINUM (BUTTON MATERIAL). PRODUCT DELIVERED T HS 813. 2L72 4F RTT00011AT 20031103000702003110300070CE 2003 11 3 2003FA0001009 120030924G3230583800901 MOTOR BEECH 33 F33A 1151425CE CONT O520 IO520BB 17032SO MLG WORN B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP071565A535 CE1331 820467R PILOT REPORTED THAT LANDING GEAR WOULD NOT EXTEND. AFTER GEAR HANDLE CYCLED TWICE GEAR CAME DOWN. UPON TROUBLESHOOTING OF THE LANDING GEAR SYSTEM FOUND LANDING GEAR DYNAMIC RELAY INTERMITTENT AND LANDING GEAR MOTOR SLOW TO RETRACT AND EXTEND IAW MM. NO RECOMMENDATIONS AT THIS TIME. 1L71 3O3 O 3A15 E5CE 20031103000712003110300071SO 2003 11 3 2003FA0001010 120030925G2435MHB6016 STARTER PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA ENGINE FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP074134T60 2843206 RL1754936A DURING ATTEMPTED START OF AIRCRAFT ENGINE WOULD NOT START. MAINTENANCE TECH TROUBLESHOOTING START SYSTEM FOUND THAT DC POWER WAS GETTING TO STARTER HOWEVER NO POWER WAS COMING OUT OF STARTER. PROBABLE CAUSE IS AN INTERNAL FAILURE WITH THE STARTER. STARTER SENT BACK TO MFG FOR ANALYSIS AND AT THIS TIME NO RECOMMENDATION TO PREVENT RECURRENCE. 1L71 3O3 O 2A13 E286 20031103000722003110300072CE 2003 11 3 2003FA0001011 120030924G3230SM50D7 RELAY BEECH 33 F33A 1151425CE CONT O520 IO520BB 17032SO MLG INTERMITTENT B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP071565A519 CE1331 PILOT REPORTED THAT LANDING GEAR WOULD NOT EXTEND. AFTER GEAR HANDLE CYCLED TWICE GEAR CAME DOWN. UPON TROUBLESHOOTING OF THE LANDING GEAR SYSTEM FOUND LANDING GEAR DYNAMIC RELAY INTERMITTENT. NO RECOMMENDATIONS AT THIS TIME. 1L71 3O3 O 3A15 E5CE 20031114000182003111400018EU 2003 11 14 2003FA0001012 120030929G2710120A4242 LEVER GROB 120 G120A 1660208EU LYC O540 AEIO540D4D5 EA AILERON BINDING B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07865AF937 85005 L2826448A DURING PRE-FLIGHT INSPECTION, FLIGHT CREW FELT BINDING ON THE AILERON SYSTEM UPON FURTHER INSPECTION FOUND BEARINGS IN AILERON LEVER 2 ASSY. TO BE DAMAGED AND BINDING. DAMAGE APPEARS TO BE CAUSED BY THE BUSHING PN 120A4435.02 IN THE FORK ENDS PN 120A4435.01. IT APPEARS THAT DESIGN LIMITATIONS OF THE FLIGHT CONTROL SYSTEM EXCEEDS LIMITATIONS OF THE BEARINGS ALLOWING BUSHING TO APPLY EXCESSIVE FORCE ON BEARING DURING FULL DEFLECTION. RECOMMEND REDESIGN OF FLIGHT CONTROL SYSTEM OR REPLACE BEARINGS WITH NEW BEARINGS THAT HAVE GREATER LIMITS. 1L71 3O3 ORTA49CE 1E4 20031114000192003111400019EU 2003 11 14 2003FA0001013 120030929G2710120A4240 LEVER GROB 120 G120A 1660208EU LYC O540 AEIO540D4D5 EA AILERON BINDING B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07867AF639 85007 RL2451848 DURING FLEET WIDE INSPECTION, FOUND BEARINGS IN AILERON LEVER 2 ASSY. PN 120A4242 TO BE DAMAGED AND BINDING. DAMAGE APPEARS TO BE CAUSED BY THE BUSHING PN 120A4435.02 IN THE FORK ENDS PN 120A4435.01. IT APPEARS THAT DESIGN LIMITATIONS OF THE BEARINGS ALLOWING BUSHING TO APPLY EXCESSIVE FORCE ON BEARING DURING FULL DEFLECTION. RECOMMEND REDESIGN OF FLIGHT CONTROL SYSTEM OR REPLACE BEARINGS WITH NEW BEARINGS WITH NEW BEARINGS THAT HAVE GREATER LIMITS. 1L71 3O3 ORTA49CE 1E4 20031114000542003111400054EU 2003 11 14 2003FA0001014 120030929G2710120A4242 LEVER GROB 120 G120A 1660208EU LYC O540 AEIO540D4D5 EA AILERON BINDING B VJ3RK NONE O OTHER ININSP/MAINT 1 WP07863AF1024 85003 DURING FLEET WIDE INSPECTION, FOUND BEARINGS IN AILERON LEVER 2 ASSY. PN 120A-4242 TO BE DAMAGED AND BINDING. DAMAGE APPEARS TO BE CAUSED BY THE BUSHING PN 120A-4435..02 IN THE FORK ENDS PN 120A4435.01. IT APPEARS THAT DESIGN LIMITATIONS OF THE FLIGHT CONTROL SYSTEM EXCEEDS LIMITATION OF THE BEARINGS ALLOWING BUSHING TO APPLY EXCESSIVE FORCE ON BEARING DURING FULL DEFLECTION. RECOMEND REDESIGN OF FLIGHT CONTROL SYSTEM OR REPLACE BEARINGS WITH NEW BEARINGS THAT HAVE GREATER LIMITS. 1L71 3O3 ORTA49CE 1E4 20031114000092003111400009EU 2003 11 14 2003FA0001015 120030929G2710120A4242 LEVER GROB 120 G120A 1660208EU LYC O540 AEIO540D4D5 EA AILERON BINDING B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07862AF 85002 DURING FLEET WIDE INSPECTION, FOUND BEARING IN AILERON LEVER 2 ASSY. PN 120A-4242 TO BE DAMAGED AND BINDING. DAMAGE APPEARS TO BE CAUSED BY THE BUSHING PN 120A-4435.02 IN THE FORK ENDS PN 120A4435.01. IT APPEARS THAT DESIGN LIMITATIONS OF THE FLIGHT CONTROL SYSTEM EXCEEDS LIMITATION OF THE BEARINGS ALLOWING BUSHING TO APPLY EXCESSIVE FORCE ON BEARING DURING FULL DEFLECTION. RECOMMEND REDESIGN OF FLIGHT CONTROL SYSTEM OR REPLACED BEARINGS WITH NEW BEARINGS THAT HAVE GREATER LIMITS. 1L71 3O3 ORTA49CE 1E4 20031114000392003111400039EU 2003 11 14 2003FA0001016 120030925G2913 MOTOR GROB 120 G120A 1660208EU LYC O540 AEIO540D4D5 EA HYD PUMP UNIT FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07864AF591 0016 85004 DURING FLIGHT TRAINING, GEAR FAILED TO RETRACT. MAINTENANCE TECHNICIAN FOUND THAT THE HYDRAULIC PUMP MOTOR OF THE RETRACT SYSTEM HAD FAILED. PROBABLE CAUSE IS OVERHEATING OF THE HYDRAULIC PUMP MOTOR. RECOMMENDATION IS TO MANUFACTURE TO INSTALL A HIGHER CAPACITY MOTOR TO OPERATE THE LANDING GEAR SYSTEM. 1L71 3O3 ORTA49CE 1E4 20031114000322003111400032SO 2003 11 14 2003FA0001017 120030929G2434 MOUNT PIPER PA28 PA28181 7102807SO LYC O320 O320D3G 41508EA ALTERNATOR BROKEN B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP074161Z365 C121824 2843129 RL3133236A DURNG PROGRESSIVE INSPECTION OF ENGINE FOUND LOWER ALTERNATOR MOUNTING HOLE BROKEN OFF. PROBABLE CAUSE IS ENGINE VIBRATION OR MISALIGNMENT OF ALTERNATOR ON ENGINE MOUNTING BRACKET. RECOMMENDATINS IS TO INSTALLED AND RUBBER SHOCK MOUNT IN THIS AREA OR SHIMES TO ALIGN THE ALTERNATOR. 1L71 3O3 O 2A13 E274 20031114000382003111400038GL 2003 11 14 2003FA0001018 220030905G7230E230397911 COUPLING ALLSN 250C 250C20B 03013GL COMPRESSOR FRETTED B HDNRO OTHER O OTHER NRNOT REPORTED 1 SW03 1425 CAE836938 COUPLING REMOVED FOR INSPECTION IAW SB T-080. HAS SEVERE FRETTING IN AREA WHICH CONTACTS IMPELLER. THIS PART WAS INSTALLED NEW IN A NEW IMPELLER. FIT IS .0005 IN. TIGHT. 3 U E4CE 20031030000082003103000008SW 2003 10 30 2003FA0001019 120030813G5751M3414MPB ROD END MOONEYM20 M20M 5870222SW LYC 0540 TIO540AF1B 41532EA MCAULY3D32C B3D32C417 GL RT AILERON BROKEN D O OTHER O OTHER NRNOT REPORTED 1 NE012171Q528 270262 L1010161A 983600 PLANE CAME IN FOR ANNUAL. CUSTOMER REPORTED AILERON CONTROL STIFF. UPON MOVING YOKE TO CONFIRM STIFFNESS. RT AILERON ROD END AT AILERON BROKE. IT BROKE WHERE THREADED PORTION MEETS BEARING. REMOVED ROD END AND FOUND BEARING WAS FROZEN. ALL MOVEMENT WAS IN THE THREADS WHICH WEAKENED IT AND FINALLY BROKE. THE WAS NO EVIDENCE OF RUST OR ANYTHING. AIRPLANE IS KEPT OUTSIDE AND LACK OF LUBRICANT IS SUSPECTED. OTHER SEAMED OKAY BUT WAS REPLACED ANYWAY. 1L71 3O3 ORT2A3 E14EA 5 CP58GL 20031113000832003111300083CE 2003 11 13 2003FA0001020 120031004G5751 CONTROL CABLE CESSNA500 550 2076604CE AILERONS MISINSTALLED B K NONE O OTHER ININSP/MAINT 1 SW05306CS 5500881 THE PILOTS CONTROL WHEEL EMITS A GRINDING NOISE WHEN OPERATING THE AILERONS. FOUND THE AFT AILERON CONTROL CABLE WAS FOUND TO BE INCORRECTLY ROUTED INSIDE THE PILOTS CONTROL COLUMN. THE CABLE TENSION WAS LOW AND THE TURNBUCKLE WAS ADJUSTED TO THE END OF ITS TRAVEL. 1L72 4F A22CE 20031031000512003103100051NM 2003 10 31 2003FA0001021 120031003G531341513017L RIB UNIVAR415 415C 0420302NM FUSELAGE CORRODED D K NONE O OTHER ININSP/MAINT 1 NM0110743 3254 DURING INSPECTION REQUIRED BY AD 2002-26-02 USING METHOD 1 AND METHOD 3, CORROSION WAS DISCOVERED IN THE VICINITY OF THE PILOT'S SIDE INBOARD RIB P/N 415-13017L THIS CORROSION CANNOT BE SEEN USING THE WING REMOVAL METHOD OF INSPECTION. HOWEVER USING THE INSPECTION OPENING METHOD OF INSPECTION, CORROSION BEHING THE FUEL TANKS, IN THE VICINITY OF THE WING ATTACH FITTINGS, AND THE SPAR CAPS CANNOT BE SEEN ADEQUATELY. I FEEL THAT BOTH METHOS 1 AND 3 ARE NEEDED TO PREFORM AN ADEQUATE INSPECTION. THIS IS THE SECOND PLANE I HAVE DISCOVERED CORROSION THAT WAS NOT DETECTED BY WING REMOVAL ALONE. 1L71 3O A718 20031031000622003103100062 2003 10 31 2003FA0001022 420031003G5301A740224N SPRING LET L23 L23 1360308EU TOW RELEASE BROKEN B K NONE O OTHER ININSP/MAINT 1 NM03420BA530 530 029007 PILOT REPORTED RELEASE HANDLE WOULD NOT RETRACT. MAINTENANCE FOUND UPON INSPECTION PART OF SPRING BROKEN. THREE ADDITIONAL SAILPLANES DEVELOPED THIS PROBLEM AT ABOUT SAME TIME IN SERVICE 1K00 RCG24EU 20031031000522003103100052NM 2003 10 31 2003FA0001023 120031003G531341513017L RIB UNIVAR415 415D 0420306NM FUSELAGE CORRODED D K NONE O OTHER ININSP/MAINT 1 NM012273H 2898 DURING INSPECTION REQUIRED BY AD 2002-26-02 USING METHOD 1 AND METHOD 3, CORROSION WAS DISCOVERED IN THE VICINITY OF THE PILOT'S SIDE INBOARD RIB P/N 415-13017L. THIS CORROSION CANNOT BE SEEN USING THE WING REMOVAL METHOD OF INSPECTION. HOWEVER USING THE INSPECTION OPENING METHOD OF INSPECTION, CORROSION BEING THE FUEL TANKS, IN THE VICINITY OF THE WING ATTACH FITTINGS, AND THE SPAR CAPS CANNOT BE SEEN ADEQUATELY. I FEEL THAT BOTH METHODS 1 AND 3 ARE NEEDED TO PERFORM AN ADEQUATE INSPECTION. THIS IS THE SECOND PLANE I HAVE DISCOVERED CORROSION THAT WAS NOT DETECTED BY WING REMOVAL ALONE. 1L71 3O A787 20031030000692003103000069SO 2003 10 30 2003FA0001024 220031001G8530 CYLINDER HEAD CONT O520 TSIO520F 17040SO ENGINE FAILED B O OTHER O OTHER NRNOT REPORTED 1 SW17 BARREL AND HEAD SEPARATION. HEAD SEPARATED BETWEEN THE THREADS AND SEAL BAND AREAS. 3 O E8CE 20031030000702003103000070SO 2003 10 30 2003FA0001025 220031001G8530 CYLINDER HEAD CONT O520 TSIO520F 17040SO ENGINE FAILED B O OTHER O OTHER NRNOT REPORTED 1 SW17 BARREL AND HEAD SEPARATION. HEAD SEPARATED BETWEEN THE THREADS AND SEAL BAND AREAS. 3 O E8CE 20031029001102003102900110EA 2003 10 29 2003FA0001026 220030930G8530 CYLINDER CESSNA182 T182T CE LYC O540 AEIO540D4A5 41532EA ENGINE WRONG PART C O OTHER O OTHER NRNOT REPORTED 1 WP07 245 T18208154 L1121161A DURING A ANNUAL INSPECTION, FOUND THE NR 1 CYLINDER TO BE INCORRECT FOR THIS INSTALLATION, INCORRECT CYLINDER INSTALLED MFG PRIOR TO INSTALLATION ON AIRCRAFT. CYLINDER WAS FOR SHORT REACH PLUGS, ENGINE USES LONG REACH. CYLINDER FOUND ON 2 ND ANNUAL INSPECTION AND HAD OPERATED FOR 245 HRS. 1H71 3O3 ONT3A13 1E4 20031029001112003102900111EA 2003 10 29 2003FA0001027 220030930G8530 CYLINDER CESSNA182 T182T CE LYC O540 TIO540* 41532EA ENGINE WRONG PART C O OTHER W INADEQUATE Q C NRNOT REPORTED 1 WP07 245 T18208154 L1121161A DURING A ANNUAL INSPECTION, FOUND THE NR 1 CYLINDER TO BE INCORRECT FOR THIS INSTALLATION, INCORRECT CYLINDER INSTALLED BY MFG PRIOR TO INSTALLATION ON AIRCRAFT. CYLINDER WAS FOR SHORT REACH PLUGS, ENGINE USES LONG REACH. CYLINDER FOUND ON 2ND ANNUAL INSPECTION AND HAD OPERATED FOR 245HRS 1H71 3O3 ONT3A13 E14EA 20031029001122003102900112EA 2003 10 29 2003FA0001028 220030930G8530 CYLINDER CESSNA182 T182T CE LYC O540 TIO540* 41532EA ENGINE WRONG PART C O OTHER O OTHER NRNOT REPORTED 1 WP07 245 T18208154 L1121161A DURING A ANNUAL INSPECTION, FOUND THE NR 1 CYLINDER TO BE INCORRECT FOR THIS INSTALLATION, INCORRECT CYLINDER INSTALLED BY CESSNA OR LYCOMING PRIOR TO INSTALLATION ON AIRCRAFT. CYLINDER WAS FOR SHORT REACH PLUGS, ENGINE USES LONG REACH. CYLINDER FOUND ON 2ND ANNUAL INSPECTION AND HAD OPERATED FOR 245HRS 1H71 3O3 ONT3A13 E14EA 20031029001172003102900117GL 2003 10 29 2003FA0001029 120031001G551081611 TERMINAL AVIAT A1 A1B 2210406GL HORIZONTAL STAB BROKEN D O OTHER O OTHER NRNOT REPORTED 1 SO152073X574 2073 LEFT FORWARD HORIZONTAL STABILIZER STRUT UPPER TERMINAL BROKE. BREAK OCCURED ON THE UPPER THREADED PORTION OF THE FITTING. 1H71 3O NCA22NM 20031114000482003111400048CE 2003 11 14 2003FA0001030 120031008G5711901100132 SPAR CAP BEECH 90 C90 1152913CE PWA PT6 PT6A21 52043EA MCAULY4HFR344HFR34C762 NE RT WING CRACKED B K NONE O OTHER ININSP/MAINT 1 GL21502SE10138 LJ740 DURING COMPLIANCE OF RAYTHEON AD 89-25-10, WING SPAR INSPECTION, A CRACK WAS DISCOVERED IN THE RIGHT WING LOWER WING SPAR CAP. 1L72 3T4 T 3A20 E4EA 6 C3PNE 20031114000532003111400053CE 2003 11 14 2003FA0001031 120031008G2720 CONTROL CABLE CESSNA182 182 2072702CE RUDDER OUT OF POSITION G K NONE O OTHER ININSP/MAINT 1 CE07 A SAFETY RECOMMENDATION WAS SUBMITTED IN RESPONSE TO SEVERAL INSTANCES WHERE THE RUDDER CONTROL CABLE HAD BEEN FOUND LODGED UNDER THE MOUNTING BOLT FOR THE ELEVATOR CONTROL CABLE PULLEY AT APPROXIMATELY STATION 156. A REVIEW OF THE INSTALLATION INDICATES THIS CONDITION COULD BE CAUSED BY INADVERTINTLY PUSHING THE CABLE DOWN ALLOWING IT TO BE TRAPPED WHEN MAINTENANCE IS BEING PERFORMED ON THE BATTERY OR AVIONICS PACKAGE WHICH ARE ALSO ACCESSED THROUGH THE STATION 156 ACCESS PANEL. FAILURE TO RECHECK THE RUDDER CONTROL RIGGING FOLLOWING WORK ON THE NOSE WHEEL STEERING OR RUDDER TRIM SYSTEMS, CAN ALSO CAUSE THE RUDDER SYSTEM TO EXHIBIT EXCESSIVE SLACK. 1H71 3O NT3A13 20031113000482003111300048 2003 11 13 2003FA0001033 420030718G2561KS1235P0723103 LIFE VEST EMERGENCY EQUIP FAILED B KQ1RK NONE L NO TEST ININSP/MAINT 1 EA07 LIFE VEST FAILED, MFG RECOMMEND CELL PRESSURE TEST IAW 25-60-7. DOM: 3/1985 20031117000062003111700006 2003 11 17 2003FA0001034 420030918G2561KSD35PO723103 LIFE VEST EMERGENCY EQUIP FAILED B KQ1RO OTHER L NO TEST NRNOT REPORTED 1 EA07 LIFE VEST FAILED. MFG RECOMMENDED CELL PRESSURE TEST IAW 25-60-7. DOM: 3/1985 20031113000582003111300058CE 2003 11 13 2003FA0001035 120030920G322013889 BEARING CESSNA421 421B 2076014CE CONT O520 GTSIO520C 17032SO NLG DESTROYED G O OTHER E VIBRATION/BUFFET TXTAXI/GRND HDL 1 NM0741053 421B0419 AIRCRAFT LANDED EXITED ONTO TAXIWAY, FELT VIBRATION IN NOSE OF AIRCRAFT, FELL NOSE FIRST ONTO TAXIWAY. THE BEARINGS IN NOSE WHEEL FROZE AND SHEARED AXIAL. LANDING GEAR STRUT STRUCK GROUND AND COLLAPSED. THE BEARING AND ROLLER RETAINER ON ONE SIDE HAD DISINTEGRATED AND IS MISSING. THE OPPOSITE BEARING IS VOID OF ANY LUBRICATION. THE BEARING EITHER WAS NOT GREASED DURING THE LAST INSPECTION OR OUTSIDE EVENTS, SUCH AS USE OF PRESSURE WASHER TO CLEAN AIRCRAFT HAS WASHED AWAY THE GREASE. 1L72 3O3 O A7CE E7CE 20031113000592003111300059EU 2003 11 13 2003FA0001036 120030929G2710120A4242 LEVER GROB 120 G120A 1660208EU LYC O540 AEIO540D4D5 EA AILERONS BINDING B VJ3RK NONE O OTHER ININSP/MAINT 1 WP07861AF1052 85001 L2802348A DURING FLEET WIDE INSPECTION, FOUND BEARINGS IN AILERON LEVER 2 ASSY. PN 120A4242 TO BE DAMAGED AND BINDING. DAMAGE APPEARS TO BE CAUSED BY THE BUSHING PN 120A4435.02 IN THE FORK ENDS PN 120A4435.01. IT APPEARS THAT DESIGN LIMITATIONS OF THE FLIGHT CONTROL SYSTEM EXCEEDS LIMITATIONS OF THE BEARINGS ALLOWING BUSHING TO APPLY EXCESSIVE FORCE ON BEARING DURING FULL DEFLECTION. RECOMMEND REDESIGN OF FLIGHT CONTROL SYSTEM OR REPLACE BEARINGS WITH NEW BEARINGS THAT HAVE GREATER LIMITS. 1L71 3O3 ORTA49CE 1E4 20031113000492003111300049SO 2003 11 13 2003FA0001037 120030929G792120710AR OIL COOLER PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA ENGINE CRACKED B VJ3RK NONE K FLUID LOSS ININSP/MAINT 1 WP074133D 20 2843117 DURING WALK AROUND OF AIRCRAFT. MAINTENANCE TECHNICIAN FOUND OIL LEAK ON OIL COOLER. PERFORMED PRESSURE CHECK ON OIL COOLER AND FOUND BOTTOM FLANGE CRACKED. THIS IS A WEAK AREA ON THE OIL COOLER. RECOMMEND FINDING A REPLACEMENT THAT IS MORE DURABLE. 1L71 3O3 O 2A13 E286 20031113000352003111300035GL 2003 11 13 2003FA0001038 220030916G7321 BEARING BELL 206 206B 1181511SW ALLSN 250C 250C20J 03013GL FUEL CONTROL MALFUNCTIONED B E ENGINE SHUTDOWN J WARNING INDICATION NRNOT REPORTED 1 WP0159479 2219 85260025 1194 WHILE IN FLIGHT PILOT EXPERIENCED ENGINE HIGH SIDE GOVERNOR FAILURE. THE PILOT WAS UNABLE TO CONTROL RISING ENGINE SPEED WITH THE THROTTLE. RPM ROSE TO 115 PERCENT AND WAS SHUT DOWN BY THE PILOT. UPON REMOVAL OF THE FUEL CONTROL, IT WAS NOTICED THAT THE DRIVESHAFT HAD AN EXCESSIVE AMOUNT OF RADIAL MOVEMENT, ALSO THE SHAFT SUPPORT BEARING WAS COMING APART, WITH THE BEARING BALLS FALLING OUT. THIS PART HAS AN ESTABLISHED OVERHAUL PERIOD OF 2500 HOURS. THE PART HAD 2219.4 HOURS SINCE LAST OVERHAUL, AND HAD BEEN REPAIRED AND FUNCTIONALLY TESTED 498.3 HRS. NOT AWARE OF THE NATURE OF THE REPAIR. 1G71 3U3 U H2SW E4CE 20031117000272003111700027EA 2003 11 17 2003FA0001039 220030917G8520SL13212A BEARING CESSNA177 177RG 2073709CE LYC O360 IO360A1B6 41514EA CONNECTING ROD MELTED G O OTHER O OTHER NRNOT REPORTED 1 GL152664V2 177RG0648 L1351651A NR 2 CYLINDER CONNECTING ROD FAILED AT THE CRANKSHAFT DUE TO OIL STARVATION AOF THE CONNECTING ROD BEARING. POSSIBLE OIL QUICK DRAIN VALVE OPENED IN FLIGHT AND DEPLETED ENGINE OIL SUPPLY. 1H71 3O3 O A20CE 1E10 20031114000692003111400069EU 2003 11 14 2003FA0001040 120030902G5302L535A1101052 FRAME UROCOPEC135 EC135T1 5620026EU TMECA ARRIUSARRIUS2B1 NE TAILBOOM CRACKED D K NONE O OTHER ININSP/MAINT 1 EA03522ME1976 R01 0144 PART CRACKED AT 90 DEGREES BEND RADIUS FROM APPROX 5 O`CLOCK POS. TO THE 10 O`CLOCK POS. BEFORE IT CRACKED TO THE OUTER SURFACE WHERE IT WAS NOTICED DURING A DAILY INSPECTION. PROBABLE CAUSE MAY HAVE BEEN AN EARLIER GROUND BUMPING INCIDENT THAT CAUSED OTHER DAMAGE TO THE AIRCRAFT. RECOMMENDATIONS TO PREVENT RECURRANCE WOULD BE TO CHOSEY INSPECTION. THIS AREA AFTER ANY TAIL BUMPING INCIDENT. 1G72 3U3 U H88EU E34NE 20031117000282003111700028NM 2003 11 17 2003FA0001041 120030807G5280FGFB291300B3 DOOR AMD FALC50FALCON2000 2730170NM CFE CFE73811B NE AUX MLG CRACKED D K NONE O OTHER ININSP/MAINT 1 WP23517PJ1101 793 94 ON POSTFLIGHT INSPECTION A CRACK WAS FOUND ON AUX GEAR DOOR NEAR UPPER RT BOLT HOLE. THERE IS NO EVIDENCE OF IMPACT BY A FOREIGN OBJECT. 2K73 4F4 FRTA50NM E44NE 20031117000222003111700022SO 2003 11 17 2003FA0001042 120030829G3820532T1M140 RELIEF VALVE GULSTMG1159 GIV 3980115SO RROYCETAY TAY6118 EU WATER HEATER FAILED D O OTHER O OTHER NRNOT REPORTED 1 EA25691RC7000 GOS10269 1079 RELIEF VALVE IS INSTALLED ON HEATER ASSY: FAILURE CAUSED ENTIRE WATER SYSTEM TO DRAIN INTO FUSELAGE. THIS RELIEF VALVE SHOULD BE PLUMBED INTO EXISTING AIRCRAFT DRAIN SYSTEM, SO WATER FLOWS OUT DRAIN MAST INSTEAD OF OUT THE FUSELAGE DRAIN HOLES. 2L72 4F4 FRTA12EA E25NE 20031117000052003111700005SO 2003 11 17 2003FA0001043 120030903G2910 SHUTTLE VALVE GULSTMGV GULFSTREAMGV3980116SO RROYCEBR700 BR700710A110 NE HYD SYSTEM LEAKING B O OTHER K FLUID LOSS NRNOT REPORTED 1 SW05130GV 630 OXYGEN ACCESS PANEL ON RIGHT SIDE OF FUSELAGE HAD A NOTICEABLE AMOUNT OF SKYDROL-500 ACCUMALATED INSIDE THE ACCESS DOOR OF THE O-2 SERVICE PANEL. IT WAS DETERMINED THAT THE FLUID WAS COMING FROM THE EMERGENCY LANDING GEAR AIR RELEASE VALVE VENT PORT DUE TO A LEAKING HYD/AIR SHUTTLE VALVE FROM THE LEFT HAND LANDING GEAR SIDE STAY ACTUATOR. THIS VENT IS FORWARD OF THE O-2 SERVICE PANEL. SKYDROL 500B-4 MSDS STATES - MATERIALS TO AVOID EXPOSURE TO STRONG OXIDIZING AGENTS. WE ADDRESSED THIS SAME PROBLEM ON A/C G-V S/N 584 IN AUGUST OF THIS YEAR. 2L72 4F4 FRTA12EA E00057EN 20031113000362003111300036NM 2003 11 13 2003FA0001044 120030715G57306587160 SKIN BOEING727 727243 138408DNM PWA JT8 JT8D9 52048NE LWR CENTER WING CORRODED B K NONE O OTHER ININSP/MAINT 1 SO19521DB 21266 DURING A C-CHECK INSPECTION, CORROSION WAS FOUND ON LOWER SURFACE OF CENTER WING, CENTER SECTION, WHICH FORMS THE UPPER WALL OF THE RAM AIR DUCT USED FOR COOLING OF THE AIR CONDITION SYSTEM ABOVE LEFT PLENUM CHAMBER ASS AT LBL 20 AND STIFFENER 5. DURING CORROSION REMOVAL THE GROUND OUT EXCEEDED ALLOWABLE LIMITS. REPAIRS ARE BEING ACCOMPLISHED IAW SRM. TAT:42266 TAC: 21515 2L73 4F4 FRTA3WE E2EA 20031113000372003111300037SO 2003 11 13 2003FA0001046 120031001G2810U60750002 FUEL CAP PIPER PA22 PA22150 7102210SO LYC O320 O320* 41508EA TANK MALFUNCTIONED D O OTHER O OTHER NRNOT REPORTED 1 SW195852D 224531 NEW FUEL CAP DID NOT VENT. FUEL TANK WAS PARTIALLY COLLAPSED AND SPEWING SOUND WAS COMING FROM THE CAP. CAP WAS TURNED FOR REMOVAL AND WHEN THE INDENTS RELEASED THE CAP, THE TANK POPPED BACK UP IN PLACE. THE CAP DOES NOT SHOW ANY DEFORMATION OR DAMAGE, IT APPEARS NORMAL IN ALL RESPECTS. SUGGEST A TESTING PROCEDURE BE DEVISED BEFORE THESE CAPS ARE INSTALLED. 1H71 3O3 O 1A6 E274 20031114000052003111400005NM 2003 11 14 2003FA0001047 120030926G3060P4E1184 BOOT PIPER PA60 PA60601 7106010NM LYC O540 TIO540* 41532EA PROP DEICE LOOSE B Q2ARO OTHER O OTHER NRNOT REPORTED 1 SW1745RN 50 610056105 DEICE BOOT (FAST BOOT) DOES NOT PROPERLY ADHERE TO BLADE. 1M72 3O3 ORTA17WE E14EA 20031117000242003111700024SO 2003 11 17 2003FA0001048 120030915G55311706702 SPAR PIPER PA23 PA23160 7102304SO LYC O320 O320* 41508EA VERTICAL STAB CRACKED B K5SRK NONE O OTHER ININSP/MAINT 1 NM074159P6249 231644 DURING COMPLIANCE WITH AD 78-08-03, FOUND CRACKS IN THE UPPER HINGE REINFORCEMENT BRACKET (PN 17067-18) OF THE VERTICAL STABILIZER. REMOVAL OF THE BRACKET WAS PERFORMED AND A CLOSE INSPECTION OF THE BOLT HOLES IN THE REAR SPAR FOR THE UPPER RUDDER HINGE CASTING REVEALED SIMILAR CRACKS THERE ALSO. 1L72 3O3 O 1A10 E274 20031114000122003111400012EU 2003 11 14 2003FA0001049 120030928G7810369D2860501 EXHAUST STACK HUGHES369 369FF 4470709EU ALLSN 250C 250C30 03013GL ENGINE CRACKED D O OTHER O OTHER NRNOT REPORTED 1 SO215841Z1627 0135FF CAE900171 THE EXHAUST STACK HAD TO BE REPAIRED SEVERAL TIMES SINCE 400.0 HOURS SINCE NEW. NOW THE AC HAS 1627.3 HOURS TT. SERVICE REPORTS WAS DONE TO MFG SINCE 12-2000. IN 3 OCCASIONS THE MFG SENT THE EXHAUST PN 369D2860501 FOR REPLACEMENT, BUT IT DID NOT FIT INTO THE AIRCRAFT. IN THE MEANTIME, IT CONTINUED CRACKING AND WE CONTINUED TO REPAIR. 1G71 3U3 U H3WE E1GL 20031114000202003111400020GL 2003 11 14 2003FA0001050 120030916G2432G243 BATTERY CIRRUSSR SR20 05628AJGL CONT O360 IO360ES SO MASTER DEFECTIVE D O OTHER O OTHER NRNOT REPORTED 1 SO14425SJ53 1342 357640 THIS BATTERY BURNED A HOLE THROUGH THE FIREWALL. NOT SURE OF CAUSE, BELIEVE THE BATTERY WAS DEFECTIVE. 1L71 3O3 ONTA00009CHE1CE 20031114000232003111400023SW 2003 11 14 2003FA0001051 120030827G63214000395 HOUSING BELL 206 206B 1181511SW ALLSN 250C 250C20 03013GL ROTOR BRAKE WORN D O OTHER O OTHER NRNOT REPORTED 1 NM096181K4301 MAY921035 4276 DURING A 100 HOUR INSPECTION IT WAS FOUND THAT THE ROTOR BRAKE RETURN SPRING HAD WORN INTO THE HOUSING. THE SPRINGS ON ALL FOUR HOUSINGS WERE COCKED AT AN ANGLE FROM TRUE CENTER, ALLOWING THE SPRING TO WEAR A GROOVE INTO THE SIDE OF THE HOUSING. THIS GROOVE HINDERED THE SPRING ACTION TO MOVE THE PUCK EITHER IN OR OUT. THE CONCERN IS THAT THE SPRING COULD BUST, OR BIND UP NOT ALLOWING THE PUCK TO MOVE BACK OFF OF THE ROTOR DISK. THE RECOMMENDATION WOULD BE TO LENGTHEN THE RETURN PISTON GUIDE BORE WHERE THE PISTON RETURN PIN MOVES THRU THE HOUSING. THIS WOULD HELP KEEP EVERYTHING IN ALIGNMENT SO THE RETURN SPRING WILL ALWAYS MOVE STRAIGHT. 1G71 3U3 U H2SW E4CE 20031114000342003111400034EU 2003 11 14 2003FA0001052 120030811G32208002104560 FITTING SOCATARALLYERALLYE235E 8400135EU LYC O540 O540B4B5 41532EA NLG DAMAGED B O OTHER O OTHER NRNOT REPORTED 1 WP15711BZ 12936 L1859840A NOSE WHEEL SHIMMY, GROUND HANDLING AND HARD LANDING. THE RT FITTING PN 880.21.0.456.2 ALSO MADE FROM THE SAME MATERIAL AND SUBJECT TO THE SAME LOADS. 1L71 3O3 O 7A1EU E295 20031114000112003111400011SO 2003 11 14 2003FA0001053 120030902G792120710AR OIL COOLER PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA ENGINE CRACKED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP074166H 302 2843119 RL2584436A DURING 50 HOUR INSPECTION PHASE MAINTENANCE TECHNICIAN FOUND OIL LEAK ON OIL COOLER. PERFORMED PRESSURE CHECK ON OIL COOLER AND FOUND BOTTOM FLANGE CRACKED. THIS IS WEAK AREA ON THE OIL COOLER. RECOMMEND FINDING REPLACEMENT THAT IS MORE DURABLE. 1L71 3O3 O 2A13 E286 20031114000272003111400027CE 2003 11 14 2003FA0001054 120030903G28206314272A20 VALVE BEECH 33 F33A 1151425CE CONT O520 IO520BB 17032SO FUEL MANIFOLD FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP075609S 146 CE1454 825752R DURING ROUTINE PHASE INSPECTION, THE MANIFOLD VALVE WAS FOUND TO BE LEAKING FUEL THROUGH THE AIR VENT. PROBABLE CAUSE IS INTERNAL FAILURE OF THE DIAPHRAGM. NO RECOMMENDATION AT THIS TIME. 1L71 3O3 O 3A15 E5CE 20031114000332003111400033SO 2003 11 14 2003FA0001055 120030421G78108743602 SHROUD PIPER PA44 PA44180 7104402SO LYC O360 IO360E1A 41514EA RT ENG EXHAUST CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CE03266ER126 448195012 L39372T THE CARB HEAT SHROUD ASSY (PN 8743602) FOR THIS AIRCRAFT SEEMS TO BE MANUFACTURED POORLY. WE SEEM TO HAVE AN UNUSUAL FAILURE RATE WHERE THE FORWARD ATTACH CLAMP IS WELDED TO THE SHROUD ASSEMBLY. WE HAVE CHANGED THIS PART 8 TIMES SINCE ENGINE INSTALLATION FOR A DEFECT IN THIS WELDED AREA. THE FOLLOWING IS A HISTORY TIMELINE OF HOURS AND DATES REPLACED. NEW 28 MAR 98 TT 0.0 HOURS, REPLACED 22 SEPT 98 TOTAL 100.0 HOURS, REPLACED. 21 JUL 01, TT 551.7 HOURS, REPLACED 22 APR 03, 677.7 HOURS I HAVE NO RECOMMENDED REPAIR OR DESIGN CHANGE THAT WOULD REMEDY THIS PROBLEM. (CE03200308406) 1L72 3O3 O A19S0 1E10 20031114000282003111400028CE 2003 11 14 2003FA0001056 120030808G71601019100495 DUCT BEECH 200 B200 1152922CE PWA PT6 PT6* 52043EA ENGINE INLET CRACKED B DINRO OTHER O OTHER NRNOT REPORTED 1 EA13260G 1616 BB1525 CRACKS ARE DEVELOPING IN LOWER DUCT SKINS (PN 101-9100495) OF THE AFT LOWER ENGINE COWLINGS. (ENGINE INLETS, BOTH NR 1 AND NR 2). CRACKS IN RIVET ROW AFT OF INSPECTION PANEL (PN 101-910049-47) AND IN AFT ROW OF NUT PLATES FOR INSPECTION PANEL AT RETAINER/ SPLICE (PN 101-910049-9). THIS PANEL IS AT THE HUMP IN THE INLET, IT AND THE SKIN AROUND IT ARE QUITE FLEXIBLE. THE IMPACT AIR MUST BE CREATING THE FLEXING AND CRACKS. SUPPORT AND STIFFENERS HAVE BEEN ADDED TO ARREST CRACK GROWTH ON OUR AIRCRAFT. 1L72 4T3 T A24CE E2NE 20031117000292003111700029CE 2003 11 17 2003FA0001057 120030808G532150440012553 FLOOR PANEL BEECH 200 B200 1152922CE PWA PT6 PT6* 52043EA ENTRY WAY MISINSTALLED B DINRO OTHER O OTHER NRNOT REPORTED 1 EA13260G 1616 BB1525 CABIN FLOOR SKIN AT THE CABIN ENTRANCE IS TOO THIN AND FLEXIBLE. THE SKIN FLEXES OVER A BULKHEAD THAT IS CENTERED IN THE ENTRANCEWAY. A BOARDING PERSON WILL PLACE THERE FEET ON EITHER SIDE OF THIS BULKHEAD. THIS CONSTANT FLEXING WOULD EVENTUALLY CRACK THE FLANGE OF THE BULKHEAD AND / OR THE FLOOR SKIN. WORKING WITH TECH REP, WE HAVE INSTALLED A HEAVY SKIN DOUBLER TO PREVENT FLEXING. 1L72 4T3 T A24CE E2NE 20031113000822003111300082CE 2003 11 13 2003FA0001058 120030804G21501015503233 PLENUM BEECH 200 B200 1152922CE PWA PT6 PT6* 52043EA FREON EVAPORATORLEAKING B DINRO OTHER O OTHER NRNOT REPORTED 1 EA13260G 1627 BB1525 WATER WAS NOTED DRIPPING FROM BELLY BEACON. AFT FREON EVAP PLENUM FOUND TO BE LEAKING. REMOVED PLENUM, FOUND PLASTIC SECTION (BOX END) OF PLENUM CRACKED AND BROKEN AT ALL LOWER MOUNTING SCREW HOLES, CRACKS RADIATING FROM OF RIVET HOLES. PLASTIC BOX END, WHERE EVAP SITS AND BLWR ATTACHES. REPLACED BOX END WITH NEW. NOTED ON INSTALL OF REPAIRED PLENUM THAT LWR FWD END OF BLWR MTNG FLANGE WAS RESTING ON A BLKHD, HOLDING BOX UP SLIGHTLY, STRESSING LOWER MOUNTING SCREW HOLES OF BOX. TRIMMED CORNER OF BLOWER MOUNT FLANGE FOR CLEARANCE. 1L72 4T3 T A24CE E2NE 20031114000162003111400016CE 2003 11 14 2003FA0001059 120030916G324695439914 WHEEL LEAR 35 35A 5170602CE GARRTTTFE731TFE731* 01518WP MLG CRACKED B QH5RO OTHER O OTHER NRNOT REPORTED 1 NM07777DM 297 WHEEL HALF CRACKED ON INSIDE O-RING FLANGE. 2L72 4F4 F A10CE E6WE 20031113000812003111300081SO 2003 11 13 2003FA0001060 120030905G321365319002 STRUT PIPER PA28 PA28161 7102803SO LYC O320 O320* 41508EA LT MLG CRACKED D O OTHER O OTHER NRNOT REPORTED 1 GL13801665620 288216081 STRUT CRACKED AT LOWER SISSOR ATTACH POINT. REPLACED WITH NEW FORGED PART 65489002 ASSY. 1L71 3O3 O 2A13 E274 20031114000422003111400042EA 2003 11 14 2003FA0001061 220030725G74146351 DISTRIBUTOR BLK CESSNA206 206H 2073301CE LYC O540 IO540AC1A5 EA MAGNETO BURNED D O OTHER O OTHER NRNOT REPORTED 1 GL133530E584 20608154 L2794148A DISTRIBUTOR BLOCK AND GEAR ASSEMBLY BURNED UP. 1H71 3O3 ORTA4CE 1E4 20031114000152003111400015EU 2003 11 14 2003FA0001062 120030924G7810369D2860501 EXHAUST STACK HUGHES369 369FF 4470709EU ALLSN 250C 250C30 03013GL ENGINE CRACKED D O OTHER O OTHER NRNOT REPORTED 1 SO215842Z 0137FF THE EXHAUST STACK HAD TO BE REPAIRED SEVERAL TIMES SINCE 400.0 HOURS SINCE NEW. NOW THE HELICOPTER HAS 1568.2 HOURS TAT. IN 3 OCCASIONS THE MFG SENT THE EXHAUST PIN 369D2860-501 FOR REPLACEMENT BUT IT DID NOT FIT INTO THE HELICOPTER. IN MEAN TIME, PART CONTINUED CRACKING AND WE REPAIRING. 1G71 3U3 U H3WE E1GL 20031113000452003111300045CE 2003 11 13 2003FA0001063 120031015G5730 SKIN CESSNA310 310 2074202CE CONT O470 O470* 17026SO RIGHT WING CORRODED B K NONE O OTHER ININSP/MAINT 1 SO25244S 35153 AFTER REMOVAL OF NACELLE AUX FUEL TANK, DISCOVERED A LARGE AREA OF CORROSION ON THE TOP WING SKIN. THE TANK HAD TRAPPED MOISTURE BETWEEN IT AND THE WING TOP OVER A PERIOD OF YEARS. THE CORROSION WAS CLEANED AND THE SKIN HAD LOST LESS THAN 10 PERCENT OF ITS ORIGINAL THICKNESS. THE AREA WAS CLEANED, TREATED AND PRIMED PRIOR TO REINSTALLATION OF THE TANK. THIS TANK WAS INSTALLED AS A PART OF THE RILEY TURBO ROCKET CONVERSION INSTALLED IN 1962. 1L72 3O3 ORT3A10 E273 20031114000132003111400013GL 2003 11 14 2003FA0001064 120031002G631028132531 CLUTCH ENSTRMF28 280C 3300505GL LYC O360 HIO360* 41514EA DRIVE BELT WORN D PNRGO OTHER O OTHER NRNOT REPORTED 1 NM09646H 4032 1099 ON DRIVE BELT CLUTCH MECHANISM, THE SPRING HAD WORN THROUGH THE SIDE OF THE HOUSING FROM MANY HOURS OF RUBBING BACK AND FORTH. THE ABOVE MENTIONED SPRING AND THE SPRING CAP WERE ALSO WORN BEYOND THE INSPECTION CRITERIA IN THE MFG MM. AS FAR AS WE COULD TELL FROM RESEARCHING RECORDS, THESE ARE ALL ORIGINAL PARTS WITH 4032.1 HOURS ON THEM. PERHAPS REGULAR INSPECTION INTERVALS, 500 TO 1000 HOURS, WOULD CATCH A PROBLEM BEFORE IT BECOMES CATASTROPHIC. 1G71 3O3 O H1CE 1E10 20031114000102003111400010GL 2003 11 14 2003FA0001065 120031002G6720 CONTROL CABLE ENSTRMF28 280C 3300505GL LYC O360 HIO360* 41514EA TAIL ROTOR WORN D PNRGO OTHER O OTHER NRNOT REPORTED 1 NM09646H 1099 BOTH REAR TAIL ROTOR CONTROLS CABLES WERE WORN WHERE THEY PASS THROUGH PLASTIC FAIR-LEADS IN AFT BULKHEAD OF TAIL BOOM. BOTH WERE WORN TO 40-50 PERCENT INSP CRITERIA. THIS IS BECOMING A CHRONIC PROBLEM AS RECORDS INDICATE THEY WERE REPLACED 1 MAY 2001, AFT OF 2821.0; 15 MAR 2002, AFT OF 3159.7, 338.7 HOURS TIME IN SERVICE ON THE CABLES; 5 FEB. 2003, AFT OF 3551.1, 391.4 HOURS TIME IN SERVICE; AND NOW, 25 SEP 2003, AFT OF 4043.9, 492.8 HOURS TIME IN SERVICE. CONTRIBUTING FACTORS MAY INCLUDE THE RECOMMENDED TENSION ON THE CABLES AND THAT THE AIRCRAFT IS USED FOR AGRICULTURAL SPRAYING AND THE ACCUMULATION OF DIRT MAY BE ABRASIVE IN THE AREA OF THE FAIR-LEADS. PERHAPS A KIT TO INSTALL PULLEYS IN THAT AREA. 1G71 3O3 O H1CE 1E10 20031113000772003111300077SO 2003 11 13 2003FA0001066 220030925G8530652541 NUT BEECH 36 A36 1151604CE CONT O550 IO550B SO NR 3 CYLINDER CRACKED B EHHRO OTHER O OTHER NRNOT REPORTED 1 EA17188KM340 E3361 684654 PILOTS REPORTED LOOSE NUT ON FORWARD NUT TOP OF NR 5 CYLINDER, ON INSPECTION FOUND THAT THE STUD THIS NUT IS ON IS A THROUGH STUD TD NR 3 CYLINDER ON THE NR 3 CYLINDER THE NUT WAS CRACKED AND OPENED DOWN THE SIDE THUS ALLOWING THE NR 5 CYLINDER NUT TO BECOME LOOSE, REPLACED NUT AND TORQUE TO SPECS CALLED OUT IN SB 96-7B. 1L71 3O3 O 3A15 E3SO 20031114000512003111400051SO 2003 11 14 2003FA0001067 120031003G270162839000 SPROCKET PIPER PA28 PA28161 7102803SO LYC O320 O320* 41508EA CONTROL WHEEL DAMAGED D K NONE O OTHER ININSP/MAINT 1 NE033077M4782 287816335 AT ANNUAL INSPECTION, FOUND BACKUP STOP PIN ON PILOT SIDE CONTROL SPROCKET TO BE DAMAGED. FURTHER INVESTIGATION REVEALED THAT THE SPROCKET TOOTH LOCATED AT THE STOP PIN WAS BROKEN OUT OF THE SPROCKET. POSSIBLE CAUSE IS STRESS FRACTURE AT THE WELD OF THE STOP PIN. SPROCKET WAS REPLACED AND AILERON SYSTEM WAS RE-RIGGED IAW MM. (NE03200401111) 1L71 3O3 O 2A13 E274 20031113000762003111300076CE 2003 11 13 2003FA0001068 120030924G750024540100 CLAMP CESSNA441 441 2076020CE GARRTTTPE331TPE33110 01514WP BLEED SUPPLY CRACKED C A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CLCLIMB 1 NE03441JK 4410197 REPORTED SMOKE IN COCKPIT UPON TAKEOFF. A/C RETURNED IMMEDIATELY AND PERFORMED NORMAL LANDING. INSP REVEALED A CRACKED V-BRAND CLAMP CONNECTING BLEED AIR SUPPLY LINES IN RT WING ROOT AREA ADJACENT TO SURFACE DEICE PRESSURE REGULATORS. SMOKE WAS DETERMINED TO ORIGINATE FROM A PLASTIC/VINYL HOSE INSIDE CABIN ADJACENT TO FUSELAGE SKIN WHICH HAD BURNED AND MELTED. SUSPECT HEAT FROM BLEED AIR SUPPLY LINES CAUSED LOCAL AREA TO CONDUCT HEAT THROUGH THE SKIN TO THE EXTENT NECESSARY TO MELT THE TUBING. INSP REVEALED NO OTHER APPARENT HEAT RELATED DAMAGE. SUBMITTER NOTES THAT THE CRACK IN THE V-BAND CLAMP OCCURRED AT JUNCTION OF BARREL BOLT, AND NO SAFETY DEVICES WERE INCORPORATED ON ANY OF CLAMPS IN AREA. 1L72 3T4 TRTA28CE E4WE 20031113000562003111300056CE 2003 11 13 2003FA0001069 120031009G3230583800901 MOTOR BEECH 58 58 1152740CE CONT O550 IO550* SO MLG INOPERATIVE B TRKRO OTHER O OTHER LDLANDING 1 SO15353P 938 TH1999 LANDING GEAR WOULD NOT EXTEND ELECTRICALLY. EXTENDED MANUALLY-3 GREEN. AIRCRAFT LANDED AND TAXIED TO FBO WITHOUT INCIDENT. PLACED A/C ON JACKS AND RETRACTED GEAR-RETRACTED EXTREMELY SLOW. ON 2ND RETRACT MOTOR STARTED SMOKING. INSTALLED OVERHAULED MOTOR AND GEAR CYCLED WITHOUT FURTHER DEFECTS. NO EXTERNAL DAMAGE TO MOTOR. APPEARS TO BE INTERNAL FAILURE. 1L72 3O3 O 3A16 E3SO 20031114000212003111400021GL 2003 11 14 2003FA0001070 120031010G3240MS28775222 O-RING PARKERHANFIN CIRRUSSR SR22 2130001GL BRAKE ASSY DEFORMED G O OTHER O OTHER LDLANDING 1 SO07891CD234 0592 BRAKE ASSY O-RING DEFORMED. 1L71 3O NTA00009CH 20031114000372003111400037SO 2003 11 14 2003FA0001071 120030905G3060 BOOT HARTZL PIPER PA31 PA31350 7103110SO LYC O540 TIO540* 41532EA HARTZLHCE3Y HCE3YR2 GL PROP DEICE DEBONDED B IGARK NONE O OTHER ININSP/MAINT 1 WP238131 6 318152032 SEPARATION OF DE-ICE BOOT AFTER MAINTENANCE PERFORMED ON PROPELLER ASSY. PROBLEM OCCURRED ON LEFT AND RIGHT PROPELLERS AFTER MAINTENANCE PERFORMED BY REPAIR STATION. 1L72 3O3 O A20SO E14EA 5 CP33EA 20031114000492003111400049CE 2003 11 14 2003FA0001072 120031014G7160BA3 FILTER ELEMENT BEECH 23 19A 1151214CE AIR INTAKE SEPARATED G A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CLCLIMB 1 SW177643R MB435 ENGINE LOST POWER SHORTLY AFTER TAKEOFF. FORCED LANDING RESULTED IN SUBSTANTIAL DAMAGE TO THE AIRCRAFT. INVESTIGATION FOUND PIECES OF THE AIR FILTER ELEMENT IN THE VENTURI OF THE CARBURETOR. THE FILTER ELEMENT HAD BEEN IMPROPERLY INSTALLED ALLOWING THE ENTIRE AFT END OF THE OVAL ELEMENT TO BE PINCHED BETWEEN THE FILTER SCREEN AND THE FILTER HOUSING. THIS ALLOWED ELEMENT PIECES TO BE SEPARATED AND INGESTED INTO THE CARBURETOR. 1L71 3O A1CE 20031114000632003111400063GL 2003 11 14 2003FA0001074 120031008G271010332002 HINGE CIRRUSSR SR22 2130001GL CONT O550 IO550N 17042SO HARTZLHCJ3Y PHCJ3YF1 GL AILERON DAMAGED H NASAK NONE O OTHER ININSP/MAINT 1 EA21501NA127 0012 685745 FP1267B INSP ON STOP-TO-STOP TRAVEL OF LT AILERON, NOTICED ODD DOUBLE BUMP SOUND, MVMT AT STOPS. LT WINGTIP, AILERON WERE REMOVED TO FACILITATE FURTHER INSP. IB AILERON HINGE MOVED UP AND DOWN WITH FORCE APPLIED TO IT. VERT MVMT (0.053”) WAS MEASURED APPROX AT BRG IN HINGE ABOUT 5 INCHES AFT OF TWO MNTING BOLTS. TORQUE-SEAL WAS STILL ON NUTS, TORQUE WAS CHECKED FIRST IN TIGHTENING DIRECTION, THEN IN LOOSENING DIRECTION. TORQUE REQUIRED TO TIGHTEN UPPER NUT WAS 75 INCH LBS, AND 55 INCH LBS TO LOOSEN. TORQUE REQUIRED TO TIGHTEN LOWER NUT WAS 40 INCH LBS AND 37 INCH LBS TO LOOSEN. BOLTHOLES IN AILERON HINGE, PULLEY BRACKET, AND FLAP HINGE WERE MEASURED FOR ELONGATION. HOLES WERE NOT ELONGATED; LARGEST DIA FOUND WAS 1L71 3O3 ONTA00009CHE3SO 5 CP36EA 20031113000402003111300040SO 2003 11 13 2003FA0001075 120031009G5711656015 SPAR CAP PIPER PA28 PA28140 7102802SO LYC O320 O320* 41508EA RT WING CORRODED D O OTHER O OTHER NRNOT REPORTED 1 SW074606R4407 2821354 RT WING REPLACED. EXISTING WING HAD EXFOLIATION CORROSION IN BOTTOM SPAR CAP AT INBOARD REAR OF FUEL TANK. THERE IS NO ACCEPTABLE REPAIR. CORROSION IS VISIBLE ONLY WHEN FUEL TANK IS REMOVED. 1L71 3O3 O 2A13 E274 20031113000432003111300043NE 2003 11 13 2003FA0001076 220030925G7230 MODULE SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE ENG COMPRESSOR DAMAGED D O OTHER O OTHER NRNOT REPORTED 1 SW016093K1403 409 2709 9564 PILOT REPORTED ENGINE WOULD NOT START AFTER FUEL STOP. AFTER 45 MINUTES ANOTHER ATTEMPT WAS MADE. ENGINE STARTED AND RAN NORMALLY. AIRCRAFT RETURNED THE FOLLOWING DAY. DURING OTHER SCHEDULED MAINTENANCE THE AXIAL COMPRESSOR WAS TURNED BY HAND. A NOTICEABLE DRAG WAS EXPERIENCED ALONG WITH A SQUEAK DURING ROTATION. THE MODULE 02/03 ASSEMBLY WAS REMOVED FOR RETURN TO MFG ENGINE FACILITY FOR EVALUATION AND/OR REPAIR. 1G71 3U3 U H9EU E19EU 20031117000092003111700009GL 2003 11 17 2003FA0001077 320031010G6114HCC2YR2 HUB HARTZLHCC2Y HCC2YR2 GL PROPELLER CRACKED B UF2RO OTHER O OTHER NRNOT REPORTED 1 GL15 7552 AU6095 PROPELLER HUB CRACKED. 5 CP920 20031114000672003111400067NE 2003 11 14 2003FA0001078 220031010G7321307080039 FUEL CONTROL AMD FALC50FALCON50MYST2730106EU GARRTTTFE731TFE73140 29001NE ENGINE LEAKING D O OTHER K FLUID LOSS NRNOT REPORTED 1 GL2323FM 1966 296 P115241 FUEL LEAKING FROM P3 VENT LINE, STATIC LEAKAGE. NO LEAKAGE PERMITTED IAW MM. 2L73 4F4 F A46EU E1NM 20031114000682003111400068SO 2003 11 14 2003FA0001079 120031007G8010 GEAR PIPER PA28 PA28161 7102803SO LYC O320 O320* 41508EA STARTER DESTROYED B OG5RO OTHER O OTHER NRNOT REPORTED 1 GL21357ND119 0070987 2842185 PILOT SQUAWKED STARTER MAKING LOUD METAL GRINDING NOISE. MECHANIC INSPECTED BURNED BENDIX GEAR HAD COME APART. THIS IS THE SECOND OCCURANCE ON A SIMILAR AIRCRAFT WITH APPROXIMATELY THE SAME TIME IN SERVICE. 1L71 3O3 O 2A13 E274 20031117000102003111700010SO 2003 11 17 2003FA0001080 120031007G8010 GEAR PIPER PA28 PA28161 7102803SO LYC O320 O320* 41508EA STARTER DESTROYED B OG5RK NONE O OTHER ININSP/MAINT 1 GL21359ND104 D070992 2842187 PILOT SQUAWKED STARTER, WOULD NOT ENGAGE. UPON MECHANIC INSPECTION FOUND BENDIX DRIVE GEAR DESTROYED. RING GEAR WAS ALSO DAMAGED. SUSPECT GEAR NOT RETRACTING AFTER START. STARTER AND RING GEAR REPLACED AIRCRAFT RETURNED TO SERVICE. 1L71 3O3 O 2A13 E274 20031117000082003111700008SO 2003 11 17 2003FA0001081 120031009G2810U60750002 FUEL CAP PIPER PA22 PA22150 7102210SO LYC O320 O320* 41508EA FUEL CELL INADEQUATE D O OTHER O OTHER NRNOT REPORTED 1 SW195852D 224531 FUEL CAP DID NOT VENT. THE FUEL CAP WAS RETURNED TO MFG AND THEY REPORTED THE CAP TO BE VENTING PROPERLY. MFG REPLACED THE CAP AND THE REPLACEMENT REFUSED TO VENT. ON THE GROUND THERE APPEARS TO BE ADEQUATE VENTING CLEARANCE BETWEEN THE FILLER NECK WASHER AND THE CAP VENT HOLES. HOWEVER, IN FLIGHT SOMETHING MOVED AND THE FILLER NECK GASKET SEALED THE VENT HOLES IN THE FUEL CAP. IN SOME INSTANCES THE FILLER NECK DOES NOT EXTEND HIGH ENOUGH ABOVE THE TANK AND FILLER NECK WASHER TO PREVENT THIS SEALING EFFECT. SUGGEST MODIFICATION OF THE CAP VENT HOLES TO PREVENT THIS TYPE OF BLOCKAGE. 1H71 3O3 O 1A6 E274 20031114000622003111400062SO 2003 11 14 2003FA0001082 220031015G8530 CYLINDER HEAD CONT O520 IO520* 17032SO ENGINE FAILED B K NONE P NO WARNING INDICATION ININSP/MAINT 1 SW17 1187 CYLINDER RECEIVED FOR TBO REPAIR. CYLINDER HEAD IS CRACKED FROM TOP SPARK PLUG BOSS AROUND THE DOME AREA ON THE EXHAUST SIDE OF THE HEAD, ALL THE WAY TO THE LOWER SPARK PLUG BOSS. NO EVIDENCE OF COMBUSTION PRODUCTS ON THE OUTSIDE OF THE CYLINDER HEAD SO CRACK HAS NOT PROGRESSED COMPLETELY THROUGH THE CYLINDER HEAD WALL. PART IS REJECTED. 3 O E5CE 20031117000072003111700007CE 2003 11 17 2003FA0001083 120031017G2434 BRUSHES CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA MCAULY1C235 1C235LFA GL ALTERNATOR WORN B K NONE O OTHER ININSP/MAINT 1 SO0324336574 A146713 17280888 L2878551A TJ054 ALTERNATOR BRUSHES EXCESSIVELY WORN FOR THE AMOUNT OF TIME ON ALTERNATOR. (3/16 IN.LONG) A NEW BRUSH IS .5 INCH LONG 1H71 3O3 ONT3A12 1E10 5 NP12EA 20031117000162003111700016CE 2003 11 17 2003FA0001084 120031015G1430 RIVET CESSNA CESSNA310 310 2074202CE LYC O540 IO540* 41532EA TORQUE TUBE LOOSE B K NONE F FLT CONT AFFECTED ININSP/MAINT 1 SO25244S 35153 THE RIVETS THAT ATTACH THE RUDDER TORQUE TUBE TO THE BELLCRANK ADDAPTOR PLATE BECAME LOOSE. THIS CAUSED THE RUDDER TO DEFLECT AS MUCH AS FIVE DEGREES FROM ITS PROPER POSSITION. 1L72 3O3 ORT3A10 1E4 20031117000172003111700017CE 2003 11 17 2003FA0001085 120031015G1430 RIVET CESSNA CESSNA310 310 2074202CE LYC O540 IO540* 41532EA TORQUE TUBE LOOSE B K NONE F FLT CONT AFFECTED ININSP/MAINT 1 SO25244S 35153 THE RIVETS THAT ATTACH THE RUDDER TORQUE TUBE TO THE BELLCRANK ADDAPTOR PLATE BECAME LOOSE. THIS CAUSED THE RUDDER TO DEFLECT AS MUCH AS FIVE DEGREES FROM ITS PROPER POSSITION. 1L72 3O3 ORT3A10 1E4 20031117000252003111700025SO 2003 11 17 2003FA0001087 120031009G25209681400 SEAT PIPER PA28 PA28140 7102802SO LYC O320 O320E2D 41508EA SNSNCH74D 74DM EA CABIN CRACKED D K NONE O OTHER ININSP/MAINT 1 NM03165834233 6 287325301 L3324227A K35135 AFTER A PURCHASE OF A/C, A/C WAS HANGERED AND PREPPED FOR INTERIOR REFURBISH. UPON INSPECTION OF LT AND RT FRONT SEATS BEFORE PRIMING AND REPAINTING, CRACKS FROM APPROX. 270 TO 320 DEGREES AROUND WERE DETECTED EXTENDING FROM WELDS AT SUPPORT BRACKETS CONNECTING UPPER TUBULARS OF SEAT FRAME. IF LEFT UNDETECTED, THE RT SEAT WOULD HAVE SEPARATED AT FRONT BRACKETS (SEAT FRAME SEPARATION) CAUSING FRONT PASSENGER TO FLING BKWD WITHOUT NOTICE. LT SEAT HAD ONLY ONE CRACK, BUT WOULD CAUSE PRESSURE ON (ADJACENT) SEAT FRAME SUPPORT BRACKETS AND POSSIBLE SEPARATION. GRIND OUT CRACKS AND WELD (TIG OR OXY/ACET GAS) BY AUTHORIZED INDIVIDUAL, OR REPLACEMENT OF SEAT FRAMES. 1L71 3O3 O 2A13 E274 5 NP88614 20031117000262003111700026SO 2003 11 17 2003FA0001088 120031009G25209681400 SEAT PIPER PA28 PA28140 7102802SO LYC O320 O320E2D 41508EA SNSNCH74D 74DM EA CABIN CRACKED D K NONE O OTHER ININSP/MAINT 1 NM03165834233 6 287325301 L3324227A K35135 SEATS WERE REMOVED, UNUPHOLSTERED, STRIPPED OF ORIGINAL PAINT FOR REPAINTING. UPON INSP OF LT AND RT FRONT SEATS BEFORE PRIMING AND REPAINTING, CRACKS APPROX. 270 TO 320 DEGREES AROUND WERE DETECTED FROM WELDS AT SUPT BRKTS CONNECTING UPPER TUBULARS OF SEAT FRAME. RT SEAT WOULD HAVE SEPARATED AT FRONT BRKTS CAUSING FRONT PASSENGER TO FLING BKWD WITHOUT NOTICE. LT SEAT HAD ONLY ONE CRACK, LT UNDETECTED MAY NOT HAVE CAUSED PILOT TO FLING BKWD BUT WOULD CAUSE PRESSURE ON OPPOSITE SEAT FRAME SUPPT BRKTS AND WOULD LEAD TO CRACKS. REPAIR/ GRIND OUT CRACKS AND WELD (TIG OR OXY/ACET GAS) BY AN AUTHORIZED INDIVIDUAL, OR REPLACEMENT OF SEAT FRAMES. THESE PARTICULAR CRACKS WERE WELDED AND 337'S PREPARED. 1L71 3O3 O 2A13 E274 5 NP88614 20031114000222003111400022SW 2003 11 14 2003FA0001089 120031023G2571360036 BOLT BELL 206 206L3 1182108SW ALLSN 250C 250C30 03013GL BATTERY MOUNT BURNED D K NONE BHASMOKE/FUMES/ODORS/SPARKS ELECT. POWER LOSS-50 PC FLAME/FIRE ININSP/MAINT 1 SW179107G 51421 DURING A SCHEDULED INSPECTIOM FOUND PRIMARY ELECTRICAL CABLE, P6D000, IN BATTERY COMPARTMENT TO HAVE A BURNED AREA ADJACENT TO RT BATTERY HOLD DOWN BOLT. MFG, STC SH297NM HAS BEEN INSTALLED ON THIS AIRCRAFT. THE BURNED AREA WAS CAUSED BY HEAVY CONTACT OF THE PRIMARY ELECTRICAL CABLE WITH THE BATTERY HOLD DOWN BOLT. THERE IS NOT ENOUGH ROOM IN THE BATTERY COMPARTMENT TO REROUTE THIS CABLE. DAMAGE TO SOME EXTENT ON THIS CABLE IS PREVALENT ON SEVERAL AIRCRAFT ON WHICH THIS STC HAS BEEN INSTALLED ON. THE DESIGN OF THE BATTERY MOUNTING BRACKET IS THE CAUSE OF DAMAGE TO THE AIRCRAFT WIRING. THIS CONDITION, IF LEFT UNRESOLVED, COULD RESULT IN SMOKE IN THE CABIN, ELECTRICAL SYSTEM FAILURE, FIRE, OR CAUSE THE BATTERY TO1G71 3U3 U H2SW E1GL 20031113000342003111300034 2003 11 13 2003FA0001094 420031009G2562E01 ELT CIRRUSSR SR20 05628AJGL LYC O360 IO360A1A 41514EA CABIN FALSE ACTIVATIONB O OTHER O OTHER NRNOT REPORTED 1 GL03213CD 1111 WHEN TRANSMITTING WITH NR 2 GN5430 COM RADIO, ELT IS BEING ACTIVATED, NR 2 COM ANTENNA IS LOCATED DIRECTLY BENEATH ELT LOCATION. 1L71 3O3 ONTA00009CH1E10 20031117000192003111700019 2003 11 17 2003FA0001095 420031009G2562E01 ELT CIRRUSSR SR22 2130001GL CONT O550 IO550* SO CABIN FALSE ACTIVATIONB O OTHER N FALSE WARNING NRNOT REPORTED 1 GL03416S 0020 WHEN TRANSMITTING WITH NR 2 GNS 430 COM RADIO ELT IS BEING ACTIVATED (TURNED ON) NR 2 COM ANTENNA IS LOCATED DIRECTLY BENEATH ELT LOCATION. 1L71 3O3 ONTA00009CHE3SO 20031114000312003111400031NE 2003 11 14 2003FA0001096 220031008G723023 MODULE SNIAS 350 AS350* EU TMECA ARRIELARRIEL1D1 NE AXIAL COMPRESSORSEIZED D O OTHER O OTHER NRNOT REPORTED 1 SW016088B705 2691 9747 PILOT REPORTED; ENGINE WOULD NOT START. WHEN START BUTTON PUSHED, IGNITERS WOULD FIRE BUT NO NG ROTATION. STARTER MADE AN (THUNK). VOLTS WERE GOOD, SUBSEQUENT INSPECTION BY MAINTENANCE PERSONNEL DETERMINED THAT THE AXIAL COMPRESSOR HAD SEIZED.(K) 1G71 3U3 U H9EU E19EU 20031113000722003111300072SO 2003 11 13 2003FA0001097 120031023G3340GE4594 LAMP PIPER PA32 PA32R301 7103218SO LYC O540 IO540K1G5 41532EA HARTZLHCI3Y HCI3YR2 GL WING TIP BURNED OUT D O OTHER O OTHER NRNOT REPORTED 1 SO03489HP 3246121 L2651048A HK328A THESE BULBS ARE BURNING OUT AT A RATE OF AT LEAST 50 FLIGHT HOURS AND SOMETIMES AS LOW AS 20 FLIGHT HOURS. THE PILOT IS NOT LEAVING ON ALL THE TIME BUT RATHER ON LANDINGS AND TAKE OFFS. THE TAXI LIGHT IS LAST NORMAL AMOUNTS OF TIME. 1L71 3O3 O A3SO 1E4 5 CP33EA 20031114000462003111400046SO 2003 11 14 2003FA0001098 220031010G8530641916CP ROCKER BOSS CESSNA150 150M 2071830CE CONT O200 O200A 17020SO NR 3 CYLINDER FAILED C A UNSCHED LANDING RJ PARTIAL RPM/PWR LOSS WARNING INDICATION NRNOT REPORTED 1 NM07452882531 385 15076825 21370971A ON APRIL 19, FLYING BACK TO LGU, THE ENGINE SUDDENLY BEGAN VIBRATING AND LOST A LOT OF POWER. COULD NOT MAINTAIN ALTITUDE, LANDED IN A FIELD. MECHANIC CAME AND FOUND THAT THE ROCKER BOSSES OF CYL NR 3 HAD FAILED. INSTALLED AN NEW CYLINDER ASSY AND FLEW IT BACK. WHERE THE OTHER 3 CYLINDERS WERE REPLACED TO PREVENT RECURRENCE. PALANE WAS UNDAMAGED. 1H71 3O3 O 3A19 E252 20031114000472003111400047SO 2003 11 14 2003FA0001100 220030920G8520A35160A2 CONNECTING ROD SWFTMSGC1B GC1B 9230104SO CONT C125 C1252 17011SO NR 6 CYL FAILED D O OTHER O OTHER NRNOT REPORTED 1 SO133721K 1414 183162 NR 6 CONNECTING ROD OR BEARING FAILED.(K) 1L71 3O3 ONCA766 E236 20031117000202003111700020EA 2003 11 17 2003FA0001101 220031005G8520 ROD BEECH 60 B60 1153605CE LYC O541 TIO541E1C4 41536EA NR 5 DESTROYED B DDERO OTHER RJ PARTIAL RPM/PWR LOSS WARNING INDICATION APAPPROACH 1 WP0157HD 4221 1187 P279 L172859 ON FINAL APPROACH, LEFT ENGINE, NR 5 ROD BROKE AND BROKE CRANKCASE. 1L72 3O3 O A12CE E10EA 20031113000742003111300074SO 2003 11 13 2003FA0001102 120031008G792120710AR OIL COOLER PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA ENGINE CRACKED B VJ3RK NONE K FLUID LOSS ININSP/MAINT 1 WP074166H 15 2843119 RL2584436A DURING PREFLIGHT PILOT FOUND AN OIL LEAK IN ENGINE COMPARTMENT OF AIRCRAFT. MAINTENANCE TECHNICIAN FOUND OIL COOLER CRACKED ON THE BOTTOM FLANGE AND LEAKING OIL. THIS IS A WEAK AREA ON THE OIL COOLER. RECOMMEND FINDING A REPLACEMENT THAT IS MORE DURABLE. (K) 1L71 3O3 O 2A13 E286 20031114000652003111400065CE 2003 11 14 2003FA0001104 120031014G2751BZ7RWT80 SWITCH CESSNA340 340A 2076405CE FLAP ACTUATOR FAILED D JQNGO OTHER O OTHER NRNOT REPORTED 1 NM09340FP2781 340A0298 AFTER LANDING WHILE TAXING BACK, THE PILOT RETRACTED THE FLAPS. THE UP MICRO SWITCH FAILED TO STOP THE FLAPS AT THEIR UP LIMIT. BOTH CHAINS ATTACHED TO THE FLAP CABLES WERE BROKEN OR DAMAGED. SEVERAL OPERATING RODS WERE DAMAGED AND A PULLEY WAS PULLED OUT OF ITS MOUNT. IT COULD NOT BE VERIFIED THAT THE MICRO SWITCH HAD AN INTERMITTENT FAILURE. A PROBABLE EXPLANATION WAS THE CAM AND UP MICRO SWITCH WERE SLIGHTLY OUT OF RIG ALLOWING THE FLAP GEAR BOX TO OVER RUN. THIS COULD HAVE HAPPENED THRU YEARS TO TWEAKING THE LT SWITCH TO RAISE THE FLAPS FULLY. WE ARE GOING TO PAY CLOSER ATTENTION TO THE FUNCTIONING AND RIGGING OF THE FLAP SYSTEM TO TRY TO KEEP THIS FROM HAPPENING AGAIN. (K) 1L72 3O 3A25 20031114000242003111400024SW 2003 11 14 2003FA0001105 120030927G323341961000 WORM GEAR DUKES MOONEYM20 M20J 5870219SW LYC O360 IO360A1A 41514EA MCAULY2D34C B2D34C212 GL ACTUATOR STRIPPED D O OTHER O OTHER NRNOT REPORTED 1 GL17201DP206 0515 240065 L1636151A 767357 LANDING GEAR UNLOCKED BUT FAILED TO RETRACT AFTER TAKEOFF. ATTEMPS TO EXTEND GEAR TO DOWN AND LOCKED ELECTRICALLY AND MANUALLY WERE UNSUCCESSFUL. GEAR COLLAPSED UPON LANDING. INVESTIGATION REVEALED THAT THE RECENTLY REPLACED WORM AND DRIVE GEARS INSIDE THE LANDING GEAR ACTUATOR WERE WORN AND STRIPPED. THE GEARS WERE REMOVED AND CASE TESTED FOR HARDNESS. TEST RESULTS REVELED THAT THE GEARS WERE SOFT AND BELOW MANUFACTURERS SPECS. SUSPECT GEARS WERE IMPROPER OR NEVER HEAT TREATED. (GL17200303131) (K) 1L71 3O3 O 2A3 1E10 5 CP7EA 20031113000842003111300084SO 2003 11 13 2003FA0001106 120031004G3230633062 TORQUE LINK PIPER PA28 PA28140 7102802SO LYC O320 O320* 41508EA MLG CRACKED D K NONE O OTHER ININSP/MAINT 1 NM01432FL 287125219 DURING INSP OF MLG IAW SB 1131, DISCOVERED CRACK IN MLG TORQUE LINK. FURTHER NDI REVEALED ALL (4) TORQUE LINKS CRACKED (PN 633062) EXACTLY AS INDICATED IN FIG 1 OF SC600. THE TORQUE LINKS WERE NOT BEING INSPECTED IAW AD BECAUSE THE AD CITES PN 6569100 OR 65691002 AS THE ONLY ONES TO BE INSPECTED. MFG SL600 DIRECTS TORQUE LINKS TO BE INSPECTED BY AC SERIAL NR AND BY PN (IF) TORQUE LINKS HAVE BEEN REPLACED. AD DOES NOT COVER THE FULL SPECTRUM OF TORQUE LINKS AS THE SL INTENDS TO COVER. THERE IS A DISPARITY BETWEEN THE AD AND LS AND ALL THE LINKS ARE NOT BEING INSPECTED AS THE SL ORIGINALLY INTENDED THEM TO BE. REVISE AND CLARIFY THE AD.(K) 1L71 3O3 O 2A13 E274 20031113000442003111300044EA 2003 11 13 2003FA0001107 220030930G732230804 FLOAT CESSNA172 172N 2072434CE LYC O320 O320* 41508EA CARBURETOR OBSTRUCTED D VJBSA UNSCHED LANDING RJ PARTIAL RPM/PWR LOSS WARNING INDICATION NRNOT REPORTED 1 EA095208D193 CK814912 17272451 L463476 PILOT DEPARTED HOME AIRPORT FOR INSTRUCTURAL FLIGHT WITH STUDENT. ON TAKE OFF ROLL AT DESTINATION AIRPORT, ENGINE LOST POWER. INSTRUCTOR LANDED ON PARALLEL RUNWAY WITHOUT INCIDENT. INSTRUCTOR RESTARTED ENGINE AND PERFORMED RUN-UP SATISFACTORY. A/C WAS INSPECTED WITHOUT ANY DEFECTS NOTED, AND NUMEROUS HIGH SPEED TAXI CHECKS AND TAKE OFF AND LANDINGS PERFORMED WITHOUT INCIDENT. INSTRUCTOR RETURNED AIRCRAFT TO HOME AIRPORT WHERE ON NINTH SEQUENTIAL FLIGHT, ENGINE LOST PARTIAL POWER. A/C WAS LANDED AGAIN WITHOUT INCIDENT. CARBURETOR WAS REMOVED AND DISASSEMBLED. APPARENT NEW STYLE PLASTIC FLOAT WAS FOUND TO BE RUBBING LOWER FUEL BOWL. THIS CAUSED THE FLOAT TO BIND AND PARTIALLY RESTRICT FUEL FLOW TO ENGINE1H71 3O3 ONT3A12 E274 20031117000142003111700014GL 2003 11 17 2003FA0001108 120031023G76022276112100 CONTROL CABLE DIAMONDA20 DA20C1 2990001GL CONT O240 IO240B 17063SO SNSNCHW69EK W69EK63 EA FUEL MIXTURE BROKEN D D RETURN TO BLOCK O OTHER TXTAXI/GRND HDL 1 NM03919AF430 C0174 MIXTURE CONTROL CABLE BROKEN AT THE FIREWALL. THIS IS THE FIFTH ONE TO FAIL ALL AT THIS LOCATION. INSPECTION OF THE 28 AIRCRAFT FLEET REVEALED 16 CABLES WITH A NOTICABLE KINK IN THE CABLE FELT WHEN LEVER IS ACTUATED AND HAND IS WRAPPED AROUND THE CABLE FORWARD OF THE FIREWALL. 1L71 3O3 ONTTA4CH E7SO 5 NTA4CH 20031114000402003111400040SO 2003 11 14 2003FA0001110 120031003G8120LW38075 BOLT PIPER PA32 PA32R301T 7103220SO LYC O540 TIO540AE2A 41532EA TURBOCHARGER MISSING B UXCRO OTHER K FLUID LOSS NRNOT REPORTED 1 SW054184X961 3257200 L1075561A THE HARDWARE ATTACHING THE TURBOCHARGER SCAVANGE SUMP TO THE TURBOCHARGER BECAME LOOSE ALLOWING LARGE QUANITY OF OIL TO LEAK FROM THE ENGINE OIL SYSTEM. ONE BOLT WAS MISSING. A FORCED LANDING WAS NECESSARY. THIS ENGINE HAD BEEN DISASSEMBLED, REPAIRED AND REASSEMBLED BY MFG FOR COMPLIANCE WITH AD 2002-19-03, ON 03/17/03 AT 699.6 HOURS. WE RECOMMEND WING PAR NR LW-38HO.25. BOLTS WHICH HAVE DRILLED HEADS AND SECURE WITH LOCKWIRE.(K) 1L71 3O3 O A3SO E14EA 20031114000292003111400029EU 2003 11 14 2003FA0001111 120031015G32300332204204 RELAY GROB 120 G120A 1660208EU LYC O540 AEIO540D4D5 EA MLG FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP07863AF1044 85003 FOLLOWING AN EMERGENCY GEAR EXTENSION, PERFORMED DURING A ROUTINE INSPECTION, SYSTEM WOULD NOT OPERATE. FAULT DETERMINED TO BE FAILED RELAY FOR HYDRAULIC CONTROL. PROBABLE CAUSE, TO MUCH LOAD FOR RELAY. MANUFACTURER CONTACTED AND MANUFACTURER STATED THAT A SB IS UNDER DEVELOPMENT TO REPLACE THIS RELAY.(K) 1L71 3O3 ORTA49CE 1E4 20031114000552003111400055SO 2003 11 14 2003FA0001112 120030923G27204004009 TORQUE TUBE PIPER PA31 PA31325 7103105SO LYC O540 TIO540F2BD 41532EA RUDDER CORRODED D O OTHER O OTHER NRNOT REPORTED 1 SO33597522687 311182 317612010 L210368A SB 1105, RUDDER TORQUE TUBE INSPECTION RUST AND CORROSION. 1L72 3O3 O A20SO E14EA 20031117000112003111700011CE 2003 11 17 2003FA0001113 120031023G8120S19212 CLAMP CESSNA337 T337G 2075726CE CONT O360 TSIO360* 17025SO TURBOCHARGER BROKEN G O OTHER O OTHER NRNOT REPORTED 1 NM074PF P3370186 236147R FRONT ENGINE TURBO EXHAUST STACK RETAINER CLAMP (TURBINE OUTLET LIP) BAND CLAMP PN S19212 STRAP PORTION FRACTURED AND EXHAUST STACK FELL OFF AIRCRAFT ON TAKEOFF. CLAMP MAY HAVE BEEN CRACKED, AND IT HAD NOT BEEN DETECTED BEFORE FAILURE OCCURRED. CLOSER VISUAL INSPECTION SHOULD BE INITIATED, DURING ROUTINE INSPECTIONS. OR PART SHOULD BE REPLACED AT ENGINE OVERHAUL.(K) 1H72 3O3 O A6CE E9CE 20031113000612003111300061SO 2003 11 13 2003FA0001114 120031008G32302101203 TUBE PIPER PA24 PA24250 7102404SO LYC O540 O540* 41532EA MLG RETRACT CRACKED C O OTHER O OTHER NRNOT REPORTED 1 NE037621E4936 242168 LANDING GEAR RETRACTION TUBE INBOARD ARM FRACTURED ABOVE THE ATTACHMENT POINTS FOR THE NOSE AND RIGHT MAIN AND NOSE GEAR COLLAPSED ON LANDING. VISUAL INSPECTION OF THE PART INDICATED A PORTION OF THE FRACTURE COULD HAVE OCCURRED AT AN EARLIER DATE. CAUSE OF THE FRACTURE UNKNOWN. THE PART IS VERY DIFFICULT TO INSPECT DUE TO THE LOCATION IN THE AIRFRAME.(K) 1L71 3O3 O 1A15 E295 20031114000612003111400061SO 2003 11 14 2003FA0001115 120031017G321378738802 AXLE PIPER PA28 PA28161 7102803SO LYC O320 O320* 41508EA LT MLG CRACKED D K NONE K FLUID LOSS ININSP/MAINT 1 NE03109GP10410 287816287 WHILE INVESTIGATING OLEO FLUID LEAK, FOUND (3) .2500 INCH LONG CRACKS RUNNING HORIZONTALLY ACROSS THE OB FACING AREA OF THE LT MAIN GEAR STRUT TUBE. CRACKS LOCATED BETWEEN 7 INCHES AND 9 INCHES UP FROM THE BASE. CRACKS VISIBLE ONLY UPON COMPLETE STRUT EXTENSION WHILE ON JACKS. THIS HOLLOW TUBE WAS FOUND TO CONTAIN FLUID, SUGGESTING IT HAS BEEN CRACKED FOR SOME TIME. RECOMMEND INSPECTING THIS AREA OF LANDING GEAR ON 100 HOUR INTERVALS, ESPECIALLY ON SCHOOL AIRCRAFT WITH HIGH CYCLES.(K) 1L71 3O3 O 2A13 E274 20031114000412003111400041SO 2003 11 14 2003FA0001116 120031008G8120557584 COUPLING PIPER PA23 PA23250 7102308SO LYC O540 TIO540C1A 41532EA TURBO OUTLET MISMANUFACTURED B DINRO OTHER W INADEQUATE Q C NRNOT REPORTED 1 EA1365SC 277405445 EXHAUST V-BAND COUPLING NEEDED FOR TURBOCHARGER OUTLET/ TAILPIPE CONNECTION ON THIS AC. ORIGINAL PN 555-511 WAS SUPERSEDED BY MFG TO THE PN 557-584 WILL NOT WORK. THE COUPLING GAP FULLY CLOSED AND BOTTOMED OUT BEFORE ADEQUATE TORQUE WAS REACHED. CONTACTED MFG REP, ENGINEERING AGREED THE PN 557584 IS NOT A VALID REPLACEMENT FOR THE PN 555-511, AND RECOMMENDED USE OF THE ORIGINAL COUPLING.(K) 1L72 3O3 O 1A10 E14EA 20031114000572003111400057GL 2003 11 14 2003FA0001117 320030925G6114B65801000 ROLL PIN BEECH 35 C35BEECH 1151508CE CONT E225 E2258 17015SO HARTZLHCA2V HCA2V204 GL OIL COLLAR BROKEN D O OTHER O OTHER NRNOT REPORTED 1 NM085836C85 D2788 36303D98R ROLL PIN BROKE ALLOWING SLIP RING TO MOVE OUT OF POSITION CAUSING A HYDRAULIC LOCK IN PROPELLER OPERATION. PROPELLER REMAINED IN LOW PITCH, HIGH RPM. REASON FOR PIN FAILURE UNKNOWN. 1L71 3O3 O A777 E267 5 CP24EA 20031114000582003111400058EU 2003 11 14 2003FA0001118 120031017G6500109042401103 BEARING AGUSTAA109 A109 0260109EU ALLSN 250C 250C28 03013GL TAIL ROTOR DRIVEFAILED D O OTHER O OTHER NRNOT REPORTED 1 WP2725RX 7220 DURING ROUTINE DAILY INSPECTION OF HELICOPTER USED IN EMS, MECHANIC NOTICED NR 5 TAIL ROTOR BEARING GREASE SEAL HAD SEPARATED FROM BEARING. FRAGMENTS OF THE PHENOLIC BEARING CAGE WERE MISSING FROM BEARING ASSY. MECHANIC REPORTED NO EVIDENCE OF RESIDUAL GREASE ON ANY OF RECOVERED PARTS. MM CALLS FOR 1.5 MM OF GREASE EACH 300 HOUR OF OPERATION. THIS A/C NEXT 300 HOUR INSPECTION IS DUE IN APPROX. 30 HOURS. PREVIOUS HISTORY ON TAIL ROTOR BEARINGS INSTALL ON THIS AC CAN INCLUDE PROBLEMS ASSOCIATED WITH OVER SERVICING OF BEARINGS. EXCESS GREASE CAUSES INITIAL HIGH HEAT CONDITION AND DEFORMATION OF THE RUBBER GREASE SEAL. CARE MUST BE TAKEN THAT BEARINGS MUST BE INSTALLED IAW PROCEDURES AS DESCRIBED IN MM. 1G72 3U3 U H7EU E1GL 20031117000122003111700012SO 2003 11 17 2003FA0001119 220030919G8530655771 EXHAUST VALVE CESSNA210 T210M 2073451CE CONT O520 TSIO520R 17040SO NR 1 CYLINDER WORN D O OTHER O OTHER NRNOT REPORTED 1 SW05732YK602 21061879 CYLINDER FAILED COMPRESSION CHECK DUE TO EXHAUST VALVE LEAKAGE. VISUAL INSPECTION REVEALED BURNED EXHAUST VALVE WITH NO SIGNS OF OVER TEMP OR CARBON BUILD UP. VALVE STEM AND GUIDE WORN BEYOND SERVICE LIMITS. EXHAUST VALVES IN CYLINDERS 4 AND 5 EXPERIENCE IDENTICAL FAILURES AT 247 HOURS TOTAL TIME. PROBABLE CAUSE IS POOR QUALITY CONTROL AT ENGINE BUILD RESULTING IN POOR ALIGNMENT BETWEEN VALVE GUIDE AND SEAT.(K) 1H71 3O3 O 3A21 E8CE 20031113000572003111300057CE 2003 11 13 2003FA0001120 120030925G3230504501018 TORQUE TUBE CESSNA402 402B 207590PCE CONT O520 TSIO520E 17040SO MCAULY3AF32C3AF32C87 GL MLG TORN D K NONE O OTHER ININSP/MAINT 1 WP1398692 402B1050 514517LT 891919 DURING A UNSCHEDULED INSPECTION, AFTER A PILOT REPORT OF THE RT LANDING GEAR NOT RETRACTING, THE MECHANIC FOUND THE RT MAIN GEAR TORQUE TUBE BROKEN OR TORN. IT IS SUSPECTED THAT FATIGUE COULD BE THE CAUSE. 1L72 3O3 O A7CE E8CE 5 CP22EA 20031113000672003111300067SO 2003 11 13 2003FA0001121 220030918G85201986050506 LIFTER CESSNA210 210B 2073410CE CONT O470 IO470S 17026SO ENGINE DAMAGED D EAVRO OTHER O OTHER NRNOT REPORTED 1 GL099690X 21057990 109344R DURING A SCHEDULED 50 HOUR OIL CHANGE. STEEL WAS FOUND IN OIL SCREEN. SUSPECTED SOURCE OF STEEL WAS COMING FROM LIFTERS. INSPECTED NR 5 CYLINDER LIFTERS THROUGH OIL FILLER NECK AND FOUND DAMAGED LIFTERS. REMOVED LIFTERS FROM ENGINE. ALL INTAKE LIFTERS WERE DAMAGED AND 1 CNT. EXHAUST LIFTER WAS DAMAGED. 400 HOURS. TIME IN SERVICE SINCE NEW FOR BOTH THE CAM AND LIFTERS. ONE YEAR IN SERVICE. 1H71 3O3 O 3A21 3E1 20031114000062003111400006EU 2003 11 14 2003FA0001123 120031021G3260120A9491105AV DIODE GROB 120 G120A 1660208EU LYC O540 IO540* 41532EA MLG SHORTED B VJ3RO OTHER N FALSE WARNING NRNOT REPORTED 1 WP07863AF 85003 L2802548A DURING FLIGHT, WHEN GEAR IS INTRANSIT, HYDRAULIC PRESSURE ANNUNCIATOR LIGHT ILLUMINATES. CAUSE OF MALFUNCTION IS UNKNOWN. NO RECOMMENDATION AT THIS TIME. 1L71 3O3 ORTA49CE 1E4 20031114000082003111400008EU 2003 11 14 2003FA0001124 120031021G3260120A9491105AV RELAY GROB 120 G120A 1660208EU LYC O540 IO540* 41532EA MLG SHORTED B VJ3RO OTHER N FALSE WARNING NRNOT REPORTED 1 WP07863AF1044 85003 L2802548A DURING FLIGHT, GEAR MOTOR WAS SLOW TO EXTEND LANDING GEAR. FURTHER INVESTIGATION DETERMINED THAT EXTENSION VALVE HAD A RESTRICTION IN THE LINE WHICH CAUSED THE LANDING GEAR MOTOR TO REQUIRE MORE CURRENT BECAUSE OF THIS DEMAND IT CAUSED THE LANDING GEAR RELAY TO SHORT WHICH ALOUD THE CURRENT TO SPIKE THE RELAY AND DIODE BOARD AND SHORT IT OUT. RECOMMENDATION IS TO INSTALL A CIRCUIT PROTECTION DEVICE IN LINE BEFORE THE RELAY AND DIODE BOARD. 1L71 3O3 ORTA49CE 1E4 20031114000592003111400059EA 2003 11 14 2003FA0001125 220031023G8520559E SCREW NAVAL N3N N3N3 6120202EA LYC R680 R6809 41540EA MASTER ROD LOOSE B RAQRO OTHER O OTHER NRNOT REPORTED 1 SW15448482623 4477 4505 SB NR 126, 4/1/46, HAD NOT BEEN COMPLIED WITH. KNUCKLE PINS HAD BACKED OUT OF THE MASTER ROD AND HAD BEEN MACHING INTO THE CRANKSHAFT. ENGINE WAS BEING REPAIRED FOR OTHER ISSUES WHEN THIS WAS DISCOVERED. FAILURE WAS IMMINENT. (SW15200402815)(K) 1Q71 3R3 R A2569 E202 20031114000562003111400056EA 2003 11 14 2003FA0001126 220031023G8520559E SCREW STNSONSR8 SR8E 8631416GL LYC R680 R68013 41540EA MASTER ROD BROKEN B RAQRO OTHER O OTHER NRNOT REPORTED 1 SW1517124 9806 SB NR 126, 41.146, HAD NOT BEEN COMPLIED WITH. THE SAFETY WIRE LOCKING THE KNUCKLE PIN LOCKPLATE SCREWS HAD BROKEN, ALLOWING THE KNUCKLE PINS TO BACK OUT OF THE MASTER ROD. THE TOPS OF THE KNUCKLE PINS WERE MACHING INTO THE CAMSHAFT. FAILURE WAS IMMINENT. (SW15200402816)(K) 1H71 3R3 R ATC609 E202 20031113000652003111300065NM 2003 11 13 2003FA0001127 120031101G5711 SPAR CAP UNIVAR415 415C 0420302NM RT & LT WING CORRODED D K NONE O OTHER ININSP/MAINT 1 GL17997341487 WHEN PERFORMING INSPECTION REQUIRED BY PARAGRAPH (A)OF AD94-18-04 R1 FOUND SEVERE INTERGRANULAR CORROSION IN BOTH LT AND RT LOWER SPAR CAPS. CORROSION WAS LOCATED 6 INCHES FROM INBOARD END OF LOWER SPAR CAP TO 18 INCHES FROM INBOARD END. CORROSION HAS PENETRATED THE UPPER SURFACE OF THE SPAR CAPS. THE CORROSION HAS ADVANCED TO EXFOLIATION AND LIFTING OF THE SURFACE HAS OCCURRED. PITTING CORROSION HAS ALSO FOUND ON THE WING SPAR WEB IN THE AREA OF THE CORROSION ON THE SPAR CAPS. THE AIRCRAFT IS A 1946 MODEL AND IT APPEARS THAT THE SPARS ARE ORIGINAL. 1L71 3O A718 20031113000662003111300066GL 2003 11 13 2003FA0001128 120031104G2140 DUCT AVIAT A1 A1B 2210406GL LYC O360 O360* 41514EA HEATER CHAFED P O OTHER O OTHER NRNOT REPORTED 1 AL0337HY 2037 GROOVES WORN IN ROCKER BOX OIL RETURN TUBE. AUXILLIARY HEAT AIR DUCT AT LOWER SIDE OF NR 1 CYL WAS RUBBING ON OIL RETURN TUBE. GROOVES APPEARED TO BE 30 PERCENT TO 50 PERCENT THROUGH TUBE. AIRPLANE WAS 2.2 HOURS TIME IN SERVICE AFTER ANNUAL / 100 HOUR INSPECTION. HEAT DUCT HAS TO BE CRUSHED TO FIT THIS INSTALLATION. THERE IS INADEQUATE ISOLATION BETWEEN DUCT AND ENGINE CYLINDER LUBRICATING OIL RETURN TUBE. 1H71 3O3 ONCA22NM E286 20031113000752003111300075SO 2003 11 13 2003FA0001129 120031031G2730MS21260S4LH TURNBUCKLE PIPER PA32 PA32RT300T 7103216SO ELEVATOR CABLE CORRODED G A UNSCHED LANDING F FLT CONT AFFECTED CLCLIMB 1 SO05395412633 32R7887104 PILOT DEPARTED SMALL AIRPORT AND CLIMBED TO 1000 FT. WHEN THE PILOT LEVELED HIS ALTITUDE, HE REALIZED THAT HE HAD LOST MOST ALL OF HIS ELEVATOR CONTROL. HE PERFORMED EMERGENCY LANDING USING ELEVATOR TRIM. UPON INVESTIGATION, FOUND THAT A TURNBUCKLE IN AN ELEVATOR CONTROL CABLE HAD BROKEN. THE BREAK WAS DUE TO CORROSION LOCATED BELOW THE SAFETY WIRE WRAPS. OTHER TURNBUCKLES IN THE AREA (APPROX 1 FT) WERE NOT CORRODED. IT IS BELIEVED THAT A VENTILATION HOSE THAT WAS DIRECTLY ABOVE THE AFFECTED TURNBUCKLE CONTRIBUTED TO THE CORROSION BY ALLOWING CONDENSATION TO DRIP DOWN ONTO THE TURNBUCKLE. 1L71 3O A3SO 20031113000782003111300078CE 2003 11 13 2003FA0001130 120031022G555304311481 BRACKET CESSNA150 152 2071835CE LYC O235 O235* 41505EA LT REAR FIN CRACKED B BGSRO OTHER O OTHER NRNOT REPORTED 1 EA21472817240 15283208 FOUND LT REAR VERTICAL FIN BRACKET CRACKED AT BASE (FITTING). 1H71 3O3 ONT3A19 E223 20031113000382003111300038EA 2003 11 13 2003FA0001131 220031010G8530SL32000WA20P CYLINDER CESSNA172 172N 2072434CE LYC O320 O320D2J 41508EA MCAULY1A100 1A100* GL ENGINE DAMAGED B WW3RO OTHER O OTHER NRNOT REPORTED 1 WP275227D 17272458 L1005139A CYLINDERS FAIL TO PASS DIFFERENTIAL COMPRESSION TEST. NR 3 POSITION. 1H71 3O3 ONT3A12 E274 5 NP918 20031113000792003111300079SO 2003 11 13 2003FA0001132 120031028G5510 CLEVIS BOLT PIPER PA36 PA36285 7103610SO CONT 6285 6285A 17038SO STAB STRUT BROKEN D O OTHER O OTHER NRNOT REPORTED 1 SW199942P 367560053 THE UPPER HORIZONTAL STABILIZER STRUT CLEVIS BOLT BROKE. THE BREAK WAS IN THE THREADED SECTION. THE AIRCRAFT TT IS 5998 HRS. THE SAME TIME IN SERVICE FOR THIS CLEVIS BOLT. THIS IS THE SECOND TIME HAVE FOUND A CLEVIS BOLT BROKEN IN THIS LOCATION, ON THIS MODEL AIRCRAFT. THIS LOCATION IS NORMALLY SO CONTAMINATED THAT A NORMAL, VISUAL INSPECTION IS NOT PRACTICAL. EVEN WITH A THOROUGH CLEANING THE BREAK MIGHT NOT HAVE BEEN DETECTED. THE BREAK HAD RUST IN A PARTIAL BREAK BEFORE THE FINAL FAILURE. SUGGEST FREQUENT AND THOROUGH INSPECTIONS OR A REDESIGNED CLEVIS BOLT FOR THIS LOCATION. 1L71 3O3 O A10SO E12CE 20031113000802003111300080NE 2003 11 13 2003FA0001133 220031023G723070BM035420 GAS GENERATOR SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE ENGINE NOISY D O OTHER O OTHER NRNOT REPORTED 1 CE07853HW6340 521 2741 RUBBING NOISE AFTER SHUT DOWN. ONLY WHEN ENGINE IS HOT. 1G71 3U3 U H9EU E19EU 20031113000512003111300051EA 2003 11 13 2003FA0001134 220031024G7314200F5003 PUMP PIPER PA31 PA31350 7103110SO LYC O540 LTIO540J2BD 41533EA NR 2 ENGINE LEAKING D O OTHER K FLUID LOSS NRNOT REPORTED 1 SO05350PC 362 318152006 L200868A FUEL LEAKING AT REGULATOR HOUSING. 1L72 3O3 O A20SO E14EA 20031113000552003111300055NE 2003 11 13 2003FA0001135 220031024G7314200F5002 PUMP PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2B NE NR 1 ENGINE LEAKING D O OTHER O OTHER NRNOT REPORTED 1 SO053581C 318052091 L179061A FUEL LEAKING AT REGULATOR HOUSING, THIS IS THE NEW STYLE PUMP, AND IS NOT YET AFFECTED BY AD 2003-14-03. WE ARE NOTING SIMILAR LEAKS WITH SEVERAL OF THESE PUMPS. 1L72 3O3 O A20SO E14EA 20031114000262003111400026CE 2003 11 14 2003FA0001136 120030901G3240 CALIPER CESSNA337 337D 2075717CE CONT IO360 IO360* 17025CE MLG BRAKE CRACKED D O OTHER O OTHER TXTAXI/GRND HDL 1 GL1385965 3371037 AIRCRAFT BEGAN TO SHAKE WHILE TAXIING, FELT LIKE SOMEONE WAS TAPPING ON THE RIGHT BRAKE PEDAL. FLANGE AT THE BEAD CRACKED (ABOUT 5 INCHES LONG) AND WAS CATCHING ON BRAKE CALIPER. NO KNOWN HARD LANDINGS. POSSIBLE CAUSE: WHEEL TOO SMALL FOR AIRCRAFT. CORROSION AND STRESS FROM 8 PLY TIRE AND 55 PSI AIR PRESSURE. SAVING THE PART. 1H72 3O3 O A6CE E1CE 20031113000622003111300062CE 2003 11 13 2003FA0001137 120031101G5270 WARNING LIGHT CESSNA750 750 2076810CE ALLSN AE3007AE3007C GL CARGO DOOR ILLUMINATED D B EMER. DESCENT J WARNING INDICATION CRCRUISE 1 GL1593S 7500189 WHILE AT CRUISE ALTITUDE, THE CREW NOTED BAGGAGE DOOR SEAL ON LIGHT. CREW BEGAN MAKING PREPARATIONS TO DESCEND TO A LOWER ALTITUDE AS REQUIRED BY AFM INSTRUCTIONS WHEN THE LIGHT (BAGGAGE DOOR SEAL) WENT OUT. INFORMED MFG TECH SUPPORT. WAITING RESOLVE. 2L72 4J4 FRTT00007WITE6CH 20031114000352003111400035CE 2003 11 14 2003FA0001138 120031023G56104556100001V11001WINDSHIELD LEAR 45 45LEAR 5170805CE GARRTTTFE731TFE731* 01518WP COCKPIT FAILED D O OTHER O OTHER CLCLIMB 1 GL11858MK822 141 CLIMBING THRU FL350, PILOTS WINDSHIELD SHATTERED. OUTER GLASS LAYER SHATTERED. 822.0 HTT / 564 CYCLES (K) 2L72 4F4 FRTT00008WIE6WE 20031113000522003111300052EA 2003 11 13 2003FA0001139 120031008G1430 RIVET DHAV DHC6 DHC6300 2802606EA PWA PT6 PT6A60A 52043NE LOWER SPAR CAP MISINSTALLED B O OTHER W INADEQUATE Q C NRNOT REPORTED 1 WP23886EA15319 756 SMOKING RIVETS OBSERVED AT WS122-140 PROX DURING SCHEDULED INSPECTION. THESE RIVETS ARE CRITICAL TO WING INTEGRITY. IT APPEARS THAT THE RIVETS DID NOT PROPERLY ENGAGE THE HOLE DURING OEM INSTALLATION. SUGGEST ALL WING BOXES WITHIN 10 SERIAL NUMBER RANGE BE CLOSELY INSPECTED FOR SAME.(K) 1H72 3T4 TRTA9EA E4EA 20031114000362003111400036CE 2003 11 14 2003FA0001140 120031006G552005130633 BRACKET CESSNA172 172G 2072420CE CONT O300 O300D 17022SO ELEV BELLCRANK BROKEN D O OTHER O OTHER NRNOT REPORTED 1 SW1761LV 3500 17253899 BADLY BROKEN BRACKET WAS HELD IN PLACE BY ONLY TWO RIVETS. TOTAL LOSS OF ELEVATOR WOULD HAVE BEEN FORTHCOMING HAD BRACKET NOT BEEN REPLACED. THIS WAS DIFFICULT TO DETECT BECAUSE CONTROL FUNCTION WAS NORMAL AND IS DIFFICULT TO VIEW (BEING BELOW THE FLOOR). IN ORDER TO DETECT THE PROBLEM. ONE MUST PUT IN THE CONTROL LOCK AND CHECK ELEVATOR FOR MOVEMENT. (MORE THAN TWO INCHES INDICATES THE PROBLEM). REPLACEMENT PART (05130633) IS MUCH STRONGER THAN THE ORIGINAL PART.(K) 1H71 3O3 ONT3A12 E253 20031113000462003111300046SO 2003 11 13 2003FA0001143 120030909G322067054008 TRUNNION PIPER PA32 PA32R301T 7103220SO LYC O540 TIO540* 41532EA NLG CRACKED B BJ3RO OTHER O OTHER NRNOT REPORTED 1 WP15720KM203 3257300 DURING AN ANNUAL INSPECTION THE NOSE TRUNION WAS FOUND TO HAVE A CRACK APPROXIMATELY ONE INCH IN LENGTH ON THE AFT SIDE. GREASE WAS SEEPING FROM THE CRACK WHICH MADE IT EASILY VISIBLE. THE CRACKED NOSE TRUNNION ASSEMBLY WAS REMOVED AND REPLACED WITH A NEW TRUNNION ASSEMBLY. AT THE TIME THE CACK WAS FOUND THE AIRCRAFT HAD 203.6 TT. THE TRUNNION HAD NOT PREVIOUSLY BEEN REPLACED ON THIS AIRCRAFT. 1L71 3O3 O A3SO E14EA 20031117000182003111700018 2003 11 17 2003FA0001144 420030609G830029A21372 DRIVE ASSY PIPER PA32 PA32R301T 7103220SO LYC O540 TIO540* 41532EA ACCESSORY CASE LEAKING B BJ3RK NONE K FLUID LOSS ININSP/MAINT 1 WP15720KM104 3257300 L1131061A OIL WAS FOUND SEEPING FROM THE TURBO SCAVENGE DRIVE ASSEMBLY. IF THE OIL WAS WIPED FROM THE PUMP IT WOULD RETURN AFTER JUST ONE SHORT FLIGHT. THE OIL WAS SEEPING FROM THE SEAM WHERE BOTH HALVES OF THE DRIVE ASSEMBLY MEET. THIS PUMP WAS REPLACED 22.1 HOURS PRIOR TO THIS INCIDENT FOR THE SAME REASONS. THE DRIVE ASSEMBLY WAS REMOVED AND REPLACED WITH A NEW DRIVE ASSEMBLY OF THE SAME PART NUMBER.(K) 1L71 3O3 O A3SO E14EA 20031113000472003111300047 2003 11 13 2003FA0001145 420030128G830029A21372 DRIVE SYSTEM PIPER PA32 PA32R301T 7103220SO LYC O540 TIO540* 41532EA TURBO SCAV LEAKING B BJ3RO OTHER K FLUID LOSS NRNOT REPORTED 1 WP15720KM82 3257300 L1131061A OIL WAS FOUND SEEPING FROM THE TURBO SCAVENGE DRIVE ASSEMBLY. IT THE OIL WAS WIPED FROM THE PUMP IT WOULD RETURN AFTER JUST ONE SHORT FLIGHT. THE OIL WAS SEEPING FROM THE SEAM WHERE BOTH HALVES OF THE DRIVE ASSEMBLY MEET. THE DRIVE ASSEMBLY WAS REMOVED AND REPLACED WITH A NEW DRIVE ASSY. 1L71 3O3 O A3SO E14EA 20031114000172003111400017SO 2003 11 14 2003FA0001146 120030929G8010 DRIVE GEAR AMRGENAG5B AG5B 3990100SO LYC O360 O360A4K 41514EA STARTER INOPERATIVE B IG8RO OTHER O OTHER NRNOT REPORTED 1 EA07940TE14 10219 WHILE ATTEMPTING TO START THE ENGINE, THE STARTER WOULD SPIN BUT WOULD NOT TURN THE ENGINE. THE ENGINE COWL WAS REMOVED AND IT WAS DETERMINED THAT THE STARTER DRIVE GEAR WOULD ENGAGE THE STARTER RING GEAR BUT WOULD NOT TURN. THE STARTER SHAFT WOULD ROTATE INSIDE THE STARTER DRIVE GEAR. THE STARTER WAS REMOVED AND RETURNED FOR REPAIR.(K) 1L71 3O3 ONT1L71 E286 20031114000432003111400043SO 2003 11 14 2003FA0001147 220031024G8530 EXHAUST VALVE CESSNA421 421C 2076016CE CONT O520 GTSIO520L 17032SO NR 4 CYLINDER BROKEN D A UNSCHED LANDING R PARTIAL RPM/PWR LOSS NRNOT REPORTED 1 GL19421ML 421C0880 604330 DURING FLIGHT .33 OF THE EXHAUST VALVE IN THE NR 4 CYLINDER BROKE CAUSING EXTENSIVE DAMAGE TO THE PISTON AND THE CYLINDER HEAD. DURING THE HIDDEN DAMAGE INSPECTION THE BROKEN VALVE WAS FOUND IN THE INTAKE PORT OF THE CYLINDER ON THE SAME CYLINDER. NO DAMAGE WAS FOUND IN THE REMAINING CYLINDERS OF THE TURBO CHARGER ON THE ENGINE. NO DEFECTS NOTED IN THE OIL FILTER. 1L72 3O3 O A7CE E7CE 20031114000662003111400066CE 2003 11 14 2003FA0001152 120031103G2912206666500 SCREEN CESSNA525 525A 2076615CE HYD SYSTEM MISSING B O OTHER O OTHER NRNOT REPORTED 1 GL0920GP 300 525A0131 WHILE PERFORMING INSPECTION FOUND THAT IN-LINE HYDRAULIC FILTER SCREENS WERE NOT INSTALLED. THIS IS THE SECOND OF THESE TYPE NEW AIRCRAFT WE HAVE FOUND MISSING THESE FILTERS SCREENS. ORDERED FILTER SCREENS AND INSTALLED. NOTIFIED MANUFACTURER THAT THESE SCREENS ARE NOT BEING INSTALLED AT THE FACTORY ON SOME AIRCRAFT. RECOMMEND CONFIRMING THESE PART NUMBER HYDRAULIC SCREENS ARE INSTALLED ON NEW AIRCRAFT AT FIRST AVAILABLE INSPECTION. 1L71 4F RTA1WI 20031117000232003111700023WP 2003 11 17 2003FA0001154 220031104G7397 WIRE LEAR 35 35A 5170602CE GARRTTTFE731TFE73122B 01518WP NR 2 ENGINE LOOSE E O OTHER O OTHER NRNOT REPORTED 1 SO1144TT 13735640 211 P74624C AC WAS TAKING OFF WHEN RT FUEL COMPUTER LIGHT CAME ON AT APPROX 100 KNOTS. PILOT ABORTED TAKE OFF. DURING TAXI BACK TO FBO NR 3 AND NR 4 MLG WHEEL FUSIBLE PLUGS BLEW DUE TO OVERHEATED BRAKES. MECH INSTALLED A SPARE WHEEL AND TIRE ASSY ON RT MLG SO THAT AC COULD BE MOVED OFF OF TAXIWAY. MAINT WAS DISPATCHED TO DETERMINE CAUSE OF ENG COMPUTER PROBLEM, CHANGE NR 3, NR 4 BRAKES, WHEEL AND TIRE ASSEMBLIES. MAINT DETERMINED THAT FUEL COMPUTER LIGHT WAS CAUSED BY LOOSE WIRE TO RT ENGINE PT2 PROBE CONNECTOR LOCATED AT NAC.STA. 188.5 NAC. BL 100.0. NO ANTI-SKID MALFUNCTION WAS NOTED. AC RETURNED WITH NO FURTHER INCIDENTS. 2L72 4F4 F A10CE E6WE 20031114000012003111400001CE 2003 11 14 2003FA0001156 120030711G801130B3749BT STARTER LEAR 25 25D 5170514CE GE CJ610 CJ6106 30006NE ENGINE VIBRATION G E ENGINE SHUTDOWN E VIBRATION/BUFFET CRCRUISE 1 SO1799NJ 333 220 WHILE IN CRUISE FLIGHT AT 370, THE FLIGHT CREW HEARD TWO FLUTTERING VIBRATION SOUNDS. THE VIBRATION NOISES BECAME LOUDER AND LOUDER. ADJUSTING THE THROTTLE ISOLATED THE VIBRATION TO THE NR 1 ENGINE. THE PILOTS DESCENDED TO FL 250 AND SHUT DOWN THE NR 1 ENGINE. A SINGLE ENGINE APPROACH AND LANDING WAS MADE AT FORT LAUDERDALE INTERNATIONAL AIRPORT. THE MAINTENANCE DEPT TROUBLE SHOT AND DISCOVERED THAT THE NR 1 ENGINE STARTER GENERATOR HAD FAILED AND WAS THE SOURCE OF THE VIBRATION. THE STARTER GENERATOR WAS REPLACED AND OPERATIONALLY CHECKED AND THE AIRCRAFT WAS RETURNED TO SERVICE. 2L72 4J4 J A10CE 1E16 20031114000042003111400004SW 2003 11 14 2003FA0001157 120031101G5711 SPAR BBAVIA7 7AC 2110102SW CONT A65 A65* 17003SO LT WING CRACKED D O OTHER O OTHER NRNOT REPORTED 1 GL13846706517 7AC3381 ANNUAL INSPECTION. PERFORMED AD2001-25-02R1. NOTED CRACK ON LEFT/AFT WING SPAR. CRACK IS ON WOOD SPAR OUTBOARD OF LIFT STRUT ATTACH POINT. AIRCRAFT TT 6517.08. SPAR ORIGIN UNKNOWN. NOTED PREVIOUS SPAR REPAIR IN DIFFERENT LOCATION DATED 1979. RECOMMEND ALL APPLICABLE AIRCRAFT SPARS BE INSPECTED AS ALREADY REQUIRED BY AD. 1H71 3O3 O A759 E205 20031114000022003111400002 2003 11 14 2003FA0001158 420031028G3400701887903014 COMPUTER GULSTMG1159 GIV 3980115SO RROYCETAY TAY6118 EU COCKPIT FAILED C O OTHER W INADEQUATE Q C NRNOT REPORTED 1 EA1780A 1348 FAILED OUT OF STOCK FROM MANUFACTURER. CAUSED FMS NR 1 TO LOCKUP. MANY DEAD KEYS ON FMS KEYBOARD. 2L72 4F4 FRTA12EA E25NE 20031117000212003111700021SO 2003 11 17 2003FA0001159 120031029G7500523030 INDICATOR GULSTMG1159 G1159A 3970109SO RROYCESPEY SPEY5118 54523EU BLEED AIR MISREPAIRED C O OTHER W INADEQUATE Q C NRNOT REPORTED 1 EA1780J 441 EVERYTIME WE HAVE SENT ONE OF THESE UNITS TO THE MANUFACTURER, WE RECEIVE IT BACK IN AN UNSATISFACTORY WORKING CONDITION. THIS UNIT HAS A CABIN RATE OF CLIMB OF +50, SITTING ON THE GROUND WITH NO AIR APPLIED.(K) 2L72 4F4 F A12EA E2EU 20031117000012003111700001CE 2003 11 17 2003FA0001160 120031027G2121MB3BA1 MOTOR CESSNA500 S550 2076607CE PWA JT15 JT15D4 52112NE BLOWER BURNED OUT B EYDRO OTHER O OTHER NRNOT REPORTED 1 SO17260BS 1092 S5500080 ON 10/25/03 AT APPROXIMATELY 2200Z THE AIRCRAFT DEPARTED ITH FOR PVD WITH 2 CREW AND 5 PASSENGERS. ON CLIMB FROM 10,000 TO FL 190 THE FLIGHT CREW SMELLED SMOKE. AT FIRST NO SMOKE WAS EVIDENT IN THE CABIN, THEN LIGHT SMOKE WAS DECLARED AND AN UNEVENTFUL LANDING WAS MADE AT HGA EIGHT MINUTES LATER. MAINTENANCE TROUBLESHOT THE PROBLEM TO A DEFECTIVE CABIN OVERHEAD BLOWER ASSEMBLY. THE MOTOR SMELLED BURNED, BUT DID NOT SHOW AND EVIDENCE OF FIRE DAMAGE. THE 20 AMP CABIN FAN CIRCUIT BREAKER DID NOT POP. THE OVERHEAD BLOWER WAS MEL`D AND THE AIRCRAFT WAS RELEASED. MFG RECOMMENDS 1200 HR OH PERIOD FOR THIS BLOWER MOTOR. MTR HAD APPROX 1100 HRS, REDUCE OH TIME TO 1000 HOURS.(K) 1L72 4F4 FRTA22CE E1NE 20031117000022003111700002 2003 11 17 2003FA0001161 420031031G22106225734002 SERVO BEECH B300 B300 1159232CE AILERON BINDING B E81RO OTHER O OTHER NRNOT REPORTED 1 GL03447TF166 FL364 INVESTIGATED PILOT COMPLAINT OF AILERON CONTROLS BINDING. NOTED BINDING/BANGING TYPE SOUNDS UNDER CENTER CABIN FLOOR. FOUND NOISES AND BINDING NOT PRESENT WITH AILERON SERVO REMOVED FROM CAPSTAN, RETURNED WHEN AILERON SERVO REINSTALLED. ALSO NOTED NOISES/BINDING NOT NOTICEABLE WITH SERVO LOOSELY FIT, NOISES/BINDING RETURNED WHEN SERVO SECURED TO CAPSTAN. REPLACED SERVO WITH OVERHAULED EXCHANGE UNIT, OPERATIONAL CHECKS SATISFACTORY. 2L72 4T RTA24CE 20031117000032003111700003CE 2003 11 17 2003FA0001162 120031107G3260P634005 SWITCH CESSNA210 T210N 2073456CE CONT O520 TSIO520* 17040SO RT MLG INTERMITTENT D RMMRO OTHER O OTHER NRNOT REPORTED 1 CE014894C 21063658 CONDITION OCCURRED APPROX 3 TIMES UNTIL OPERATOR WOULD NOT FLY UNTIL REPAIRED. AFTER RUN UP A LT TURN WAS NEGOTIATED, DOWN INDICATOR LIGHT WENT (OUT) AND HORN SOUNDED. MAINT DID INITIAL CHECK FOR BROKEN WIRES. SUPPORTED AC, POWER APPLIED, SHORT RUN OF GEAR PUMP & LIGHT (ON) NO HORN. PROBLEM COULD NOT DUPLICATED. SEVERAL FLTS AND SAME FAULT WITH SAME RESULT. TROUBLESHOOTING; EACH GEAR DOWN SWITCH REMOVED FROM BRKT, HAND OPERATED SEVERAL TIMES REINSTALLED. FINAL RESULT, KICKING VIBRATION ON ALL GEAR (TIRES) AC ON JACKS, SQUAT SWITCH OUT OF BRACKET, RT GEAR DOWN SWITCH DUPLICATED FAULT. REPLACED SWITCH, ADJUSTED, GEAR CYCLED SEVERAL TIMES, AC RETURNED TO SERVICE. 1H71 3O3 O 3A21 E8CE 20031117000042003111700004NE 2003 11 17 2003FA0001163 220031024G72303476 MODULE SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE AXIAL COMPRESSORSEIZED G O OTHER O OTHER NRNOT REPORTED 1 SW016093K1994 23 2709 9564 ON 17, OCT. 2003, FIRST START OF THE DAY, PILOT REPORTED ENGINE WOULD NOT START. SUBSEQUENT INSPECTION REVEALED THAT AXIAL COMPRESSOR WAS SEIZED. ONLY WITH GREAT EFFORT COULD THE AXIAL COMPRESSOR BE TURNED BY HAND. ENGINE WAS REMOVED FOR RETURNED TO FACILITY WHERE EVALUATION AND REPAIRS ARE TO BE ACCOMPLISHED. MODULES 02/03 WERE INSTALLED, 24 SEPT, 2003. TT SINCE REPAIR WAS 23.1 HOURS. 1G71 3U3 U H9EU E19EU 20031230000032003123000003SW 2003 12 30 2003FA0001164 120031002G3233B10076 SHAFT DUKES MOONEYM20 M20J 5870219SW LYC O360 IO360A1A 41514EA MLG ACTUATOR WORN D O OTHER O OTHER NRNOT REPORTED 1 WP27201MX94 240266 SET OF SUBJECT GEARS WERE INSTALLED AT 4280.14 TT. OWNER CALLED AND WAS HAVING PROBLEM WITH ACTUATOR NOT SHOWING DOWN AND LOCKED. TOLD HIM NOT TO FLY THE AC AND TO BRING THE ACTUATOR. DISASSEMBLED ACTUATOR, FOUND WORN GEAR, PN B100-76 TO BE SO WORN THAT PINION GEAR WOULD NOT ENGAGE WORN GEAR. ONE MORE OPERATION AND GEAR WOULD HAVE PROBABLY COLLAPSED. THERE HAVE BEEN NO GEAR KITS AVAILABLE FROM MFG NOR HAS THERE BEEN ANY ACTION TO MAKE OWNER AWARE OF PROBLEM OF GEARS THAT WERE SOLD BUT HAD NOT BEEN CARBURIZED. SOFT GEARS EFFECT EVERY MODEL THAT USES THESE ACTUATORS BUT IT HAS HAD MOST SEVERE EFFECT ON THIS AC. MGF CHANGED GEAR RATIO IN THOSE ACTUATORS, CAUSING THEM TO WEAR OUT FASTER. 1L71 3O3 O 2A3 1E10 20031230000022003123000002SO 2003 12 30 2003FA0001165 120031117G323067042013 TRUNNION PIPER PA44 PA44180 7104402SO LYC O360 O360* 41514EA HARTZLHCC2Y HCC2YF2 GL RT MLG BROKEN B O OTHER J WARNING INDICATION LDLANDING 1 SO15926ER4911 43 4496016 ON LANDING, THE RT LANDING GEAR DOWN LIGHT FLICKERED. THE CREW OPTED TO SHUT DOWN ONCE OFF THE RUNWAY AND MAKE A VISUAL INSPECTION OF THE LANDING GEAR. THEY NOTICED THAT THE RMG WAS AT AN ODD ANGLE AND CALLED MAINTENANCE. THE MAINTENANCE CREW FOUND THAT THE AFT TRUNION (P/N-67042-013) WAS BROKEN IN SEVERAL LOCATIONS. ALL FLEET AIRCRAFT WERE GROUNDED AND WILL HAVE NEW PARTS INSTALLED. 1L72 3O3 O A19S0 E286 5 CP920 20031230000962003123000096CE 2003 12 30 2003FA0001166 120031016G793053001081617 LINE CESSNA340 340CESSNA 2076404CE OIL SYSTEM CORRODED D O OTHER K FLUID LOSS NRNOT REPORTED 1 SO03695075534 3400344 2 TO 3 DAYS AFTER FLIGHT, NOTICED SIGNIFICANT OIL PUDDLE FORMED UNDER FUSELAGE AT THE MAIN CABIN DOOR STATION. UPON VISUAL INSPECTION, LOCATED LEAK IN FLOOR AT STATION UNDER PILOT AND CO-PILOT'S SEATS. THE SOURCE OF THE LEAK WAS BOTH THE RIGHT AND LEFT OIL PRESSURE INDICATOR SUPPLY LINES (HARD LINES) BEING CORRODED AND CRACKED AS A RESULT OF LAYING AGAINST A CABIN AIR SCAT HOSE AS THEY WERE ROUTED IN THE BUNDLE. THE LINES ARE APPROXIMATELY 5 FEET IN LENGTH. APPROXIMATELY .5 TO .75 QUARTS OF OIL WERE REMOVED FROM THE FLOOR SECTION ADJACENT TO THE SEAT PEDESTALS. 1L72 3O 3A25 20031230000172003123000017EA 2003 12 30 2003FA0001167 220031028G852014H21950 OIL RING MOONEYM20 M20J 5870219SW LYC O360 IO360A3B6 41514EA NR 3 CYLINDER BROKEN B FZPRA UNSCHED LANDING RJ PARTIAL RPM/PWR LOSS WARNING INDICATION NRNOT REPORTED 1 NM11923DH1136 243368 L2671551A AIRCRAFT WAS IN FLIGHT WHEN THE PILOT NOTICED HIGH CHT TEMPS AND LOW EGT TEMPS ON NR 3 CYLINDER ON HIS JPI ENGINE ANALYZER. HE THEN NOTICED HIS OIL TEMP GO UP AND AS THE OIL PRESSURE DROPPED THE OIL TEMP THEN BEGAN TO DROP OFF. HE THEN PULLED THE POWER OFF AND LANDED THE AIRCRAFT. 2-3 QUARTS OF OIL WERE STILL REMAINING IN THE ENGINE. COMPRESSION CHECKS WERE NORMAL BUT NR 3 CYLINDER WAS REMOVED TO FIND THE OIL CONTROL RING PN 14H21950 TO BE BROKEN AND SEIZED INTO THE PISTON. COMPRESSION RINGS WERE STILL INTACT. CONNECTING ROD BUSHINGS WERE FINE, VISUAL INSPECTION OF INSIDE OF ENGINE ACCESSIBLE THROUGH THE REMOVED CYLINDER OPENING APPEARED NORMAL. 1L71 3O3 O 2A3 1E10 20031230000302003123000030EA 2003 12 30 2003FA0001168 220031101G852077450 CONNECTING ROD MOONEYM20 M20J 5870219SW LYC O360 IO360A3B6 41514EA ENGINE BROKEN B AHRRO OTHER O OTHER NRNOT REPORTED 1 GL11201SL 240191 L1703751AC IT APPEARED NR 3 CONNECTING ROD FAILED DUE TO OIL STARVATION, CAUSING ROD TO BREAK AT CAP. THE ROD THEN HIT CRANKCASE CAUSING A HOLE IN CRANKCASE AND CAUSED THE CRANKSHAFT TO SEIZE. WHILE REMOVING ENGINE FROM AIRCRAFT, DRAINED 2 QTS OF OIL OUT OF OIL PAN. 1L71 3O3 O 2A3 1E10 20031230000272003123000027EA 2003 12 30 2003FA0001169 220031013G850061261516 STUD CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA ENGINE CASE BROKEN D O OTHER O OTHER NRNOT REPORTED 1 WP093386E 17271526 L818376T STUD BROKEN AT CENTER, CAUSE UNKNOWN. NO RECOMMENDATIONS. 1H71 3O3 ONT3A12 E274 20031230000422003123000042SW 2003 12 30 2003FA0001170 120031104G3213 HOUSING GULSTM114 114B O145001SW LYC O540 IO540* 41532EA MLG STRUT CORRODED B SL5RO OTHER O OTHER NRNOT REPORTED 1 NE036048B244 14676 DURING NORMAL INSPECTION, HEAVY CORROSION WAS FOUND ON BOTH MAIN LANDING GEAR HOUSING`S UNDER AND AROUND CLAMPS SECURING LANDING LIGHTS AND HYDRAULIC HOSES AND TUBES. REMOUND CLAMPS FOUND CLAMP WHERE INSTALLED PRIOR TO FINAL PAINT WITH NO PRIMER OR ANY CORROSION PROTECTION, CLAMPS ARE STAINLESS STEEL HOUSINGS ARE ALUMINUM. REMOVE CLAMP AND PRIMED AND PAINT BETWEEN SURFACES. NOTE: CKD SECOND AC, BOTH MAIN GEAR HOUSINGS HAVE SAME CORROSION. 1L71 3O3 ORTA12SO 1E4 20031230000442003123000044SW 2003 12 30 2003FA0001171 120031104G323397200M488372C3 ACTUATOR GULSTM114 114B O145001SW LYC O540 IO540* 41532EA RT MLG FROZEN B SL5RK NONE O OTHER ININSP/MAINT 1 NE036048B244 14676 DURING NORMAL INSPECTION, CYCLED LANDING GEAR. HEARD A SQUEAL FOLLOWED BY APOP FROM THE RT MAIN LANDING GEAR, FOUND THAT THE LANDING GEAR HYD ACTUATOR ATTACH BEARING WAS FROZEN CAUSING THE ACTUATOR HOUSINGS AROUND THE BEARING TO BREAK AND PULL APART. DURING THE RETRACTION CYCLE. RECOMMEND: INSPECTION AND LUBEING THESE AREAS AT MORE FREQUENT INTERVALS (AT OIL CHANGES). NOTE: INSPECTED LT SIDE, BEARING WAS GOOD. INSPECTED A SECOND AC FOUND BOTH MAIN GEAR ACTUATOR BEARINGS FROZEN, LUBED AND WORKED FREE. 1L71 3O3 ORTA12SO 1E4 20031230000932003123000093SO 2003 12 30 2003FA0001172 120031110G7714SL76121 DRIVE SHAFT PIPER PA28 PA28161 7102803SO LYC O320 O320D3G 41508EA TACHOMETER LOOSE B WS9RO OTHER O OTHER NRNOT REPORTED 1 NM079557C2 287816492 L798039A THE PRESSED IN SLEEVE THAT DRIVES THE TACH CABLE CAME LOOSE AND SPINS IN THE TACH SHAFT. RESULTS IS NO TACH INDICATION. SLEEVE TOO SMALL OR TACH SHAFT BORED OUT TOO MUCH, CAUSING INSUFICENT PINCH ON ASSEMBLY. 1L71 3O3 O 2A13 E274 20031230000432003123000043EA 2003 12 30 2003FA0001173 220031027G853072877 TAPPET PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA ENGINE CYLINDER BROKEN B WS9RO OTHER O OTHER NRNOT REPORTED 1 NM074237D 380 317305055 L868161A TAPPET BODY SEPARATED AND CAUSED ENGINE TO BECOME CONTAMINATED WITH METAL. THIS WAS RECONDITIONED TAPPET BODY. HAVE BEEN USING THESE TAPPETS FOR ALMOST 20 YEARS AND THIS IS THE FIRST ONE THAT HAVE HAD TO BREAK. 1L72 3O3 O A20SO E14EA 20031230000322003123000032GL 2003 12 30 2003FA0001174 120030724G35103891350170 LINE BOMBDRBD700 BD7001A10 1390006GL RROYCEBR700 BR700710A110 NE MANIFOLD RUPTURED D O OTHER O OTHER TXTAXI/GRND HDL 1 SW17324SM1461 1461 9023 OXYGEN LINE CONNECTING NR 3 CYL TO AC OXYGEN PRESS PLUMBING RUPTURED AT SWEDGE WHILE OTHER MAINT WAS BEING PERFORMED. ALL 4 OXYGEN CYL WERE SELECTED TO OFF BEFORE COMPLETE DEPLETION OCCURRED. AS PRECAUTION ALL REMAINING ORIGINAL PRESSURIZED OXYGEN SUPPLY LINES BETWEEN OXYGEN CYL AND THE OXYGEN SYS CONT PANEL WERE REPLACED WITH NEW LINES IAW AMM. ALL LINES REPLACED WERE VISUALLY INSP. NOTED THAT ONE OF THESE LINES HAD BEGAN TO DEVELOP BLISTER AT ONE OF CONNECTORS. A MFG ENGINEER WORKING THIS ISSUE REPORTED THAT LINE WITH THE BLISTER FAILED (RUPTURED) AT APPROX HALF OF THE CERTIFIED PSI RATING. RUPTURE OF ANY ONE OF THESE LINES ALLOW UNCONTROLLED RELEASE OF ENTIRE OXYGEN SUPPLY INTO HIGHLY ELECTRONIC ENVIRMT. 2L72 4F4 FRTT00003NYE00057EN 20031230000332003123000033CE 2003 12 30 2003FA0001175 120031117G5711122100511 SPAR CESSNA210 T210N 2073456CE WING CRACKED D K NONE O OTHER ININSP/MAINT 1 WP237568N6605 21063235 CRACKED WING SPAR WEB AT ATTACHMENT FOR RECIPROCATING FUEL PUMP ASSOCIATED WITH FLINT WING TIP AUXILIARY FUEL SYSTEM. VIBRATION ASSOCIATED WITH FUEL PUMP OPERATION CAUSES THIN SPAR WEB (.025 INCH) TO FLEX AND CRACK AT OUTSIDE RADIUS OF ATTACHMENT HARDWARE. 1H71 3O 3A21 20031230000362003123000036GL 2003 12 30 2003FA0001176 120030622G35103891150110 LINE BOMBDRBD700 BD7001A10 1390006GL OXYGEN SYSTEM RUPTURED D O OTHER O OTHER TXTAXI/GRND HDL 1 SW17324SM1432 1432 9023 AC HAD BEEN PARKED FOR APPROX 2 WEEKS ON RAMP IN A TROPICAL CLIMATE. WHEN FLIGHT CREW CONDUCTED THEIR PREFLIGHT INSPECTION, IT WAS NOTED THAT THE O2 SYS QTY WAS INDICATING 0 PSI ON EICAS AND DIRECT READING GAUGE ON EXTERIOR OF AC. SERVICING OF O2 SYSTEM WAS ATTEMPTED, HOWEVER PRESSURE REMAINED AT ZERO. UPON FURTHER INVESTIGATION IT WAS DISCOVERED THAT LINE INSTALLED UNDER PILOTS SIDE CONSOLE CONNECTING THE PILOTS OXYGEN MASK BOX TO OXYGEN SUPPLY WAS RUPTURED AT END FITTING (HOSE HAD COME UN-SWEDGED). A REPLACEMENT LINE WAS ORDERED FROM MFG AND INSTALLED IAW AMM. AS PRECAUTION O2 CYLINDER REPLACED WITH SERVICEABLE UNITS AND O2 SYSTEM WAS PURGED IAW AMM. AC WAS THEN RELEASED FOR SERVICE. 2L72 4F RTT00003NY 20031229001872003122900187CE 2003 12 29 2003FA0001177 120031107G2121903840311 BLOWER BEECH 90 F90 1152909CE PWA PT6 PT6* 52043EA COCKPIT FLOOR DEFECTIVE D O OTHER O OTHER NRNOT REPORTED 1 SO06188BF4698 LA105 PILOT NOTIFIED MAINTENANCE FACILITY OF DEFECTIVE VENT BLOWER. INSPECTED AND FOUND VENT BLOWER SEIZED. REPLACED VENT BLOWER WITH OVERHAULED PART. SYSTEMS OPS CHECKED NORMAL. REPLACED CURRENT LIMITER ALSO. OVERHAUL TIME LIMIT OR MOTOR.(K) 1L72 4T3 T A31CE E2NE 20031230000652003123000065CE 2003 12 30 2003FA0001178 120031030G324036800111 CALIPER CESSNA150 150L 2071826CE CONT O200 O200* 17020SO LT BRAKE CORRODED G O OTHER O OTHER NRNOT REPORTED 1 EA25427JW 15073873 LT BRAKE CALIPER REMOVED AND INSPECTION OF PART FOUND CORROSION AND PITTING ON CALIPER PISTON WALLS. PISTON WAS BINDING WHEN MOVED. THE PISTON WOULD NOT MOVE FREELY WITHIN CALIPER HOUSING. 1H71 3O3 O 3A19 E252 20031230000702003123000070NE 2003 12 30 2003FA0001180 320031027G6114660714255 HUB ROTOL R390 R3904123F27 NE PROPELLER CRACKED B MS2RO OTHER O OTHER NRNOT REPORTED 1 EA27 122263511 DRG123490 PART FOUND CRACKED AT NR 2 BLADE POSITION IN RADIUS AT BEARING ABUTMENT FACE AND BEARING BORE. PART REJECTED FROM FURTHER SERVICE.(K) 6 CP31NE 20031230000772003123000077NE 2003 12 30 2003FA0001181 320031028G61116607132886 BLADE ROTOL R389 R389* NE PROPELLER CRACKED B MS1RO OTHER O OTHER NRNOT REPORTED 1 EA27 198717462 DR6549989 PROPELLER RECIEVED FOR OVERHAUL. AT DISASSEMBLY AND CLEANING FOUND BLADE S/N 1139 HAD A CRACKED OUTER SLEEVE AT ROOT END OF BLADE. BLADE REJECTED FROM FURTHER SERVICE. 6 CP30NE 20031230000572003123000057CE 2003 12 30 2003FA0001182 120030825G5540R2700001 MOUNT III 650 650TCN CE RUDDER HINGE CRACKED D O OTHER O OTHER NRNOT REPORTED 1 NE05271SA714 CN001 THE LOWER HINGE POINT MOUNT AS WELL AS THE REST OF THE RUDDER ASSY IS MADE OF CARBON FIBER. THE MOUNT HAS CRACKED, DELAMINATED, AND SEPARATED FROM RUDDER ASSY AND IS ONLY ATTACHED BY A FEW FIBERS. THE BALL JOINT THAT CONTROLS THE RUDDER HAS ALSO BEEN BENT AND DAMAGED. POSSIBLE CAUSE: OVER EXTENSION OF RUDDER ASSEMBLY. PREVENTION: INSTALLATION OF RUDDER GUST LOCKS (FOR GROUND OPS) AND THE INSTALLATION OF RUDDER CONTROL STOPS (FOR INFLIGHT OPS).(K) 1H71 3O NTA41CE 20031230000632003123000063EA 2003 12 30 2003FA0001184 220031007G8520 CONNECTING ROD LYC O540 TIO540V2AD 41532EA NR 5 CYLINDER BROKEN G O OTHER O OTHER NRNOT REPORTED 1 WP15 L8523614 FOUND NR 5 CYLINDER LT ENGINE DETACHED FROM THE CASE. ALL CYLINDER BASE STUDS AND THE THRU BOLTS BROKEN OR PULLED OUT OF CRANKCASE. PIECES OF THE CRANKCASE WERE ALSO BROKEN AWAY IN THE AREA OF THE CYLINDER MOUNTING BASE. BOTH ROD BOLTS WERE ALSO BROKEN AND CONNECTING ROD CAP WAS SEVERELY DISTORTED. THE CYLINDER CONTAINED VERY MINOR DAMAGE AND NO VALVE DAMAGE. AIRCRAFT WAS IN NORMAL CRUISE FLIGHT WHEN OPERATOR NOTICED CYLINDER TEMP WAS COLD. THEN REPORTED ENGINE BEGAN RUNNING ROUGH AND SHUT IT DOWN. PROBABLE CAUSE MY BE FAILURE OF ONE ROD END BOLT CAUSING THE FAILURE OF THE OTHER BOLT.(K) 3 O E14EA 20031229001992003122900199EA 2003 12 29 2003FA0001185 220031016G853017726 WASHER STNSON10 10B 8632106GL FRNKLN6A41506A4150B3 27024EA MCAULY1A170 1A170DM GL VALVE SPRING BROKEN D A UNSCHED LANDING R PARTIAL RPM/PWR LOSS NRNOT REPORTED 1 GL138868K 1081868 13561 52849 SEVERE ENGINE ROUGHNESS OCCURRED WHILE IN FLIGHT. AN OFF AIRPORT LANDING WAS MADE WITH NO DAMAGE TO AIRCRAFT AND NO INJURIES. NR 1 CYLINDER FOUND TO HAVE NO COMPRESSION. FOUND THAT PN 17726 VALVE SPRING WASHER HAD FAILED ALLOWING INTAKE VALVE TO DROP INTO CYLINDER NR 1. ENGINE TSMOH 1106. TIME SINCE TOP OVERHAUL 418.45. I WAS UNABLE TO DETERMINE IF PART WAS REPLACED AT MAJOR OVERHAUL OR TOP OVERHAUL. THIS REPORT IS SUBMITTED AS A CORRECTION TO THE DIFFICULTY DATE. PREVIOUS REPORT HAD DATE OF 11/19/2003. ACTUAL DATE OF OCCURENCE WAS 10/16/2003. 1H71 3O3 O A738 E238 5 NP857 20031230000252003123000025EA 2003 12 30 2003FA0001188 220031119G853017726 WASHER UNIVAR108 1081 9230404NM FRNKLN6A41506A4150B3 27024EA MCAULY1A170 1A170DM GL VALVE SPRNG BROKEN D A UNSCHED LANDING R PARTIAL RPM/PWR LOSS NRNOT REPORTED 1 GL138868K 1081868 13561 52849 SEVERE ENGINE ROUGHNESS OCCURRED WHILE IN FLIGHT. AN OFF AIRPORT LANDING WAS MADE WITH NO DAMAGE TO AIRCRAFT AND NO INJURIES. NR 1 CYLINDER FOUND TO HAVE NO COMPRESSION. FOUND THAT PN 17726 VALVE SPRING WASHER HAD FAILED ALLOWING INTAKE VALVE TO DROP INTO CYLINDER NR 1. ENGINE TSMOH 1106. TSO 418.45. UNABLE TO DETERMINE IF PART WAS REPLACED AT MAJOR OVERHAUL OR TOP OVERHAUL. 1H71 3O3 O A767 E238 5 NP857 20031230000792003123000079SW 2003 12 30 2003FA0001189 120031020G323014533107 LINK TMPSONNAVIONNAVIONA 6150104SW CONT E185 E185* 17014SO RT MLG CRACKED G O OTHER O OTHER TXTAXI/GRND HDL 1 SW114808K NAV41808 AC MLG FAILED DURING LANDING ROLLOUT. SCISSOR LINK ASSY HAD FRACTURED DURING THIS OPERATION CAUSING RT MAIN WHEEL TO BE TOE-IN. LANDING ROLLOUT WITH WHEEL IN THIS CONFIGURATION CAUSED MAIN TRUNION TO FAIL AND GEAR TO COLLAPSE. AN INSP OF AC RT MLG LINK ASSY SHOWED SIGNS OF A PREVIOUS, UNLOCATED, FRACTURE THAT PROPAGATED FROM THIS INCIDENT. DISASSEMBLY OF LINKAGE WAS ACCOMPLISHED, IT WAS NOTED THAT THE SPACER AND LOWER BUSHING BLOCK INNER WALL SHOWED SIGNS OF CORROSION. FURTHER INSP REVILED OB AREA OF SPACER HAD NO LUBE. (REST OF SPACER HAD MINIMAL LUBRICATION) LUBE WAS REMOVED FROM BUSHING BLOCK. GREASE HAD A DISCOLORATION DUE TO HIGH USAGE AND POSSIBLE BURNING. 1L71 3O3 O A782 E246 20031229002092003122900209EA 2003 12 29 2003FA0001190 220031031G73103011849 LINE BEECH 100 A100 1152915CE PWA PT6 PT6* 52043EA FUEL SYSTEM FAILED D A UNSCHED LANDING KB FLUID LOSS SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 NM07601PC B225 PILOT REPORTED SMOKE IN CABIN IMMEDIATELY AFTER TAKEOFF. LANDED IMMEDIATELY AND FOUND FUEL DRAINING FROM LEFT ENGINE. FOUND SEVERED FUEL LINE JUST BEHIND FORWARD B-NUT FITTING. LINE FAILURE SEEMS TO BE A FATIGUE FRACTURE. 1L72 3T3 T A14CE E2NE 20031230000782003123000078NE 2003 12 30 2003FA0001191 220031106G7310 LINE NAMER T6 SNJ4 6400414GL PWA R1340 R1340AN1 52016NE HAMSTD12D 12D40 NE FUEL PRIMER CHAFED D K NONE K FLUID LOSS ININSP/MAINT 1 GL157070C1256 8813164 10486 DURING AN ANNUAL INSPECTION, THE FUEL PRIMER LINE WAS FOUND TO BE CHAFED THROUGH AND COMPLETELY SEPARATED AT THE CLAMP ON THE INTAKE TUBE. THERE WAS EVIDENCE OF THIS LINE SQUIRTING FUEL ALL OVER THE ENGINE WHEN THE PRIMER IS USED. ALL OF THE OTHER PRIMER LINES WERE FOUND TO BE IN ALMOST THE SAME CONDITION. THEY WERE ALL ABOUT READY TO BREAK AT THE CLAMP AREA. ALL PRIMER LINES WERE REPLACED. THIS COULD BE A POTENTIALLY DANGEROUS SITUATION, SINCE WITH THE COWLING ON THE AIRCRAFT, THE FUEL SPRAYING ON THE ENGINE DURING PRIMING MAY NOT BE NOTICEABLE. THE CHAFFING IS NOT READILY VISIBLE WITHOUT CLOSELY LOOKING AT THE CLAMP AREA. THE NEWER PRIMER LINES CAME WITH AN ANTI-CHAFE SLEEVE ON THEM. 1L71 3R3 R A2575 5E2 5 CP257 20031229001862003122900186SO 2003 12 29 2003FA0001193 120031114G3246 WHEEL MAULE M4 M4220C 5460114SO FRNKLN6AV3506V350* 27043EA TAIL FAILED C O OTHER E VIBRATION/BUFFET TXTAXI/GRND HDL 1 SO152033U 2025C TAILWHEEL SHIMMIED SHORTLY AFTER TOUCHDOWN, WHEN WEIGHT ON WHEELS INCREASED. SHIMMY STOPPED FOR ABOUT A SECOND THEN RETURNED VIOLENTLY. DIRECTIONAL CONTROL WAS LOST WHEN RUDDER BECAME INEFFECTIVE AND A SLOW TURN TO THE RIGHT DEVELOPED (WIND WAS 65 DEGREE TO THE RIGHT OF RUNWAY HEADING AT 8K) FULL LEFT RUDDER AND BRAE WERE APPLIED EARLY ON BUT HAD LITTLE EFFECT. THE RIGHT TURN TIGHTENED UNTIL THE LEFT GEAR FAILED FROM SIDE LOAD. DAMAGE WAS TO LEFT WING TIP, LEFT GEAR AND PROPELLER TIPS. INSP OF TIRE REVEALED, OUT OF BALANCE, OUT OF ROUND AND DRY ROTTED. UPON TEARDOWN, DISCOVERED DETENTS THAT LOCK STEERING WERE WORN. THE BRONZE BUSHING IN THE VERT SHAFT WAS WORN. (PTRS SO15200406316) 1H71 3O3 O 3A23 E9EA 20031229001932003122900193SO 2003 12 29 2003FA0001194 120031202G214023D04 REGULATOR PIPER PA44 PA44180 7104402SO FUEL PRESSURE LEAKING B K NONE K FLUID LOSS ININSP/MAINT 1 WP28573ER307 4496149 DURING SCHEDULED INSPECTION IAW SB 107A. FOUND HEATER FUEL PRESSURE REGULATOR LEAKING THROUGH ONE OF THE THREADED MOUNT HOLES. UNIT REPLACED. 1L72 3O A19S0 20031230000232003123000023SO 2003 12 30 2003FA0001196 120031028G792120710AR OIL COOLER PIPER PA28 PA28181 7102807SO LYC O360 O360A4A 41514EA ENGINE CRACKED B VJ3RK NONE K FLUID LOSS ININSP/MAINT 1 WP074133D14 14 2843117 RL202836A DURING A MAINTENANCE INSPECTION OF THIS AIRCRAFT, THE OIL COOLER WAS FOUND TO BE CRACKED. PROBABLE CAUSE IS VIBRATION. RECOMMEND MANUFACTURER LOOK AT PROVIDING A SOLID PIECE OIL COOLER AS REPLACEMENT. 1L71 3O3 O 2A13 E286 20031230000502003123000050CE 2003 12 30 2003FA0001197 120031118G550004320049 SUPPORT BRACKET CESSNA150 152 2071835CE EMPENNAGE CRACKED D O OTHER O OTHER NRNOT REPORTED 1 SW15692548550 15282586 SUPPORT BRACKET WAS FOUND TO HAVE A CRACK IN THE WELD WHILE INSPECTING NUTPLATES IAW AD. CRACK WAS LOCATED JUST FORWARD OF NUTPLATE INSIDE BRACKET ABOUT .7500 INCH LONG. WITH DYE PENETRANT INSPECTION, DYE PENETRATED COMPLETELY THROUGH WELD TO OUTSIDE BRACKET. BRACKET HAS APPROXIMATELY 8550 TOTAL HOURS-NUTPLATES CHECKED OK. 1H71 3O NT3A19 20031230000512003123000051CE 2003 12 30 2003FA0001198 120031020G8011642087A64 ADAPTER BEECH 36 A36 1151604CE CONT O550 IO550B SO STARTER SPLIT D O OTHER O OTHER NRNOT REPORTED 1 SW078064N E2578 DOWEL AT 7 O`CLOCK POSITION CAUSED (PN 655714) COVER TO SPLIT AT STUD HOLE. DOWEL HOLE IN PN 655715A1 HOUSING WAS CUT TOO DEEP CAUSING WSHER TO SINK INTO THE COVER INSTEAD OF BOTTOMING ON THE DOWEL. 1L71 3O3 O 3A15 E3SO 20031229002072003122900207SO 2003 12 29 2003FA0001199 120030903G55001709303 FITTING PIPER PA23 PA23 7102302SO LYC O320 O320* 41508EA EMPENNAGE CRACKED D O OTHER O OTHER NRNOT REPORTED 1 NM0764M 23534 DISCOVERED CRACKS DURING ROUTINE INSPECTION. AD 58-01-06 HAD BEEN COMPLIED WITH BY REPLACEMENT OF PN 1709303. 1L72 3O3 O 1A10 E274 20031230000462003123000046CE 2003 12 30 2003FA0001200 120031118G57121013017 RIB CESSNA182 182P 2075816CE CONT O470 IO470* 17026SO LT WING CRACKED D O OTHER O OTHER NRNOT REPORTED 1 NM0729821300 18261233 OUTBOARD RIB OF EACH CANARD WING, CRACKED. OUTBOARD HINGE TAB, LEFT SIDE CANARD BROKEN IN TWO. OUTBOARD HINGE TAB OF RT CANARD WING CRACKED. 1H71 3O3 ONTTA13 E1CE 20031230000752003123000075CE 2003 12 30 2003FA0001201 120031118G57201013016 TAB CESSNA182 182P 2075816CE CONT O470 IO470* 17026SO WING BROKEN D O OTHER O OTHER NRNOT REPORTED 1 NM0729821300 18261233 OUTBOARD RIB OF EACH CANARD WING CRACKED. OUTBOARD TAB LEFT SIDE CANARD BROKEN IN TWO. OUTBOARD HINGE TAB OF RT CANARD WING CRACKED. 1H71 3O3 ONTTA13 E1CE 20031229001922003122900192CE 2003 12 29 2003FA0001203 120031024G2497VR600A VOLT REGULATOR CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA MCAULY1C160 1C160DTM GL ELECTRICAL BURNED D O OTHER B SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 EA13734HL1619 17268866 L138376 729772 A/C ARRIVED AT SHOP AFTER EXPERIENCING SMOKE IN THE CABIN. ELEC SYS WAS SHUT OFF (MASTER SWITCH). INSPECTION OF ELEC SYS SHOWED EVIDENCE OF A FIRE INSIDE OF VOLTAGE REG. VOLTAGE REG WAS INSTALLED IAW INSTRUCTION SHEET NR PPS-2020. THE VOLTAGE REGULATORS INTERNAL OVER VOLTAGE RELAY FAILED. THIS RESULTED IN AN (OVER VOLTAGE CONDITION). FOUND MULTIPLE ELEC UNITS (BLOWN) FROM LND LTS, FUEL QUANTITY GAUGES, BEACON FLASHER AND LAMP, TO ALL RADIOS. THE ORIGINAL OVER VOLTAGE RELAY (FROM MFG) IS DISCONNECTED W/ OTHER UNIT INSTALLATION IAW ABOVE INSTRUCTIONS. 1H71 3O3 ONT3A12 E274 5 NP910 20031229001952003122900195EA 2003 12 29 2003FA0001204 120031120G2810C6P115731 PAD DHAV DHC6 DHC6* 2802606EA PWA PT6 PT6* 52043EA NR 5 FUEL CELL DETERIORATED D O OTHER O OTHER NRNOT REPORTED 1 NM07143Z 12818 437 REPORTED (AFT FUEL LOW) LIGHT ILLUMINATING WITH 300-400 LBS REMAINING ON GAUGE. (SHOULD BE 110 LBS). TROUBLESHOOTING REVEALED FLAPPER PAD (SEAL) WAS DETERIORATED TO THE CONSISTENCY OF A (GUMMY BEAR). AS FUEL IS MOVED INTO THE NR 5 (ENG FEED) TANK, BY MOTIVE FLOW SYSTEM, IT WOULD BEAK BACK OUT THROUGH THIS SEAL INTO SUBSIDIARY CELLS. A/C UNABLE TO KEEP NR 5 CELL FULL. A CALL TO MFG REVEALED THIS HAS BEEN REPORTED SEVERAL TIMES WHEN A/C OPERATED IN HOT ENVIRONMENTS. (S. AFRICA) THIS A/C OPERATED FROM ID TO NEW MEX. MFG CLAIMS WORKING ON DEVELOPING NEW SEAL. 1H72 3T3 T A9EA E2NE 20031229002122003122900212CE 2003 12 29 2003FA0001205 120031202G282005560203 VENT CESSNA172 172N 2072434CE LYC O320 O320* 41508EA FUEL SYSTEM CORRODED D K NONE K FLUID LOSS NRNOT REPORTED 1 SO05734BZ3800 68738 FOUND FUEL LEAK RT DOOR FRAME, CAUSED BY CORROSION AND CHAFING OF FUEL VENT PIPE IN WING ROOT. INSPECTED L/S AND FOUND BEGINNINGS OF LEAK ON THAT SIDE ALSO. 1H71 3O3 ONT3A12 E274 20031229002062003122900206CE 2003 12 29 2003FA0001207 120031118G2430 PULLEY FORD CESSNA150 152 2071835CE LYC O235 O235* 41505EA ALTERNATOR LOOSE B E81RO OTHER B SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 GL0369042 15282455 RFD CONTROL TOWER NOTED SPARKS COMING FROM COWLING AREA. UPON COWL REMOVAL NOTED ALTERNATOR AND ALTERNATOR PULLEY HAD BEEN LOOSE AND WOBBLING. ALTERNATOR HOUSING GOUGED, PULLEY SEVERELY DAMAGED FROM EXCESSIVE WOBBLING AND VIBRATION. ROTOR SHAFT END AND THREADS GOUGED AND SEVERELY WORN. ALTERNATOR FORD PN DOFF 10300B.TRANSIENT AIRCRAFT, MAINTENANCE HISTORY UNKNOWN. 1H71 3O3 ONT3A19 E223 20031230000892003123000089CE 2003 12 30 2003FA0001209 120031104G28100426508910 SKIN CESSNA150 150F 2071814CE CONT O200 O200* 17020SO LT, RT WING TANKCORRODED D O OTHER O OTHER NRNOT REPORTED 1 AL038006S 15061606 LOWER TANK SKINS CORRODED THROUGH IN STRAINER ASSEMBLY SUMP. CORROSION NOTED IN OTHER AREAS OF TANK LOWER SURFACE CONSISTENT WITH STANDING BEADS OF WATER. CORROSION NOTED AROUND FUEL DRAIN VALVE PAD. STRAINER ASSEMBLY SUMP IS LOW POINT IN THE TANK AND HAS NO PROVISIONS FOR DRAIN. BOTH LT AND RT TANKS AFFECTED. AIRCRAFT INACTIVE FOR ABOUT A YEAR.(AL03200409911) 1H71 3O3 O 3A19 E252 20031230000642003123000064CE 2003 12 30 2003FA0001210 120031112G2820 LINE CESSNA185 A185E 2072818CE CONT O520 IO520* 17032SO FUEL SYSTEM SWOLLEN B O OTHER O OTHER NRNOT REPORTED 1 AL0370713 18501878 FUEL LINES IN LT AND RT DOOR POSTS FOUND SWOLLEN AND POROUS. RADIUS BEND AREA NEAR LOWER PORTION OF DOOR POST IS THE AREA AFFECTED. 1H71 3O3 O 3A24 E5CE 20031230000902003123000090SO 2003 12 30 2003FA0001211 220031112G8500IO520F CRANKCASE CONT O520 IO520F 17032SO BEARING BOSS CRACKED B O3ORO OTHER O OTHER NRNOT REPORTED 1 AL03 821524R LT SIDE (2.4.6) CRACKED IN CENTER MAIN BEARING BOSSES IN LOWER OIL ANNALYSIS. 3 O E5CE 20031230000882003123000088GL 2003 12 30 2003FA0001215 120031125G2420BC4101 CASE CIRRUSSR SR22 2130001GL CONT O550 IO550* SO NR 2 ALTERNATORCRACKED B O OTHER O OTHER NRNOT REPORTED 1 GL03813CD540 0141 ALTERNATOR CASE CRACKED AT MOUNTING FLANGE ALLOWING ALTERNATOR TO DEPART THE ACCESSORY CASE. THE ALTERNATOR ARMATURE STILL ROTATED FREELY. PROBABLE CAUSE: ENGINE VIBRATION, MFG REPORTED THAT THIS WAS THE 9TH ALTERNATOR TO FAIL THIS WAY. 1L71 3O3 ONTA00009CHE3SO 20031230000042003123000004SO 2003 12 30 2003FA0001216 220030923G8540CAM539568 GEAR CESSNA182 182B 2072706CE CONT O470 O470L 17026SO STARTER ADAPTER WORN B CY4RO OTHER O OTHER NRNOT REPORTED 1 AL037150E18 52150 670926L TEETH TOO SHALLOW, TOOTH DEPTH WAS 0.152, NORMAL .0.180 TO 0.185. 1H71 3O3 ONT3A13 E273 20031230000662003123000066SO 2003 12 30 2003FA0001218 220031105G8530ECITIST712ACA CYLINDER HEAD CONT O520 TSIO520M 17040SO ENGINE SEPARATED B O OTHER O OTHER NRNOT REPORTED 1 AL03 269 511157 CYLINDER HEAD SEPARATED FROM THE BARREL. 3 O E8CE 20031230000592003123000059SO 2003 12 30 2003FA0001219 220030918G8500 CRANKCASE CONT O520 IO520F 17032SO ENGINE CRACKED B O3ORO OTHER O OTHER NRNOT REPORTED 1 AL03 3689 1891 814966R THIS ENGINE WAS RECEIVED AS CORE ENGINE. THIS IS WHAT WE FOUND WHEN WE LIQUID PENETRANT INSPECTED IT: CRACKED IN BEARING SADDLES, LT SIDE BEARING BOSSES CENTERED. 3 O E5CE 20031230000692003123000069SO 2003 12 30 2003FA0001220 220030918G8500IO520F CRANKCASE CONT O520 IO520F 17032SO ENGINE CRACKED B O3ORO OTHER O OTHER NRNOT REPORTED 1 AL03 812318R PHASE 3 CASE, 7TH STUD. CRACKED IN MAIN BEARING SADDLE AREA BOTH CENTER SADDLES. I OIL ANNULUS AREA. 3 O E5CE 20031230000682003123000068SO 2003 12 30 2003FA0001221 220030910G8500 CRANKCASE CONT O520 IO520F 17032SO ENGINE CRACKED B O3ORO OTHER O OTHER NRNOT REPORTED 1 AL03 1806 814783R THIS ENGINE WAS DISMANTLED, CLEANED AND LIQUID PENETRANT INSPECTED. FOUND THIS CENTER REAR MAIN BEARING SADDLE LEFT SIDE CRACKED. MAIN BEARING PART NR 653547. 3 O E5CE 20031230000762003123000076SO 2003 12 30 2003FA0001222 220030904G8500649043 CRANKCASE CONT O520 IO520F 17032SO ENGINE BROKEN B O3ORK NONE O OTHER ININSP/MAINT 1 AL03 3497 1798 818770R THIS ENGINE WAS DISMANTLED FOR OVERHAUL, FOUND THE REAR CENTER MAIN BEARING SADDLE ON THE LEFT SIDE OF THE CRANKCASE IN A CONDITION THAT APPEARS TO BE CRUMBLING APART. 3 O E5CE 20031230000212003123000021SO 2003 12 30 2003FA0001223 220030805G8520SA631475 PISTON CONT O520 IO520F 17032SO SKIRT DESTROYED B O3ORO OTHER O OTHER NRNOT REPORTED 1 AL03 1766 1766 814594R AT DISMANTLING THIS ENGINE WE FOUND NR 5 PISTON SKIRT TO BE BROKEN AT THE RING LAND FOR THE SCRAPER RING. 3 O E5CE 20031230000312003123000031NE 2003 12 30 2003FA0001224 220031006G7200 ENGINE SNIAS 350 AS350BA 8680817EU TMECA ARRIELARRIEL1 60030NE FAILED C O OTHER O OTHER NRNOT REPORTED 1 CE07408EM 2434 ENGINE SHUT DOWN WITH LOUD BANG. AIRCRAFT WAS IN LEVEL FLIGHT AT APPROX 1500 FT ABOVE GROUND. THE CAUSE OF THE ENGINE FAILURE HAS NOT BEEN DETERMINED. 1G71 3U3 UNCH9EU E19EU 20031230000192003123000019SW 2003 12 30 2003FA0001225 120030211G6520206040439001 SHAFT BELL 206 206B 1181511SW ALLSN 250C 250C20 03013GL T/R GEARBOX WORN B QS7RK NONE O OTHER ININSP/MAINT 1 NM09921RB6702 846 ALO11974 2624 DURING ANNUAL INSPECTION, FOUND KNURLED NUT WORN BEYOND LIMIST. UPON REMOVAL OF THE KNURLED NUT AND TAIL ROTOR BALANCE WHEEL FOUND THREADS ON TAIL ROTOR GEARBOX OUTPUT SHAFT, UNDER BALANCE WHEEL, EXCESSIVELY WORN AND GALLED. CUSTOMERS PILOT REPORTED THAT THEY EXPERIENCED DIFFICULTY IN MAINTAINING TORQUE ON THE KNURLED NUT. 1G71 3U3 U H2SW E4CE 20031230000182003123000018NE 2003 12 30 2003FA0001226 220031126G7250400100025 NOZZLE LYC LTS101LTS101750B1 41560NE POWER TURBINE CRACKED B K NONE O OTHER ININSP/MAINT 1 NM07 P/T NOZZLE SEPARATION AND CRACKED. 3 U E5NE10 20031229002052003122900205EA 2003 12 29 2003FA0001229 220031205G7320 FUEL CONTROL PIPER PA32 PA32300 7103212SO LYC O540 IO540* 41532EA ENGINE OUT OF ADJUST D O OTHER YJ ENGINE STOPPAGE WARNING INDICATION LDLANDING 1 GL1521850 32R795644 L1882748A PILOT, UPON TOUCHDOWN TO LANDING, HAD HIS ENGINE QUIT AND WOULD NOT START AND NEEDED A TOW IN. HE ALSO FOUND THAT HE COULD NOT ADVANCE HIS THROTTLE. INSPECTED FUEL SERVO AND FOUND PIN OUT ON THE IDLE MIXTURE SETTING. INSTALLED OLD PIN, WITH HAS HELD PARTICALY IN PLACE WITH THE SPRING, NEW WASHER P/N 177718 AND COTTER PIN 901200. RUN UP CHECK GOOD. 1L71 3O3 O A3SO 1E4 20031230000472003123000047SO 2003 12 30 2003FA0001230 220031205G85102224111000 BRACKET DIAMONDA20 DA20C1 2990001GL CONT O240 IO240B 17063SO ALTERNATOR CRACKED C K NONE O OTHER ININSP/MAINT 1 NM03 474 C0172 ALTERNATOR BRACKET FAILED AFTER THE HEAD BROKE OFF THE AN4-5A BOLT THAT RETAINS THE BRACKET TO THE SPACER BETWEEN THE CASE AND BRACKET. 1L71 3O3 ONTTA4CH E7SO 20031230000972003123000097CE 2003 12 30 2003FA0001231 120031210G323322430291 FITTING CESSNA182 R182 2072734CE NLG ACTUATOR CRACKED B K NONE K FLUID LOSS ININSP/MAINT 1 WP2835G 4767 R18201785 DURING ANNUAL INSPECTION FOUND THE AFT ATTACH FITTING FOR THE NOSE GEAR ACTUATOR CRACKED IN TWO PLACES. THE CRACKS START AT THE ACTUATOR PIN BOSS AND PROGRESS UPWARD THROUGH THE FLANGE AREA TO THE EDGE OF THE FITTING. UNABLE TO DETERMINE CAUSE (AGE, FATIGUE OR HARD LANDINGS). THIS IS THE SECOND ONE FOUND IN THE FLEET(THE OTHER ONE ON S/N R18200008). ONE OF THE FITTINGS HAS BEEN RETURNED TO MFG FOR THEIR EVALUATION. 1H71 3O RT3A13 20031230000342003123000034EA 2003 12 30 2003FA0001232 220031101G8530 CYLINDER LYC O235 O235L2C 41505EA ENGINE WORN D O OTHER O OTHER NRNOT REPORTED 1 SW99 L2028915 WHILE PERFORMING OIL AND FILTER CHANGE, CUT FILTER AND NOTICE OIL PARTICLES IN FILTER. CALLED MFG TECH SUPPORT, IAW THEIR REQUEST PULLED CYLINDERS. CYLINDERS NR 1, 3, AND 4 WORN SCORED ON PISTON AND CYLINDER WALL. ENGINE IS FACTORY OVERHAUL W/250 SMOH. ENGINE WAS PURCHASED IN JAN 2003. 3 O E223 20031230000992003123000099SO 2003 12 30 2003FA0001233 120031112G78206871800 MUFFLER PIPER PA32 PA32260 7103206SO LYC O540 O540E4B5 41532EA HARTZLHCC2Y HCC2YK1 GL ENGINE EXHAUST DETACHED D O OTHER O OTHER NRNOT REPORTED 1 EA213580W1769 32473 RL1067040 CH33934B EXHAUST TUBE ON MUFFLER, BECAME DETACHED FROM MUFFLER AND DEPARTED AIRCRAFT DURING NORMAL FLIGHT UNDER NORMAL CONDITIONS. RECOMMENDATIONS: CHANGE MUFFLER AT MFG RECOMMEND TIME OF 1000 HOURS OF USE. 1L71 3O3 O A3SO E295 5 CP920 20031230000352003123000035SO 2003 12 30 2003FA0001234 120030918G27421159SCC20033 ACTUATOR GULSTMG1159 G1159A 3970109SO RROYCESPEY SPEY5118 54523EU HORIZONTAL STAB STUCK C O OTHER O OTHER NRNOT REPORTED 1 SW99388CW 489 DURING FINAL APPROACH, FLAPS WOULD NOT EXTEND BEYOND 35 DEGREES TO THE NORMAL 39 DEGREES, NOR COULD THE FLAPS RETRACT. LANDING WAS UNEVENTFUL. IT WAS LATER DISCOVERED THAT HORIZ STAB ACT (WHICH BEGINS TO MOVE HORZ STAB DOWN WHEN FLAPS GO BEYOND 10 DEGREES) WOULD SEIZ AND BIND AT 33-35 DEGREES. LACK OF LUB (UNIT CAN NOT BE LUBRICATED-SEALED UNIT) SEVERE INTERNAL CORROSION. 2L72 4F4 F A12EA E2EU 20031230000052003123000005NE 2003 12 30 2003FA0001235 220030809G7320189111 HMU LEAR 60 60LEAR 5170707CE PWA 305 PW305A 52128NE ENGINE MALFUNCTIONED C O OTHER O OTHER NRNOT REPORTED 1 SW99 NO FUEL FLOW AT START. MANUFACTURER CLAIMS CAUSED BY DIEGME FUEL CONTAMINATION. FUEL SYSTEM CLEANED, NO EVIDENCE OF CONTAMINATION FOUND. REPLACEMENTS UNITS INSTALLED, REPEAT OCCURRENCE 3 FLIGHT HOURS LATER. ALSO NO CONTAMINATION IN EVIDENCE, EVEN FROM EXTENSIVE LABORATORY TESTING OF FUEL SAMPLES. IT SEEMS THAT THESE UNITS ARE INTOLERANT OF FUEL THAT MEETS ALL ASTM STANDARDS. AIRFRAME FILTRATION MAY BE INADEQUATE. THESE UNITS ALSO ON G200, HAWKER 1000, AND DO328JET. WE ARE AWARE OF NO LESS THAN 20 OTHER INCIDENTS. 2L72 4F4 FRTA10CE E35NE 20031230000142003123000014EU 2003 12 30 2003FA0001236 120031211G7830F50B2459A2 MOUNT BRACKET AMD FALC50FALCON50MYST2730106EU THRUST REVERSER BROKEN C O OTHER O OTHER NRNOT REPORTED 1 GL09370KP6387 103 THRUST REVERSER CHECK VALVE MOUNT BRACKET WAS FOUND TO BE BROKEN AWAY FROM AIRCRAFT STRUCTURE. WHEN HYDRAULIC POWER WAS APPLIED TO AIRCRAFT DURING MAINTENANCE THE LINE TO CHECK VALVE CRACKED AND BEGAN SPRAYING HYDRAULIC FLUID. REPLACEMENT OF LINE AND MOUNT BRACKET WAS ACCOMPLISHED. SUSPECT THAT CHECK VALVE MOUNT BRACKET BEGINS TO CRACK OVER TIME AND EVENTUALLY BREAKS AWAY FROM AIRCRAFT STRUCTURE. THIS IS SECOND FAILURE OF THIS MOUNT THAT WE HAVE FOUND ON THIS AC. SUSPECT LINE FAILED DUE TO VIBRATION WORK HARDENING FROM NOT BEING SECURED IN PLACE. RECOMMEND INSPECTING THIS CHECK VALVE MOUNT AT EARLIEST CONVENIENCE TO PREVENT POSSIBLE FAILURE OF THRUST REVERSER HYDRAULIC LINE WHEN UNDER PRESSURE. 2L73 4F A46EU 20031230000262003123000026SO 2003 12 30 2003FA0001237 120031111G3710 PUMP PIPER PA32 PA32R300 7103213SO LYC O540 TIO540* 41532EA VACUUM SYS DAMAGED G O OTHER O OTHER NRNOT REPORTED 1 WP235922V 32R7780378 THE VACUUM PUMPS OVERBOARD AIR LINE SHOWED SIGNS OF DAMAGED THREADS, AND WORKED OUT OF THE PUMP. WHEN IT FELL, ITS PRESUMED THAT IT BECAME CAUGHT IN THE NOSE GEARS DOWN LOCK MECHANISM. ON LANDING, THE NOSE GEAR WOULD NOT FULLY EXTEND OR LOCK, CAUSING A SAFE NOSE GEAR UP LANDING AT SMO. (WP200404833/ INCIDENT NR IWP 23004004) 1L71 3O3 O A3SO E14EA 20031230000202003123000020SW 2003 12 30 2003FA0001238 120031201G2710730048503 PUSHROD TUBE MOONEYM20 M20K 5870220SW CONT O360 TSIO360* 17025SO AILERON CORRODED D O OTHER O OTHER NRNOT REPORTED 1 NE03231PF 250102 FOUND BOTH AILERON OB PUSH ROD TUBES RUSTING INTERNALLY. IF RUST IS NOTICED ON EXTERIOR OF TUBE, IT IS ALREADY AT POINT OF FAILURE. TT 5140 HRS RECOMMEND REPLACING BOTH AILERON PUSH ROD TUBE ASSEMBLIES ON ANY AC WHICH HAVE NOT BEEN REPLACED IN PAST FIVE YEARS. WATER MOISTURE COLLECTING. (NE03200404128) 1L71 3O3 O 2A3 E9CE 20031230000482003123000048EA 2003 12 30 2003FA0001239 220031205G8530AEL65102NST44R COOLING FINS CESSNA182 TR182 2072735CE LYC O540 O540L3C5 41532EA ENGINE CYLINDER BLOCKED D K NONE O OTHER ININSP/MAINT 1 WP254922S500 R18201461 L2227740A VISUAL INSPECTION REVEALED MAJORITY OF COOLING FINGS BETWEEN INTAKE AND EXHAUST PORTS BLOCKED. VIRTUALLY NO AIR FLOW ALLOWED TO PASS BETWEEN ALL FINS ON ALL CYLINDERS. 1H71 3O3 O 3A13 E295 20031230000412003123000041 2003 12 30 2003FA0001240 420031202G2562BP1020 BATTERY PACK ELT LEAKING D O OTHER K FLUID LOSS NRNOT REPORTED 1 GL19 REPLACED THE ELT`S BATTERY PACK DURING AN ANNUAL INSPECTION. BATTERY PACK WAS GOOD TILL JAN 2004. THE EXTERIOR OF THE PACK WAS IN GOOD CONDITION. REMOVED THE CARDBOARD COVERING AND FOUND ONE OF THE "D" CELL BATTERY`S WAS LEAKING ACID AND IF LEFT IN THE ELT, IT WOULD HAVE CAUSED CORROSION ON THE INTERNAL CIRCUIT BOARD OF THE ELT. THE CAUSE OF THE LEKING BATTERY IS UNKNOWN, ALL THE OTHER BATTERIES IN THE PACK WERE OK. RECOMMEND THAT WHEN AN ELT BATTERY PACK IS CHANGED, IF IT IS POSSIBLE, REMOVE THE PACK COVERING AND CHECK THE ACTUAL CONDITION OF THE BATTERIES. 20031230000122003123000012SW 2003 12 30 2003FA0001241 120031212G2730110227 GUARD BBAVIA8 8GCBC 1220803SW ELEVATOR OUT OF ADJUST D O OTHER P NO WARNING INDICATION NRNOT REPORTED 1 GL27186AC2843 36994 THE CABLE GUIDE ON THE AFT PULLEY (BEFORE ATTACHING TO THE ELEVATOR BELLCRANK) WAS INSTALLED AT AN ANGLE WHICH ALLOWED THE CABLE TO WEAR AGAINST THE GUIDE. TWO OF THE SEVEN STRANDS ON THE 7 X 19 CABLE WERE FOUND WORN THROUGH ON AN ANNUAL INSPECTION. 1H71 3O A21CE 20031230000282003123000028CE 2003 12 30 2003FA0001242 120031205G3297 CONTACTOR BEECH 18 H18 1151012CE PWA R985 R985* 52008NE MLG ACTUATOR MALFUNCTIONED C O OTHER J WARNING INDICATION LDLANDING 1 CE07170LG12523 BA666 UPON LANDING THE AIRCRAFT, THE LANDING GEAR FAILED TO EXTEND DUE TO A MALFUNCTION OF THE LANDING GEAR MOTOR CONTRACTOR. PROBLEM WAS DUPLICATED WITH THE AIRCRAFT ON JACKS. TAPPING THE CONTACTOR WITH THE LANDING GEAR SELECTOR IN THE DOWN POSITION WOULD OPERATE THE LANDING GEAR. REPLACEMENT OF THE CONTACTOR CORRECTED THE GEAR MALFUNCTION. 1L72 3R3 R A765 5E1 20031230000812003123000081SO 2003 12 30 2003FA0001243 120031203G792120710AR OIL COOLER PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA ENGINE CRACKED B VJ3RO OTHER K FLUID LOSS NRNOT REPORTED 1 WP074122F 7 2843118 RL3347036A DURING PREFLIGHT OF AIRCRAFT PILOT REPORTED OIL LEAKING FROM ENGINE. MAINTENANCE TECHNICIAN FOUND OIL LEAK ON OIL COOLER. PERFORMED PRESSURE CHECK ON OIL COOLER AND FOUND TOP FLANGE CRACKED. THIS IS A WEAK AREA ON THE OIL COOLER. RECOMMEND FINDING A REPLACEMENT THAT IS MORE DURABLE. 1L71 3O3 O 2A13 E286 20031230000822003123000082SO 2003 12 30 2003FA0001244 120031205G8011MHB601 GEAR PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA STARTER FAILED B VJ3RO OTHER O OTHER NRNOT REPORTED 1 WP074163W43 2843127 RL2987536A PILOT REPORTED AIRCRAFT WOULD NOT START, UPON INSPECTION FOUND BENDIX ON STARTER SHATTERED AND THE TEETH ON STARTER RING GALLED. RECOMMEND RE-EVALUATE STRENGTH OF MATERIAL USED TO MANUFACTURE BENDIX. 1L71 3O3 O 2A13 E286 20031229001972003122900197GL 2003 12 29 2003FA0001245 120031215G35103891150110 LINE BOMBDRBD700 BD7001A10 1390006GL OXYGEN SYSTEM SWOLLEN C K NONE O OTHER ININSP/MAINT 1 SW17324SM1567 9023 OXYGEN SYSTEM LEAKING AT A RATE OF 3 TO 4 PERCENT OF TOTAL VOLUME IN A 24 HOUR PERIOD. VISUAL INSPECTION OF SUSPECT LINE P/N 38911-5-0110 REVEALED SLIGHT BLISTERING AT THE SWEDGE AS WELL AS MISALIGNMENT OF PROTECTIVE HOSE WEBBING. REMOVED AND REPLACED LINE WITH A NEW UNIT IAW AMM. LEAK RATE DROPPED TO LESS THAN 1 PERCENT OVER 24 HOURS. THIS LINE HAS HAD A HISTORY OF RUPTURING WITH 2 OCCURRENCES WITH THIS OPERATOR AND AT LEAST 8 OTHER OCCURRENCES ON OTHER MFG PRODUCTS. 2L72 4F RTT00003NY 20031229002082003122900208NM 2003 12 29 2003FA0001246 120031216G2710 LINK LANCARLC40 LC40550FG 5150000NM CONT O550 IO550N 17042SO HARTZLHCC3Y PHCC3YF1 GL AILERON MISMANUFACTURED C K NONE W INADEQUATE Q C ININSP/MAINT 1 EA21 40008 683385 FP1223B WHILE RIGGING AC, USING TORQUE SPEC FROM MFG MM. AILERON FINAL CONTROL LINK THREADS WERE DESTROYED WHILE ATTEMPTING TO REACH LOW END OF SPECIFIED TORQUE (REF MFG MM CHAP 27, SECT 27-10, B., STEP 9). THE MFG WAS NOTIFIED OF THIS SITUATION AND RESPONDED WITH: USE SPECIFIED TORQUE FOR LINK (REF DWG LA57275900 REV B, WHICH DIFFERS FROM MM). NEW LINK WAS ORDERED AND DURING TORQUING PROCEDURE, THREADS ON LINK WERE DESTROYED AGAIN. TORQUE WRENCH USED IN BOTH INSTANCES WAS CHECKED WITH OUR IN SHOP CHECKER AND VERIFIED TO BE WITHIN SPEC. TRIED TO CONTACT COMPANY REP BUT HAD NO RESPONSE TO OUR INQUIRES. 1L71 3O3 ORTA00003SAE3SO 5 CP25EA 20031230000062003123000006CE 2003 12 30 2003FA0001247 120031216G5533 ANGLE BEECH 200 B200 1152922CE PWA PT6 PT6* 52043EA VERTICAL STAB DAMAGED D K NONE O OTHER ININSP/MAINT 1 EA196WU BB1668 TWO ANGLES THAT ARE THE FORWARD MOUNTING STRUCTURE OF THE VERTICAL STABILIZER TO THE HORIZONTAL STABILIZER HAVE 2 HOLES EACH WITH BOLTS THAT ATTACH THE HORIZONTAL STAB., AND 5 HOLES EACH WITH 4 LOCKBOLTS INSTALLED THAT ATTACH TO THE VERTICAL STAB. THE TOP HOLE ON EACH ANGLE IS DRILLED THRU EACH STRUCTURAL PART EXCEPT P/N 101-640011-11 WHICH IS THE PRIMARY HOLE OF THESE INTERCONNECTING PARTS AND THIS FASTENER WAS NEVER INSTALLED. 1L72 4T3 T A24CE E2NE 20031230000942003123000094NM 2003 12 30 2003FA0001249 120031217G5730 SKIN LKHEEDP2V P2V7 5260112NM WRIGHTR3350 R3350* 67040EA LT WING CRACKED F K NONE O OTHER ININSP/MAINT 1 NM04139HP9034 145906 CRACKS EMANATING FROM THE LT AND RT MLG FORWARD LOWER CUT-OUTS IN THE CENTER WING SKIN. CRACKS RUN FORWARD FROM THE INBOARD CORNERS TO THE FIRST AND SECOND RIVETS. CRACKS DO NOT CONTINUE TO THE EDGE OF SKIN. LOCATIONS OF THE CUTOUTS ARE JUST INBOARD OF THE NACELLE WALLS AT WING STATIONS RT 128.5, 171.5 AND LT 128.5, 171.5. 2M72 4R4 RRTA1RM E272 20031230000952003123000095NM 2003 12 30 2003FA0001250 120031217G5730 SKIN LKHEEDP2V P2V7 5260112NM WRIGHTR3350 R3350* 67040EA RT WING CRACKED F K NONE O OTHER ININSP/MAINT 1 NM04140HP9966 140443 CRACKS EMANATING FROM THE LT AND RT MLG FORWARD LOWER CUT-OUTS IN THE CENTER WING SKIN. CRACKS RUN FORWARD FROM THE INBOARD CORNERS TO THE FIRST AND SECOND RIVETS. CRACKS DO NOT CONTINUE TO THE EDGE OF SKIN. LOCATIONS OF THE CUTOUTS ARE JUST INBOARD OF THE NACELLE WALLS AT WING STATIONS RT 128.5, 171.5 AND LT 128.5, 171.5. 2M72 4R4 RRTA1RM E272 20031230000602003123000060SO 2003 12 30 2003FA0001251 120031202G3233452729 ROD END PIPER PA28 PA28R201 7102816SO LYC O360 IO360A1A 41514EA NLG ACTUATOR BROKEN B OG5RO OTHER J WARNING INDICATION NRNOT REPORTED 1 GL21804ND1832 199 2837004 PILOT REPORTED NOSE GEAR RETRACTED AND A THUMPING NOISE WAS NOTED, UPON WHICH THE NOSE GEAR EXTENDED AND LOCKED. MAIN GEAR WERE EXTENDED AND PRECAUTIONARY LANDING MADE. INSPECTION BY MECHANIC PERSONNEL FOUND NOSE GEAR ACTUATOR ROD END HAD SHEARED AT THE END OF THE THREADS ON THE BEARING END. NO OTHER DAMAGE NOTED. 1L71 3O3 O 2A13 1E10 20031230000742003123000074CE 2003 12 30 2003FA0001252 120031118G5210071100159 PIN CESSNA172 172M 2072418CE LYC O320 O320* 41508EA PILOT DOOR HINGEBROKEN D O OTHER O OTHER NRNOT REPORTED 1 NE0120215 17261101 DURING THE ANNUAL INSPECTION ON THIS AIRCRAFT, FOUND THE TOP PILOT DOOR HINGE PIN OVER HALF MISSING AND ONLY A SMALL PORTION HOLDING THE HINGE TOGETHER, AM SUBMITTING THIS REPORT BECAUSE HAVE FOUND THIS PROBLEM ON MANY THIS TYPE AC HINGES IN THE LAST FEW YEARS. IF THE PIN FAILED COMPLETELY, THE DOOR WILL COME OFF AND MAYBE HIT THE TAIL. 1H71 3O3 ONT3A12 E274 20031230000612003123000061SO 2003 12 30 2003FA0001253 220031208G8500 ENGINE BEECH 36 A36 1151604CE CONT O550 IO550B SO FAILED G O OTHER Y ENGINE STOPPAGE CRCRUISE 1 SO056677Y E1594 297367R AT CRUISE THE AIRCRAFT EXPERIENCED TOTAL POWER LOSS. REMOVING THE ENGINE, THE TECH NOTED GEAR TEETH IN THE OIL SUMP. ENGINE WAS SHIPPED TO MFG FOR ANALYSIS. NO DATA YET. 1L71 3O3 O 3A15 E3SO 20031230000622003123000062CE 2003 12 30 2003FA0001254 120031126G214004530181 VALVE CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA CABIN HEAT BROKEN D O OTHER B SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 GL03350771575 17281062 OWNER COMPLAINED OF NO HEAT IN CABIN AND CONTROL FROZEN. FOUND FLAPPER VALVE PN NR 04530181 BROKEN AT LT SIDE HINGE NOT ALLOWING DOOR TO OPEN AND CONTROL SHAFT GO OVER CENTER. REMOVED CABIN HEAT BOX AND REPLACED VALVE AND REASSEMBLED. OPS CHECKED OK. PART REPLACED UNDER MFG WARRANTY. 1H71 3O3 ONT3A12 1E10 20031230000532003123000053NM 2003 12 30 2003FA0001255 120031208G5711 SPAR UNIVAR415 415C 0420302NM CONT A75 A75* 17005SO WING CORRODED D O OTHER O OTHER NRNOT REPORTED 1 GL19941071300 1430 LEFT FRONT SPAR SHOWS EXFOLIATION CORROSION ABOUT 12 INCHES FROM ROOT. HAD BEEN INSPECTED AND COATED WITH PRIMER, THEN SIGNED OFF AS AIRWORTHY. THIS CORROSION APPEARED TO BE 75 PERCENT THROUGH BOTTOM SPAR FLANGE. 1L71 3O3 O A718 E213 20031230000912003123000091NM 2003 12 30 2003FA0001256 120031208G3240 BRAKE ASSY UNIVAR415 415C 0420302NM CONT A75 A75* 17005SO MLG CORRODED D O OTHER O OTHER NRNOT REPORTED 1 GL19941071300 1430 WHEEL HALVES BADLY CORRODED, GALVANIC CORROSION WHERE STEEL KEYS ARE LOCATED IN INNER WHEEL HALF. APPEARS TO BE FROM LONG TIME SETTING OUT OF USE. OUTSIDE STORAGE APPARENTLY AFFECTED CORROSION. 1L71 3O3 O A718 E213 20031230000092003123000009SO 2003 12 30 2003FA0001257 220031208G8510 BEARING UNIVAR415 415C 0420302NM CONT C75 C75* 17005SO ENGINE WRONG PART D O OTHER O OTHER NRNOT REPORTED 1 GL1994107 1430 1579612 ENGINE STOPPAGE INFLIGHT, FIRST DIAGNOSIS WAS CARBURETOR PROBLEM. SECOND STOPPAGE INDICATED A DIFFERENT PROBLEM. TEARDOWN OF ENGINE REVEALED A SERIES OF FRONT MAIN JOURNAL BEARING HAD BEEN INSTALLED, BLOCKING AN OIL GALLERY, CAUSING SEVERE WEAR AND SEIZURE OF ENGINE. CONFERRED WITH MFG TECH, CONFIRMED DIAGNOSIS AS CAUSING THIS PROBLEM. NOTE: THIS ENGINE HAD 3 STOPPAGES BETWEEN DEPARTURE AND DESTINATION, ALL CARB ICE. 1L71 3O3 O A718 E233 20031230000832003123000083NM 2003 12 30 2003FA0001258 120031208G534341531920 MOUNT UNIVAR415 415C 0420302NM CONT A75 A75* 17005SO NLG STRUT BENT D O OTHER O OTHER NRNOT REPORTED 1 GL19941071300 1430 LOWER TUBES FROM LOWER NOSE STRUT MOUNT TO FIRE WALL ATTACHMENT SLIGHTLY BENT. INSPECTION OF AIRPLANE INDICATED IT HAD BEEN ON ITS BACK AT SOMETINE IN THE PAST. 1L71 3O3 O A718 E213 20031230000852003123000085CE 2003 12 30 2003FA0001259 120031007G531207126103 BULKHEAD CESSNA182 TR182 2072735CE LYC O540 O540* 41532EA TAIL CONE CRACKED D O OTHER O OTHER NRNOT REPORTED 1 EA215125T2050 R18201818 DURING THE MFG OF THIS AC, THE OPTIONAL FACTORY OXYGEN SYS WAS INSTALLED. IT LOOKS LIKE THIS WAS KNOWN WHEN THE TAIL CONE WAS BUILT AS RIVETS IN THE AREA WHERE THE OXYGEN BOTTLE BRACKETS WERE OMITTED TO PROVIDE FOR INSTALLING THE BRACKETS. ONCE THE BRACKETS WERE INSTALLED, THE ORIGINAL RIVET PATTERN WAS NOT PICKED UP TO THE SIDES OF THE BRACKET MOUNTING. THREE OF THE FOUR BRACKETS COULD HAVE AT LEAST ON THE RIVET ON EACH SIDE OF THE BRACKET ADDED. SOME ON BOTH SIDES. THIS LARGE SPACING WITH NO RIVETS IN THE STRINGERS MAY HAVE LEAD TO THE CRACKING OF BOTH THE STRINGER AND THE BULKHEAD. THERE IS NO EVIDENCE THAT ANY OF THESE COMPONENTS HAVE EVER BEEN CHANGED. 1H71 3O3 O 3A13 E295 20031230000842003123000084SW 2003 12 30 2003FA0001260 120031119G32302032071 CLUTCH SPRING MOONEYM20 M20S 5870226SW CONT O550 IO550* SO MCAULY2A34C 2A34C* GL MLG BROKEN B OF1RO OTHER O OTHER NRNOT REPORTED 1 EA172234X178 300001 679343 983151 IN FLIGHT, 178.3 HOURS SINCE COMPLIANCE WITH MFG SB AND MANDATORY REPLACEMENT OF NO BACK CLUTCH SPRING WITH NEW. BOTH TANG ENDS BROKE OFF OF SPRING INSIDE OF LANDING GEAR ACTUATOR WHEN GEAR WAS SELECTED DOWN FOR LANDING. ONE BROKEN TANG APPARENTLY JAMMED BETWEEN THE NO BACK CLUTCH SPRING AND THE NO BACK CLUTCH SPRING HOUSING MAKING EITHER ELECTRICAL OR EMERGENCY MANUAL EXTENSION OF THE LANDING GEAR IMPOSSIBLE. AC WAS LANDED, GEAR UP, UNEVENTFULLY BUT SUBSTANTIAL DAMAGE TO PROPELLER AND BOTTOM OF FUSELAGE WAS CAUSED BY CONTACT WITH RUNWAY. INVESTIGATION UNDER WAY, OTHER REPORTS OF IDENTICAL FAILURES. 1L71 3O3 ORT2A3 E3SO 5 CP3EA 20031230000562003123000056CE 2003 12 30 2003FA0001261 120031128G7500131823EM1360 LINE BEECH B300 B300 1159232CE RT BLEED AIR LEAKING B E81RO OTHER O OTHER NRNOT REPORTED 1 GL03447TF199 FL364 PILOT REPORTED RT BLEED AIR LINE FAIL ANNUNCIATOR CAME ON, CLIMBING THROUGH FL 260. INVESTIGATED AND TROUBLESHOT IAW MM 26-11-00. FOUND SMALL HOLE IN BLEED AIR WARNING EVA TUBING IN FORWARD RT CABIN UNDERFLOOR AREA. NO BLEED AIR LEAKS NOTED ADJACENT TO AREA DURING ENGINE GROUND RUNS. TUBING NOT CHAFED ON ADJACENT STRUCTURE OR COMPONENTS. SPLICE-REPAIRED TUBING IAW MM AND RETURNED TO SERVICE. POSSIBLE TUBING MFG DEFECT, SECOND SIMILAR OCCURRENCE NOTED IN LATE MODEL AIRCRAFT. 2L72 4T RTA24CE 20031230000672003123000067GL 2003 12 30 2003FA0001262 120031120G2820 VENT AVIAT A1 A1A 2210405GL LYC O360 O360* 41514EA FUEL SYSTEM OBSTRUCTED D V2ARO OTHER O OTHER NRNOT REPORTED 1 AL0349349 1149 ON RUNUP, ENGINE WOULD QUIT. ALLOWED TO SIT APPROX 3 MINUTES, IT WOULD START AND RUN, THEN QUIT. WHEN FUEL CAP WAS REMOVED A WHOOSH OF INCOMING AIR WAS HEARD. ENGINE RAN WITH THE CAP OFF. SUSPECT ICE BLOCKING FUEL VENT LINES INSIDE WING. AFTER OVERNIGHT IN HANGER, BOTH VENTS FREE. 1H71 3O3 ONCA22NM E286 20031229001882003122900188CE 2003 12 29 2003FA0001263 120031209G3260622EN186 SQUAT SWITCH CESSNA525 525 2076601CE WILINTFJ44 FJ44 66000GL LT MLG MISSING B WC7RO OTHER O OTHER NRNOT REPORTED 1 GL25431YD 5250431 PILOT REPORTED THE SQUAT SWITCH WAS INOPERATIVE. AFTER INVESTIGATION MAINTENANCE FOUND THAT SCREW AND NUT THAT FASTEN THE ROLLER TO THE SWITCH PLUNGER HAD FALLEN OFF AND THE ROLLER DEPARTED THE AIRPLANE RENDERING THE SQUAT SWITCH INOPERATIVE. SUGGEST A MORE POSITIVE METHOD OF ATTACHING THE ROLLER, PERHAPS A STEEL RIVET, TO PREVENT THIS FROM HAPPENING AGAIN. 1L72 4F4 FRTA1WI E3GL 20031230000982003123000098CE 2003 12 30 2003FA0001264 120031125G5540905241093 BRACKET BEECH 90 C90A 1152911CE PWA PT6 PT6* 52043EA RUDDER BOOST GOUGED B E81RO OTHER O OTHER NRNOT REPORTED 1 GL03439PW842 LJ1589 DURING SCHEDULED PHASE INSPECTION NOTED OB SIDE OF RT RUDDER BOOST BRACKET AT FS 303 GOUGED DEEPLY THROUGH BY ADJACENT CABLE AT AFT END. LOCATION JUST IB OF AFT FUSELAGE ACCESS DOOR. APPEARS BRACKET HAD BEEN INSTALLED INCORRECTLY AT MFG OR HAD SOMEHOW BECOME BENT OVER REPLACED BRACKET WITH NEW PN 905241093 BRACKET. AFTER BRACKET REPLACEMENT ADEQUATE CABLE CLEARANCE NOTED. WOULD RECOMMEND CHAFE PROTECTION TO BE BONDED TO BRACKET TO PREVENT CABLE/BRACKET DAMAGE IN CASE OF BRACKET BEING BENT SLIGHTLY. 1L72 3T3 TRT3A20 E2NE 20031229002042003122900204SO 2003 12 29 2003FA0001265 120031111G322040336000 DRAG BRACE PIPER PA31T PA31T 7103124SO PWA PT6 PT6* 52043EA NLG CRACKED B GW1RK NONE O OTHER ININSP/MAINT 1 EA03202HC 31T7820036 DURING ROUTINE EVENT, 2 INSPECTION IT WAS DISCOVERED THE NOSE LANDING GEAR UPPER RT SIDE DRAG BRACE RETRACTION LUG ATTACH POINT EXHIBITED A CRACK INDICATION. THE CRACK INDICATION WAS DISCOVERED USING (FPI). REMOVAL OF THE NLG UPPER RT SIDE DRAG BRACE IS RECOMMENDED TO FACILITATE THE INSPECTION. NUMEROUS CRACK INDICATIONS HAVE BEEN DETECTED ON ALL MODELS OF AC. 1L72 3T3 T A8EA E2NE 20031229002032003122900203CE 2003 12 29 2003FA0001266 120031126G2710 CONTROL CABLE CESSNA650 650 2076802CE GARRTTTFE731TFE731* 01518WP AILERONS DAMAGED D K NONE O OTHER ININSP/MAINT 1 SW05559AM 6507107 DURING A PHASE 5 AIRFRAME INSPECTION, THE RT SIDE AILERON CABLES WERE FOUND TO BE RUBBING THE RT SPOILER ACTUATOR HYDRAULIC LINE. THE DAMAGED AREAS ON THE CABLES WERE AT RT WING STA 266 ON THE AFT SIDE OF THE WING REAR SPAR. THE PROTECTIVE SLEEVES ON THE CABLES WERE NEARLY WORN THROUGH TO THE POINT OF STARTING TO WEAR INTO THE CABLE STRANDS. THIS DAMAGE WAS CAUSED DUE TO THE LOCK NUT, SECURING THE ACTUATOR HYDRAULIC LINE ELBOW, HAVING COME LOOSE ALLOWING THE HYDRAULIC LINE TO ROTATE AND THE B-NUTS, ON THE LINE, TO COME IN CONTACT WITH THE CABLES. THIS HYDRAULIC LINE SHOULD BE CHECKED FREQUENTLY FOR SIGNS OF LOOSENING. 2L72 4F4 F A9NM E6WE 20031229001962003122900196SO 2003 12 29 2003FA0001267 220031108G8530538304 PUSHROD CESSNA182 182R 2072731CE CONT O470 O470* 17026SO MCAULY2A34C C2A34C204 GL NR 1 CYL EXHAUSTFAILED D CMISA UNSCHED LANDING EJ VIBRATION/BUFFET WARNING INDICATION NRNOT REPORTED 1 NM075497N 1071 18267760 470501 807508 ON ROUTINE FLT PILOT HEARD A BANG AND ENGINE LOST POWER BUT CONTINUED TO RUN. UNABLE TO MAINTAIN ALTITUDE PILOT MADE AN OFF AIRPORT LANDING. FOUND EXHAUST PUSHROD BENT, WORN AND BROKEN. REMOVED ALL CYLINDERS AND FOUND NR 1 CYLINDER INTAKE PUSHROD BENT SLIGHTLY AND NR 5 CYLINDER EXHAUST PUSHROD BENT SEVERELY. SUSPECT PUSHRODS WERE BENT BY BINDING OF THE VALVES. THIS ENGINE WAS REMANUFACTURED ON 11-18-99 USING NEW CYLINDERS. 1L71 3O3 ONT3A13 E273 5 CP3EA 20031229001892003122900189SO 2003 12 29 2003FA0001268 120031125G8011 BUSHING PIPER PA28 PA28161 7102803SO LYC O320 O320D3G 41508EA STARTER FAILED B WS9RO OTHER O OTHER NRNOT REPORTED 1 NM079557C D062804 287816492 L798039A BUSHING ON DRIVE END OF STARTER CAME OUT AFTER LESS THAN 5 HRS. THIS WAS A NEW STARTER INSTALLED ON A NEWLY OVERHAULED ENGINE. EITHER BUSHING DID NOT FIT TIGHT ENOUGH IN HOUSING OR IT WAS TOO SOFT OF MATERIAL. 1L71 3O3 O 2A13 E274 20031230000072003123000007CE 2003 12 30 2003FA0001269 120031208G552012604301 BEARING CESSNA210 210N 2073453CE CONT O520 IO520* 17032SO ELEVATOR INOPERATIVE B L3CRO OTHER O OTHER NRNOT REPORTED 1 SO196490N 21063064 (ELEVATOR ARM ASSY) THE BEARING OF THE ARM CAME OFF DURING FLIGHT AND JAMMED THE ELEVATOR. 1H71 3O3 O 3A21 E5CE 20031230000082003123000008SO 2003 12 30 2003FA0001270 120031202G5540 TORQUE TUBE PIPER PA31 PA31350 7103110SO LYC O540 TIO540* 41532EA RUDDER CORRODED D O OTHER O OTHER NRNOT REPORTED 1 EA03273295958 316120 317752150 WHEN COMPLYING WITH MFG SB 1105A, RUDDER TORQUE TUBE INSPECTION, CORROSION WAS FOUND. UPON REMOVING THE EFFECTED PARTS FOR REPLACEMENT, THE LARGEST AREA OF CORROSION WAS FOUND ON THE BOTTOM RIB FORWARD OF THE FRONT SPAR. THIS AREA IS NOT ADDRESSED IN THE SB AS TO BE INSPECTED. THE SB ONLY COVERS THE AREA AFT OF THE FRONT SPAR. I FEEL THAT IN ORDER TO PERFORM A THOROUGH INSPECTION OF THE AFFECTED AREA THE SB NEEDS TO BE REVISED TO NCORPORATE PROVISIONS FOR ACCESS TO THIS AREA FOR INSPECTION. 1L72 3O3 O A20SO E14EA 20031229002002003122900200EA 2003 12 29 2003FA0001271 220031202G8500 CRANKCASE GULSTM500 500S 0141107SW LYC O540 IO540E1B5 41532EA ENGINE FAILED D A UNSCHED LANDING EY VIBRATION/BUFFET ENGINE STOPPAGE NRNOT REPORTED 1 EA03570623785 3172 L1844848 DURING ROUTINE FLIGHT, LOUD NOISE WAS HEARD. RT ENGINE WAS SHUT DOWN AND SECURED. AFTER AN UNEVENTFUL LANDING, AN INSPECTION REVEALED A CATASTROPHIC CRANKCASE FAILURE AT THE NR 3 CYLINDER LOCATION HAD OCCURRED. CYLINDER WAS COMPLETELY SEPARATE FROM CASE. CASE WAS CRACKED AROUND BASE STUD AREA. CAUSE WAS DETERMINED TO BE IN THE CRANKCASE ITSELF. ENGINE HAD 217 HOURS SINCE OVERHAUL AND WAS RUNNING NORMAL WITH NO PROBLEMS REPORTED. 1H72 3O3 O 6A1 1E4 20031229002132003122900213SO 2003 12 29 2003FA0001272 120031202G2497587866 MASTER SWITCH PIPER PA31 PA31350 7103110SO LYC O540 TIO540* 41532EA COCKPIT LOOSE D O OTHER O OTHER NRNOT REPORTED 1 EA03273295950 317752150 DURING VISUAL INSPECTION, 2 OR THE 8 EXTERNAL WIRE CONNECTIONS WERE FOUND TO BE LOOSE. DISASSEMBLY OF THE SWITCH REVEALED LOOSE INTERNAL CONNECTIONS AS WELL. CORRECT ELECTRICAL OPERATION WAS QUESTIONABLE. SEVERAL REPORTS OF HAVING A SPLIT POWER BUSS WERE OBSERVED. THIS SHOULD NOT BE. TIME AND USE OF A NEWLY INSTALLED SWITCH WILL VERIFY IF THIS WAS THE CAUSE OR IF OTHER PROBLEMS EXIST. TIME ON DEFECTIVE SWITCH WAS APPROX 5950 HOURS. RECOMMEND A THOROUGH VISUAL INSPECTION BE ACCOMPLISHED AT ANNUAL. 1L72 3O3 O A20SO E14EA 20031229002102003122900210CE 2003 12 29 2003FA0001273 120031205G246070000150 CIRCUIT BREAKER BEECH 200 B200 1152922CE COCKPIT TRIPPED B A UNSCHED LANDING H ELECT. POWER LOSS-50 PC CLCLIMB 1 EA2187SA 8491 BB1089 DURING CLIMB, AC RT NR 1 BUSS FEEDER 50 AMP BREAKER OPEN. LT NR 1 BUSS FEEDER BREAKER OPENED SHORTLY AFTERWARD RESULTING IN LOSS OF PILOT SIDE EFIS, MFD, AND VARIOUS OTHER SYS. CREW RETURNED TO FLIGHT ORIG POINT, LANDED WITHOUT INCIDENT. VISUAL INSP OF CB PANEL REVEALED NO DEFECTS. COMPLETED ELECTRICAL LOAD DISTRIBUTION INSP IAW MFG 200 SERIES MM. NO DEFECTS SEEN, UNABLE TO DUPLICATE FAULT. FLIGHT PERMIT OBTAINED TO MAINT. FACILITY. INSP COMPLETED WITH AC LOAD CALCULATION, COULD NOT DUP FAULT. MFG TECH CONTACTED AND INFORMED OF DIFFICULTY. MFG STATED THIS FAILURE IS NOT UNCOMMON DUE TO CB FATIGUE OVER TIME IN SERVICE. REMOVED AND REPLACED BREAKERS WITH NEW, OPS CK NORMAL. AC RETURNED TO SERVICE. 1L72 4T A24CE 20031230000162003123000016EU 2003 12 30 2003FA0001274 120031219G5311 FRAME AGUSTAA109 A109E 0260119EU FUSELAGE CRACKED B O OTHER O OTHER NRNOT REPORTED 1 SW071YU 11130 CRACKED FRAMES AT TB/VERTICAL FIN JUNCTION. ADDITIONALLY THE VERTICAL FIN STRUCTURE IS CRACKED AS WELL. THIS IS THE SECOND SHIP IN THE LAST 90 DAYS THAT HAS HAD THIS SAME DAMAGE FOUND. THE SRM DETAILS THE INDICATIONS AND REPAIR FOR THE FRAMES. AUGUSTA PROVIDED DATA FOR THE VERTICAL FIN REPAIR. THIS REPORT IS SUBMITTED IAW OUR IPM AND AS REQUIRED BY 14 CFR 145.63. 1G72 3U RTH7EU 20031230000492003123000049GL 2003 12 30 2003FA0001275 120031205G8011642083A10 STARTER CIRRUSSR SR22 2130001GL CONT O550 IO550N 17042SO HARTZLHCJ3Y PHCJ3YF1 GL ENGINE WORN P K NONE O OTHER TXTAXI/GRND HDL 1 SO05 96 0374 686704 STARTER ADAPTER FAILURE. STARTER WOULD NOT TURN ENGINE. NO METAL CHIPS FOUND IN ENGINE OIL AT THIS TIME BUT POTENTIAL EXISTS WITH THIS TYPE OF FAILURE. 1L71 3O3 ONTA00009CHE3SO 5 CP36EA 20031230000522003123000052CE 2003 12 30 2003FA0001276 120031219G2720 PULLEY CESSNA650 650 2076802CE GARRTTTFE731TFE731* 01518WP RUDDER CHAFED B K NONE O OTHER ININSP/MAINT 1 SW99791QS 6507091 INITIAL INSPECTION DURING A PHASE 5 OF AFT, OB RUDDER PULLEY, FOUND PULLEY TO HAVE WEAR ON IB EDGE. FURTHER INVEST FOUND AFT PULLEY TO BE CHAFING ON MOUNTING BRACKETS, & BE WEARING TO A KNIFE EDGE ON THE IB EDGE. ALSO FOUND, RUDDER CABLE TO HAVE BROKEN STRANDS BEYOND LIMITS IAW MM. FURTHER INVESTIGATION FOUND OB RUDDER CABLE TO BE MISALIGNED ENOUGH THAT IT PUT A SIDE LOAD ON AFT PULLEY, CAUSING THE PULLEY TO CHAFE ON THE PULLEY BRACKETS. IT ALSO CAUSED THE WEAR OF THE PULLEY, AND HAD WORN THE PULLEY ENOUGH TO ALLOW IT TO CHAFE ON THE EXIT HOLE. IT APPEARED THAT SOMEONE ELSE HAD NOTICED THIS BEFORE, UNKNOWN WHEN, AND HAD BENT THE PULLEY BRACKETS TO TRY AND KEEP THE CABLE FROM CHAFING ON THE EXIT HOLE. 2L72 4F4 F A9NM E6WE 20031230000542003123000054NM 2003 12 30 2003FA0001277 120031218G5730 SKIN LKHEEDP2V P2V7 5260112NM WRIGHTR3350 R3350* 67040EA LT WING CRACKED F K NONE O OTHER ININSP/MAINT 1 NM04139HP9034 145906 CRACKS EMANATING FROM THE LT AND RT MLG FORWARD LOWER CUTOUTS IN THE CENTER WING SKIN. CRACKS RUN FORWARD FROM THE IB CORNERS TO THE FIRST AND SECOND RIVETS. CRACKS DO NOT CONTINUE TO THE EDGE OF THE SKIN. LOCATIONS OF THE CUTOUTS ARE JUST INBOARD OF THE NACELLE WALLS AT WING STATIONS RT 128.5, 171.5 AND LT 128.5,171.5. 2M72 4R4 RRTA1RM E272 20031230000552003123000055CE 2003 12 30 2003FA0001278 120031214G275051155382 BRACKET CESSNA402 402C 207590RCE TE FLAP BROKEN E L ABORTED APPROACH F FLT CONT AFFECTED APAPPROACH 1 SW13442BK 402C0332 FAILURE OF RT FLAP INBOARD ACTUATING BELLCRANK BRACKET P/N 5115538-2 WHICH IN TURN CAUSED FAILURE OF FLAP BELLCRANK P/N 0822275-55. AIRCRAFT LANDED WITHOUT INCIDENT, WITH FLAPS RETRACTED. 1L72 3O A7CE 20031230000862003123000086CE 2003 12 30 2003FA0001279 120031219G5530 FRAME CESSNA150 150M 2071830CE CONT O200 O200* 17020SO EMPENNAGE CRACKED B O OTHER O OTHER NRNOT REPORTED 1 SW071YU 15077311 CRACKED FRAME AT TB/VERTICAL FIN SPAR JUNCTION. THIS IS THE SECOND SHIP WITH AN IDENTICAL CRACK THAT HAS BEEN SEEN IN THE LAST 90 DAYS. THE MFG SRM DETAILS THE REQUIRED REPAIRS. DETECTION IS POSSIBLE USING BRIGHT LIGHT AND MIRROR, OR BY DIRECT OBSERVATION. ADDITIONALLY THE VERTICAL FIN STRUCTURE ON BOTH SHIPS WAS CRACKED AND REQUIRED SUBSTANTIAL REPAIR USING DATA TO FABRICATE AND INSTALL DOUBLERS. 1H71 3O3 O 3A19 E252 20040427000492004042700049GL 2004 4 27 2003FA0001280 120030116G2435642083A10 STARTER GEN CIRRUSSR SR22 2130001GL CONT O550 IO550N 17042SO ENGINE FAILED P O OTHER J WARNING INDICATION TXTAXI/GRND HDL 1 SO05 41 41 STARTER ADAPTER FAILED. WOULD NOT TURN PROP. NO METAL WAS FOUND IN THE ENGINE OIL THIS TIME BUT POTENTIAL EXISTS WITH THIS TYPE FAILURE. 1L71 3O3 ONTA00009CHE3SO 20040212001632004021200163CE 2004 2 12 2003FA0001281 120031216G5320MM67036511002 INTERCOSTAL LEAR 60 60LEAR 5170707CE GE CF34 CF34* NE AFT CARGO BAY CRACKED B WVERK NONE O OTHER ININSP/MAINT 1 EA09247FX 187 RT HYDRAULIC INTERCOSTAL (LUNCHBOX PAN) IS CRACKED AT THE CASE DRAIN LINE IN THE AFT CARGO BAY AT FS 1082. STRESS FATIGUE AT THE RADIUS OF THE PAN. RECOMMENDATION: REMOVED UNSERVICEABLE LUNCH BOX PAN (PN MM670-365-002, LOCATED AND DRILLED NEW SERVICEABLE LUNCH BOX PAN (PN MM670-36511-002), AND INSTALLED SERVICEABLE LUNCH BOX PAN IAW CRJ SRM 51-42-21, 51-42-06, AND THE CRJ AMM 51-23-00. PRESSURIZATION LEAK CHECK OF THE LUNCH BOX PAN IS GOOD IAW CRJ700 AMM 21-31-00-910-801-A01. (EA09200401239) 2L72 4F4 FRTA10CE E15NE 20040212001862004021200186NM 2004 2 12 2003FA0001282 120031125G2913123412 COVER BOEING737 737* NM HYD VALVE CRACKED C IU6RO OTHER L NO TEST NRNOT REPORTED 1 NM01 COVER CRACKED UPON FUNCTIONAL TESTING. IMPROPER PROCESSING (STRESSED). (WC/ NR 182380) 2L72 4F RTA16WE 20040212001872004021200187NM 2004 2 12 2003FA0001283 120031111G32306F230926 HOUSING BOEING737 737* NM RESTRICTOR CRACKED B IU6RO OTHER O OTHER NRNOT REPORTED 1 NM01 64322 1495 BODY IS CRACKED. MATERIAL IN THIS AREA IS WEAK. IMPROVE DESIGN TO ADD MORE MATERIAL TO THIS AREA. (FXS NR 181999) 2L72 4F RTA16WE 20040123000712004012300071NM 2004 1 23 2003FA0001284 120031111G323066F23095 HOUSING CRISSAIR BOEING737 737* NM RESTRICTOR CRACKED B IU6RO OTHER O OTHER NRNOT REPORTED 1 NM01 64322 1413 BODY IS CRACKED. MATERIAL IN THIS AREA IS WEAK. NEED TO IMPROVE DESIGN TO ADD MORE MATERIAL TO THIS AREA. (FXS NR 181999). 2L72 4F RTA16WE 20040212001882004021200188NM 2004 2 12 2003FA0001285 120031111G323045035 HOUSING PNEUDRAULICS BOEING737 737* NM VALVE CORRODED B IU6RO OTHER O OTHER NRNOT REPORTED 1 NM01 3192611123 18556M BORE IS PITTED CAUSING LEAKAGE. MOISTURE ALLOWED THRU VENT, CORRODED UPPER BORE WEAKENING THE MATERIAL. NEED TO IMPROVE DESIGN TO PREVENT MOISTURE FROM REACHING BORE. (FXS NR 182014) 2L72 4F RTA16WE 20040212001892004021200189NM 2004 2 12 2003FA0001286 120031111G323045035 HOUSING PNEUDRAULICS BOEING737 737* NM VALVE CORRODED B IU6RO OTHER O OTHER NRNOT REPORTED 1 NM01 3192611123 18511M BORE IS PITTED CAUSING LEAKAGE. MOISTURE ALLOWED THRU VENT CORRODED UPPER BORE WEAKING THE MATERIAL. NEED TO IMPROVE DESIGN TO PREVENT MOISTURE FROM REACHING BORE. (FXS NR 182014) 2L72 4F RTA16WE 20040212001902004021200190NM 2004 2 12 2003FA0001287 120031111G323045035 HOUSING BOEING737 737* NM VALVE CORRODED B IU6RO OTHER O OTHER NRNOT REPORTED 1 NM01 9002 BORE IS PITTED CAUSING LEAKAGE. MOISTURE ALLOWED THRU VENT CORRODED UPPPER BORE WEAKING THE MATERIAL. NEED TO IMPROVE DESIGN TO PREVENT MOISTURE FROM REACHING BORE. (FXS NR 181814) 2L72 4F RTA16WE 20040212001932004021200193SO 2004 2 12 2003FA0001288 120030911G2720 CONTROL CABLE PIPER PA18 PA18150 7101828SO LYC O360 O360* 41514EA RT RUDDER FRAYED G O OTHER O OTHER NRNOT REPORTED 1 NM01390CC650 9944CC RUDDER CABLE WAS FRAYED WHERE IT PASSES THROUGH THE FAIRLEADS, 5 OUT OF 7 BUNDLES WERE CUT THROUGH THE STAINLESS STEEL CABLE. 1H71 3O3 O 1A2 E286 20040213000052004021300005CE 2004 2 13 2003FA0001289 120031229G321112116014 ATTACH FITTING CESSNA206 TU206D 2073344CE CONT O520 TSIO520M 17040SO MCAULYD3A34 D3A34C403 GL MLG CRACKED B K NONE O OTHER ININSP/MAINT 1 SW99 7642 1230 U20605485 291553R 779503 ON SCHEDULED 200 HRS VISUAL. INSPECTION REVEALED ATTACHMENT FITTING MAIN LANDING GEAR OB CRACKED IN AREA OF REAR. UPPER RADIUS, HISTORICAL RECORD REVELEAD ITS THIRD CHANGE. 1H71 3O3 O A4CE E8CE 5 CP47GL 20040213000072004021300007CE 2004 2 13 2003FA0001290 120031229G321112116014 ATTACH FITTING CESSNA206 TU206D 2073344CE CONT O520 TSIO520M 17040SO MCAULYD3A34 D3A34C403 GL ZONE 100 CRACKED B K NONE O OTHER ININSP/MAINT 1 SW99 7642 1230 U20605485 291553R 779503 ON SCHEDULED 200 HRS VISUAL, INSPECTION REVEALED ATTACHMENT FITTING MAIN LANDING GEAR OB CRACKED IN AREA OF REAR UPPER RADIUS, HISTORICAL RECORD REVELEAD ITS FOURTH CHANGE. 1H71 3O3 O A4CE E8CE 5 CP47GL 20040213000042004021300004CE 2004 2 13 2003FA0001291 120031229G321112116013 ATTACH FITTING CESSNA206 TU206G 2073357CE CONT O520 TSIO520M 17040SO MCAULYD3A34 D3A34C403 GL MLG CRACKED B K NONE O OTHER ININSP/MAINT 1 SW99 7642 1820 U20605485 291553R 779503 ON SCHEDULED 200 HRS VISUAL INSPECTION, REVEALED ATTACHMENT FITTING MAIN LANDING GEAR OB CRACKED IN AREA OF FWD. LOWER RADIUS CLOSE THE BOLT HOLE HISTORY RECORD REVELEAD ITS THIRD CHANGE. 1H71 3O3 O A4CE E8CE 5 CP47GL 20040212001542004021200154CE 2004 2 12 2003FA0001292 120031222G2520 CUSHION CESSNA560 560XL 2076702CE SEAT MISSING B K NONE O OTHER ININSP/MAINT 1 GL09687QS 5605187 NR 6 AND NR 8 CABIN SEATS WERE AT MAINTENANCE FACILITY FOR ROUTINE REFURBISHMENT. DURING DISASSEMBLY IT WAS FOUND THAT THE SEAT PAN CUSHIONS WERE MISSING. IT APPEARS THEY HAD NEVER BEEN INSTALLED. NEW SEAT PAN CUSHIONS WERE FABRICATED AND INSTALLED FROM APPROPRIATELY BURN TESTED MATERIAL. 2L72 4F RTA22CE 20040213000132004021300013CE 2004 2 13 2003FA0001293 120031230G4940A31290 SWITCH CESSNA560 560XL 2076702CE APU START ERRATIC B O OTHER O OTHER TXTAXI/GRND HDL 1 GL09916CS1195 5605153 UPON SHUT DOWN OF APU AFTER ENGINE STARTS, AS THE APU SLOWED TO APPROX. 5 PERCENT THE APU STARTED ITSELF WITHOUT ANY INPUT FROM THE CONTROL PANEL. SUBSEQUENT SHUTDOWN ATTEMPTS RESULTED IN THE SAME RESULTS UNTIL THE FIFTH TIME, AT WHICH, THE MASTER SWITCH WAS TURNED OFF AS THE APU SLOWED TO 10 PERCENT. THIS RESULTED IN A SUCCESSFUL SHUTDOWN. THIS IS THE SECOND THAT WE HAVE ENCOUNTERED THIS PROBLEM ON. THE MANUFACTURER RECOMMENDED THAT WE CHANGE THE START/STOP SWITCH WHICH WE DID. THIS CORRECTED THE PROBLEM FOR THE TIME BEING. RECOMMENDED TO THE MFG THAT A SERVICE BULLETIN BE ISSUED TO CHANGE THE APU START/STOP SWITCH ON THIS MODEL AIRCRAFT. 2L72 4F RTA22CE 20040212001662004021200166CE 2004 2 12 2003FA0001294 120031218G275299105863RX JACKSCREW CESSNA208 208 2073702CE FLAP ACTUATOR BACKED OUT B C ABORTED TAKEOFF O OTHER TOTAKEOFF 1 SW07 114 20800191 FLAP ACTUATOR JACKSCREW SEPARATED FROM THE ACTUATOR ASSEMBLY CAUSING FAILURE OF THE FLAP SYSTEM DURING TAKE OFF. TEAR DOWN REVEALED THAT THE JACKSCREW RETAINING NUT HAD LOOSENED AND SEPARATED FROM THE JACKSCREW ALLOWING IT TO BE PULLED FROM THE ACTUATOR ASSEMBLY. RETAINING NUT HAD NO SAFETY LOCKING DEVICE INSTALLED. 1H71 3T NTA37CE 20040212001652004021200165CE 2004 2 12 2003FA0001295 120031218G2752 JACKSCREW CESSNA208 208 2073702CE FLAP ACTUATOR BACKED OUT B C ABORTED TAKEOFF O OTHER TOTAKEOFF 1 SW07 114 20800191 FLAP ACTUATOR JACKSCREW SEPARATED FROM THE ACTUATOR ASSEMBLY CAUSING FAILURE OF THE FLAP SYSTEM DURING TAKE OFF. TEAR DOWN REVEALED THAT THE JACKSCREW RETAINING NUT HAD LOOSENED AND SEPARATED FROM THE JACKSCREW ALLOWING IT TO BE PULLED FROM THE ACTUATOR ASSEMBLY. RETAINING NUT HAD NO SAFETY LOCKING DEVICE INSTALLED. 1H71 3T NTA37CE 20040212001672004021200167 2004 2 12 2003FA0001296 420031223G2297 WIRE GULSTM114 114B O145001SW LYC O540 IO540* 41532EA CONNECTOR MISROUTED B K NONE O OTHER ININSP/MAINT 1 NE036050Z 14660 DURING OPERATIONAL TEST OF AIRCRAFT PRIOR TO BEGINNING ANNUAL INSPECTION, FOUND WHEN RUNNING MANUAL ELECTRIC TRIM, WHILE PRESSING AND HOLDING DOWN TRIM INTERRUPT BUTTON, TRIM WOULD CONTINUE TO RUN THOUGH AT A MUCH SLOWER RATE. IF TRIM INTERRUPT SWITCH WAS HELD FIRST, THEN THE MANUAL ELECTRIC TRIM ACTUATED, IT WOULD NOT RUN. (KFC-200 AUTOPILOT) FOUND AVIONICS COOLING FAN GROUND WIRE WAS CONNECTED TO A JUNCTION TYING TRIM SERVO PIN C, AP COMPUTER P1 PIN N, P2 PIN Z THROUGH AUTOPILOT DISCONNECT RELAY TO SERVO PIN A. COOLING FAN CIRCUIT BREAKER SUPPLIED VOLTAGE THROUGH THE MOTOR TO THIS CONNECTION CAUSING TRIM TO RUN WHEN TRIM INTERRUPT WAS DEPRESSED. 1L71 3O3 ORTA12SO 1E4 20040213000062004021300006CE 2004 2 13 2003FA0001297 120031229G321112116014 ATTACH FITTING CESSNA206 TU206D 2073344CE CONT O520 TSIO520M 17040SO MCAULYD3A34 D3A34C403 GL ZONE 100 CRACKED B K NONE O OTHER ININSP/MAINT 1 SW99 7642 1230 U20605485 291553R 779503 ON SCHEDULED 200 HRS VISUAL. INSPECTION REVEALED ATTACHMENT FITTING MAIN LANDING GEAR OB CRACKED IN AREA OF REAR UPPER RADIUS, HISTORICAL RECORD REVELEAD ITS FOURTH CHANGE. 1H71 3O3 O A4CE E8CE 5 CP47GL 20040217001842004021700184GL 2004 2 17 2003FA0001298 220031201G725023055438 NOZZLE ALLSN 250C 250C30S 03013GL ENGINE CRACKED B YKERK NONE O OTHER ININSP/MAINT 1 EA17 613 CAE890607S RECEIVED THE ENGINE FOR REPAIR DUE TO HIGH OIL TEMPERATURE. DURING INSPECTION OF THE PARTS FOUND THE WELD ON 1 OF THE 5 TURBINE NOZZLE DIAPHRAGM RETAINING KEYS WAS CRACKED THROUGH THE CENTER FOR ALMOST ITS ENTIRE LENGTH. TURBINE TSO 613 HOURS (KES WO NR A03611) 3 U E1GL 20040217001852004021700185SO 2004 2 17 2003FA0001299 120031124G281078012 BLADDER PIPER PA44 PA44180 7104402SO LYC O360 O360* 41514EA FUEL CELL FAILED B AKGRK NONE K FLUID LOSS ININSP/MAINT 1 CE052234B2770 116 447995107 DISCOVERED FUEL LEAKING, LOWER WING LT ENGINE NACELLE. REMOVED FUEL BLADDER AND FOUND THE LOWER IB NIPPLE CRACKED AND ALLOWING FUEL TO LEAK. FUEL CELL HAD BEEN REPAIRED A YEAR EARLIER. DATE OF MFG AUGUST 1978. INSTALLED NEW BLADDER, IT WAS FELT THAT THIS BLADDER HAD REACHED ITS USEFUL LIFE LIMIT. 1L72 3O3 O A19S0 E286 20040506000812004050600081SW 2004 5 6 2004F00092 120030901G812046C19836G TURBOCHARGER GULSTM500 500B 0141106SW LYC O540 IO540E1B5 41532EA ENGINE MALFUNCTIONED G O OTHER B SMOKE/FUMES/ODORS/SPARKS APAPPROACH 1 NM02698R 71 500A91019 L320248 TURBOCHARGER REPORTED BY TOWER TO BE SMOKING DURING APPROACH. TURBOCHARGER SHIPPED TO MFG FOR INSPECTION. PRELIMINARY EVALUATION: COMPRESSOR RUB. 1H72 3O3 O 6A1 1E4 20040506000822004050600082SW 2004 5 6 2004F00093 120030901G812046C19836G TURBOCHARGER GULSTM500 500B 0141106SW LYC O540 TIO540AE2A 41532EA ENGINE FAULTY G O OTHER R PARTIAL RPM/PWR LOSS CRCRUISE 1 NM02222LE39 1525187 CK4927B TURBOCHARGER LOW IN PERFORMANCE DURING FLIGHT. TURBOCHARGER SHIPPED TO MFG, FOR INSPECTION. PRELIMINARY EVALUATION: COMPRESSOR RUB. 1H72 3O3 O 6A1 E14EA 20040223000032004022300003 2004 2 23 2004FA0000000 420030918G2397GMA340 WIRE PIPER PA28 PA28161 7102803SO LYC O320 O320* 41508EA AUDIO PANEL CONNMISINSTALLED D K NONE O OTHER ININSP/MAINT 1 NM0153215 2842170 SB 1135 DOES NOT APPLY DUE TO AIRCRAFT SERIAL NUMBER, HOWEVER, CONNECTOR WAS WIRED WITH PILOT HEADPHONES WIRE IN LOCATION 31 INSTEAD OF 16. AIRCRAFT WAS CORRECTED TO ALLOW FAILSAFE USE OF NR 1 COM. 1L71 3O3 O 2A13 E274 20040123000592004012300059SO 2004 1 23 2004FA0000001 120031219G325063300014 HORN PIPER PA28 PA28181 7102807SO LYC O360 O360* 41514EA NLG STEERING BROKEN D ULOVO OTHER O OTHER NRNOT REPORTED 1 SW13354MR1015 2843315 FOUND RUDDER LOOSE, FOUND RT ARM TO NOSE WHEEL STEERING ARM BROKEN OFF. PART APPEARED TO HAVE BEEN CRACKED FOR SOME TIME. RESEARCH SHOWS WHEEL FAIRINGS REMOVED FOR REPAIR DUE TO HARD CROSSWIND LANDING 145 HOURS. PREVIOUSLY, AND CABLE TENSION ADJUSTED AT LATER DATE. SUGGEST HORN BE INSPECTED AFTER HARD LANDINGS OR EXCESS CABLE TENSION ADJUSTMENT REQUIRED. 1L71 3O3 O 2A13 E286 20040223000052004022300005SO 2004 2 23 2004FA0000002 220031108G8530538304 PUSHROD CESSNA182 182R 2072731CE CONT O470 O470* 17026SO MCAULY2A34C C2A34C204 GL NR 1 CYLINDER WORN D CMISA UNSCHED LANDING R PARTIAL RPM/PWR LOSS NRNOT REPORTED 1 NM075497N 1071 1265 18267760 470501 807508 ON ROUTINE FLIGHT PILOT HEARD A BANG AND ENGINE LOST POWER BUT CONTINUED TO RUN. UNABLE TO MAINTAIN ALTITUDE, PILOT MADE AN OFF AIRPORT LANDING. FOUND NR 1 EXHAUST PUSHROD BENT, WORN AND BROKEN. REMOVED ALL CYLINDERS AND FOUND NR 1 CYLINDER INTAKE PUSHROD BENT SLIGHTLY AND NR 5 CYLINDER EXHAUST PUSHROD BENT SEVERELY. SUSPECT PUSHRODS WERE BENT BY BINDING OF THE VALVES. THIS ENGINE WAS REMANUFACTURED 11/18/99 USING NEW CYLINDERS. 1L71 3O3 ONT3A13 E273 5 CP3EA 20040123000452004012300045CE 2004 1 23 2004FA0000003 120031112G2510551900921 SEAT CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE COCKPIT CRACKED D O OTHER O OTHER NRNOT REPORTED 1 CE05204CF 5500238 UPPER CHAIR BASE ASSEMBLY CRACKED AT CHAIR BACK ATTACH POINTS. STRESS ON CHAIR BACK AND METAL FATIGUE PROBABLE CAUSE. CHAIR WAS REPAIRED IAW STC ST01042WI STRUCTURAL SEAT REPAIR. 1L72 4F4 F A22CE E1NE 20040123000272004012300027CE 2004 1 23 2004FA0000004 120031009G3000654A58 SWITCH BEECH MU300 400A 1155402CE PWA JT15 JT15D5 52112NE DE ICE SYSTEM FAILED D O OTHER O OTHER NRNOT REPORTED 1 NM01440DS RK8 MULTIPLE FAILURES OF TAIL DEICE SYSTEM. ALWAYS GROUND TESTED GOOD. FINALLY FLEW AIRCRAFT BACK TO MANUFACTURER FOR REPAIR. 2H72 4F4 FRTA16SW E25EA 20040123000282004012300028EA 2004 1 23 2004FA0000005 220031002G8520 CAMSHAFT CESSNA182 182T 2072703CE LYC O540 IO540AB1A5 EA ENGINE SPALLED D O OTHER J WARNING INDICATION NRNOT REPORTED 1 NM01102LP407 18281121 L2791548A ENGINE MAKING METAL, MFG DETERMINED IT TO BE CAMSHAFT/ LIFTER MATERIAL ENGINE RETURNED TO FACTORY FOR REPAIR. THIS IS THE SECOND OCCURRANCE OF CAMSHAFT/ LIFTER SPALLING AND 5TH OCCURANCE OF ENGINES MAKING METAL IN A FLEET OF 5. POSSIBLE MANUFACTURING AND MATERIAL PROBLEMS FROM THE MFG. 1H71 3O3 ONT3A13 1E4 20040123000292004012300029NM 2004 1 23 2004FA0000006 120031015G5753654792327 SPAR BOEING737 737300 1384610NM GE CFM56 CFM56* 13802NE LT WING TE FLAP CRACKED D SWAAO OTHER O OTHER NRNOT REPORTED 1 NM01379SW 1898 26586 CRACKED AT OB AFT FLAP TRACK LOWER ATTACH HOLES. 2L72 4F4 FRTA16WE E2GL 20040223000082004022300008CE 2004 2 23 2004FA0000007 120031014G561010138402522 WINDSHIELD BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA COCKPIT BROKEN C WXHMO OTHER O OTHER CRCRUISE 1 NM01222KA1384 BB49 WHILE AT CRUISE 25,000 FT, WINDSHIELD ON LOW, INNER PANEL OF CO-PILOTS WINDOW SHATTERED. MFG INSPECTED AND DETERMINED FAILURE RESULT ON (CHIP PLY) FAILURE. (NM13PLV200401669) 1L72 4T4 T A24CE E4EA 20040108000532004010800053EA 2004 1 8 2004FA0000008 220031017G741435255514 MAGNETO CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA ENGINE SHORTED D O OTHER O OTHER NRNOT REPORTED 1 EA094763D 17272354 AIRCRAFT HAD PAST HISTORY OF ENGINE RUNNING RUFF AT TIMES. AT 12 MILES OUT FROM AIRPORT, ENGINE STARTED TO RUN RUFF. AT 6 MILES OUT FROM AIRPORT ENGINE SHUT DOWN AND WOULD NOT START AGAIN. THE AIRCRAFT MADE IT TO RUNWAY, OK. CHECKED MAG AND FOUND BOTH CAPACITORS P LEADS SHORTED TO COVER. COIL ALSO BAD. BURNS ON BACK COVER SHOW THAT CAPACITOR LEADS HAVE BEEN ARCHING TO COVER FOR SOME TIME. THE SPADE CLIPS ON CAPACITOR LEADS WERE LOOSE AND COULD SLIDE REARWARD TO THE PORT WHERE ARCHED TO REAR COVER SHUTTING DOWN ENGINE OR RUNNING RUFF. 1H71 3O3 ONT3A12 E274 20040223000132004022300013NM 2004 2 23 2004FA0000009 120031212G5700 FLYING WIRE CHRIS HUSKY A1 221020XNM LYC O360 O360A1D 41514EA TAIL UP BROKEN D O OTHER O OTHER NRNOT REPORTED 1 GL132868M3992 1005 UPPER LT FLYING WIRE TAIL BROKE ABOUT 6 INCHES FROM TOP ATTACH POINT. WHILE FLYING, FLAT TYPE WIRE. 1H71 3O3 ONCA22NM E286 20040223000142004022300014 2004 2 23 2004FA0000010 420031206G2561GA12 LIFE VEST CABIN FAILED B KQ1RK NONE L NO TEST ININSP/MAINT 1 EA07 INDIVIDUAL FLOAT DEVICE FAILED, CELL PRESSURE TEST DUE TO TWO (2) SMALL PUNCTURE HOLES IN CELL. BEYOND MFG RECOMMENDED REPAIR LIMITS. DOM: FEB 1990. 20040223000152004022300015 2004 2 23 2004FA0000011 420031121G2561KSE35L8P0723E105LIFE VEST CELL DAMAGED B KQ1RK NONE L NO TEST ININSP/MAINT 1 EA07 ONE CELL DAMAGED DUE TO HIGH IMPACT. DAMAGE BEYOND REPAIR MANUAL LIMITS. 20040223000212004022300021EA 2004 2 23 2004FA0000014 220031119G8550STD91 PLUG PIPER PA46 PA46350P 7104602SO LYC O540 TIO540AE2A 41532EA ENGINE LOOSE C HPFRO OTHER K FLUID LOSS NRNOT REPORTED 1 WP094170D 4636300 L1059461A PLUG WAS FOUND LOOSE, BEGAN TO LEAK OIL. CONTINUED OPERATION WOULD HAVE CAUSED PLUG TO FALL OUT RESULTING IN EXTREME OIL LOSS. THIS IS THE SECOND TIME THIS PLUG WAS LOOSE. 1L71 3O3 ORTA25SO E14EA 20040223000222004022300022SO 2004 2 23 2004FA0000015 120031210G533068501801 SKIN PIPER PA32 PA32301 7103207SO LYC O540 IO540* 41532EA FUSELAGE CORRODED B E81RO OTHER O OTHER NRNOT REPORTED 1 GL034304W1390 328306029 AFTER REMOVING RT SIDE LOWER CENTER FUSELAGE EXTERIOR HAD ASSY STIFFENER AND PN 62544-01 FORWARD FAIRING TO FACILITATE OTHER REPAIRS, FOUND CONSIDERABLE CORROSION ON MOUNTING FLANGES AND ADJACENT FUSELAGE SKIN. AREA IS SUBJECT TO ENGINE EXHAUST AND MUD/DIRT, ETC. TOSSED UP BY NOSEWHEEL. HAT SECTIONS ARE NOT SEALED TO FUSELAGE SKIN, ALLOWING CORROSIVE PRODUCTS TO SEEP IN OVER TIME. SUGGEST ALL SIMILAR PA28/PA32 AIRCRAFT SHOULD HAVE 1-TIME INSPECTION AFTER 10 YEARS, HATS/SKIN REPLACED OR REPAINTED WITH EPOXY PAINT, THEN REINSTALLED WITH 2 PART MIS-S8802 TYPE SEALANT OR SIMILAR. 1L71 3O3 O A3SO 1E4 20040223000232004022300023SO 2004 2 23 2004FA0000016 120031219G27222018500 BELLCRANK PIPER PA24 PA24260 7102406SO LYC O540 TIO540* 41532EA RUDDER CRACKED B GFZRK NONE O OTHER ININSP/MAINT 1 NE05801PC5500 244256 DURING ANNUAL INSPECTION, A CRACK WAS FOUND IN THE BELLCRANK BOLT HOLE. ON CLOSER INSPECTION IT WAS FOUND THAT ALL FOUR BOLT HOLES HAD CRACKS IN VARIOUS STAGES OF PROGRESSION. THE CRACKS BEGIN AT THE END OF THE PART AND PROCEED TOWARDS THE BOLT HOLE, ONLY ONE HAS MADE IT ALL THE WAY TO THE BOLT HOLE. THE LARGEST CRACK COULD BE SEEN CLEARLY BUT THE REMAINING THREE REQUIRED MAGNIFICATION. A DYE PEN INSPECTION PRODUCED THE MOST CLEAR RESULTS. ADDITIONALLY, AFTER THE INITIAL CLEANING, A CRACK WAS FOUND AT ONE OF THE HOLES FOR THE RUDDER CABLE ATTACHMENT HARDWARE. THIS FIFTH CRACK PROGRESSES ALL THE WAY FROM THE HOLE TO THE OUTER EDGE. THIS AIRCRAFT HAS SPEED MODS AND IS NOT RESTRICTED TO 203 MPH. 1L71 3O3 O 1A15 E14EA 20040123000812004012300081SO 2004 1 23 2004FA0000017 120031219G55302070703 BRACKET PIPER PA24 PA24260 7102406SO LYC O540 TIO540* 41532EA RUDDER CRACKED B GFZRO OTHER O OTHER NRNOT REPORTED 1 NE05801PC5500 244256 DURING RUDDER REMOVAL FOR REQUIRED MAINTENANCE, A CRACK WAS FOUND IN MIDDLE RUDDER HINGE BRACKET MOUNTED ON THE VERTICAL FIN. THE CRACK IS AT THE HINGE BEARING HOLE. DUE TO THE LOCATION, THIS CRACK WOULD NOT HAVE BEEN VISIBLE WITHOUT REMOVING THE RUDDER FIRST. THIS AIRCRAFT HAS SPEED MODS AND IS NOT RESTRICTED TO 203 MPH. 1L71 3O3 O 1A15 E14EA 20040223000262004022300026SO 2004 2 23 2004FA0000018 120031124G2823 O-RING PIPER PA44 PA44180 7104402SO LYC O360 O360* 41514EA SHUTOFF VALVE LEAKING B AKGRO OTHER K FLUID LOSS NRNOT REPORTED 1 CE052234B2770 236405 447995107 WHILE ATTEMPTING TO REPAIR A FUEL SEEPAGE PROBLEM ON THE LT ENGINE PRIMER PUMP, IT WAS DISCOVERED THAT THE FUEL SUPPLY COULD NOT BE SHUT OFF. AFTER REMOVING THE FUEL FROM THE LT AND RT WINGS. THE LT WING FUEL VALVE WAS REMOVED FROM THE SYSTEM AND DISASSEMBLED. THE O-RINGS HAD DETERIORATED AND COME OUT OF THE RETAINING GROOVE AND WERE IN PIECES ROLL UP IN THE CENTER OF THE VALVE BODY. 1L72 3O3 O A19S0 E286 20040223000282004022300028 2004 2 23 2004FA0000019 420031231G3130 CONVERTER AEROSPATR42 ATR42300 8680920EU PWA 120 PW120 NE AFDAU INTERMITTENT B SVURO OTHER O OTHER NRNOT REPORTED 1 SW19271AT2243 307 273 FDAU STA LIGHT ON. CONVERTER INTERMITTENT (WO NR 34227) 2H72 4T4 TRTA53EU E20NE 20040223000462004022300046CE 2004 2 23 2004FA0000021 120031226G7930639305 VERNATHERM CESSNA210 T210M 2073451CE CONT O520 TSIO520R 17040SO OIL COOLER FAILED C O OTHER O OTHER NRNOT REPORTED 1 SW05732YK650 21061879 294273R VERNATHERM FAILED TO BYPASS OIL COOLER WHEN OIL TEMPS LOW. 1H71 3O3 O 3A21 E8CE 20040223000472004022300047 2004 2 23 2004FA0000022 420031231G2215 MOTOR TRIM ACTUATOR FAILED B SVURO OTHER O OTHER NRNOT REPORTED 1 SW19 5294 398 MOTOR FAILED SPEED OF DISPLACEMENT. SLOW SPEED. (WO NR 33814) 20040223000552004022300055CE 2004 2 23 2004FA0000027 120031117G3230583800901 MOTOR BEECH 58 58 1152740CE CONT O520 IO520* 17032SO MLG FAILED B FFKRO OTHER O OTHER NRNOT REPORTED 1 SO05958MC2498 TH552 LANDING GEAR ELECTRIC MOTOR FAILED INFLIGHT PILOT HAD TO MANUALLY EXTEND GEAR. INSTALLED NEW MOTOR. OPS CHECK GOOD. 1L72 3O3 O 3A16 E5CE 20040223000622004022300062SO 2004 2 23 2004FA0000029 120031105G572062086002 STIFFENER PIPER PA28 PA28181 7102807SO LYC O360 O360* 41514EA SNSNCH76E 76EM8 EA RT WING CRACKED B FQARK NONE O OTHER ININSP/MAINT 1 WP07430PA2684 2843488 L3222236A 33529K DURING A ROUTINE INSPECTION, A MECHANIC NOTED THE AFT STIFFING CHANNEL, PN 62086-002, CRACKED AT THE MIDDLE LIGHTENING HOLE. ADDITIONAL INSPECTION REVEALED NO FURTHER DAMAGE. THE CRACKS APPEAR NEW. THIS CRACK IS NOT TYPICAL OF THE CRACKS FOUND PREVIOUSLY. THIS IS A MFG INSTALLED PART. 1L71 3O3 O 2A13 E286 5 NP4EA 20040217001822004021700182SO 2004 2 17 2004FA0000030 220031231G8520 PISTON CONT BEECH 35 J35 1151522CE CONT O470 IO470C 17026SO CYLINDER FAILED G EBA ENGINE SHUTDOWN EMER. DESCENT UNSCHED LANDING Y ENGINE STOPPAGE CRCRUISE 1 SW13617Q 213 D5670 715769C THE PISTON IN NR 4 CYLINDER SEPARATED AT THE PISTON PIN BOSS AREA ALLOWING THE CONNECTING ROD END TO PROTRUDE THROUGH THE ENGINE CASE AND THE COWLING. THE CYLINDER HAD THE CERMINIL PROCESS PERFORMED ON IT IN APRIL 14,2000 BY THE ECI (ENGINE COMPONENT INC.).THE CYLINDER TAG SHOWS TO HAVE BEEN A COMPLETE ASSEMBLY WHEN PURCHASED. 1L71 3O3 O 3A15 E273 20040122001442004012200144NM 2004 1 22 2004FA0000038 120031219G2730 SEAL DORNERDO32 DO328100 2996000NM PWA 119 PW119B NE PITCH TRIM UNIT LEAKING B SVURO OTHER O OTHER NRNOT REPORTED 1 SW19459PS3736 132 3070 CAS MISCOMPARE MESSAGE AT 25000 FT. ALSO THE MOISTURE INDICATOR IS PINK. (WO NR 33910) 2H72 4T4 TRTA45NM E20NE 20040223001162004022300116CE 2004 2 23 2004FA0000049 120031230G323398820041 PISTON CESSNA172 172RG 2072438CE LYC O360 O360F1A6 41514EA MLG ACTUATOR BROKEN D O OTHER O OTHER NRNOT REPORTED 1 EA019666B 172RG0955 L2990336A RT MAIN LANDING GEAR ACTUATOR PISTON BROKE IN TWO PIECES ON GEARED PORTION. CAUSING RT GEAR TO FAIL TO LOCK IN DOWN POSITION. RESULT WAS GEAR UP LANDING. 1H71 3O3 O 3A17 E286 20040223001282004022300128CE 2004 2 23 2004FA0000056 120031120G2830STCSA01110CH O-RING BEECH 33 35B33 1151406CE CONT O550 IO550B SO QUICK DRAIN CRACKED P K NONE K FLUID LOSS ININSP/MAINT 1 GL03930Q 3300 100 CD388 DURING A PREFLIGHT INSPECTION, PILOT IDENTIFIED SEEPAGE FROM LT WING QUICK DRAIN. FLUSHING DID NOT REVEAL DEBRIS THAT WOULD HAVE CAUSED LEAK, AND DID NOT ARREST LEAK. QUICK DRAIN INSTALLED 2 YEARS PRIOR DURING FUEL CELL REPLACEMENT. ON DISASSEMBLY, IDENTIFIED THAT THE O-RING WAS SEVERELY DISTRESSED, AND COVERED WITH CRACKS, PROVIDED THE CORRECT O-RINGS AS REPLACEMENTS. REQUESTED TO FILE SDR, SO OWNER FILING SDR TO IDENTIFY THIS ISSUE FOR TRENDING. NOT A FLIGHT SAFETY ISSUE - LEAK WAS MINOR. HOWEVER, IT APPEARS THAT THE WRONG O-RINGS WERE PROVIDED WITH QUICK DRAINS BY OEM. PART NUMBER UNKNOWN. 1L71 3O3 O 3A15 E3SO 20040223001382004022300138SO 2004 2 23 2004FA0000060 120031224G5511121C3100011 RIB MARSH S2F S2F3S 3951007SO GARRTTTPE331TPE331* 01514WP STABILIZER CRACKED C K NONE O OTHER ININSP/MAINT 1 WP25424DF5132 154820 DURING A 400 HOUR INSP OF THE LT HORZ STAB, CRACKS WERE FOUND AT LE RIBS OF HORZ STAB AT STA 66.108, 80.608, AND 95.108. CRACKS WERE NOTED WHERE RIBS ATTACH TO THE LE SKIN. THIS AC HAS A TT 5132.1 AND 1458.1 TT SINCE IT WAS CONVERTED TO TURBOPROP POWERED FIRE FIGHTING AC. THE LT HORZ SHOT DAMPER WAS REMOVED DURING TURBOPROP CONVERSION. IT WAS ORIGINALLY INSTALLED TO COUNTERACT ORIGINAL RADIAL ENG INSTALLATION 3 BLADED PROP HARMONIC VIBRATION AT 2300 RPM. IT IS BELIEVED THAT CRACKING COULD BE CAUSED BY VIBRATION FROM TURBO PROP INSTALLATION. ACTUAL CAUSE OF CRACKING IS CURRENTLY BEING INVESTIGATED AND HAS YET TO BE DETERMINED. LT HORZ STAB LE SKIN RIBS SHOULD BE INSP FOR CRACKS. 2H72 4O3 TRTA51NM E2WE 20040123000562004012300056GL 2004 1 23 2004FA0000061 220031223G8520 MASTER ROD BELL 47 47G3B1 1181028SW ALLSN 250C 250C20 03013GL ENGINE CRACKED B E5WRO OTHER O OTHER NRNOT REPORTED 1 GL218548F 6507 CRACK-LIKE INDICATION DETECTED BETWEEN WELD AND HOLE 2 AND END OF ROD. FLUORESCENT PENETRANT INSPECTION AND MT INSPECTION USED. 1G71 3O3 U 2H3 E4CE 20040223001392004022300139SW 2004 2 23 2004FA0000062 120031223G7120476121711289 MOUNT BELL 47 47G3B1 1181028SW ALLSN 250C 250C20 03013GL ENGINE CRACKED B E5WRK NONE O OTHER ININSP/MAINT 1 GL218548F 6507 CRACK-LIKE INDICATIONS DETECTED ON WELD EDGES-AREAS IDENTIFIED. FLUORESCENT AND MT INSPECTION USED. 1G71 3O3 U 2H3 E4CE 20040223001472004022300147SW 2004 2 23 2004FA0000063 120031223G5320471202523 GRIP BELL 47 47G3B1 1181028SW ALLSN 250C 250C20 03013GL THREAD CRACKED B E5WRO OTHER O OTHER NRNOT REPORTED 1 GL218548F 6507 CRACK LIKE INDICATION DETECTED IN THREAD AREA WHICH EXCEEDS 10 PERCENT. EDDY CURRENT INSPECTION USED. 1G71 3O3 U 2H3 E4CE 20040223001542004022300154SO 2004 2 23 2004FA0000065 120031204G7602ALCON93882 CONTROL CABLE PIPER PA24 PA24250 7102404SO LYC O540 O540A1D5 41532EA MIXTURE MISROUTED D O OTHER O OTHER NRNOT REPORTED 1 WP097369P 242549 L385740 MIXTURE CONTROL CABLE SECURED AND/OR ROUTED INCORRECTLY WHEN MIXTURE CONTROL CABLE WAS REPLACED AND/OR LUBED. WHEN THE CABLE CAME IN CONTACT WITH NOSE GEAR EXTENSION DURING FINAL APPROACH TO RUNWAY. THE NOSE GEAR ASSEMBLY CAUGHT THE MIXTURE CONTROL CABLE SOMEWHERE BETWEEN THE FIREWALL AND CARBURETOR PULLING THE MIXTURE CONTROL CABLE DOWN. SHUTTING OFF THE MIXTURE AT THE CARBURETOR WITH ENOUGH FORCE TO BRAKE THE STOP ON THE MIXTURE CONTROL ARM OF THE CARBURETOR. CORRECTED BY ROUTING MIXTURE CONTROL CABLE CORRECTLY AND PERFORMING GEAR RETRACTION CHECKING OPERATION. 1L71 3O3 O 1A15 E295 20040223001552004022300155 2004 2 23 2004FA0000066 420031228G2561P0201GA12 LIFE VEST CELL FAILED B KQ1RK NONE L NO TEST ININSP/MAINT 1 EA07 INDIVIDUAL FLOAT DEVICE CELL TESTED AND FAILED MFG RECOMMENDED PRESSURE TEST. DOM: OCT 1979 20040223001562004022300156SW 2004 2 23 2004FA0000067 120031223G632047620991 HOUSING BELL 47 47G3B1 1181028SW ALLSN 250C 250C20 03013GL TRANSMISSION CRACKED B E5WRO OTHER O OTHER NRNOT REPORTED 1 GL218548F 6507 CRACK-LIKE INDICATION DETECTED AT FLUID HOLE AREA. FP INSPECTION USED. 1G71 3O3 U 2H3 E4CE 20040223001622004022300162CE 2004 2 23 2004FA0000069 120031223G781089243 EXHAUST RISER CESSNA421 421C 2076016CE CONT O520 GTSIO520* 17032SO LT ENGINE DAMAGED D A UNSCHED LANDING RJ PARTIAL RPM/PWR LOSS WARNING INDICATION NRNOT REPORTED 1 WP11485DS 421C0459 272250R WHILE IN IFR FLIGHT, PILOT REPORTED LOSS OF MANIFOLD PRESSURE AND EXHAUST GAS TEMPERATURE INSTRUMENTATION READINGS. HOWEVER MP STABILIZED AT LOWER THAN NORMAL READINGS. MADE PRECAUTIONARY LANDING AT CLOSEST AIRPORT, WHICH MET IFR MINIMUMS. TECH PRESSURE CHECKED THE EXHAUST SYSTEM AND FOUND A 2.5 INCH HOLE AT THE EXHAUST DATA PLATE ON LT INSIDE EXHAUST RISER. THIS WAS NOT VISIBLE WITHOUT MIRROR. CAUSE WAS POSSIBLY BECAUSE OF UNEVEN HEATING AND COOLING OF PIPE UNDER THE DATA PLATE. WHICH IS WELDED TO THE PIPE. SUGGEST THAT THE DATA PLATE BE WELDED ON THE OUTSIDE OF PIPE TO BETTER INSPECT. OR ELIMINATE DATA PLATE AND ELECTRONICALLY ETCH INFORMATION ON TO THE RISER, AS DONE ON SOME JET ENGINE PARTS. 1L72 3O3 O A7CE E7CE 20040223001652004022300165SO 2004 2 23 2004FA0000070 120031224G5511121CS100011 RIB MARSH S2F S2F3S 3951007SO GARRTTTPE331TPE331* 01514WP HORIZONTAL STAB CRACKED C K NONE O OTHER ININSP/MAINT 1 WP25422DF5151 154817 DURING 400 HR PROGRESSIVE INSP OF THE LT HORIZ STAB, CRACKS WERE FOUND AT THE LEADING EDGE RIBS OF THE HORIZ STAB AT STATIONS 66.108, 80.608, AND 95.108. CRACKS WERE NOTED WHERE THE RIBS ATTACH TO THE LEADING EDGE SKIN. THIS AC HAS A TT 5151.2 AND 1146.6 TIME SINCE CONVERTED TO A TURBOPROP POWERED FIRE FIGHTING AC. THE LT HORIZ SHOT DAMPER WAS REMOVED DURING TURBOPROP CONVERSION. IT WAS ORIGINALLY INSTALLED TO COUNTERACT THE ORIGINAL RADIAL ENGINE INSTALLATION 3 BLADED PROP HARMONIC VIBRATION AT 2300 RPM. CRACKING COULD BE CAUSED BY VIBRATION FROM TURBO PROP INSTALLATION. ACTUAL CAUSE OF CRACKING HAS YET TO BE DETERMINED. LT HORIZONTAL STABILIZER LE SKIN RIBS SHOULD BE INSPECTED FOR CRACKS. 2H72 4O3 TRTA51NM E2WE 20040223001702004022300170CE 2004 2 23 2004FA0000071 120031015G2720505243649 ARM BEECH 58 58 1152740CE CONT O520 IO520CB 17032SO RUDDER PEDAL CRACKED D O OTHER O OTHER NRNOT REPORTED 1 SO05210CH7523 TH1067 PILOT WAS REMOVING RUDDER PEDAL GUST LOCK AND STATED THE TOP OF THE PEDAL (JUST FELL OFF). PEDAL ARM HAD SEPARATED NEAR THE TOP END. CROSS SECTION AREA, AT THE POINT OF SEPARATION IS AN (H) PATTERN. A PRE-EXISTING CRACK WAS EVIDENT BY ITS DARK COLOR AS OPPOSED TO THE BRIGHT CLEAN AREA OF THE RECENT CRACK AREA. PRE-EXISTING CRACK COVERAGE IS APPROXIMATELY 25 PERCENT OF THE (H) CROSS SECTION. 1L72 3O3 O 3A16 E5CE 20040223001832004022300183CE 2004 2 23 2004FA0000074 120031219G29103A0900002 LINE CESSNA185 A185F 2072821CE HYD SYSTEM CRACKED E O OTHER KJ FLUID LOSS WARNING INDICATION APAPPROACH 1 AL056590E 18504058 12/19/03 AIRCRAFT ENCOUNTERED UNEXPECTED TURBULENT AIR, POSSIBLE WINDSHEAR. THE FORCES ACTING ON THE AIRFRAME CAUSED THIS 3.88 INCH HYDRAULIC LINE TO FRACTURE. THE LINE CONNECTS TO A BULKHEAD ON ONE END AND TO A TEE ON THE OTHER. FROM THE TEE, IT CONNECTS TO A LENGTHY LINE THAT RUNS THROUGH THE FORWARD SPREADER BAR. IT APPEARS TO BE THE MOVEMENT OF THE LONGER LINE THAT ACTED ON THE FAILED LINE CAUSING IT TO FRACTURE AT THE BULKHEAD. SUBSEQUENTLY, HYDRAULIC OIL WAS PUMPED FROM THE SYSTEM AS PRESSURE DROPPED AND THE PUMP ATTEMPTED TO MAINTAIN PRESSURE. TROUBLESHOOTING EFFORTS ALSO ASSISTED IN DEPLETING THE HYDRAULIC FLUID RESERVOIR. THE AIRCRAFT LANDED WITHOUT INCIDENT ON THE GRASS ADJACENT TO THE RUNWAY. 1H71 3O 3A24 20040223001962004022300196CE 2004 2 23 2004FA0000075 120031214G8097S15771 CONTACTOR CESSNA182 R182 2072734CE LYC O540 O540J3C5 41532EA MCAULY2D34C B2D34C214 GL STARTER SHORTED D O OTHER O OTHER NRNOT REPORTED 1 EA214702R20 R18200605 L2414236A 27025K A NEW LIGHT WEIGHT STARTER WAS INSTALLED WHEN THE EXISTING STARTER FAILED. THE STARTER CONTACTOR WELDS ITSELF TOGETHER AFTER ABOUT 15 STARTS. 2 NEW MFG CONTACTORS WERE INSTALLED AND HAD THE SAME RESULTS. A HEAVY DUTY CONTACTOR HAS BEEN INSTALLED IAW MFG SERVICE BULLETIN. THE SUSPICION IS THAT THE NEWER STARTERS DRAW SO MUCH MORE IN RUSH AMPERAGE WITH THE LARGER ENGINES CAUSING THE CONTACT TO WELD AND STICK. 1H71 3O3 ORT3A13 E295 5 CP7EA 20040225000222004022500022EA 2004 2 25 2004FA0000078 120031120G3213C3UF811 STRUT DHAV DHC3 DHC3 2800202EA PWA PT6 PT6A135 52043NE HARTZLHCB3T HCB3TN3 GL MLG FLOAT CRACKED D K NONE O OTHER ININSP/MAINT 1 AL05959PA 159 PCEPZ0016 BUA24456 LOWER END OF STRUT CRACKED BETWEEN INNER AND OUTER ATTACH LUGS (IN THE WEB) FROM BOTTOM OF STRUT UP .7500-1 INCH. THERE WERE NO ABNORMAL CIRCUMSTANCES THAT CAUSED THE CRACK. THE CRACK WAS VERY OBVIOUS, VIEW WAS UNOBSTRUCTED AND EASILY DETECTED DURING 100 HOUR INSP. DO NOT THINK THERE IS ANY WAY TO PREVENT THIS KIND OF CRACK. 1H71 3R4 T A815 E4EA 6 CP15EA 20040225000352004022500035EA 2004 2 25 2004FA0000082 220030701G7322105217MP45PA CARBURETOR CESSNA172 172N 2072434CE LYC O320 O320D2J 41508EA ENGINE FAILED D O OTHER O OTHER NRNOT REPORTED 1 WP276288D 457 17272694 L1384639A CARBURETOR FAILED AFTER 457.6 HOURS. ENGINE WAS INSTALLED AUG 6, 2002. PROBABLE CAUSE OF FAILURE; REPAIRED AS CHEAPLY AS POSSIBLE. WARRANTY EXPIRED NO INSTALLATION TIME BAD ATTITUDE. 1H71 3O3 ONT3A12 E274 20040225000362004022500036CE 2004 2 25 2004FA0000083 120030630G321122411001 FITTING CESSNA172 172RG 2072438CE LYC O360 O360F1A6 41514EA MLG CRACKED D K NONE O OTHER ININSP/MAINT 1 WP276464R 172RG0184 L2878136A FITTING CRACKED ON IB SIDE. DISCOVERED ON 100 HOUR INSPECTION. NO RECOMMENDATION, EXCEPT, CLOSE INSPECTION, ONE TIME INSPECTION ANNUALLY. 1H71 3O3 O 3A17 E286 20040225000372004022500037EA 2004 2 25 2004FA0000084 220030701G7322105267 CARBURETOR CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA ENGINE LEAKING D K NONE K FLUID LOSS ININSP/MAINT 1 WP276439M 15284727 21906625 FUEL LEAKING AT PRODUCTION BREAK. LACK OF QUALITY CONTROL AT OVERHAUL. 1H71 3O3 ONT3A19 E223 20040225000382004022500038SO 2004 2 25 2004FA0000085 220031205G7414 IMPULSE COUPLINGSLICK CESSNA188 T188C 2073012CE CONT O520 TSIO520* 17040SO MAGNETOR LOOSE D O OTHER O OTHER NRNOT REPORTED 1 NM059700J 96082264 T18803840T IMPULSE COUPLING RIVET BECAME LOOSE IN HUB, ALLOWING INTERFERENCE BETWEEN PAWL AND MAGNETO HOUSING. PAWL HAD WORN THROUGH HOUSING, CRACKING THE MOUNTING FLANGE. 1L71 3O3 O A9CE E8CE 20040225000392004022500039EA 2004 2 25 2004FA0000086 120031227G3213190503 AXLE CNDAIRCL600 CL6002B16 1900305EA GE CF34 CF34* NE LT MLG FLAKING B WVERK NONE O OTHER ININSP/MAINT 1 EA09314FX 5372 WHEN REMOVING AND REPLACING OB BRAKE ASSEMBLY ON LT MLG. THE AXLE WAS FOUND TO HAVE CHROME FLAKING OFF. MFG EVALUATE.(EA09200401322) 2L72 4F4 FRTA21EA E15NE 20040225000402004022500040CE 2004 2 25 2004FA0000087 120031222G2400CM358950 MASTER SWITCH CESSNA441 441 2076020CE GARRTTTPE331TPE331* 01514WP COCKPIT DESTROYED D O OTHER O OTHER NRNOT REPORTED 1 SO063NC 7879 4410238 AT APPROXIMATELY FIFTY MINUTES INTO THE ONE HOUR FLIGHT, THE CREW STARTED TO NOTICE SLIGHT AVIONICS PROBLEMS ON THE COPILOTS SIDE. SMOKE THEN STARTED TO EMERGE FROM THE RT AVIONICS MASTER SWITCH BREAKER. THE CREW WAS UNABLE TO PHYSICALLY TURN OFF THE SWITCH. SOON THE SMOKE STOPPED AND ALL AVIONICS POWERED BY THAT SWITCH FAILED. THE AC LANDED WITH NO FURTHER PROBLEMS. MAINTENANCE REMOVED DEFECTIVE SWITCH AND DISASSEMBLE TO FIND THE MAIN WIRE FROM THE LINE SIDE HAD COME OFF CAUSING THE POWER TO FIND ITS WAY THROUGH THE SPRING INSIDE THE SWITCH UNTIL ITS FINAL FAILURE. 1L72 3T3 TRTA28CE E2WE 20040225000512004022500051SO 2004 2 25 2004FA0000089 120031015G324460064PLY TIRE PIPER PA28 PA28R200 7102811SO LYC O360 IO360A1A 41514EA MLG DEFECTIVE D BSYAK NONE O OTHER ININSP/MAINT 1 EA1733142 28R7535126 DURING PREFLIGHT A LARGE BUBBLE WAS FOUND ON THE SIDEWALL OF THE TIRE, NEAR THE TREAD AREA. THE BUBBLE WAS APPROX 5 INCHES, 1 INCH WIDE, AND STUCK ABOUT .5000 INCH. THE TIRE WAS REFORMED TO SPECIALTY TIRE CO FOR EVALUATION. 1L71 3O3 O 2A13 1E10 20040225000542004022500054NM 2004 2 25 2004FA0000090 120031212G5720 STIFFENER UNIVAR415 415CD 0420304NM CONT C75 C75* 17005SO CENTER WING DAMAGED D O OTHER O OTHER NRNOT REPORTED 1 GL0799780 2403 10058612R IN COMPLIANCE WITH AD, INSPECTED WING CENTER SECTION IAW SB AND AC. FOUND MINOR CORROSION IN RT WING CENTER SECTION ON FIRST STIFFENER AHEAD OF REAR SPAR IB, ITEM. REPLACED STIFFENER. FOUND DAMAGED STIFFENER IB FRONT OF MAIN SPAR, ITEM. REPLACED STIFFENER. REPAIRED TWO CRACKS IN BOTTOM SKIN IB BEHIND FRONT SPAR WITH PATCH 4 INCHES X 5 INCHES RIVETED, ITEM. REPAIRED MINOR SKIN DAMAGE TO LT GEAR OPENING WITH 3 INCHES X 4 INCH PATCH RIVETED, ITEM. REPAIRED SMALL SKIN CRACK WITH 2 INCH X 2 INCH PATCH RIVETED, ITEM E. 1L71 3O3 O A718 E233 20040225000552004022500055SO 2004 2 25 2004FA0000091 220030825G8520 PISTON CESSNA182 182R 2072731CE CONT O470 O470U 17026SO ENGINE FAILED D O OTHER O OTHER NRNOT REPORTED 1 WP239815H600 18268044 THE PISTON WAS INSTALLED NEW AT TIME OF MAJOR OVERHAUL. ONE SIDE OF PISTON SKIRT, AT LOWER SCRAPER RING BROKE AWAY AND BECAME SMALL CHUNKS OF ALUMINUM, AND RING PIECES IN THE OIL PAN. THE PROBLEM WAS DETECTED BY APPROX 5 EACH. .020 X .040 PIECES OF CAST ALUMINUM IN THE CUT OPEN OIL FILTER. NO OTHER INDICATION OF A PROBLEM. BY CHANCE AN OIL ANALYSIS HAD BEEN TAKEN DURING THIS SAME OIL CHANGE, THE RESULTS CAME BACK (NORMAL AND OK). 1L71 3O3 ONT3A13 E273 20040225000592004022500059CE 2004 2 25 2004FA0000096 120030525G3220 BEARING CESSNA CESSNA310 310Q 2074242CE NLG FAILED D A UNSCHED LANDING P NO WARNING INDICATION LDLANDING 1 SO153310D 310Q0630 NOSE GEAR STRUT JAMMED AT NORMAL EXTENSION. ON RETRACTION NOSE GEAR JAMS ON NOSE GEAR DOOR HINGES AND CAUSES NOSE GEAR BELLCRANK TO BREAK. ACTUAL PROBLEM IS DUE TO STRUT UPPER BEARING FAILURE, BUT COULD EASILY BE MISDIAGNOSED AS A DEFECTIVE BELLCRANK. IT IS VERY DIFFICULT TO DETECT THIS FAILURE BEFORE FLIGHT. I BELIEVE THAT AN AD SHOULD BE ISSUED TO CHANGE ALL NOSE STRUT UPPER BEARINGS AND INCLUDE A LIFE LIMIT TO THE PART. THIS IS A SIMILAR FAILURE TO A CURRENT AD ON THIS MODEL OF MAIN GEAR STRUT UPPER BEARING FAILURE. 1L72 3O 3A10 20040225000732004022500073CE 2004 2 25 2004FA0000098 120031122G7603363800611 THROTTLE CABLE BEECH 35 S35 1151532CE CONT O520 IO520BB 17032SO ENGINE INOPERATIVE G O OTHER F FLT CONT AFFECTED LDLANDING 1 EA05277RB D7473 DURING LANDING PILOT REPORTED THAT HE COULD NOT RETARD THROTTLE. SUSPECT BEARINGS INSIDE CABLE ARE FREEZING UP. REMOVED AND REPLACED CABLE ASSY. 1L71 3O3 O 3A15 E5CE 20040225000752004022500075CE 2004 2 25 2004FA0000099 120031221G24978824V2LA CONTACTOR CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA RELAY FAILED C O OTHER O OTHER NRNOT REPORTED 1 WP09296SP 172S9481 RELAY, CONTACTOR FAILS UNDER LOAD ACCROSS TERMINALS. CAUSE IS CONTACTOR NOT DESIGNED TO HANDLE CONTINOUS LOAD, (CURRENT). SEVERAL FAILURES NOTED IN THE PAST. MFG WILL NOT ADDRESS THE PROBLEM. SEVERAL OCCURRENCES NOTED IN LAST 3 YEARS. 1H71 3O3 ONT3A12 1E10 20040225000772004022500077CE 2004 2 25 2004FA0000100 120031209G2497X610007 CONTACTOR CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA RELAY FAILED D O OTHER O OTHER NRNOT REPORTED 1 WP09936GW 172S9036 RELAY, CONTACTOR FAILED UNDER LOAD ACROSS TERMINALS. CAUSE IS CONTACTOR NOT DESIGNED TO HANDLE CONTINOUS LOAD, (CURRENT). SEVERAL FAILURES NOTED IN PAST. 1H71 3O3 ONT3A12 1E10 20040217001662004021700166CE 2004 2 17 2004FA0000103 120031229G27205052432626 ARM BEECH 90 T44A CE RUDDER PEDAL CRACKED M K NONE O OTHER ININSP/MAINT 1 SW17 15341 033 (BUNO 60981) DYE TESTING REVEALED A CRACK IN THE PILOT SIDE RIGHT RUDDER PEDAL ASSEMBLY ARM. THE FAILED RUDDER PEDAL ASSEMBLY WAS MAGNESIUM, BUT WAS REPLACED WITH AN ALUMINUM ASSEMBLY (SAME PART NUMBER). THE TESTING WAS PERFORMED AS PART OF A NAVY T-44A FLEET WIDE INSPECTION AFTER 4 RUDDER PEDALS FAILED DURING GROUND OPERATIONS IN A 3 MONTH PERIOD. THE CRACK FOUND ON THIS AIRCRAFT WAS ONE OF 16 DISCOVERED IN A FLEET OF 54 AIRCRAFT. 1L72 3T EXPA1L72 20040225000642004022500064CE 2004 2 25 2004FA0000104 120031229G27205052432625 ARM BEECH 90 T44A CE RUDDER PEDAL CRACKED M K NONE P NO WARNING INDICATION ININSP/MAINT 1 SW17 16292 014 (BUNO 60852) DYE TESTING REVEALED A CRACK IN THE PILOT SIDE LEFT RUDDER PEDAL ASSEMBLY ARM. THE FAILED RUDDER PEDAL ASSEMBLY WAS MAGNESIUM, BUT WAS REPLACED WITH AN ALUMINUM ASSEMBLY (SAME PART NUMBER). THE TESTING WAS PERFORMED AS PART OF A NAVY T-44A FLEET WIDE INSPECTION AFTER 4 RUDDER PEDALS FAILED DURING GROUND OPERATIONS IN A 3 MONTH PERIOD. THE CRACK FOUND ON THIS AIRCRAFT WAS ONE OF 16 DISCOVERED IN A FLEET OF 54 AIRCRAFT. 1L72 3T EXPA1L72 20040225000702004022500070CE 2004 2 25 2004FA0000105 120031229G27205052432625 ARM BEECH 90 T44A CE RUDDER PEDAL CRACKED M K NONE P NO WARNING INDICATION ININSP/MAINT 1 SW17 15791 039 (BUNO 61057) DYE TESTING REVEALED A CRACK IN THE PILOT SIDE LEFT (AS APPROPRIATE) RUDDER PEDAL ASSEMBLY ARM. THE FAILED RUDDER PEDAL ASSEMBLY WAS MAGNESIUM, BUT WAS REPLACED WITH AN ALUMINUM ASSEMBLY (SAME PART NUMBER). THE TESTING WAS PERFORMED AS PART OF A NAVY T-44A FLEET WIDE INSPECTION AFTER 4 RUDDER PEDALS FAILED DURING GROUND OPERATIONS IN A 3 MONTH PERIOD. THE CRACK FOUND ON THIS AIRCRAFT WAS ONE OF 16 DISCOVERED IN A FLEET OF 54 AIRCRAFT. 1L72 3T EXPA1L72 20040225000722004022500072CE 2004 2 25 2004FA0000106 120031229G27205052432625 ARM BEECH 90 T44A CE RUDDER PEDAL CRACKED M K NONE P NO WARNING INDICATION ININSP/MAINT 1 SW17 15677 047 (BUNO 61065) DYE TESTING REVEALED A CRACK IN THE PILOT SIDE LEFT RUDDER PEDAL ASSEMBLY ARM. THE FAILED RUDDER PEDAL ASSEMBLY WAS MAGNESIUM, BUT WAS REPLACED WITH AN ALUMINUM ASSEMBLY (SAME PART NUMBER). THE TESTING WAS PERFORMED AS PART OF A NAVY T-44A FLEET WIDE INSPECTION AFTER 4 RUDDER PEDALS FAILED DURING GROUND OPERATIONS IN A 3 MONTH PERIOD. THE CRACK FOUND ON THIS AIRCRAFT WAS ONE OF 16 DISCOVERED IN A FLEET OF 54 AIRCRAFT. 1L72 3T EXPA1L72 20040225000742004022500074CE 2004 2 25 2004FA0000107 120031229G27205052432626 ARM BEECH 90 T44A CE RUDDER PEDAL CRACKED M K NONE P NO WARNING INDICATION ININSP/MAINT 1 SW176106615210 048 (BUNO 61066) DYE TESTING REVEALED A CRACK IN THE PILOT SIDE RIGHT RUDDER PEDAL ASSEMBLY ARM. THE FAILED RUDDER PEDAL ASSEMBLY WAS MAGNESIUM, BUT WAS REPLACED WITH AN ALUMINUM ASSEMBLY (SAME PART NUMBER). THE TESTING WAS PERFORMED AS PART OF A NAVY T-44A FLEET WIDE INSPECTION AFTER 4 RUDDER PEDALS FAILED DURING GROUND OPERATIONS IN A 3 MONTH PERIOD. THE CRACK FOUND ON THIS AIRCRAFT WAS ONE OF 16 DISCOVERED IN A FLEET OF 54 AIRCRAFT. 1L72 3T EXPA1L72 20040225000682004022500068CE 2004 2 25 2004FA0000108 120031229G27205052432625 ARM BEECH 90 T44A CE RUDDER PEDAL CRACKED M K NONE P NO WARNING INDICATION ININSP/MAINT 1 SW17 15664 035 (BUNO 60983) DYE TESTING REVEALED A CRACK IN THE PILOT SIDE LEFT RUDDER PEDAL ASSEMBLY ARM. THE FAILED RUDDER PEDAL ASSEMBLY WAS MAGNESIUM, BUT WAS REPLACED WITH AN ALUMINUM ASSEMBLY (SAME PART NUMBER). THE TESTING WAS PERFORMED AS PART OF A NAVY T-44A FLEET WIDE INSPECTION AFTER 4 RUDDER PEDALS FAILED DURING GROUND OPERATIONS IN A 3 MONTH PERIOD. THE CRACK FOUND ON THIS AIRCRAFT WAS ONE OF 16 DISCOVERED IN A FLEET OF 54 AIRCRAFT. 1L72 3T EXPA1L72 20040225000822004022500082CE 2004 2 25 2004FA0000109 120031229G27205052432625 ARM BEECH 90 T44A CE RUDDER PEDAL BROKEN M D RETURN TO BLOCK O OTHER TXTAXI/GRND HDL 1 SW17 15341 033 (BUNO 60981) WHILE REMOVING RUDDER CONTROL LOCK DURING PREFLIGHT, THE PILOT SIDE LEFT RUDDER PEDAL BROKE OFF. THE FAILED RUDDER PEDAL ASSEMBLY WAS MAGNESIUM, BUT WAS REPLACED WITH AN ALUMINUM ASSEMBLY (SAME PART NUMBER). THIS WAS ONE OF SEVERAL FAILURES RESULTING IN A NAVY T-44A FLEET WIDE INSPECTION. 1L72 3T EXPA1L72 20040225000662004022500066CE 2004 2 25 2004FA0000110 120031229G27205052432625 ARM BEECH 90 T44A CE RUDDER PEDAL CRACKED C K NONE P NO WARNING INDICATION ININSP/MAINT 1 SW17 15522 017 (BUNO 60855) DYE TESTING REVEALED A CRACK IN THE PILOT SIDE LEFT RUDDER PEDAL ASSEMBLY ARM. THE FAILED RUDDER PEDAL ASSEMBLY WAS MAGNESIUM, BUT WAS REPLACED WITH AN ALUMINUM ASSEMBLY (SAME PART NUMBER). THE TESTING WAS PERFORMED AS PART OF A NAVY T-44A FLEET WIDE INSPECTION AFTER 4 RUDDER PEDALS FAILED DURING GROUND OPERATIONS IN A 3 MONTH PERIOD. THE CRACK FOUND ON THIS AIRCRAFT WAS ONE OF 16 DISCOVERED IN A FLEET OF 54 AIRCRAFT. 1L72 3T EXPA1L72 20040225000812004022500081CE 2004 2 25 2004FA0000111 120031229G27205052432625 ARM BEECH 90 T44A CE RUDDER PEDAL CRACKED M K NONE P NO WARNING INDICATION ININSP/MAINT 1 SW17 15562 038 (BUNO 60986) DYE TESTING REVEALED A CRACK IN THE PILOT SIDE LEFT RUDDER PEDAL ASSEMBLY ARM. THE FAILED RUDDER PEDAL ASSEMBLY WAS MAGNESIUM, BUT WAS REPLACED WITH AN ALUMINUM ASSEMBLY (SAME PART NUMBER). THE TESTING WAS PERFORMED AS PART OF A NAVY T-44A FLEET WIDE INSPECTION AFTER 4 RUDDER PEDALS FAILED DURING GROUND OPERATIONS IN A 3 MONTH PERIOD. THE CRACK FOUND ON THIS AIRCRAFT WAS ONE OF 16 DISCOVERED IN A FLEET OF 54 AIRCRAFT. 1L72 3T EXPA1L72 20040225000792004022500079CE 2004 2 25 2004FA0000112 120031229G27205052432625 ARM BEECH 90 T44A CE RUDDER PEDAL CRACKED M K NONE P NO WARNING INDICATION ININSP/MAINT 1 SW17 14058 055 (BUNO 61073) DYE TESTING REVEALED A CRACK IN THE PILOT SIDE LEFT RUDDER PEDAL ASSEMBLY ARM. THE FAILED RUDDER PEDAL ASSEMBLY WAS MAGNESIUM, BUT WAS REPLACED WITH AN ALUMINUM ASSEMBLY (SAME PART NUMBER). THE TESTING WAS PERFORMED AS PART OF A NAVY T-44A FLEET WIDE INSPECTION AFTER 4 RUDDER PEDALS FAILED DURING GROUND OPERATIONS IN A 3 MONTH PERIOD. THE CRACK FOUND ON THIS AIRCRAFT WAS ONE OF 16 DISCOVERED IN A FLEET OF 54 AIRCRAFT. 1L72 3T EXPA1L72 20040225000802004022500080CE 2004 2 25 2004FA0000113 120031229G27205052432625 ARM BEECH 90 T44A CE RUDDER PEDAL CRACKED M K NONE P NO WARNING INDICATION ININSP/MAINT 1 SW176107613475 058 (BUNO 61076) DYE TESTING REVEALED A CRACK IN THE PILOT SIDE LEFT RUDDER PEDAL ASSEMBLY ARM. THE FAILED RUDDER PEDAL ASSEMBLY WAS MAGNESIUM, BUT WAS REPLACED WITH AN ALUMINUM ASSEMBLY (SAME PART NUMBER). THE TESTING WAS PERFORMED AS PART OF A NAVY T-44A FLEET WIDE INSPECTION AFTER 4 RUDDER PEDALS FAILED DURING GROUND OPERATIONS IN A 3 MONTH PERIOD. THE CRACK FOUND ON THIS AIRCRAFT WAS ONE OF 16 DISCOVERED IN A FLEET OF 54 AIRCRAFT. 1L72 3T EXPA1L72 20040225000622004022500062CE 2004 2 25 2004FA0000114 120031229G27205052432625 ARM BEECH 90 C90 1152913CE RUDDER PEDAL CRACKED M K NONE P NO WARNING INDICATION ININSP/MAINT 1 SW17 16868 008 (BUNO 60846) DYE TESTING REVEALED A CRACK IN THE PILOT SIDE LEFT RUDDER PEDAL ASSEMBLY ARM. THE FAILED RUDDER PEDAL ASSEMBLY WAS MAGNESIUM, BUT WAS REPLACED WITH AN ALUMINUM ASSEMBLY (SAME PART NUMBER). THE TESTING WAS PERFORMED AS PART OF A NAVY T-44A FLEET WIDE INSPECTION AFTER 4 RUDDER PEDALS FAILED DURING GROUND OPERATIONS IN A 3 MONTH PERIOD. THE CRACK FOUND ON THIS AIRCRAFT WAS ONE OF 16 DISCOVERED IN A FLEET OF 54 AIRCRAFT. FOR ADDITIONAL INFORMATION CONTACT LCDR KEITH KINTZLEY, VT-31 SAFETY OFFICER, (361) 961-3210, KEITH.KINTZLEY@NRS.NAVY.MIL OR GARY GOORIS, QUALITY ASSURANCE MANAGE, (361) 961-3226, GARY.GOORIS@L-3COM.COM.(( 1L72 3T 3A20 20040225000762004022500076CE 2004 2 25 2004FA0000115 120031229G27205052432625 ARM BEECH 90 T44A CE RUDDER PEDAL CRACKED M K NONE P NO WARNING INDICATION ININSP/MAINT 1 SW17 12461 053 (BUNO 61071) DYE TESTING REVEALED A CRACK IN THE PILOT SIDE LEFT RUDDER PEDAL ASSEMBLY ARM. THE FAILED RUDDER PEDAL ASSEMBLY WAS MAGNESIUM, BUT WAS REPLACED WITH AN ALUMINUM ASSEMBLY (SAME PART NUMBER). THE TESTING WAS PERFORMED AS PART OF A NAVY T-44A FLEET WIDE INSPECTION AFTER 4 RUDDER PEDALS FAILED DURING GROUND OPERATIONS IN A 3 MONTH PERIOD. THE CRACK FOUND ON THIS AIRCRAFT WAS ONE OF 16 DISCOVERED IN A FLEET OF 54 AIRCRAFT. 1L72 3T EXPA1L72 20040225000612004022500061CE 2004 2 25 2004FA0000121 120031229G27205052432626 ARM BEECH 90 C90 1152913CE RUDDER PEDAL CRACKED M K NONE P NO WARNING INDICATION ININSP/MAINT 1 SW176084414509 006 DYE TESTING REVEALED A CRACK IN THE PILOT SIDE RIGHT RUDDER PEDAL ASSEMBLY ARM. THE FAILED RUDDER PEDAL ASSEMBLY WAS MAGNESIUM, BUT WAS REPLACED WITH AN ALUMINUM ASSEMBLY (SAME PART NUMBER). THE TESTING WAS PERFORMED AS PART OF A NAVY T-44A FLEET WIDE INSPECTION AFTER 4 RUDDER PEDALS FAILED DURING GROUND OPERATIONS IN A 3 MONTH PERIOD. THE CRACK FOUND ON THIS AIRCRAFT WAS ONE OF 16 DISCOVERED IN A FLEET OF 54 AIRCRAFT. 1L72 3T 3A20 20040225000632004022500063CE 2004 2 25 2004FA0000123 120031229G27205052432626 ARM BEECH 90 C90 1152913CE RUDDER PEDAL CRACKED M K NONE P NO WARNING INDICATION ININSP/MAINT 1 SW176084715948 009 (BUNO 60847) DYE TESTING REVEALED A CRACK IN THE PILOT SIDE RT RUDDER PEDAL ASSEMBLY ARM. THE FAILED RUDDER PEDAL ASSEMBLY WAS MAGNESIUM, BUT WAS REPLACED WITH AN ALUMINUM ASSEMBLY (SAME PN). THE TESTING WAS PERFORMED AS PART OF A NAVY T-44A FLEET WIDE INSPECTION AFTER 4 RUDDER PEDALS FAILED DURING GROUND OPERATIONS IN A 3 MONTH PERIOD. THE CRACK FOUND ON THIS AIRCRAFT WAS ONE OF 16 DISCOVERED IN A FLEET OF 54 AIRCRAFT. FOR ADDITIONAL INFORMATION CONTACT LCDR KEITH KINTZLEY, VT-31 SAFETY OFFICER, (361) 961-3210, KEITH.KINTZLEY@NRS.NAVY.MIL OR GARY GOORIS, QUALITY ASSURANCE MANAGE, (361) 961-3226, GARY.GOORIS@L-3COM.COM. 1L72 3T 3A20 20040225000692004022500069CE 2004 2 25 2004FA0000124 120031229G27205052432625 ARM BEECH 90 T44A CE RUDDER PEDAL CRACKED M K NONE P NO WARNING INDICATION ININSP/MAINT 1 SW09 14829 036 (BUNO 60984) DYE TESTING REVEALED A CRACK IN THE PILOT SIDE LEFT RUDDER PEDAL ASSEMBLY ARM. THE FAILED RUDDER PEDAL ASSEMBLY WAS MAGNESIUM, BUT WAS REPLACED WITH AN ALUMINUM ASSEMBLY (SAME PART NUMBER). THE TESTING WAS PERFORMED AS PART OF A NAVY T-44A FLEET WIDE INSPECTION AFTER 4 RUDDER PEDALS FAILED DURING GROUND OPERATIONS IN A 3 MONTH PERIOD. THE CRACK FOUND ON THIS AIRCRAFT WAS ONE OF 16 DISCOVERED IN A FLEET OF 54 AIRCRAFT. 1L72 3T EXPA1L72 20040225000782004022500078CE 2004 2 25 2004FA0000125 120031229G27205052432626 ARM BEECH 90 T44A CE RUDDER PEDAL CRACKED M K NONE P NO WARNING INDICATION ININSP/MAINT 1 SW17 12461 053 (BUNO 61071) DYE TESTING REVEALED A CRACK IN THE PILOT SIDE RIGHT RUDDER PEDAL ASSEMBLY ARM. THE FAILED RUDDER PEDAL ASSEMBLY WAS MAGNESIUM, BUT WAS REPLACED WITH AN ALUMINUM ASSEMBLY (SAME PART NUMBER). THE TESTING WAS PERFORMED AS PART OF A NAVY T-44A FLEET WIDE INSPECTION AFTER 4 RUDDER PEDALS FAILED DURING GROUND OPERATIONS IN A 3 MONTH PERIOD. THE CRACK FOUND ON THIS AIRCRAFT WAS ONE OF 16 DISCOVERED IN A FLEET OF 54 AIRCRAFT. 1L72 3T EXPA1L72 20040225000842004022500084CE 2004 2 25 2004FA0000127 120031210G27205052432626 ARM BEECH 90 T44A CE RUDDER PEDAL BROKEN M D RETURN TO BLOCK O OTHER TXTAXI/GRND HDL 1 SW17 14459 052 (BUNO 61070) WHILE REMOVING RUDDER CONTROL LOCK DURING PREFLIGHT, THE PILOT SIDE RIGHT RUDDER PEDAL BROKE OFF. THE FAILED RUDDER PEDAL ASSEMBLY WAS MAGNESIUM, BUT WAS REPLACED WITH AN ALUMINUM ASSEMBLY (SAME PART NUMBER). THIS WAS ONE OF SEVERAL FAILURES RESULTING IN A NAVY T-44A FLEET WIDE INSPECTION. 1L72 3T EXPA1L72 20040225000832004022500083CE 2004 2 25 2004FA0000128 120031217G27205052432626 ARM BEECH 90 T44A CE RUDDER PEDAL BROKEN M D RETURN TO BLOCK O OTHER TXTAXI/GRND HDL 1 SW176098615562 038 (BUNO 60986) AFTER CONDUCTING STANDARD BRAKE CHECK WITH LINEMAN FOLLOWING ENGINE STARTS, THE PILOT SIDE RIGHT RUDDER PEDAL BROKE OFF AS PILOT ATTEMPTED TO SET PARKING BRAKE. THE FAILED RUDDER PEDAL ASSEMBLY WAS MAGNESIUM, BUT WAS REPLACED WITH AN ALUMINUM ASSEMBLY (SAME PART NUMBER). THIS WAS ONE OF SEVERAL FAILURES RESULTING IN A NAVY T-44A FLEET WIDE INSPECTION. 1L72 3T EXPA1L72 20040225000962004022500096SO 2004 2 25 2004FA0000131 220031030G7414M3050 IMPULSE COUPLINGSLICK BEECH 36 A36 1151604CE CONT O550 IO550B SO RT MAGNETO BROKEN D O OTHER O OTHER NRNOT REPORTED 1 EA238201T1282 93080059 E2838 675866 THE IMPULSE COUPLING SPRING WAS BROKEN IN 4 PIECES. THE MAGNETO TIMING ONLY SHOWED THE RT MAGNETO TO ONLY BE OFF BY 4 DEGREES. (EA23200404783) 1L71 3O3 O 3A15 E3SO 20040227000622004022700062CE 2004 2 27 2004FA0000141 120031105G2910 LINE CESSNA650 650 2076802CE HYDRAULIC SYSTEMCHAFED E O OTHER K FLUID LOSS LDLANDING 1 SO1924237 6500102 ON LANDING OF THE AIRCRAFT, THE HYDRAULIC FAN PRESSURE LINE BURST WHICH RESULTED IN LOSS OF MAIN HYDRAULIC SYSTEM FLUID. AIRCRAFT RAN OFF THE END OF RUNWAY 5 AT AIRPORT. AIRCRAFT TURNED 90 DEGREES TO THE RT WHICH RESULTED IN THE LT WING TIP TO DIG INTO THE SAND IN THE EMERGENCY RUN OFF AREA BREAKING OFF WING TIP. BOTH ENGINES INGESTED A LOT OF SAND. 2L72 4F A9NM 20040227001002004022700100GL 2004 2 27 2004FA0000145 120031104G323019428030 LEG ASSY BLANCA17 1730A 1220433GL MLG CRACKED D O OTHER O OTHER NRNOT REPORTED 1 SW116601V2677 30294 A CRACK HAD FORMED, PREVIOUS TO INCIDENT, AROUND THE BUSHING BOSS ON THE INBOARD END OF THE MOUNT PORTION OF THE UPPER MAIN GEAR LEG. THE RESULT WAS THAT THE MAIN GEAR COLLAPSED IN THE OUTBOARD DIRECTION WHILE TURNING AIRCRAFT AROUND AT THE END OF THE RUNWAY. RECOMMEND THAT INSPECTION BE MADE AT CERTAIN TIME INTERVAL AND /OR IF HARD LANDING NOTED. GEAR REMOVAL REQUIRED FOR INSPECTION. 1L71 3O A18CE 20040217000852004021700085SO 2004 2 17 2004FA0000147 120030221G2140 HEATER PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA COCKPIT CONTAMINATED C O OTHER B SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 EA176530C 287890379 PILOT REPORTED SMOKE IN COCKPIT. INSPECTION FOUND HYDRAULIC FLUID ON CARPET COVERING HEATER DUCT. (EA17200405081) 1L71 3O3 O 2A13 E286 20040211001502004021100150GL 2004 2 11 2004FA0000150 320031015G6110C7409 GASKET CESSNA182 182T 2072703CE LYC O540 IO540* 41532EA MCAULY3D36C B3D36C431 GL PROP CYLINDER LEAKING B R5DRK NONE K FLUID LOSS ININSP/MAINT 1 SW09431AF 18281193 020981 RED DYE OIL LEAKAGE AT THE CYLINDER TO HUB ATTACH POINT. OIL IS LEAKING PAST THE CYLINDER GASKET TO THE ATTACHING SCREWS AND FOLLOWING THE THREADS OUT. ADDITIONAL SEALANT NEEDS TO BE ADDED TO THE SCREWS DURING INSTALLATION AND PARTICULAR ATTENTION SHOULD BE GIVEN TO TORQUING THE SCREWS TO ASSURE PROPER SEATING OF THE GASKET. (K) 1H71 3O3 ONT3A13 1E4 5 C 20040211001522004021100152GL 2004 2 11 2004FA0000151 320031016G6110C7409 GASKET CESSNA182 182T 2072703CE LYC O540 IO540* 41532EA MCAULY3D36C B3D36C431 GL PROP CYLINDER LEAKING C R5DRO OTHER K FLUID LOSS NRNOT REPORTED 1 SW09521AF215 18281194 020788 RED DYE OIL LEAKAGE AT THE CYLINDER TO HUB ATTACH POINT. OIL IS LEAKING PAST THE CYLINDER GASKET TO THE ATTACHING SCREWS AND FOLLOWING THE THREADS OUT. ADDITIONAL SEALANT NEEDS TO BE ADDED TO THE SCREWS DURING INSTALLATION AND PARTICULAR ATTENTION SHOULD BE GIVEN TO TORQUING THE SCREWS TO ASSURE PROPER SEATING OF THE GASKET. (K) 1H71 3O3 ONT3A13 1E4 5 C 20040211001542004021100154GL 2004 2 11 2004FA0000152 320031015G6110C7409 GASKET CESSNA182 182T 2072703CE LYC O540 IO540* 41532EA MCAULY3D36C B3D36C431 GL PROP CYLINDER LEAKING B R5DRO OTHER K FLUID LOSS NRNOT REPORTED 1 SW09252AF135 18281185 020731 RED DYE OIL LEAKAGE AT THE CYLINDER TO HUB ATTACH POINT. OIL IS LEAKING PAST THE CYLINDER GASKET TO THE ATTACHING SCREWS AND FOLLOWING THE THREADS OUT. ADDITIONAL SEALANT NEEDS TO BE ADDED TO THE SCREWS DURING INSTALLATION AND PARTICULAR ATTENTION SHOULD BE GIVEN TO TORQUING THE SCREWS TO ASSURE PROPER SEATING OF THE GASKET. (K) 1H71 3O3 ONT3A13 1E4 5 C 20040211001552004021100155GL 2004 2 11 2004FA0000153 320031015G6110C7409 GASKET CESSNA182 182T 2072703CE LYC O540 IO540* 41532EA MCAULY3D36C B3D36C431 GL PROP CYLINDER LEAKING B R5DRO OTHER K FLUID LOSS NRNOT REPORTED 1 SW09372AF215 18281191 020833 RED DYE OIL LEAKAGE AT THE CYLINDER TO HUB ATTACH POINT. OIL IS LEAKING PAST THE CYLINDER GASKET TO THE ATTACHING SCREWS AND FOLLOWING THE THREADS OUT. ADDITIONAL SEALANT NEEDS TO BE ADDED TO THE SCREWS DURING INSTALLATION AND PARTICULAR ATTENTION SHOULD BE GIVEN TO TORQUING THE SCREWS TO ASSURE PROPER SEATING OF THE GASKET. (K) 1H71 3O3 ONT3A13 1E4 5 C 20040211001572004021100157GL 2004 2 11 2004FA0000154 320031015G6110C7409 GASKET CESSNA182 182T 2072703CE LYC O540 IO540* 41532EA MCAULY3D36C B3D36C431 GL PROP CYLINDER LEAKING B R5DRO OTHER K FLUID LOSS NRNOT REPORTED 1 SW09811AF101 18281196 020725 RED DYE OIL LEAKAGE AT THE CYLINDER TO HUB ATTACH POINT. OIL IS LEAKING PAST THE CYLINDER GASKET TO THE ATTACHING SCREWS AND FOLLOWING THE THREADS OUT. ADDITIONAL SEALANT NEEDS TO BE ADDED TO THE SCREWS DURING INSTALLATION AND PARTICULAR ATTENTION SHOULD BE GIVEN TO TORQUING THE SCREWS TO ASSURE PROPER SEATING OF THE GASKET. (K) 1H71 3O3 ONT3A13 1E4 5 C 20040211001582004021100158GL 2004 2 11 2004FA0000155 320031015G6110C7409 GASKET CESSNA182 182T 2072703CE LYC O540 IO540* 41532EA MCAULY3D36C B3D36C431 GL PROP CYLINDER LEAKING B R5DRO OTHER K FLUID LOSS NRNOT REPORTED 1 SW09271AF286 18281188 020783 RED DYE OIL LEAKAGE AT THE CYLINDER TO HUB ATTACH POINT. OIL IS LEAKING PAST THE CYLINDER GASKET TO THE ATTACHING SCREWS AND FOLLOWING THE THREADS OUT. ADDITIONAL SEALANT NEEDS TO BE ADDED TO THE SCREWS DURING INSTALLATION AND PARTICULAR ATTENTION SHOULD BE GIVEN TO TORQUE THE SCREWS TO ASSURE PROPER SEATING OF THE GASKET. (K) 1H71 3O3 ONT3A13 1E4 5 C 20040211001782004021100178GL 2004 2 11 2004FA0000156 320031015G6110C7409 GASKET CESSNA182 182T 2072703CE LYC O540 IO540* 41532EA MCAULY3D36C B3D36C431 GL PROP CYLINDER LEAKING B R5DRO OTHER K FLUID LOSS NRNOT REPORTED 1 SW09382AF148 18281192 RED DYE OIL LEAKAGE AT THE CYLINDER TO HUB ATTACH POINT. OIL IS LEAKING PAST THE CYLINDER GASKET TO THE ATTACHING SCREWS AND FOLLOWING THE THREADS OUT. ADDITIONAL SEALANT NEEDS TO BE ADDED TO THE SCREWS DURING INSTALLATION AND PARTICULAR ATTENTION SHOULD BE GIVEN TO TORQUING THE SCREWS TO ASSURE PROPER SEATING OF THE GASKET. (K) 1H71 3O3 ONT3A13 1E4 5 C 20040211001792004021100179GL 2004 2 11 2004FA0000157 320031015G6110C7409 GASKET CESSNA182 182T 2072703CE LYC O540 O540* 41532EA MCAULY3D36C B3D36C431 GL PROP CYLINDER LEAKING B R5DRO OTHER K FLUID LOSS NRNOT REPORTED 1 SW09251AF151 18281184 020738 RED DYE OIL LEAKAGE AT THE CYLINDER TO HUB ATTACH POINT. OIL IS LEAKING PAST THE CYLINDER GASKET TO THE ATTACHING SCREWS AND FOLLOWING THE THREADS OUT. ADDITIONAL SEALANT NEEDS TO BE ADDED TOT HE SCREWS DURING INSTALLATION AND PARTICULAR ATTENTION SHOULD BE GIVEN TO TORQUING THE SCREWS TO ASSURE PROPER SEATING OF THE GASKET. (K) 1H71 3O3 ONT3A13 E295 5 C 20040211001802004021100180GL 2004 2 11 2004FA0000158 320031015G6110C7409 GASKET CESSNA182 182T 2072703CE LYC O540 IO540* 41532EA MCAULY3D36C B3D36C431 GL PROP CYLINDER LEAKING B R5DRO OTHER K FLUID LOSS NRNOT REPORTED 1 SW09522AF152 18281195 020742 RED DYE OIL LEAKAGE AT THE CYLINDER TO HUB ATTACH POINT. OIL IS LEAKING PAST THE CYLINDER GASKET TO THE ATTACHING SCREWS AND FOLLOWING THE THREADS OUT. ADDITIONAL SEALANT NEEDS TO BE ADDED TO THE SCREWS DURING INSTALLATION AND PARTICULAR ATTENTION SHOULD BE GIVEN TO TORQUING THE SCREWS TO ASSURE PROPER SEATING OF THE GASKET. (K) 1H71 3O3 ONT3A13 1E4 5 C 20040301000202004030100020CE 2004 3 1 2004FA0000159 120031231G521007110381 HINGE PIN CESSNA CESSNA150 150M 2071830CE CONT O200 O200* 17020SO CABIN DOOR BROKEN G O OTHER O OTHER NRNOT REPORTED 1 NE01714MG 15079277 DURING A 100 HOUR INSPECTION, THIS BROKEN DOOR HINGE PIN WAS FOUND. FIND MANY OF THESE PINS BROKEN.(K) (NE01200402925) 1H71 3O3 O 3A19 E252 20040301000212004030100021CE 2004 3 1 2004FA0000160 120031204G61201317651F ROD END BEECH 58 58 1152740CE CONT O550 IO550* SO PROP CONTROL WORN D O OTHER O OTHER NRNOT REPORTED 1 WP27870JA395 TH2036 THREE ROD END BEARINGS WORN, ONE ON EACH PROP CONTROL AT GOVERNOR, ONE ON THROTTLE. ONE WAS CLOSE TO FAILURE AND TO ONLY BEING RETAINED BY PN 100951S0632ZK LARGE AREA WASHER. 1L72 3O3 O 3A16 E3SO 20040301000352004030100035GL 2004 3 1 2004FA0000161 220030902G723023039791C COUPLING ALLSN 250C 250C20B 03013GL COMPRESSOR CRACKED B QD5RO OTHER O OTHER NRNOT REPORTED 1 NM07 CAC305250 DETECTED CRACK VIA VISUAL AND MPI INSPECTIONS DURING ROUTINE INSPECTION OF COMPRESSOR MODULE, COMPRESSOR ROTOR ASSEMBLY. DISASSEMBLED FOR INSPECTION OF FUTURE INSTALLATION. NOTED HEAVY FRETTING WEAR ON COUPLING ADAPTER OD TO IMPELLER ID FIT DIMENSION. THE CRACK EXTENDS APPROX 60 PERCENT OF THE OUTSIDE DIAMETER OF THE PART. THE CRACKING IS POSSIBLY DUE TO THE FRETTING WEAR ON THE ADAPTER OD. 3 U E4CE 20040301000362004030100036GL 2004 3 1 2004FA0000162 220030902G723023039791C COUPLING ALLSN 250C 250C20B 03013GL COMPRESSOR CRACKED B QD5RO OTHER O OTHER NRNOT REPORTED 1 NM07 CAC30525F DETECTED CRACK VIA VISUAL AND MPI INSPECTIONS DURING ROUTINE INSPECTION OF COMPRESSOR MODULE, COMPRESSOR ROTOR ASSEMBLY. DISASSEMBLED FOR INSPECTION OF FUTURE INSTALLATION. NOTED HEAVY FRETTING WEAR ON COUPLING ADAPTER OD TO IMPELLER ID FIT DIMENSION. THE CRACK EXTENDS APPROX 60 PERCENT OF THE OUTSIDE DIAMETER OF THE PART. THE CRACKING IS POSSIBLY DUE TO THE FRETTING WEAR ON THE ADAPTER OD. 3 U E4CE 20040217000872004021700087CE 2004 2 17 2004FA0000165 120030120G2120 DUCT BEECH 100 B100 1152919CE GARRTTTPE331TPE3315 01514WP ENVIRON SYST MELTED G O OTHER O OTHER NRNOT REPORTED 1 WP1145LU 6350 BE8 IN LATE JAN 1999, IN FLIGHT, THE TEMPERATURE CONTROL CIRCUIT BREAKER OPENED. AS A RESULT THE CREW EXPERIENCED AN OVERTEMP CONDITION OF THE ENVIRONMENTAL SYSTEM. THE ENVIRONMENTAL CONTROL WAS SELECTED OFF AND THE AIRCRAFT LANDED SAFELY. SUBSEQUENT INSPECTION SHOWED THAT THE ENVIRONMENTAL DUCTING UNDER THE RT CABIN FLOOR, AS WELL AS COAX CABLES FOR THE NAV RADIOS AND THE NR 2 COM HAD BEEN DAMAGED. A WIRE TO THE ELECTRIC HEAT RELAY WAS FOUND DAMAGED AND MISROUTED. ALL DAMAGED COMPONENTS WERE REPLACED, AND THE WIRING REPAIRED. 1L72 4T4 T A14CE E4WE 20040217000882004021700088EA 2004 2 17 2004FA0000166 220030129G7314200F5003 GARLOCK SEAL PIPER PA31 PA31350 7103110SO LYC O540 LTIO540J2BD 41533EA FUEL PUMP LEAKING D O OTHER O OTHER NRNOT REPORTED 1 SO05101TT18 318252050 L262268A THIS ENGINE DRIVEN FUEL PUMP WAS INSTALLED ON A MFG FACTORY OVERHAULED ENGINE. FOUND ENGINE DRIVEN FUEL PUMP LEAKING FROM THE GARLOCK SEAL ON THE DRIVE END OF THE FUEL PUMP, LEAVING FUEL STAIN ON BOTTOM ENGINE COWL. 1L72 3O3 O A20SO E14EA 20040301000562004030100056EA 2004 3 1 2004FA0000167 220030122G74146351 MAGNETO CESSNA182 182T 2072703CE LYC O540 IO540AB1A5 EA ENGINE FAILED G O OTHER O OTHER NRNOT REPORTED 1 GL13214FA 18281214 L2870848A IT APPEARS THAT THE IMPULSE COUPLING FAILED, THEREFORE SEIZING THE MAGNETO AND SHEARING GUIDE SHAFT OF RETAINER GEAR ASSEMBLY AND BREAKING APART (INTO PIECES) THE RETAINER ASSEMBLY, ITSELF. SENDING PIECES OF METAL INTO THE ACCESSORY CASE AND POSSIBLY INTO THE ENGINE, THERE ARE MARKS/IMPRESSIONS IN THE BALL BEARING SUPPORT FROM INCIDENT. REMOVED AND REPLACED RT ENGINE. (RT MAGNETO) 1H71 3O3 ONT3A13 1E4 20040301000592004030100059SO 2004 3 1 2004FA0000168 120030118G2497 WIRE MAULE MX7 MXT7180 5470206SO LYC O360 O360C1F 41514EA RT SEAT CONVERTEDAMAGED D O OTHER O OTHER NRNOT REPORTED 1 SO114198R163 14096C CHECK LIST TELLS YOU TO REMOVE LOWER PANELS UNDER SEATS FOR INSP. REMOVED PANELS FOR INSP AND COMPLIANCE WITH SB 64 ON ELEVATOR CABLES. FOUND THAT UNDER RT SEAT THERE IS CONVERTER THAT IS FOR INSTRUMENT LIGHTS. WIRING WAS ROUTED FROM INSTRUMENT PANEL TO CONVERTER IT WAS PULLED TOO TIGHT ALLOWING 3 WIRES TO CHAFE ON 45 DEGREE SPAR BRACE. INSULATION WAS WORN OFF WITH DIRECT WELDING CONTACT OF WIRES ON SPAR MEMBER. NO CB POPPED. EQUIP NOT WORKING IAW MM IS INSTR LIGHTS, THEY ARE ON BUT DO NOT DIM AS REQUIRED. THIS CREATED FIRE WHICH MELTED SIDE KICK PANEL, BURNED INSULATION, CREATED FLAME PATH OF ABOUT 8 INCHES. THIS DAMAGE COULD NOT BE SEEN WITH PANELS INSTALLED. PILOT NEVER SMELLED SMOKE IN COCKPIT. 1H71 3O3 ONC3A23 E286 20040301000702004030100070EA 2004 3 1 2004FA0000169 220031215G7314LW16335 PUMP BEECH 23 C23 1151242CE LYC O360 O360A4K 41514EA ENGINE INOPERATIVE D A UNSCHED LANDING YJ ENGINE STOPPAGE WARNING INDICATION NRNOT REPORTED 1 EA216756B M2276 AIRCRAFT EXPERIENCED ENGINE FAILURE DUE TO LOSS OF FUEL PRESSURE DURING TRAINING FLIGHT. STUDENT FAILED TO TURN ON ALTERNATOR SWITCH AND BATTERY POWER WAS INSUFFICIENT TO OPERATE ELECTRIC FUEL PUMP. FAILURE OCCURRED IN VICINITY OF AIRPORT AND SAFE LANDING WAS EXECUTED. DURING RUN-UP AT FULL POWER, FUEL PRESSURE WOULD DECREASE FROM NORMAL 5 PSI TO 2.5 PSI AND RETURNED TO NORMAL WHEN POWER REDUCED. REMOVED PUMP AND DISASSEMBLED. NO GLARING DEFECTS. THE ONLY QUESTIONABLE CONDITION FOUND WAS THE BOTTOM CHAMBER DIAPHRAGM (WHICH PURPOSE, SUSPECT IS TO DAMPEN PULSATIONS) WAS STRETCHED AND POSSIBLY NOT ALLOWING THE PUMP TO DRAW IN ENOUGH FUEL FOR HIGH POWER APPLICATION. 1L71 3O3 O A1CE E286 20040301000772004030100077EU 2004 3 1 2004FA0000174 120030513G2560349141012070 BUCKLE SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE SEAT BELT BROKEN C O OTHER O OTHER NRNOT REPORTED 1 AL05391NS168 3481 9772 LT OB SEATBELT BUCKLE BROKEN. 1G71 3U3 U H9EU E19EU 20040301000782004030100078EU 2004 3 1 2004FA0000175 120030505G2820 COUPLER SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE HEATER HOSE SEIZED C O OTHER O OTHER NRNOT REPORTED 1 AL05391NS162 3481 P2 HEATER HOSE SEIZED ONTO THE FITTING AT THE ENGINE. 1G71 3U3 U H9EU E19EU 20040301000792004030100079EU 2004 3 1 2004FA0000176 120030317G2910813468 SHIM SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE HYD FILTER MISSING C O OTHER W INADEQUATE Q C NRNOT REPORTED 1 AL05391NS76 3481 HYDRAULIC FILTER BYPASS BUTTON POPPED (NO SHIMS INSTALLED). 1G71 3U3 U H9EU E19EU 20040301000852004030100085CE 2004 3 1 2004FA0000177 120031008G5711901100132 SPAR CAP BEECH 90 C90 1152913CE PWA PT6 PT6A60A 52043NE MCAULY4HFR344HFR34C762 NE RT WING CRACKED B FJJSK NONE O OTHER ININSP/MAINT 1 GL21502SE10138 LJ740 DURING COMPLIANCE OF AD, INSPECTION, A CRACK WAS DISCOVERED IN THE LOWER WING SPAR CAP. 1L72 3T4 T 3A20 E4EA 6 C3PNE 20040217000802004021700080SO 2004 2 17 2004FA0000179 120031210G2140A23D04 REGULATOR PIPER PA31 PA31350 7103110SO LYC O540 TIO540* 41532EA HEATER FUEL FAILED D K NONE O OTHER ININSP/MAINT 1 SO053581C154 318052091 AD HAS YOU PERFORM PRESSURE LEAKAGE CHECK ON THESE HEATER FUEL PRESSURE REGULATORS. WHEN NEW AND BEFORE INSTALLATION INTO AIRCRAFT. WE FIND THAT MANY OF THESE UNITS FAIL AFTER A SHORT TIME OF USE. THEY START LEAKING AROUND HOUSING DIAPHRAGM AND NOTICED FUEL STAIN FROM DRAIN ON THE NOSE SECTION OF THE AIRCRAFT. 1L72 3O3 O A20SO E14EA 20040301001172004030100117SO 2004 3 1 2004FA0000180 120031210G7334A23D04 REGULATOR PIPER PA31 PA31350 7103110SO LYC O540 TIO540* 41532EA FUEL SYSTEM FAILED D K NONE O OTHER ININSP/MAINT 1 SO05101TT165 318252050 AD HAS YOU PERFORM PRESSURE LEAKAGE CHECK ON THESE HEATER FUEL PRESSURE REGULATORS WHEN NEW AND BEFORE INSTALLATION INTO AIRCRAFT. WE FIND THAT MANY OF THESE UNITS FAIL AFTER A SHORT TIME OF USE. THE PART STARTS LEAKING AROUND HOUSING DIAPHRAGM AND NOTICE FUEL STAIN FROM DRAIN ON THE NOSE SECTION OF THE AIRCRAFT. 1L72 3O3 O A20SO E14EA 20040301001112004030100111GL 2004 3 1 2004FA0000194 120031117G7170 DRAIN LINE AVIAT A1 A1A 2210405GL LYC O360 O360* 41514EA HARTZLHCC2Y HCC2YK1 GL ENGINE OIL CHAFED C K NONE K FLUID LOSS ININSP/MAINT 1 SW05478DM 1450 L3657436A CH33326B OIL LEAK NOTED ON LOWER COWL. DURING ANNUAL INSPECTION, NR 1 OIL DRAIN TUBE FOUND CHAFED BY CARB HEAT SCAT HOSE. SCAT HOSE WAS ROUTED BETWEEN OIL DRAIN TUBE AND NR 1CYCLINDER EXHAUST STACK. 1H71 3O3 ONCA22NM E286 5 CP920 20040303000912004030300091SW 2004 3 3 2004FA0000200 120030710G3233B10076 GEAR DUKES MOONEYM20 M20J 5870219SW LYC O360 IO360A1A 41514EA MLG ACTUATOR WORN D K NONE O OTHER ININSP/MAINT 1 SW17201HB84 0288 240209 AIRCRAFT EXPERIENCING POPPING OF THE MAIN LANDING GEAR CB ON RETRACTION AND WAS MAKING NOISE. AIRCRAFT WAS FLOWN, GEAR DOWN AS A PRECAUTION. REMOVAL AND INSPECTION OF THE GEAR ACTUATOR REVEALED AN EXCESSIVELY WORN WORM GEAR IN THE JACKSCREW ASSEMBLY THAT WAS BINDING WITH THE PINION GEAR CAUSING JAMMING. 1L71 3O3 O 2A3 1E10 20040303000922004030300092SW 2004 3 3 2004FA0000201 120030610G3233B10076 WORM GEAR MOONEYM20 M20J 5870219SW LYC O360 IO360A1A 41514EA MLG ACTUATOR WORN D K NONE O OTHER ININSP/MAINT 1 SW17201DD112 0110 240102 THIS GEAR WAS REMOVED FROM THE GEAR ACTUATOR AFTER COMPLAINTS THAT THE LANDING GEAR CIRCUIT BREAKER WAS POPPING DURING RETRACTION. REPLACED THE GEARS IAW SB M20-190B EXACTLY 112.8 AIRCRAFT HOURS AGO. THE GEAR REMOVED IS SEVERELY WORN. 1L71 3O3 O 2A3 1E10 20040304000782004030400078CE 2004 3 4 2004FA0000231 120030423G323398820001 ACTUATOR CESSNA210 P210N 2073454CE CONT O520 TSIO520P 17040SO MCAULYD3A34 D3A34C402 GL MLG CRACKED D RA7RO OTHER O OTHER NRNOT REPORTED 1 GL25210PF2807 1974 P21000018 513932 002238 LT MLG ACTUATOR CRACKED ALLOWING ALL HYDRAULIC FLUID TO LEAK OB ON RETRACTION AFTER TAKEOFF. COULD NOT EXTEND LANDING GEAR WHICH RESULTED IN A GEAR UP LANDING. NOTE, THIS ACTUATOR WAS PREVIOUSLY OVERHAULED ON 04/21/1983 AT 833 HOURS TIME IN SERVICE. THERE ARE NO SIGNS OF CORROSION OR DAMAGE TO ACTUATOR. IT SIMPLY SPLIT APPROX 3.5 INCHES LONG, LENGTH WISE OF THE PISTON BARREL. 1H71 3O3 O 3A21 E8CE 5 CP47GL 20040304000792004030400079NM 2004 3 4 2004FA0000233 120031216G2741 MOTOR EATON BOEING717 717200 1383700NM TRIM POWER DRIVEFOD D E20RO OTHER C F.O.D. NRNOT REPORTED 1 WP23 397 FOD WITHIN MOTOR ASSEMBLY, PIECE OF ASSEMBLY TOOLING LODGED IN STATOR WINDING CAUSED FAILURE OF STATOR. 2L72 4F TRA6WE 20040401001572004040100157GL 2004 4 1 2004FA0000252 120031106G5750 AILERON AVIAT A1 A1B 2210406GL LYC O360 O360* 41514EA WINGS MISLOCATED B V2ARO OTHER O OTHER NRNOT REPORTED 1 AL03354C 2119 FOUND RIVET IN AILERON LEADING EDGE HAD CAUGHT CORNER OF RIB INSTEAD OF THROUGH CENTER OF RIB. CONDITION IN BOTH LEFT AND RIGHT AILERONS AT WS123. REPAIRED CONDITION IAW MFG LETTER OF INSTRUCTION. 1H71 3O3 ONCA22NM E286 20040401001582004040100158CE 2004 4 1 2004FA0000253 120031124G2140 DUCT CESSNA172 172S 2072439CE LYC O360 IO360A1A 41514EA HEATER MISROUTED B FE4RO OTHER O OTHER NRNOT REPORTED 1 AL03792SP 172S8717 DURING A ROUTINE INSPECTION, WE FOUND THAT THE PLASTIC GLOVEBOX WAS MELTED AT THE FORWARD RIGHT SIDE. WE FOUND THE HEATER DUCTING WAS ROUTED UP AGAINST THE GLOVEBOX CAUSING THE BOX TO MELT. REROUTED HEAT DUCTING TO PREVENT FUTURE OCCURANCE. 1H71 3O3 ONT3A12 1E10 20040401001592004040100159CE 2004 4 1 2004FA0000254 120031124G2140 DUCT CESSNA172 172S 2072439CE HEATER MISROUTED B FE4RO OTHER W INADEQUATE Q C NRNOT REPORTED 1 AL0335339 172S8891 DURING A ROUTINE INSPECTION, WE FOUND THAT THE PLASTIC GLOVEBOX WAS MELTED AT THE FORWARD RIGHT SIDE. WE FOUND THAT THE HEATER DUCTING WAS ROUTED UP AGAINST THE GLOVE BOX CAUSING THE BOX TO MELT. REOUTED HEAT DUCTING TO PREVENT FUTURE OCCURANCE. 1H71 3O NT3A12 20040401001772004040100177SO 2004 4 1 2004FA0000268 120031126G2820 O-RING PIPER PA22 PA22135 7102206SO LYC O290 O290* 41506EA CHECK VALVE WORN D PS0MO OTHER O OTHER NRNOT REPORTED 1 SO133347A1299 221617 THE CHECK VALVE BETWEEN THE AUXILIARY FUEL TANK AND THE RT MAIN TANK FAILED, ALLOWING FUEL FROM THE RT MAIN TO DRAIN INTO THE AUX TANK AND OVERFLOW FROM THE FILLER NECK. THE PUMP AND VALVE ASSEMBLY IS INTENDED TO MOVE FUEL FROM THE AUX TANK TO THE RT MAIN TANK AND PREVENT REVERSE FLOW. RECOMMEND A POSITIVE SHUT OF VALVE BETWEEN THE RIGHT MAIN TANK AND THE AUX TANK PUMP TO PREVENT AN IN-FLIGHT DRAINING OF FUEL FROM THE RT MAIN TANK. 1H71 3O3 O 1A6 E229 20040422001512004042200151EA 2004 4 22 2004FA0000283 220030817G7314154734500 PUMP CESSNA172 172S 2072439CE LYC O360 IO360A1A 41514EA FUEL SYS BURNED G O OTHER O OTHER NRNOT REPORTED 1 NE0335073 17258875 PROBABLE CAUSE ENGINE COMPARTMENT FIRE OF UNDETERMINED SOURCE. REPORT CONCERNING SEPARATION OF FUEL LINE FROM FUEL PUMP. ACC REPORT NR IAD02FA086. 1H71 3O3 ONT3A12 1E10 20040505001082004050500108 2004 5 5 2004FA0000299 420031120G6122C290D35 GOVERNOR CESSNA172 172RG 2072438CE LYC O360 O360F1A6 41514EA ENGINE MALFUNCTIONED B LW5RA UNSCHED LANDING O OTHER CLCLIMB 1 GL179515B5660 1410 172RG0846 L2774336A WHILE ON CLIMB OUT AT 2500 RPM AND 25 INCHES, ENGINE RPM SUDDENLY WENT TO 3000 AND PILOT WAS UNABLE HAVE ANY EFFECT WITH PROPELLER CONTROL. AIRCRAFT RETURNED TO AIRPORT USING THROTTLE TO CONTROL RPM. ENGINE CONTROLS WERE ALL FOUND TO BE INTACT AND OPERATING NORMAL. UNIT REMOVED AND SENT TO PROP SHOP FOR REPAIR. 1H71 3O3 O 3A17 E286 20040506000772004050600077CE 2004 5 6 2004FA0000319 120031204G28201200406131 FUEL LINE CESSNA210 210M 2073450CE CONT O520 IO520* 17032SO LT WING CORRODED D O OTHER K FLUID LOSS NRNOT REPORTED 1 CE07761AN2983 21062103 FRONT FUEL LINE FROM LT WING TANK WAS IN CONTACT WITH FRESH AIR DUCT IN THE WING, AERO DUCT PN CEET 1.5 INCH. THIS CAUSED CORROSION ON THE ALUMINUM FUEL LINE. PROBLEM WAS FOUND WHEN FUEL STARTED LEAKING OUT OF THE WING. REPLACED FUEL LINE AND FRESH AIR DUCT. FABRICATED A STANDOFF TO PREVENT REOCCURRENCE. 1H71 3O3 O 3A21 E5CE 20040503001302004050300130EU 2004 5 3 2004FA0000326 120031210G2435150SG122Q STARTER GEN SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE ENGINE INOPERATIVE D O OTHER O OTHER NRNOT REPORTED 1 WP05961SD288 288 3516 9791 PILOT REPORTED DEFECT AND MAINTENANCE. STARTER/GENERATOR LIGHT CAME ON IN FLIGHT. REPLACED STARTER/GENERATOR AND 16 AMP FUSE. 1G71 3U3 U H9EU E19EU 20040503001312004050300131EU 2004 5 3 2004FA0000327 120031210G2435150SG122Q STARTER GEN SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE ENGINE INOPERATIVE D O OTHER O OTHER NRNOT REPORTED 1 WP05961SD288 288 3516 9791 PILOT REPORTED DEFECT AND MAINTENANCE CORRECTIVE ACTION: GENERATOR LIGHT CAME ON IN FLIGHT, WILL NOT RESET. REPLACED STARTER/GENERATOR AND 16 AMP FUSE. 1G71 3U3 U H9EU E19EU 20040503001422004050300142EU 2004 5 3 2004FA0000328 120031229G2435150SG122Q STARTER GEN SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE ENGINE INOPERATIVE D O OTHER O OTHER NRNOT REPORTED 1 WP05960SD331 331 3501 9787 PILOT REPORTED DEFECT AND MAINTENANCE CORRECTIVE ACTION: ON 3RD HOP, 2 MINUTES INTO FLIGHT VOLTMETER READ 23 VOLTS. NO GENERATOR LIGHT. SHUT DOWN FOR 10 MINUTES. CONTINUED FLIGHT FOR 3 HOURS. AT 29 VOLTS ON 4TH HOP, JUST PRIOR TO LIFT-OFF, GENERATOR LIGHT CAME ON AND WOULD NOT RE-SET. REPLACED STARTER/GENERATOR AND BATTERY. 1G71 3U3 U H9EU E19EU 20040504000102004050400010EU 2004 5 4 2004FA0000335 120031022G2435150SG122Q STARTER GEN SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE ENGINE INOPERATIVE D O OTHER O OTHER NRNOT REPORTED 1 WP05962SD291 200 3517 9790 PILOT REPORTED DEFECT AND MAINTENANCE CORRECTIVE ACTION: GENERATOR WENT OFF-LINE. REPLACED GENERATOR AND BATTERY 1G71 3U3 U H9EU E19EU 20040514000732004051400073SW 2004 5 14 2004FA0000393 120031227G2720AN32022 COTTER PIN BBAVIA7 7ECA 21101NNSW LYC O235 O235C1 41505EA RUDDER PEDAL SHEARED G O OTHER O OTHER NRNOT REPORTED 1 WP01538791554 113676 COTTER KEY USED TO SECURE THE CLEVIS PIN BETWEEN THE RT RUDDER PEDAL AND RT BRAKE MASTER CYLINDER FAILED. THE HEAD OR TANGS OF THE COTTER KEY STRIKE AN ANGLE BRACKET ON THE FIREWALL WHEN THE RUDDER PEDAL IS FULLY DEPRESSED, DEPENDING UPON WHICH WAY THE CLEVIS PIN HAS ROTATED. AFTER THE COTTER KEY FALLS OUT OF THE CLEVIS PIN, THE CLEVIS PIN SEPARATES FROM THE RUDDER PEDAL AND BRAKE MASTER CYLINDER ASSY. THE RUDDER PEDAL FALLS FORWARD, ALLOWING THE TOP OF THE RUDDER PEDAL TO COME IN CONTACT WITH THE FIREWALL WHEN DEPRESSED. THIS RESULTS IN A LOSS OF RUDDER PEDAL TRAVEL. THE COTTER KEY TANGS SHEARED AT THE CLEVIS PIN. 1H71 3O3 O A759 E223 20040526000722004052600072SO 2004 5 26 2004FA0000412 120031206G25106956800 SEAT FRAME PIPER PA28 PA28140 7102802SO LYC O320 O320E3D 41508EA SNSNCH74D 74DM EA CABIN CRACKED D K NONE O OTHER ININSP/MAINT 1 NM03165834213 287325301 L3324227A K35135 PILOTS TUBULAR SEAT FRAME (UPPER TUBULAR AT FWD CONNECTING BRACKETS) FOUND CRACKED AT LEAST 270 DEGREES CIRCUMFERENCE BOTH SIDES. THIS DISCREPANCY COULD RESULT IN SEPARATION OF THE SEAT FRAME RESULTING IN PILOTS LOSS OF CONTROL OF THE AC ESPECIALLY DURING FINAL LANDING APPROACH OR DURING TAKEOFF. REPLACEMENT OF SEAT FRAME OR WELDING OF FRAME TUBULAR WITH 30 DEGREE TUBULAR SPLICE PATCHES WOULD RESOLVE THIS DISCREPANCY. THIS DISCREPANCY WAS ALSO FOUND BOTH SIDES ON UPPER TUBULAR OF NON-ARTICULATING FWD RT SEAT. NOTE: THESE DISCREPANCIES WERE FOUND DUE TO AN INTERIOR REPLACEMENT AND SEAT RE-UPHOLSTERY. NORMAL MAINTENANCE INSPECTIONS WOULD PROBABLY NOT DETECT THESE CRACKS AS THEY ARE HIDDEN BY THE SEAT MATERIAL. 1L71 3O3 O 2A13 E274 5 NP88614 20040914001892004091400189 2004 9 14 2004FA0000526 420031224G6113D7309 BULKHEAD PIPER PA34 PA34220T 7103420SO CONT O360 TSIO360* 17025SO LT PROP SPINNER CRACKED B K NONE O OTHER ININSP/MAINT 1 SW1712699 3449262 DURING ANNUAL INSPECTION, FOUND THE LT PROP SPINNER BULKHEAD CRACKED IN SEVERAL PLACES. THE CRACKS ARE LOCATED AT JUST ABOUT EVERY BOLT HOLE FOR ATTACHING THE BULKHEAD TO THE PROP BULKHEAD HAD TO BE REPLACED. 1L72 3O3 O A7SO E9CE 20040712000262004071200026EU 2004 7 12 2004FA0000533 120031117G2720 CONTROL ROD AMD FALC10FALCON10 2730101EU RUDDER CHAFED D O OTHER O OTHER NRNOT REPORTED 1 SO05707AM6523 159 TIP FROM AUG 03 AC 43-16A RUDDER CONTROL ROD CHAFED. RUDDER CONTROL ROD CRANK AT FRAME NR 37. FOUND YAW DAMPNER ATTACHMENT PIN INSTALLED 180 DEGREE OUT. COTTER KEY AND NUT CHAFED THE ELEVATOR SERVO HYDRAULIC LINE, NO DAMAGE TO LINE NOTED. ID TAG GOUGED. CORRECTED IAW F-10 IPC 27-22-01, FIG 5 SHEET 2 OF 2. CYCLED RUDDER FULL TRAVEL, PROPER OPERATION INDICATED. 2L72 4F A33EU 20040915000832004091500083SO 2004 9 15 2004FA0000582 120030307G2820102487 CHECK VALVE PIPER PA46 PA46500TP 7104622SO PWA PT6 PT6A42 52043NE FUEL SYSTEM STUCK H O OTHER S AFFECT SYSTEMS APAPPROACH 1 WP23522RF308 4697119 PCERM0124 CHECK VALVE, GRAVITY/SUPPLY LINE FOUND STUCK OPEN ALLOWING FUEL DISPLACEMENT FROM HEADER TANK. AIRCRAFT INVOLVED IN FATAL ACCIDENT 03/07/03 1L71 3O4 TRTA25SO E4EA 20040915000842004091500084SO 2004 9 15 2004FA0000583 120030307G2820 CHECK VALVE PIPER PA46 PA46500TP 7104622SO FUEL FLOW MISALIGNED H O OTHER S AFFECT SYSTEMS APAPPROACH 1 WP23522RF308 4697119 HINGE PIN DISPLACED, FLAPPER DOOR MISALIGNED, ALLOWING REVERSE FUEL FLOW. PART MARKED 99240/2S6952. 1L71 3O RTA25SO 20040920001232004092000123SO 2004 9 20 2004FA0000592 120030307G2820102487 CHECK VALVE PIPER PA46 PA46500TP 7104622SO PWA PT6 PT6A42 52043NE ZONE 600 STUCK D O OTHER S AFFECT SYSTEMS APAPPROACH 1 WP23522RF308 4697119 PCERM0124 CHECK VALVE ASSY. GRAVITY/SUPPLY LINE FOUND STUCK OPEN ALLOWING FUEL DISPLACEMENT FROM HEADER TANK. 1L71 3O4 TRTA25SO E4EA 20040920001242004092000124SO 2004 9 20 2004FA0000593 120030307G2820102487 CHECK VALVE PIPER PA46 PA46500TP 7104622SO PWA PT6 PT6A42 52043NE ZONE 600 STUCK H O OTHER O OTHER APAPPROACH 1 WP23522RF308 4697119 PCERM0124 CHECK VALVE ASSY. GRAVITY/SUPPLY LINE FOUND STUCK OPEN ALLOWING FUEL DISPLACEMENT FROM HEADER TANK. 1L71 3O4 TRTA25SO E4EA 20040908001752004090800175SO 2004 9 8 2004FA0000611 120030117G1430AN175C33A BOLT PIPER PA30 PA30 7103002SO LYC O320 IO320* 41508EA STABILATOR CORRODED D Q76EO OTHER O OTHER NRNOT REPORTED 1 SW158560Y 301707 DURING ANNUAL INSPECTION THE STABILATOR WAS REMOVED FOR FURTHER INSPECTION. THIS IS DUE TO PREVIOUS PROBLEMS ON OTHER PA24 AND PA30/39 AIRCRAFT WITH STABILATOR TORQUE TUBE AND ATTACHMENT BOLTS WITH EXCESSIVE CORROSION. BOTH BOLTS AN175C33A THAT ATTACHES THE STABILATOR HORN ASSY TO THE TORQUE TUBE WERE SEVERELY CORRODED. ASLO CORRODED WERE THE FOLLOWING BOLTS: AN24-46A (400-932), AN174-22A (402-321). AND THE TORQUE TUBE. TT UNKNOWN 1L72 3O3 O A1EA 1E12 20040908001692004090800169SO 2004 9 8 2004FA0000612 120030528G1430AN175C33A BOLT PIPER PA24 PA24260 7102406SO LYC O540 TIO540* 41532EA STABILATOR CORRODED D Q76EO OTHER O OTHER NRNOT REPORTED 1 SW158660P3705 244106 DURING ANNUAL INSPECTION THE STABILATOR WAS REMOVED FOR FURTHER INSPECTION. THIS IS DUE TO PREVIOUS PROBLEMS ON OTHER PA24 AND PA30/39 AIRCRAFT WITH STABILATOR TORQUE TUBE AND ATTACHMENT BOLTS WITH EXCESSIVE CORROSION. BOTH BOLTS AN175C33A THAT ATTACHES THE STABILATOR HORN ASSY TO THE TORQUE TUBE WERE SEVERELY CORRODED. ALSO CORRODED WERE THE FOLLOWING BOLTS: AN24-46A (400-932), AN174-22A (402-321). AND THE TORQUE TUBE. TT 3705. 1L71 3O3 O 1A15 E14EA 20040908001742004090800174SO 2004 9 8 2004FA0000613 120030630G1430AN175C33A BOLT PIPER PA30 PA30 7103002SO LYC O320 IO320* 41508EA STABILATOR CORRODED B Q76EO OTHER O OTHER NRNOT REPORTED 1 SW158458Y 301617 DURING ANNUAL INSPECTION THE STABILATOR WAS REMOVED FOR FURTHER INSPECTION. THIS IS DUE TO PREVIOUS PROBLEMS ON THE PA24 AND PA30/39 AIRCRAFT WITH STABILATOR TORQUE TUBE AND ATTACHMENT BOLTS WITH EXCESSIVE CORROSION. BOTH BOLTS AN175C33A THAT ATTACHES THE STABILATOR HORN ASSY TO THE TORQUE TUBE WERE SEVERELY CORRODED. ALSO CORRODED WERE THE FOLLOWING BOLTS: AN24-46A (400-932), AN174-22A (402-321). AND THE TORQUE TUBE. 1L72 3O3 O A1EA 1E12 20040908001722004090800172SO 2004 9 8 2004FA0000616 120030630G1430AN175C33A BOLT PIPER PA30 PA30 7103002SO LYC O320 IO320* 41508EA STABILATOR CORRODED D Q76EO OTHER O OTHER NRNOT REPORTED 1 SW157321Y 30365 DURING ANNUAL INSPECTION THE STABILATOR WAS REMOVED FOR FURTHER INSPECTION. THIS IS DUE TO PREVIOUS PROBLEMS ON OTHER PA24 AND PA30/39 AIRCRAFT WITH STABILATOR TORQUE TUBE AND ATTACHMENT BOLTS WITH EXCESSIVE CORROSION. BOTH BOLTS AN175C33A THAT ATTACHES THE STABILATOR HORN ASSY TO THE TORQUE TUBE WERE SEVERELY CORRODED. ALSO CORRODED WERE THE FOLLOWING BOLTS: AN24-46A (400-932), AN174-22A (402-321). AND THE TORQUE TUBE. 1L72 3O3 O A1EA 1E12 20040908001772004090800177SO 2004 9 8 2004FA0000617 120030922G1430AN175C33A BOLT PIPER PA24 PA24260 7102406SO LYC O540 TIO540* 41532EA STABILATOR CORRODED D O OTHER O OTHER NRNOT REPORTED 1 SW158921P 244377 DURING ANNUAL INSPECTION THE STABILATOR WAS REMOVED FOR FURTHER INSPECTION. THIS IS DUE TO PREVIOUS PROBLEMS ON OTHER PA24 AND PA30/39 AIRCRAFT WITH STABILATOR TORQUE TUBE AND ATTACHMENT BOLTS WITH EXCESSIVE CORROSION. BOTH BOLTS AN175C33A THAT ATTACHES THE STABILATOR HORN ASSY TO THE TORQUE TUBE WERE SEVERELY CORRODED. ALSO CORRODED WERE THE FOLLOWING BOLTS: AN24-46A (400-932), AN174-22A (402-321). AND THE TORQUE TUBE. TT 3023. 1L71 3O3 O 1A15 E14EA 20040908001762004090800176SO 2004 9 8 2004FA0000621 120031111G1430AN175C33A BOLT PIPER PA24 PA24250 7102404SO LYC O540 O540* 41532EA STABILATOR CORRODED D Q76EO OTHER O OTHER NRNOT REPORTED 1 SW15727DS 24276 DURING ANNUAL INSPECTION THE STABILATOR WAS REMOVED FOR FURTHER INSPECTION. THIS IS DUE TO PREVIOUS PROBLEMS ON OTHER PA24 AND PA30/39 AIRCRAFT WITH STABILATOR TORQUE TUBE AND ATTACHMENT BOLTS WITH EXCESSIVE CORROSION. BOTH BOLTS AN175C33A THAT ATTACHES THE STABILATOR HORN ASSY TO THE TORQUE TUBE WERE SEVERELY CORRODED. ALSO CORRODED WERE THE FOLLOWING BOLTS: AN24-46A (400-932), AN174-22A (402-321). AND THE TORQUE TUBE. 1L71 3O3 O 1A15 E295 20040908001672004090800167SO 2004 9 8 2004FA0000623 120031025G1430AN175C33A BOLT PIPER PA24 PA24260 7102406SO LYC O540 TIO540* 41532EA STABILATOR CORRODED D Q76EO OTHER O OTHER NRNOT REPORTED 1 SW158843P5837 244298 DURING ANNUAL INSPECTION THE STABILATOR WAS REMOVED FOR FURTHER INSPECTION. THIS IS DUE TO PREVIOUS PROBLEMS ON OTHER PA24 AND PA30/39 AIRCRAFT WITH STABILATOR TORQUE TUBE AND ATTACHMENT BOLTS WITH EXCESSIVE CORROSION. BOTH BOLTS AN175C33A THAT ATTACHES THE STABILATOR HORN ASSY TO THE TORQUE TUBE WERE SEVERELY CORRODED. ALSO CORRODED WERE THE FOLLOWING BOLTS: AN24-46A (400-932), AN174-22A (402-321) AND THE TORQUE TUBE. TT 5837. 1L71 3O3 O 1A15 E14EA 20040831000402004083100040SO 2004 8 31 2004FA0000624 120030117G1430 BOLT PIPER PA30 PA30 7103002SO LYC O320 IO320* 41508EA STABILATOR CORRODED D O OTHER O OTHER NRNOT REPORTED 1 SW158560Y 301707 DURING ANNUAL INSPECTION THE STABILATOR WAS REMOVED FOR FURTHER INSPECTION. THIS IS DUE TO PREVIOUS PROBLEMS ON OTHER PA24 AND PA30/39 AIRCRAFT WITH STABILATOR TORQUE TUBE AND ATTACHMENT BOLTS WITH EXCESSIVE CORROSION. BOTH BOLTS AN175C33A THAT ATTACHES THE STABILATOR HORN ASSY TO THE TORQUE TUBE WERE SEVERELY CORRODED. ALSO CORRODED WERE THE FOLLOWING BOLTS: AN24-46A (400-932), AN174-22A (402-321) AND TORQUE TUBE. 1L72 3O3 O A1EA 1E12 20050505000632005050500063SO 2005 5 5 2005FA0000589 120031210G8011 RING GEAR PIPER PA28 PA28161 7102803SO STARTER FAILED D O OTHER L NO TEST TXTAXI/GRND HDL 1 EA15149LH76 53 2842192 STARTER FAILED ON AIRCRAFT WITH 76.9 HOURS TT. FAILURE DAMAGED RING GEAR, REQUIRING REPLACEMENT. 1L71 3O 2A13 20050816002142005081600214SO 2005 8 16 2005FA0001130 220030719G8500 SOLENOID VALVE CESSNA210 210C 2073412CE CONT O470 IO470S 17026SO ENGINE FAILED D O OTHER O OTHER NRNOT REPORTED 1 SW093611Y1544 21058111 1028863S1 ENG BECAME ROUGH, THEN FAILED ENTIRELY. RESTART WAS ACHIEVED, LANDING MADE. FOLLOWING DAY ENG STARTED AND RAN NORMALLY, UP TO FULL STATIC RPM. ALL SUMPS WERE DRAINED, ALL FUEL FILTERS INSPECTED, ALL TANK VENTS CHECKED WITH NO EVIDENCE OF CONTAMINATION, BLOCKAGE, OR WATER. FLIGHT BACK TO BASE AIRPORT WAS UNEVENTFUL. INVESTIGATION PRODUCED NO EVIDENT CAUSE UNTIL SOLENOID WAS REMOVED FROM VAPOR/FUEL RETURN LINE BETWEEN ENG-DRIVEN FUEL PUMP AND FUEL SELECTOR WAS CAPABLE OF STICKING IN CLOSED OR NEARLY-CLOSED POSITION. THIS HAPPENED DURING ENG STARTING ON SUBJECT FLIGHT AND CAUSED A VAPOR LOCK CONDITION TO DEVELOP. FUEL DELIVERY TO ENG WAS INTERRUPTED WHEN ENG-DRIVEN FUEL PUMP FILLED WITH VAPOR. 1H71 3O3 O 3A21 3E1 20060623000042006062300004SO 2006 6 23 2006FA0000583 120031031G273062701159 CONTROL CABLE PIPER PA32 PA32RT300T 7103216SO STABILATOR BROKEN G A UNSCHED LANDING O OTHER CLCLIMB 1 SO05395412633 32R7887104 MS21260S4LH STABILATOR PRIMARY CONTROL CABLE TERMINAL END FRACTURED SHORTLY AFTER THE PILOT ROTATED AND STARTED HIS CLIMB OUT. THE PILOT MADE AN EMERGENCY LANDING AND THE AIRCRAFT SUSTAINED SUBSTANTIAL DAMAGE TO THE PROP, ENGINE, COWLING, AND NOSE GEAR. THE PILOT WAS NOT INJURED. THE .040 SAFETY WIRE USED TO SAFETY THE ELEVATOR TURNBUCKLE MAINTAINED THE INTEGRITY OF THE CONTROL SYSTEM ALLOWING THE PILOT TO MAINTAIN CONTROL UTILIZING THE TRIM AND ENGINE POWER. NTSB SAFETY RECOMMENDATION A-01-6 THROUGH -8 DATED APRIL 16, 2001 AND SPECIAL AIRWORTHINESS ALERT BULLETIN CE-02-05R1 ADDRESS THIS PROBLEM AND ATTRIBUTE IT TO CHLORIDE STRESS CORROSION OVER A PROLONGED CALENDAR TIME OF 18-20 YEARS. 1L71 3O A3SO 20070131000632007013100063EU 2007 1 31 2007FA0000087 120031111G3411 PITOT HEAD FOKKERF28 F28MK4000 4990810EU PITOT/STATIC SYSOBSTRUCTED D C ABORTED TAKEOFF O OTHER TOTAKEOFF 1 GL23159AD 11227 FLIGHT NR 7, STAGE OF FLIGHT: TAKEOFF ROLL, 2ND ATTEMPT, CAPTAINS AIR SPEED INDICATOR INOPERATIVE. REMOVED CAPTAINS AIRSPEED INDICATOR QUICK DISCONNECTS, PURGED WITH NITROGEN, FOUND BLOCKAGE AT PITOT HEAD, REMOVED BLOCKAGE RECONNECTED QUICK DISCONNECTS. OPS CHECK GOOD, ALL WORK DONE IAW AMM, CHP 34. (K) 2L72 4F RTA20EU 20070131000652007013100065EU 2007 1 31 2007FA0000088 120031111G3411 DRAIN LINE FOKKERF28 F28MK4000 4990810EU PITOT/STATIC SYSOBSTRUCTED C C ABORTED TAKEOFF O OTHER TOTAKEOFF 1 GL23159AD 11227 FLIGHT NR 7, STAGE OF FLIGHT: TAKEOFF ROLL, CAPTAINS AIR SPEED INDICATOR DID NOT WORK. REMOVED PITOT DRAIN LANE, PURGED WITH AIR, RECONNECTED QUICK DISCONNECT. OPS CHECK OK IAW F28, CHP 34. (K) 2L72 4F RTA20EU 20070309000422007030900042CE 2007 3 9 2007FA0000211 120030729G8011 BEARING CONT IO360DB CESSNA172 R172E 2072413CE CONT O360 IO360DB 17025SO STARTER NOISY D K NONE O OTHER ININSP/MAINT 1 EA177884N 92 6261973DR R1720275 6261973DR DURING 100 HOUR INSPECTION A NOISE WAS HEARD COMING FROM STARTER ADAPTER WHILE PROP WAS BEING PULLED THRU FOR COMPRESSION CHECKS. STARTER ADAPTER WAS REMOVED AND INSPECTED. NO OBVIOUS DEFECTS WERE NOTED. ASSEMBLY (635048A1) SENT OUT FOR EVALUATION/REPAIR AND A NEW CLUTCH SPRING BEARING WAS INSTALLED. 1H71 3O3 O 3A17 E1CE 20070613002212007061300221CE 2007 6 13 2007FA0000406 120030611G781002R3022406 EXHAUST DUCT BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA ENGINE CRACKED D K NONE O OTHER ININSP/MAINT 1 SO09 6002 3009 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. 1L72 4T4 T A24CE E4EA 20070613002262007061300226CE 2007 6 13 2007FA0000433 120030629G781002R3022406 EXHAUST DUCT BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA ENGINE CRACKED D K NONE O OTHER ININSP/MAINT 1 SO09 116691171 WHILE PREFORMING SCHEDULED MAINTENANCE,REMOVED EXHAUST STACKS TO FACILTATE INSPECTING THE EXHAUST DUCT.A CRACK WAS FOUND IN THE SKI SLOPE. EXHAUST DUCT SB HAD BEEN COMPLIED WITH 1171 HOURS PRIOR. POWER SECTION WAS REMOVED FOR REPAIR. 1L72 4T4 T A24CE E4EA 20070613002152007061300215CE 2007 6 13 2007FA0000440 120030514G781002R3022406 EXHAUST DUCT BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA ENGINE CRACKED D K NONE O OTHER ININSP/MAINT 1 SO09 104981892 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. 1L72 4T4 T A24CE E4EA 20030919000262003091900026CE 2003 9 19 200FA0000645 120030411G552150610000487 RIB BEECH 90 E90 1152914CE PWA PT6 PT6A60A 52043NE ELEVATOR CRACKED C O OTHER O OTHER NRNOT REPORTED 1 EA23355JS LW257 END RIB CRACKED SEVERAL PLACES. FWD SPAR, INBOARD END CRACKED. 1L72 3T4 T 3A20 E4EA 20031229001942003122900194 2003 12 29 2204 420031202G2562AK450 G SWITCH YAKLEVYAK YAK52W 05607ANGL ZONE 200 WILL NOT TEST B BD6RK NONE L NO TEST ININSP/MAINT 1 NE05520JE252 0012210 G-SWITCH FAILS TO ACTIVATE DURING TEST. 1L71 3R RTEXPA1L71 20031230000922003123000092 2003 12 30 22041 420031202G2562AK450 ELT YAKLEVYAK YAK52W 05607ANGL TAILCONE DETACHED B BD6RK NONE D INFLIGHT SEPARATION ININSP/MAINT 1 NE05520JE252 0012210 AUXILLARY ANTENNA FELL OFF OF UNIT, WAS FOUND IN TAILCONE NEAR CONTROL SURFACE LINKAGES. 1L71 3R RTEXPA1L71 20031114000602003111400060EU 2003 11 14 258125 120031015G34122T2D126 RELAY BRAERODH125 BAE125800A 1500285EU GARRTTTFE731TFE731* 01518WP COCKPIT ARCED D O OTHER B SMOKE/FUMES/ODORS/SPARKS LDLANDING 1 SW09802X 5233 NA0418 PILOT REPORTED SMOKE IN COCKPIT JUST PRIOR TO LANDING. AIRCRAFT LANDED WITHOUT HAVING TO DECLARE AN EMERGENCY. MAINTENANCE FOUND RELAY K30 IN THE TAS PROBE HEAT CIRCUIT HAD OVERHEATED DUE TO A FAILED CONNECTION ON THE POWER FEED TO THE PROBE HEATER. RELAY K30 AND K25 AND K11 WERE REPLACED. K25 AND K11 WERE REPLACED FOR PERCAUTIONARY REASONS DUE TO THE HEAT DAMGE FROM RELAY K30. 2L72 4F4 FRTA3EU E6WE 20030826000972003082600097CE 2003 8 26 265522130 120030606G2730265522130 BELLCRANK RKWELLNA265 NA265 6402602CE ELEVATOR CORRODED B K NONE O OTHER ININSP/MAINT 1 SW99XASMQ11964 28250 ELEVATOR BIAS BUNGEE OPERATING BELLCRANK INSPECTED AND FOUND TO HAVE MAJOR CORROSION AT ATTACHMENT FORK FOR FOR BIAS BUNGEE TRIM TURNBUCKLE. 2L72 4J A2WE 20040213000222004021300022CE 2004 2 13 3 120031230G1430464P5A42 BOLT CESSNA206 TU206D 2073344CE CONT O520 TSIO520M 17040SO MCAULYD3A34 D3A34C403 GL NLG CRACKED B K NONE O OTHER ININSP/MAINT 1 SW99 560 560 U20605485 291553R 779503 DURING THE REMOVE THE NOSE LANDING GEAR FOR ITS SERVICING AND LUBRICATION, THE TECHNICIAN DISCOVERED THE DRAG LINK REAR ATTACHMENT BOLT (NAS 464P5A42) WAS SHEARED. 1H71 3O3 O A4CE E8CE 5 CP47GL 20030313000252003031300025SO 2003 3 13 3054K 120030304G2421ALU306 SHAFT ELECTROSYS PIPER PA34 PA34200T 7103406SO ALTERNATOR BROKEN B O OTHER H ELECT. POWER LOSS-50 PC CRCRUISE 1 GL213054K497 A73067 347970102 AIRCRAFT RIGHT ALTERNATOR DROPPED OFF LINE IN FLIGHT. PILOT RETURNED TO AIRPORT WITHOUT INCIDENT. REMOVED ALTERNATOR AND DISCOVERED DRIVE SHAFT SHEARED. THIS AIRCRAFT HAS THE SINGLE PIECE COUPLING INSTALLED. WHEN SHAFT SHEARS WE HAVE SEEN PIECES CONTAMINANT OIL SYSTEM AND SUBSEQUENTLY CAUSE OIL PUMP FAILURES. 1L72 3O A7SO 20030918001372003091800137CE 2003 9 18 310EE 120030808G532008113031 SUPPORT BRACKET CESSNA310 310J 2074226CE CONT O470 IO470U 17026SO MCAULY2AF34CD2AF34C81 GL FUSELAGE BROKEN B O OTHER O OTHER LDLANDING 1 EA09310EE6431 310J0001 RH LANDING GEAR COLLAPSED ON LANDING. FOUND THAT THE UPPER BELLCRANK BRACKETT P/N 0811303-1 WHICH SUPPORTS AND GUIDES THE RT MAIN LANDING GEAR PUSH/PULL TUBES FROM GEAR BOX TO GEAR ASSEMBLY SEPERATED FROM BULKHEAD DUE TO MOUNTING RIVET FAILURE. THIS SEPERATION WOULD NOT ALLOW THE RT GEAR ASSEMBLY TO STAY IN A (DOWN AND LOCKED) POSITION. 1L72 3O3 O 3A10 3E1 5 CP5EA 20030922000152003092200015EU 2003 9 22 3144032403 120030324G6720350A33214501 PITCH LINK SNIAS 350 AS350B3 8680954EU TMECA ARRIELARRIEL2B NE TAIL ROTOR WORN E O OTHER O OTHER NRNOT REPORTED 1 WP075226R1916 3144 22090 TAIL ROTOR PC LINK WORN. 1G71 3U3 U H9EU E00054EN 20030917000372003091700037WP 2003 9 17 3298S 220030724G7250 BLADE BRAERODH125 BAE125800A 1500285EU ALIDSGTFE731TFE7313AR WP NR 2 ENGINE MISSING B WTXREA ENGINE SHUTDOWN UNSCHED LANDING EJ VIBRATION/BUFFET WARNING INDICATION CRCRUISE 1 NM03800VC4299 NA0415 P95159 3298S- AIRCRAFT EXPERIENCED VIBRATION IN FLIGHT. NR 2 ENGINE WAS SHUTDOWN IN-FLIGHT. AIRCRAFT ARRIVED SAFETLY. VISUAL INSPECTION OF NR 2 ENGINE REVEALED A 1.0 TO 1.5 INCH PIECE OF 1EA 3RD STAGE TURBINE WHEEL BLADE WAS MISSING. ENGINE WAS SWAPPED WITH A LOANER AND THE DEFECTIVE ENGINE WAS SENT TO HONEYWELL. 2L72 4F4 FRTA3EU E6WE 20030919001282003091900128EU 2003 9 19 3602081003 120030810G21210500846 BLOWER MOTOR SNIAS 350 AS350B3 8680954EU TMECA ARRIELARRIEL2B NE AIR CONDITIONER DAMAGED E S4WAK NONE O OTHER ININSP/MAINT 1 WP07820NA306 3602 22342 AIR CONDITIONING BLOWER POPS CIRCUIT BREAKER. 1G71 3U3 U H9EU E00054EN 20030915000342003091500034CE 2003 9 15 38850 120030718G2913AN9181D FITTING BEECH 18 D18S 1151004CE HYD POWER PACK CRACKED B O OTHER KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 GL09600M A820 AIRCRAFT GEAR STARTED TO DROP DURING FLIGHT. FOUND TWO AN CROSS FITTINGS CRACKED. THESE ARE MOUNTED AT THE HYDRAULIC POWER PACK UNDER THE PEDESTAL IN THE COCKPIT. REPLACED FITTINGS AND ELBOWS WITH NEW. 1L72 3R A765 20030916000232003091600023NM 2003 9 16 3983 120030717G5530500N39507 TORQUE TUBE DOUG 600N 600N 3027377NM VERTICAL STAB CRACKED B K NONE O OTHER ININSP/MAINT 1 WP05660MC489 239 RN012 PILOT NOTED DURING PREFLIGHT INSP ON RAMP, THAT THE UPPER LT VERTICAL STAB WAS BENT IN APPRX 3 INCHES AT THE TOP. VIDEO FOOTAGE OF THE FBO WAS REVIEWED AND IT WAS SEEN THAT THE AIRCRAFT LANDED IN THIS DAMAGE (WAS NOT CAUSED BY PERSONS OR EQUIPMENT ON THE GROUND). THE VERTICAL STAB WAS REMOVED AND A CRACK RUNNING THROUGH ONE OF THE CONTROL SURFACE ATTACH HOLES AND 330 DEGREES AROUND THE TUBE. THE RT SIDE WAS INSPECTED IAW MD SB600N-30R1, NO DEFECTS FOUND. CRACKED PART AND EXPANDABLE BOLTS BEING SENT TO MFG FOR EVALUATION. NEW TORQUE TUBE AND ATTACHING HARDWARE BEING INSTALLED. POSSIBLE FIX WOULD BE INTERNAL TUBE ACTING AS A SECOND LOAD PATH. 1G71 3U NCH3WE 20031229002112003122900211SO 2003 12 29 39906 120031125G2820 LINE PIPER PA34 PA34220T 7103420SO FUEL SYSTEM LEAKING B K NONE K FLUID LOSS ININSP/MAINT 1 GL092741L1040 3449116 FUEL ODOR IN CABIN CAUSED US TO REMOVE SIDEWALLS TO TRACE LINES. FOUND BOTH CROSSOVER LINES AND SCUPPERS WET WITH FUEL. COULD NOT GET LINES TO STOP LEAKING BY TORQUING. DEFUELED AND DISASSEMBLED ALL FITTINGS ASSOCIATED. CLEANED AND INSPECTED AND FOUND ALL TO BE OK. NO CRACKS OR DEFORMITIES WERE NOTED. RE-ASSEMBLED WITH CONICAL SEALS AT ALL JOINTS. RE-FUELED AND NO FURTHER LEAKING WAS NOTED. 1L72 3O A7SO 20030916001512003091600151EU 2003 9 16 3998 120030724G6310350A35109120 COUPLING SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE TRANSMISSION OVERHEATED B A UNSCHED LANDING BMJSMOKE/FUMES/ODORS/SPARKS OVER TEMP WARNING INDICATION CRCRUISE 1 WP05557CB345 3431 DURING FLT, AIRCREW NOTED BURNING RUBBER ODOR. DURING UNEVENTFULL, UN-PLANNED LANDING AIRCREW NOTED THE AIR-CONDITIONING BELT HAD BURNED UP AND MELTED TO AIR-CONDITIONING COMPRESSOR. THIS WAS DUE TO AN SEIZED AIR-CONDITIONING COMPRESSOR. IT IS OUR EXPERIENCE DURING A FAILURE OF THIS TYPE THE DRIVE BELT SHEARS IN HALF, PREVENTING DAMAGE TO DRIVE PULLEY. FURTHER INSPECTION REVEALED THAT DURING FAILURE OF COMPRESSOR AND BELT, THE ENGINE TO TRANSMISSION INPUT COUPLING HAD OVER-HEATED CAUSING WHAT APPEARS TO BE THOUSANDS OF HEAT RELATED STRESS CRACKS IN THE COUPLING. THIS OCCURED BECAUSE THE DRIVE BELT DID NOT SHEAR. 1G71 3U3 U H9EU E19EU 20030324000362003032400036SO 2003 3 24 3M1 120030311G2497220CC02 CONTACTOR GULSTMGV GULFSTREAMGV3980116SO RROYCEBR700 BR700710A110 NE LEFT PDB STICKS B LD2RO OTHER H ELECT. POWER LOSS-50 PC NRNOT REPORTED 1 GL1533M 1121 594 295312 CONTACTOR STICKS INTERMITTENLY. REPLACED CONTACTOR OPERATIONAL CHECKS NORMAL. 2L72 4F4 FRTA12EA E00057EN 20030324000372003032400037SO 2003 3 24 3M2 120030318G2497220CC02 CONTACTOR GULSTMGV GULFSTREAMGV3980116SO RROYCEBR700 BR700710A110 NE LEFT PDB FAILED B LD2RO OTHER H ELECT. POWER LOSS-50 PC NRNOT REPORTED 1 GL1533M 1124 594 295312 CONTACTOR INTERMITTENLY FAILS TO CONNECT TO THE BUS. REPLACED CONTACTOR. 2L72 4F4 FRTA12EA E00057EN 20030506002482003050600248SO 2003 5 6 3M24031 120030411G3240 ROTOR GULSTMGV GULFSTREAMGV3980116SO RROYCEBR700 BR700710A110 NE BRAKE ASSY CRACKED B LD2RK NONE O OTHER ININSP/MAINT 1 GL1523M 1499 579 261262 BRAKE ROTOR SPLINTERING AT KEYWAY CLIPS. 2L72 4F4 FRTA12EA E00057EN 20030506002502003050600250SO 2003 5 6 3M24032 120030411G3240 ROTOR GULSTMGV GULFSTREAMGV3980116SO RROYCEBR700 BR700710A110 NE BRAKE ASSY CHIPPED B LD2RK NONE O OTHER ININSP/MAINT 1 GL1523M 57 579 261262 ROTOR IS CHIPPED AT BRAKE KEYWAY CLIP. 2L72 4F4 FRTA12EA E00057EN 20030506002512003050600251SO 2003 5 6 3M24033 120030411G32401159SCL5043 ROTOR GULSTMGV GULFSTREAMGV3980116SO RROYCEBR700 BR700710A110 NE BRAKE ASSY CRACKED B LD2RK NONE O OTHER ININSP/MAINT 1 GL1523M 1499 579 261262 ROTOR IS SPLINTERING AT KEYWAY CLIPS. 2L72 4F4 FRTA12EA E00057EN 20030604002362003060400236SO 2003 6 4 3M25603 120030506G3233 CLAMP GULSTMGV GULFSTREAMGV3980116SO RROYCEBR700 BR700710A110 NE MLG OUT OF POSITION B LD2RK NONE O OTHER ININSP/MAINT 1 GL1523M 579 261262 CLAMP ON RIGHT HAND MAIN GEAR SIDE BRACE ACTUATOR IS CONTACTING GEAR ACTUATION FLEX LINE. REPOSITIONED CLAMP TO CLEAR LINE. 2L72 4F4 FRTA12EA E00057EN 20030604002372003060400237SO 2003 6 4 3M35603 120030506G3233 CLAMP GULSTMGV GULFSTREAMGV3980116SO RROYCEBR700 BR700710A110 NE MLG OUT OF POSITION B LD2RK NONE O OTHER ININSP/MAINT 1 GL1533M 594 295312 CLAMP ON RIGHT HAND MAIN LANDING GEAR SIDE BRACE ACTUATOR IS CONTACTING ACTUATOR FLEX LINE. REPOSITION CLAMP TO CLEAR LINE. 2L72 4F4 FRTA12EA E00057EN 20031030000742003103000074SO 2003 10 30 3M5940903 120030930G32421159SCH5285 METERING VALVE GULSTMGV GULFSTREAMGV3980116SO RROYCEBR700 BR700710A110 NE NLG BRAKES INTERMITTENT B LD2RO OTHER E VIBRATION/BUFFET LDLANDING 1 GL1533M 1388 1388 594 1129511312 BRAKES ARE VERY GRABBY WILL NOT APPLY EVENLY. 2L72 4F4 FRTA12EA E00057EN 20031030000752003103000075SO 2003 10 30 3M59409031 120030930G32421159SCH5285 METERING VALVE GULSTMGV GULFSTREAMGV3980116SO RROYCEBR700 BR700710A110 NE BRAKES INTERMITTENT B LD2RO OTHER O OTHER LDLANDING 1 GL1533M 1388 1388 594 1129511312 METERING VALVES CAUSING GRABBY BRAKES UNABLE TO APPLY EVENLY 2L72 4F4 FRTA12EA E00057EN 20031114000032003111400003SO 2003 11 14 421C111003DG 220031112G8530654654 CYLINDER CESSNA421 421C 2076016CE CONT O520 GTSIO520* 17032SO ENGINE WORN B JBZRO OTHER B SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 WP2727RX 1158 421C0404 292378R ON ENGINE START-UP, REAR PASSENGERS NOTED GREATER THAN USUAL SMOKE EMITTED FROM EXHAUST ON NR 1 ENGINE. THE PILOT SHUT DOWN AND PERFORMED A VISUAL INSPECTION OF THE ENGINE NACELLE FOR OIL AND/OR OTHER ABNORMAL CONDITIONS: NONE NOTED. THE PILOT PERFORMED ANOTHER START WITH SIMILAR RESULTS OF LIGHT SMOKE WHICH DISSAPEARED WITH INCREASED RPM. THERE WERE NO UNUSUAL GAUGE INDICATIONS ON HIGH POWER RUN-UP. MAINTENANCE WAS CALLED TO INVESTIGATE. THE NEXT START-UP PRODUCED LITTLE SMOKE. A PRECAUTIONARY CYLINDER COMPRESSION CHECK REVEALED NR 1 CYLINDER TO HAVE BELOW SPEC. COMPRESSION. THE CYLINDER WAS REMOVED FOR INVESTIGATION AND REVEALED WORN CYLINDER WALLS AND A STUCK OIL CONTROL RING. THE CYLINDER/PISTON AS1L72 3O3 O A7CE E7CE 20030218002632003021800263SW 2003 2 18 53075 120030205G792023063412 HOSE BELL 407 407 1182206SW ENGINE CHAFED B JBZAO OTHER O OTHER NRNOT REPORTED 1 WP27108SD3447 53075 THIS HOSE DETERIORATES RAPIDLY DUE TO THE FACT THAT THE HOSE IS A CORRUGATED TUBE HOUSED IN A STEEL BRAID THAT CHAFES THE TUBE CAUSING CHAFE DAMAGE TO THE HOSE AND SUBSEQUENT OIL LEAK. THIS HOSE SHOULD BE REDESIGNED TO EXTEND RELIABILITY. THE HOSES LAST ABOUT 2 YEARS, 1,000 HOURS. 1G71 3U O H2SW 20030604000472003060400047EA 2003 6 4 5906L 220030422G85501116 HOSE AMRGENAA1 AA1 0630610SO LYC O320 O320A2B 41508EA ENGINE OIL SEPARATED F B EMER. DESCENT KB FLUID LOSS SMOKE/FUMES/ODORS/SPARKS CLCLIMB 1 SW075906L AA10206 L3798627A THE 111-6 HOSE ASSEMBLY ORIGINALLY MANUFACTURED IN 1996 BY MFG WAS OVERHAULED/REPAIRED BY UNKNOWN PERSONS ON 7-02 AS STATED IN OWNERS ENGINE LOG BOOK ENTRY AND STAMP IMPRESSIONS DATED ON ORIGINAL TAG. THE ORIGINAL HOSE ASSEMBLY WAS TAKEN APART AND A NEW HOSE ASSEMBLED INTO THE ORIGINAL FITTINGS. THE HOSE FITTING BLEW OFF THE 111-6 HOSE JUST AFTER TAKE OFF AND THE CABIN FILLED WITH SMOKE ACCORDING TO THE PILOT/OWNER. UPON INVESTIGATION, IT APPEARS THE HOSE ASSEMBLY MAY NOT HAVE BEEN ASSEMBLED PROPERLY. THE NIPPLE WAS NOT INSERTED INTO THE INSIDE DIAMETER OF THE HOSE IAW MFG. 1L71 3O3 O A11EA E274 20030205000052003020500005SW 2003 2 5 62691 120030116G3244 TIRE GULSTM690TP 690D 3970405SW MLG GROOVED B K NONE W INADEQUATE Q C ININSP/MAINT 1 GL25909HH 15035 THIS AIRCRAFT HAS CLEVELAND BRAKES INSTALLED. THE CLEARANCE BETWEEN THE TIRE SIDEWALL AND BRAKE IN MINIMAL. WHEN THE SIDEWALL FLEXES DURING LANDING IT CONTACTS THE BRAKE CAUSING A 360 DEGREE GROVE IN THE TIRE SIDEWALL. THIS DOES NOT SEEM TO OCCUR WITH OTHER TIRE MANUFACTURES, ONLY WITH GOODYEAR FLIGHT CUSTOM II. 1H72 3T 2A4 20031229002022003122900202GL 2003 12 29 649122003 120031217G2730 CARTRIDGE CIRRUSSR SR20 05628AJGL CONT O360 IO360ES SO ELEVATOR FAILED B O OTHER F FLT CONT AFFECTED APAPPROACH 1 GL15938CD 1338 ON APPROACH, PILOT DISENGAGED AUTOPILOT, FOUND ELEVATOR CONTROL TO BE STUCK IN FIXED POSITION, PITCH TRIM CONTROL WAS STILL AVAILABLE BOTH UP AND DOWN. AFTER SEVERAL ATTEMPTS TO (FREE) CONTROL WITH NO SUCCESS THE PILOT "JERKED" CONTROL BACK. CONTROL BROKE FREE ENOUGH TO PROVIDE "UP" ELEVATOR CONTROL. PILOT LANDED WITHOUT INCIDENT. AC WAS MOVED INTO HEATED HANGAR WHERE INITIAL INSPECTION REVEALED ELEVATOR TO BE VERY DIFFICULT TO MOVE IN EITHER DIRECTION. ELEVATOR WAS ABLE TO BE MOVED TO FULL TRAVELS IN BOTH DIRECTIONS WITH RELATIVE EASE ALTHOUGH PITCH TRIM CARTRIDGE MADE MORE "NOISE" THAN NORMAL. PITCH TRIM CARTRIDGE WAS REMOVED AND REPLACED WITH NEW PART. REMOVED PART WAS INSPECTED WITH NO ANOMALIES NOTED. 1L71 3O3 ONTA00009CHE1CE 20031015000192003101500019 2003 10 15 8010304 420031013G2563 LANYARD CIRRUSSR SR22 2130001GL CONT O550 IO550N 17042SO HARTZLHCJ3Y PHCJ3YF1 GL PARACHUTE MISROUTED C K NONE W INADEQUATE Q C ININSP/MAINT 1 SW09 940 100 0047 686664 THE AIRCRAFT CAME INTO OUR FACILITY FOR AN ANNUAL INSPECTION. WHILE PERFORMING THE INSPECTION IT WAS NOTED THAT THE PARACHUTE LANYARD CABLES THAT CONNECT THE ROCKET PICK-UP COLLAR TO THE PARACHUTE WERE MISROUTED. THIS WAS MOST LIKELY DONE WHEN ACCOMPLISHING CAPS SYSTEM MAINTENANCE. IT IS OF PARTICULAR CONCERN SINCE CABLE MISROUTING WOULD MOST LIKELY RENDER THE PARACHUTE INEFFECTIVE. THE CABLES WERE REROUTED IN ACCORDANCE WITH THE CIRRUS AIRFRAME PARACHUTE SYSTEM COMPONENT MANUAL. 1L71 3O3 ONTA00009CHE3SO 5 CP36EA 20030915000292003091500029CE 2003 9 15 84031 120030804G771231017262 TORQUE SENSOR BEECH 100 B100 1152919CE GARRTTTPE331TPE3316252B 01514WP ENGINE MALFUNCTIONED B EA ENGINE SHUTDOWN UNSCHED LANDING YJ ENGINE STOPPAGE WARNING INDICATION CRCRUISE 1 NM03949SW BE34 P27071 TEMP, TORQUE AND FUEL FLOW ALL DECLINED. ENGINE WAS SECURED AND PROP FEATHERED AND AN UNEVENTFUL LANDING WAS MADE AT GJT. UPON ENGINE DISASSEMBLY, THE TORQUE SENSOR SHAFT WAS FOUND SHEARED. 1L72 4T4 T A14CE E2WE 20030708000302003070800030WP 2003 7 8 852186 220030611G855030743723 VALVE LEAR 35 35A 5170602CE GARRTTTFE731TFE73122B 01518WP ENGINE FAILED B ZN3RK NONE O OTHER ININSP/MAINT 1 WP07ZN3R DE-OIL VALVE FAILED TO OPEN AND ALLOW OIL TO THE 4/5 CAVITY. THEREBY CAUSING THE NR 4 AND NR 5 BEARINGS TO SEIZE, AND THE ENGINE TO LOCK UP AFTER 17 MIN OF OPERATION. 2L72 4F4 F A10CE E6WE 20031114000442003111400044GL 2003 11 14 95195 120031017G3240 CONTROL CABLE TCRAFTBC BC12D 8850316GL CONT A65 A65* 17003SO BRAKE BROKEN G O OTHER O OTHER TXTAXI/GRND HDL 1 NM0995195 9595 LEFT BRAKE PEDAL CABLE BROKE APPROXIMATELY 10 INCHES AFT OF BRAKE PEDAL. 1H71 3O3 O A696 E205 20031113000392003111300039CE 2003 11 13 97CW 120031015G2897 WIRE HARNESS AIRBORNE CESSNA500 550 2076604CE FUEL PUMP CHAFED B K NONE O OTHER ININSP/MAINT 1 SW01797CW7553 7AG141 5500232 FUEL PUMP WIRING HARNESS IS NOT SUPPORTED WITHIN THE FUEL CELL AND CHAFED ON THE FUEL LINE FROM THE PRIMARY PUMP TO THE CHECK VALVE INSIDE THE FUEL CELL. THERE WAS .006 INCH DAMAGE TO THE WALL OF THE FUEL LINE AND THE PUMP HARNESS SHIELDING WAS CHAFED THROUGH. THERE WAS NO EVIDENCE OF ARCING. 1L72 4F A22CE 20031117000132003111700013CE 2003 11 17 97CW1 120030926G2897 WIRE HARNESS CESSNA500 550 2076604CE ZONE 600 CHAFED B R3R2K NONE O OTHER ININSP/MAINT 1 SW01797CW7553 997 7AG141 5500232 THE FUEL PUMP WIRING HARNESS IS NOT SUPPORTED WITHIN THE FUEL CELL AND CHAFED ON THE ALUMINUM FUEL LINE FROM THE PRIMARY PUMP TO THE CHECK VALVE INSIDE THE FUEL CELL. THERE WAS .006 INCHES DAMAGE TO THE WALL OF THE FUEL LINE AND THE SHIELDING ON THE PUMP WIRING HARNESS WAS CHAFED THROUGH. THERE WAS NO EVIDENCE OF ARCING. 1L72 4F A22CE 20030509000992003050900099SW 2003 5 9 AC2A086260 120030409G2930 TRANSMITTER BELL 430 430 1182150SW HYD SYSTEM FALSE INDICATIONE AC2AO OTHER O OTHER NRNOT REPORTED 1 SO07430CT 49089 AFTER FLIGHT IN RAIN, NR 2 HYDRAULIC PRESSURE INCREASED TO 1760 PSI AND NR 2 HYDRAULIC TEMPERATURE INCREASED TO 44 DEGREES C. CLEANED WATER FROM NR 2 HYDRAULIC PRESSURE TRANSMITTER CONNECTOR PLUG. 1G72 3U RTH9SW 20030509001012003050900101SW 2003 5 9 AC2A086262 120030409G6320 CONNECTOR BELL 430 430 1182150SW GEARBOX SUMP DAMAGED E AC2AO OTHER N FALSE WARNING NRNOT REPORTED 1 SO07430CM 49090 TRANSMISSION SUMP CHIP LITE WOULD NOT PULSE. CLEANED MOISTURE FROM SUMP CONNECTOR PLUG. AIRCRAFT GROUND RUN O.K. 1G72 3U RTH9SW 20030509001032003050900103 2003 5 9 AC2A086264 420030410G3421430375002109 TUBE EFIS MISMANUFACTURED E AC2AO OTHER O OTHER NRNOT REPORTED 1 SO07 TUBE CAME IN WITH BUTTONS IN WRONG LOCATIONS, WAS NOT INSTALLED IN AIRCRAFT. REPLACED WITH REPAIRED TUBE. 20030509000972003050900097NE 2003 5 9 AC2A086265 220030410G732123072726 HYDROMECH UNIT BELL 430 430 1182150SW ALLSN 250C 250C40B 03032NE NR 2 ENGINE LEAKING E AC2AK NONE O OTHER ININSP/MAINT 1 SO07430CV3084 49072 844078 REMOVED FOR HMU BACKLASH CHECK. FOUND TO BE LEAKING FUEL FROM DRIVE SPLINE SEAL. REPLACED HMU. 1G72 3U3 URTH9SW E1GL 20030514002332003051400233NE 2003 5 14 AC2A086266 120030411G2435M20021 BRUSHES SKRSKYS76 S76A 8143006NE STARTER GEN DETACHED E AC2AO OTHER O OTHER NRNOT REPORTED 1 SO075401G295 5325 760137 PART IS DISBONDED. THE ATTACHING LEAD AND SPRING WEAR PLATE AND RIVET CAME APART. REPLACED ALL FOUR BRUSHES AND RAN IN BRUSHES. 1G72 3U H1NE 20030509001042003050900104SW 2003 5 9 AC2A086267 120030417G3340900601 LIGHT BELL 430 430 1182150SW EXTERIOR DEFECTIVE E AC2AO OTHER O OTHER ININSP/MAINT 1 SO07430CT428 49089 PART IS DEFECTIVE. LANDING LIGHT WILL NOT ILLUMINATE. CHANGING BULB DID NOT SOLVE PROBLEM. LIGHT ASSEMBLY WAS REPLACED. 1G72 3U RTH9SW 20030509000982003050900098SW 2003 5 9 AC2A086268 120030417G3213206323021 CROSSTUBE BELL 206 206L3 1182108SW MLG CORRODED H AC2AO OTHER O OTHER NRNOT REPORTED 1 SO07175921019 51535 PART IS CORRODED. CORROSION PITS BEYOND LIMITS. WILL COMPLETE NEW PART INFORMATION FOR THIS MMIR WHEN 592 RETURNS FROM RE-FURB. OLD CROSSTUBE WILL BE RETURNED AT THAT TIME ALSO. PART WAS REPLACED. 1G71 3U H2SW 20030619000082003061900008NE 2003 6 19 AC2A086761 120030522G28211737391 RING SKRSKYS76 S76A 8143006NE ALLSN 250C 250C30 03013GL FUEL FILTER BROKEN E AC2AK NONE O OTHER ININSP/MAINT 1 SO077266F 760273 DURING FUEL FILTER CHANGE, RETAINING RING INSIDE FUEL FILTER HOUSING CAME OUT IN SEVERAL PIECES. REPLACED FILTER HOUSING AND RETAINING RING. 1G72 3U3 U H1NE E1GL 20030619000102003061900010NE 2003 6 19 AC2A086767 120030529G63107636104008103 DISC PACK SKRSKYS76 S76A 8143006NE MAIN ROTOR CRACKED H AC2AK NONE O OTHER ININSP/MAINT 1 SO075402T 760140 DISC PACK IS CRACKED. DISC PACK WAS FOUND CRACKED IN EIGHT PLACES DURING SCHEDULED INSPECTION. PART WAS REPLACED. 1G72 3U H1NE 20030926000182003092600018EU 2003 9 26 AELLCDG001 120030827G291011745020V002 HYDRAULIC SYSTEM BOLKMS117 BK117A3 5626015EU MISOVERHAULED B VY1RK NONE W INADEQUATE Q C ININSP/MAINT 1 SW19 1800 SEVERAL COMPONENTS OF THIS TANDEM HYDRAULIC UNIT RECENTLY OVERHAULED, SEEM TO HAVE BEEN TREATED IN A WAY THAT NEITHER CORRESPONDS TO THE ORIGINAL DRAWINGS/SPECIFICATIONS OF THE UNIT NOR THE MBB-BK 117 REPAIR MANUAL (REM, CHAPTER 401) 1G72 3U H13EU 20030203000772003020300077SW 2003 2 3 ALGA084066 120030130G6510214010530101 BEARING BELL 214 214ST 1182106SW TAIL ROTOR WORN H ALGAO OTHER O OTHER NRNOT REPORTED 1 FS01390AL1070 28198 TAIL ROTOR BEARING WORN. 2G72 4U H10SW 20030318000092003031800009EU 2003 3 18 ALGA085106 120030306G3110B19030FB02 DISPLAY UROCOPEC120 EC120B 8680987EU TMECA ARRIUSARRIU2F NE COCKPIT DEFECTIVE H ALGAO OTHER O OTHER NRNOT REPORTED 1 FS01523AL610 1262 LANE NR 1 CALCULATOR FAILURE. 1G72 3U3 UNCR0001RD E34NE 20030318000102003031800010 2003 3 18 ALGA085108 420030306G8300E6893672 PINION GEAR CLARK 1000 1000CLARK 2230102SW GEARBOX SPALLED H ALGAO OTHER O OTHER NRNOT REPORTED 1 FS01PARTO150 CAG90222 HEAVY SPALLING ON DRIVE SIDE OF PINION GEAR TEETH CAUSING METAL IN OIL.THIS IS A REOCCURRING EVENT. VENDOR NEEDS TO UPGRADE THEIR QUALITY CONTROL ON GEAR MATERIAL AND FABRICATION OF GEARS. 1Q71 3R 2A6 20030423000692003042300069SW 2003 4 23 ALGA085884 120030401G6320E6893672 PINION GEAR BELL 407 407 1182206SW ALLSN 250C 250C47B GL GEARBOX SPALLED H ALGAO OTHER O OTHER NRNOT REPORTED 1 SW03527AL621 CAG47087 53211 CAE847258 DUE TO IMPROPER MESHING OF GEARS, PINION GEAR HAD EXCESSIVE SPALLING ON GEAR TEETH. REMOVED AND REPLACED. 1G71 3U3 UO H2SW E1GL 20030423000702003042300070 2003 4 23 ALGA085885 420030401G8300E6898785 GEAR BELL 407 407 1182206SW ALLSN 250C 250C47B GL PTO GEAR DEFECTIVE H ALGAO OTHER O OTHER NRNOT REPORTED 1 SW03527AL621 CAG47087 53211 CAE847258 REMOVED PTO GEAR IAW EXTEX MANDATORY BULLETIN NR T-075 REMOVED AND REPLACED. 1G71 3U3 UO H2SW E1GL 20030423000712003042300071GL 2003 4 23 ALGA085886 220030401G731323008054 NOZZLE CLARK 1000 1000CLARK 2230102SW ALLSN 250C 250C* GL ENGINE DISTORTED H ALGAO OTHER O OTHER NRNOT REPORTED 1 SW03 MATING SURFACE FOR SEALING PURPOSES BETWEEN NR1 & NR2 NOZZLES IS OUT OF CONCENTICITY CAUSING AIR LEAKAGE, CREATING LOW POWER CONDITIONS. RETURNED PART TO MFG FOR WARRANTY EXCHANGE. 1Q71 3R3 U 2A6 E4CE 20030423000782003042300078SW 2003 4 23 ALGA085888 120030401G6220406310405101 UNIVERSAL BELL 407 407 1182206SW ROTOR HEAD ROUGH E ALGAO OTHER O OTHER NRNOT REPORTED 1 SW03403AL1694 53478 MAIN ROTOR HEAD UNIVERSAL BEARING ROUGH AND RATCHETY. REMOVED IAW 407, MM. 1G71 3U O H2SW 20030410002282003041000228SW 2003 4 10 ALGA085897 120030402G79212660162401 IMPELLER BELL 412 412 1182202SW COOLER BLOWER CRACKED E ALGAO OTHER O OTHER NRNOT REPORTED 1 FS01XASYL 51001248 36101 IMPELLER FOUND CRACKED DURING NDI. CRACK WAS 1/4 INCH LONG EMINATING FROM BLADE TIP, IMMEDIATELY ADJACENT TO REINFORCMENT RING, EXTENDING STRAIGHT IN DIRECTION OF BLADE ROOT. REPLACED WITH NEW IMPELLER. 1G72 4U H4SW 20030509001072003050900107SW 2003 5 9 ALGA086243 120030423G6220406310405101 BEARING BELL 407 407 1182206SW ALLSN 250C 250C47B GL MAIN ROTOR DEFECTIVE E ALGAO OTHER O OTHER NRNOT REPORTED 1 SW03577AL1012 53247 FOUND BEARING DEFECTIVE, EXCESSIVE PLAY AND ROUGH/RATCHETING. 1G71 3U3 UO H2SW E1GL 20030509001082003050900108SW 2003 5 9 ALGA086244 120030423G6220406310405101 BEARING BELL 407 407 1182206SW ALLSN 250C 250C47B GL MAIN ROTOR WORN E ALGAO OTHER O OTHER NRNOT REPORTED 1 SW03627AL1434 53284 FOUND BEARING TO BE WORN AND RATCHETING. 1G71 3U3 UO H2SW E1GL 20030509001092003050900109SW 2003 5 9 ALGA086247 120030423G6220406310405101 BEARING BELL 407 407 1182206SW ALLSN 250C 250C47B GL UNIVERSAL WORN E ALGAO OTHER O OTHER NRNOT REPORTED 1 SW03587AL1978 53248 FOUND UNIVERSAL BEARING WORN AND ROUGH. 1G71 3U3 UO H2SW E1GL 20030529000212003052900021SW 2003 5 29 ALGA086490 120030522G6220406310405101 UNIVERSAL BELL 407 407 1182206SW MAIN ROTOR STICKING H ALGAO OTHER O OTHER NRNOT REPORTED 1 FS01497AL 53172 UNIVERSAL STICKING, RATCHETY AND WORN. REMOVED AND REPLACED WITH SERVCIABLE PART. SUBMITTED BY: PRESTON BARZARE 1G71 3U O H2SW 20030529000222003052900022SW 2003 5 29 ALGA086492 120030523G6220406310405101 UNIVERSAL BELL 407 407 1182206SW MAIN ROTOR STICKING H ALGAO OTHER O OTHER NRNOT REPORTED 1 FS01409AL526 53494 UNIVERAL STICKING, RATCHETY AND WORN. REMOVED AND REPLACED WITH SERVICABLE PART. SUBMITTED BY: PRESTON BARZARE 1G71 3U O H2SW 20030528001062003052800106SW 2003 5 28 ALGA086493 120030523G6220406310405101 UNIVERSAL BELL 407 407 1182206SW MAIN ROTOR WORN H ALGAO OTHER O OTHER NRNOT REPORTED 1 FS01417AL1337 53054 BEARING WORN AND RATCHETY. 1G71 3U O H2SW 20030205000262003020500026EU 2003 2 5 AMCR200300001 120030107G32601EN114N119 SQUAT SWITCH BRAERODH125 BAE125800A 1500285EU MLG FAILED B AMCRGBA O2 MASK DEPLOYED EMER. DESCENT UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 GL09526AC4274 258169 AFTER 2 HOURS INTO FLIGHT AT A CRUISE ALTITUDE OF FL370, THE CABIN ALTITUDE SUDDENLY STARTED TO CLIMB AT A RAPID RATE. THE CABIN ALTITUDE WARNING SOUNDED, THE PAX O2 MASKS DROPPED, THE CREW IMMEDIATELY DONNED THEIR MASKS AND STARTED AN EMERGENCY DESCENT. AFTER STABILIZING BELOW 10000 FT, THE CREW NOTICED OTHER INDICATIONS THAT LED MAINTENANCE TO THE SQUAT SWITCH. UPON LANDING AT THE NEAREST AIRPORT, MAINTENANCE FOUND THE LEFT SQUAT SWITCH HAD FAILED, CAUSING THE AIRPLANE TO THINK IT WAS ON THE GROUND, AND CAUSING THE CABIN VENTURI TO TURN ON, WHICH OPENED THE OUTFLOW VALVE. 2L72 4F RTA3EU 20030917000172003091700017NM 2003 9 17 AMCR200300002 120030725G2751BACP30F4 PULLEY BOEING727 72717 1384008NM ZONE 600 FAILED B AMCRK NONE P NO WARNING INDICATION ININSP/MAINT 1 GL09624VA30995 20327 UPON WING INSPECTION, FOUND RIGHT FLAP INDICATOR PULLEY SEVERELY OFFSET. FOUND THE BEARING HAD FAILED. NO INDICATION PROBLEMS HAD SURFACED YET. PULLEY REPLACED. 2L73 4F A3WE 20030919000732003091900073GL 2003 9 19 AMCR200300003 120030812G575110332002 HINGE FITTING CIRRUSSR SR22 2130001GL AILERON LOOSE B O OTHER O OTHER NRNOT REPORTED 1 GL09279DV212 0196 DURING PILOT'S PREFLIGHT, NOTICED THE RIGHT AILERON, INBOARD SIDE, HAVING EXCESSIVE PLAY. FURTHER INSPECTION REVEALED THAT THE TWO BOLTS (AN4-12A)HOLDING THE INBOARD AILERON HINGE AND THE OUTBOARD FLAP HINGE WERE LOOSE. THIS ALLOWED THE AILERON HINGE BRACKET TO MOVE UP AND DOWN ABOUT 3/16". THE NUTS WERE TORQUE-SEAL STRIPED. MAINTENANCE RE-TORQUED THE NUTS AND DID A RIGGING CHECK. NO FURTHER ACTION REQUIRED. THE LEFT WING WAS INSPECTED AND THE HARDWARE WAS FOUND TO BE TIGHT. 1L71 3O NTA00009CH 20031114000302003111400030EU 2003 11 14 AMCR200300004 120031028G3240AC69784 VALVE BRAERODH125 BAE125800A 1500285EU NLG BRAKE LEAKING B AMCRK NONE O OTHER TXTAXI/GRND HDL 1 GL09526AC4643 258169 CREW NOTICED THAT WHEN THEY ENGAGED THE PARKING BRAKE, A VERY LOUD SQUEALING NOISE COMING FROM THE NOSE AREA, WHICH IS THE LOCATION OF THE EMERGENCY PRESSURE REDUCING VALVE. CHANGED VALVE, PROBLEM SOLVED. SUSPECT INTERNAL LEAKAGE OF VALVE. 2L72 4F RTA3EU 20031114000252003111400025SO 2003 11 14 AMCR200300005 120031028G281079C20H DRAIN VALVE GULSTMGV GULFSTREAMGV3980116SO RT WING BROKEN B AMCRK NONE O OTHER ININSP/MAINT 1 GL09250DV261 691 DURING SUMPING OPERATION OF RT WING HOPPER, THE INTERNAL PIN BROKE, WHICH PREVENTED THE SUMP DRAIN FROM LOCKING IN FLUSH. BY VIRTUE OF THE UNIT BEING ALL PLASTIC, THIS MAY HAVE CONTRIBUTED TO THE PREMATURE FAILURE OF VALVE. 2L72 4F RTA12EA 20031113000642003111300064EU 2003 11 13 AMCR200300006 120031030G28420204KTU4 PROBE BRAERODH125 BAE125800A 1500285EU GARRTTTFE731TFE731* 01518WP FUEL QTY INTERMITTENT B AMCRO OTHER N FALSE WARNING CLCLIMB 1 GL09255DV9187 258070 AFTER TAKE-OFF, PILOT NOTICED A INTERMITTENT DROP ON THE LEFT FUEL QUANTITY GAUGE OF ABOUT 500 LBS, THEN EVERYTHING WAS NORMAL. ON NEXT LEG, AFTER TAKE-OFF, PILOT NOTICED THE SAME THING. INVESTIGATION UNCOVERED AN INTERMITTENT NR 4 FUEL PROBE IN THE LEFT WING. THE INTERMITTENT OPERATION WAS DISCOVERED ONLY AFTER EXPOSING THE PROBES, AND USING A BARFIELD BOX, AND THEN TAPPING ON EACH PROBE, UNTIL THE PROBLEM WAS FOUND. 2L72 4F4 FRTA3EU E6WE 20031117000152003111700015EU 2003 11 17 AMCR200300007 120031030G2622898052 EXTINGUISHER AMD FALC90FALCON900B 2730171EU GARRTTTFE731TFE731* 01518WP CABIN LEAKING B AMCRK NONE K FLUID LOSS ININSP/MAINT 1 GL09522AC3947 148 DURING BASIC INSPECTION, TECHNICIAN FOUND THE COCKPIT FIRE EXTINGUISHER PRESSURE GAUGE TO BE READING AT VERY BOTTOM OF GREEN RANGE. FURTHER INSPECTION REVEALED THE GAUGE TO BE LOOSE, AND SLIGHTLY TWISTING GAUGE CAUSED THE BOTTLE TO LEAK. 2L73 4F4 FRT E6WE 20031230000802003123000080EU 2003 12 30 AMCR200300008 120031118G282011590001 CONTROL VALVE BRAERODH125 BAE125800A 1500285EU FUEL SYSTEM LEAKING B AMCRO OTHER K FLUID LOSS TXTAXI/GRND HDL 1 GL09527AC8145 NA0405 UPON RETURN FROM FLIGHT, MINOR FUEL LEAKAGE WAS OBSERVED ON AFT FUSELAGE. DURING FUELING, FOUND THE FUELING PRESSURE CONTROL VALVE LEAKING. INVESTIGATION REVEALED THAT EXCESSIVE FUELING PRESSURE MAY HAVE BEEN EXCEEDED WHEN AWAY FROM BASE. SUGGEST OPERATORS MONITOR FBO'S FUELING TRUCKS FOR PROPER SINGLE POINT PRESSURE. (VALVE MFG: FLIGHT REFUELING LTD.) 2L72 4F RTA3EU 20031208000382003120800038NM 2003 12 8 ANCF173EE 120031022G32135935348501 CYLINDER DOUG MD80 MD83 3023681NM MLG CRACKED W K NONE O OTHER ININSP/MAINT 1 SW99632CT9094 9094 SCPT1526 49632 AS RESULT OF MAGNETIC PARTICLE INSPECTION AS REQUIRED BY AVIANCA ENGINEERING ORDER 83-32-031 R4 REFERING SB MD80-32A286R3 WAS FOUND THE SHOCK STRUT CYLINDER AT LT MLG WITH CRACKS 2L72 4F RT 20030210000672003021000067SO 2003 2 10 AUS20030008 220030106G855007401061 CONTROL VALVE CONT IO360HB PAC CT4 CT4B GL CONT O360 IO360HB 17025SO HARTZLHCC2Y BHCC2YF1 GL RECIPROCATING ENJAMMED W K NONE EKIVIBRATION/BUFFET FLUID LOSS FLT. ATTITUDE INST. NRNOT REPORTED 1 AUS 120 (AUS) AFTER FIVE MINUTES OF AEROBATICS A LOW OIL PRESSURE INDICATIONWAS NOTED. GROUND CHECK FOUND THE ENGINE OIL QUANTITY OK. ONREMOVAL OF THE AEROBATIC OIL SYSTEM VALVE ASSEMBLY BOTTOM PLUG A1/4IN UNC SCREW WITH ATTACHED LOCKWASHER WAS FOUND. SUSPECT SCREW WAS A LYCOMING ROCKER HAT SCREW. PERSONNEL/MAINTENANCE ERROR. FOD 1L71 3O3 ORTA9PC E1CE 5 CP920 20030210000682003021000068CE 2003 2 10 AUS20030009 120030103G323012805978 TUBE CESSNA210 210M 2073450CE CONT O520 IO520L 17032SO MCAULYD3A34 D3A34C404 GL LANDING GEAR RETCORRODED W K NONE O OTHER LDLANDING 1 AUS (AUS) LANDING GEAR ACCUMULATOR LINE CONTAINED A SMALL CORROSION PINHOLE. LOSS OF HYDRAULIC FLUID. 1H71 3O3 O 3A21 E5CE 5 CP47GL 20030210000692003021000069CE 2003 2 10 AUS20030011 120030107G7602S17773 CABLE LYC O320E2D CESSNA172 172K 2072430CE LYC O320 O320E2D 41508EA AMTR C8289 C8289 GL MIXTURE CONTROL WORN W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) ENGINE MIXTURE CONTROL INNER CABLE WORN. 1H71 3O3 ONT3A12 E274 5 NEXPP5N 20030210000702003021000070CE 2003 2 10 AUS20030012 120030102G5410 FIREWALL CESSNA182 182Q 2072732CE CONT O470 O470U 17026SO MCAULY2A34C C2A34C204 GL NACELLE/PYLON, MDAMAGED W K NONE F FLT CONT AFFECTED NRNOT REPORTED 1 AUS (AUS) PILOT REPORTED THAT THE RUDDER TRIM WAS NOT WORKING.INVESTIGATION FOUND DAMAGE TO THE FIREWALL AND SUPPORTING STRUCTURE. 1H71 3O3 ONT3A13 E273 5 CP3EA 20030210000712003021000071CE 2003 2 10 AUS20030015 120030104G6120C2995120101 CABLE MCAULY D3A34C404 CESSNA210 210R 2073458CE CONT O520 IO520L 17032SO MCAULYD3A34 D3A34C404 GL PROPELLER CONTROFAILED W K NONE I FLT. ATTITUDE INST. CRCRUISE 1 AUS (AUS) AIRCRAFT EXPERIENCED AN UNCOMMANDED INCREASE IN PROPELLER RPM AND FAILED TO RESPOND TO FURTHER COMMANDS. INVESTIGATION FOUND THAT THE STAINLESS STEEL SHAFT END OF THE PROPELLER PITCH CONTROLCABLE HAD FAILED THROUGH THE THREADS LEVEL WITH RODEND LOCATEDNEAR THE PROPELLER GOVERNOR. SUSPECT INITIAL CRACKING WAS CAUSEDBY PREVIOUS INCORRECT RIGGING. PERSONNEL/MAINTENANCE ERROR. 1H71 3O3 ORT3A21 E5CE 5 CP47GL 20030210000722003021000072SO 2003 2 10 AUS20030020 220030110G8530655771 EXHAUST VALVE CONT IO520F CESSNA206 U206G 2073356CE CONT O520 IO520F 17032SO MCAULY3A32C D3A32C90 GL RECIPROCATING ENWORN W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) NO4 CYLINDER EXHAUST VALVE SEAT LEAKING. FOLLOWING VALVE REMOVALSEVERE EROSION WAS THEN FOUND ON THE NECK OF THE VALVE. NO5 CYLINDER EXHAUST VALVE WAS ALSO FOUND TO HAVE A SIMILAR EROSION PROBLEM. ALL OTHER VALVES WERE CHECKED AND FOUND TO BE IN NORMALCONDITION. 1H71 3O3 O A4CE E5CE 5 CP21EA 20030210000732003021000073EA 2003 2 10 AUS20030028 220030113G8520SL16711 BEARING LYC O320D2J CESSNA172 172P 2072436CE LYC O320 O320D2J 41508EA MCAULY1C160 1C160DTM GL RECIPROCATING ENFAILED W K NONE O OTHER ININSP/MAINT 1 AUS 887 L1611539A (AUS) NO4 MAIN BEARING FAILED. BEARING MATERIAL MISSING FROM BEARINGSHELL. AREA OF MISSING MATERIAL APPROXIMATELY 15MM BY 10MM(0.59IN BY 0.39IN). A SMALLER AREA OF BEARING MATERIAL WAS ALSO FOUND MISSING FROM NO3 MAIN BEARING SHELL. THE AREA OF BEARINGMATERIAL DELAMINATED/ERODED FROM NO3 BEARING IS APPROXIMATELY 7MM BY 5MM (0.275IN BY 0.196IN). THE BEARING SURFACE CONTAINED CRACKS AND EVIDENCE THAT AJOINING AREAS OF THE BEARING SURFACE WEREDISTRESSED AND WOULD FAIL IN THE NEAR FUTURE. METAL CONTAMINATION OF OIL SYSTEM. 1H71 3O3 ONT3A12 E274 5 NP910 20030210000742003021000074EU 2003 2 10 AUS20030029 120030114G57305702010404800 WING MUDRY 10 CAP10B 0950102EU LYC O360 AEIO360B2F 41514EA HOFMANHO29 HO29HM180 EU WING, PLATES/SKIFAULTY W K NONE OF OTHER FLT CONT AFFECTED ININSP/MAINT 1 AUS 013 (AUS) LH AILERON INBOARD FORWARD EDGE BINDING ON TRAILING EDGE OF LOWER WING SKIN. SUSPECT MANUFACTURING ERROR. 1L71 3O3 O A36EU 1E10 5 NP3EU 20030210000752003021000075NM 2003 2 10 AUS20030042 120030120G5730 SKIN BOEING727 7272J4 1384006NM PWA JT8 JT8D17 52049NE WING, PLATES/SKICORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) WING CENTRE SECTION LOWER SKIN CORRODED AT BS 840 LBL30, WL168. 2L73 4F4 FRTA3WE E2EA 20030210000762003021000076NM 2003 2 10 AUS20030046 120030120G5730 SKIN BOEING727 7272J4 1384006NM PWA JT8 JT8D17 52049NE WING, PLATES/SKICORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) WING CENTRE SECTION LOWER SKIN CORRODED AT BS 800 LBL20, WL168.1. 2L73 4F4 FRTA3WE E2EA 20030210000772003021000077NM 2003 2 10 AUS20030050 120030120G57106521630187 WING BOEING727 7272J4 1384006NM PWA JT8 JT8D17 52049NE WING, MAIN FRAMEDELAMINATED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LH WING DELAMINATED. 2L73 4F4 FRTA3WE E2EA 20030210000782003021000078NM 2003 2 10 AUS20030051 120030120G57536521630187 SKIN BOEING727 7272J4 1384006NM PWA JT8 JT8D17 52049NE TRAILING EDGE FLDELAMINATED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) INBOARD FORE FLAP LOWER SKIN DELAMINATED. 2L73 4F4 FRTA3WE E2EA 20030210000792003021000079NM 2003 2 10 AUS20030052 120030120G57536521630188 SKIN BOEING727 7272J4 1384006NM PWA JT8 JT8D17 52049NE TRAILING EDGE FLDELAMINATED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) INBOARD FORE FLAP LOWER SKIN DELAMINATED. 2L73 4F4 FRTA3WE E2EA 20030212000362003021200036EA 2003 2 12 AUS20030063 220030116G8550STD1339 SCREW GIPPLDGA8 GA8 EU LYC O540 IO540K1A5 41532EA HARTZLHCC2Y HCC2YR1 GL ENGINE LOOSE W K NONE O OTHER ININSP/MAINT 1 AUS 300 (AUS) ENGINE OIL PUMP BODY 'ALLEN' SCREW LOOSE. FOUND DURING INSPECTION IAW LYCOMING SB/555. 1H71 3O3 ONT 1E4 5 CP920 20030326000192003032600019SO 2003 3 26 AUS20030104 120030131G5330CECONITE101 FABRIC MAULE MX7 MX7180 5460185SO LYC O360 O360C1F 41514EA HARTZLHCC2Y HCC2YR1 GL FUSELAGE FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FUSELAGE AND EMPENNAGE FABRIC COVERING FAULTY. THE 76.2MM (3IN) LINEAR STRAIGHT AND PINKED TAPES COULD BE REMOVED BY LIGHTLYHOLDING THE TAPE BETWEEN THUMB AND FOREFINGER AND WALKING AWAYFROM THE AIRCRAFT REMOVING THE COMPLETE FUSELAGE LENGTH. TAPESFROM THE TAILPLANE WERE HANGING ON THE GROUND. DOPE DISPLAYED POOR PENETRATION AND ADHESION. THE PAINT USED WAS EXTREMELY BRITTLE AND DID NOT APPEAR TO CONTAIN ANY ELASTIC ADDITIVE. 1H71 3O3 ONC3A23 E286 5 CP920 20030326000202003032600020SO 2003 3 26 AUS20030105 120030131G1430 BOLT MAULE MX7 MX7180 5460185SO LYC O360 O360C1F 41514EA HARTZLHCC2Y HCC2YR1 GL WRONG PART W K NONE W INADEQUATE Q C ININSP/MAINT 1 AUS (AUS) THE MAJORITY OF THE BOLTS USED IN THE AIRCRAFT ARE AN TYPE BOLTS WITH A DRILLED SHANK COMBINED WITH A SELF LOCKING NUT. UNAPPROVED PART. PERSONNEL/MAINTENANCE ERROR. 1H71 3O3 ONC3A23 E286 5 CP920 20030326000212003032600021SO 2003 3 26 AUS20030107 120030131G8011 BRUSHES PRESTOLITE MAULE MX7 MX7180 5460185SO LYC O360 O360C1F 41514EA HARTZLHCC2Y HCC2YR1 GL STARTER WORN W K NONE W INADEQUATE Q C ININSP/MAINT 1 AUS 4Y000105 (AUS) STARTER MOTOR BRUSHES WORN UNEVENLY. THE STARTER MOTOR WASREMOVED DUE TO CONTAMINATION WITH ENGINE OIL FROM A LEAKING CRANKSHAFT SEAL. THE UNIT WAS REMOVED AND DISASSEMBLED AND THEFOLLOWING DEFECTS WERE NOTED: BRUSHES FITTED WERE AUTOMOTIVE PARTS AND MUCH HARDER THAN THE COMMUTATOR. THE BRUSH FACE WEAR WAS ANGLED. THE COMMUTATOR HAD BEEN DAMAGED BY THE HARDER BRUSHES. THE STARTER WAS CONTAMINATED EXTERNALLY AND INTERNALLY WITH OIL FROM THE LEAKING CRANKSHAFT SEAL UNAPPROVED PART. PERSONNEL/MAINTENANCE ERROR. 1H71 3O3 ONC3A23 E286 5 CP920 20030326000302003032600030EU 2003 3 26 AUS20030127 120030109G3260J0892 CONNECTOR FOKKERF27 F27MK50 EU PWA PWA120PW125B NE MLG CORRODED W O OTHER O OTHER CRCRUISE 1 AUS (AUS) RT MAIN LANDING GEAR WEIGHT ON WHEELS (WOW) SWITCH JUNCTION BOX CONNECTORS J0892A AND J0892B CORRODED AND CONTAMINATED. 2H72 4T4 TRTA817 E20NE 20030326000322003032600032CE 2003 3 26 AUS20030131 120030113G7602S29991 ROD END CESSNA340 340CESSNA 2076404CE CONT O520 TSIO520K 17040SO MCAULY3AF32C3AF32C87 GL MIXTURE CONTROL SEPARATED W O OTHER E VIBRATION/BUFFET CRCRUISE 1 AUS (AUS) MIXTURE CONTROL SYSTEM ROD END FAULTY. 1L72 3O3 O 3A25 E8CE 5 CP22EA 20030326000392003032600039NM 2003 3 26 AUS20030176 120030214G31501741010201 DISPLAY BOEING737 737800* NM CENTRAL WARNING FAULTY W O OTHER B SMOKE/FUMES/ODORS/SPARKS LDLANDING 1 AUS (AUS) NR 1 MULTIPURPOSE CONTROL DISPLAY UNIT (MCDU) FAULTY. INVESTIGATION FOUND AN INTERNAL SHORT CIRCUIT CAUSED BY A LOOSE OBJECT. 2L72 4F RTA16WE 20030326000152003032600015NE 2003 3 26 AUS20030226 220030224G7200CFM567B24 ENGINE BOEING737 737800* NM GE CFM56 CFM563BUS 13802NE BIRD STRIKE W O OTHER C F.O.D. NRNOT REPORTED 1 AUS 2888 (AUS) ENGINE BIRD STRIKE. REMAINS OF BIRD FOUND INSIDE THRUST REVERSER, IDG OIL COOLER AND BOOSTER INTAKE AREA. BOROSCOPE INSPECTION FOUND DAMAGE TO BLADES IN THE BOOSTER AREA. (P) 2L72 4F4 FRTA16WE E2GL 20030423000272003042300027NM 2003 4 23 AUS20030227 120030217G2710 CONTROL CABLE DHAV DHC8 DHC8202 2809007NM PWA 120 PW123D 52152NE HAMSTD14SF 14SF23 NE AILERONS MISRIGGED W O OTHER F FLT CONT AFFECTED CRCRUISE 1 AUS (AUS) FLIGHT CONTROL PROBLEMS. SUSPECT CAUSED BY AILERON CONTROL SYSTEM RIGGING. PROBLEM WAS FOUND TO BE AN INHERENT CHARACTERISTIC OF THIS SERIES AIRCRAFT. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030423000262003042300026EU 2003 4 23 AUS20030243 120030303G5347DAN1521 FITTING AIRBUS320 A320* EU CFMINTCFM56 CFM565A1 NE SEAT/CARGO ATTACCORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) NUMEROUS TIEDOWN FITTINGS LOCATED BETWEEN FRAME 24 AND FRAME 35 CONTAINED LEVEL 2 CORROSION. FOUND DURING INSPECTION IAW MRBR 53-21-80. 2L72 4F4 FRTA46NM E29NE 20030423000042003042300004EU 2003 4 23 AUS20030253 120030303G5415D5725018320000 SLEEVE AIRBUS320 A320211 3930320EU CFMINTCFM56 CFM565A1 NE RT PYLON CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT PYLON SPIGOT BEARING SLEEVE PITTED AND CORRODED ON INSIDE SURFACE. FOUND DURING INSPECTION IAW J9-IA57-0824(2). 2L72 4F4 FRTA28NM E29NE 20030423000052003042300005EU 2003 4 23 AUS20030254 120030225G71601156602 FLAPPER VALVE GROB G115 G115C 1660303EU LYC O360 O360A1F6 41514EA HARTZLHCF2Y HCF2YR1 GL ENG AIR INTAKE SEPARATED W O OTHER ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS DEDESCENT 1 AUS (AUS) CARBURETOR AIR BOX FLAPPER VALVE SEPARATED FROM SPINDLE SHAFTDUE TO WEAR. 1L71 3O3 ONTA57EU E286 5 CP27EA 20030423000032003042300003 2003 4 23 AUS20030261 420030207G3414415062 INDICATOR CESSNA150 150G 2071816CE CONT O200 O200A 17020SO MCAULY1A102 1A102OCM GL AIRSPEED MISMARKED W K NONE W INADEQUATE Q C ININSP/MAINT 1 AUS (AUS) AIR SPEED INDICATOR (ASI) LIMITS INCORRECTLY MARKED. 1H71 3O3 O 3A19 E252 5 NP918 20030414000772003041400077CE 2003 4 14 AUS20030262 120030224G3260S13771 DOWNLOCK SWITCH CESSNA210 210M 2073450CE CONT O520 IO520L 17032SO MCAULYD3A34 D3A34C404 GL MLG STICKING W O OTHER O OTHER LDLANDING 1 AUS (AUS) RT MAIN LANDING GEAR DOWNLOCK SWITCH STUCK. RT LANDING GEAR COLLAPSED ON LANDING. 1H71 3O3 O 3A21 E5CE 5 CP47GL 20030429001312003042900131CE 2003 4 29 AUS20030264 120030303G275014601007 CONTROL CABLE CESSNA337 337A 2075704CE CONT O360 IO360C 17025SO MCAULY2AF34CD2AF34C306 GL TE FLAP CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FLAP CONTROL CABLES PN 14601007 AND PNO 14601008 CORRODED AND FRAYED. 1H72 3O3 O A6CE E1CE 5 CP5EA 20030423000092003042300009CE 2003 4 23 AUS20030265 120030205G793113P2002 INDICATOR BEECH 58 58 1152740CE CONT O520 IO520C 17032SO MCAULY3AF34C3AF34C502 GL ENG OIL PRESSUREMISMARKED W K NONE W INADEQUATE Q C ININSP/MAINT 1 AUS (AUS) ENGINE OIL PRESSURE GAUGE LIMITS INCORRECTLY MARKED.PERSONNEL/MAINTENANCE ERROR. 1L72 3O3 O 3A16 E5CE 5 CP22EA 20030423000142003042300014NM 2003 4 23 AUS20030267 120030108G5730 SKIN BOEING727 727277 138408SNM PWA JT8 JT8D15 52051NE CENTER WING CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) WING CENTER SECTION UPPER SKIN CONTAINED LEVEL 2 CORROSION AT SECTION 46 STN 825 RBL 13. FOUND DURING INSPECTION IAW CPCP C53-224-05. 2L73 4F4 FRTA3WE E2EA 20030423000162003042300016NE 2003 4 23 AUS20030277 220030224G853071167 EXHAUST VALVE DHAV DHC3 DHC3 2800202EA PWA R1340 S3H1 52016NE HAMSTD23D 23D40 NE ENGINE SEPARATED W O OTHER ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CRCRUISE 1 AUS 921 (AUS) ENGINE EXHAUST VALVE FAILED. VALVE HEAD SEPARATED FROM VALVE STEM CAUSING DAMAGE TO CYLINDER. 1H71 3R3 R A815 E143 6 CP719 20030423000152003042300015NM 2003 4 23 AUS20030292 120030212G5320 BRACKET BOEING727 727277 138408SNM PWA JT8 JT8D15 52051NE FUSELAGE CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) ANGLE BRACKET LOCATED AT CARGO FLOOR LEVEL BS 720D BL 21L CONTAINED LEVEL 2 CORROSION. FOUND DURING CPCP INSPECTION IAW C53-113-01. 2L73 4F4 FRTA3WE E2EA 20030429001422003042900142NM 2003 4 29 AUS20030300 120030212G5311 FRAME BOEING727 727277 138408SNM PWA JT8 JT8D15 52051NE FUSELAGE CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FUSELAGE FRAME LOCATED AT BS 950B BETWEEN STRINGER 27R AND STRINGER 28R CONTAINED LEVEL 2 CORROSION ON THE LOWER FLANGE. FOUND DURING CPCP INSPECTION IAW C53-113-01. 2L73 4F4 FRTA3WE E2EA 20030423000242003042300024NM 2003 4 23 AUS20030304 120030102G5720 STIFFENER BOEING727 727277 138408SNM PWA JT8 JT8D15 52051NE WING SPAR CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FORWARD SPAR LEADING EDGE VERTICAL STIFFENER CONTAINED LEVEL 2CORROSION LOCATED AT STN236. FOUND DURING CPCP INSPECTION IAW C57-562-02. 2L73 4F4 FRTA3WE E2EA 20030423000312003042300031NE 2003 4 23 AUS20030312 220030227G7260 DRIVE SHAFT BOEING727 7272J4 1384006NM PWA JT8 JT8D17 52049NE ENGINE FAILED W O OTHER E VIBRATION/BUFFET NRNOT REPORTED 1 AUS (AUS) NR 1 ENGINE TOWER DRIVE SHAFT FAILED. 2L73 4F4 FRTA3WE E2EA 20030423000322003042300032CE 2003 4 23 AUS20030313 120030310G5521043200121 SPAR CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA MCAULY1A103 1A103TCM GL ELEVATOR CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) ELEVATOR SPAR CRACKED AROUND UPPER RIVET HOLE FOR HINGE BRACKET ATTACHMENT. CRACK LENGTH 30.04MM (1.183IN). CRACK TRAVELS INBOARD AND OUTBOARD FROM RIVET HOLE. 1H71 3O3 ONT3A19 E223 5 NP50GL 20030507000022003050700002CE 2003 5 7 AUS20030314 120030311G5521043200121 SPAR CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA MCAULY1A103 1A103TCM GL ELEVATOR CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT ELEVATOR CORRODED IN AREA OF TORQUE TUBE. CAUSED BY LACK OF PRIMER DURING ASSEMBLY. INSPECTION ALSO FOUND RACKS FOUND EMANATING FROM UPPER AND LOWER RIVET HOLES EXTENDING TOWARDS INBOARD END OF ELEVATOR SPAR AND OUTBOARD END. UPPER RIVET CRACK18.9MM (0.745IN) LONG. LOWER RIVET CRACK 15.8MM (0.625IN) LONG. A CRACK WAS ALSO FOUND IN CIRCUMFERENCE OF HOLE IN THE SPAR THAT THE ELEVATOR TRIM TAB ACTUATOR ROD PASSES THROUGH. 1H71 3O3 ONT3A19 E223 5 NP50GL 20030507000052003050700005GL 2003 5 7 AUS20030319 320030301G6114C84060 HUB BEECH 200 B200C 1152924CE PWA PT6 PT6A42 52043NE HARTZLHCB3T HCB3TN3 GL PROPELLER CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 1873 (AUS) PROPELLER HUB CONTAINED A RADIAL CRACK IN THE OUTBOARD END OF THE NR 1 HUB ARM AT THE HUB/PILOT TUBE JOINT. CRACK WAS CONFIRMEDUSING MAGNETIC PARTICLE INSPECTION (MPI). CRACK LENGTH APPROXIMATELY 25.4MM (1IN). FOUND DURING DISASSEMBLY AND INSPECTION FOLLOWING LIGHTNING STRIKE ON NR 3 BLADE. THE PILOT TUBE PLUGS WERE REMOVED AND NR 1 AND NR 2 HUB ARMS WERE FOUND TO CONTAIN APPROXIMATELY 10ML WATER IN EACH (ALONG WITH CORROSION PREVENTATIVE COMPOUND). 1L72 4T4 T A24CE E4EA 6 CP15EA 20030507000062003050700006EA 2003 5 7 AUS20030320 120030207G5753 HINGE DHAV DHC6 DHC6300 2802606EA PWA PT6 PT6A27 52043EA HARTZLHCB3T HCB3TN3 GL TE FLAP CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LEVEL 1 CORROSION WAS FOUND ON EXTERNAL SURFACES IN VARIOUS LOCATIONS. LEVEL 2 CORROSION WAS FOUND ON FLAP HINGE ARMS,VERTICAL AND HORIZONTAL FORWARD ATTACHMENT FITTINGS. FOUND DURING INSPECTION IAW AD/DHC-6/69, LEVEL 1 AND LEVEL 2 CORROSION WAS FOUND AS OUTLINED IN PSM 1-GEN-5. 1H72 3T4 TRTA9EA E4EA 6 CP15EA 20030507000162003050700016CE 2003 5 7 AUS20030322 120030314G3230124166345 HOOK CESSNA210 210L 2073448CE CONT O520 IO520L 17032SO MCAULY2A34C E2A34C73 GL MLG DOWNLOCK CONTAMINATED W O OTHER N FALSE WARNING LDLANDING 1 AUS (AUS) RT MAIN LANDING GEAR DOWNLOCK HOOK CONTAMINATED WITH DIRT WHICH PREVENTED CORRECT SEATING OF THE HOOK AND ACTIVATION OF THE MICROSWITCH. 1H71 3O3 O 3A21 E5CE 5 CP3EA9 20030507000272003050700027NM 2003 5 7 AUS20030330 120030313G7830 STRIP BOEING767 767338 1385151NM RROYCERB211 RB211524* NE THRUST REVERSER MISSING W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT THRUST REVERSER BULLNOSE STRIP MISSING. THRUST REVERSER METALSEAL STRIP DAMAGED. DAMAGE TO NR 4 AND 9 BLOCKER DOORS AND NR 4, 5, 6 AND 7 CASCADES. 2L72 4F4 FRTA1NM E12EU 20030507000322003050700032EU 2003 5 7 AUS20030336 120030320G5311D53113405200 FRAME AIRBUS320 A320211 3930320EU CFMINTCFM56 CFM565A1 NE FUSELAGE CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FORWARD PRESSURE BULKHEAD FRAME 1 CONTAINED LEVEL 2 CORROSION INAREA AROUND UPPER RIGHT HAND LOCATING CLIP, LEFT HAND LOWER LOCATING CLIP AND RIGHT HAND LOWER LOCATING CLIP. 2L72 4F4 FRTA28NM E29NE 20030507000342003050700034EU 2003 5 7 AUS20030338 120030321G531342L STRINGER AIRBUS320 A320* EU CFMINTCFM56 CFM565A1 NE FUSELAGE CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FORWARD FUSELAGE STRINGER 44 AND STRINGER 42L LOCATED BETWEEN FRAME 28 AND FRAME 29CONTAINED LEVEL 2 CORROSION AROUND RIVET TAILS. 2L72 4F4 FRTA46NM E29NE 20030507000422003050700042 2003 5 7 AUS20030341 420030314G3442071131900 SENSOR BENDIX DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE WEATHER RADAR SYFAILED W O OTHER O OTHER CRCRUISE 1 AUS 3481 (AUS) WEATHER RADAR SENSOR FAILED. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030507000442003050700044CE 2003 5 7 AUS20030343 120030321G1430654811 BOLT BEECH 95 95B55 1152729CE CONT O470 IO470L 17026SO MCAULY2AF34C2AF34C55 GL ENGINE CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) CONNECTING ROD BOLTS CONTAINED PITTING ON GROUND SURFACES. BOLTSWERE NEW ITEMS FOR FITMENT FOLLOWING STRIP AND INSPECTION FOR PROPELLER STRIKE. 1L72 3O3 ORT3A16 3E1 5 CP5EA 20030507000462003050700046SO 2003 5 7 AUS20030345 220030307G8520630826 BEARING CESSNA206 U206 2073306CE CONT O520 IO520A 17032SO MCAULY2A34C D2A34C58 GL ENGINE WORN W K NONE O OTHER ININSP/MAINT 1 AUS 500 (AUS) CONNECTING ROD BIG END BEARING WORN EXCESSIVELY. 1H71 3O3 O A4CE E5CE 5 CP3EA 20030507000472003050700047CE 2003 5 7 AUS20030346 120030202G5312 BULKHEAD CESSNA207 207A 2073604CE FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FORWARD DOORPOST BULKHEAD CRACKED AS INDICATED IN AD/C207/32.2. 1H71 3O A16CE 20030507000482003050700048SO 2003 5 7 AUS20030347 120030314G3210967615 LANDING GEAR PIPER PA34 PA34200 7103405SO LYC O360 IO360C1E6 41514EA HARTZLHCC2Y HCC2YK2 GL MAINS CORRODED W O OTHER O OTHER NRNOT REPORTED 1 AUS (AUS) RT MAIN LANDING GEAR CORRODED (RUSTY). 1L72 3O3 O A7SO 1E10 5 CP920 20030507000492003050700049CE 2003 5 7 AUS20030348 120030319G712004135731 BRACKET CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA MCAULY1A103 1A103TCM GL ENGINE MOUNT LOOSE W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LOWER LH ENGINE MOUNT BRACKET RIVETS SHEARED. SUSPECT CAUSED BY UNREPORTED HEAVY LANDING. 1H71 3O3 ONT3A19 E223 5 NP50GL 20030507000512003050700051CE 2003 5 7 AUS20030350 120030317G3230 DOWNLOCK CESSNA210 210L 2073448CE CONT O520 IO520L 17032SO MCAULYD3A34 D3A34C404 GL RT MLG OUT OF ADJUST W O OTHER J WARNING INDICATION LDLANDING 1 AUS (AUS) LANDING GEAR FAILED TO EXTEND CORRECTLY. INVESTIGATION FOUND THE RT MAIN LANDING GEAR SWITCH AND DOWNLOCK OUT OF ADJUSTMENT. LANDING GEAR CIRCUIT BREAKER CONTAINED A HAIRLINE CRACK. 1H71 3O3 O 3A21 E5CE 5 CP47GL 20030507000542003050700054CE 2003 5 7 AUS20030353 120030317G2436C6110010101 VOLT REGULATOR CESSNA185 185A 2072804CE CONT O520 IO520D 17032SO HARTZLHCC3Y PHCC3YF1 GL DC SYSTEM UNSERVICEABLE W O OTHER B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 AUS (AUS) VOLTAGE REGULATOR FAULTY. VIBRATING CONTACTS WELDED CLOSED CAUSING OVER VOLTAGE WHICH DAMAGED SOME AVIONICS EQUIPMENT. 1H71 3O3 O 3A24 E5CE 5 CP25EA 20030507000612003050700061CE 2003 5 7 AUS20030360 120030305G323312801204 ACTUATOR CESSNA210 210L 2073448CE CONT O520 IO520F 17032SO MCAULYD3A34 D3A34C404 GL MLG FAULTY W O OTHER O OTHER LDLANDING 1 AUS (AUS) LANDING GEAR DOWNLOCK ACTUATOR FAULTY. SUSPECT LEAKING INTERNALLY AS REPLACEMENT OF SEALS FIXED PROBLEM. 1H71 3O3 O 3A21 E5CE 5 CP47GL 20030507000742003050700074CE 2003 5 7 AUS20030366 120030325G1430 RIVET CESSNA182 182P 2075816CE RT WING SPAR MISSING W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) AIRCRAFT CONTAINED NUMEROUS DEFECTS. FOUND WHEN NEW OWNER TOOK DELIVERY. PERIODIC INSPECTION HAD BEEN CARRIED OUT SIX WEEKS (13HOURS) PREVIOUSLY. DEFECTS FOUND WERE: MISSING RIVETS ON THE RT WING MAIN SPAR DUE TO CORROSION. PROPELLER HAD 97 HTR NOT 597 AS REPORTED AND ADVISED BY PREVIOUS MRO. FIXED ELT HAD EXPIRED - NO MENTION ON CURRENT MAINTENANCE RELEASE. TWO SMALL HOLES IN THE LT FUSELAGE SKIN NEAR BATTERY BOX, POSSIBLY DUE TO ELECTRICAL CONTACT. RT FUEL CAP SEALS UNSERVICEABLE AND CAP NOT ATTACHED TO AIRCRAFT. LT AND RT LANDING GEAR LEG FAIRINGS LOOSE ON AIRCRAFT. THROTTLE CABLE ATTACHMENT CLAMP MODIFIED WITH NO SUPPORTING APPROVAL DOCUMENTATION FOUND. 1H71 3O NTTA13 20030507000802003050700080SO 2003 5 7 AUS20030367 120030325G32307642603 LINK PIPER PA28 PA28R201T 7102813SO CONT O360 TSIO360F 17025SO HARTZLHCC2Y BHCC2YF2 GL NLG FAILED W O OTHER J WARNING INDICATION CLCLIMB 1 AUS (AUS) NOSE LANDING GEAR DRAG LINK ASSEMBLY SHEARED IN AREA LOCATEDFORWARD OF THE RH ATTACHMENT POINT. 1L71 3O3 O 2A13 E9CE 5 CP920 20030507000822003050700082EU 2003 5 7 AUS20030370 120030327G5753D5755103020000 FLAP TRACK AIRBUS320 A320* EU CFMINTCFM56 CFM565A1 NE TE FLAPS CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT WING NR 4 FLAP TRACK AFT SPIGOT AND BUSH CONTAINED LEVEL 2 CORROSION. FOUND DURING INSPECTION IAW J9-IA57-0408. 2L72 4F4 FRTA46NM E29NE 20030507000832003050700083SO 2003 5 7 AUS20030371 120030226G55009587100 SPAR CAP PIPER PA34 PA34200T 7103406SO CONT O360 TSIO360E 17025SO HARTZLHCC2Y BHCC2YF2 GL STABILATOR CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RH STABILATOR LOWER SPAR CAP CORRODED. 1L72 3O3 O A7SO E9CE 5 CP920 20030507000852003050700085EA 2003 5 7 AUS20030373 220030317G8500TIO540J2BD ENGINE PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2 GL MAKING METAL W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) ENGINE OIL FILTER CONTAMINATED WITH SMALL BRIGHT NON-FERROUSMETAL FLAKES. 1L72 3O3 O A20SO E14EA 5 CP33EA 20030507000872003050700087CE 2003 5 7 AUS20030375 120030312G554007606041 BAR CESSNA182 182Q 2072732CE CONT O470 O470U 17026SO MCAULY2A34C 2A34C203 GL RUDDER CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RUDDER BAR CRACKED AT BASE OF RUDDER PEDAL POST. 1H71 3O3 ONT3A13 E273 5 CP3EA 20030507000962003050700096 2003 5 7 AUS20030379 420030328G34427008470912 TRANSCEIVER FOKKERF27 F27MK50 EU PWA PWA120PW125B NE WEATHER RADAR FAILED W O OTHER O OTHER CLCLIMB 1 AUS 10415 (AUS) WEATHER RADAR TRANSCEIVER FAILED. 2H72 4T4 TRTA817 E20NE 20030507001002003050700100CE 2003 5 7 AUS20030383 120030327G2710 PIN CESSNA172 172N 2072434CE AILERON CONTROL MISSING W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT AILERON CHAIN CLEVIS BOLT SPLIT PINS MISSING AND TOP NUT LOOSE. THE AIRCRAFT HAD ONLY FLOWN FOR TWO HOURS SINCE THE LAST ANNUAL INSPECTION. 1H71 3O NT3A12 20030507001112003050700111EU 2003 5 7 AUS20030387 220030326G7320737M28500011 VALVE BOEING737 737376 NM CFMINTCFM56 CFM563C 13802EU RT ENGINE FAULTY W O OTHER E VIBRATION/BUFFET NRNOT REPORTED 1 AUS 571 (AUS) RT ENGINE SPAR VALVE FAULTY. 2L72 4F4 FRTA16WE E21EU 20030507001282003050700128SO 2003 5 7 AUS20030395 220030304G73146462121 PUMP CESSNA210 210N 2073453CE CONT O520 IO520L 17032SO MCAULYD3A34 D3A34C404 GL ENGINE FUEL FAULTY W O OTHER E VIBRATION/BUFFET NRNOT REPORTED 1 AUS (AUS) ENGINE DRIVEN FUEL PUMP FAULTY. 1H71 3O3 O 3A21 E5CE 5 CP47GL 20030507001432003050700143SO 2003 5 7 AUS20030401 120030331G2434 ALTERNATOR PIPER PA28 PA28181 7102807SO LYC O360 O360* 41514EA AMTR C8289 C8289 GL ENGINE FAILED W O OTHER H ELECT. POWER LOSS-50 PC CRCRUISE 1 AUS (AUS) ALTERNATOR FAILED. COMPLETE LOSS OF ELECTRICAL POWER. 1L71 3O3 O 2A13 E286 5 NEXPP5N 20030507001442003050700144CE 2003 5 7 AUS20030402 120030402G324540135 TUBE CESSNA402 402C 207590RCE CONT O520 TSIO520VB 17040SO MCAULY3AF32C3AF32C87 GL TIRE DAMAGED W C ABORTED TAKEOFF O OTHER TOTAKEOFF 1 AUS (AUS) LT MAIN WHEEL TIRE DEFLATED DUE TO PINCHED TUBE. 1L72 3O3 O A7CE E8CE 5 CP22EA 20030509000912003050900091EU 2003 5 9 AUS20030403 120030406G3610W901B24DE CLAMP REIMS 406 F406 7535723EU PWA PT6 PT6A112 52043NE MCAULY3G34C73GFR34C701 GL PNEUMATIC SYS CORRODED W O OTHER J WARNING INDICATION CRCRUISE 1 AUS (AUS) NR 1 ENGINE SHUT DOWN FOLLOWING LT WING OVERHEAT WARNING.INVESTIGATION FOUND THE CLAMP ATTACHED TO THE PNEUMATIC FLOWCONTROL VALVE DOWNSTREAM FROM THE NO1 ENGINE BLEED PORT CORRODEDAND RUPTURED CAUSING EXCESSIVE AIR LEAKS. 1L72 3T3 TRTA54EU E4EA 5 CP60GL 20030509000922003050900092EA 2003 5 9 AUS20030404 220030408G8530SL54002NLC CYLINDER LYC O540 TIO540A2B 41532EA ENGINE FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) CYLINDER ASSY INLET VALVE SPRING RETAINER INCORRECT PART. EXHAUST VALVE SPRING RETAINER FITTED. SIX NEW CYLINDERS WERESUPPLIED&IT FOUND THAT NOT ONLY DID PREVMENTIONED CYLINDER HAVE WRONG SPRING RETAINER FITTED BUT ALLCYLINDERS HAD AN AMOUNT OF ALUMINIUM SWARF IN THE ROCKER BOX AREA WHICH RESULTED IN HAVING TO REMOVE ALL SPRINGS&VALVES FROMCYLINDERS TO WASH THEM OUT. ONCE SPRINGS WERE REMVD ITFOUND THAT INCORRECT INLET LOWER SPRING SEATS HAD BEEN FITTED TO ALL CYLINDERS (EXHAUST LOWER SPRING SEATS HAD BEEN FITTEDINSTEAD). ON FURTHER INSPECTION IT FOUND ON ONE CYLINDER THAT THERE WAS RAISED BURRS AROUND CYLINDER BASE STUD HOLES. THEREFORE BEING NARROW DECK CYLINDERS THEY HAVE HOLD DOWN PLATES FITTED.WHEN A 3 O E14EA 20030509000932003050900093EU 2003 5 9 AUS20030405 220030404G7321 FUEL CONTROL BOEING737 737376 NM CFMINTCFM56 CFM563C 13802EU ENGINE FAULTY W O OTHER ERJVIBRATION/BUFFET PARTIAL RPM/PWR LOSS WARNING INDICATION CRCRUISE 1 AUS (AUS) NR 2 ENGINE POWER MANAGEMENT CONTROL (PMC) FAULTY. 2L72 4F4 FRTA16WE E21EU 20030515001632003051500163EU 2003 5 15 AUS20030407 120030405G5610D20543405 WINDSHIELD FOKKERF28 F28MK0100 4990807EU RROYCETAY TAY62015 04564NE COCKPIT CRACKED W O OTHER O OTHER CRCRUISE 1 AUS (AUS) LT WINDSHIELD CRACKED. SUSPECT CAUSED BY MOISTURE INGRESS. 2L72 4F4 FRT E25NE 20030602000462003060200046SO 2003 6 2 AUS20030412 120030403G571162054 SPAR PIPER PA28 PA28140 7102802SO LYC O320 O320* 41508EA AMTR C8289 C8289 GL LT WING CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LEFT WING REAR SPAR HEAVILY CORRODED UNDER THE REAR SPAR ATTACHMENT PLATE. 1L71 3O3 O 2A13 E274 5 NEXPP5N 20030602000482003060200048EA 2003 6 2 AUS20030414 220030314G8520SL74309M03 BEARING PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2 GL ENGINE DELAMINATED W K NONE O OTHER ININSP/MAINT 1 AUS 2050 (AUS) NR 5 CONNECTING ROD BEARING DELAMINATED. AREA OF DELAMINATION APPROXIMATELY 8MM BY 2MM (0.314IN BY 0.078IN). 1L72 3O3 O A20SO E14EA 5 CP33EA 20030602000552003060200055CE 2003 6 2 AUS20030416 120030410G2823C2915030101 SELECTOR CESSNA210 210L 2073448CE CONT O520 IO520L 17032SO MCAULYD3A34 D3A34C404 GL FUEL SYSTEM WRONG PART W O OTHER WE INADEQUATE Q C VIBRATION/BUFFET CRCRUISE 1 AUS 5 (AUS) FUEL SELECTOR FAULTY. INVESTIGATION FOUND THAT THE SELECTOR HAD BEEN INCORRECTLY ASSEMBLED DURING OVERHAUL 5 HOURS PREVIOUSLY. 1H71 3O3 O 3A21 E5CE 5 CP47GL 20030602000712003060200071EA 2003 6 2 AUS20030418 220030401G8520LW12696 CRANKCASE CESSNA150 A152 2071836CE LYC O235 O235L2C 41505EA MCAULY1A103 1A103TCM GL ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) CRANKCASE CRACKED BEYOND REPAIR AT LH CENTRE CAM JOURNAL BEARINGBASE. CRACK RUNS ACROSS THE JOURNAL SURFACE AND THEN DOWN FOR APPROXIMATELY 76.2MM (3IN) BEFORE TRAVELLING FOR ANOTHER 76.2MM (3IN) REARWARDS. SUMP INDUCTION TUBES LOOSE. THREE CYLINDERS CRACKED. SUSPECT SB/530A NOT CARRIED OUT ON CRANKSHAFT. INSIDEDIAMETER OF CRANKSHAFT CORRODED BEYOND LIMITS. 1H71 3O3 O 3A19 E223 5 NP50GL 20030602000722003060200072CE 2003 6 2 AUS20030419 120030411G7603S122210A CONTROL CABLE CESSNA206 U206 2073306CE CONT O520 IO520A 17032SO MCAULY2A34C D2A34C58 GL POWER LEVER SEPARATED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) THROTTLE CABLE OUTER GUIDE SEPARATED FROM SWAGED SWIVEL JOINT ALLOWING CABLE TO FAIL IN COMPRESSION. 1H71 3O3 O A4CE E5CE 5 CP3EA 20030602000742003060200074EU 2003 6 2 AUS20030421 220030413G7250 BLADE BOEING737 737400 138449ANM CFMINTCFM56 CFM563C 13802EU TURBINE SECTION DAMAGED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) NR 2 ENGINE HIGH PRESSURE TURBINE BLADES DAMAGED. ONE BLADE HAD MATERIAL MISSING AND TWO BLADES HAD IMPACT CRACKING. FOUND DURING BOROSCOPE INSPECTION. 2L72 4F4 FRTA16WE E21EU 20030602000772003060200077NM 2003 6 2 AUS20030424 120030416G2740 TRIM PANEL BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU STABILIZER FAULTY W O OTHER F FLT CONT AFFECTED TOTAKEOFF 1 AUS (AUS) STABILISER TRIM SYSTEM FAULTY. HORIZONTAL STABILISER MAIN TRIMACTUATOR AND HORIZONTAL STABILISER TRIM RELAY R64 REPLACED. 2L72 4F4 FRTA16WE E21EU 20030605000132003060500013EU 2003 6 5 AUS20030438 120030421G4930P93A19203 PUMP AIRBUS330 A330202 3930316EU GE CF6 CF680 30025NE APU FUEL FAILED W O OTHER J WARNING INDICATION NRNOT REPORTED 1 AUS (AUS) APU FUEL PUMP FAILED. AFT PUMP HAD THE COVER BLOWN OFF AND FUEL IN THE ELECTRICAL WINDINGS. 2L72 4F4 FRTA46NM E13NE 20030605000152003060500015CE 2003 6 5 AUS20030441 120030416G7713 HOSE CESSNA402 402C 207590RCE CONT O520 TSIO520VB 17040SO MCAULY3AF32C3AF32C93 GL MANIFOLD PRESS CRACKED W O OTHER EI VIBRATION/BUFFET FLT. ATTITUDE INST. DEDESCENT 1 AUS (AUS) MANIFOLD PRESSURE GAUGE HOSE CRACKED. 1L72 3O3 O A7CE E8CE 5 CP22EA 20030707000032003070700003NE 2003 7 7 AUS20030443 220030403G7310430137601 MANIFOLD BOLKMS117 BK117B2 5626013EU LYC LTS101LTS101750B1 41560NE FUEL DIST CRACKED W K NONE K FLUID LOSS ININSP/MAINT 1 AUS (AUS) NR 1 ENGINE FUEL MANIFOLD LEAKING DUE TO CRACKING AT THE SOLID TUBE/RAIL LOCATED AT THE 4 O'CLOCK POSITION. 1G72 3U3 UNCH13EU E5NE10 20030707000042003070700004NE 2003 7 7 AUS20030444 220030403G7310430128602 MANIFOLD BOLKMS117 BK117B2 5626013EU LYC LTS101LTS101750B1 41560NE FUEL DIST FAULTY W O OTHER K FLUID LOSS NRNOT REPORTED 1 AUS (AUS) NR 1 ENGINE REPLACEMENT FUEL MANIFOLD FAULTY. SUSPECT FLOW DIVIDER PROBLEM. MANIFOLD WAS FITTED TO REPLACE A CRACKED AND LEAKING MANIFOLD. SEE MDR 03/0443 FOR DEFECT. 1G72 3U3 UNCH13EU E5NE10 20030707000052003070700005CE 2003 7 7 AUS20030445 120030414G7331C6620200118 INDICATOR CESSNA402 402C 207590RCE CONT O520 TSIO520VB 17040SO MCAULY3AF32C3AF32C93 GL FUEL FLOW FAULTY W O OTHER N FALSE WARNING TOTAKEOFF 1 AUS (AUS) RT ENGINE FUEL FLOW INDICATOR FAULTY. 1L72 3O3 O A7CE E8CE 5 CP22EA 20030707000062003070700006SO 2003 7 7 AUS20030446 220030410G8520646438 CRANKSHAFT PIPER PA46 PA46310P 7104605SO CONT O520 TSIO520B 17040SO HARTZLHCC2Y BHCC2YF1 GL ENGINE CRACKED W O OTHER E VIBRATION/BUFFET LDLANDING 1 AUS (AUS) CRANKSHAFT CRACKED RADIALLY IN AREA LOCATED BEHIND THE PROPELLER FLANGE. CRACK LENGTH APPROXIMATELY 50.8MM (2IN). 1L71 3O3 ORTA25SO E8CE 5 CP920 20030707000072003070700007EA 2003 7 7 AUS20030447 220030413G8530 INTAKE VALVE ROBSINR22 R22BETA 7640110NM LYC O320 O320B2C 41508EA ENGINE FAILED W O OTHER E VIBRATION/BUFFET LDLANDING 1 AUS (AUS) INLET VALVE FACE BREAKING UP. 1G71 3O3 O H10WE E274 20030707000082003070700008SW 2003 7 7 AUS20030448 120030425G651040734033910B BEARING BELL 407 407 1182206SW ALLSN 250C 250C47B GL TAIL ROTOR DRIVEWORN W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) TAIL ROTOR DRIVESHAFT BEARING WORN AND ROUGH IN OPERATION.BEARING GREASE EXPELLED. GREASE WAS DISCOLORED. 1G71 3U3 UO H2SW E1GL 20030707000092003070700009WP 2003 7 7 AUS20030449 120030409G6720HS105324 CONTROL CABLE HILLERUH12 UH12E 4360122WP LYC O540 VO540C2A 41532EA TAIL ROTOR FAILED W O OTHER F FLT CONT AFFECTED TOTAKEOFF 1 AUS (AUS) TAIL ROTOR CONTROL CABLE FAILED. CABLE RUNS FROM RT PEDAL TO FIREWALL LOCATED BEHIND THE PILOT SEAT. CABLE HAD BEEN SUBJECTEDTO HEAT SOURCE, POSSIBLY CONTACT WITH CIRCUIT BREAKER LOCATED IN CENTER TUNNEL WHEN TENSION WAS RELEASED DURING MAINTENANCE. PERSONNEL/MAINTENANCE ERROR. 1G71 3O3 O 4H11 E304 20030707000102003070700010EU 2003 7 7 AUS20030450 120030409G5713KB574601 STRINGER FOKKERF28 F28MK0100 4990807EU RROYCETAY TAY62015 04564NE RT CENTER WING CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS 5950 (AUS) RT CENTER WING STRINGER CONNECTING ANGLE LOCATED AT ZONE 138 STA 16511 CONTAINED EXFOLIATION CORROSION. 2L72 4F4 FRT E25NE 20030707000142003070700014EU 2003 7 7 AUS20030451 220030420G7200 ENGINE BOEING737 7373Q8 1384670NM CFMINTCFM56 CFM563C 13802EU NR 1 VIBRATES W O OTHER EF VIBRATION/BUFFET FLT CONT AFFECTED DEDESCENT 1 AUS (AUS) NR 1 ENGINE SURGED AND SEVERAL LOUD BANGS WERE HEARD. MAXIMUM VIBRATION RECORDED ON VIBRATION INDICATOR. 2L72 4F4 FRTA16WE E21EU 20030707000162003070700016NM 2003 7 7 AUS20030453 120030430G361097918011 VALVE BOEING747 747338 NM RROYCERB211 RB211524D43954555NE PNEUMATIC SYS FAULTY W O OTHER MJ OVER TEMP WARNING INDICATION CRCRUISE 1 AUS (AUS) STRUT OVERHEAT WARNING. HIGH STAGE VALVES AND PYLON VALVES REPLACED. LIMITED INFORMATION PROVIDED. 2L72 4F4 FRTA20WE E12EU 20030707000172003070700017CE 2003 7 7 AUS20030454 120030324G7921636900RC OIL COOLER CESSNA402 402C 207590RCE CONT O520 TSIO520VB 17040SO MCAULY3AF32C3AF32C93 GL ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT ENGINE OIL COOLER CRACKED IN AREA NEAR OIL PRESSURE MOUNTHOLE. 1L72 3O3 O A7CE E8CE 5 CP22EA 20030707000182003070700018CE 2003 7 7 AUS20030455 120030428G3710216CW PUMP CESSNA402 402C 207590RCE CONT O520 TSIO520VB 17040SO MCAULY3AF32C3AF32C87 GL VACUUM SYS FAILED W O OTHER O OTHER NRNOT REPORTED 1 AUS 300 15171 (AUS) RT ENGINE DRIVEN VACUUM PUMP FAILED. 1L72 3O3 O A7CE E8CE 5 CP22EA 20030707000192003070700019GL 2003 7 7 AUS20030456 120030419G3246AN364428 NUT AMTR VANS RV8 GL LYC O360 IO360A1A 41514EA HARTZLHCC2Y HCC2YK1 GL MLG WHEEL FAILED W O OTHER D INFLIGHT SEPARATION LDLANDING 1 AUS (AUS) NOSE LANDING GEAR AXLE BOLT NUT FAILED. NOSEWHEEL SEPARATED FROM AIRCRAFT. 1L71 3O3 ONTEXPA1L711E10 5 CP920 20030707000202003070700020EU 2003 7 7 AUS20030457 120030422G3233 SWITCH REIMS 406 F406 7535723EU PWA PT6 PT6A112 52043NE MCAULY3G34C73GFR34C701 GL ACTUATOR FAILED W K NONE O OTHER ININSP/MAINT 1 AUS 109 (AUS) NOSE LANDING GEAR ACTUATOR FAULTY. SWITCH OUT OF ADJUSTMENT. 1L72 3T3 TRTA54EU E4EA 5 CP60GL 20030707000222003070700022EA 2003 7 7 AUS20030459 220030422G8520LW13923 BUSHING PIPER PA28 PA28R200 7102811SO LYC O360 IO360C1C 41514EA HARTZLHCC2Y HCC2YK1 GL NR 4 CYLINDER FAILED W O OTHER EY VIBRATION/BUFFET ENGINE STOPPAGE CRCRUISE 1 AUS 582 (AUS) NR 4 CYLINDER CONNECTING ROD FAILED. ENGINE SEVERELY DAMAGED. METAL CONTAMINATION OF OIL SYSTEM. INVESTIGATION FOUND CONNECTING ROD LITTLE END BUSH FAILED. ALL OTHER LITTLE END BUSHES EXHIBITED SIGNS OF CRACKING AND UNUSUAL WEAR PATTERNS. 1L71 3O3 O 2A13 1E10 5 CP920 20030707000232003070700023CE 2003 7 7 AUS20030460 120030427G3230 BOLT BEECH 200 B200C 1152924CE PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL MLG SHEARED W O OTHER J WARNING INDICATION LDLANDING 1 AUS (AUS) NOSE LANDING GEAR UPPER DRAG BRACE BENT AND FORK END OF NOSELANDING GEAR ACTUATOR SPREAD. FURTHER INVESTIGATION ALSO FOUND THE ACTUATOR UPPER SUPPORT BEARINGS ROUGH AND UNSERVICEABLE. SUSPECT CAUSED BY SHEARING OF THE CLEVIS BOLT WHICH ALLOWED THE ACTUATOR TO SEPARATE FROM THE DRAG BRACE. 1L72 4T4 T A24CE E4EA 6 CP15EA 20030902000062003090200006NM 2003 9 2 AUS20030461 120030430G6310A1902 DRIVE BELT ROBSIN ROBSINR22 R22BETA 7640110NM LYC O360 O360J2A 41514EA CLUTCH MOTOR DISTORTED W O OTHER F FLT CONT AFFECTED CRCRUISE 1 AUS 5880 (AUS) ENGINE TO TRANSMISSION DRIVE BELTS STRETCHED. CLUTCH MOTOR DAMAGED. 1G71 3O3 O H10WE E286 20030902000072003090200007EU 2003 9 2 AUS20030463 120030409G5315BL600LBL600RBLO FLOORBEAM FOKKERF28 F28MK0100 4990807EU RROYCETAY TAY62015 04564NE FUSELAGE CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FORWARD FUSELAGE FLOORBEAMS CONTAINED EXFOLIATION CORROSION IN AREA BELOW THE FORWARD CABIN FLOOR PANELS. CORROSION WAS PRESENT AT SEVERAL FASTENER HOLES ON EACH OF THE FOUR FLOORBEAMS ATBL600L, BL600R AND BL 1127R. SUSPECT CAUSED BY GALLEY SPILLAGES. 2L72 4F4 FRT E25NE 20030902000082003090200008NE 2003 9 2 AUS20030465 220030430G72103030988 SEAL STBROSSD3 SD360 8100606EU PWA PT6 PT6A67R 52043NE HARTZLHCA6A HCA6A3 NE TURBINE ENGINE LEAKING W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT ENGINE PROPELLER SHAFT SEAL DETERIORATED AND LEAKING. 2H72 4T4 T A41EU E26NE 6 CP14NE 20030902000092003090200009NM 2003 9 2 AUS20030466 120030427G324221565 BRAKE DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE MLG FAULTY W O OTHER O OTHER TXTAXI/GRND HDL 1 AUS 59 (AUS) NR 3 MAIN WHEEL BRAKE WOULD NOT RELEASE. DURING TAXI, THE BRAKE OVERHEATED AND THE THERMAL RELIEF PLUG IN NR 3 MAIN WHEEL BLEW. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030902000102003090200010NE 2003 9 2 AUS20030467 220030421G73103035987 LINE DHAV DHC8 DHC8202 2809007NM PWA 120 PW123D 52152NE HAMSTD14SF 14SF23 NE ENGINE CHAFED W K NONE O OTHER ININSP/MAINT 1 AUS 11481 (AUS) ENGINE FUEL LINE CHAFED IN AREA OF FIREWALL SEAL. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030617000012003061700001NM 2003 6 17 AUS20030468 120030420G2841 INDICATOR BOEING737 737376 NM CFMINTCFM56 CFM563C 13802EU FUEL QTY FALSE INDICATIONW O OTHER KN FLUID LOSS FALSE WARNING CLCLIMB 1 AUS (AUS) NR 1 FUEL GAUGE INDICATING FUEL LEAK. INSPECTION COULD FIND NO EVIDENCE OF LEAKS. 2L72 4F4 FRTA16WE E21EU 20030617000022003061700002SW 2003 6 17 AUS20030469 120030501G3230 DRAG LINK SWRNGNSA227 SA227* SW GARRTTTPE331TPE331* 01514WP MCAULY4HFR344HFR34C652 NE MLG WORN W O OTHER O OTHER APAPPROACH 1 AUS 15490 (AUS) RT MAIN LANDING GEAR SLOW TO OPERATE. SUSPECT CAUSED BY A COMBINATION OF DOOR RIGGING AND DRAG LINK WEAR. THE DOOR RIGGING WAS CLOSELY EXAMINED AND THE INBOARD DOOR ADJUSTMENT WAS CONSIDERED TO BE A BIT TIGHT. THE INBOARD DOOR WAS ADJUSTED. THE EMERGENCY EXTENSION ACTUATOR WAS REPLACED AND MINOR ADJUSTMENTS MADE TO THE RIGGING. THE DRAG BRACE LOWER LINK INBOARD UPPER BUSH FOUND TO BE SLIGHTLY OFF CENTER AND WAS ADJUSTED TO BE CENTRALIZED. THE UPPER OUTBOARD DRAG LINK BUSHING WAS FOUND FLOATING IN THE CASTING AND WAS SECURED. THE RT LANDING GEAR, GEAR UP AND GEAR DOWN HYDRAULIC LINES WERE THEN FLUSHED CLEAN. FUNCTIONAL CHECKS WERE CARRIED OUT WITHOUT FAULT. 2L72 4T3 TRTA5SW E2WE 6 C3PNE 20030617000032003061700003SW 2003 6 17 AUS20030470 120030502G5313108771 LONGERON AIRTRCAT500 AT502 0390303SW PWA PT6 PT6A15AG 52043NE HARTZLHCB3T HCB3TN3 GL FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FUSELAGE LONGERON CRACKED IN AREA INDICATED IN SL195. 1L71 3T4 TNCA9SW E4EA 6 CP15EA 20030617000042003061700004NM 2003 6 17 AUS20030471 120030502G5270835109 CIRCUIT CARD BOEING767 767338 1385151NM RROYCERB211 RB211524* NE DOOR WARNING SYSFAULTY W O OTHER N FALSE WARNING CRCRUISE 1 AUS (AUS) CARGO DOOR WARNING. INVESTIGATION FOUND CARD 007 FAULTY. 2L72 4F4 FRTA1NM E12EU 20030617000062003061700006SO 2003 6 17 AUS20030473 120030502G322167054003 TRUNNION PIPER PA28 PA28R200 7102811SO CONT IO360 IO360* 17025CE HARTZLHCC2Y HCC2YK1 GL NLG CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) NOSE LANDING GEAR UPPER TRUNNION CRACKED AT DRAG BRACE ATTACHMENT POINT. SUSPECT CAUSED BY EXCEEDING TURNING LIMITS DURING GROUND HANDLING. 1L71 3O3 O 2A13 E1CE 5 CP920 20030617000152003061700015CE 2003 6 17 AUS20030479 120030309G275014601007 CONTROL CABLE CESSNA337 M337B 2075708CE CONT O360 IO360D 17025SO MCAULY2AF34CD2AF34C59 GL TE FLAPS FRAYED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LH TRAILING EDGE FLAP CONTROL CABLE CONTAINED BROKEN STRANDS IN AREA APPROXIMATELY 25.4MM (1IN) FROM SWAGE AT BELLCRANK END. 1H72 3O3 ORTA6CE E1CE 5 CP5EA 20030617000172003061700017SO 2003 6 17 AUS20030481 120030507G7922SL53E19600 VALVE PIPER PA31 PA31350 7103110SO LYC O540 LTIO540J2BD 41533EA HARTZLHCE3Y HCE3YR2 GL ENG OIL TEMP FAILED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) ENGINE OIL SYSTEM THERMOSTATIC OIL COOLER BYPASS VALVE SHAFT NUTLOCK PIN SHEARED. NUT SEPARATED FROM SHAFT AND WAS FOUND IN THE OIL COOLER FLEX LINE. MAIN BODY CIRCLIP GROOVE SHOULDER FAILED FOR APPROXIMATELY 25 PERCENT OF CONTACT AREA. 1L72 3O3 O A20SO E14EA 5 CP33EA 20030617000332003061700033CE 2003 6 17 AUS20030485 120030426G3246AN515A BOLT CESSNA441 441 2076020CE GARRTTTPE331TPE3318 01514WP HARTZLHCB3T HCB3TN5 GL WHEEL MISSING W K NONE O OTHER ININSP/MAINT 1 AUS 1090 (AUS) MAIN WHEEL BRAKE DISC RETAINING BOLTS (3OFF) MISSING AND FIVE BOLTS LOOSE. 1L72 3T4 TRTA28CE E4WE 6 CP15EA 20030617000342003061700034NM 2003 6 17 AUS20030486 120030430G6310A1902 DRIVE BELT ROBSINR22 R22BETA 7640110NM LYC O320 O320B2C 41508EA ENGINE/XMSN STRETCHED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) ENGINE TO TRANSMISSION DRIVE BELTS STRETCHED BEYOND LIMITS. 1G71 3O3 O H10WE E274 20030617000412003061700041EU 2003 6 17 AUS20030494 120030206G5315 FLOORBEAM AIRBUS320 A320* EU CFMINTCFM56 CFM565A1 NE FUSELAGE CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FLOORBEAMS CONTAINED LEVEL 2 CORROSION BETWEEN FR 64 AND FR 69.THE FOLLOWING FLOORBEAMS WERE AFFECTED:- 1) FLOORBEAM (PN D5347217220390) FROM FR66 TO FR68 RT IN TWO AREAS AT Y1292.0 RT 2) FLOORBEAM (PN D5347218920200) ON AFT OF FR69 AT Y1162.5 RT. 2L72 4F4 FRTA46NM E29NE 20030617000832003061700083NM 2003 6 17 AUS20030501 120030509G5270S15 SWITCH BOEING727 727277 138408SNM PWA JT8 JT8D15 52051NE DOOR WARNING SYSOUT OF ADJUST W O OTHER N FALSE WARNING CRCRUISE 1 AUS (AUS) MAIN CARGO DOOR AFT AUXILIARY LATCH SWITCH OUT OFADJUSTMENT. 2L73 4F4 FRTA3WE E2EA 20030617000842003061700084GL 2003 6 17 AUS20030502 320030122G6111106GA0 BLADE CESSNA208 208B 2073701CE PWA PT6 PT6A114A 52043NE MCAULY3AF34C3GFR34C703 GL PROPELLER DAMAGED W O OTHER C F.O.D. LDLANDING 1 AUS 1913 (AUS) PROPELLER NR 3 BLADE CONTAINED STONE DAMAGE AT THE 50 INCH STATION. BLADE LEADING EDGE CONTAINED A 6.350MM TO 12.7MM (0.25IN TO 0.5IN) TEAR. DAMAGE EXCEEDED REPAIRABLE LIMITS. 1H71 3T3 T A37CE E4EA 5 CP60GL 20030617000852003061700085NE 2003 6 17 AUS20030503 220030205G732132448973 FUEL CONTROL CESSNA208 208B 2073701CE PWA PT6 PT6A114A 52043NE MCAULY3AF34C3GFR34C703 GL ENGINE FAULTY W O OTHER EJ VIBRATION/BUFFET WARNING INDICATION CRCRUISE 1 AUS 1072 (AUS) ENGINE POWER FLUCTUATIONS. SUSPECT FAULTY FCU. 1H71 3T3 T A37CE E4EA 5 CP60GL 20030617000862003061700086GL 2003 6 17 AUS20030504 320030328G6111931836 BLADE CESSNA208 208B 2073701CE PWA PT6 PT6A114A 52043NE MCAULY3AF34C3GFR34C703 GL PROPELLER DAMAGED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) PROPELLER BLADES (2OFF) CONTAINED DEEP SCORING ON THE CAMBER SIDE LOCATED APPROXIMATELY 76.2MM TO 127MM (3IN TO 5IN) FROM THE TIP. 1H71 3T3 T A37CE E4EA 5 CP60GL 20030617000882003061700088CE 2003 6 17 AUS20030505 120030327G215026012672 DRIVE SHAFT CESSNA208 208B 2073701CE PWA PT6 PT6A114A 52043NE MCAULY3AF34C3GFR34C703 GL CABIN COOLING WORN W K NONE O OTHER ININSP/MAINT 1 AUS 902 (AUS) AIR CONDITIONING DRIVE UNIT DRIVESHAFT SPLINE WORN. OIL LEAK.CORRESPONDING SPLINE IN THE GEAROX SHAFT GEAR PNO 3100450-01 ALSO WORN. SUSPECT CAUSED BY LACK OF LUBRICATION. 1H71 3T3 T A37CE E4EA 5 CP60GL 20030617000892003061700089CE 2003 6 17 AUS20030506 120030108G2150MRC206SZZC BEARING CESSNA208 208B 2073701CE PWA PT6 PT6A114A 52043NE MCAULY3AF34C3GFR34C703 GL CABIN COOLING SYSEIZED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) AIRCONDITIONING DRIVE UNIT BEARING FAILED CAUSING DRIVE BELT TO FAIL. 1H71 3T3 T A37CE E4EA 5 CP60GL 20030617000912003061700091GL 2003 6 17 AUS20030508 320030513G6114D5904C90 HUB CESSNA206 U206F 2073333CE CONT O520 IO520* 17032SO MCAULY3A32C D3A32C90 GL PROPELLER CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 898 (AUS) PROPELLER HUB CRACKED IN NR 1 BLADE SOCKET. FOUND DURING INSPECTION IAW AD/PMC/41. 1H71 3O3 O A4CE E5CE 5 CP21EA 20030617000922003061700092NE 2003 6 17 AUS20030509 220030514G7320P1018 FILTER CESSNA208 208B 2073701CE PWA PT6 PT6A114A 52043NE MCAULY3AF34C3GFR34C703 GL FUEL CONTROL FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) P3 FILTER FAULTY. FILTER END CAPS SEPARATED FROM FILTER ELEMENT. SUSPECT PROBLEMS WITH GLUE USED TO HOLD END CAPS ON. 1H71 3T3 T A37CE E4EA 5 CP60GL 20030617000932003061700093SO 2003 6 17 AUS20030510 220030515G85506547201 DRIVE SHAFT PIPER PA34 PA34200T 7103406SO CONT O360 LTSIO360E 17025SO MCAULY3AF34C3AF34C503 GL ENG OIL PUMP FAILED W O OTHER EKJVIBRATION/BUFFET FLUID LOSS WARNING INDICATION CLCLIMB 1 AUS 1066 (AUS) ENGINE OIL PUMP DRIVESHAFT FAILED. 1L72 3O3 O A7SO E9CE 5 CP22EA 20030625001402003062500140EA 2003 6 25 AUS20030513 220030327G732225765362 FUEL CONTROL CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA MCAULY1C235 1C235LFA GL ENGINE CONTAMINATED W K NONE EY VIBRATION/BUFFET ENGINE STOPPAGE NRNOT REPORTED 1 AUS 586 (AUS) FUEL CONTROL UNIT AIR CHAMBER CONTAMINATED WITH FUEL. CAUSED BY OVERPRIMING. 1H71 3O3 ONT3A12 1E10 5 NP12EA 20030625001412003062500141WP 2003 6 25 AUS20030514 120030515G53412430572R SPACER FLTCHR24 FU24AAIRPTS 3530204WP LYC O720 IO720A1B 41546EA HARTZLHCC3Y HCC3YR GL WING TO BODY FRACTURED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) WING TO FUSELAGE RT SPACER FRACTURED. 1L71 3O3 O 4A12 1E15 5 CP25EA 20030625001422003062500142NM 2003 6 25 AUS20030516 120030515G321365B051308 AXLE BOEING747 747400 NM GE CF6 CF680C2* GL MLG BROKEN W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT WING MAIN LANDING GEAR, LT FRONT AXLE SHEARED AT BOGIE. 2L74 4F4 FRTA20WE E23EA 20030702000612003070200061GL 2003 7 2 AUS20030517 320030519G6114C58 HUB CESSNA188 A188B 2073005CE CONT O520 IO520* 17032SO MCAULY2A34C D2A34C58 GL PROPELLER CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) PROPELLER HUB CRACKED IN BLADE SOCKET THREADED AREA. 1L71 3O3 O A9CE E5CE 5 CP3EA 20030702000662003070200066 2003 7 2 AUS20030518 420030518G2310 RADIO BOEING747 747338 NM RROYCERB211 RB211524D41954555NE HF COMMS FAILED W O OTHER O OTHER NRNOT REPORTED 1 AUS (AUS) DUAL HF SYSTEM FAILURE. ON ARRIVAL IT WAS REPORTED THAT NR 1 HF SYSTEM WANDERS OFF FREQUENCY AND BECOMES GARBLED. NR 2 HF WOULD NOT TUNE TO THE FREQUENCY SELECTED. THE NR 1 SYSTEM WAS RE-RACKED AND OPERATED NORMALLY. THE NR 2 SYSTEM TRANSCEIVER AND COUPLER WERE REPLACED. 2L72 4F4 FRTA20WE E12EU 20030702000672003070200067NM 2003 7 2 AUS20030519 120030504G7830D40672P CONNECTOR BOEING737 737800* NM GE CFM56 CFM567B24 NE THRUST REVERSER FAULTY W O OTHER O OTHER LDLANDING 1 AUS (AUS) NR 1 ENGINE THRUST REVERSER FAULTY. SUSPECT CAUSED BY FAULTY CONNECTOR D40672P. 2L72 4F4 FRTA16WE E00055EN 20030702000682003070200068NM 2003 7 2 AUS20030520 120030519G49202345119059 CLAMP BOEING767 767277 1385128NM GE CF6 CF680A 30025NE APU ENGINE FAILED W K NONE O OTHER ININSP/MAINT 1 AUS 32823 (AUS) APU FUEL CONTROL UNIT LOOSE ON GEARBOX DUE TO BROKEN CLAMP BOLT. 2L72 4F4 FRTA1NM E13NE 20030702000692003070200069WP 2003 7 2 AUS20030521 120030517G5311 FRAME HUGHES269 269C 4470504WP LYC O360 HIO360D1A 41514EA FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FUSELAGE FRAME RT CLUSTER CRACKED. 1G71 3O3 O 4H12 1E10 20030702000702003070200070GL 2003 7 2 AUS20030522 120030512G5753573100105 BRACKET EAGLE XTS EAGLEXTS150 05607BZGL CONT O240 IO240A SO MCAULY1A135 1A135BRM GL TE FLAPS CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FLAP HINGE SUPPORT BRACKETS (PN 5731001-05 AND PN 5731001-02) CRACKED. RT INNER BRACKET FAILED AND LT INNER BRACKET CRACKED. 1H71 3I3 ONCA00005LAE7SO 5 NP842 20030702000712003070200071NM 2003 7 2 AUS20030523 120030514G6310A1851 BRACKET ROBSINR22 R22BETA 7640110NM LYC O320 O320B2C 41508EA ENGINE/XMSN CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) ENGINE TO TRANSMISSION LOWER ACTUATOR BEARING MOUNT BRACKET CRACKED ON RH SIDE. CRACK RUNS THROUGH BOLT HOLE AND THEN FOR AN EXTRA 12.7MM (0.5IN) TOWARD THE CENTER OF THE BRACKET. 1G71 3O3 O H10WE E274 20030702000722003070200072EA 2003 7 2 AUS20030524 220030429G8520LW13683 BEARING NEWZE FU24 FU24954 6280102WP LYC O720 IO720A1B 41546EA HARTZLHCC3Y HCC3YR GL ENGINE FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) REAR MAIN BEARING SURFACE SEPARATED FROM BEARING SHELL. 1L71 3O3 O A9PC 1E15 5 CP25EA 20030702000732003070200073 2003 7 2 AUS20030525 420030520G23108220987003 COUPLER BOEING767 767338 1385151NM GE CF6 CF680C2* GL HF COMMS FAILED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT HF SYSTEM UNABLE TO TRANSMIT. RT HF SYSTEM UNABLE TO RECEIVE. HF COUPLER FAULTY. 2L72 4F4 FRTA1NM E23EA 20030702000742003070200074NM 2003 7 2 AUS20030526 120030520G28226098976 PUMP BOEING747 747438 NM RROYCERB211 RB211524* NE FUEL BOOST FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS 4654 (AUS) NR 3 FORWARD BOOST PUMP FAILED RESISTANCE CHECK. FOUND DURING INSPECTION IAW AD/B747/173. 2L74 4F4 FRTA20WE E12EU 20030702000872003070200087NE 2003 7 2 AUS20030527 120030519G29137655009808102 PUMP SKRSKYS76 S76C 8143008NE TMECA ARRIELARRIEL1S 60030NE HYDRAULIC SYS FAULTY W O OTHER J WARNING INDICATION NRNOT REPORTED 1 AUS 248 (AUS) NR 1 HYDRAULIC SYSTEM PUMP FAULTY. HYDRAULIC FLUID LOST THROUGH PUMP CASE DRAIN. 1G72 3U3 UNCH1NE E19EU 20030702000882003070200088NM 2003 7 2 AUS20030528 120030520G28226098906 PUMP BOEING747 747438 NM RROYCERB211 RB211524* NE FUEL BOOST FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) NR 3 FORWARD BOOST PUMP FAILED RESISTANCE CHECK. FOUND DURING INSPECTION IAW AD/B747/173. 2L74 4F4 FRTA20WE E12EU 20030702000892003070200089 2003 7 2 AUS20030529 420030509G3451DMC632 ANTENNA BELL 206 206L1 1182107SW ALLSN 250C 250C30P 03013GL DME/TACAN SYS FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) HOMING SYSTEM CO-AXIAL CABLES SHORT CIRCUITING TO GROUND. ANTENNAS OPEN CIRCUITED. 1G71 3U3 U H2SW E1GL 20030702000902003070200090CE 2003 7 2 AUS20030530 120030520G2820075062413 LINE CESSNA182 182S 2072701CE LYC O540 IO540AB1A5 EA MCAULY3D36C B3D36C431 GL FUEL SYSTEM CRACKED W K NONE K FLUID LOSS ININSP/MAINT 1 AUS (AUS) STAINLESS STEEL FUEL PIPE LOCATED BETWEEN FUEL FILTER BOWL AND BOWL DRAIN VALVE CRACKED BENEATH (B) NUT FERRULE AT DRAIN VALVE END. 1H71 3O3 ONT3A13 1E4 5 C 20030702000912003070200091SO 2003 7 2 AUS20030531 120030420G56101159SCB310212 WINDSHIELD GULSTMG1159 GIV 3980115SO RROYCETAY TAY6118 EU COCKPIT FAILED W O OTHER O OTHER CRCRUISE 1 AUS (AUS) COPILOTS WINDSHIELD OUTER LAYER SHATTERED. 2L72 4F4 FRTA12EA E25NE 20030702000922003070200092CE 2003 7 2 AUS20030532 120030523G2140AO2060019 SOLENOID BEECH 95 95B55 1152729CE CONT O470 IO470L 17026SO MCAULY2A34C 2A34C* GL HEATING SYSTEM FAULTY W K NONE K FLUID LOSS ININSP/MAINT 1 AUS AO2060019 (AUS) HEATER LEAKING FUEL FROM CASE DRAIN. INVESTIGATION FOUND THAT THE SOLENOID HAD NOT CLOSED AFTER THE HEATER WAS LAST USED. 1L72 3O3 ORT3A16 3E1 5 CP3EA 20030702000942003070200094NM 2003 7 2 AUS20030534 120030522G2612 CONNECTOR BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU DETECTION SYSTEMDIRTY W E ENGINE SHUTDOWN EN VIBRATION/BUFFET FALSE WARNING NRNOT REPORTED 1 AUS (AUS) NR 1 ENGINE FIRE DETECTION SYSTEM FAULTY. SUSPECT CAUSED BY DIRTY CONNECTOR. 2L72 4F4 FRTA16WE E21EU 20030702000952003070200095EA 2003 7 2 AUS20030535 220030520G8520LW1563185 CRANKCASE PIPER PA31 PA31350 7103110SO LYC O540 LTIO540J2BD 41533EA HARTZLHCE3Y HCE3YR2 GL ENGINE DAMAGED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) MAGNETO DRIVE GEAR SLEEVES INCORRECT FIT. SLEEVES SHEARED DOWELS AND REVOLVED IN CRANKCASE CAUSING METAL CONTAMINATION OF ENGINE OIL. 1L72 3O3 O A20SO E14EA 5 CP33EA 20030702000962003070200096SO 2003 7 2 AUS20030536 120030414G3397L430E20 WIRE GULSTMG1159 GIV 3980115SO RROYCETAY TAY6118 EU LIGHTS FAILED W O OTHER O OTHER CRCRUISE 1 AUS (AUS) STROBE LIGHT WIRING LOCATED IN TAILCONE SHORTED TO SHIELDING. INVESTIGATION FOUND KAPTON POWER WIRE INSULATION CRACKED THROUGH TO INNER WIRES. SUSPECT CRACKING OCCURRED DUE TO LENGTH OF UNSUPPORTED WIRE, CONSTANT REMOVAL OF TAILCONE AND PROPERTIES OF KAPTON WIRE. 2L72 4F4 FRTA12EA E25NE 20030702000972003070200097NE 2003 7 2 AUS20030537 220030519G7230CFM567B26 COMPRESSOR BOEING737 737800* NM GE CFM56 CFM567B24 NE ENGINE CONTAMINATED W O OTHER B SMOKE/FUMES/ODORS/SPARKS DEDESCENT 1 AUS (AUS) FUMES IN COCKPIT. NR 1 ENGINE FIFTH STAGE BLEED DUCT CONTAMINATED WITH ENGINE OIL. NINTH STAGE, DUST CONTAINED OIL RESIDUE. BOROSCOPE INSPECTION FOUND OIL STREAKING ON FIRST AND SECOND STAGE HPC BLADES AND STATORS. 2L72 4F4 FRTA16WE E00055EN 20030702001062003070200106NM 2003 7 2 AUS20030538 120030526G2497 WIRE HARNESS BOEING747 747438 NM RROYCERB211 RB211524G19 NE ELECTRICAL POWERBURNED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) WIRING LOOM W8712 LOCATED NEAR NR 1 LT DOOR BURNED AND LIGHTING CIRCUIT BREAKER TRIPPED. 2L74 4F4 FRTA20WE E30NE 20030703000262003070300026NM 2003 7 3 AUS20030539 120030520G4990 OIL SYSTEM BOEING737 737* NM GE CFM56 CFM567B24 NE APU FAULTY W O OTHER EK VIBRATION/BUFFET FLUID LOSS CRCRUISE 1 AUS (AUS) APU HAS EXCESSIVE OIL CONSUMPTION. SUSPECT AIR/OIL SEPARATOR. 2L72 4F4 FRTA16WE E00055EN 20030703000272003070300027EA 2003 7 3 AUS20030540 220030509G8520LW13886 MAIN BEARING PIPER PA31 PA31350 7103110SO LYC O540 LTIO540J2BD 41533EA HARTZLHCE3Y HCE3YR2 GL ENGINE DELAMINATED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) METAL CONTAMINATION OF ENGINE OIL SYSTEM RESULTED IN BULK STRIP AND INSPECTION OF ENGINE. INSPECTION FOUND LOSS OF BEARING MATERIAL FROM THE FRONT MAIN BEARING AND DELAMINATION OF METAL FROM THE OTHER MAIN AND BIG END BEARINGS. 1L72 3O3 O A20SO E14EA 5 CP33EA 20030703000282003070300028SO 2003 7 3 AUS20030541 120030521G575162373000 DOUBLER PIPER PA28 PA28180 7102808SO LYC O360 O360* 41514EA AMTR C8289 C8289 GL AILERON CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 100 (AUS) RT AILERON OUTBOARD HINGE DOUBLER CRACKED. FOUND DURING INSPECTION IAW AD/PA28/16A2. 1L71 3O3 O 2A13 E286 5 NEXPP5N 20030703000292003070300029CE 2003 7 3 AUS20030542 120030529G57110024300139 SPAR BEECH 36 A36 1151604CE CONT O520 IO520B 17032SO MCAULY3A32C 3A32C76 GL WING CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) WING CARRY THROUGH ASSEMBLY PNO 002-430013-9 CRACKED ON LOWER FACES OF FORWARD WEB PNO 002-430018-1. CRACKS ARE BETWEEN HUCKBOLTS AND JOIN THREE HUCK BOLTS ON EACH SIDE. CRACKS ALSO FOUND IN WEB RADIUS ON BOTH SIDES. CRACKING IS IAW MFG SB2360 FIGURE 1. FOUND DURING INSPECTION IAW AD/36/37. 1L71 3O3 O 3A15 E5CE 5 CP21EA 20030703000302003070300030EU 2003 7 3 AUS20030543 120030515G2750 COMPUTER BAC 146 146200A 1500266EU LYC ALF502ALF502R5 41580NE TE FLAPS OUT OF TOLERANCEW O OTHER F FLT CONT AFFECTED DEDESCENT 1 AUS (AUS) FLAP COMPUTER FAULTY AND FLAP CONTROL UNIT RESOLVER OUT OF TOLERANCE. 2H74 4F4 F A49EU E6NE 20030718000482003071800048NM 2003 7 18 AUS20030545 120030430G5340 ATTACH FITTING BOEING737 737376 NM CFMINTCFM56 CFM563C 13802EU FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FUSELAGE FRAME CLEATS CRACKED. SMALL CRACK IN CLEAT AT UPPER AFT FASTENER HOLE IN BS707 STRINGER 10L. FOUND DURING EDDY CURRENT INSPECTION. 2L72 4F4 FRTA16WE E21EU 20030718000512003071800051NM 2003 7 18 AUS20030548 120030518G32518900115 ACTUATOR DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE NLG STEERING FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS 10887 (AUS) NOSE WHEEL STEERING ACTUATOR FAULTY. ACTUATOR GLAND NUT DISPLACED TO ONE SIDE. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030718000522003071800052EA 2003 7 18 AUS20030549 220030516G7310630193507 SEPARATOR GULSTM500 500S 0141107SW LYC O540 IO540E1B5 41532EA HARTZLHCA3V HCA3VK2 GL FUEL DIST CONTAMINATED W O OTHER E VIBRATION/BUFFET NRNOT REPORTED 1 AUS (AUS) RT ENGINE FUEL VAPOUR SEPARATOR BLOCKED BY PARTICLES OF UNKNOWN TYPE. 1H72 3O3 O 6A1 1E4 5 CP6EA 20030718000532003071800053CE 2003 7 18 AUS20030550 120030515G2197B4050 HEATER BEECH 76 76 1153005CE LYC O360 O360A1G 41514EA HARTZLHCM2Y HCM2YR GL AIR CONDITIONINGMISWIRED W K NONE W INADEQUATE Q C ININSP/MAINT 1 AUS (AUS) HEATER INCORRECTLY WIRED. INVESTIGATION FOUND THAT THE OVERHEAT CUTOUT AND COMBUSTION PRESSURE SWITCH HAD NOT BEEN WIRED UP. THIS ALLOWED THE HEATER TO SOURCE FUEL AND IGNITION WITHOUT AIRFLOW AND OVERHEAT PROTECTION. 1L72 3O3 O A29CE E286 5 CP43GL 20030718000542003071800054 2003 7 18 AUS20030551 420030522G2562ELT1104 ELT CABIN FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) ELT UNITS (3 OFF) HAD CONTINUOUS TRANSMISSION IN BOTH ON AND OFF MODES. 20030718000552003071800055CE 2003 7 18 AUS20030552 120030604G5310571305718 WEB CESSNA441 441 2076020CE GARRTTTPE331TPE3318 01514WP FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) BEAM WEB CRACKED. CRACK LENGTH APPROXIMATELY 25.4MM (1IN). 1L72 3T4 TRTA28CE E4WE 20030718000562003071800056NM 2003 7 18 AUS20030553 120030603G5530 HINGE PIPER PA60 PA60600A 7106002NM LYC O540 IO540* 41532EA HARTZLHCC3Y HCC3YR2 NE VERTICAL STAB MISLOCATED W K NONE W INADEQUATE Q C ININSP/MAINT 1 AUS (AUS) VERTICAL STABILIZER CENTRE HINGE FITTED IN WRONG LOCATION. MANUFACTURING ERROR. 1M72 3O3 ORTA17WE 1E4 5 CP25EA 20030718000572003071800057NE 2003 7 18 AUS20030554 220030602G7230 BLADE PILATSPC12 PC12 7090550EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL COMPRESSOR FOD W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FIRST STAGE COMPRESSOR BLADES SEVERELY DAMAGED BY FOD. FOUND DURING INSPECTION IAW AD/ENG/5 A7. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030718001022003071800102EU 2003 7 18 AUS20030555 120030604G5730HC573H0002000 SKIN BAG BAE146BAE146300A 1500267EU LYC ALF502ALF502R5 41580NE LT & RT WING CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT AND RT LOWER WING SKINS CORRODED IN AREA OF FUEL PUMP WATER SCAVENGE GUARDS AT RIB 15. FOUND DURING INSPECTION IAW ER BA6-28-10-7 AND ISB 28-028. 2H74 4F4 FRTA49EU E6NE 20030718001032003071800103 2003 7 18 AUS20030556 420030515G345710706 ANTENNA DHAV DHC8 DHC8202 2809007NM PWA 120 PW123D 52152NE HAMSTD14SF 14SF23 NE GPS FAULTY W O OTHER O OTHER CRCRUISE 1 AUS (AUS) GLOBAL POSITIONING SYSTEM (GPS) ANTENNA SUSPECT FAULTY. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030721000022003072100002NE 2003 7 21 AUS20030558 220030606G7200200304016 ENGINE BAC 146 146200A 1500266EU LYC ALF502ALF502R5 41580NE NR 2 BIRD INGESTION W O OTHER CJ F.O.D. WARNING INDICATION LDLANDING 1 AUS (AUS) NR 2 ENGINE BIRDSTRIKE. BIRD HAD ENTERED CORE OF ENGINE. ENGINE REMOVED FOR REPAIR. 2H74 4F4 F A49EU E6NE 20030721000072003072100007SW 2003 7 21 AUS20030563 120030610G55512743062022 ATTACH FITTING SWRNGNSA227 SA227* SW GARRTTTPE331TPE33112UHR WP MCAULY4HFR344HFR34C652 NE HORIZONTAL STAB CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) HORIZONTAL STABILIZER PITCH TRIM ACTUATOR RT ATTACHMENT FITTING OUTBOARD LUG CRACKED. 2L72 4T4 TRTA5SW E4WE 6 C3PNE 20030721000102003072100010SO 2003 7 21 AUS20030565 120030601G324221585 BRAKE EMB 120 EMB120 3260201SO PWA 118 PW118A NE HAMSTD14RF 14RF9 NE RT MLG UNSERVICEABLE W K NONE O OTHER ININSP/MAINT 1 AUS 1824 (AUS) RT INBOARD BRAKE FAULTY. INVESTIGATION FOUND TWO CRACKED ROTORS. 2L72 4T4 TRTA31SO E20NE 6 CP11NE 20030721000112003072100011 2003 7 21 AUS20030566 420030610G25641000107 LIFE RAFT EMERG EQUIP FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS 082 (AUS) LIFE RAFT FOUND PARTIALLY INFLATED ON STORAGE SHELF. THIS IS A REOCCURANCE OF DEFECT REPORTED AS MDR 03/0132 WHICH WAS THOUGHT TO HAVE BEEN RECTIFIED. REPAIR FACILITY BELIEVES THAT THE PROBLEM IS DUE TO FAULTY COMPONENTS IN THE CYLINDER VALVE OVERHAUL KITS THAT ARE SUPPLIED. 20030721000142003072100014EU 2003 7 21 AUS20030570 120030607G2910HC291B0059000 LINE BAC 146 146200A 1500266EU LYC ALF502ALF502R5 41580NE HYD SYSTEM LEAKING W O OTHER K FLUID LOSS NRNOT REPORTED 1 AUS (AUS) YELLOW HYDRAULIC SYSTEM QUANTITY LOW. INVESTIGATION FOUND PIPELEAKING FROM SWAGE ADJACENT TO T' PIECE CONNECTION FOR THE YELLOW SYSTEM PRESSURE SUPPLY TO THE HP MANIFOLD. 2H74 4F4 F A49EU E6NE 20030721000152003072100015EA 2003 7 21 AUS20030571 220030426G8500IO540E1B5 ENGINE GULSTM500 500S 0141107SW LYC O540 IO540E1B5 41532EA HARTZLHCA3X HCA3XK2 GL LEFT FAILED W O OTHER E VIBRATION/BUFFET NRNOT REPORTED 1 AUS 1381 (AUS) LT ENGINE FAILED TO RESTART IN FLIGHT AFTER AN INTENTIONAL SHUTDOWN. INVESTIGATION COULD FIND NO PROBLEMS WITH THE ENGINE. SUSPECT CAUSED BY OVERPRIMING OF THE FUEL SYSTEM. 1H72 3O3 O 6A1 1E4 5 CP913 20030721000162003072100016SO 2003 7 21 AUS20030572 120030520G33104773209 TRANSISTOR PIPER PA31 PA31 7103102SO LYC O540 TIO540A2C 41532EA HARTZLHCE3Y HCE3YR2 GL COCKPIT LIGHTS FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 AUS (AUS) INSTRUMENT LIGHTING SOLID STATE DIMMER TRANSISTORS BLOWN DUE TO WATER INGRESS THROUGH CRACKED WINDSCREEN. ELECTRICAL EQUIPMENTAND LOOMS CONTAMINATED WITH WATER. 1L72 3O3 O A20SO E14EA 5 CP33EA 20030721000172003072100017SW 2003 7 21 AUS20030573 120030604G27212742004003 ACTUATOR SWRNGNSA227 SA227AC 8780603SW GARRTTTPE331TPE33111U 01514WP ROTOL R321 R321482F8 GL RUDDER TAB FAULTY W O OTHER F FLT CONT AFFECTED NRNOT REPORTED 1 AUS 557 (AUS) RUDDER TRIM TAB ACTUATOR FAULTY. 2L72 4T4 TRTA8SW E4WE 6 CP61GL 20030721000282003072100028EU 2003 7 21 AUS20030574 120030603G2731DL3827M157 ACTUATOR SAAB SF340 SF340A 7850100EU GE CT7TP CT75A 30030NE ROTOL R354 R3544123F13 NE ELEVATOR TAB UNSERVICEABLE W O OTHER F FLT CONT AFFECTED CLCLIMB 1 AUS 16157 (AUS) STANDBY PITCH TRIM ACTUATOR FAULTY. 2L72 4T4 TRTA52EU E8NE 6 CP61GL 20030721000382003072100038EU 2003 7 21 AUS20030575 120030604G53504995100V1 RADOME REIMS 406 F406 7535723EU PWA PT6 PT6A112 52043NE MCAULY3G34C73GFR34C701 GL NOSE BIRD STRIKE W O OTHER C F.O.D. TOTAKEOFF 1 AUS (AUS) BIRDSTRIKE ON SURVEILLANCE RADOME. 1L72 3T3 TRTA54EU E4EA 5 CP60GL 20030721000392003072100039EU 2003 7 21 AUS20030576 120030605G7797 WIRE SAAB SF340 SF340A 7850100EU GE CT7TP CT75A2 30030NE ROTOL R389 R3894123F25 NE ENGINE INDICATORBROKEN W O OTHER EM VIBRATION/BUFFET OVER TEMP CLCLIMB 1 AUS (AUS) LT PROPELLER GEARBOX OIL TEMPERATURE INDICATION FAILED. INVESTIGATION FOUND A BROKEN WIRE TO THE TEMPERATURE SENSOR. 2L72 4T4 TRTA52EU E8NE6 6 CP30NE 20030721000402003072100040 2003 7 21 AUS20030577 420030508G34174083602901 MODULE BOEING717 717200 1383700NM RROYCEBR700 BR700715A130 NE ADC FAULTY W O OTHER J WARNING INDICATION CLCLIMB 1 AUS (AUS) PITOT AIR DATA MODULE FAULTY. INVESTIGATION FOUND A SMALL AMOUNT OF WATER IN THE LT AND RT PITOT SUMP DRAINS. 2L72 4F4 FTRA6WE E00061EN 20030721000412003072100041EU 2003 7 21 AUS20030578 120030417G8011 MOTOR GE CF680E1 AIRBUS330 A330202 3930316EU GE CF6 CF680 30025NE STARTER FAILED W K NONE E VIBRATION/BUFFET NRNOT REPORTED 1 AUS (AUS) ENGINE STARTER MOTOR FAILED. DAMAGE CAUSED TO ENGINE. 2L72 4F4 FRTA46NM E13NE 20030721000422003072100042 2003 7 21 AUS20030579 420030609G34189754421422 TRANSMITTER PILATSPC12 PC12 7090550EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL STALL WARNING FAILED W K NONE O OTHER ININSP/MAINT 1 AUS 0380 (AUS) ANGLE OF ATTACK (AOA) TRANSMITTER STUCK. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030721000432003072100043NM 2003 7 21 AUS20030580 120030606G57445926059510 FITTING BOEING717 717200 1383700NM RROYCEBR700 BR700715A130 NE WING CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT WING INBOARD SPOILER MAIN ACTUATOR SUPPORT FITTING CRACKED IN THE OUTBOARD SUPPORT CHANNEL AND PASSING THROUGH THE SPOILER DOWNSTOP PAD FITTING REAR RIVET HOLE. FOUND DURING INSPECTION IAW MFG ALERT SB 717-57A0016. 2L72 4F4 FTRA6WE E00061EN 20030721000502003072100050CE 2003 7 21 AUS20030581 120030605G531350440014523 STRINGER BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) NR 7 STRINGER RT SIDE CRACKED. FOUND DURING INSPECTION IAW AD 200/55 AMDT1. 1L72 4T4 T A24CE E4EA 6 CP15EA 20030721000552003072100055NM 2003 7 21 AUS20030583 120030604G3260S106 SENSOR BOEING737 737376 NM GE CFM56 CFM563B1 13802NE MLG FAULTY W O OTHER N FALSE WARNING CLCLIMB 1 AUS (AUS) MAIN LANDING GEAR AIR SENSOR S106 FAULTY. 2L72 4F4 FRTA16WE E2GL 20030721000562003072100056WP 2003 7 21 AUS20030584 220030121G73133103235 NOZZLE SWRNGNSA227 SA227AC 8780603SW GARRTTTPE331TPE33111U 01514WP ROTOL R321 R321482F8 GL ENGINE BLOCKED W O OTHER EM VIBRATION/BUFFET OVER TEMP NRNOT REPORTED 1 AUS 200 (AUS) ENGINE FUEL NOZZLES PARTIALLY BLOCKED. 2L72 4T4 TRTA8SW E4WE 6 CP61GL 20030908000802003090800080WP 2003 9 8 AUS20030585 120030604G281017482571 FUEL TANK NAMER F51 P51C 6402302WP PCKARDV1650 V16507 49001SO HAMSTD24D 24D50 NE RT WING CONTAMINATED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT WING FUEL TANK CONTAMINATED WITH RUBBER FROM DELAMINATING FUEL TANK. TANK MANUFACTURED IN SEPTEMBER 1944. 1L71 4V4 V L113 EXP4V 6 CP784 20030721000582003072100058CE 2003 7 21 AUS20030586 120030408G781053551084 SLIP JOINT CONT TSIO520N CESSNA340 340A 2076405CE CONT O520 TSIO520N 17040SO MCAULY3AF32C3AF32C505 GL ENGINE COLLECTORCRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 1268 514392 (AUS) RT ENGINE EXHAUST SYSTEM SLIP COUPLING CRACKED IN AREA NEAR TRANSITION DUCT. 1L72 3O3 O 3A25 E8CE 5 CP22EA 20030721000592003072100059NM 2003 7 21 AUS20030587 120030523G324613889 BEARING PIPER PA60 PA60600A 7106002NM LYC O540 IO540K1J5 41532EA HARTZLHCC3Y HCC3YR2 NE MLG WHEEL FAILED W O OTHER O OTHER LDLANDING 1 AUS (AUS) RT MAIN WHEEL INBOARD BEARING ASSEMBLY FAILED. 1M72 3O3 ORTA17WE 1E4 5 CP25EA 20030721000602003072100060CE 2003 7 21 AUS20030589 120030301G2913202401CF SHAFT CESSNA 202401CF CESSNA210 210A 2073408CE CONT O470 IO470E 17026SO HARTZLHCA2X HCA2XF1 GL HYD PUMP FAULTY W K NONE K FLUID LOSS ININSP/MAINT 1 AUS (AUS) HYDRAULIC PUMP DRIVE SHAFT CASE HARDENING HAD FAILED IN AREA OF KEYWAY ALLOWING KEY TO TILT AND JAM. RESIDUAL METAL FROM FAILED AREA HAD DAMAGED SHAFT SEAL LEADING TO FLUID LEAKAGE. 1H71 3O3 ORT3A21 3E1 5 CP908 20030721000612003072100061CE 2003 7 21 AUS20030590 120030301G7820125025113 MUFFLER CESSNA210 210A 2073408CE CONT O470 IO470E 17026SO HARTZLHCA2X HCA2XF1 GL ENGINE EXHAUST CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT MUFFLER PIPE CRACKED FOR APPROXIMATELY 75 PERCENT OF CIRCUMFERENCE AROUND JOINT AREA. CRACK WAS HIDDEN BY EXHAUST CLAMPS. 1H71 3O3 ORT3A21 3E1 5 CP908 20030721000622003072100062CE 2003 7 21 AUS20030591 120030516G5753052323123 FLAP TRACK CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA MCAULY1A103 1A103TCM GL TE FLAPS CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS 9762 (AUS) LT WING FLAP TRACK CORRODED ON INNER FACE. MATERIAL THICKNESS REDUCED BY APPROXIMATELY 25 PERCNET. TRACK IS LOCATED AT STN 312.75. 1H71 3O3 ONT3A19 E223 5 NP50GL 20030721000632003072100063CE 2003 7 21 AUS20030592 120030415G5311002430018N SPAR BEECH 58 58 1152740CE CONT O520 IO520F 17032SO MCAULY3AF34C3AF34C502 GL LT WING CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) SPAR WEB CONTAINED TWO CRACKS IN THE AREA OF LT UPPER WING ATTACHMENT POINT. CRACK WAS LOCATED AROUND HUCK BOLTS. CRACK LENGTH 12.7MM (0.5IN). AIRCRAFT HAD SUFFERED A WHEELS UP LANDING IN THE PAST. 1L72 3O3 O 3A16 E5CE 5 CP22EA 20030721000732003072100073SO 2003 7 21 AUS20030593 120030513G55136524500 BRACE PIPER PA28 PA28151 7102805SO LYC O320 O320* 41508EA AMTR C8289 C8289 GL HORIZONTAL STAB CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) HORIZONTAL STABILIZER TRIM DIAGONAL BRACE CRACKED. SUSPECT BRACE WAS BENT OUT OF THE WAY FOR ACCESS. STABILIZER HINGE BOLTS HAD MISSING SPACER WASHERS. PERSONNEL/MAINTENANCE ERROR. 1L71 3O3 O 2A13 E274 5 NEXPP5N 20030721000782003072100078EA 2003 7 21 AUS20030594 220030523G73132541946 NOZZLE PIPER PA31 PA31350 7103110SO LYC O540 LTIO540J2BD 41533EA HARTZLHCE3Y HCE3YR2 GL FUEL INJECTOR BLOCKED W O OTHER O OTHER NRNOT REPORTED 1 AUS 18 (AUS) RT ENGINE NR 1 CYLINDER FUEL INJECTOR NOZZLE PARTIALLY BLOCKED BY WHAT APPEARS TO BE PLANT/VEGETABLE MATTER. FOD. 1L72 3O3 O A20SO E14EA 5 CP33EA 20030721000792003072100079CE 2003 7 21 AUS20030595 120030604G5310571305717 BEAM CESSNA441 441 2076020CE GARRTTTPE331TPE3318 01514WP FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) BEAM WEB CRACKED. CRACK LENGTH APPROXIMATELY 25.4MM (1IN). 1L72 3T4 TRTA28CE E4WE 20030721000802003072100080NE 2003 7 21 AUS20030596 220030403G7230110125004 COMPRESSOR BELL 205 205A1 1181414SW LYC T53 T5313B 41549NE ENGINE FOD W K NONE C F.O.D. ININSP/MAINT 1 AUS (AUS) ENGINE VARIABLE INLET GUIDE VANES (VIGV) AND COMPRESSOR BLADES DAMAGED BY FOD. INVESTIGATION FOUND THAT DAMAGE HAD BEEN CAUSED BY AN OBJECT WITH A DIAMETER OF APPROXIMATELY 3.175MM TO 4.762MM(0.125IN TO 0.1875IN). AN OBJECT OF THIS SIZE COULD NOT PASS THROUGH THE AIR INLET SCREEN WITHOUT CAUSING DAMAGE TO THE SCREENS. THE INLET SCREENS CONTAINED NO DAMAGE. SCREENS HAD NOT BEEN REMOVED SINCE MAINTENANCE CHECK APPROXIMATELY 26 HOURS PREVIOUSLY. 1G71 4U4 U H1SW E17EA 20030721000812003072100081CE 2003 7 21 AUS20030597 120030530G3213 PIN CESSNA310 310R 2074245CE CONT O520 IO520M 17032SO MCAULY3AF32C3AF32C87 GL MLG MISLOCATED W K NONE W INADEQUATE Q C ININSP/MAINT 1 AUS (AUS) LANDING GEAR FORK BOLT CLEVIS PIN INCORRECTLY FITTED. CLEVIS PIN WAS FITTED BACK TO FRONT AND CONTACTED WHEEL WELL STRUCTURE CAUSING DAMAGE TO TORQUE TUBE SUPPORT BRACKETS PN 5027002-5. PERSONNEL/MAINTENANCE ERROR. 1L72 3O3 O 3A10 E5CE 5 CP22EA 20030721000822003072100082CE 2003 7 21 AUS20030598 120030424G5711122210523 SPAR CAP CESSNA206 U206F 2073333CE CONT O520 IO520* 17032SO MCAULY3A32C D3A32C90 GL RT WING CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT WING SPAR CAP RIVET HEADS MISSING. INVESTIGATION FOUND THE SPAR CAP EXTENSIVELY CORRODED. 1H71 3O3 O A4CE E5CE 5 CP21EA 20030721000832003072100083CE 2003 7 21 AUS20030599 120030325G3230NAS464P5A42 BOLT CESSNA206 U206G 2073356CE CONT O520 IO520* 17032SO MCAULY3A32C D3A32C90 GL MLG DRAGLINK BROKEN W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) NOSE LANDING GEAR DRAG LINK ATTACHMENT BOLT HEAD SEPARATED FROM SHANK. 1H71 3O3 O A4CE E5CE 5 CP21EA 20030721000842003072100084EA 2003 7 21 AUS20030600 220030526G8550AN9114D ADAPTER MOONEYM20 M20J 5870219SW LYC O360 IO360A3B6 41514EA MCAULY2D34C B2D34C214 GL ENGINE SHEARED W O OTHER EK VIBRATION/BUFFET FLUID LOSS CRCRUISE 1 AUS (AUS) OIL DRAIN VALVE BROKEN OFF FLUSH WITH SURFACE OF OIL SUMP. THREADED PORTION OF DRAIN VALVE ADAPTER STILL LOCATED IN SUMP. DRAIN VALVE AND REST OF ADAPTER MISSING. LOSS OF ENGINE OIL. 1L71 3O3 O 2A3 1E10 5 CP7EA 20030721000852003072100085CE 2003 7 21 AUS20030601 220030526G8530653098 CYLINDER MOONEYM20 M20K 5870220SW CONT O360 TSIO360MB 17025CE MCAULYD3A36 D3A36C410 GL ENGINE FAILED W O OTHER E VIBRATION/BUFFET CRCRUISE 1 AUS 80 (AUS) ENGINE NR 1 CYLINDER BARREL FAILED IN AREA APPROXIMATELY TWO FINS FROM TOP OF BARREL. CYLINDER HEAD AND ATTACHED SECTION OF BARREL SEPARATED. SEVERE DAMAGE TO ENGINE. 1L71 3O3 O 2A3 E9CE 5 CP47GL 20030721000962003072100096SO 2003 7 21 AUS20030603 120030519G29164802800 RESERVOIR PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2 GL HYD SYSTEM CONTAMINATED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) HYDRAULIC RESERVOIR CONTAMINATED. CONTAMINANT WAS A BLACK SLUDGE WHICH MAY INDICATE BIOLOGICAL GROWTH. SUSPECT PROBLEM ORIGINATES FROM WATER LYING IN SPILL TRAY AROUND FILLER NECK. 1L72 3O3 O A20SO E14EA 5 CP33EA 20030721000972003072100097 2003 7 21 AUS20030605 420030605G34979C98A22 WIRE PILATSPC12 PC12 7090550EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL NAVIGATION WORN W O OTHER O OTHER CRCRUISE 1 AUS (AUS) ALTIMETER POWER WIRING CHAFING IN AREA APPROXIMATELY 175MM(6.8IN) FROM ALTITUDE SELECT CONTROL PANEL. WORN WIRING GROUNDED ON INSTRUMENT PANEL FRAMEWORK. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030721000982003072100098CE 2003 7 21 AUS20030606 120030618G5520179856 ELEVATOR CESSNA206 U206G 2073356CE CONT O520 IO520F 17032SO MCAULY3A32C D3A32C90 GL LEFT FOD W O OTHER F FLT CONT AFFECTED LDLANDING 1 AUS (AUS) ELEVATOR JAMMED. INVESTIGATION FOUND A PIECE OF METAL PROTRUDING FROM THE LT ELEVATOR BALANCE HORN DIRECTLY BEHIND THE BALANCE WEIGHT ATTACHMENT RIB. METAL MEASURED 12.7MM BY 57.15MM (0.5IN BY 2.25IN) WITH A THICKNESS OF 0.8128MM (0.032IN) AND APPEARS TO BE ALCLAD. THE METAL CONTAINED A HOLE INTO WHICH A PK TYPE SCREW HAD BEEN INSERTED AT SOME STAGE. SUSPECT METAL HAD AT ONE TIME BEEN ATTACHED TO THE ELEVATOR TIP CUFF AND HAD COME ADRIFT. FOD. 1H71 3O3 O A4CE E5CE 5 CP21EA 20030721000992003072100099WP 2003 7 21 AUS20030609 220030504G72508675697 ENGINE GARRTT SWRNGNSA226 SA226TC 8780404SW GARRTTTPE331TPE3313U 01514WP HARTZLHCB3T HCB3TN5 GL LEFT SEIZED W O OTHER E VIBRATION/BUFFET LDLANDING 1 AUS PO3437 (AUS) LT ENGINE SEIZED IN FLIGHT. INVESTIGATION FOUND SEVERE DAMAGE TO ALL TURBINES AND STATORS. 2L72 4T4 TRTA8SW E4WE 6 CP15EA 20030721001002003072100100CE 2003 7 21 AUS20030610 120030505G2750S18193 ROD END CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA MCAULY1A103 1A103TCM GL TE FLAPS SEIZED W O OTHER O OTHER NRNOT REPORTED 1 AUS (AUS) LT FLAP ASSEMBLY PUSH/PULL ROD END BEARING SEIZED CAUSING CONTROL ROD TO SNAP. 1H71 3O3 ONT3A19 E223 5 NP50GL 20030721001062003072100106SO 2003 7 21 AUS20030611 120030620G32604198500 BRACKET PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2 GL MLG CRACKED W O OTHER N FALSE WARNING DEDESCENT 1 AUS (AUS) LT MAIN LANDING GEAR SWITCH BRACKET CRACKED RESULTING IN SWITCH OUT OF ADJUSTMENT. 1L72 3O3 O A20SO E14EA 5 CP33EA 20030721001072003072100107CE 2003 7 21 AUS20030612 120030616G531150420013954 FRAME BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 200 (AUS) FUSELAGE FRAME CRACKED AT FLOOR HEIGHT ON RT SIDE. FRAME IS LOCATED AT FS 207.125. 1L72 4T4 T A24CE E4EA 6 CP15EA 20030721001082003072100108EA 2003 7 21 AUS20030613 220030606G7322105217 PLUNGER LYC ROBSINR22 R22BETA 7640110NM LYC O320 O320B2C 41508EA CARBURETOR BINDING W O OTHER E VIBRATION/BUFFET TOTAKEOFF 1 AUS CK35050 (AUS) CARBURETOR ACCELERATOR PUMP PLUNGER BINDING IN BORE. 1G71 3O3 O H10WE E274 20030721001092003072100109NM 2003 7 21 AUS20030614 120030617G6310A1902 BELT ROBSINR22 R22BETA 7640110NM LYC O320 O320B2C 41508EA ENGINE/XMSN STRETCHED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) ENGINE TO TRANSMISSION DRIVE VEE BELTS STRETCHED BEYOND LIMITS. 1G71 3O3 O H10WE E274 20030721001102003072100110WP 2003 7 21 AUS20030615 120030609G6320269A51039 PINION GEAR HUGHES269 269C 4470504WP LYC O360 HIO360D1A 41514EA M/R GEARBOX FAILED W O OTHER F FLT CONT AFFECTED CLCLIMB 1 AUS 36 125194 (AUS) MAIN TRANSMISSION TAIL ROTOR DRIVESHAFT PINION FAILED IN AREA LOCATED JUST IN FRONT OF THE THREADED AREA ALLOWING THE TAIL ROTOR DRIVE TO SEPARATE. AIRCRAFT STRUCK THE GROUND CAUSING EXTENSIVE DAMAGE TO THE LANDING GEAR. 1G71 3O3 O 4H12 1E10 20030721001112003072100111SO 2003 7 21 AUS20030616 120030616G2510452680 INERTIA REEL PIPER PA28 PA28161 7102803SO LYC O320 O320D3G 41508EA SNSNCH74D 74DM EA COCKPIT DAMAGED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) SEAT BELT INERTIA REEL MAIN SHAFT CUT THROUGH BY BELT SUPPORT ARM. 1L71 3O3 O 2A13 E274 5 NP88614 20030721001122003072100112CE 2003 7 21 AUS20030617 120030402G2820120040676 LINE CESSNA206 U206F 2073333CE CONT O520 IO520F 17032SO MCAULY3A32C D3A32C90 GL FUEL SYSTEM CHAFED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FUEL LINE CHAFED BY AILERON CABLE. 1H71 3O3 O A4CE E5CE 5 CP21EA 20030822000972003082200097EA 2003 8 22 AUS20030620 220030616G8550 GASKET ROBSINR44 R44 7640120WP LYC O540 O540F1B5 41532EA ENGINE DAMAGED W O OTHER EK VIBRATION/BUFFET FLUID LOSS CLCLIMB 1 AUS (AUS) ENGINE OIL FILTER INTERNAL RUBBER GASKET DAMAGED. A PIECE OF THE RUBBER GASKET WAS FOUND TO BE STUCK UNDER THE OIL PRESSURE RELIEF VALVE CAUSING LOSS OF OIL PRESSURE. NEW FILTER HAD BEEN FITTED APPROXIMATELY ONE HOUR PREVIOUSLY. FURTHER INVESTIGATION FOUNDTHE OIL LINES WERE CROSSED DURING INSTALLATION OF AIR WOLF SPIN-ON OIL FILTER MODIFICATION. ENGINE OIL PRESSURE FRACTURED THE FILTER HOUSING INTERNAL RUBBER CHECK VALVE ON START-UP. RUBBER PARTICLES CIRCULATED IN THE OIL SYSTEM UNTIL ONE FRAGMENT UNSEATED THE ENGINE OIL PRESSURE REGULATING VALVE, CAUSING LOSS OF OIL PRESSURE. FRAGMENTS OF THE RUBBER CHECK VALVE. ERROR DUE TO CONFUSING INSTRUCTIONS IN THE DATA SENT WITH THE KIT. 1G71 3O3 O H11NM E295 20030822000992003082200099CE 2003 8 22 AUS20030621 120030617G323012802091 PIN CESSNA182 R182 2072734CE LYC O540 O540J3C5 41532EA MCAULY2D34C B2D34C214 GL MLG SHEARED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) NOSE LANDING GEAR DOWNLOCK PIN SHEARED. 1H71 3O3 ORT3A13 E295 5 CP7EA 20030822001002003082200100EU 2003 8 22 AUS20030622 120030526G3213100A703029 STRUT BAG JETSTMJETSTM3201 1500217EU GARRTTTPE331TFE33112UHR WP MCAULY4HFR344HFR34C653 NE MLG UNSERVICEABLE W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT MAIN LANDING GEAR CYLINDER, SLIDING TUBE, SPHERICAL BEARING AND SPHERICAL BEARING HOUSING DAMAGED. INVESTIGATION FOUND THE DAMAGE WAS CAUSED BY A LOOSE GRUB SCREW WHICH HAD COME LOOSE AND FALLEN OUT OF THE SLIDING TUBE INTO THE BODY OF THE LANDING GEAR. SUSPECT CAUSED BY INCORRECT STAKING OF THE GRUB SCREW DURING THE LAST OVERHAUL. 2L72 4T4 TRTA56EU E4WE 6 C3PNE 20030822001012003082200101GL 2003 8 22 AUS20030623 320030616G6110B338421H BOLT EMB 110 EMB110* SO HARTZLHCB3T HCB3TN3 GL PROPELLER SHEARED W K NONE O OTHER ININSP/MAINT 1 AUS 3462 (AUS) PROPELLER COUNTERWEIGHT BOLT HEAD SHEARED. THE OTHER BOLT HEAD ALSO SHEARED WHEN THE LOCKWIRE WAS REMOVED. PROPELLER CAME FROM A NEW ZEALAND REGISTERED AIRCRAFT. 1L72 4T RTA21SO 6 CP15EA 20030822001022003082200102NM 2003 8 22 AUS20030624 120030613G28226072101 PUMP BOEING747 747438 NM RROYCERB211 RB211524* NE FUEL BOOST FOD W O OTHER F FLT CONT AFFECTED NRNOT REPORTED 1 AUS (AUS) NR 2 AFT OVERRIDE JETTISON PUMP INGESTED PART OF THE INLET CHECK VALVE. 2L74 4F4 FRTA20WE E12EU 20030822001032003082200103CE 2003 8 22 AUS20030625 120030611G7722 INDICATOR CESSNA441 441 2076020CE GARRTTTPE331TPE331* 01514WP HARTZLHCB3T HCB3TN5 GL EGT FAULTY W O OTHER EM VIBRATION/BUFFET OVER TEMP NRNOT REPORTED 1 AUS (AUS) RT ENGINE EGT SYSTEM FAULTY. EGT INDICATOR AND EGT COMPENSATOR REMOVED AND SENT FOR INVESTIGATION/REPAIR. 1L72 3T3 TRTA28CE E2WE 6 CP15EA 20030822001052003082200105SO 2003 8 22 AUS20030626 120030620G32309529900 STUD PIPER PA28 PA28R201T 7102813SO CONT O360 TSIO360F 17025SO HARTZLHCC2Y BHCC2YF1 GL MLG CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) MAIN LANDING GEAR SIDE BRACE STUD CONTAINED LONGITUDINAL MPI INDICATIONS. FOUND DURING INSPECTION IAW AD/PA28/91 AMDT1. 1L71 3O3 O 2A13 E9CE 5 CP920 20030822001122003082200112NE 2003 8 22 AUS20030627 220030623G73100301007720 PIPE SKRSKYS76 S76C 8143008NE TMECA ARRIELARRIEL1S 60030NE FUEL DIST CRACKED W K NONE EK VIBRATION/BUFFET FLUID LOSS NRNOT REPORTED 1 AUS (AUS) ENGINE START FUEL INJECTOR PIPE FRACTURED AT FLARE UNDER (B NUT). 1G72 3U3 UNCH1NE E19EU 20030822001142003082200114SW 2003 8 22 AUS20030628 120030622G2460ANL400 CURRENT LIMITER SWRNGNSA227 SA227* SW GARRTTTPE331TPE33112UHR WP MCAULY4HFR344HFR34C652 NE DC POWER DAMAGED W O OTHER B SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 AUS (AUS) RT GENERATOR CURRENT LIMITER TERMINAL LOOSE. POOR CONNECTION CAUSED LOCALISED HEATING OF THE CURRENT LIMITER RESULTING IN A BURNING SMELL. 2L72 4T4 TRTA5SW E4WE 6 C3PNE 20030822001152003082200115NE 2003 8 22 AUS20030629 220030624G7261 O-RING BEECH 200 200BEECH 1152920CE PWA PT6 PT6A42 52043NE MCAULY4HFR344HFR34C754 NE ENGINE WRONG PART W O OTHER EK VIBRATION/BUFFET FLUID LOSS NRNOT REPORTED 1 AUS (AUS) ENGINE OIL SYSTEM CHECK VALVE O' RING JAMMED CHECK VALVE IN OPEN POSITION. SB3178R2 DELETES THE O' RING FROM THE CHECK VALVE. PERSONNEL/MAINTENANCE ERROR. ENGINE SERIAL NUMBER PCE-93117. 1L72 4T4 T A24CE E4EA 6 C3PNE 20030822001162003082200116NE 2003 8 22 AUS20030630 220030624G7261 O-RING BEECH 200 200BEECH 1152920CE PWA PT6 PT6A42 52043NE MCAULY4HFR344HFR34C754 NE ENGINE WRONG PART W K NONE EKWVIBRATION/BUFFET FLUID LOSS INADEQUATE Q C ININSP/MAINT 1 AUS (AUS) ENGINE OIL SYSTEM CHECK VALVE O' RING JAMMED CHECK VALVE IN OPEN POSITION. SB3178R2 DELETES THE O' RING FROM THE CHECK VALVE. PERSONNEL/MAINTENANCE ERROR. ENGINE SERIAL NUMBER PCE-93183. SEEALSO MDR 03/0629 FOR SIMILAR DEFECT ON OTHER ENGINE OF SAME AIRCRAFT. 1L72 4T4 T A24CE E4EA 6 C3PNE 20030822001172003082200117CE 2003 8 22 AUS20030631 120030528G3230NAS464P5A42 BOLT CESSNA206 U206G 2073356CE CONT O520 IO520F 17032SO MCAULY3A32C D3A32C90 GL MLG FAILED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) NOSE LANDING GEAR DRAG LINK ATTACHMENT BOLT HEAD SEPARATED FROM SHANK. 1H71 3O3 O A4CE E5CE 5 CP21EA 20030822001192003082200119NM 2003 8 22 AUS20030632 120030620G24314011769 BATTERY DHAV DHC8 DHC8202 2809007NM PWA 120 PW123D 52152NE HAMSTD14SF 14SF23 NE MASTER OVERHEATED W O OTHER HMJELECT. POWER LOSS-50 PC OVER TEMP WARNING INDICATION CRCRUISE 1 AUS 130 (AUS) MAIN BATTERY OVERHEATED. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030822001202003082200120NM 2003 8 22 AUS20030633 120030621G7830 FAIRING RROYCE BOEING767 767* NM RROYCERB211 RB211524* NE THRUST REVERSER FAILED W O OTHER ED VIBRATION/BUFFET INFLIGHT SEPARATION LDLANDING 1 AUS (AUS) RT ENGINE FAIRING FAILED. FAIRING WAS LOCATED ON THE STRUT AT THE 6 O'CLOCK POSITION. A SMALL AMOUNT OF DAMAGE WAS NOTED ON SEVERAL BLOCKER DOORS AND ONE CASCADE SEGMENT. 2L72 4F4 FRTA1NM E12EU 20030822001212003082200121 2003 8 22 AUS20030634 420030619G25657A144748 SLIDE BOEING747 747338 NM RROYCERB211 RB211524D41954555NE PAX DOOR FAILED W K NONE L NO TEST ININSP/MAINT 1 AUS 6197 (AUS) DOOR NR 1 RT SLIDE RAFT FAILED. 2L72 4F4 FRTA20WE E12EU 20030822001232003082200123EU 2003 8 22 AUS20030635 120030618G7602C10310UNF BALL JOINT LYC BNORM BN2 BN2B20 1520302EU LYC O540 IO540K1B5 41532EA HARTZLHCC2Y HCC2YK2 GL MIXTURE CONTROL BROKEN W O OTHER O OTHER CLCLIMB 1 AUS (AUS) RT ENGINE MIXTURE CONTROL BALL JOINT FAILED. 1H72 3O3 O A17EU 1E4 5 CP920 20030822001242003082200124CE 2003 8 22 AUS20030636 120030612G353019900192551779 REGULATOR CESSNA182 182Q 2072732CE CONT O470 O470* 17026SO MCAULY2A34C C2A34C204 GL PORTABLE OXYGEN LEAKING W K NONE O OTHER ININSP/MAINT 1 AUS 6468287 (AUS) PORTABLE OXYGEN SYSTEM REGULATOR LEAKING PAST TEFLON SEAL.OXYGEN LEAKING FROM HIGH PRESSURE SIDE TO LOW PRESSURE SIDE INCREASED TO OUTLET PRESSURE ABOVE THE REGULATED 50PSI. RELIEFVALVE OPENED AND LOW PRESSURE OUTLET TUBING BURST. 1H71 3O3 ONT3A13 E273 5 CP3EA 20030822001252003082200125NM 2003 8 22 AUS20030637 120030619G5280 DOOR BOEING767 767338 1385151NM GE CF6 CF680C2* GL MLG MISSING W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT MAIN LANDING GEAR SHOCK STRUT DOOR MISSING. DAMAGE TO A NUMBER OF HYDRAULIC LINES. 2L72 4F4 FRTA1NM E23EA 20030822001262003082200126 2003 8 22 AUS20030639 420030601G34006229436100 SYMBOL GENERATOR BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU NAVIGATION SYS FAILED W O OTHER O OTHER CRCRUISE 1 AUS (AUS) NR 1 SYMBOL GENERATOR FAILED. 2L72 4F4 FRTA16WE E21EU 20030822001272003082200127NM 2003 8 22 AUS20030640 120030613G2612 CONNECTOR BOEING737 737376 NM GE CFM56 CFM563B1 13802NE FIRE DETECTION FAULTY W O OTHER N FALSE WARNING CRCRUISE 1 AUS (AUS) RT ENGINE FIRE DETECTION SYSTEM FAULTY. SUSPECT FAULTY CONNECTOR. 2L72 4F4 FRTA16WE E2GL 20030822001282003082200128SO 2003 8 22 AUS20030641 220030506G7313811536R INJECTOR CESSNA310 310R 2074245CE CONT O520 IO520M 17032SO MCAULY3AF32C3AF32C87 GL FUEL SYSTEM BLOCKED W O OTHER E VIBRATION/BUFFET CRCRUISE 1 AUS 833 (AUS) RT ENGINE OIL FILTER CONTAMINATED WITH METAL. INVESTIGATION FOUND NR 5 CYLINDER INJECTOR NOZZLE WAS PARTIALLY BLOCKED CAUSING TORCHING OF NR 5 PISTON. 1L72 3O3 O 3A10 E5CE 5 CP22EA 20030822001292003082200129NM 2003 8 22 AUS20030642 120030625G27507321870018 SHUTOFF VALVE BOEING767 767238 1385114NM PWA JT9 JT9D7R4E 52054NE HYD SYSTEM FAULTY W O OTHER F FLT CONT AFFECTED TXTAXI/GRND HDL 1 AUS (AUS) FLAP/SLAT HYDRAULIC SHUTOFF VALVE FAULTY. 2L72 4F4 FRTA1NM E3NE 20030822001302003082200130 2003 8 22 AUS20030643 420030610G22116224591512 COMPUTER BOEING767 767238 1385114NM PWA JT9 JT9D7R4E 52054NE AUTOPILOT FAULTY W O OTHER F FLT CONT AFFECTED APAPPROACH 1 AUS (AUS) LT FLIGHT CONTROL COMPUTER (FCC) FAULTY. 2L72 4F4 FRTA1NM E3NE 20030822001322003082200132SW 2003 8 22 AUS20030644 120030630G27312743027041 BUSHING SWRNGNSA227 SA227AT 8780610SW GARRTTTPE331TPE33111U 01514WP ROTOL R321 R321482F8 GL ELEVATOR TAB MISSING W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) PITCH TRIM SERVO ACTUATOR LOWER ATTACHMENT POINT PIVOT BUSHING MISSING AND ATTACHMENT BOLTS WORN. 2L72 4T4 TRTA5SW E4WE 6 CP61GL 20030822001332003082200133CE 2003 8 22 AUS20030646 120030626G8011652406 DRIVE GEAR CESSNA206 U206G 2073356CE CONT O520 IO520F 17032SO MCAULY3A32C D3A32C90 GL ENGINE STARTER DAMAGED W O OTHER E VIBRATION/BUFFET NRNOT REPORTED 1 AUS 849 (AUS) ENGINE STARTER DRIVE GEAR TEETH (7OFF) MISSING. INVESTIGATION ALSO FOUND CORRESPONDING CRANKSHAFT DRIVE GEAR TEETH DAMAGED. 1H71 3O3 O A4CE E5CE 5 CP21EA 20030902000012003090200001NM 2003 9 2 AUS20030648 120030629G2497 WIRE BOEING767 767338 1385151NM GE CF6 CF680C2* GL ELECTRICAL BURNED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) ELECTRICAL WIRING LOCATED IN THE BILGE AREA AT STA 570 IN THE FORWARD CARGO COMPARTMENT BURNED. 2L72 4F4 FRTA1NM E23EA 20030902000112003090200011NM 2003 9 2 AUS20030649 120030622G3260189915 SENSOR BOEING737 737376 NM CFMINTCFM56 CFM563B2 13802EU RT MLG FAULTY W O OTHER J WARNING INDICATION CLCLIMB 1 AUS (AUS) RT MAIN LANDING GEAR UPLOCK SENSOR FAULTY. 2L72 4F4 FRTA16WE E21EU 20030905000512003090500051CE 2003 9 5 AUS20030650 120030630G57110523315 PLATE CESSNA182 182F 2072714CE CONT O470 O470R 17026SO WING SPAR CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT WING FRONT SPAR CAP DOUBLER PLATE CONTAINED INTERGRANULAR CORROSION. 1H71 3O3 ONT3A13 E273 20030905000522003090500052CE 2003 9 5 AUS20030651 120030630G5711122210522 ANGLE CESSNA182 182F 2072714CE CONT O470 O470R 17026SO WING SPAR CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT WING FRONT SPAR CAP ANGLE CORRODED. 1H71 3O3 ONT3A13 E273 20030905000532003090500053NM 2003 9 5 AUS20030652 120030428G5310 BEAR STRAP BOEING737 737376 NM CFMINTCFM56 CFM563C 13802EU GALLEY DOORS CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FORWARD GALLEY DOOR CRACKED. SEVEN CRACKS FOUND ON FORWARD UPPER CORNER (BEAR STRAP AND INTERNAL DOUBLER) AND ONE CRACK FOUND ON THE AFT UPPER CORNER (BEAR STRAP DOUBLER). FOUND DURING EDDY CURRENT INSPECTION IAW ENGINEERING INSTRUCTION 737-53-14R4. 2L72 4F4 FRTA16WE E21EU 20030905000542003090500054CE 2003 9 5 AUS20030653 120030619G5511043200156 SPAR CESSNA CESSNA150 A150K 2071824CE CONT O200 O200A 17020SO MCAULY1A101 1A101DCM GL HORIZONTAL STAB CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS A1500155 (AUS) STABILIZER SPAR CRACKED IN AREA AROUND ATTACHMENT BRACKET NUT PLATE. CRACK LENGTH 12.7MM (0.5 IN). 1H71 3O3 O 3A19 E252 5 NP918 20030905000552003090500055SO 2003 9 5 AUS20030654 120030630G321167198000 WASHER PIPER PA34 PA34220T 7103420SO CONT O360 TSIO360KB 17025SO MLG WRONG PART W K NONE W INADEQUATE Q C ININSP/MAINT 1 AUS (AUS) LT AND RT MAIN LANDING GEAR FORWARD TRUNNION WASHERS INCORRECT PARTS. CORRECT WASHERS HAVE A CHAMFER ON THE INTERNAL BORE WHICH ALLOWS CLEARANCE FOR THE TRUNNION SHOULDER RADIUS. THE WASHERS FITTED DID NOT HAVE THE CHAMFER. IN THIS CASE THE DAMAGE WAS MINIMAL. PERSONNEL/MAINTENANCE ERROR. UNAPPROVED PART. 1L72 3O3 O A7SO E9CE 20030905000562003090500056NM 2003 9 5 AUS20030655 120030630G2497 WIRE BOEING747 747338 NM ELECTRICAL POWERDAMAGED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) ELECTRICAL WIRING CHAFED AND BURNED IN AREA LOCATED ABOVE TOILET CEILING. 2L72 4F RTA20WE 20030905000572003090500057NE 2003 9 5 AUS20030656 320030617G6110 PROPELLER PIPER PA60 PA60600A 7106002NM LYC O540 IO540K1J5 41532EA HARTZLHCC3Y HCC3YR2 NE ASSY FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) PROPELLER REMOVED DUE TO OIL LEAK. DISASSEMBLY AND INVESTIGATION FOUND THE FOLLOWING DEFECTS; INCORRECT LOCKING OF BALANCE WEIGHT SCREWS. SCREWS WERE LOCKWIRED IN A MANNER THAT THE SCREWS WERE UNDOING EACH OTHER. PN A2433 LONG BOLTS WERE USED INSTEAD OF PN A2432 SHORTER BOLTS. LONG BOLTS ARE USED FOR BULKHEAD MOUNT. BULKHEAD SPACERS WERE USED TO COMPENSATE FOR EXTRA LENGTH. CADMIUM PLATED PN A20431 NYLOCK NUTS USED. NO HYDRAULIC FLUID WAS USED IN PISTON. 1M72 3O3 ORTA17WE 1E4 5 CP25EA 20030905000582003090500058SO 2003 9 5 AUS20030657 120030618G32304198300 DOWNLOCK HOOK PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2 GL MLG LACK OF LUBE W O OTHER WJ INADEQUATE Q C WARNING INDICATION DEDESCENT 1 AUS (AUS) LT MAIN LANDING GEAR DOWNLOCK HOOK STIFF IN OPERATION DUE TO LACK OF LUBRICATION. SUSPECT CAUSED BY INCORRECT CLEANING TECHNIQUES. 1L72 3O3 O A20SO E14EA 5 CP33EA 20030905000592003090500059SO 2003 9 5 AUS20030658 120030620G6120M832481110 O-RING EMB 120 EMB120 3260201SO PWA 118 PW118A NE HAMSTD14RF 14RF9 NE PROP CONTROL DAMAGED W O OTHER O OTHER LDLANDING 1 AUS (AUS) RT PROPELLER OIL TRANSFER TUBE O-RING SEAL DAMAGED. 2L72 4T4 TRTA31SO E20NE 6 CP11NE 20030905000602003090500060SO 2003 9 5 AUS20030659 220030630G8520530658 ROD BEARING CESSNA421 421B 2076014CE CONT O520 GTSIO520H 17032SO MCAULY3AF34C3AF34C92 GL ENGINE WORN W K NONE O OTHER ININSP/MAINT 1 AUS 152 (AUS) CONNECTING ROD LITTLE END BEARING MOVED AND WORE ON PISTON. INVESTIGATION FOUND TWO MORE LITTLE END BEARINGS LOOSE. 1L72 3O3 O A7CE E7CE 5 CP22EA 20030905000612003090500061SO 2003 9 5 AUS20030660 220030630G7313 INJECTOR CESSNA421 421B 2076014CE CONT O520 GTSIO520H 17032SO MCAULY3AF34C3AF34C92 GL ENGINE MISINSTALLED W K NONE W INADEQUATE Q C ININSP/MAINT 1 AUS 152 (AUS) FUEL INJECTOR NOZZLE INCORRECTLY FITTED. TWO RUBBER SEALS AND ONE METAL WASHER FITTED INSTEAD OF THE CORRECT FIT OF ONE RUBBER SEAL AND ONE METAL WASHER. PERSONNEL/MAINTENANCE ERROR. 1L72 3O3 O A7CE E7CE 5 CP22EA 20030905000622003090500062NM 2003 9 5 AUS20030661 120030630G57306545407 SKIN BOEING737 73733A 1384673NM RT WING CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT WING UPPER SKIN LOWER SURFACE AND STIFFENERS CONTAINED LEVEL 2 CORROSION IN THE AREA OF THE RT WING VENT TANK BETWEEN WS557 AND WS583. FOUND DURING INSPECTION IAW A-B73-5791-51. 2L72 4F RTA16WE 20030905000632003090500063NM 2003 9 5 AUS20030662 120030702G3242215152 BRAKE ASSY BOEING747 747438 NM RT MLG FIRE W O OTHER A FLAME/FIRE LDLANDING 1 AUS 3121 (AUS) RT WING LANDING GEAR BRAKE FIRE. NR 5F AND NR 7F BRAKES REPLACED. 2L74 4F RTA20WE 20030905000642003090500064NM 2003 9 5 AUS20030663 120030703G5711654532525 SPAR BOEING737 73733A 1384673NM RT WING CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT WING AFT SPAR LOWER SECTION CONTAINED LEVEL 2 CORROSION IN AREAOF RH WING VENT TANK LOCATED BETWEEN WS557 AND WS583. FOUND DURING INSPECTION IAW A-B73-5791-51. 2L72 4F RTA16WE 20030905000652003090500065CE 2003 9 5 AUS20030664 120030701G27500510105193 CONTROL CABLE CESSNA172 172RG 2072438CE LYC O360 O360F1A6 41514EA MCAULY2D34C B2D34C220 GL TE FLAPS BROKEN W O OTHER F FLT CONT AFFECTED LDLANDING 1 AUS (AUS) LT FORWARD FLAP CONTROL BROKEN. 1H71 3O3 O 3A17 E286 5 CP7EA 20030905000662003090500066WP 2003 9 5 AUS20030665 220030605G723031020224 HOUSING SWRNGNSA227 SA227AC 8780603SW GARRTTTPE331TPE33111U 01514WP MCAULY4HFR344HFR34C652 NE COMPRESSOR DAMAGED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) SECOND STAGE COMPRESSOR HOUSING PLASMA METAL COATING SEPARATED CAUSING BLOCKAGE OF NOZZLE VANE SEGMENT COOLING AIR SLOTS INFIRST STAGE TURBINE NOZZLE AND METAL SPRAY DEPOSITS ON DIFFUSER VANES. 2L72 4T4 TRTA8SW E4WE 6 C3PNE 20030905000672003090500067SO 2003 9 5 AUS20030666 220030702G8530653452 CYLINDER CESSNA421 421B 2076014CE CONT O520 GTSIO520H 17032SO MCAULY3AF34C3AF34C92 GL RT ENGINE WRONG PART W K NONE W INADEQUATE Q C ININSP/MAINT 1 AUS 152 (AUS) RT ENGINE HAD TWO UNAPPROVED CYLINDERS FITTED. PN 653452 CYLINDERS ARE NOT APPROVED FOR THE GTSIO520-H MODEL CYLINDERS UNLESS MODIFIED. THE TWO CYLINDERS FITTED WERE NOT MODIFIED IAW APPROVED SCHEME. THE REMAINING PN 653453A4 CYLINDERS FITTED ARE APPROVED FOR THIS MODEL ENGINE. PERSONNEL/MAINTENANCE ERROR. UNAPPROVED PART. 1L72 3O3 O A7CE E7CE 5 CP22EA 20030905000682003090500068 2003 9 5 AUS20030667 420030702G25657A141824 SLIDE BOEING747 747438 NM NR 3 DEFLATED W O OTHER A FLAME/FIRE NRNOT REPORTED 1 AUS GT1686 (AUS) NR 3 RT DOOR ESCAPE SLIDE DEFLATED DURING EMERGENCY EVACUATION OF AIRCRAFT FOLLOWING BRAKE FIRE. 2L74 4F RTA20WE 20030905000692003090500069NM 2003 9 5 AUS20030668 120030628G323011972 SOLENOID DHAV DHC8 DHC8315 2809010NM HAMSTD14SF 14SF15 NE MLG SECT VALVE FAULTY W O OTHER J WARNING INDICATION LDLANDING 1 AUS (AUS) LANDING GEAR SELECTOR VALVE SOLENOID COIL A RESISTANCE HIGH. 2H72 4T RTA13NM 6 CP7NE 20030905000702003090500070 2003 9 5 AUS20030669 420030618G2210 HANDLE DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE AUTOPILOT SYSTEMTRANSPOSED W K NONE W INADEQUATE Q C ININSP/MAINT 1 AUS (AUS) AIRCRAFT PITCH AND ROLL DISCONNECT HANDLES TRANSPOSED. THE ROLL DISCONNECT HANDLE WAS IN THE PITCH DISCONNECT HANDLE POSITION AND THE PITCH DISCONNECT HANDLE WAS IN THE ROLL HANDLE POSITION. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030905000712003090500071SO 2003 9 5 AUS20030670 220030622G8530639272 CYLINDER BEECH 36 A36 1151604CE CONT O520 IO520B 17032SO MCAULY2A36C 2A36C23 GL ENGINE CRACKED W O OTHER E VIBRATION/BUFFET TXTAXI/GRND HDL 1 AUS 1312 (AUS) NR 2 CYLINDER CRACKED BETWEEN VALVES. NR 3 AND NR 4 CYLINDERS REMOVED FOR LOW COMPRESSION. 1L71 3O3 O 3A15 E5CE 5 CP880 20030905000722003090500072NM 2003 9 5 AUS20030671 120030703G242131708001A GENERATOR DHAV DHC8 DHC8202 2809007NM PWA 120 PW123D 52152NE HAMSTD14SF 14SF23 NE NR 1 FAILED W O OTHER H ELECT. POWER LOSS-50 PC CRCRUISE 1 AUS 9386 (AUS) NR 1 AC GENERATOR FAILED. LIMITED INFORMATION PROVIDED. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030905000732003090500073CE 2003 9 5 AUS20030672 120030527G5310VARIOUS STRUCTURE BEECH 200 200BEECH 1152920CE PWA PT6 PT6A42 52043NE HARTZLHCB3T HCB3TN3 GL FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) REAR BULKHEAD BEAM EXTENSION CLEATS LOCATED AT STRINGER 5,STRINGER 7, STRINGER 8 AND STRINGER 11 CRACKED. CLEATS ARE INSTALLED DUE TO WIDENING OF THE REAR FUSELAGE FOR STC SA2192CE. FOUND DURING INSPECTION IAW AD/BEECH200/55 AMDT1 AND AD/BEECH200/21 AMDT11. 1L72 4T4 T A24CE E4EA 6 CP15EA 20030905000742003090500074NE 2003 9 5 AUS20030673 220030629G7200 ENGINE BEECH 200 200BEECH 1152920CE PWA PT6 PT6A42 52043NE LEFT FLUCTUATES W O OTHER E VIBRATION/BUFFET CLCLIMB 1 AUS (AUS) LT ENGINE TORQUE FLUCTUATING. ITT 900 DEGREES C. 1L72 4T4 T A24CE E4EA 20030905000752003090500075EU 2003 9 5 AUS20030674 220030703G7320 PMC BOEING737 737376 NM CFMINTCFM56 CFM563B2 13802EU NR 2 ENGINE FAULTY W C ABORTED TAKEOFF E VIBRATION/BUFFET TOTAKEOFF 1 AUS (AUS) NR 2 ENGINE LOW POWER. SUSPECT CAUSED BY FAULTY POWER MANAGEMENT CONTROL (PMC). 2L72 4F4 FRTA16WE E21EU 20030905000762003090500076SW 2003 9 5 AUS20030675 120030529G5310 STRUCTURE SWRNGNSA227 SA227* SW GARRTTTPE331TPE33112UHR WP MCAULY4HFR344HFR34C652 NE FUSELAGE ANIMAL STRIKE W O OTHER C F.O.D. LDLANDING 1 AUS (AUS) AIRCRAFT HIT A KANGAROO DURING LANDING ROLL. INITIAL IMPACT APPEARS TO BE ON THE LT PROPELLER CAUSING SUBSTANTIAL DAMAGE TO THE PROPELLER. ANIMAL REMAINS WERE ALSO INGESTED INTO THE LT ENGINE. FOLLOWING THE IMPACT, THE KANGAROO WAS EJECTED FORWARD AND OVER THE AIRCRAFT IMPACTING THE RT PROPELLER. ENGINEERING INSPECTION FOUND THAT THE LT PROP HAD BENT BLADES AND THE LT ENGINE HAD INGESTED ANIMAL REMAINS. THE RT PROP AND ENGINE ARE SUSPECTED OF SUFFERING AN IMPACT AND MINOR FODDAMAGE TO THE ENGINE. 2L72 4T4 TRTA5SW E4WE 6 C3PNE 20030905000772003090500077CE 2003 9 5 AUS20030676 120030328G5711351100611 SPAR BEECH 33 35C33 1151408CE CONT O470 IO470K 17026SO AMTR C8289 C8289 GL RT & LT CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) WING SPARS PN 35110061-1 (LT) AND PN 351100612 (RT) CONTAINED EXFOLIATION CORROSION IN THE UPPER AND LOWER SPAR CAPS. 1L71 3O3 O 3A15 3E1 5 NEXPP5N 20030905000792003090500079SO 2003 9 5 AUS20030677 120030701G5711 SPAR PIPER PA28 PA28140 7102802SO LYC O320 O320E2A 41508EA SNSNCH74DM M74DM EA LT WING CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT WING MAIN SPAR WEB CRACKED. CRACK LOCATED AT THE TOP OF THE MAIN LANDING GEAR LEG ATTACHMENT AREA. CRACK LENGTH 100MM (4IN). 1L71 3O3 O 2A13 E274 5 NP88614 20030905000802003090500080SW 2003 9 5 AUS20030678 120030704G3230HMX6G ROD END GULSTM500 500U 0141108SW LYC O540 IO540E1B5 41532EA HARTZLHCA3X HCA3XK2 GL MLG FRACTURED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) MAIN LANDING GEAR ACTUATOR RODEND FRACTURED AT GREASE NIPPLE HOLE. 1H72 3O3 O 6A1 1E4 5 CP913 20030905000812003090500081NM 2003 9 5 AUS20030679 120030601G2781114T642125 WASHER BOEING767 767338 1385151NM GE CF6 CF680C2* GL LE SLAT MISSING W O OTHER FJ FLT CONT AFFECTED WARNING INDICATION TXTAXI/GRND HDL 1 AUS (AUS) NR 5 LEADING EDGE SLAT INBOARD SENSOR TARGET MISSING. 2L72 4F4 FRTA1NM E23EA 20030905000822003090500082CE 2003 9 5 AUS20030680 120030429G3246MS2125005016 BOLT CESSNA441 441 2076020CE MLG WHEEL SHEARED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) MAIN WHEEL HUB BOLT SHEARED. 1L72 3T RTA28CE 20030905000832003090500083NM 2003 9 5 AUS20030681 120030702G3242215152 BRAKE BOEING747 747438 NM MLG FIRE W O OTHER AJ FLAME/FIRE WARNING INDICATION NRNOT REPORTED 1 AUS A0252 (AUS) RT BODY LANDING GEAR BRAKE FIRE. 2L74 4F RTA20WE 20030905000842003090500084SW 2003 9 5 AUS20030682 120030705G521027 SEAL SWRNGNSA227 SA227* SW MCAULY4HFR344HFR34C652 NE PAX DOOR FAULTY W O OTHER O OTHER CRCRUISE 1 AUS (AUS) PASSENGER DOOR SEAL NOT INFLATING CORRECTLY. 2L72 4T RTA5SW 6 C3PNE 20030905000852003090500085EA 2003 9 5 AUS20030683 220030707G74141O1630052 MAGNETO ROBSINR22 R22BETA 7640110NM LYC O360 O360J2A 41514EA ENGINE WORN W K NONE O OTHER ININSP/MAINT 1 AUS 51 (AUS) MAGNETO CASE SCREWS LOOSE CAUSING FRETTING BETWEEN CASE HALVES. METAL CONTAMINATION OF MAGNETO. 1G71 3O3 O H10WE E286 20030905000862003090500086SW 2003 9 5 AUS20030684 120030708G29102781032675 TUBE SWRNGNSA227 SA227* SW MCAULY4HFR344HFR34C652 NE HYDRAULIC SYSTEMLOOSE W O OTHER KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 AUS (AUS) HYD SYSTEM SUCTION TUBE LOOSE AT FITTING ON INBOARD NACELLE LOCATED FORWARD OF HYDRAULIC ACCUMULATOR. 2L72 4T RTA5SW 6 C3PNE 20030905000872003090500087NM 2003 9 5 AUS20030685 120030621G5310 STRUCTURE DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE FUSELAGE LIGHTNING STRIKEW O OTHER O OTHER NRNOT REPORTED 1 AUS (AUS) AIRCRAFT LIGHTNING STRIKE. BURN MARKS AROUND RIVET HEADS AND ON SKIN. MOST DAMAGE IN AREA LOCATED NEAR STRINGER 31P BETWEEN STN X120 AND STN X653. LH ELEVATOR OUTBOARD REAR STATIC WICK HADSIGNS OF BURNING. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030905000882003090500088EU 2003 9 5 AUS20030686 220030627G7230 COMPRESSOR BOEING737 73733A 1384673NM CFMINTCFM56 CFM563C 13802EU ENGINE FOD W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) NR 2 ENGINE COMPRESSOR SIXTH, SEVENTH AND EIGHTH STAGES CONTAINED SUBSTANTIAL FOD DAMAGE. 2L72 4F4 FRTA16WE E21EU 20030905000892003090500089EU 2003 9 5 AUS20030687 220030627G7230724468 BLADE BOEING737 73733A 1384673NM CFMINTCFM56 CFM563C 13802EU ENG COMPRESSOR FOD W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) NR 1 ENGINE SEVENTH STAGE COMPRESSOR BLADES DAMAGED BY FOD. 2L72 4F4 FRTA16WE E21EU 20030905000902003090500090NM 2003 9 5 AUS20030688 120030707G215078279018 ACM DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE CABIN COOLING SYSEIZED W O OTHER O OTHER CRCRUISE 1 AUS 5821 (AUS) CABIN AIR CYCLE MACHINE SEIZED. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030905000912003090500091 2003 9 5 AUS20030689 420030525G83003037223 CARBON SEAL FOKKERF27 F27MK50 EU PWA PWA120PW125B NE LT ENG ACC GB WORN W O OTHER EJ VIBRATION/BUFFET WARNING INDICATION TOTAKEOFF 1 AUS 9399 (AUS) LT ENGINE ACCESSORY GEARBOX OIL BREATHER CARBON SEAL WORN AND LEAKING. 2H72 4T4 TRTA817 E20NE 20030905000922003090500092SO 2003 9 5 AUS20030690 220030708G8520655004 CONNECTING ROD CESSNA421 421B 2076014CE CONT O520 GTSIO520H 17032SO MCAULY3AF34C3AF34C92 GL ENGINE DAMAGED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) NR 2 CYLINDER CONNECTING ROD PN 655004 BIGEND CAP CONTACTING CAMSHAFT PN 653056 NR 2 CYLINDER EXHAUST LOBE. INSPECTION FOUND A SIMILAR PROBLEM WITH NR 6 CYLINDER CONNECTING ROD BIG END CAP. 1L72 3O3 O A7CE E7CE 5 CP22EA 20030905000932003090500093WP 2003 9 5 AUS20030691 120030703G5711H36831A SPAR DHAVXXDH82 DH82AROBRTSN2801002WP DHAVXXGIPSY GIPSYMAJOR1 20004WP DHAV DH5220DH5220P WP LT WING DAMAGED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT WING SPAR DAMAGED. LOOSE RIBS FOUND DURING PERIODIC INSPECTION WHEN SECTION OF FABRIC WAS REMVD TO CARRY OUT RIBREPAIRS REMOVED FABRIC REVEALED NONAPPROVED REPAIR TO REAR SPAR TOP FACE & REPAIRED AREA COVERED BY PAINT. FURTHER FABRIC REMOVAL FOUND SEVERE DAMAGE TO SPAR LOWER FLANGES AT SEVERAL LOCATIONS. AREAS OF DAMAGE WERE NOT VISIBLE FROM EXISTING INSPECTION HOLE LOCATIONS. 1Q71 3I3 I A8EU A8EU 5 NA8EU 20030905000942003090500094NM 2003 9 5 AUS20030692 120030502G5312500N34215 BULKHEAD DOUG 600N 600N 3027377NM ALLSN 250C 250C47M 03013GL FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FUSELAGE BULKHEAD CRACKED AT TOP RT TAIL BOOM FITTING BRACKET.FOUND DURING INSPECTION IAW AD/HU389/108. 1G71 3U3 UNCH3WE E1GL 20030905000952003090500095CE 2003 9 5 AUS20030693 120030707G5751AN470AD4 RIVET CESSNA182 182G 2072716CE CONT O470 O470R 17026SO HARTZLHCC2Y BHCC2YF1 GL AILERONS FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) AILERON MASS BALANCE WEIGHT ATTACHMENT RIVETS FAULTY. APPROXIMATELY HALF OF THE RIVETS FAILED TESTING AND INSPECTION IAW AD/CESSNA180/28. 1H71 3O3 ONT3A13 E273 5 CP920 20030905000962003090500096SO 2003 9 5 AUS20030694 220030708G852035972 BOLT CESSNA182 182H 2072718CE CONT O470 IO470* 17026SO MCAULY2A34C 2A34C66 GL CONNECTING ROD FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) CONNECTING ROD BOLT FAULTY. LONGITUDINAL DISCONTINUITY FOUND DURING MAGNETIC PARTICLE INSPECTION IAW AD/ENG/4 AMDT8. 1H71 3O3 ONT3A13 E1CE 5 CP3EA 20030905000972003090500097 2003 9 5 AUS20030695 420030713G830031011447 PLANETARY GEAR CASA C212 C212200 2410304EU GARRTTTPE331TPE33110 01514WP GEARBOX DAMAGED W K NONE O OTHER ININSP/MAINT 1 AUS 217 (AUS) ENGINE GEARBOX SUN GEAR DAMAGED WHICH IN TURN CAUSED DAMAGE TO THE PLANETARY GEARS. SUSPECT SUN GEAR INCORRECTLY HARDENED DURING MANUFACTURE. FOUND AS A RESULT OF SOAP SAMPLE TESTING. 2H72 4T4 TRTA43EU E4WE 20030905000982003090500098CE 2003 9 5 AUS20030696 120030708G323312810013 HOUSING CESSNA172 172RG 2072438CE LYC O360 O360F1A6 41514EA MCAULY2D34C B2D34C220 GL MLG ACTUATOR CRACKED W O OTHER J WARNING INDICATION CLCLIMB 1 AUS 8674 (AUS) RT MAIN LANDING GEAR ACTUATOR BODY SEVERELY CRACKED FROM PINION GEAR ACCESS HOLE TO THE OUTER FACE OF THE ACTUATOR. SLIGHT CRACKING WAS ALSO FOUND FROM THE ACCESS HOLE TO THE NEEDLE BEARING HOUSING. 1H71 3O3 O 3A17 E286 5 CP7EA 20030905000992003090500099EA 2003 9 5 AUS20030697 220030616G8530SL75089 PISTON PIPER PA23 PA23250 7102308SO LYC O540 O540A1D5 41532EA HARTZLHCE2Y HCE2YK2 GL ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) PISTON CRACKED THROUGH OIL RING LAND. 1L72 3O3 O 1A10 E295 5 CP9EA 20030905001002003090500100NM 2003 9 5 AUS20030698 120030712G3310RV4NBYSD502A RHEOSTAT DHAV DHC8 DHC8202 2809007NM PWA 120 PW123D 52152NE HAMSTD14SF 14SF23 NE COCKPIT BURNED OUT W O OTHER B SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 AUS (AUS) FLIGHT COMPARTMENT LIGHTING RHEOSTAT BURNED OUT. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030905001022003090500102NM 2003 9 5 AUS20030699 120030711G27316355B000103 ACTUATOR BOEING737 737800* NM ELEVATOR TAB FAULTY W O OTHER F FLT CONT AFFECTED CRCRUISE 1 AUS 1511 (AUS) STABILISER TRIM ACTUATOR FAULTY. ACTUATOR MOTOR UNSERVICEABLE. 2L72 4F RTA16WE 20030905001092003090500109NM 2003 9 5 AUS20030700 120030704G324226123121 BRAKE BOEING737 737800* NM RT MLG SEIZED W O OTHER O OTHER LDLANDING 1 AUS (AUS) RT INBOARD BRAKE SEIZED. ON REMOVAL OF WHEEL THE BRAKE PAD WAS FOUND TO BE DISLODGED AND JAMMING THE STATORS/ROTORS. 2L72 4F RTA16WE 20030905001112003090500111NM 2003 9 5 AUS20030701 120030705G2910 LINE BOEING767 767383 1385214NM HYDRAULIC SYSTEMLEAKING W O OTHER K FLUID LOSS DEDESCENT 1 AUS (AUS) RT ENGINE DRIVEN HYDRAULIC PUMP CASE DRAIN LINE LEAKING. LOSS OF HYDRAULIC FLUID. 2L72 4F RTA1NM 20030905001132003090500113SO 2003 9 5 AUS20030703 220030701G8520655004 CONNECTING ROD CESSNA404 404CESSNA 2075901CE CONT O520 GTSIO520M 17032SO MCAULY3FF32 3FF32C501 GL ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 1391 (AUS) CONNECTING ROD CONTAINED A CRACK INDICATION ON THE SHANK BELOW THE LITTLE END. 1L72 3O3 O A25CE E7CE 5 CP45GL 20030905001142003090500114EU 2003 9 5 AUS20030704 120030712G5610NP1701022 WINDSHIELD BAC 146 146200A 1500266EU LYC ALF502ALF502R5 41580NE COCKPIT FAILED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT WINDSHIELD SHATTERED. 2H74 4F4 F A49EU E6NE 20030905001152003090500115 2003 9 5 AUS20030705 420030714G2397 WIRE BOEING767 767338 1385151NM GE CF6 CF680C2* GL ENTERTAIN SYS BURNED W O OTHER B SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 AUS (AUS) PSU WIRING BURNED IN AREA ABOVE SEAT 53AB. WIRING ARCING ON SUPPORT BRACKET. 2L72 4F4 FRTA1NM E23EA 20030905001182003090500118NM 2003 9 5 AUS20030706 120030711G4920380029812 APU BOEING767 767338 1385151NM GE CF6 CF680C2* GL APU BAY SMOKE W O OTHER B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 AUS (AUS) APU FAULTY. SMOKE IN CABIN. WORKSHOP INVESTIGATION COULD FIND NO EVIDENCE OF OIL LEAK. SUSPECT OIL WAS RESIDUE FROM A PREVIOUS OIL LEAK. 2L72 4F4 FRTA1NM E23EA 20030905001202003090500120NM 2003 9 5 AUS20030707 120030625G5310 DOOR FRAME BOEING737 737376 NM CFMINTCFM56 CFM563B2 13802EU FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) DOOR FRAME CRACKED. FORWARD CORNER HAS CRACK INDICATIONS IN FIVEHOLES. AFT CORNER HAS CRACK INDICATION IN ONE HOLE. FOUND DURINGEDDY CURRENT INSPECTION IAW QANTAS ENGINEERING INSTRUCTION733-53-14R4, BOEING SB:737-53-1116 AND CASA AD/B737/24. 2L72 4F4 FRTA16WE E21EU 20030905001212003090500121SO 2003 9 5 AUS20030708 120030715G3230554401 CABLE PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2 GL MLG FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LANDING GEAR CABLE HAD SLIGHT BINDING. DURING INVESTIGATION OF THE BINDING PROBLEM A CRIMPED FERRULE SEPARATED FROM THE CABLE. CABLE WAS A NEW ITEM AND WAS BEING INSPECTED BEFORE FITMENT.CABLE IS FITTED BETWEEN LANDING GEAR SELECTOR HANDLE AND POWERPACK. 1L72 3O3 O A20SO E14EA 5 CP33EA 20030905001222003090500122EA 2003 9 5 AUS20030709 220030716G7414K3823 GEAR PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2 GL MAGNETO LOOSE W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT ENGINE MAGNETO DISTRIBUTOR GEAR POINTER LOOSE AND CONTACTING DISTRIBUTOR CAP AND POSTS. 1L72 3O3 O A20SO E14EA 5 CP33EA 20030905001242003090500124NM 2003 9 5 AUS20030710 120030703G27316355B000103 ACTUATOR BOEING737 737800* NM ELEVATOR TAB FAULTY W O OTHER FJ FLT CONT AFFECTED WARNING INDICATION NRNOT REPORTED 1 AUS (AUS) HORIZONTAL STABILISER TRIM ACTUATOR FAULTY. 2L72 4F RTA16WE 20030905001262003090500126EA 2003 9 5 AUS20030711 220030711G8530L227667A BUSHING PIPER PA31 PA31350 7103110SO LYC O540 LTIO540J2BD 41533EA HARTZLHCE3Y HCE3YR2 GL ENGINE MISINSTALLED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT ENGINE OIL FILTER CONTAMINATED WITH FINE ALUMINIUM/BRONZE METAL PARTICLES. STRIP AND INSPECTION FOUND THAT THE SOURCE OF THE METAL CONTAMINATION WAS FROM THE VALVE ROCKER THRUST WASHER AREAS. SEVERAL OF THE ROCKER PEDESTAL BUSHES HAD BEEN INSTALLED PROUD OF THE THRUST FACE AT MANUFACTURE. THIS HAS RESULTED IN THE THRUST WASHERS INITIALLY BEARING ON THE EDGE OF THE BUSHINGS, EVENTUALLY WEARING THEM DOWN, THEN ON TO THE ROCKER PEDESTAL THRUST FACES. SOME OF THE BUSHING MATERIAL RUBBED OFF DURING THIS TIME HAD LODGED BETWEEN THE THRUST WASHERS AND PEDESTALS RESULTING IN ABRASION OF THE THRUST FACE. PERSONNEL/MAINTENANCE ERROR. 1L72 3O3 O A20SO E14EA 5 CP33EA 20030905001282003090500128NM 2003 9 5 AUS20030712 120030714G2910AE81566J FITTING BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU HYDRAULIC SYSTEMCRACKED W O OTHER KJ FLUID LOSS WARNING INDICATION CLCLIMB 1 AUS (AUS) NR 1 ENGINE HYDRAULIC SYSTEM FIREWALL QUICK DISCONNECT FITTING CRACKED. LOSS OF A-SYSTEM HYDRAULIC FLUID. 2L72 4F4 FRTA16WE E21EU 20030905001292003090500129GL 2003 9 5 AUS20030713 320030630G6114D2438 HUB PIPER PA30 PA39 7103902SO LYC O320 O320* 41508EA HARTZLHCE2Y HCE2YL2 GL PROPELLER MISREPAIRED W K NONE W INADEQUATE Q C ININSP/MAINT 1 AUS 829 (AUS) UNAPPROVED MACHINING CARRIED OUT ON PROPELLER HUB PRE-LOAD SHELF. PERSONNEL/MAINTENANCE ERROR. UNAPPROVED PROCEDURE. 1L72 3O3 O A1EA E274 5 CP9EA 20030905001302003090500130NM 2003 9 5 AUS20030714 120030715G2150 ODOR BOEING737 737376 NM AIR CONDITIONINGDETECTED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 AUS (AUS) FUMES WITH SLIGHT SULPHUR ODOR REPORTED BY CABIN CREW AROUND REAR GALLEY AND REAR CABIN VENTS. DURING INVESTIGATION AND GROUND RUNNING THE EQUIPMENT COOLING EXHAUST FAN FAILED AND THE CIRCUIT BREAKER POPPED. 2L72 4F RTA16WE 20030905001312003090500131SW 2003 9 5 AUS20030715 120030715G2910 LINE SWRNGNSA227 SA227AC 8780603SW GARRTTTPE331TPE33111U 01514WP MCAULY4HFR344HFR34C652 NE MLG HYD SYS CORRODED W O OTHER K FLUID LOSS CRCRUISE 1 AUS (AUS) LANDING GEAR RETRACTION SYSTEM HYDRAULIC LINE CORRODED AND LEAKING. 2L72 4T4 TRTA8SW E4WE 6 C3PNE 20030905001332003090500133CE 2003 9 5 AUS20030716 120030708G27100510105365 CABLE CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA MCAULY1C235 1C235LFA GL AILERON CONTROL MISINSTALLED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) AILERON CROSSOVER CABLE LOCATED IN RT WING WORN FLAT IN AREA WHERE CABLE RUNS ON FAIR LEAD. CABLE WAS INCORRECTLY ROUTED. PERSONNEL/MAINTENANCE ERROR. 1H71 3O3 ONT3A12 1E10 5 NP12EA 20030905001342003090500134SO 2003 9 5 AUS20030717 120030707G27315299 ACTUATOR EMB 120 EMB120 3260201SO PWA 118 PW118A NE HAMSTD14RF 14RF9 NE ELEVATOR TAB FAULTY W O OTHER F FLT CONT AFFECTED CRCRUISE 1 AUS (AUS) LT AND RT HORIZONTAL STABILISER TRIM ACTUATORS JAMMED. 2L72 4T4 TRTA31SO E20NE 6 CP11NE 20030905001352003090500135CE 2003 9 5 AUS20030718 120030716G8011632101 GEAR CESSNA404 404CESSNA 2075901CE CONT O520 GTSIO520M 17032SO MCAULY3FF32 3FF32C501 GL ENGINE STARTER FAILED W O OTHER E VIBRATION/BUFFET NRNOT REPORTED 1 AUS 1281 (AUS) STARTER ADAPTER DRIVESHAFT GEAR TEETH STRIPPED. 1L72 3O3 O A25CE E7CE 5 CP45GL 20030905001372003090500137EA 2003 9 5 AUS20030719 220030716G8520LW13521 ROD BEARING BNORM BN2 BN2A27 1520227EU LYC O540 O540E4C5 41532EA HARTZLHCC2Y HCC2YR2 GL ENGINE DELAMINATED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) CONNECTING ROD BEARING DELAMINATED. METAL CONTAMINATION OF OIL FILTER. 1H72 3O3 O A17EU E295 5 CP920 20030905001382003090500138SO 2003 9 5 AUS20030720 220030610G7414103493921 FLANGE CESSNA404 404CESSNA 2075901CE CONT O520 GTSIO520M 17032SO MCAULY3FF32 3FF32C501 GL MAGNETO BROKEN W K NONE O OTHER ININSP/MAINT 1 AUS 562 (AUS) MAGNETO FLANGE BROKEN. SUSPECT CAUSED BY OVERTENSIONING OF HOLD DOWN NUTS. PERSONNEL/MAINTENANCE ERROR. 1L72 3O3 O A25CE E7CE 5 CP45GL 20030905001402003090500140EA 2003 9 5 AUS20030721 220030719G8520LW10646 CONNECTING ROD PIPER PA32 PA32R301T 7103220SO LYC O540 TIO540S1AD 41532EA HARTZLHCE2Y HCE2YR1 GL ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) CONNECTING ROD CONTAINED A CRACK INDICATION ADJACENT TO THE LITTLE END. LENGTH OF CRACK APPROXIMATELY 6.35MM (0.25IN). CAP ON ANOTHER CONNECTING ROD CONTAINED CRACK INDICATION ADJACENT TO BOLT HOLE. CRACK LENGTH 3.175MM (0.125IN). CRACKS FOUND DURINGMAGNETIC PARTICLE INSPECTION IAW AD/ENG/4 AMDT8. 1L71 3O3 O A3SO E14EA 5 CP9EA 20030905001412003090500141CE 2003 9 5 AUS20030722 120030717G3230511723956 CABLE CESSNA402 402C 207590RCE CONT O520 TSIO520VB 17040SO MCAULY3AF32C3AF32C93 GL MLG UNSERVICEABLE W O OTHER O OTHER CRCRUISE 1 AUS 10369 (AUS) EMERGENCY LANDING GEAR BLOWDOWN BOTTLE ACTUATING CABLE FAULTY. 1L72 3O3 O A7CE E8CE 5 CP22EA 20030905001432003090500143SO 2003 9 5 AUS20030723 220030717G8550402C0026 VALVE CESSNA402 402C 207590RCE CONT O520 TSIO520VB 17040SO MCAULY3AF32C3AF32C93 GL LT ENGINE CONTAMINATED W O OTHER K FLUID LOSS CRCRUISE 1 AUS 10369 (AUS) LT ENGINE LOST OIL PRESSURE AND WAS SHUT DOWN. INVESTIGATION FOUND HARD CARBON PARTICLES IN THE LT ENGINE OIL PRESSURE RELIEF VALVE. 1L72 3O3 O A7CE E8CE 5 CP22EA 20030905001452003090500145NM 2003 9 5 AUS20030724 120030719G28227G774 PRESSURE SWITCH DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE FUEL PUMP FAILED W O OTHER KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 AUS (AUS) RT AUXILIARY FUEL PUMP INDICATOR PRESSURE SWITCH FAILED. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030905001462003090500146EU 2003 9 5 AUS20030725 120030717G27529787320307 ACTUATOR PILATSPC12 PC12 7090550EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL TE FLAPS FAILED W O OTHER F FLT CONT AFFECTED LDLANDING 1 AUS 2098 (AUS) RT TRAILING EDGE FLAP OUTER LINEAR ACTUATOR FAILED. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030905001482003090500148EU 2003 9 5 AUS20030726 120030717G27529787320307 ACTUATOR PILATSPC12 PC12 7090550EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL TE FLAPS FAILED W O OTHER F FLT CONT AFFECTED LDLANDING 1 AUS 2182 (AUS) LT TRAILING EDGE FLAP INNER LINEAR ACTUATOR FAILED. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030905001492003090500149NM 2003 9 5 AUS20030727 120030704G52306547952524 STRUCTURE BOEING737 737376 NM CARGO DOOR CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 1121 (AUS) AFT CARGO DOOR OUTER TEE STRUCTURE CRACKED IN AFT LOWER CORNER. CRACK WAS LOCATED BETWEEN TWO FASTENERS. CRACK LENGTH APPROXIMATELY 19.05MM (0.75IN). 2L72 4F RTA16WE 20030905001522003090500152WP 2003 9 5 AUS20030728 220030722G751031030791 NUT SWRNGNSA227 SA227* SW GARRTTTPE331TPE33112UHR WP MCAULY4HFR344HFR34C652 NE ENG ANTI-ICE LOOSE W O OTHER EBJVIBRATION/BUFFET SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CLCLIMB 1 AUS (AUS) LT ENGINE FIRE WARNING. THE ENGINE WAS SHUT DOWN AND THE FIRE EXTINGUISHER ACTIVATED. SUBSEQUENT INSPECTION COULD FIND NO EVIDENCE OF FIRE. PRELIMINARY INVESTIGATION SUGGESTS AN ENGINEANTI-ICE BLEED AIR LEAK. FURTHER INVESTIGATION FOUND THE NUT ON THE ENGINE ANTI-ICE BLEED AIR TUBE HAD COME LOOSE. SUSPECT DUE TO INSUFFICIENT TIGHTENING DURING MAINTENANCE. PERSONNEL/MAINTENANCE ERROR. 2L72 4T4 TRTA5SW E4WE 6 C3PNE 20030905001532003090500153NM 2003 9 5 AUS20030729 120030720G56105887275505 WINDSHIELD BOEING717 717200 1383700NM RROYCEBR700 BR700715A130 NE COCKPIT CRACKED W O OTHER O OTHER CRCRUISE 1 AUS (AUS) COCKPIT CENTER WINDSHIELD CRACKED IN LOWER LT CORNER. SLIGHT BURN MARKS NOTICED ADJACENT TO THE CRACKS. SUSPECT WINDOW HEAT SYSTEM SHORT CIRCUIT. 2L72 4F4 FTRA6WE E00061EN 20031020000132003102000013GL 2003 10 20 AUS20030730 120030708G6120 PLUG DIAMONDA40 DA40 GL PROP CONTROL LOOSE W O OTHER O OTHER CRCRUISE 1 AUS (AUS) PROPELLER PITCH CONTROL VALVE PLUG LOOSE. SUSPECT PLUG LOCKING RING BUMPED DURING EXAMINATION OF PLUG PRIOR TO FLIGHT. 1L71 3O NTA47CE 20030908000012003090800001CE 2003 9 8 AUS20030731 120030723G3260H111541 UPLOCK SWITCH BEECH 1900 1900C 1154161CE PWA PT6 PT6A65B 52043EA LANDING GEAR POSUNSERVICEABLE W O OTHER N FALSE WARNING CLCLIMB 1 AUS (AUS) RT MAIN LANDING GEAR UPLOCK SWITCH UNSERVICEABLE. 2L72 4T4 TRTA24CE E4EA 20030908000022003090800002CE 2003 9 8 AUS20030732 120030717G2422 INVERTER BEECH 200 B200C 1152924CE PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL AC SYSTEM BURNED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 AUS (AUS) 240 VAC INVERTER BURNED. 1L72 4T4 T A24CE E4EA 6 CP15EA 20030908000032003090800003SO 2003 9 8 AUS20030733 220030718G8500TSIO520VB ENGINE CESSNA402 402C 207590RCE CONT O520 TSIO520VB 17040SO MCAULY3AF32C3AF32C93 GL LEFT FAILED W O OTHER EY VIBRATION/BUFFET ENGINE STOPPAGE CLCLIMB 1 AUS 1541 402C0026 (AUS) LT ENGINE FAILED. ENGINE STARTED RUNNING ROUGH WITH ASSOCIATED VIBRATION. OIL PRESSURE AND MANIFOLD PRESSURE DROPPED AND ENGINE APPEARED TO BE WINDMILLING. ENGINE WAS SHUTDOWN AND PROPELLER FEATHERED. 1L72 3O3 O A7CE E8CE 5 CP22EA 20030908000042003090800004NE 2003 9 8 AUS20030734 220030717G73210164448440 FCU AEROSPAS365 AS365N2 8680815EU TMECA ARRIELARRIEL1A 60030NE ENGINE CLOGGED W O OTHER E VIBRATION/BUFFET NRNOT REPORTED 1 AUS 503 (AUS) FUEL CONTROL UNIT FAULTY. INVESTIGATION FOUND PRESSURE BALANCE UNIT PARTIALLY CLOGGED. 1G72 3U3 URTH10EU E19EU 20030908000052003090800005 2003 9 8 AUS20030735 420030723G3418285A10106 COMPUTER BOEING737 737800* NM STALL WARNING FAULTY W O OTHER J WARNING INDICATION CLCLIMB 1 AUS (AUS) STALL WARNING COMPUTER SUSPECT FAULTY. 2L72 4F RTA16WE 20030908000062003090800006NM 2003 9 8 AUS20030736 120030717G5311 FRAME BOEING737 737400 138449ANM CFMINTCFM56 CFM563C 13802EU FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FUSELAGE FRAMES CRACKED AT PSU ATTACHMENT POINTS. FOUR FRAMES ONTHE LT SIDE AND THREE FRAMES ON THE RT SIDE CRACKED. FOUND DURING EDDY CURRENT INSPECTION IAW EI 737-53-68R1 AND NDT TECHNIQUES E-13 AND E-18. 2L72 4F4 FRTA16WE E21EU 20030908000072003090800007NM 2003 9 8 AUS20030737 120030722G5610141T480149 WINDOW BOEING767 767338 1385151NM GE CF6 CF680C2* GL COCKPIT CRAZED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT NR 1 COCKPIT WINDOW OUTER PANE CRAZED DUE TO ELECTRICAL ARCING. 2L72 4F4 FRTA1NM E23EA 20030908000082003090800008NE 2003 9 8 AUS20030738 220030708G7320114E6112G119 EEC BOEING717 717200 1383700NM RROYCEBR700 BR700715A130 NE LT ENGINE FAULTY W O OTHER E VIBRATION/BUFFET NRNOT REPORTED 1 AUS 30 (AUS) LT ENGINE ELECTRONIC ENGINE CONTROLLER (EEC) SUSPECT FAULTY. 2L72 4F4 FTRA6WE E00061EN 20030908000092003090800009EU 2003 9 8 AUS20030739 120030626G2421503106680000 GENERATOR BAC 146 146200A 1500266EU LYC ALF502ALF502R5 41580NE NR 1 FAILED W O OTHER HJ ELECT. POWER LOSS-50 PC WARNING INDICATION CRCRUISE 1 AUS (AUS) NR 1 GENERATOR FAILED. 2H74 4F4 F A49EU E6NE 20030908000102003090800010NE 2003 9 8 AUS20030740 220030723G7200M50 MAIN BEARING BAC 146 146200A 1500266EU LYC ALF502ALF502R5 41580NE ENGINE FAILED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) ENGINE CHIP DETECTOR METAL CONTAMINATION. INVESTIGATION FOUND THE METAL TO BE M50 MATERIAL FROM THE MAIN ENGINE BEARINGS. 2H74 4F4 F A49EU E6NE 20030908000112003090800011 2003 9 8 AUS20030741 420030701G2562ELT1104 ELT CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA MCAULY1C160 1C160DTM GL CABIN FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS 54513 (AUS) ELT ACTIVATED. THE AIRCRAFT WAS IN THE HANGAR AT THE TIME. THE ELT WAS UNABLE TO BE DE-ACTIVATED EXCEPT BY DISCONNECTING THE BATTERY. 1H71 3O3 ONT3A12 E274 5 NP910 20030908000122003090800012SO 2003 9 8 AUS20030742 220030715G8530 CYLINDER HEAD BEECH 23 A23A 1151208CE CONT O346 IO346A 17033SO SNSNCH74DC M74DC EA ENGINE SEPARATED W O OTHER ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CRCRUISE 1 AUS (AUS) NR 1 CYLINDER HEAD SEPARATED AT HEAD TO BARREL JOINT. 1L71 3O3 O A1CE E3CE 5 NP88614 20030908000132003090800013EU 2003 9 8 AUS20030743 120030724G29103268 VALVE SAAB SF340 SF340A 7850100EU GE CT7TP CT75A 30030NE ROTOL R354 R3544123F13 NE HYDRAULIC SYS FAULTY W O OTHER KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 AUS (AUS) HYDRAULIC SYSTEM LOW PRESSURE WARNING. NO LOSS OF FLUID. INVESTIGATION FOUND THAT THE EMERGENCY ACCUMULATOR DUMP VALVE ALLOWED PRESSURE IN THE EMERGENCY AND MAIN HYDRAULIC SYSTEMS TO DROP. 2L72 4T4 TRTA52EU E8NE 6 CP61GL 20030908000142003090800014CE 2003 9 8 AUS20030744 120030530G321112941511 SADDLE CESSNA210 210J 2073439CE CONT O520 IO520J 17032SO MCAULY3A32C D3A32C88 GL LT MLG CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT MAIN LANDING GEAR SADDLE CRACKED AND LEAKING HYDRAULIC BRAKE FLUID. FURTHER INSPECTION FOUND RT MAIN LANDING GEAR SADDLE ALSO CRACKED. 1H71 3O3 O 3A21 E5CE 5 CP21EA 20030908000152003090800015CE 2003 9 8 AUS20030745 120030716G5511123260029 SPAR CESSNA210 210N 2073453CE CONT O520 IO520L 17032SO MCAULYD3A34 D3A34C404 GL HORIZONTAL STAB CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) HORIZONTAL STABILISER FRONT SPAR CENTRE LAMINATE CRACKED. FOUND DURING INSPECTION IAW AD C21069. 1H71 3O3 O 3A21 E5CE 5 CP47GL 20030908000162003090800016NM 2003 9 8 AUS20030746 120030715G3040 CONTROLLER BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU WINDSHIELD HEAT FAULTY W O OTHER J WARNING INDICATION NRNOT REPORTED 1 AUS (AUS) LT SIDE WINDOW OVERHEAT INDICATION. WINDOW HEAT TURNED OFF, BUT LIGHT STAYED ON. SUSPECT FAULTY & INTERMITTENT WINDOW HEAT CONTROLLER. 2L72 4F4 FRTA16WE E21EU 20030908000172003090800017NM 2003 9 8 AUS20030747 120030717G5230 ACTUATOR BOEING747 747438 NM CARGO DOOR FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) AFT CARGO DOOR HOOK ACTUATOR FAULTY. ACTUATOR RUNNING OUT OFSEQUENCE. 2L74 4F RTA20WE 20030908000182003090800018EA 2003 9 8 AUS20030748 220030714G8530LW13622 INTAKE VALVE BNORM BN2 BN2A20 1520220EU LYC O540 IO540K1B5 41532EA HARTZLHCC2Y HCC2YR2 GL NR 6 CYLINDER FAILED W O OTHER ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS LDLANDING 1 AUS (AUS) NR 6 CYLINDER INTAKE VALVE BROKEN OFF AT UPPER PART OF VALVE STEM. BROKEN INTAKE VALVE CAUSED EXTENSIVE DAMAGE TO CYLINDER. 1H72 3O3 O A17EU 1E4 5 CP920 20030908000192003090800019GL 2003 9 8 AUS20030749 320030701G6110 DOWEL PIN CESSNA182 182Q 2072732CE CONT O470 O470U 17026SO MCAULY2A34C C2A34C204 GL PROP FLANGE MISINSTALLED W K NONE O OTHER ININSP/MAINT 1 AUS 1200 (AUS) CRANKSHAFT PROPELLER MOUNTING FLANGE PROPELLER LOCATING DOWELS INCORRECTLY FITTED. DOWELS HAVE A SLIGHT TAPER WHICH ALLOWS FOR A SLIP FIT INTO THE CRANKSHAFT AND AN INTERFERENCE FIT ONTO THE PROPELLER. THE DOWELS WERE INCORRECTLY FITTED WITH THE INTERFERENCE FIT ONTO THE CRANKSHAFT. THE INCORRECT FITMENT OFTHE DOWELS DAMAGED THE CRANKSHAFT. PERSONNEL/MAINTENANCE ERROR. 1H71 3O3 ONT3A13 E273 5 CP3EA 20030908000202003090800020CE 2003 9 8 AUS20030750 120030716G32464077 WHEEL CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA MCAULY1C235 1C235LFA GL NLG CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS 21371364 (AUS) NOSE WHEEL CORRODED. 1H71 3O3 ONT3A12 1E10 5 NP12EA 20030908000212003090800021EU 2003 9 8 AUS20030751 120030722G3230VARIOUS UPLOCK SENSOR BAC 146 146100A 1500260EU LYC ALF502ALF502R5 41580NE MLG DIRTY W O OTHER N FALSE WARNING CRCRUISE 1 AUS (AUS) LT MLG UNSAFE LIGHT AND GEAR HANDLE WARNING LIGHT ILLUMINATED IN CRUISE AFTER 45 MINUTES IN FLIGHT. LIGHT REMAINED ON FOR 60 MINUTES BEFORE EXTINGUISHING 15 MINUTES PRIOR TO LANDING. BOTH LT DOOR AND GEAR UPLOCK SENSORS FOUND TO BE DIRTY. LT DOOR UPLOCK ACTUATOR PROXIMITY CONTACT ARM FOUND LOOSE. 2H74 4F4 FRTA49EU E6NE 20030908000222003090800022NE 2003 9 8 AUS20030752 220030725G7261AC9718F25 FILTER SAAB SF340 SF340A 7850100EU GE CT7TP CT75A2 30030NE ROTOL R375 R3754123F21 NE SCAVE PUMP CONTAMINATED W O OTHER KEJFLUID LOSS VIBRATION/BUFFET WARNING INDICATION CRCRUISE 1 AUS (AUS) LT ENGINE ACCESSORY GEARBOX -B- SUMP SCAVENGE FILTER CONTAMINATED WITH CARBON DEPOSITS. 2L72 4T4 TRTA52EU E8NE6 6 CP17NE 20030908000232003090800023NE 2003 9 8 AUS20030753 220030725G72613011357 PIPE AIRTRCAT500 AT502 0390303SW PWA PT6 PT6A34AG 52053NE HARTZLHCB3T HCB3TN3 GL NR 2 BEARING WORN W K NONE O OTHER ININSP/MAINT 1 AUS 3941 (AUS) ENGINE EXTERNAL NR 2 BEARING OIL SCAVENGE LINE WORN AND LEAKING AT REAR FIRE SEAL. SEAL HAD CONTACTED PIPE WHICH HAD CRACKED IN THE WORN AREA. 1L71 3T4 TNCA9SW E4EA 6 CP15EA 20030908000242003090800024EA 2003 9 8 AUS20030754 220030521G7414EO2FA018R DISTRIBUTOR BLK ROBSINR44 R44 7640120WP LYC O540 O540F1B5 41532EA MAGNETO COLLAPSED W K NONE O OTHER ININSP/MAINT 1 AUS 71 (AUS) MAGNETO DISTRIBUTOR BLOCK COLLAPSED. 1G71 3O3 O H11NM E295 20030908000252003090800025 2003 9 8 AUS20030755 420030728G2561 VALVE EAAEROMARINE LIFE JACKET STUCK W K NONE O OTHER ININSP/MAINT 1 AUS 595272 (AUS) LIFE JACKET ORAL INFLATION TUBE JAMMED IN OPEN POSITION. A SECOND JACKET HAD THE SAME PROBLEM WHILE A THIRD JACKET FROM THE SAME BATCH DID NOT. JACKETS ARE USED ON DASH-8 AIRCRAFT. 20030908000262003090800026EU 2003 9 8 AUS20030756 120030725G3241AE202558 COMPUTER BAC 146 146100A 1500260EU LYC ALF502ALF502R3A 41580NE BRAKE ANTISKID FAULTY W O OTHER J WARNING INDICATION TOTAKEOFF 1 AUS (AUS) ANTI-SKID FAULT LIGHT ILLUMINATED DURING TAKEOFF ROLL. THE PROBLEM WAS FIXED BY RERACKING THE ANTI-SKID COMPUTER. 2H74 4F4 FRTA49EU E6NE 20030908000272003090800027CE 2003 9 8 AUS20030757 120030730G553151310244 DOUBLER CESSNA402 402C 207590RCE CONT O520 TSIO520VB 17040SO MCAULY3AF32C3AF32C505 GL VERTICAL STAB CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) VERTICAL STABILISER FORWARD SPAR DOUBLER ASSEMBLY CONTAINED EXFOLIATION CORROSION. 1L72 3O3 O A7CE E8CE 5 CP22EA 20030908000282003090800028 2003 9 8 AUS20030758 420030729G3418906100004 COMPUTER DHAV DHC8 DHC8315 2809010NM PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE STALL WARNING FAILED W O OTHER FJ FLT CONT AFFECTED WARNING INDICATION CRCRUISE 1 AUS (AUS) NR 1 STALL WARNING COMPUTER FAILED. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030908000292003090800029SW 2003 9 8 AUS20030759 120030731G6321412040301101 PINION GEAR BELL 412 412 1182202SW PWA PT6T PT6T3 52045EA MAIN ROTOR BRAKECRACKED W O OTHER J WARNING INDICATION CRCRUISE 1 AUS 121 (AUS) MAIN ROTOR BRAKE QUILL PINION GEAR CRACKED FOR APPROXIMATELY 75 PERCENT ACROSS GEAR FACE. TRANSMISSION CHIP DETECTOR ACTIVATED. INSPECTION OF CHIP DETECTOR AND FILTER FOUND NO SIGNIFICANT CONTAMINATION. 1G72 4U4 U H4SW E22EA 20030908000302003090800030NM 2003 9 8 AUS20030760 120030718G27202379003001 REGULATOR VALVE DHAV DHC8 DHC8202 2809007NM PWA 120 PW123D 52152NE HAMSTD14SF 14SF23 NE RUDDER CONTROL FAILED W O OTHER FJ FLT CONT AFFECTED WARNING INDICATION CLCLIMB 1 AUS (AUS) RUDDER DUAL PRESSURE REGULATOR VALVE FAILED. SUSPECT SOLENOID FAILURE. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030908000312003090800031NM 2003 9 8 AUS20030761 120030720G5730 ACCESS PANEL BOEING737 737376 NM FUEL STORAGE LEAKING W O OTHER KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 AUS (AUS) FUEL LEAKING FROM WING AND RUNNING OVER UPPER SURFACE OF INBOARD FLAPS. INVESTIGATION FOUND THE FUEL LEAKING FROM THE FUEL TANK PANEL ACCESS DOOR AT LOWER WING SKIN CUTOUT NR 7404R LOCATED BETWEEN WBL 157 AND WBL 183.4. THE FUEL TANK CUTOUT HAD BEEN RECENTLY REPAIRED DUE TO INTERGRANNULAR CORROSION AT THE REBATE LIP. THE TANK PANEL HAD THEN BEEN REFITTED USING EXCESSIVE SEALANT PREVENTING THE CORRECT INSTALLATION OF THE PANEL ACCESS DOOR. PERSONNEL/MAINTENANCE ERROR. 2L72 4F RTA16WE 20030908000322003090800032NM 2003 9 8 AUS20030762 120030705G2731AR7077M3 ACTUATOR BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU ELEVATOR TAB FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS U0104 (AUS) HORIZONTAL STABILISER TRIM ACTUATOR FAULTY. 2L72 4F4 FRTA16WE E21EU 20030908000332003090800033WP 2003 9 8 AUS20030763 220030707G8520 CRANKSHAFT DHAVXXDH82 DH82AROBRTSN2801002WP DHAVXXGIPSY GIPSYMAJOR1 20004WP AMTR C8289 C8289 GL ENGINE FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) CRANKSHAFT FAILED ULTRASONIC INSPECTION. FOUND DURING MAGNETIC PARTICLE INSPECTION IAW AD/DHE/18 AMDT5. 1Q71 3I3 I A8EU A8EU 5 NEXPP5N 20030908000342003090800034CE 2003 9 8 AUS20030764 120030723G571100243001811 SPAR BEECH 58 58 1152740CE MCAULY3AF32C3AF32C512 GL WING CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) CARRY THROUGH SPAR FORWARD AND AFT SPAR WEBS PN 00243001811 (FORWARD) AND PN 00243001813 (AFT) CRACKED IN LOWER RADIUS ON LT SIDE. 1L72 3O 3A16 5 CP22EA 20030908000352003090800035SO 2003 9 8 AUS20030765 120030731G27525311281 YOKE GULSTMG1159 GIV 3980115SO RROYCETAY TAY6118 EU TE FLAPS ACT CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT AND RT INBOARD FLAP ACTUATOR HARDWARE SEIZED DUE TO CORROSION. 2L72 4F4 FRTA12EA E25NE 20030908000362003090800036SO 2003 9 8 AUS20030766 120030731G27601159SCH2135 SWITCH GULSTMG1159 GIV 3980115SO RROYCETAY TAY6118 EU DRAG CONTROL SYSFAILED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) GROUND SPOILER PRESSURE SWITCH CONNECTOR SEPARATED FROM SWITCH HOUSING AND SHORT CIRCUITING TO GROUND. SWITCH IS LOCATED IN LT UNDER CARRIAGE BAY. 2L72 4F4 FRTA12EA E25NE 20030908000372003090800037WP 2003 9 8 AUS20030767 120030708G5710H36831A STRUCTURE DHAVXXDH82 DH82AROBRTSN2801002WP DHAVXXGIPSY GIPSYMAJOR1 20004WP AMTR C8289 C8289 GL RT WING MISREPAIRED W K NONE W INADEQUATE Q C ININSP/MAINT 1 AUS (AUS) LOWER RT WING FAULTY. SUSPECT CAUSED BY FAULTY WORKMANSHIP WHEN REPAIRING DAMAGE AND AGED COMPONENTS. PERSONNEL/MAINTENANCE ERROR. UNAPPROVED PART. 1Q71 3I3 I A8EU A8EU 5 NEXPP5N 20030908000382003090800038EA 2003 9 8 AUS20030768 120030714G5553C6TFM102227 ADAPTER DHAV DHC6 DHC6300 2802606EA PWA PT6 PT6A27 52043EA HARTZLHCB3T HCB3TN3 GL VERTICAL STAB CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FORWARD VERTICAL FIN ATTACHMENT BRACKET CRACKED THROUGH BOLT MOUNTING HOLE. 1H72 3T4 TRTA9EA E4EA 6 CP15EA 20030908000392003090800039CE 2003 9 8 AUS20030769 120030730G2910AN92440 NUT CESSNA210 210L 2073448CE CONT O520 IO520L 17032SO MCAULY2A34C E2A34C73 GL HYD SYSTEM LOOSE W O OTHER K FLUID LOSS NRNOT REPORTED 1 AUS (AUS) SHUTTLE VALVE ELBOW FITTING JAM NUT VIBRATED LOOSE. LOSS OF FLUID. 1H71 3O3 O 3A21 E5CE 5 CP3EA9 20030908000402003090800040NM 2003 9 8 AUS20030770 120030731G7112A1851 BRACKET ROBSINR22 R22BETA 7640110NM LYC O320 O320B2C 41508EA ENG AIR BAFFLE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) ENGINE COOLING SCROLL BRACKET CRACKED FROM NOTCH ON RT SIDE OF THE BRACKET TO THE BOLT HOLE THEN CONTINUING FOR APPROXIMATELY 12.7MM (0.5IN) PAST THE BOLT HOLE TOWARDS THE CENTER OF THE BRACKET. FOUND DURING INSPECTION IAW AD/R22/24 AMDT1. 1G71 3O3 O H10WE E274 20030908000412003090800041NM 2003 9 8 AUS20030771 120030717G5610 WINDOW BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU COCKPIT FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FLIGHT DECK SLIDING WINDOW 2R FAILED THE EMERGENCY RELEASE TEST. INVESTIGATION FOUND THE CAUSE OF THE PROBLEM WAS EITHER LACK OF LUBRICANT OR ADJUSTMENT OF THE WINDOW. 2L72 4F4 FRTA16WE E21EU 20030908000422003090800042NM 2003 9 8 AUS20030772 120030730G2497 WIRE BOEING767 767238 1385114NM PWA JT9 JT9D7R4E 52054NE AC POWER SHORTED W O OTHER H ELECT. POWER LOSS-50 PC NRNOT REPORTED 1 AUS (AUS) RT ENGINE GENERATOR A' PHASE FEEDER CABLE CHAFED AND SHORT CIRCUITING TO ENGINE COWL. 2L72 4F4 FRTA1NM E3NE 20030908000432003090800043EU 2003 9 8 AUS20030773 120030804G32425002572 BRAKE DISC FOKKERF27 F27MK50 EU PWA PWA120PW125B NE BRAKE WRONG PART W K NONE W INADEQUATE Q C ININSP/MAINT 1 AUS 2241 (AUS) DURING OVERHAUL OF BRAKE UNIT IT WAS DISCOVERED THAT TWO DIFFERENT PN`S, STATOR DISCS WERE FITTED TO THE SAME BRAKE UNIT. DURING THE INVESTIGATION TO ASCERTAIN IF THIS SITUATION WAS ALLOWABLE IT WAS FOUND THAT PN 5002572 STAMPED ON ONE OF THE DISCS IS THE PN FOR THE BRAKE UNIT FITTED TO THE FOKKER F28. THE CORRECT DISC PN FOR THE F50 AS STATED IN THE CMM IS PN 5002525. PERSONNEL/MAINTENANCE ERROR. UNAPPROVED PART. 2H72 4T4 TRTA817 E20NE 20030908000442003090800044EU 2003 9 8 AUS20030774 120030724G3230184822 HOUSING BAG JETSTMJETSTM3107 1500215EU ROTOL R333 R333482F12 GL LT MLG LOOSE W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT MAIN LANDING GEAR RADIUS ROD BEARING HOUSING INCORRECTLY SWAGED ALLOWING BEARING TO MIGRATE APPROXIMATELY 0.381MM(0.015IN). FOUND DURING INSPECTION IAW AD/JETSTREAM/96. 2L72 4T RTBA15CAA 6 CP61GL 20030908000452003090800045EU 2003 9 8 AUS20030775 120030731G2150ES611081 MOTOR REIMS 406 F406 7535723EU PWA PT6 PT6A112 52043NE MCAULY3G34C73GFR34C701 GL AIR CONDITIONER FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 AUS 696 (AUS) FORWARD AIR CONDITIONER ELECTRIC MOTOR FAILED. 1L72 3T3 TRTA54EU E4EA 5 CP60GL 20030908000462003090800046CE 2003 9 8 AUS20030776 120030728G574008113509 FITTING CESSNA402 402C 207590RCE CONT O520 TSIO520VB 17040SO MCAULY3AF32C3AF32C505 GL WING ATTACH MISREPAIRED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT FORWARD UPPER INBOARD WING ATTACHMENT FITTING HAD THREE BOLTS MISSING. INVESTIGATION FOUND THAT THE FITTING DOES NOT LINE UP WITH THE BOLT HOLES DUE TO MISALIGNMENT. FURTHER INVESTIGATION FOUND THAT THE HOLES AND THE ATTACHING CHANNELS HAVE BEEN DRILLED OUT BY APPROXIMATELY 0.381MM (0.015IN) TO TRY TO MAKE THE BOLTS FIT. LOOSE BOLTS ALSO FOUND ON RT ATTACHMENT FITTING. PERSONNEL/MAINTENANCE ERROR. 1L72 3O3 O A7CE E8CE 5 CP22EA 20030908000472003090800047SO 2003 9 8 AUS20030777 120030801G3246 WHEEL PIPER PA34 PA34200 7103405SO LYC O360 IO360C1E6 41514EA HARTZLHCC2Y HCC2YK2 GL NLG COLLAPSED W O OTHER O OTHER LDLANDING 1 AUS (AUS) NOSE WHEEL COLLAPSED DURING LANDING. 1L72 3O3 O A7SO 1E10 5 CP920 20030908000482003090800048EU 2003 9 8 AUS20030778 120030802G772210151N01T100 INDICATOR FOKKERF27 F27MK50 EU PWA PWA120PW125B NE ENGINE FAILED W O OTHER EM VIBRATION/BUFFET OVER TEMP TOTAKEOFF 1 AUS 30368 (AUS) LT ENGINE ITT INDICATOR FAILED. ANALOG INDICATION DROPPED TO ZERO AND DIGITAL READING WAS FLUCTUATING. 2H72 4T4 TRTA817 E20NE 20030908000492003090800049CE 2003 9 8 AUS20030779 120030725G323051413121 UPLOCK HOOK CESSNA402 402C 207590RCE CONT O520 TSIO520VB 17040SO MCAULY3AF32C3AF32C93 GL RT MLG CRACKED W O OTHER O OTHER NRNOT REPORTED 1 AUS (AUS) RT MAIN LANDING GEAR UPLOCK HOOK CRACKED. 1L72 3O3 O A7CE E8CE 5 CP22EA 20030908000502003090800050NM 2003 9 8 AUS20030780 120030718G5210 LATCH BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU PAX DOOR UNLOCKED W O OTHER N FALSE WARNING CRCRUISE 1 AUS (AUS) DOOR L1 HANDLE MOVED UP CAUSING AIR NOISE DURING FLIGHT. HANDLE MOVED ON SEVERAL OCCASIONS. SUSPECT CAUSED BY INCORRECT RIGGING/ADJUSTMENT. 2L72 4F4 FRTA16WE E21EU 20030908000512003090800051EA 2003 9 8 AUS20030781 220030804G7313L83868A INJECTOR PIPER PA31 PA31350 7103110SO LYC O540 LTIO540J2BD 41533EA HARTZLHCE3Y HCE3YR2 GL RT ENGINE OBSTRUCTED W O OTHER E VIBRATION/BUFFET CRCRUISE 1 AUS L83868A (AUS) RT ENGINE NR 5 CYLINDER PN LW12966 HAD A BURNED PISTON. PISTON ALSO ERODED AROUND RING LANDS. COMPRESSION LEAKING INTO CRANKCASE AND VENTING OIL OVERBOARD VIA BREATHER. INVESTIGATION FOUND THE TORCHING CAUSED BY A PARTIALLY BLOCKED INJECTOR NOZZLE. 1L72 3O3 O A20SO E14EA 5 CP33EA 20030908000522003090800052EU 2003 9 8 AUS20030782 220030731G7250CFM563C1 TURBINE BOEING737 7374Q8 138447QNM CFMINTCFM56 CFM563C 13802EU NR 1 ENGINE DAMAGED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) NR 1 ENGINE HPT AND LPT DAMAGED BEYOND LIMITS. 2L72 4F4 FRTA16WE E21EU 20030908000532003090800053CE 2003 9 8 AUS20030783 120030721G32331053840001 ACTUATOR BEECH 76 76 1153005CE LYC O360 O360A1G6D EA HARTZLHCM2Y HCM2YR GL MLG CRACKED W O OTHER O OTHER LDLANDING 1 AUS (AUS) NOSE LANDING GEAR ACTUATOR CRACKED AND LEAKING. INVESTIGATION FOUND A CRACK IN THE CYLINDER BODY END CAP THREAD ROOT LOCATED APPROXIMATELY THREE THREADS FROM THE SEALING CHAMFER. 1L72 3O3 O A29CE E286 5 CP43GL 20030908000542003090800054NM 2003 9 8 AUS20030784 120030731G276133205504 ACTUATOR BOEING747 747438 NM NR 10 SPOILER FAILED W O OTHER F FLT CONT AFFECTED TXTAXI/GRND HDL 1 AUS 90V1318 (AUS) NR 10 SPOILER PANEL ACTUATOR FAILED. 2L74 4F RTA20WE 20030908000552003090800055NM 2003 9 8 AUS20030785 120030729G28226072101 PUMP BOEING747 747438 NM RROYCERB211 RB211524G19 NE FUEL BOOST FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT CENTER BOOST PUMP FAILED RESISTANCE CHECK CARRIED OUT IAW AD/B747/173. 2L74 4F4 FRTA20WE E30NE 20030908000562003090800056EU 2003 9 8 AUS20030786 120030728G5521NB31D088 RIB BNORM BN2 BN2A26 1520226EU LYC O540 O540E4C5 41532EA HARTZLHCC2Y HCC2YK2 GL ELEVATOR CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) ELEVATOR END RIB CRACKED. FOUND DURING INSPECTION IAW SB-190. 1H72 3O3 O A17EU E295 5 CP920 20030908000572003090800057NM 2003 9 8 AUS20030787 120030731G2750285T004953 FSEU BOEING767 767338 1385151NM GE CF6 CF680C2* GL TE FLAPS FAULTY W O OTHER FJ FLT CONT AFFECTED WARNING INDICATION APAPPROACH 1 AUS (AUS) FLAP/SLAT ELECTRONIC UNIT (FSEU) SUSPECT FAULTY. 2L72 4F4 FRTA1NM E23EA 20030908000582003090800058NE 2003 9 8 AUS20030788 120030604G2730CR321443 RIVET CONAERLA4 LA4200 5110310NE LYC O360 IO360A1B 41514EA HARTZLHCC2Y HCC2YK1 GL ELEVATOR CONTROLCORRODED W O OTHER O OTHER NRNOT REPORTED 1 AUS (AUS) ELEVATOR PUSHROD AFT END FITTING RIVETS CORRODED. END FITTING SEPARATED FROM PUSHROD CAUSING LOSS OF CONTROL CAUSING DAMAGE TO AIRCRAFT DURING HEAVY LANDING. 1H71 3O3 O 1A13 1E10 5 CP920 20030908000592003090800059SO 2003 9 8 AUS20030789 220030731G8530654966A CYLINDER CESSNA404 404CESSNA 2075901CE CONT O520 GTSIO520M 17032SO MCAULY3FF32 3FF32C501 GL ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 1373 (AUS) ENGINE CYLINDER CRACKED. 1L72 3O3 O A25CE E7CE 5 CP45GL 20030908000602003090800060SW 2003 9 8 AUS20030790 120030712G5753422783 HINGE GULSTM112 112A 7630302SW LYC O360 IO360C1D6 41514EA HARTZLHCE2Y HCE2YR1 GL TE FLAP CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT INBOARD TRAILING EDGE FLAP HINGE BRACKET RIVETS CORRODED AND FAILED. BRACKET WAS HELD ON BY ONLY ONE OF NINE RIVETS WHICH ALSO FAILED WITH LITTLE EFFORT. 1L71 3O3 O A12SO 1E10 5 CP9EA 20030908000612003090800061SW 2003 9 8 AUS20030791 120030806G3234246006 SELECTOR VALVE SWRNGNSA227 SA227* SW MLG UNSERVICEABLE W O OTHER J WARNING INDICATION DEDESCENT 1 AUS 7225 (AUS) LANDING GEAR SELECTOR VALVE FAILED. 2L72 4T RTA5SW 20030908000622003090800062SW 2003 9 8 AUS20030792 120030528G3233ED12758 CLEVIS GULSTM500 500S 0141107SW LYC O540 IO540E1B5 41532EA HARTZLHCC3Y HCC3YR2 NE LT MLG FRACTURED W K NONE O OTHER ININSP/MAINT 1 AUS 2376 (AUS) LT MAIN LANDING GEAR ACTUATOR CLEVIS FRACTURED. 1H72 3O3 O 6A1 1E4 5 CP25EA 20030908000632003090800063EU 2003 9 8 AUS20030793 120030807G1430AN37 BOLT GIPPLDGA8 GA8 EU LYC O540 IO540K1A5 41532EA HARTZLHCC2Y HCC2YR1 GL HORIZONTAL STAB SHEARED W O OTHER O OTHER NRNOT REPORTED 1 AUS (AUS) HORIZONTAL STABILISER RT REAR PIVOT ATTACHMENT BOLT SHEARED. 1H71 3O3 ONT 1E4 5 CP920 20030908000642003090800064NM 2003 9 8 AUS20030794 120030530G324139353 VALVE BOEING737 737800* NM BRAKE ANTISKID FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) MAIN LANDING GEAR BRAKING SYSTEM ANTI-SKID VALVE FAULTY. WORKSHOP INVESTIGATION FOUND VALVE STICKING DUE TO FAILURE OF SPOOL INNER MOST RUBBER SEAL WHICH WAS SEVERELY ERODED CAUSING RUBBER CONTAMINATION. 2L72 4F RTA16WE 20030908000652003090800065NM 2003 9 8 AUS20030795 120030730G5754015T1507357 SLAT BOEING767 767338 1385151NM GE CF6 CF680C2* GL LEADING EDGE WRONG PART W K NONE W INADEQUATE Q C ININSP/MAINT 1 AUS (AUS) NO3 LEADING EDGE SLAT INCORRECT PART. PART NUMBER OF SLAT WAS FOR A 200 MODEL AIRCRAFT INSTEAD OF FOR A 300 MODEL. UNAPPROVED PART. PERSONNEL/MAINTENANCE ERROR. 2L72 4F4 FRTA1NM E23EA 20030908000662003090800066CE 2003 9 8 AUS20030796 120030424G2612302158 FIRE DETECTOR BEECH 200 200BEECH 1152920CE PWA PT6 PT6A42 52043NE LT ENGINE FAULTY W O OTHER N FALSE WARNING CRCRUISE 1 AUS (AUS) LT ENGINE FIRE WARNINGS. EXTINGUISHER DISCHARGED. NO EVIDENCE OF FIRE FOUND. FAULTY FIRE DETECTORS PN 302158 AND PN 473275. 1L72 4T4 T A24CE E4EA 20030908000672003090800067EA 2003 9 8 AUS20030797 220030808G7414M3548 ROTOR BEECH 23 C23 1151242CE LYC O360 O360A4G 41514EA SNSNCH76E 76EM8S5 EA MAGNETO FAILED W O OTHER E VIBRATION/BUFFET LDLANDING 1 AUS (AUS) RT MAGNETO ROTATING MAGNETO DRIVE END SNAPPED IN AREA WHERE IT PASSES THROUGH THE REAR BEARING. 1L71 3O3 O A1CE E286 5 NP4EA 20030908000682003090800068SW 2003 9 8 AUS20030798 120030801G28972764034055 WIRE HARNESS SWRNGNSA227 SA227* SW FUEL BOOST PUMP WORN W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) BOOST PUMP WIRING HARNESS CHAFED. FOUND DURING INSPECTION IAW AD/SWSA226/88. 2L72 4T RTA5SW 20030908000692003090800069CE 2003 9 8 AUS20030799 120030610G57115356 SPAR BBAVIA8 8KCAB 2110612CE LYC O360 AEIO360* EA AMTR C8289 C8289 GL LT WING CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT WING REAR SPAR CONTAINED A NUMBER OF LENGTH WISE CRACKS. FOUND DURING INSPECTION IAW AD/CHA/23. 1H71 3O3 O A21CE 1E10 5 NEXPP5N 20030908000702003090800070 2003 9 8 AUS20030800 420030809G22114082260937 PANEL BOEING737 7377BX 13844D2NM AUTOPILOT COMPUTFAULTY W O OTHER F FLT CONT AFFECTED CRCRUISE 1 AUS (AUS) MODE CONTROL PANEL (MCP) FAULTY. INVESTIGATION FOUND ANALOGUE SENSOR Q145 FAILED. CONNECTORS CONTAMINATED WITH METAL PARTICLES. 2L72 4F RTA16WE 20030908000712003090800071NE 2003 9 8 AUS20030801 320030805G6111BL106LA0 BLADE SWRNGNSA227 SA227* SW MCAULY4HFR344HFR34C652 NE PROPELLER ANIMAL STRIKE W O OTHER C F.O.D. LDLANDING 1 AUS 1412 (AUS) RT PROPELLER BLADE SEVERELY DAMAGED FOLLOWING WALLABY STRIKE. BLADE TIP BENT BACKWARDS ABOUT 50.8MM (2IN) FROM BLADE TIP. 2L72 4T RTA5SW 6 C3PNE 20030908000722003090800072CE 2003 9 8 AUS20030802 120030804G2434ALT9522 ALTERNATOR BEECH 58 58 1152740CE CONT O520 IO520C 17032SO HARTZLHCJ3Y PHCJ3YF2 GL DC SYSTEM FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS D010314 (AUS) ALTERNATOR FAILED. INVESTIGATION FOUND HIGH RESISTANCE IN BRUSH BLOCK AND GLAZED BRUSHES. 1L72 3O3 O 3A16 E5CE 5 CP36EA 20030908000732003090800073CE 2003 9 8 AUS20030803 120030708G2430ALT9522 ALTERNATOR BEECH 58 58 1152740CE CONT O520 IO520C 17032SO HARTZLHCJ3Y PHCJ3YF2 GL DC SYS FAULTY W O OTHER H ELECT. POWER LOSS-50 PC NRNOT REPORTED 1 AUS (AUS) RT ENGINE ALTERNATOR FAILED. INVESTIGATION FOUND HIGH RESISTANCE IN THE BRUSH BLOCK AND GLAZED BRUSHES. 1L72 3O3 O 3A16 E5CE 5 CP36EA 20030908000742003090800074CE 2003 9 8 AUS20030804 120030515G2434ALT9522 ALTERNATOR BEECH 58 58 1152740CE CONT O520 IO520C 17032SO HARTZLHCJ3Y PHCJ3YF2 GL DC SYS FAILED W O OTHER H ELECT. POWER LOSS-50 PC NRNOT REPORTED 1 AUS (AUS) RT ENGINE ALTERNATOR FAILED. INVESTIGATION FOUND HIGH RESISTANCEIN THE BRUSH BLOCK AND GLAZED BRUSHES. 1L72 3O3 O 3A16 E5CE 5 CP36EA 20030908000752003090800075CE 2003 9 8 AUS20030805 120030515G2434ALT9522 ALTERNATOR BEECH 58 58 1152740CE CONT O520 IO520C 17032SO HARTZLHCJ3Y PHCJ3YF2 GL DC SYS FAILED W K NONE O OTHER ININSP/MAINT 1 AUS D010314 (AUS) RT ENGINE ALTERNATOR FAILED. INVESTIGATION FOUND HIGH RESISTANCE IN THE BRUSH BLOCK AND GLAZED BRUSHES. 1L72 3O3 O 3A16 E5CE 5 CP36EA 20030908000762003090800076NE 2003 9 8 AUS20030806 320030809G6114R3894123F26 HUB SAAB SF340 340B 7860101EU GE CT7TP CT79B 30030NE ROTOL R389 R3894123F25 NE PROPELLER CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 2967 (AUS) LT PROPELLER HUB HAD TWO CRACK INDICATIONS EMANATING FROM DOWEL HOLES. FOUND DURING INSPECTION IAW AD/PR/33. 2L72 4T4 TRTA52EU E8NE 6 CP30NE 20030908000772003090800077SO 2003 9 8 AUS20030807 120030805G1430402377 BOLT PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2 GL MLG FRACTURED W O OTHER O OTHER LDLANDING 1 AUS (AUS) MAIN LANDING GEAR TORQUE LINK BOLT FRACTURED CAUSING TORQUE LINK TO FRACTURE AS WELL. 1L72 3O3 O A20SO E14EA 5 CP33EA 20030908000782003090800078CE 2003 9 8 AUS20030808 120030821G27801013800006 SHAFT BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3A NE LE SLAT CONTROL BROKEN W O OTHER F FLT CONT AFFECTED CLCLIMB 1 CA (CAN) DURING CLIMB, CREW SELECTED FLAPS '0' BUT NOTED THAT PANEL NR 4 DID NOT APPEAR TO RETRACT ALL THE WAY UP. FLIGHT CONTINUED TO DESTINATION AND FLAPS WERE CONFIRMED TO BE ALL UP EXCEPT NR 4 WHICH WAS HANGING DOWN BY APPROX 4 DEGREES. THE .5000 & .7500 PANEL PAIRS ARE PROTECTED BY A 3 TO 6 DEGREE SPLIT IN PAIR WHICH LOCKS SYSTEM, ONLY RESETTABLE ON GROUND. MAINT FOUND THAT FLEXIBLE DRIVE CABLE FOR NR 4 WAS BROKEN INSIDE OF EXTERNAL COVERING. A FACTORY INSTALLED CLAMP APPEARS TO HAVE BEEN OVERTIGHENED WHICH CAUSED A LOSS OF COVERING INTEGRITY ALLOWING MOISTURE TO ENTER CABLE SHEATH. LOW PORTION COLLECTED MOISTURE AND EVENTUALLY CORRODED ENOUGH TO ALLOW TORQUE TO BREAK STRANDS. MFG HAS BEEN NOTIFIED. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20030908000792003090800079EA 2003 9 8 AUS20030809 220030807G7421RHM38E SPARK PLUG MOONEYM20 M20J 5870219SW LYC O360 IO360A3B6 41514EA MCAULY2D34C B2D34C214 GL NR 1 CYLINDER CRACKED W O OTHER E VIBRATION/BUFFET TOTAKEOFF 1 AUS (AUS) NR 1 CYLINDER UPPER SPARK PLUG FAILED DUE TO CRACKED CERAMIC INSULATOR. NR 1 CYLINDER LOWER SPARK PLUG CONTAMINATED WITH DEBRIS FROM FAILED UPPER SPARK PLUG. 1L71 3O3 O 2A3 1E10 5 CP7EA 20030908000812003090800081NE 2003 9 8 AUS20030810 120030811G2497 BUSS BAR CONAERLA4 LA4250 5110320NE LYC O540 IO540C4B5 41532EA HARTZLHCE3Y HCE3YR1 GL DC POWER SHORTED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) AVIONICS BUSS BAR CONTACTING CIRCUIT BREAKERS CAUSING CONTINUOUS POWER TO BE SUPPLIED TO THE BUSS BAR WITH THE AVIONICS MASTERSWITCH TURNED OFF. 1H71 3O3 O 1A13 1E4 5 CP33EA 20030908000822003090800082EA 2003 9 8 AUS20030811 220030808G7421RHM38E SPARK PLUG MOONEYM20 M20J 5870219SW LYC O360 IO360A3B6 41514EA MCAULY2D34C B2D34C214 GL ENGINE CRACKED W O OTHER E VIBRATION/BUFFET CRCRUISE 1 AUS (AUS) LOWER SPARK PLUG CENTER ELECTRODE INSULATOR CRACKED. 1L71 3O3 O 2A3 1E10 5 CP7EA 20030908000832003090800083GL 2003 9 8 AUS20030813 320030512G6114D4883C55 HUB BEECH 55 D55 1152730CE CONT O520 IO520C 17032SO MCAULY2AF34C2AF34C55 GL PROPELLER CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 370 (AUS) PROPELLER HUB CRACKED IN BLADE RETENTION THREADS. FOUND DURING INSPECTION IAW AD/PMC/47 AMDT1. 1L72 3O3 O 3A16 E5CE 5 CP5EA 20030908000842003090800084EU 2003 9 8 AUS20030814 120030813G27529787320307 ACTUATOR PILATSPC12 PC12 7090550EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL TE FLAPS FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS 2004 (AUS) FLAP LINEAR ACTUATOR FAILED BACKLASH TEST IAW AD/PC-12/13. FLAP BACKLASH 0.8128MM (0.032IN). MAXIMUM BACKLASH LIMIT 0.508MM (0.020IN). 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030908000852003090800085GL 2003 9 8 AUS20030815 320030625G6114D4349C35 HUB BEECH 58 58 1152740CE CONT O520 IO520* 17032SO MCAULY3A32C D3A32C* GL PROPELLER CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 488 (AUS) PROPELLER HUB CRACKED IN BLADE RETENTION THREADS. FOUND DURING INSPECTION IAW AD/PMC/47 AMDT1. 1L72 3O3 O 3A16 E5CE 5 CP21EA 20030908000862003090800086SW 2003 9 8 AUS20030816 120030811G6230204011401125 RING BELL 412 412 1182202SW PWA PT6T PT6T3 52045EA SWASHPLATE LOOSE W K NONE O OTHER ININSP/MAINT 1 AUS 1361 (AUS) SWASHPLATE INNER RING LOOSE. INVESTIGATION FOUND GIMBAL BOLTS PNO 212-011-463-001 STEPPED AND BUSHING PNO 204-010-496-003 MOVING IN INNER RING HOLE. HOLE HAD BEEN ENLARGED BY APPROXIMATELY 0.762MM(0.030IN). SUSPECT CAUSED BY EXCESSIVE USE OF SEALANT ON BOLTS DURING ASSEMBLY. 1G72 4U4 U H4SW E22EA 20030908000872003090800087EA 2003 9 8 AUS20030817 220030729G7210311718001 GEARBOX BELL 412 412 1182202SW PWA PT6T PT6T3 52045EA ENG REDUCTION MAKING METAL W K NONE O OTHER ININSP/MAINT 1 AUS 2103 (AUS) REDUCTION GEARBOX OIL FILTER CONTAMINATED WITH FINE METAL PARTICLES. 1G72 4U4 U H4SW E22EA 20030908000882003090800088EU 2003 9 8 AUS20030818 120030729G2897 WIRE PILATSPC12 PC12 7090550EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL FUEL BOOST PUMP CHAFED W K NONE O OTHER ININSP/MAINT 1 AUS 555 (AUS) LT AND RT FUEL BOOST PUMP WIRING CHAFING. FOUND DURING INSPECTION IAW SB PC12/37. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030908000892003090800089EU 2003 9 8 AUS20030819 120030731G2897 WIRE PILATSPC12 PC12 7090550EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL FUEL BOOST PUMP WORN W K NONE O OTHER ININSP/MAINT 1 AUS 863 (AUS) FUEL BOOST PUMP WIRING CHAFING. FOUND DURING INSPECTION IAW SBPC12/37. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030908000902003090800090EU 2003 9 8 AUS20030820 120030806G2897 WIRE PILATSPC12 PC12 7090550EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL FUEL BOOST PUMP CHAFED W K NONE O OTHER ININSP/MAINT 1 AUS 3265 (AUS) FUEL BOOST PUMP WIRING CHAFING NEAR PLUG. FOUND DURING INSPECTION IAW SB PC12/37. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030908000912003090800091NM 2003 9 8 AUS20030821 120030806G291082950010109 LINE DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE HYD SYSTEM CHAFED W O OTHER K FLUID LOSS LDLANDING 1 AUS (AUS) LT LIFT DUMP PRESSURE LINE CHAFED AGAINST SPOILER SELECT PRESSURE LINE DUE TO FAILURE OF GROUND SPOILER PRESSURE LINE SUPPORT BRACKET. LOSS OF NR 1 SYSTEM HYDRAULIC FLUID. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030908000922003090800092CE 2003 9 8 AUS20030822 120030428G55311016400109 SPAR BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL VERTICAL STAB CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) VERTICAL STABILIZER REAR SPAR ANGLES PNO 101-640010-9 AND PN 10164001010 CONTAINED INTERGRANNULAR CORROSION. CORROSION ORIGINATED FROM RIVETS. 1L72 4T4 T A24CE E4EA 6 CP15EA 20030908000932003090800093NM 2003 9 8 AUS20030823 120030812G32308400105 ACTUATOR DHAV DHC8 DHC8315 2809010NM PWA PW120 PW123 NE HAMSTD14SF 14SF15 NE MLG DRAG STRUT FAULTY W O OTHER J WARNING INDICATION LDLANDING 1 AUS (AUS) NOSE LANDING GEAR DRAG STRUT ACTUATOR FAULTY. WORKSHOP INVESTIGATION COULD NOT REPRODUCE THE FAULT. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030908000942003090800094NM 2003 9 8 AUS20030824 120030814G2421761574B IDG BOEING737 737724 13844BYNM GE CFM56 CFM567B24 NE AC SYSTEM FAULTY W O OTHER HJ ELECT. POWER LOSS-50 PC WARNING INDICATION LDLANDING 1 AUS 991 (AUS) NR 2 INTEGRATED DRIVE GENERATOR (IDG) FAULTY. INVESTIGATION FOUND PHASE -A- WIRING HAD HIGH RESISTANCE. 2L72 4F4 FRTA16WE E00055EN 20030908000952003090800095GL 2003 9 8 AUS20030825 220030625G72616870815 LABYRINTH SEAL BELL 206 206B 1181511SW ALLSN 250C 250C20B 03013GL COMPRESSOR DETERIORATED W O OTHER E VIBRATION/BUFFET NRNOT REPORTED 1 AUS 725 (AUS) COMPRESSOR LARGE LABYRINTH SEAL ABRADABLE COATING DEBONDED CAUSING COMPRESSOR LOCKUP. 1G71 3U3 U H2SW E4CE 20030908000962003090800096SO 2003 9 8 AUS20030826 120030807G2721666600 ARM PIPER PA28 PA28161 7102803SO LYC O320 O320D3G 41508EA SNSNCH74D 74DM EA RUDDER TAB CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RUDDER TRIM ARM CRACKED. FOUND DURING INSPECTION IAW AD/PA28/23 AMDT2. 1L71 3O3 O 2A13 E274 5 NP88614 20030908000972003090800097EA 2003 9 8 AUS20030827 220030807G725040077 TURBINE WHEEL DHAV DHC6 DHC6300 2802606EA PWA PT6 PT6A27 52043EA HARTZLHCB3T HCB3TN3 GL ENGINE SEIZED W K NONE O OTHER ININSP/MAINT 1 AUS 996 (AUS) ENGINE POWER SECTION SEIZED. 1H72 3T4 TRTA9EA E4EA 6 CP15EA 20030908000982003090800098NM 2003 9 8 AUS20030828 120030724G57116549469 SPAR BOEING737 737377 NM LT WING CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT WING VENT BOX NR 10 STIFFENER CORRODED ON AFT FACE BETWEEN STN 557 & 583. CORROSION WAS FOUND IN 4 AREAS. 3 AREAS WERE LOCATED BETWEEN 100MM & 177.8MM OUTBOARD OF WS 557 & WERE APPROX 25.4MM INDIAMETER. ONE AREA LOCATED BETWEEN 304.8MM & 381MM OUTBOARD OF WS 557 & MEASURED APPROX 100MM BY 38.1MM. LOWER SECTION OF WING REAR SPAR CONTAINED CORROSION AT 8 FASTENER HOLES IN 254MM SPAN AT WS 583. BLEND DEPTHS WERE BETWEEN 0.0254MM & 0.1778MM VENT BOX CHANNEL CENTER FLANGE LOCATED BETWEEN STIFFENERS NR 9 & NR 10 AT WS 557 CONTAINED TWO AREAS OF CORROSION AT INTERSECTION WITH STRINGER 9 & 10. 2, CORRODED AREAS WERE APPROX 19.05MM IN DIAMETER. 2L72 4F RTA16WE 20030908000992003090800099NM 2003 9 8 AUS20030829 120030724G57116545407 SPAR BOEING737 737376 NM RT WING CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT WING VENT BOX CORRODED. NR 10 STIFFENER AFT FACE CORRODED IN AN AREA LOCATED BETWEEN WS563 & WS 578 OVER AN AREA APPROX 381MM BY 63.5MM. RT WING UPPER SKIN INNER SURFACE CORRODED BETWEEN WS 557 & 583 IN AN AREA BETWEEN STIFFENER NR 11 & WING REAR SPAR. 7 PATCHES OF CORROSION WERE FOUND VARYING BETWEEN 25.4MM (1IN) SQUARE & 177.8MM BY 76.2MM. MAX CORROSION DEPTH AFTER BLENDOUT RANGED FROM 0.1016MM TO 0.381MM. IN ONE 177.8MM BY 76.2MM PATCH PARTIALLY BENEATH STIFFENER NR 10 AT WS 566 TO WS 573 CORROSION DEPTH RANGED FROM 0.127MM TO MAX OF 11.43MM IN ONE VERY SMALL AREA. RT WING REAR SPAR LOWER SECTION CONTAINED CORROSION LOCATED BETWEEN WS 557 & WS 583. 2L72 4F RTA16WE 20030908001002003090800100EU 2003 9 8 AUS20030830 120030817G2760NAS16126 SEAL BAG BAE146BAE146300A 1500267EU LYC ALF502ALF502* 41580EA DRAG CONTROL SYSFAILED W O OTHER KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 AUS (AUS) LT GROUND SPOILER FLOW VALVE RETURN LINE CONNECTOR O-RING SEAL LEAKING. GRADUAL LOSS OF APPROXIMATELY TEN LITRES OF HYDRAULIC FLUID. 2H74 4F4 FRTA49EU E6NE 20030908001012003090800101SW 2003 9 8 AUS20030831 120030818G32132751501001 CYLINDER SWRNGNSA227 SA227* SW GARRTTTPE331TPE33112UHR WP MCAULY4HFR344HFR34C652 NE MLG FAILED W O OTHER O OTHER LDLANDING 1 AUS (AUS) RT MAIN LANDING GEAR OLEO FLAT. INVESTIGATION FOUND A FAILURE IN THE CIRCLIP GROOVE LOCATED IN THE LOWER CYLINDER ASSEMBLY. 2L72 4T4 TRTA5SW E4WE 6 C3PNE 20030908001022003090800102EU 2003 9 8 AUS20030832 120030523G2510TB1079011315 FITTING SOCATATB10 TB10TOBAGO 8680696EU LYC O360 O360A1A 41514EA HARTZLHCC2Y HCC2YK1 GL COCKPIT CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) REAR SEAT BELT OUTBOARD FITTINGS CONTAINED EXFOLIATION CORROSION. 1L71 3O3 ORTA51EU E286 5 CP920 20030908001032003090800103EU 2003 9 8 AUS20030833 120030525G5540TB1032000111 BRACKET SOCATATB10 TB10TOBAGO 8680696EU LYC O360 O360A1A 41514EA HARTZLHCC2Y HCC2YK1 GL RUDDER STRUCTURECORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RUDDER LOWER HINGE SUPPORT BRACKET CONTAINED EXFOLIATION CORROSION. FOUND DURING INSPECTION IAW AD TB10 31. 1L71 3O3 ORTA51EU E286 5 CP920 20030908001042003090800104EU 2003 9 8 AUS20030834 120030403G5711TB2011003100 SPAR SOCATATB20 TB20TRINIDAD8680695EU LYC O540 IO540C4D5 41532EA HARTZLHCC2Y HCC2YK1 GL LT WING CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT WING MAIN SPAR WEB CORRODED IN AREA BEHIND RIB PN TB20.11.003.100 LOCATED AT WS 660. 1L71 3O3 ORTA51EU 1E4 5 CP920 20030908001052003090800105EU 2003 9 8 AUS20030835 120030724G5711TB1011011101 SPAR SOCATATB10 TB10TOBAGO 8680696EU LYC O360 O360A1A 41514EA HARTZLHCC2Y HCC2YK1 GL RT WING CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT WING MAIN SPAR UPPER CAP CONTAINED CORROSION ON THE AFT FACE. RT WING LEADING EDGE INTERCOSTAL CONTAINED CORROSION ON THE LOWER FLANGE. FOLLOWING REMOVAL OF WINGS FOR REPAIR FURTHER CORROSION WAS FOUND ON THE TOP SURFACE OF THE LT AND RT MAIN SPAR UPPER CAP NEAR THE SPAR JOINT. 1L71 3O3 ORTA51EU E286 5 CP920 20030908001062003090800106EU 2003 9 8 AUS20030836 120030812G2822480500 PUMP BNORM BN2 BN2B20 1520302EU LYC O540 IO540K1B5 41532EA HARTZLHCC2Y HCC2YK2 GL FUEL BOOST MISMARKED W K NONE W INADEQUATE Q C ININSP/MAINT 1 AUS (AUS) LT FUEL TRANSFER PUMP UNAPPROVED PART. PUMP HAD A LABEL ATTACHED STATING THE MANUFACTURER DOES NOT RECOMMEND USAGE IN AIRCRAFT APPLICATIONS. PUMP WAS SUPPLIED FROM VENDOR UNDER THE CORRECT PN 480500 BUT WAS ACTUALLY PN 476088. FURTHER INCORRECT PUMPS WERE FOUND IN STOCK. PERSONNEL/MAINTENANCE ERROR. UNAPPROVED PART. 1H72 3O3 O A17EU 1E4 5 CP920 20030908001072003090800107NM 2003 9 8 AUS20030837 120030812G26214739551 CONTROL PANEL BOEING737 737800* NM NR 1 EXTINGUISH MALFUNCTIONED W F ACTIVATE FIRE EXT. O OTHER NRNOT REPORTED 1 AUS 2897 (AUS) UNCOMMANDED OPERATION OF NR 1 AFT CARGO HOLD FIRE EXTINGUISHER. SUSPECT CAUSED BY FAULTY FIRE DETECTION AND EXTINGUISHER CONTROL PANEL. 2L72 4F RTA16WE 20030908001082003090800108CE 2003 9 8 AUS20030838 120030729G28225100004RX PUMP CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA MCAULY1A170 1A170E GL FUEL BOOST FAILED W O OTHER E VIBRATION/BUFFET NRNOT REPORTED 1 AUS 711 (AUS) FUEL BOOST PUMP FAILED. INVESTIGATION FOUND ONE VANE MISSING AND SIGNS OF ABRASION. 1H71 3O3 ONT3A12 1E10 5 NP857 20030908001092003090800109SO 2003 9 8 AUS20030839 220030716G8550629243 HOUSING CESSNA421 421C 2076016CE CONT O520 GTSIO520N 17032SO MCAULY3FF32 3FF32C501 GL ENG OIL PUMP FAULTY W O OTHER EK VIBRATION/BUFFET FLUID LOSS CRCRUISE 1 AUS 304 (AUS) RT ENGINE OIL PUMP HOUSING FAULTY. 1L72 3O3 O A7CE E7CE 5 CP45GL 20030908001102003090800110NM 2003 9 8 AUS20030840 120030818G2434ALY8520R ALTERNATOR ROBSINR22 R22BETA 7640110NM LYC O320 O320B2C 41508EA DC SYSTEM FAILED W O OTHER HJ ELECT. POWER LOSS-50 PC WARNING INDICATION CRCRUISE 1 AUS 1159 AOL0871 (AUS) ALTERNATOR FAILED. INVESTIGATION FOUND BEARING AND DIODE FAILED. 1G71 3O3 O H10WE E274 20030908001112003090800111NM 2003 9 8 AUS20030841 120030816G2750S012T236205 LINK BOEING767 767238 1385114NM PWA JT9 JT9D7R4E 52054NE TE FLAPS SHEARED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT INBOARD TRAILING EDGE FLAP LINK SHEARED ON OUTBOARD HINGE. LINK IS LOCATED BETWEEN AFT FLAP AND SLAVE DRIVE BELLCRANK. 2L72 4F4 FRTA1NM E3NE 20030908001122003090800112CE 2003 9 8 AUS20030842 120030815G551004320041 BRACKET CESSNA150 A150K 2071824CE CONT O200 O200A 17020SO AMTR C8289 C8289 GL HORIZONTAL STAB CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) HORIZONTAL STABILISER BRACKET CRACKED AROUND NUT PLATES. 1H71 3O3 O 3A19 E252 5 NEXPP5N 20030908001132003090800113NM 2003 9 8 AUS20030843 120030819G6310V31001 LIMIT SWITCH ROBSINR22 R22BETA 7640110NM LYC O320 O320B2C 41508EA ENGINE/TRANSMISSFAILED W O OTHER E VIBRATION/BUFFET NRNOT REPORTED 1 AUS (AUS) ACTUATOR UP LIMIT SWITCH FAILED. 1G71 3O3 O H10WE E274 20030908001142003090800114EU 2003 9 8 AUS20030844 120030819G5711 SPAR SOCATATB10 TB10TOBAGO 8680696EU LYC O360 O360A1A 41514EA HARTZLHCC2Y HCC2YK1 GL LT & RT WING CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT AND RT WING MAIN SPARS CONTAINED SEVERE EXFOLIATION CORROSION. 1L71 3O3 ORTA51EU E286 5 CP920 20030908001152003090800115WP 2003 9 8 AUS20030845 120030820G5711H35096 SPAR DHAVXXDH82 DH82AROBRTSN2801002WP DHAVXXGIPSY GIPSYMAJOR1 20004WP AMTR C8289 C8289 GL LT WING CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT LOWER WING FORWARD SPAR CRACKED. 1Q71 3I3 I A8EU A8EU 5 NEXPP5N 20030908001162003090800116WP 2003 9 8 AUS20030846 120030820G5720H35471A STRUT DHAVXXDH82 DH82AROBRTSN2801002WP DHAVXXGIPSY GIPSYMAJOR1 20004WP AMTR C8289 C8289 GL LT WING CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT REAR STRUT CORRODED INTERNALLY AT LOWER END. FOUND DURING X-RAY INSPECTION. 1Q71 3I3 I A8EU A8EU 5 NEXPP5N 20030908001172003090800117WP 2003 9 8 AUS20030847 120030820G5720H35471A STRUT DHAVXXDH82 DH82AROBRTSN2801002WP DHAVXXGIPSY GIPSYMAJOR1 20004WP AMTR C8289 C8289 GL LT WING CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT REAR STRUT CONTAINED INTERNAL CORROSION ON THE LOWER END. FOUND DURING X-RAY INSPECTION. 1Q71 3I3 I A8EU A8EU 5 NEXPP5N 20030908001182003090800118SO 2003 9 8 AUS20030848 120030813G27315299 ACTUATOR EMB 120 EMB120 3260201SO PWA 118 PW118A NE HAMSTD14RF 14RF9 NE ELEVATOR TAB CONTAMINATED W O OTHER F FLT CONT AFFECTED CRCRUISE 1 AUS 1428 (AUS) ELEVATOR TRIM TAB ACTUATORS CONTAMINATED WITH WATER FROM OVERNIGHT RAIN. WATER FROZE AT ALTITUDE AND LOCKED ELEVATOR TRIM. 2L72 4T4 TRTA31SO E20NE 6 CP11NE 20030908001192003090800119EU 2003 9 8 AUS20030849 120030819G7797 WIRE BAG JETSTMJETSTM3201 1500217EU GARRTTTPE331TPE33112UHR WP MCAULY4HFR344HFR34C653 NE EGT INDICATOR CHAFED W O OTHER N FALSE WARNING CLCLIMB 1 AUS (AUS) EGT COMPENSATOR WIRE CHAFED ON PITOT/STATIC LINE LOCATED AT STN 145 LBL 90. CAUSED BY POOR INSTALLATION DURING COMPLIANCE WITH SB 77-JA910271. PERSONNEL/MAINTENANCE ERROR. 2L72 4T4 TRTA56EU E4WE 6 C3PNE 20030908001242003090800124SW 2003 9 8 AUS20030850 120030813G2131 CONTROLLER SWRNGNSA227 SA227* SW GARRTTTPE331TPE33112UA 01514WP MCAULY4HFR344HFR34C652 NE CABIN PRESSURE FLUCTUATES W O OTHER O OTHER CLCLIMB 1 AUS (AUS) CABIN PRESSURISATION FLUCTUATING. INVESTIGATION CONTINUING. 2L72 4T4 TRTA5SW E4WE 6 C3PNE 20030908001252003090800125NM 2003 9 8 AUS20030851 120030815G6310A1902 DRIVE BELT ROBSINR22 R22BETA 7640110NM LYC O320 O320B2C 41508EA ENGINE/TRANSMISSDISTORTED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) ENGINE TO TRANSMISSION DRIVE BELTS STRETCHED BEYOND LIMITS. 1G71 3O3 O H10WE E274 20030908001262003090800126NM 2003 9 8 AUS20030852 120030815G6410A0291 BEARING ROBSINR22 R22BETA 7640110NM LYC O320 O320B2C 41508EA TAIL ROTOR BLADELOOSE W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) TAIL ROTOR BLADE OUTBOARD BEARING LOOSE IN HOUSING. 1G71 3O3 O H10WE E274 20030908001272003090800127 2003 9 8 AUS20030853 420030812G612231039391 ELBOW SWRNGNSA227 SA227* SW GARRTTTPE331TPE33111U 01514WP ROTOL R321 R321482F8 GL PROP GOVERNOR CRACKED W O OTHER E VIBRATION/BUFFET CRCRUISE 1 AUS (AUS) RT PROPELLER GOVERNOR OUTLET PRESSURE ELBOW CRACKED IN AREA ABOVE LOCKNUT. 2L72 4T4 TRTA5SW E4WE 6 CP61GL 20030908001282003090800128EU 2003 9 8 AUS20030854 120030815G5520TB203421102 FITTING SOCATATB10 TB10TOBAGO 8680696EU LYC O360 O360A1D 41514EA HARTZLHCC2Y HCC2YK1 GL ELEVATOR CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) ELEVATOR HINGE FITTING BRACKET CRACKED. 1L71 3O3 ORTA51EU E286 5 CP920 20030908001292003090800129NM 2003 9 8 AUS20030855 120030821G2751H24EN1036 SWITCH BOEING727 727277 138408SNM PWA JT8 JT8D15 52051NE TE FLAPS FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) TRAILING EDGE FLAP 27.5 SWITCH (S294) FAULTY. FOUND DURING INSPECTION IAW AD/B727/105. 2L73 4F4 FRTA3WE E2EA 20030908001312003090800131EU 2003 9 8 AUS20030856 120030814G27529787320003 PDU PILATSPC12 PC12 7090550EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL TE FLAPS FAULTY W O OTHER F FLT CONT AFFECTED LDLANDING 1 AUS (AUS) FLAP POWER DRIVE UNIT (PDU) FAULTY. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030908001322003090800132NM 2003 9 8 AUS20030857 120030821G243523088002B STARTER GEN DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE NR 1 FAULTY W O OTHER HJ ELECT. POWER LOSS-50 PC WARNING INDICATION TOTAKEOFF 1 AUS (AUS) NR 1 STARTER-GENERATOR FAULTY. STARTER-GENERATOR HAD ONLY JUST BEEN REPLACED. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030908001332003090800133EU 2003 9 8 AUS20030858 220030821G7200 ENGINE BOEING737 737376 NM CFMINTCFM56 CFM563B2 13802EU NR 1 MALFUNCTIONED W O OTHER EJ VIBRATION/BUFFET WARNING INDICATION CLCLIMB 1 AUS 35829 (AUS) NR 1 ENGINE MOMENTARILY LOST POWER. POWER LOSS NOTED ON ENGINE GAUGES AND AIRCRAFT YAWED. NO REOCCURRENCE DURING FLIGHT. VIBRATION NOTICEABLE AT FLIGHT IDLE. 2L72 4F4 FRTA16WE E21EU 20030908001342003090800134NM 2003 9 8 AUS20030859 120030820G25103A2960007011 SEAT BOEING737 737800* NM GE CFM56 CFM567B24 NE COCKPIT FAILED W O OTHER O OTHER CRCRUISE 1 AUS 38704 (AUS) CAPTAINS SEAT FAILED. ROLL PINS SHEARED AT OPERATING BAR ASSEMBLIES. SUSPECT CAUSED BY FAILURE OF THE LIFT MECHANISM ASSEMBLY. 2L72 4F4 FRTA16WE E00055EN 20030908001352003090800135NM 2003 9 8 AUS20030860 120030816G2434B040390 DIODE ROBSINR22 R22MARINER 7640115NM LYC O320 O320B2C 41508EA DC ALTERNATOR FAILED W K NONE O OTHER ININSP/MAINT 1 AUS B040390 (AUS) DC ALTERNATOR DIODE FAILED. 1G71 3O3 O H10WE E274 20030908001362003090800136EU 2003 9 8 AUS20030861 120030724G3220 LEVER BAC 146 146200A 1500266EU LYC ALF502ALF502R5 41580NE NLG CORRODED W O OTHER J WARNING INDICATION CLCLIMB 1 AUS DLG0051 (AUS) NOSE LANDING GEAR WOULD NOT RETRACT. INVESTIGATION FOUND SEVERE CORROSION IN THE FOLLOWING LOWER PLUNGER LEVER ASSEMBLY COMPONENTS: 1. LEVER PN 2011386052. LEVER PN 2011386063. SHAFT PN 200876762 2H74 4F4 F A49EU E6NE 20030908001382003090800138CE 2003 9 8 AUS20030862 120030818G575305250011 RIVET CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA MCAULY1C235 1C235LFA GL TE FLAPS LOOSE W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT FLAP INBOARD TRACK LOWER ATTACHMENT RIVETS WORKING. 1H71 3O3 ONT3A12 1E10 5 NP12EA 20030908001392003090800139CE 2003 9 8 AUS20030863 120030818G575305250011 RIVET CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA MCAULY1C235 1C235LFA GL TE FLAP TRACK SHEARED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT FLAP INBOARD TRACK LOWER ATTACHMENT RIVETS SHEARED. OTHER RIVETS WORKING. 1H71 3O3 ONT3A12 1E10 5 NP12EA 20030908001402003090800140NM 2003 9 8 AUS20030864 120030820G2435 BRUSHES LEARSIEGLER DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE NR 1 STARTER GENWRONG PART W O OTHER HW ELECT. POWER LOSS-50 PC INADEQUATE Q C CRCRUISE 1 AUS 122 701 (AUS) NR 1 STARTER-GENERATOR FAILED. INVESTIGATION FOUND BRUSHES SHATTERED. SUSPECT BRUSHES WERE TOO LONG. SUSPECT UNAPPROVED PART. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030908001412003090800141NM 2003 9 8 AUS20030865 120030827G2761A44700009 ACTUATOR DHAV DHC8 DHC8106 2809020NM PWA PW121 PW121 52124NE HAMSTD14SF 14SF7 NE DRAG CONTROL FAILED W K NONE O OTHER ININSP/MAINT 1 AUS 24622 (AUS) LT OUTBOARD ROLL SPOILER ACTUATOR INTERNAL FAILURE. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030908001422003090800142NM 2003 9 8 AUS20030866 120030810G2913165W01020 PUMP BOEING737 737376 NM CFMINTCFM56 CFM563B1US GL HYD SYSTEM FAILED W K NONE K FLUID LOSS ININSP/MAINT 1 AUS A0264 (AUS) STANDBY HYDRAULIC PUMP FAILED. PUMP RUNS BUT FAILS TO PRODUCE PRESSURE. SUSPECT FAILED SHAFT. 2L72 4F4 FRTA16WE E2GL 20030908001432003090800143NM 2003 9 8 AUS20030867 120030823G27521267629 ACTUATOR BOEING747 747438 NM RROYCERB211 RB211524G19 NE TE FLAPS FAULTY W O OTHER F FLT CONT AFFECTED CLCLIMB 1 AUS 255 (AUS) FLAP ACTUATOR FAULTY. INVESTIGATION FOUND RECTIFIER AND PRIMARY DRIVE SOLENOID VALVE ASSEMBLY ELECTRICAL CONNECTOR NOT FULLY ENGAGED. 2L74 4F4 FRTA20WE E30NE 20030908001452003090800145NM 2003 9 8 AUS20030868 120030822G282424C2092 TRANSFER VALVE BOEING767 767338 1385151NM GE CF6 CF680C2* GL FUEL SYSTEM MISSING W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT MAIN FUEL TANK OUTBOARD PRESSURE FUELING SYSTEM SWING CHECK VALVE NOT FITTED. VALVE COUPLING, BONDING LEAD AND BONDING LEAD CLAMP ALSO MISSING. 2L72 4F4 FRTA1NM E23EA 20030908001472003090800147NM 2003 9 8 AUS20030869 120030714G6310V31001 LIMIT SWITCH ROBSIN ROBSINR22 R22BETA 7640110NM LYC O360 O360J2A 41514EA ENGINE/XMSN ACT FAILED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) CLUTCH ACTUATOR UP LIMIT SWITCH FAILED. 1G71 3O3 O H10WE E286 20030908001492003090800149 2003 9 8 AUS20030870 420030815G22114018369905 COMPUTER BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL AUTOPILOT FAILED W O OTHER F FLT CONT AFFECTED DEDESCENT 1 AUS (AUS) FLIGHT DIRECTOR COMPUTER FAILED. 1L72 4T4 T A24CE E4EA 6 CP15EA 20031017000012003101700001EU 2003 10 17 AUS20030871 120030829G6520330A33990320 BEARING UROCOP SNIAS AS332 AS332L 8680809EU TMECA MAKILAMAKILA1A 60040EU T/R GEARBOX BROKEN W O OTHER F FLT CONT AFFECTED DEDESCENT 1 AUS M305 (AUS) TAIL ROTOR GEARBOX PITCH CHANGE BEARING FAILED. PITCH CHANGESHAFT SERVO END NUT AND LOCKWASHER MISSING. SUSPECT FAILURE OF BEARING DUE TO CONTAMINATION BY H5606 ACTUATOR OIL CAUSING THE LUBRICATING CHARACTERISTICS OF THE SEALED BEARING TO CHANGE. 2G72 4U4 U H4EU E12NE 20031017000042003101700004NM 2003 10 17 AUS20030872 120030829G5711 SPAR BOEING737 737377 NM LT WING CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT WING VENT TANK SKIN ATTACHMENT FLANGES AND WEBS OF STIFFENERSNO9, NR 10 AND NR 11 CORRODED BEYOND LIMITS. LOWER SECTION OF REAR SPAR ALSO CORRODED. 2L72 4F RTA16WE 20031017000052003101700005NE 2003 10 17 AUS20030873 220030829G7260109060166107 GASKET AGUSTAA109 A109E 0260119EU PWA PW206 PW206B 0 NE GEARBOX FAILED W O OTHER EK VIBRATION/BUFFET FLUID LOSS CRCRUISE 1 AUS (AUS) NR 2 ENGINE ACCESSORY GEARBOX COVERPLATE GASKET FAILED. LOSS OF ENGINE OIL. 1G72 3U3 URTH7EU E42NE 20031017000062003101700006EU 2003 10 17 AUS20030874 120030828G5210 FRAME BAC 146 146200A 1500266EU LYC ALF502ALF502R5 41580NE PAX DOOR CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) NR 2L PASSENGER DOOR CRACKED IN UPPER HINGE ARM ATTACHMENT BOSS. 2H74 4F4 F A49EU E6NE 20031017000072003101700007NM 2003 10 17 AUS20030875 120030802G6310A1902 DRIVE BELT ROBSINR22 R22BETA 7640110NM LYC O360 O360J2A 41514EA ENGINE/XMSN STRETCHED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) ENGINE TO TRANSMISSION DRIVE BELTS STRETCHED. 1G71 3O3 O H10WE E286 20031017000082003101700008CE 2003 10 17 AUS20030876 120030826G53111014300263 FRAME BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FUSELAGE FRAMES PN 1014300263 LT AND PN 10143002611 RT CRACKED. FOUND DURING INSPECTION IAW AD/BEECH200/65 AMDT1. 1L72 4T4 T A24CE E4EA 6 CP15EA 20031017000092003101700009NM 2003 10 17 AUS20030877 120030828G6510B2243 DRIVE SHAFT ROBSINR22 R22BETA 7640110NM LYC O360 O360J2A 41514EA TAIL ROTOR BENT W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) TAIL ROTOR DRIVESHAFT BENT. 1G71 3O3 O H10WE E286 20031017000102003101700010 2003 10 17 AUS20030878 420030830G3452G699010 CONTROL PANEL BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU ATC TRANSPONDER FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS 1738 (AUS) ATC TRANSPONDER CONTROL PANEL FAULTY. PANEL WAS FOUND TO BE EXCESSIVELY HOT TO TOUCH. 2L72 4F4 FRTA16WE E21EU 20031017000122003101700012SO 2003 10 17 AUS20030879 220030815G8550642336 REGULATOR CESSNA404 404CESSNA 2075901CE CONT O520 GTSIO520M 17032SO MCAULY3FF32 3FF32C501 GL ENGINE FOD W O OTHER EK VIBRATION/BUFFET FLUID LOSS CLCLIMB 1 AUS 929 (AUS) LT ENGINE OIL PRESSURE REGULATOR CONTAMINATED WITH FOD BETWEEN PLUNGER AND SEAT. LOSS OF ENGINE OIL PRESSURE. 1L72 3O3 O A25CE E7CE 5 CP45GL 20031017000132003101700013SW 2003 10 17 AUS20030880 120030830G2731DL5040M6 ACTUATOR SWRNGNSA227 SA227AC 8780603SW GARRTTTPE331TPE33111U 01514WP ROTOL R321 R321482F8 GL ELEVATOR TAB FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS 7467 (AUS) PITCH TRIM ACTUATOR ROD ENDS HAD EXCESSIVE FREE PLAY. FOUND DURING INSPECTION IAW AD/SWSA226/68A5. 2L72 4T4 TRTA8SW E4WE 6 CP61GL 20031017000142003101700014CE 2003 10 17 AUS20030881 120030901G555410563000011 HINGE BEECH 76 76 1153005CE LYC O360 O360A1G6D EA HARTZLHCM2Y HCM2YR GL RUDDER TAB CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RUDDER HINGE BRACKET CORRODED (RUSTED). 1L72 3O3 O A29CE E286 5 CP43GL 20031017000152003101700015NM 2003 10 17 AUS20030882 120030831G3244B7502 TIRE BOEING747 747338 NM RROYCERB211 RB211524D41954555NE MLG FAILED W O OTHER O OTHER LDLANDING 1 AUS (AUS) NR 5F TIRE TREAD SEPARATED FROM CASING. TIRE REMAINED INFLATED. NIL DAMAGE EVIDENT TO REST OF AIRCRAFT. SUSPECT CAUSED BY FAILURE OF TREAD TO BOND TO CASING DURING RETREAD. 2L72 4F4 FRTA20WE E12EU 20031017000162003101700016SW 2003 10 17 AUS20030883 120030830G55142743062913 FITTING SWRNGNSA227 SA227AC 8780603SW GARRTTTPE331TPE33111U 01514WP ROTOL R321 R321482F8 GL H/S ACTUATOR CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) HORIZONTAL STABILIZER PITCH TRIM ACTUATOR UPPER ATTACHMENT BRACKETS CRACKED ALONG LUG. FURTHER INVESTIGATION REVEALED THAT THERE WAS CONSIDERABLE CLEARANCE BETWEEN THE BUSHINGS AND ACTUATOR ROD ENDS WHICH RESULTED IN THE LUGS BEING STRESSED WHEN THE ATTACHING HARDWARE WAS TORQUED UP. COMPARISON WITH REPLACEMENT BRACKET FOUND THAT THE BUSHES INSTALLED IN BOTH BRACKETS WERE TOO SHORT THEREFORE ALLOWING THE LUGS TO BE STRESSED INWARDS PRIOR TO CLAMPING ONTO THE ROD END. THIS CAUSED BOTH BRACKETS TO CRACK ALONG THE OUTBOARD LUG. FOUND DURING INSPECTION IAW AD/SWSA226/68. 2L72 4T4 TRTA8SW E4WE 6 CP61GL 20031017000172003101700017SW 2003 10 17 AUS20030884 120030827G29102781032075 LINE SWRNGNSA227 SA227AC 8780603SW GARRTTTPE331TPE33111U 01514WP MCAULY4HFR344HFR34C652 NE HYDRAULIC SYSTEMLEAKING W O OTHER KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 AUS (AUS) HYDRAULIC PRESSURE LINE LOCATED IN AREA BELOW PILOTS RUDDER PEDALS CRACKED AND LEAKING. LOSS OF HYDRAULIC FLUID. 2L72 4T4 TRTA8SW E4WE 6 C3PNE 20031017000182003101700018NM 2003 10 17 AUS20030885 120030802G6520B0211 SHAFT ROBSIN ROBSINR22 R22BETA 7640110NM LYC O360 O360J2A 41514EA T/R GEARBOX BENT W K NONE O OTHER ININSP/MAINT 1 AUS 0317 (AUS) TAIL ROTOR GEARBOX OUTPUT SHAFT BENT. 1G71 3O3 O H10WE E286 20031020000012003102000001 2003 10 20 AUS20030886 420030718G34254019700902 INDICATOR BAC 146 146100A 1500260EU LYC ALF502ALF502R5 41580NE FO ATTITUDE DIR FAILED W O OTHER J WARNING INDICATION CLCLIMB 1 AUS 24989 (AUS) FIRST OFFICER'S ATTITUDE DIRECTOR INDICATOR (ADI) FAILED. INVESTIGATION FOUND FAULT WAS CAUSED BY A DRY SOLDER JOINT ON THE MULTI-LAYER FLEX CABLE CONNECTING MODULES A1-A4. 2H74 4F4 FRTA49EU E6NE 20031020000022003102000002CE 2003 10 20 AUS20030887 120030901G77141143800075 INDICATOR BEECH 1900 1900C 1154161CE PWA PT6 PT6A65B 52043EA HARTZLHCB4M HCB4MP3 GL ENGINE RPM INOPERATIVE W O OTHER EI VIBRATION/BUFFET FLT. ATTITUDE INST. NRNOT REPORTED 1 AUS 450 8501136 (AUS) LT ENGINE PERCENT RPM INDICATOR FAULTY. 2L72 4T4 TRTA24CE E4EA 6 CP56GL 20031020000032003102000003NM 2003 10 20 AUS20030888 120030830G7830 THRUST REVERSER BOEING767 767338 1385151NM RROYCERB211 RB211524* NE LT ENGINE FAULTY W O OTHER J WARNING INDICATION LDLANDING 1 AUS (AUS) LT ENGINE THRUST REVERSER FAULTY. LIMITED INFORMATION PROVIDED. 2L72 4F4 FRTA1NM E12EU 20031020000092003102000009GL 2003 10 20 AUS20030889 320030903G6114 INSERT PAC CT4 CT4B GL CONT O360 IO360HB 17025SO HARTZLHCC2Y BHCC2YF1 GL PROPELLER HUB WRONG PART W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) ENGINE CRANKSHAFT FLANGE CRACKED AND LEAKING AROUND FACE. CRACK ORIGINATED AT DOWEL HOLE AND PROGRESSED APPROXIMATELY 75 PERCENT OF THE WAY AROUND THE FLANGE. INVESTIGATION FOUND THAT THE PROPELLER HAD BEEN MODIFIED BY THE FITMENT OF A STEEL INSERT IN THE MAIN BORE OF THE HUB. THE INSERT DID NOT HAVE THE REQUIRED INTERNAL CHAMFER FOR CORRECT MATING WITH THE PROPELLER FLANGE SO THAT WHEN THE PROPELLER BOLTS WERE TORQUED THE RESULTING BENDING LOADS CAUSED THE FLANGE TO CRACK. PERSONNEL /MAINTENANCE ERROR. UNAPPROVED PART. 1L71 3O3 ORTA9PC E1CE 5 CP920 20031020000102003102000010CE 2003 10 20 AUS20030890 120030821G2434DOFF10300BR ALTERNATOR CESSNA172 172N 2072434CE LYC O360 O360A4M 41514EA AMTR C8289 C8289 GL DC SYSTEM FAILED W O OTHER H ELECT. POWER LOSS-50 PC CRCRUISE 1 AUS (AUS) ALTERNATOR FAILED IN FLIGHT. LIMITED INFORMATION PROVIDED. 1H71 3O3 ONT3A12 E286 5 NEXPP5N 20031020000112003102000011EA 2003 10 20 AUS20030891 220030813G854076118 SPACER AMTR VANS RV8 GL LYC O540 IO540K1B5 41532EA HARTZLHCC2Y HCC2YK1 GL TACH DRIVE WORN W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) ENGINE OIL FILTER CONTAMINATED WITH BRONZE PARTICLES. INVESTIGATION FOUND THE TACHOMETER DRIVESHAFT SPACER HAD COME LOOSE FROM THE CAMSHAFT AND WAS WEARING ON THE SHAFT ROLL PIN. 1L71 3O3 ONTEXPA1L711E4 5 CP920 20031020000122003102000012NE 2003 10 20 AUS20030892 220030905G73211853M56P07 HMU BOEING737 7377BX 13844D2NM GE CFM56 CFM56* 13802NE FUEL CONTROL FAULTY W O OTHER EJ VIBRATION/BUFFET WARNING INDICATION TXTAXI/GRND HDL 1 AUS (AUS) ENGINE HYDROMECHANICAL UNIT (HMU) FAULTY. 2L72 4F4 FRTA16WE E2GL 20031020000142003102000014CE 2003 10 20 AUS20030893 120030904G57418178610 BOLT BEECH 200 200BEECH 1152920CE PWA PT6 PT6A42 52043NE MCAULY4HFR344HFR34C754 NE WING TO BODY CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT AFT UPPER WING ATTACHMENT BOLT CRACKED IN THREADED AREA. 1L72 4T4 T A24CE E4EA 6 C3PNE 20031020000152003102000015NM 2003 10 20 AUS20030894 120030824G323083231027001 CONNECTING ROD DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE LT MLG BROKEN W O OTHER O OTHER CRCRUISE 1 AUS (AUS) LT MAIN LANDING GEAR CONNECTING ROD BROKEN AT NECK END. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20031020000162003102000016NM 2003 10 20 AUS20030895 120030903G5730 PANEL BOEING747 747438 NM RROYCERB211 RB211524G19 NE LT WING MISINSTALLED W K NONE K FLUID LOSS ININSP/MAINT 1 AUS (AUS) LT OUTBOARD SURGE TANK ACCESS DOOR INCORRECTLY FITTED. FUEL LEAKING. DOOR WAS DAMAGED DUE TO BEING FITTED 180 DEGREES OUT.DOOR IS FITTED WITH ONE RAISED NUT WHICH FITS INTO ACORRESPONDING NOTCH TO PREVENT INCORRECT FITMENT. PERSONNEL/MAINTENANCE ERROR. 2L74 4F4 FRTA20WE E30NE 20031020000172003102000017CE 2003 10 20 AUS20030896 120030304G7120 MOUNT BEECH 23 A2324 1151226CE LYC O360 IO360A1B 41514EA MCAULY2D34C 2D34C9 GL ENGINE WRONG PART W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) INCORRECT ENGINE MOUNTS FITTED. MANUFACTURER'S ILLUSTRATED PARTS CATALOGUE (IPC) INDICATES INCORRECT NUMBER. CORRECT PART NUMBER AND INSTALLATION PROCEDURES ARE FOUND IN THE MM. IPC INCORRECT. 1L71 3O3 O A1CE 1E10 5 CP7EA 20031020000182003102000018NM 2003 10 20 AUS20030897 120030906G2761A44700009 ACTUATOR DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE DRAG CONTROL FAILED W O OTHER K FLUID LOSS CLCLIMB 1 AUS 5062 (AUS) LT OUTBOARD SPOILER ACTUATOR BODY FAILED. LOSS OF NR 2 HYDRAULIC SYSTEM FLUID. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20031020000192003102000019NE 2003 10 20 AUS20030898 220030908G73100311007710 LINE SKRSKYS76 S76C 8143008NE TMECA ARRIELARRIEL1S 60030NE ENGINE FUEL DISTCRACKED W O OTHER EK VIBRATION/BUFFET FLUID LOSS NRNOT REPORTED 1 AUS 99999 (AUS) NR 1 ENGINE FUEL INJECTOR FUEL SUPPLY PIPE CRACKED IN FLARE. 1G72 3U3 UNCH1NE E19EU 20031020000202003102000020NM 2003 10 20 AUS20030899 120030907G3244324525172 TIRE BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU RT NLG FAILED W C ABORTED TAKEOFF O OTHER TOTAKEOFF 1 AUS (AUS) RT NOSE WHEEL TIRE BLOWN OUT. LT TIRE FAILED DUE TO OVERLOAD. 2L72 4F4 FRTA16WE E21EU 20031020000212003102000021EU 2003 10 20 AUS20030900 120030908G5711635 SPAR SOCATATB10 TB10TOBAGO 8680696EU LYC O360 O360A1A 41514EA HARTZLHCC2Y HCC2YK1 GL RT WING CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT WING MAIN SPAR AFT LOWER WEB CONTAINED EXFOLIATION CORROSION. CORROSION WAS MAINLY LOCATED IN AREA ADJACENT TO MAIN LANDING GEAR LEG. 1L71 3O3 ORTA51EU E286 5 CP920 20031020000222003102000022EU 2003 10 20 AUS20030901 120030908G5711770 SPAR SOCATATB10 TB10TOBAGO 8680696EU LYC O360 O360A1A 41514EA HARTZLHCC2Y HCC2YK1 GL LT & RT WINGS CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT AND RT WING MAIN SPAR AFT LOWER WEBS CONTAINED EXFOLIATION CORROSION. CORROSION MAINLY LOCATED IN AREA ADJACENT TO MAIN LANDING GEAR. 1L71 3O3 ORTA51EU E286 5 CP920 20031020000232003102000023NM 2003 10 20 AUS20030902 120030909G57306545407 SKIN AAR BOEING737 737377 NM RT WING CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT WING VENT TANK UPPER SKIN LOWER SURFACE CORRODED. LOWER CHORD OF REAR SPAR AND WEBS OF STIFFENERS NR 9 AND NR 10 ALSO CORRODED. 2L72 4F RTA16WE 20031020000242003102000024SW 2003 10 20 AUS20030903 120030730G6210206015001115 BLADE BELL 206 206L3 1182108SW ALLSN 250C 250C30P 03013GL MAIN ROTOR DAMAGED W K NONE O OTHER DEDESCENT 1 AUS (AUS) M/R BLADE UPPER SKIN TORN IN AREA LOCATED AT BLADE TIP IMMEDIATELY INBOARD OF TIP CAP. INSP FOUND SKIN HAD LIFTED IMMEDIATELY BEHIND SPAR &TORN IN SPAN WISE DIRECTION FROM TIP TO APPROX 50.8MM INBOARD OF TIP & 25.4MM AFT OF SPAR.SKIN & ADHESIVE HAD SEPARATED FROM THE CORE MATERIAL WITH EVIDENCE OF CORROSION UNDER THE ADHESIVE. BLADE R & FWDED TO REPAIR FACILITY. FURTHER INSP AT REPAIR FACILITY REVEALED OTHER AREAS OF CORROSION AND PITTING IN GRIP DOUBLERS ON LOWER SURFACE OF BLADE & ALSO IN AREA UNDER THE LATCH PLATES BONDED TO GRIP TANGS. PHOTOGRAPHS REVEALED CORROSION IN DOUBLERS STARTING IN MIDDLE OF BONDED JOINT & NOT EMANATING FROM MOISTURE INGRESS FROM EDGE OF JOINT AS WOULD NORMALLY BE EXPECTED. 1G71 3U3 U H2SW E1GL 20031020000252003102000025GL 2003 10 20 AUS20030904 320030624G61143AF32C87JN HUB MCAULY3AF32C3AF32C87 GL PROPELLER CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) PROPELLER HUB CRACKED IN NR 3 BLADE SOCKET. CRACK LOCATED AT APPROXIMATELY 11 O'CLOCK POSITION. FOUND DURING INSPECTION IAWAD/PMC/41. 5 CP22EA 20031020000262003102000026GL 2003 10 20 AUS20030906 320030625G6114D2A34C580 HUB MCAULY2A34C D2A34C58 GL PROPELLER CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) PROPELLER HUB CRACKED AT APPROXIMATELY 12 O'CLOCK POSITION IN BOTH BLADE SOCKETS. FOUND DURING INSPECTION IAW AD/PMC/41. 5 CP3EA 20031020000272003102000027CE 2003 10 20 AUS20030907 120030908G3230AN2415M BOLT BEECH 55 E55 1152732CE CONT O520 IO520C 17032SO HARTZLHCJ2Y BHCJ2YF2 GL MLG MISINSTALLED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LH LANDING GEAR PUSH-PULL ROD BOLT INCORRECTLY FITTED. BOLT HEADWAS INSTALLED IN THE WRONG DIRECTION CAUSING HEAD TO FOUL ONINBOARD END RIB IN THE LH WHEEL WELL. CORRECT FITMENT DIRECTION OF THE BOLT WAS CLEARLY PLACARDED. PERSONNEL/MAINTENANCEERROR. 1L72 3O3 O 3A16 E5CE 5 CP37EA 20031020000282003102000028NM 2003 10 20 AUS20030908 120030905G2710 AILERON BOEING737 737400 138449ANM CFMINTCFM56 CFM563C 13802EU AILERON CONTROL MALFUNCTIONED W O OTHER F FLT CONT AFFECTED APAPPROACH 1 AUS (AUS) AILERON CONTROL SYSTEM NOTCHY' WITH A CONSIDERABLE DEAD BAND IN THE CENTRE. 2L72 4F4 FRTA16WE E21EU 20031020000292003102000029GL 2003 10 20 AUS20030909 320030802G61142A36C23CP HUB MCAULY2A36C 2A36C23 GL PROPELLER CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) PROPELLER HUB CONTAINED CRACK INDICATIONS IN THE NR 2 BLADESOCKET AT THE 2.30 O'CLOCK AND 6 O'CLOCK POSITIONS. 5 CP880 20031020000302003102000030GL 2003 10 20 AUS20030910 320030906G61143AF32C87N1 HUB MCAULY3AF32C3AF32C87 GL PROPELLER CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) PROPELLER HUB CONTAINED CRACK INDICATIONS IN THE NR 2 BLADE SOCKET AT THE 1.30 O'CLOCK POSITION. 5 CP22EA 20031020000312003102000031GL 2003 10 20 AUS20030911 320030606G6114D2A34C58NO HUB MCAULY2A34C D2A34C58 GL PROPELLER CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) PROPELLER HUB CONTAINED CRACK INDICATIONS IN THE NR 2 BLADE SOCKET AT THE 5.30 O'CLOCK POSITION. 5 CP3EA 20031020000322003102000032CE 2003 10 20 AUS20030912 120030908G5310 STRUCTURE CESSNA337 337G 2075730CE CONT O360 IO360G 17025SO MCAULY2AF34CD2AF34C306 GL TAILBOOM CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT TAILBOOM LOWER STRUCTURE CORRODED IN AREA OF ATTACHMENT TO WING STRUCTURE. CORROSION IS BOTH INTERNAL AND EXTERNAL. RT TAILBOOM CONTAINED INTERNAL CORROSION ONLY. 1H72 3O3 O A6CE E1CE 5 CP5EA 20031020000332003102000033CE 2003 10 20 AUS20030913 120030905G571105230202 SPAR CAP CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA MCAULY1C160 1C160DTM GL RT WING CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT WING UPPER SPAR CAP ANGLE CORRODED. ANGLE IS LOCATED IN FUEL TANK BAY. 1H71 3O3 ONT3A12 E274 5 NP910 20031020000342003102000034EA 2003 10 20 AUS20030914 220030902G852076220P02 BOLT PIPER PA31 PA31350 7103110SO LYC O540 LTIO540J2BD 41533EA HARTZLHCE3Y HCE3YR2 GL ENGINE SHEARED W K NONE O OTHER ININSP/MAINT 1 AUS 866 (AUS) CRANKCASE THROUGH BOLT LOCATED AT NO1 CYLINDER FORWARD LOWERPOSITION SHEARED. 1L72 3O3 O A20SO E14EA 5 CP33EA 20031020000352003102000035 2003 10 20 AUS20030915 420030908G3425LMD5001P RELAY BEECH 200 200BEECH 1152920CE PWA PT6 PT6A42 52043NE MCAULY4HFR344HFR34C754 NE INTEGRATED FLIGHCORRODED W K NONE O OTHER ININSP/MAINT 1 AUS 3933 (AUS) EFIS RELAY PN 3921K10 CORRODED. INVESTIGATION FOUND EXTENSIVE CORROSION THROUGHOUT THE RELAY MODULE. 1L72 4T4 T A24CE E4EA 6 C3PNE 20031020000362003102000036NM 2003 10 20 AUS20030916 120030910G2824 PLUG BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU TRANSFER VAVLE LOOSE W O OTHER J WARNING INDICATION TXTAXI/GRND HDL 1 AUS (AUS) FUEL CROSSFEED VALVE PLUG LOOSE. 2L72 4F4 FRTA16WE E21EU 20031020000372003102000037SW 2003 10 20 AUS20030917 120030905G6410406016100119 BLADE BELL 407 407 1182206SW ALLSN 250C 250C47B GL TAIL ROTOR CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) TAIL ROTOR BLADE CRACKED CHORDWISE FROM WATER DRAIN HOLE LOCATED AT BLADE ROOT. CRACK LENGTH APPROXIMATELY 40MM (1.57IN). 1G71 3U3 UO H2SW E1GL 20031020000382003102000038EA 2003 10 20 AUS20030918 220030908G732225765362 FCU CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA MCAULY1C235 1C235LFA GL ENGINE FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS 1137 (AUS) FUEL CONTROL UNIT AIR CHAMBER CONTAMINATED WITH FUEL. 1H71 3O3 ONT3A12 1E10 5 NP12EA 20031020000392003102000039SW 2003 10 20 AUS20030919 120030910G2932SS10127 SWITCH SWRNGNSA227 SA227* SW GARRTTTPE331TPE33112UHR WP MCAULY4HFR344HFR34C652 NE HYD PRESSURE FAULTY W O OTHER KJ FLUID LOSS WARNING INDICATION CLCLIMB 1 AUS (AUS) LT HYD SYS LOW PRESSURE WARNING SWITCH FAULTY. 2L72 4T4 TRTA5SW E4WE 6 C3PNE 20031020000402003102000040 2003 10 20 AUS20030920 420030911G341628702552 ALTIMETER SWRNGNSA227 SA227* SW GARRTTTPE331TPE33112UHR WP MCAULY4HFR344HFR34C652 NE COCKCPIT FAILED W O OTHER I FLT. ATTITUDE INST. CLCLIMB 1 AUS 5 (AUS) PILOTS ALTIMETER FAILED. ALTIMETER HAD BEEN INSTALLED FOR 5.4 HOURS SINCE REPAIR. 2L72 4T4 TRTA5SW E4WE 6 C3PNE 20031020000412003102000041NM 2003 10 20 AUS20030921 120030911G5330 STRAP BOEING747 747400 NM GE CF6 CF680C2* GL FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) CIRCUMFERENTIAL CRACK IN SKIN PRODUCTION JOINT SPLICE STRAP ATLOCATED AT BS 2181 BETWEEN STRINGERS 1R AND 4R. CRACK LENGTH APPROXIMATELY 762MM (30IN). 2L74 4F4 FRTA20WE E23EA 20031020000422003102000042EU 2003 10 20 AUS20030922 120030910G3230SA7670006123 HOSE BAG BAE146BAE146300A 1500267EU LYC ALF502ALF502* 41580EA LT MLG RUPTURED W O OTHER K FLUID LOSS NRNOT REPORTED 1 AUS (AUS) LT MLG RETRACTION JACK FLEXIBLE HYDRAULIC HOSE RUPTURED. LOSS OF GREEN SYSTEM HYD FLUID. 2H74 4F4 FRTA49EU E6NE 20031020000432003102000043CE 2003 10 20 AUS20030923 120030909G323312810013 HOUSING CESSNA182 R182 2072734CE LYC O540 O540* 41532EA MCAULY2D34C B2D34C214 GL MLG ACTUATOR CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 2428 (AUS) LANDING GEAR ACTUATOR BODY CRACKED. FOUND DURING INSPECTION IAW CESSNA SB 01-2 REV1. 1H71 3O3 ORT3A13 E295 5 CP7EA 20031020000452003102000045CE 2003 10 20 AUS20030924 120030908G243503600918 BEARING LUCAS BEECH 1900 1900C 1154161CE PWA PT6 PT6A65B 52043EA STARTER-GEN COLLAPSED W O OTHER H ELECT. POWER LOSS-50 PC CRCRUISE 1 AUS 812 97249 (AUS) LT ENGINE STARTER-GENERATOR DRIVE END BEARING COLLAPSED. 2L72 4T4 TRTA24CE E4EA 20031020000472003102000047CE 2003 10 20 AUS20030925 120030915G2933511700712 SIGHT GLASS CESSNA402 402C 207590RCE CONT O520 TSIO520VB 17040SO MCAULY3AF32C3AF32C87 GL HYD QTY CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) HYDRAULIC SYSTEM SIGHT TUBE CRACKED. LOSS OF HYDRAULIC FLUID. 1L72 3O3 O A7CE E8CE 5 CP22EA 20031020000482003102000048CE 2003 10 20 AUS20030927 120030903G534312116013 ATTACH FITTING CESSNA206 U206G 2073356CE CONT O520 IO520F 17032SO MCAULY3A32C D3A32C90 GL MLG CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT MAIN LANDING GEAR OUTBOARD ATTACHMENT FITTING CRACKED IN AREAOF UPPER REAR RADIUS. 1H71 3O3 O A4CE E5CE 5 CP21EA 20031020000492003102000049SW 2003 10 20 AUS20030928 120030910G27702770066001 PLUNGER SWRNGNSA227 SA227* SW GARRTTTPE331TPE33112UHR WP MCAULY4HFR344HFR34C652 NE GUST LOCK DAMPERFRACTURED W K NONE F FLT CONT AFFECTED LDLANDING 1 AUS (AUS) RUDDER GUST LOCK PLUNGER BROKEN INTO TWO PARTS. 2L72 4T4 TRTA5SW E4WE 6 C3PNE 20031020000512003102000051EU 2003 10 20 AUS20030929 120030912G2424700122490420 GCU BAG BAE146BAE146300A 1500267EU AC GENERATOR FAILED W O OTHER H ELECT. POWER LOSS-50 PC CLCLIMB 1 AUS (AUS) NR 1 GENERATOR CONTROL UNIT (GCU) FAILED. 2H74 4F RTA49EU 20031020000522003102000052NM 2003 10 20 AUS20030930 120030911G5754114T41457 BOLT BOEING767 767338 1385151NM GE CF6 CF680C2* GL LE SLAT FAILED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LEADING EDGE SLAT BOLT FAILED. 2L72 4F4 FRTA1NM E23EA 20031020000532003102000053CE 2003 10 20 AUS20030931 120030904G2434DOFF10300B ALTERNATOR CESSNA150 A152 2071836CE LYC O235 O235L2C 41505EA MCAULY1A103 1A103TCM GL DC SYSTEM FAILED W O OTHER H ELECT. POWER LOSS-50 PC CRCRUISE 1 AUS A122793 (AUS) ALTERNATOR FAILED. 1H71 3O3 O 3A19 E223 5 NP50GL 20031020000542003102000054SW 2003 10 20 AUS20030932 120030910G2434902014 BEARING MOONEYM20 M20J 5870219SW LYC O360 IO360A3B6 41514EA MCAULY2D34C B2D34C214 GL DC GENERATOR DISINTEGRATED W O OTHER H ELECT. POWER LOSS-50 PC CRCRUISE 1 AUS 1290 (AUS) ALTERNATOR SLIP RING END ROLLER BEARING DISINTEGRATED. ROTORPOLED. 1L71 3O3 O 2A3 1E10 5 CP7EA 20031020000552003102000055CE 2003 10 20 AUS20030933 120030829G8011NONEINIPC SCREW LYC CESSNA150 A152 2071836CE LYC O235 O235L2C 41505EA MCAULY1A103 1A103TCM GL STARTER LOOSE W O OTHER B SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 AUS A112529 (AUS) STARTER MOTOR INTERMEDIATE BEARING SECURING SCREW FELL OUT ANDSHORT CIRCUITED FIELD WINDINGS. 1H71 3O3 O 3A19 E223 5 NP50GL 20031020000572003102000057CE 2003 10 20 AUS20030934 120030913G3297320559 WIRE CESSNA310 310R 2074245CE CONT O520 IO520M 17032SO MLG CONNECTOR LOOSE W O OTHER O OTHER NRNOT REPORTED 1 AUS (AUS) LANDING GEAR SAFETY SWITCH WIRE LOOSE AT INLINE CONNECTOR. 1L72 3O3 O 3A10 E5CE 20031020000592003102000059NE 2003 10 20 AUS20030935 220030909G7261120032 OIL SYSTEM PW120A DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE ENGINE LOW W O OTHER EKJVIBRATION/BUFFET FLUID LOSS WARNING INDICATION NRNOT REPORTED 1 AUS (AUS) NR 1 ENGINE OIL SYSTEM LOW QUANTITY. TWO QUARTS OF ENGINE OIL WERE ADDED TO TOP UP OIL QUANTITY. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20031021000012003102100001NM 2003 10 21 AUS20030936 120030913G2720 PEDAL BOEING737 737* NM GE CFM56 CFM567B24 NE RUDDER CONTROL VIBRATES W O OTHER F FLT CONT AFFECTED DEDESCENT 1 AUS (AUS) MODERATE VIBRATION FELT THROUGH RUDDER PEDALS. INVESTIGATION COULD FIND NO FAULT. 2L72 4F4 FRTA16WE E00055EN 20031020000652003102000065GL 2003 10 20 AUS20030937 320030915G6114D42145 HUB BEECH 76 76 1153005CE LYC O360 O360A1G6D EA HARTZLHCM2Y HCM2YR GL PROPELLER UNSERVICEABLE W K NONE O OTHER ININSP/MAINT 1 AUS 1394 (AUS) PROPELLER HUB DAMAGED IN AREA OF PRELOAD PLATE SHELF. PROPELLER HAD BEEN REMOVED AND DISMANTLED FOLLOWING GROUND STRIKE. 1L72 3O3 O A29CE E286 5 CP43GL 20031020000662003102000066EU 2003 10 20 AUS20030938 120030916G3213200920604 NUT STBROSSD3 SD360 8100606EU PWA PT6 PT6A67R 52043NE HARTZLHCA6A HCA6A3 NE MLG CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT MAIN LANDING GEAR STRUT SHOCK ABSORBER GLAND NUT CRACKED. FOUND DURING INSPECTION IAW AD/SD3-60/42. 2H72 4T4 T A41EU E26NE 6 CP14NE 20031020000672003102000067SW 2003 10 20 AUS20030939 120030912G27702770066001 PLUNGER SWRNGNSA227 SA227AC 8780603SW GARRTTTPE331TPE33111U 01514WP ROTOL R321 R321482F8 GL GUST LOCK DAMPERCRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RUDDER GUST LOCK ASSEMBLY PLUNGER CORRODED, BENT AND CRACKED. 2L72 4T4 TRTA8SW E4WE 6 CP61GL 20031020000692003102000069GL 2003 10 20 AUS20030940 120030912G531012843003 DOOR FRAME AAR 12843004 CIRRUSSR SR20 05628AJGL CONT O360 IO360E 17025SO HARTZLHCJ3Y PHCJ3YF1 GL FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT ENTRY DOOR FRAME PN 12843003 AND RT ENTRY DOOR FRAME PN 12843004 CRACKED IN AREA ABOVE SIDE WINDOW. CRACK LENGTHS APPROXIMATELY 457.2MM (18IN). 1L71 3O3 ONTA00009CHE1CE 5 CP36EA 20031020000702003102000070SW 2003 10 20 AUS20030941 120030915G2460ANL400 CURRENT LIMITER SWRNGNSA227 SA227* SW GARRTTTPE331TPE33112UHR WP MCAULY4HFR344HFR34C652 NE DC POWER MISMANUFACTURED W O OTHER W INADEQUATE Q C NRNOT REPORTED 1 AUS (AUS) CURRENT LIMITER INCORRECTLY ASSEMBLED CAUSING ARCING AT THE CONNECTION POINT. PERSONNEL/MAINTENANCE ERROR. 2L72 4T4 TRTA5SW E4WE 6 C3PNE 20031020000712003102000071NM 2003 10 20 AUS20030942 120030917G7830 WARNING LIGHT BOEING737 737376 NM GE CFM56 CFM563B1 13802NE THRUST REVERSER INTERMITTENT W O OTHER EJ VIBRATION/BUFFET WARNING INDICATION CLCLIMB 1 AUS (AUS) NR 2 ENGINE THRUST REVERSER UNLOCK LIGHT ILLUMINATING INTERMITTENTLY. 2L72 4F4 FRTA16WE E2GL 20031020000722003102000072CE 2003 10 20 AUS20030943 120030830G561010138402518 WINDSHIELD BEECH 200 B200C 1152924CE PWA PT6 PT6A42 52043NE MCAULY3G34C73GFR34C701 GL COCKPIT FAILED W O OTHER O OTHER CRCRUISE 1 AUS (AUS) RT WINDSHIELD INNER PANE SHATTERED. 1L72 4T4 T A24CE E4EA 5 CP60GL 20031020000732003102000073EU 2003 10 20 AUS20030944 120030911G5302355A2305000407 SKIN AEROSPAS355 AS355F1 8680810EU ALLSN 250C 250C20F 03013GL TAILBOOM CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) TAILBOOM SKIN CRACKED IN AREA LOCATED AFT OF THE TAIL ROTOR GEARBOX. CRACK ORIGINATED FROM RIVET HOLE IN TAIL ROTOR GEARBOX COWL BRACKET. CRACKED HAD EXTENDED AFT FOR APPROX 50.8MM TO 76. 2MM (2IN TO 3IN) IN AN AREA NOT NORMALLY VISIBLE WITH VERTICAL STABILIZERS INST CRACK HAD ALSO EXTENDED FWD&DOWN APPROXIMATELY 50.8MM TO 76.2MM (2IN TO 3IN). 1ST 25.4MM (1IN) OR SO NOT NORMALLY VISIBLE WITH TAIL ROTOR GEARBOX COWL INST LAST 25.4MM (1IN) OR SO OF CRACKIN FWD & DOWN DIRECTION HAD PROTUDED FROM BENEATH TAIL ROTOR GEARBOX COWL MAKING IT VISIBLE DURING DAILY INSPECTION. TAIL ROTOR GEARBOX COWL ATTACHMENT BRACKET HAD BEEN FRETTING ON TAILBOOM SKIN CAUSING THE 1/8IN RIVETS (3OFF) TO BECOME LOOSE. AFTMOST HOLE F1G72 3U3 U H11EU E4CE 20031020000742003102000074CE 2003 10 20 AUS20030945 120030908G3213 STRUT CESSNA172 172G 2072420CE CONT O300 O300C 17022SO MCAULY1C172 1C172EM GL MLG CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT AND RT MAIN LANDING GEAR LEGS CORRODED. 1H71 3O3 ONT3A12 E253 5 NP910 20031020000752003102000075NM 2003 10 20 AUS20030948 120030917G2612 FIRE LOOP BOEING737 737376 NM GE CFM56 CFM563B1 13802NE NR 1 ENGINE FAULTY W O OTHER EBJVIBRATION/BUFFET SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CLCLIMB 1 AUS (AUS) NR 1 ENGINE FIRE DETECTION SYSTEM FAULTY. NR 1 ENGINE LOOP `B` FAULTY. 2L72 4F4 FRTA16WE E2GL 20031020000762003102000076NE 2003 10 20 AUS20030949 320030911G6114A163372 O-RING BAG JETSTMJETSTM3201 1500217EU GARRTTTPE331TPE33112UA 01514WP MCAULY4HFR344HFR34C653 NE PROP HUB LEAKING W O OTHER K FLUID LOSS NRNOT REPORTED 1 AUS (AUS) RT PROPELLER LEAKING OIL. THE PROPELLER HAD JUST BEEN REMOVED AND REFITTED FOLLOWING REPAIR TO THE DEICE BOOT. NEW O-RING SEALS PN A163372 HAD BEEN FITTED AT INSTALLATION. THOROUGH INVESTIGATION COULD FIND NO REASON FOR THE LEAK. 2L72 4T4 TRTA56EU E4WE 6 C3PNE 20031020000772003102000077NM 2003 10 20 AUS20030950 120030917G2612 FIRE LOOP BOEING737 737376 NM GE CFM56 CFM563B1 13802NE NR 1 ENGINE FAULTY W O OTHER EBJVIBRATION/BUFFET SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CLCLIMB 1 AUS (AUS) NR 1 ENGINE FIRE DETECTION SYSTEM FAULTY. INVESTIGATION FOUND A HIGH RESISTANCE (2000OHMS) SENSOR IN LOOP B'. MEL APPLIED BUT DEFECT OCCURRED DURING NEXT TAKEOFF AND ON SUBSEQUENT FAULT FINDING GROUND RUN. SEE MDR 03/0948 FOR RELATED INCIDENT. 2L72 4F4 FRTA16WE E2GL 20031020000792003102000079EU 2003 10 20 AUS20030952 220030912G7200MAKILA1A1 ENGINE SNIAS AS332 AS332L 8680809EU TMECA MAKILAMAKILA1A 60040EU NR 1 MAKING METAL W K NONE O OTHER ININSP/MAINT 1 AUS 833 (AUS) NR 1 ENGINE REAR BEARING CHIP DETECTOR CONTAMINATED WITH METAL. 2G72 4U4 U H4EU E12NE 20031020000802003102000080NE 2003 10 20 AUS20030953 220030710G7230 COMPRESSOR UROCOPEC120 EC120B 8680987EU TMECA ARRIUSARRIU2F NE ENGINE FOD W O OTHER EF VIBRATION/BUFFET FLT CONT AFFECTED NRNOT REPORTED 1 AUS (AUS) ENGINE VIBRATION DURING START. POWER BELOW LIMITS. FOUND DURING TEST RUNS FOLLOWING CENTRIFUGAL COMPRESSOR CHANGE DUE TO FOD. 1G72 3U3 UNCR0001RD E34NE 20031020000812003102000081EA 2003 10 20 AUS20030954 220030917G73222576535A FUEL CONTROL CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA MCAULY1C235 1C235LFA GL ENGINE CONTAMINATED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FUEL CONTROL UNIT CONTAMINATED IN IMPACT DIAPHRAGM CHAMBER AND TUBES. VENTURI ALSO CONTAMINATED. 1H71 3O3 ONT3A12 1E10 5 NP12EA 20031020000842003102000084EA 2003 10 20 AUS20030955 220030919G74143170 MAGNETO GULSTM500 500S 0141107SW LYC O540 IO540E1B5 41532EA HARTZLHCA3X HCA3XK2 GL LT ENGINE OUT OF ADJUST W O OTHER RE PARTIAL RPM/PWR LOSS VIBRATION/BUFFET CRCRUISE 1 AUS (AUS) LT ENGINE LOST OIL PRESSURE. INSPECTION FOUND NR 4 PISTON FAILED DUE TO DETONATION. FURTHER INVESTIGATION FOUND THE LT MAGNETO TIMING HAD MOVED FROM 20 DEGREES BTDC TO 35 DEGREES BTDC. MAGNETO GASKET HAD BEEN REPLACED AT PREVIOUS PERIODIC INSPECTION. 1H72 3O3 O 6A1 1E4 5 CP913 20031020000852003102000085SO 2003 10 20 AUS20030956 120030921G322279110003 FORK PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA SNSNCH76E 76EM8 EA NLG FRACTURED W O OTHER O OTHER LDLANDING 1 AUS (AUS) NOSE LANDING GEAR FORK FRACTURED. NLG COLLAPSED CAUSING PROPELLER TO DIG INTO GROUND. 1L71 3O3 O 2A13 E286 5 NP4EA 20031020000872003102000087CE 2003 10 20 AUS20030957 120030923G5753 RIB BEECH 76 76 1153005CE TE FLAP CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT AND RT TRAILING EDGE FLAP SUPPORT RIBS CORRODED AT HINGE BRACKETS. MINOR EXTERNAL CORROSION ON FLAPS RESULTED IN FLAPS BEING DE-SKINNED AND INSPECTED UPON WHICH THE SERIOUS INTERNAL CORROSION WAS FOUND. 1L72 3O A29CE 20031020000882003102000088CE 2003 10 20 AUS20030958 120030924G5753 RIB BEECH 76 76 1153005CE TE FLAP CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT AND RT TRAILING EDGE FLAP SUPPORT RIBS CORRODED AT HINGE BRACKETS. MINOR EXTERNAL CORROSION ON FLAPS RESULTED IN FLAPS BEING DE-SKINNED AND INSPECTED UPON WHICH THE SERIOUS INTERNAL CORROSION WAS FOUND. 1L72 3O A29CE 20031020000902003102000090EU 2003 10 20 AUS20030959 120030919G26117211121100 SMOKE DETECTOR SAAB SF340 340B 7860101EU GE CT7TP CT79B 30030NE ROTOL R375 R3754123F21 NE E/E BAY FAULTY W O OTHER N FALSE WARNING CRCRUISE 1 AUS (AUS) AVIONICS RACK SMOKE WARNING ACTIVATION. INVESTIGATION FOUND NOEVIDENCE OF SMOKE BUT REPLACED THE SMOKE DETECTOR AS APRECAUTION. SUSPECT CAUSED BY DUST CONTAMINATION OF SMOKE DETECTOR. 2L72 4T4 TRTA52EU E8NE 6 CP17NE 20031020000932003102000093NM 2003 10 20 AUS20030960 120030920G5532593614318 SKIN BOEING717 717200 1383700NM RROYCEBR700 BR700715A130 NE VERTICAL STAB CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) VERTICAL STABILISER TIP SKIN CRACKED IN TWO PLACES ON RT SIDE. ONE CRACK WAS APPROXIMATELY 304.8MM IN LENGTH RUNNING VERTICALLY ALONG THE RIVET LINE JUST AFT OF STA YV157 APPROXIMATELY 12.7MM AFT OF HORIZONTAL STABILIZER RUB STRIP. THE SECOND CRACK WAS APPROXIMATELY 25.4MM IN LENGTHAND RUNS HORIZONTALLY ALONG THE LOWER EDGE OF THE SKIN. BOTH CRACKS GO COMPLETELY THROUGH THE SKIN AND ARE VISIBLE ON THE INSIDE OF THE STABILIZER. 2L72 4F4 FTRA6WE E00061EN 20031020001022003102000102SO 2003 10 20 AUS20030961 220030815G8530AEC631397A CYLINDER HEAD CESSNA210 210N 2073453CE CONT O520 IO520L 17032SO MCAULYD3A34 D3A34C404 GL ENGINE CRACKED W O OTHER ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CLCLIMB 1 AUS 1101 (AUS) ENGINE CYLINDER HEAD CRACKED. 1H71 3O3 O 3A21 E5CE 5 CP47GL 20031020001032003102000103CE 2003 10 20 AUS20030962 120030915G575316911000045 HINGE BEECH 23 C24R 1151254CE LYC O360 IO360A1B6 41514EA TE FLAP CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FLAP HINGES CRACKED ON BOTH EDGES. 1L71 3O3 O A1CE 1E10 20031020001052003102000105EU 2003 10 20 AUS20030963 120030916G55205551012001 STRUCTURE PILATSPC12 PC12 7090550EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL ELEVATOR DAMAGED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT ELEVATOR DAMAGED. LT HINGE POINT ON HORIZONTAL STABILISER ANDTRIM ACTUATOR ALSO DAMAGED. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20031020001072003102000107EU 2003 10 20 AUS20030964 120030912G56101172465509 WINDOW BOLKMS117 BK117B1 5626012EU LYC LTS101LTS101750B1 41560NE COCKPIT SEPARATED W O OTHER D INFLIGHT SEPARATION CRCRUISE 1 AUS (AUS) COPILOTS SLIDING WINDOW SEPARATED AND CONTACTED TAIL ROTOR. WINDOW HAD BEEN ACCIDENTALLY CONTACTED BY PASSENGER. CAUSED BYCHANNEL SURROUND DISBONDING AFTER ACCIDENTAL CONTACT. EXAMINATION OF THE CHANNEL SURROUND REVEALED APPROXIMATELY 33 PERCENT OF TOTAL LENGTH (50 PERCENT OF TOP AND BOTTOM SIDES) DISBONDED FROM MAIN WINDOW. THE CHANNEL MATERIAL APPEARED STIFF AND HAD A POWDERY EXTERIOR SURFACE. 1G72 3U3 U H13EU E5NE10 20031020001082003102000108EU 2003 10 20 AUS20030965 120030919G2611721112211000 SMOKE DETECTOR SAAB SF340 340B 7860101EU GE CT7TP CT79B 30030NE ROTOL R375 R3754123F21 NE E/E BAY CONTAMINATED W O OTHER N FALSE WARNING CLCLIMB 1 AUS (AUS) AVIONICS RACK SMOKE DETECTOR ACTIVATED. INVESTIGATION COULD FIND NO EVIDENCE OF SMOKE. SUSPECT DETECTOR CONTAMINATED WITH DUST. 2L72 4T4 TRTA52EU E8NE 6 CP17NE 20031020001092003102000109EU 2003 10 20 AUS20030967 120030917G5711635 SPAR SOCATATB10 TB10TOBAGO 8680696EU LYC O360 O360A1A 41514EA HARTZLHCC2Y HCC2YK1 GL LT WING CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT UPPER AFT REAR SPAR WEB CONTAINED LIGHT EXFOLIATION CORROSIONIN AREA ADJACENT TO MAIN LANDING GEAR. FOUND DURING INVESTIGATION FOLLOWING CORROSION IN RT WING SPAR. SEE MDR 03/0900. 1L71 3O3 ORTA51EU E286 5 CP920 20031020001102003102000110EA 2003 10 20 AUS20030968 220030923G8520LW16812 TAPPET CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA MCAULY1C160 1C160DTM GL ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) TAPPETS (8OFF) CRACKED AROUND INSIDE OF PLUNGER BODY. 1H71 3O3 ONT3A12 E274 5 NP910 20031020001122003102000112SO 2003 10 20 AUS20030969 120030926G214088D951 TUBE PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2 GL HEATER CRACKED W O OTHER B SMOKE/FUMES/ODORS/SPARKS TXTAXI/GRND HDL 1 AUS 105 (AUS) CABIN HEATER COMBUSTION TUBE CRACKED AND BULGING. 1L72 3O3 O A20SO E14EA 5 CP33EA 20031020001132003102000113SO 2003 10 20 AUS20030970 120030919G32134025700 TORQUE LINK PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2 GL LT MLG BROKEN W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT MAIN LANDING GEAR TORQUE LINK LUG BROKEN. 1L72 3O3 O A20SO E14EA 5 CP33EA 20031020001142003102000114CE 2003 10 20 AUS20030971 120030829G2910572700219 LINE CESSNA441 441 2076020CE HYD SYSTEM CRACKED W K NONE K FLUID LOSS ININSP/MAINT 1 AUS (AUS) HYDRAULIC LINE LOCATED IN LT WING ADJACENT TO RESERVOIR CRACKED AND LEAKING. 1L72 3T RTA28CE 20031020001212003102000121NM 2003 10 20 AUS20030972 120030920G383026513116 DRAIN VALVE BOEING737 73733A 1384673NM CFMINTCFM56 CFM563C 13802EU FWD LAVATORY LEAKING W K NONE K FLUID LOSS ININSP/MAINT 1 AUS (AUS) FORWARD TOILET DRAIN VALVE LEAKING. FOUND DURING INSPECTION IAW AD/737/25. 2L72 4F4 FRTA16WE E21EU 20031020001222003102000122SW 2003 10 20 AUS20030973 120030915G3233ED12758 PIN GULSTM680 680FL 0141608SW LYC O720 IO720B1B 41546EA HARTZLHCB3Z HCB3Z302 GL MLG CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT AND RT MAIN LANDING GEAR ACTUATOR CLEVIS PINS CRACKED. 1H72 3O3 O 2A4 1E15 5 CP907 20031020001242003102000124SW 2003 10 20 AUS20030974 120030815G3233ED12758 PIN GULSTM500 500S 0141107SW LYC O540 IO540E1B5 41532EA HARTZLHCA3V HCA3VK2 GL MLG CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT AND RT MAIN LANDING GEAR ACTUATOR CLEVIS PINS CRACKED. 1H72 3O3 O 6A1 1E4 5 CP6EA 20031020001262003102000126SW 2003 10 20 AUS20030975 120030916G3233ED12758 PIN GULSTM500 500S 0141107SW LYC O540 IO540E1B5 41532EA HARTZLHCC3Y HCC3YR2 NE MLG CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT AND RT MAIN LANDING GEAR ACTUATOR CLEVIS PINS CRACKED. 1H72 3O3 O 6A1 1E4 5 CP25EA 20031020001272003102000127SW 2003 10 20 AUS20030976 120030903G3233ED12758 PIN GULSTM500 500S 0141107SW LYC O540 IO540E1B5 41532EA HARTZLHCC3Y HCC3YR2 NE MLG CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT AND RT MAIN LANDING GEAR ACTUATOR CLEVIS PINS CRACKED. 1H72 3O3 O 6A1 1E4 5 CP25EA 20031020001282003102000128CE 2003 10 20 AUS20030977 120030918G28222B729 PUMP CESSNA404 404CESSNA 2075901CE CONT O520 GTSIO520M 17032SO MCAULY3FF32 3FF32C501 GL FUEL BOOST FAILED W O OTHER O OTHER NRNOT REPORTED 1 AUS (AUS) LT AND RT AUXILIARY FUEL BOOST PUMP PRESSURES BELOW REQUIRED LIMITS. ONE OF THE REPLACEMENT PUMPS ALSO HAD LOW FUEL PRESSURE. 1L72 3O3 O A25CE E7CE 5 CP45GL 20031020001302003102000130NM 2003 10 20 AUS20030978 120030921G215078279018 ACM DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE CABIN COOLING FAILED W O OTHER O OTHER NRNOT REPORTED 1 AUS 3998 (AUS) AIR CYCLE MACHINE FAILED. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20031020001322003102000132CE 2003 10 20 AUS20030979 120030924G5753 RIB BEECH 76 76 1153005CE TE FLAP CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT AND RT TRAILING EDGE FLAP SUPPORT RIBS CORRODED AT HINGE BRACKETS. MINOR EXTERNAL CORROSION ON FLAPS RESULTED IN FLAPS BEING DESKINNED AND INSPECTED UPON WHICH THE SERIOUS INTERNAL CORROSION WAS FOUND. 1L72 3O A29CE 20031020001332003102000133CE 2003 10 20 AUS20030980 120030924G5753 RIB BEECH 76 76 1153005CE TE FLAP CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT AND RT TRAILING EDGE FLAP SUPPORT RIBS CORRODED AT HINGE BRACKETS. MINOR EXTERNAL CORROSION ON FLAPS RESULTED IN FLAPS BEING DESKINNED AND INSPECTED UPON WHICH THE SERIOUS INTERNAL CORROSION WAS FOUND. 1L72 3O A29CE 20031020001352003102000135CE 2003 10 20 AUS20030981 120030924G5753 RIB BEECH 76 76 1153005CE TE FLAP CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT AND RT TRAILING EDGE FLAP SUPPORT RIBS CORRODED AT HINGE BRACKETS. MINOR EXTERNAL CORROSION ON FLAPS RESULTED IN FLAPS BEING DESKINNED AND INSPECTED UPON WHICH THE SERIOUS INTERNAL CORROSION WAS FOUND. 1L72 3O A29CE 20031020001362003102000136CE 2003 10 20 AUS20030982 120030925G5753 RIB BEECH 76 76 1153005CE TE FLAP CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT AND RT TRAILING EDGE FLAP SUPPORT RIBS CORRODED AT HINGE BRACKETS. MINOR EXTERNAL CORROSION ON FLAPS RESULTED IN FLAPS BEING DESKINNED AND INSPECTED UPON WHICH THE SERIOUS INTERNAL CORROSION WAS FOUND. 1L72 3O A29CE 20031020001382003102000138SO 2003 10 20 AUS20030983 220030520G8530SA10204 EXHAUST VALVE CESSNA172 172E 2072412CE CONT O300 O300B 17022SO MCAULY1A170 1A170DM GL ENGINE STICKING W O OTHER E VIBRATION/BUFFET CLCLIMB 1 AUS 264 (AUS) ENGINE EXHAUST VALVE STUCK OPEN. TWO OTHER VALVES ALSO STICKING.DURING RECTIFICATION FOR THE STICKING VALVES IT WAS NOTICED THAT THE CARBURETTOR BUTTERFLY SHAFT TO BUSHING FITTING SEEMED EXCESSIVE (EXCESSIVE END FLOAT AND AXIAL WEAR). 1H71 3O3 ONT3A12 E253 5 NP857 20031020001392003102000139EU 2003 10 20 AUS20030984 120030922G5610NP1701022 WINDSHIELD BAC 146 146100A 1500260EU LYC ALF502ALF502R5 41580NE COCKPIT CRACKED W O OTHER O OTHER CRCRUISE 1 AUS 15409 (AUS) COPILOTS B-WINDSHIELD OUTER PLY CRACKED. 2H74 4F4 FRTA49EU E6NE 20031020001412003102000141WP 2003 10 20 AUS20030985 120030919G6320 FREEWHEEL UNIT HUGHES HUGHES269 269A 4470402WP LYC O360 HIO360B1A 41514EA M/R GEARBOX LOOSE W K NONE O OTHER ININSP/MAINT 1 AUS 1265545 (AUS) FREEWHEEL UNIT LOOSE. 1G71 3O3 O 4H12 1E10 20031106000272003110600027EU 2003 11 6 AUS20030986 220030919G72301590M2P01 FAN BLADE BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU COMPRESSOR CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 1228 (AUS) NR 2 ENGINE FAN BLADE FRACTURE SURFACE CONTAINED EVIDENCE OF FATIGUE CRACKING. ENGINE AND FAN BLADE HAD BEEN INVOLVED IN A BAT STRIKE AND THE ENGINE HAD BEEN REMOVED FOR WORKSHOP INSPECTION. 2L72 4F4 FRTA16WE E21EU 20031106000282003110600028NM 2003 11 6 AUS20030987 120030919G243423088002A STARTER GEN DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE DC SYSTEM FAULTY W O OTHER H ELECT. POWER LOSS-50 PC CLCLIMB 1 AUS 1191 (AUS) NR 1 DC STARTER-GENERATOR SUSPECT FAULTY. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20031106000292003110600029NM 2003 11 6 AUS20030988 120030919G273065C2546515 CONTROL UNIT BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU ELEVATOR FAULTY W C ABORTED TAKEOFF F FLT CONT AFFECTED TOTAKEOFF 1 AUS (AUS) ELEVATOR FEEL AND CENTERING UNIT SPRING BROKEN. 2L72 4F4 FRTA16WE E21EU 20031106000302003110600030NM 2003 11 6 AUS20030989 120030922G2820316A101045 LINE BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU FUEL SYSTEM LEAKING W K NONE K FLUID LOSS ININSP/MAINT 1 AUS (AUS) NR 1 ENGINE FUEL FEED LINE FROM FRONT SPAR TO PYLON LEAKING. LINE WAS WORN IN AREA OF O RING SEAL. 2L72 4F4 FRTA16WE E21EU 20031106000312003110600031NM 2003 11 6 AUS20030990 120030921G5330 SKIN BOEING747 747* NM GE CF6 CF680C2* GL FUSELAGE DAMAGED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FUSELAGE SKIN CONTAINED SCORES AND GOUGES AT BUTT JOINTS BS2181,BS1961, BS1741, BS1480, STRINGER 4L TO STRINGER 45. 2L74 4F4 FRTA20WE E23EA 20031106000322003110600032NM 2003 11 6 AUS20030991 120030923G2910S332A00513 FITTING BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU HYD SYSTEM SPLIT W O OTHER K FLUID LOSS NRNOT REPORTED 1 AUS (AUS) NR 2 ENGINE HYDRAULIC PUMP PRESSURE LINE QUICK DISCONNECT FITTING SPLIT. 2L72 4F4 FRTA16WE E21EU 20031106000332003110600033WP 2003 11 6 AUS20030992 220030820G72608968085 GEAR SWRNGNSA227 SA227* SW GARRTTTPE331TPE33112UHR WP MCAULY4HFR344HFR34C652 NE ENGINE MISREPAIRED W K NONE W INADEQUATE Q C ININSP/MAINT 1 AUS (AUS) TACHOMETER GEAR HAD UNAPPROVED REPAIR CARRIED OUT IN THREADED AREA. LACK OF INTERFERENCE FIT BETWEEN GEAR AND BEARING PN 358272. PN 3103580-3 NR 2 IDLER GEAR HOUSING SUSPECT UNAPPROVED PART. PERSONNEL/MAINTENANCE ERROR. UNAPPROVED PART. UNAPPROVED REPAIR. 2L72 4T4 TRTA5SW E4WE 6 C3PNE 20031106000352003110600035NE 2003 11 6 AUS20030993 220030922G7530 CONTROLLER BOEING767 767* NM RROYCERB211 RB211* 54555NE COMPRESSOR BLEEDFAULTY W O OTHER ERJVIBRATION/BUFFET PARTIAL RPM/PWR LOSS WARNING INDICATION CLCLIMB 1 AUS (AUS) RT ENGINE STALLED. ENGINE MOVED INTO RED ZONE (115 PERCENT N1). INVESTIGATION FOUND VIGV CONTROLLER FAULTY. LT AND RT VIGV ACTUATORS ALSO FAULTY. 2L72 4F4 FRTA1NM A12EU 20031110000012003111000001WP 2003 11 10 AUS20030994 220030820G72603103580 HOUSING SWRNGNSA227 SA227* SW GARRTTTPE331TPE33112UHR WP MCAULY4HFR344HFR34C652 NE GEARBOX WRONG PART W K NONE W INADEQUATE Q C ININSP/MAINT 1 AUS (AUS) ENGINE IDLER GEAR HOUSING SUSPECT UNAPPROVED PART. HOUSING WAS A LOOSE FIT ONTO THE BACK OF THE DIAPHRAGM. PERSONNEL/MAINTENANCE ERROR. UNAPPROVED PART. SEE ALSO M OR D 03/0992 FOR ADDITIONAL INFORMATION. 2L72 4T4 TRTA5SW E4WE 6 C3PNE 20031106000532003110600053NM 2003 11 6 AUS20030995 120030518G2761A44700009 ACTUATOR DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE DRAG CONTROL CRACKED W K NONE K FLUID LOSS ININSP/MAINT 1 AUS (AUS) LT WING OUTBOARD ROLL SPOILER ACTUATOR LEAKING. INVESTIGATION FOUND ACTUATOR CRACKED. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20031106001742003110600174NE 2003 11 6 AUS20030996 220030918G7530 ACTUATOR BOEING737 737376 NM GE CFM56 CFM563B1 13802NE COMPRESSOR BLEEDBINDING W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) NR 1 ENGINE VARIABLE BLADE VALVE ACTUATORS AT THE 4 O'CLOCK AND 5 O'CLOCK POSITIONS BINDING AND INTERNAL HEXAGONAL DRIVES WORN. 2L72 4F4 FRTA16WE E2GL 20031107000022003110700002SO 2003 11 7 AUS20030997 220030920G7310 HOSE CESSNA206 U206G 2073356CE CONT O520 IO520F 17032SO MCAULY3A32C D3A32C90 GL ENGINE FUEL LOOSE W O OTHER KB FLUID LOSS SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 AUS (AUS) STRONG SMELL OF FUEL IN COCKPIT. INVESTIGATION FOUND A LOOSE HOSE NUT CONNECTION ON THE FCU AND A LOOSE HOSE ON THE FUEL STRAINER ASSEMBLY. PERSONNEL/MAINTENANCE ERROR. 1H71 3O3 O A4CE E5CE 5 CP21EA 20031107000032003110700003SW 2003 11 7 AUS20030998 120030917G6220206010101129 YOKE BELL BELL 206 206B 1181511SW ALLSN 250C 250C20 03013GL MAIN ROTOR HEAD DAMAGED W K NONE O OTHER ININSP/MAINT 1 AUS 1059 JILM11383 (AUS) MAIN ROTOR BLADE GRIP BEARINGS CAUSED BRINELLING ON YOKE ARMS. 1G71 3U3 U H2SW E4CE 20031107000042003110700004NM 2003 11 7 AUS20030999 120030930G2760NAS16126 O-RING DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE DRAG CONTROL SYSFAILED W O OTHER K FLUID LOSS CRCRUISE 1 AUS (AUS) GROUND SPOILER PRESSURE LINE TO OUTBOARD GROUND ACTUATOR TEE FITTING O-RING BLEW OUT. LOCK NUT WAS FOUND TO BE LOOSE. LOSS OF HYDRAULIC FLUID. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20031107000052003110700005SO 2003 11 7 AUS20031000 120030930G5346 STRUCTURE PIPER PA36 PA36300 7103612SO LYC O720 IO720D1C 41546EA HARTZLHCC2Y HCC2YF1 GL NACELLE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) AIRCRAFT STRUCTURE CRACKED IN TOP RT ENGINE MOUNT ATTACHMENT AREA WHEN LOOKING FORWARD. FOUND DURING INSPECTION IAW AD/PA36/20AMDT1. 1L71 3O3 O A10SO 1E15 5 CP920 20031107000062003110700006NM 2003 11 7 AUS20031001 120030926G3010 ANTI-ICE SYSTEM BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU RT WING FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT WING ANTI-ICE SYSTEM OPERATING WITH ANTI-ICE SWITCH IN THE OFF POSITION. 2L72 4F4 FRTA16WE E21EU 20031107000072003110700007NM 2003 11 7 AUS20031002 120030928G3520 HOSE BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU PASSENGER OXYGENDAMAGED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) PASSENGER SERVICE UNIT (PSU) OXYGEN HOSE SEVERED AT OXYGEN GENERATOR FITTING ON THE PSU. 2L72 4F4 FRTA16WE E21EU 20031107000422003110700042EA 2003 11 7 AUS20031003 220030929G7322D2782 CONTROL BOX ROBSINR44 R44 7640120WP LYC O540 O540F1B5 41532EA GOVERNOR FAILED W K NONE F FLT CONT AFFECTED CRCRUISE 1 AUS (AUS) GOVERNOR CONTROL BOX FAILED. 1G71 3O3 O H11NM E295 20031107000432003110700043NM 2003 11 7 AUS20031004 120030928G2424948F4583 GCU BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU AC SYS FAULTY W O OTHER H ELECT. POWER LOSS-50 PC TOTAKEOFF 1 AUS (AUS) APU GENERATOR CONTROL UNIT (GCU) FAULTY. 2L72 4F4 FRTA16WE E21EU 20031107000442003110700044NM 2003 11 7 AUS20031005 120030928G2497 CONNECTOR BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU AC POWER BURNED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) NR 1 GENERATOR DISCONNECT PLUG CONNECTOR BURNT. 2L72 4F4 FRTA16WE E21EU 20031107000452003110700045NM 2003 11 7 AUS20031006 120030901G3260 SENSOR DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE MLG OUT OF ADJUST W O OTHER N FALSE WARNING NRNOT REPORTED 1 AUS (AUS) LT MAIN LANDING GEAR REAR DOOR SENSOR OUT OF ADJUSTMENT. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20031107000462003110700046EA 2003 11 7 AUS20031007 220031001G7414S6LSC204T MAGNETO ROBSINR44 R44 7640120WP LYC O540 O540F1B5 41532EA ENGINE FAULTY W O OTHER E VIBRATION/BUFFET NRNOT REPORTED 1 AUS (AUS) MAGNETO FAULTY. 1G71 3O3 O H11NM E295 20031107000472003110700047SO 2003 11 7 AUS20031008 220030917G7310124F0014CR0140 HOSE CESSNA206 U206G 2073356CE CONT O520 IO520F 17032SO HARTZLHCJ3Y PHCJ3YF1 GL ENGINE FUEL LOOSE W K NONE K FLUID LOSS ININSP/MAINT 1 AUS (AUS) FUEL PUMP TO FCU HOSE LOOSE AND LEAKING. 1H71 3O3 O A4CE E5CE 5 CP36EA 20031107000482003110700048NM 2003 11 7 AUS20031009 120030928G5210 ROLLER BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU PAX DOOR FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) DOOR L1 HAD THE LATCHING ROLLERS OUTSIDE OF THE LATCHING CAM WITH THE DOOR CLOSED. 2L72 4F4 FRTA16WE E21EU 20031107000492003110700049EU 2003 11 7 AUS20031010 120031002G5610NP1701012 WINDSHIELD BAC 146 146100A 1500260EU LYC ALF502ALF502R3A 41580NE COCKPIT CRACKED W O OTHER O OTHER CLCLIMB 1 AUS (AUS) RT WINDSCREEN (A) PANEL CRACKED IN OUTER PLY. 2H74 4F4 FRTA49EU E6NE 20031107000502003110700050SO 2003 11 7 AUS20031011 120030930G2730PE6700255 CHAIN EMB 120 EMB120 3260201SO PWA 118 PW118A NE HAMSTD14RF 14RF9 NE ELEVATOR CONTROLBROKEN W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) ELEVATOR CONTROL CHAIN BROKEN. 2L72 4T4 TRTA31SO E20NE 6 CP11NE 20031107000512003110700051NE 2003 11 7 AUS20031012 320030809G611166071326610 BLADE SAAB SF340 SF340A 7850100EU GE CT7TP CT79B 30030NE ROTOL R389 R3894123F25 NE PROPELLER CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 2959 (AUS) PROPELLER BLADE BUTT CRACKED IN OUTER BLADE SLEEVE. 2L72 4T4 TRTA52EU E8NE 6 CP30NE 20031107000522003110700052EU 2003 11 7 AUS20031013 120031002G3260602EN556B SWITCH REIMS 406 F406 7535723EU PWA PT6 PT6A112 52043NE MCAULY3G34C73GFR34C701 GL MLG FAULTY W O OTHER O OTHER TOTAKEOFF 1 AUS (AUS) RT MAIN LANDING GEAR UPLOCK SWITCH FAILED. 1L72 3T3 TRTA54EU E4EA 5 CP60GL 20031107000532003110700053NM 2003 11 7 AUS20031014 120031003G3213 SEAL BOEING767 767338 1385151NM GE CF6 CF680C2* GL MLG STRUT LEAKING W K NONE K FLUID LOSS ININSP/MAINT 1 AUS (AUS) LT MAIN LANDING GEAR OLEO STRUT SEALS LEAKING. 2L72 4F4 FRTA1NM E23EA 20031107000542003110700054NM 2003 11 7 AUS20031015 120031002G2760BACB28BA1012063 BUSHING BOEING737 737* NM GE CFM56 CFM56* 13802NE DRAG CONTROL SYSMISSING W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) GROUND SPOILER BUSHES (2 OFF) MISSING FROM NUT END OF NR 1 AND NR 12 SPOILERS. THIS IS A NEW AIRCRAFT AND WAS DELIVERED FROM THE FACTORY WITH THE BUSHINGS MISSING. MANUFACTURING ERROR. 2L72 4F4 FRTA16WE E2GL 20031107000562003110700056SW 2003 11 7 AUS20031016 120031005G2497 WIRE SWRNGNSA227 SA227AC 8780603SW GARRTTTPE331TPE33111U 01514WP ROTOL R321 R321482F8 GL HARNESS WORN W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) CHAFED WIRES WITHIN LOOM LOCATED IN RT ENGINE NACELLE. 2L72 4T4 TRTA8SW E4WE 6 CP61GL 20031107000572003110700057NM 2003 11 7 AUS20031017 120031006G2121732591C COOLING FAN BOEING767 767338 1385151NM GE CF6 CF680C2* GL AIR DISTRIBUTIONFAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS DEDESCENT 1 AUS 2339 (AUS) FORWARD EQUIPMENT COOLING FAN FAILED. 2L72 4F4 FRTA1NM E23EA 20031107000582003110700058SO 2003 11 7 AUS20031018 120031003G2730710563 SPRING PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2 GL ELEVATOR CONTROLBROKEN W O OTHER F FLT CONT AFFECTED CLCLIMB 1 AUS (AUS) ELEVATOR DOWN SPRING BROKEN APPROXIMATELY FIVE COILS FROM THE FORWARD ATTACHMENT MOUNTING POINTS. INSPECTION USING AN EIGHT POWER MAGNIFYING GLASS REVEALS INTERGRANNULAR CORROSION. 1L72 3O3 O A20SO E14EA 5 CP33EA 20031107000602003110700060NM 2003 11 7 AUS20031019 120031003G32463515 BOLT BOEING747 747438 NM RROYCERB211 RB211* 54555NE NR 2 WHEEL SHEARED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) NR 2 MAIN WHEEL ASSEMBLY TIE BOLT (1OFF) SHEARED AND MISSING. 2L74 4F4 FRTA20WE A12EU 20031107000742003110700074NM 2003 11 7 AUS20031020 120031003G2520207810112561 SEAT BELT BOEING747 747438 NM RROYCERB211 RB211524G19 NE CABIN FOULED W O OTHER O OTHER CRCRUISE 1 AUS (AUS) PASSENGERS SEAT BELT LOCATED AT 11K BECAME JAMMED BETWEEN SEAT DURING FLIGHT CAUSING SKYBED' SEAT TO FAIL ELECTRICALLY. 2L74 4F4 FRTA20WE E30NE 20031107000752003110700075NE 2003 11 7 AUS20031021 220031007G7250BRH19759 PLUG RROYCE BOEING717 717200 1383700NM RROYCEBR700 BR700715A130 NE TURBINE SECTION MISSING W K NONE O OTHER ININSP/MAINT 1 AUS 41131191 (AUS) RT ENGINE HAD FIVE HP TURBINE STAGE 1 COVER PLATE LOCKING PLUGS PN BRH19759 AND THEIR RESPECTIVE RETAINING STRIPS PN BRH19728 MISSING. FOUND DURING BOROSCOPE INSPECTION IAW RR SB-BR700-72-900330. 2L72 4F4 FTRA6WE E00061EN 20031107000762003110700076NE 2003 11 7 AUS20031022 220031006G7250BHR19759 PLUG RROYCE BOEING717 717200 1383700NM RROYCEBR700 BR700715A130 NE TURBINE SECTION MISSING W K NONE O OTHER ININSP/MAINT 1 AUS 41131188 (AUS) LT ENGINE HAD THREE HP TURBINE STAGE 1 COVER PLATE LOCKING PLUGS PN BRH19759 AND THEIR RESPECTIVE RETAINING STRIPS PN BRH19728 MISSING. FOUND DURING BOROSCOPE INSPECTION IAW RR SB-BR700-72-900330. 2L72 4F4 FTRA6WE E00061EN 20031107000772003110700077NE 2003 11 7 AUS20031023 220031007G7250BHR19729 PLUG RROYCE RROYCEBR700 BR700715A130 NE TURBINE SECTION MISSING W K NONE O OTHER ININSP/MAINT 1 AUS 41131119 (AUS) ENGINE HAD FIVE HP TURBINE STAGE 1 COVER PLATE LOCKING PLUGS PN BRH19759 AND THEIR RESPECTIVE RETAINING STRIPS PN BRH19728 MISSING. FOUND DURING BOROSCOPE INSPECTION IAW RR SB-BR700-72-900330. ENGINE WAS A SPARE UNIT AND NOT FITTED TO AN AIRCRAFT. 4 F E00061EN 20031107000782003110700078EU 2003 11 7 AUS20031024 120031004G3251AIR860021 SELECTOR VALVE BAG JETSTMJETSTM3107 1500215EU GARRTTTPE331TPE33110U 01514WP ROTOL R333 R333482F12 GL STEERING UNIT MALFUNCTIONED W O OTHER O OTHER TXTAXI/GRND HDL 1 AUS LK9004521 (AUS) STEERING SELECTOR VALVE INTERNAL FAULT. 2L72 4T4 TRTBA15CAA E4WE 6 CP61GL 20031107000792003110700079EU 2003 11 7 AUS20031026 120031009G56107256100501 WINDSHIELD SAAB SF340 340B 7860101EU GE CT7TP CT79B 30030NE ROTOL R375 R3754123F21 NE COCKPIT CRACKED W O OTHER O OTHER CLCLIMB 1 AUS (AUS) LT WINDSHIELD CRACKED FROM BOTTOM RT SIDE. THE CRACK QUICKLY EXTENDED THE WIDTH OF THE WINDSHIELD. INVESTIGATION FOUND THAT THE WINDSHIELD WAS CRACKED IN THE OUTER NON-STRUCTURAL LAYER OF GLASS. 2L72 4T4 TRTA52EU E8NE 6 CP17NE 20031107000802003110700080EU 2003 11 7 AUS20031027 220031001G7250 TURBINE BLADES BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU TURBINE SECTION CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 40232 (AUS) NUMEROUS HPT BLADE CRACKS (RADIAL TIP CRACK TURNING AXIAL) WERE FOUND WITH THE POTENTIAL FOR BLADE TIP CORNER SEPARATION. FOUND DURING ROUTINE BOROSCOPE INSPECTION. 2L72 4F4 FRTA16WE E21EU 20031107000812003110700081NE 2003 11 7 AUS20031028 220031004G7200 ENGINE BOEING767 767* NM RROYCERB211 RB211* 54555NE RIGHT MALFUNCTIONED W C ABORTED TAKEOFF E VIBRATION/BUFFET TOTAKEOFF 1 AUS (AUS) RT ENGINE FAILED TO ACHIEVE TAKEOFF POWER. THRUST SHORTFALL REQUIRED WAS 1.73 BUT ONLY 1.71 WAS ACHIEVED WITH ASSOCIATED EICAS MESSAGE RT ENGINE RPM LIMIT. TAKE OFF WAS ABORTED AT 110 KNOTS GROUND SPEED. 2L72 4F4 FRTA1NM A12EU 20031107000822003110700082CE 2003 11 7 AUS20031029 120030916G5340642985 BRACKET CESSNA404 404CESSNA 2075901CE CONT O520 GTSIO520M 17032SO MCAULY3FF32 3FF32C501 GL DC GENERATOR CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) ALTERNATOR CAPACITOR BRACKET FAILED ALLOWING CAPACITOR TO SHORT CIRCUIT ON POSITIVE PLATE. 1L72 3O3 O A25CE E7CE 5 CP45GL 20031107000832003110700083EA 2003 11 7 AUS20031030 220031002G7200 ENGINE BEECH 1900 1900C 1154161CE PWA PT6 PT6A65B 52043EA HARTZLHCB4M HCB4MP3 GL LEFT FLUCTUATES W C ABORTED TAKEOFF E VIBRATION/BUFFET TOTAKEOFF 1 AUS (AUS) LT ENGINE TORQUE FLUCTUATIONS. FUEL FLOW, N1 AND ITT STABLE. GROUND RUN CARRIED OUT. UNABLE TO FAULT. DEFECT NOT CONFIRMED. 2L72 4T4 TRTA24CE E4EA 6 CP56GL 20031107000842003110700084CE 2003 11 7 AUS20031031 120030925G3222AN557 BOLT CESSNA310 310R 2074245CE CONT O520 IO520M 17032SO MCAULY3AF32C3AF32C87 GL NLG SEPARATED W O OTHER O OTHER NRNOT REPORTED 1 AUS (AUS) NOSE WHEEL AXLE BOLT NUT SEPARATED ALLOWING AXLE CAP TO FALL OFF THE NOSE WHEEL ASSEMBLY. DURING LANDING THE NOSE WHEEL CAME OUT OF THE FORK AND WEDGED UNDER THE NOSE WHEEL FAIRING. THE NOSE WHEEL TIRE HAD BEEN CHANGED APPROXIMATELY 10 HOURS PREVIOUSLY. 1L72 3O3 O 3A10 E5CE 5 CP22EA 20031107000922003110700092GL 2003 11 7 AUS20031032 320030915G6114E6605 HUB CESSNA210 210M 2073450CE CONT O520 IO520L 17032SO MCAULY3A32C D3A32C88 GL PROPELLER CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 987 772145 (AUS) PROPELLER HUB CRACKED IN AREA OF FOURTH THREAD AT THE 2 O'CLOCK POSITION. CRACK LENGTH APPROXIMATELY 25.4MM (1IN). 1H71 3O3 O 3A21 E5CE 5 CP21EA 20031107000932003110700093NM 2003 11 7 AUS20031033 120031004G2810EC776 SEALANT BOEING727 7272J4 1384006NM PWA JT8 JT8D17 52049NE FUEL CELL DETERIORATED W K NONE K FLUID LOSS ININSP/MAINT 1 AUS (AUS) NR 2 FUEL TANK LEAKING. INVESTIGATION FOUND TANK WING TO CENTERBOX LOWER ATTACHMENT FITTING INBOARD FASTENER SEALANT LIFTING. REMOVED SEALANT FOUND TO HAVE INCLUSIONS AND VOIDS RESULTING FROM IMPROPER CLEANING AT PREVIOUS SEALANT APPLICATION. 2L73 4F4 FRTA3WE E2EA 20031107000942003110700094SO 2003 11 7 AUS20031034 120031013G5514AN17532A BOLT PIPER PA23 PA23250 7102308SO LYC O540 IO540C4B5 41532EA HARTZLHCE2Y HCE2YK2 GL HORIZONTAL STAB CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) STABILATOR BALANCE WEIGHT ATTACHMENT BOLTS AND ACTUATOR COLLAR ATTACHMENT BOLTS CORRODED (RUSTED). BOLT PART NUMBERS PN AN175-32A AND PN AN175-33A. 1L72 3O3 O 1A10 1E4 5 CP9EA 20031107000952003110700095EA 2003 11 7 AUS20031035 220031007G73222576535A FUEL CONTROL CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA MCAULY1C235 1C235LFA GL ENGINE CONTAMINATED W K NONE O OTHER ININSP/MAINT 1 AUS 323 70255902 (AUS) FUEL CONTROL UNIT IMPACT DIAPHRAGM CHAMBER CONTAMINATED WITH FUEL/OIL. 1H71 3O3 ONT3A12 1E10 5 NP12EA 20031107000962003110700096CE 2003 11 7 AUS20031036 120030925G5520 RIVET CESSNA441 441 2076020CE GARRTTTPE331TPE33112UA 01514WP MCAULY4HFR344HFR34C653 NE ELEVATOR LOOSE W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT HORIZONTAL STABILIZER ELEVATOR HINGE ATTACHMENT RIVETS (3OFF) LOOSE. RIVETS WERE CHERRY-MAX TYPE. FOUND DURING INSPECTION IAW AD/CESSNA400/012 AMDT3. 1L72 3T4 TRTA28CE E4WE 6 C3PNE 20031107000972003110700097NE 2003 11 7 AUS20031037 220031013G7261 ENGINE BAC 146 146200A 1500266EU LYC ALF502ALF502R5 41580NE LEAKING W O OTHER EK VIBRATION/BUFFET FLUID LOSS CRCRUISE 1 AUS (AUS) ENGINE SHUT DOWN DUE TO TOTAL LOSS OF OIL. DETAILED INVESTIGATION COULD FIND NO SOURCE OF LEAK. ENGINE HAD ONLY BEEN FITTED THREE DAYS PREVIOUSLY FOLLOWING HSI SO WAS REMOVED AND FORWARDED TO MANUFACTURER FOR FURTHER INVESTIGATION/REPAIR. 2H74 4F4 F A49EU E6NE 20031107001102003110700110NM 2003 11 7 AUS20031038 120031007G7603T3A4 CONTROL CABLE RROYCE BOEING747 747338 NM RROYCERB211 RB211524* NE POWER LEVER WORN W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) NO3 ENGINE THRUST CABLE T3A-4 WORN AT LOCATION ILES 564. FOUNDDURING INSPECTION IAW EI 743-076-0002R02 (FAA AD 2000-05-30 AND CASA AD/B747/229). 2L72 4F4 FRTA20WE E12EU 20031107001112003110700111NM 2003 11 7 AUS20031039 120031010G3244161U00011 TIRE BOEING747 747438 NM RROYCERB211 RB211524* NE MLG DEFLATED W O OTHER O OTHER CLCLIMB 1 AUS 873 (AUS) LT BODY GEAR NR 3 AFT OUTBOARD TIRE DEFLATED. 2L74 4F4 FRTA20WE E12EU 20031107001122003110700112NM 2003 11 7 AUS20031040 120031012G5753 PLATE BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU TE FLAP SEPARATED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT INBOARD FLAP INBOARD SEAL PLATE SEPARATED. 2L72 4F4 FRTA16WE E21EU 20031107001132003110700113NM 2003 11 7 AUS20031041 120031013G5280 STRUCTURE BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU MLG DOOR DAMAGED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT MAIN LANDING GEAR DOOR DAMAGED. FURTHER INVESTIGATION FOUND LT MAIN LANDING GEAR BRAKE SWIVEL BRACKET AND OUTER DOOR ATTACHMENT FITTING LOOSE WITH TWO BOLTS SHEARED AND ANOTHER TWO BOLTS LOOSE. 2L72 4F4 FRTA16WE E21EU 20031110000062003111000006EU 2003 11 10 AUS20031043 120031012G24105243212137 DRIVE SHAFT PILATSPC12 PC12 7090550EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL GENERATOR SHEARED W O OTHER H ELECT. POWER LOSS-50 PC CRCRUISE 1 AUS 248471 (AUS) NR 2 GENERATOR DRIVESHAFT SHEARED. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20031110000072003111000007SO 2003 11 10 AUS20031044 120030930G27501642300 BELLCRANK PIPER PA23 PA23160 7102304SO LYC O320 O320D1A 41508EA HARTZLHC82X HC82XL2 GL TE FLAPS CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FLAP BELLCRANK CORRODED. FOUND DURING INSPECTION IAW AD/PA23/50. 1L72 3O3 O 1A10 E274 5 CP878 20031110000082003111000008SO 2003 11 10 AUS20031045 120030930G27501763400 TORQUE TUBE PIPER PA23 PA23160 7102304SO LYC O320 O320D1A 41508EA HARTZLHC82X HC82XL2 GL TE FLAP WORN W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FLAP TORQUE TUBE WORN BEYOND LIMITS. FOUND DURING INSPECTION IAWAD/PA23/89. 1L72 3O3 O 1A10 E274 5 CP878 20031110000092003111000009NM 2003 11 10 AUS20031046 120031014G2510 SEAT BOEING737 737* NM GE CFM56 CFM567B24 NE COCKPIT COLLAPSED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) CAPTAINS SEAT VERTICAL ADJUSTMENT COLLAPSED. 2L72 4F4 FRTA16WE E00055EN 20031110000102003111000010 2003 11 10 AUS20031047 420031014G8300L168468A GEAR PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2 GL ACCESSORY DRIVE BROKEN W O OTHER EY VIBRATION/BUFFET ENGINE STOPPAGE CRCRUISE 1 AUS (AUS) RT ENGINE FAILED. INVESTIGATION FOUND ACCESSORY CASE DRIVE GEARS WITH BROKEN TEETH. 1L72 3O3 O A20SO E14EA 5 CP33EA 20031110000112003111000011 2003 11 10 AUS20031048 420031013G2370 CVR SAAB SF340 340B 7860101EU GE CT7TP CT79B 30030NE ROTOL R375 R3754123F21 NE COCKPIT FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) COCKPIT VOICE RECORDER BULK ERASE FUNCTION INOPERATIVE. FOUND DURING INSPECTION IAW AD/REC/1 REQUIREMENT 2. 2L72 4T4 TRTA52EU E8NE 6 CP17NE 20031110000122003111000012NM 2003 11 10 AUS20031049 120031013G2437522778 MONITOR DHAV DHC8 DHC8315 2809010NM PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE DC INDICATING SYFAULTY W O OTHER H ELECT. POWER LOSS-50 PC CLCLIMB 1 AUS 7891 (AUS) DC POWER MONITOR FAULTY. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20031110000132003111000013NM 2003 11 10 AUS20031050 120031014G2120 ODOR BOEING737 737* NM GE CFM56 CFM567B24 NE AIR CONDITIONINGDETECTED W O OTHER B SMOKE/FUMES/ODORS/SPARKS DEDESCENT 1 AUS (AUS) OIL ODOR IN CABIN. LIMITED INFORMATION PROVIDED. 2L72 4F4 FRTA16WE E00055EN 20031110000142003111000014EU 2003 11 10 AUS20031051 220031009G7230857592 SEAL BOEING737 737* NM CFMINTCFM56 CFM563C 13802EU ENGINE FAILED W K NONE O OTHER ININSP/MAINT 1 AUS 22249 (AUS) NR 1 ENGINE FORWARD STATIONARY AIR/OIL SEAL FAILED IN THE AREA OF ADHESION OF THE ABRADABLE MATERIAL TO THE SEAL ASSEMBLY. 2L72 4F4 FRTA16WE E21EU 20031110000152003111000015EA 2003 11 10 AUS20031052 120030815G2823TC17300 SELECTOR VALVE DHAV DHC2 DHC2MK1 2800102EA PWA R985 R985AN14B 52008NE HARTZLHCB3R HCB3R304 GL FUEL SYSTEM WRONG PART W O OTHER EY VIBRATION/BUFFET ENGINE STOPPAGE TOTAKEOFF 1 AUS (AUS) FUEL SELECTOR VALVE INCORRECTLY ASSEMBLED. VALVE HAD BEEN FITTED WITH SHAFT 180 DEGREES OUT OF POSITION. PERSONNEL/MAINTENANCE ERROR. 1H71 3R3 R A806 5E1 5 CP28EA 20031110000162003111000016NM 2003 11 10 AUS20031053 120031016G2761NAS161210 PACKING BOEING767 767338 1385151NM GE CF6 CF680C2* GL DRAG CONTROL ACTDISTORTED W O OTHER KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 AUS (AUS) NR 4 LT OUTBOARD SPOILER ACTUATOR FILTER CAP PACKING DEFORMED. LOSS OF HYDRAULIC FLUID. 2L72 4F4 FRTA1NM E23EA 20031110000172003111000017EA 2003 11 10 AUS20031054 220030924G8540 BUSHING PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2 GL ENGINE SEPARATED W K NONE O OTHER ININSP/MAINT 1 AUS 1072 (AUS) GOVERNOR IDLE SHAFT BUSHING BROKEN AWAY AND ENTERED ENGINE LUBRICATION SYSTEM CAUSING METAL CONTAMINATION. 1L72 3O3 O A20SO E14EA 5 CP33EA 20031110000182003111000018NM 2003 11 10 AUS20031056 120031018G3233NAS759011 BUSHING DHAV DHC8 DHC8315 2809010NM PWA PW120 PW123 NE HAMSTD14SF 14SF15 NE MLG ACTUATOR MISSING W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) NOSE LANDING GEAR RETRACTION ACTUATOR BUSHING MISSING. BUSHING HAD NOT BEEN FITTED DURING MANUFACTURE. SUPPORT BRACKET PNO 85310340-015 DAMAGED. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20031110000192003111000019NM 2003 11 10 AUS20031057 120030925G7120310A10415 BOLT BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU ENGINE MOUNT CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 1638 (AUS) NR 2 ENGINE MOUNTING SYSTEM FORWARD MOUNT CONE BOLT CRACKED. FOUND DURING NDT INSPECTION. 2L72 4F4 FRTA16WE E21EU 20031110000202003111000020EU 2003 11 10 AUS20031058 220031017G7200 ENGINE BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU EGT ERRATIC W O OTHER E VIBRATION/BUFFET TOTAKEOFF 1 AUS 46070 (AUS) NR 1 ENGINE EGT REACHED AT LEAST 1100 TO 1200 DEGREES AND WAS ERRATIC. ALL OTHER INDICATIONS NORMAL. 2L72 4F4 FRTA16WE E21EU 20031110000212003111000021EA 2003 11 10 AUS20031059 220030828G854013S19648 GEAR BNORM BN2 BN2A8 1520209EU LYC O540 O540E4C5 41532EA HARTZLHCC2Y HCC2YK2 GL CRANKSHAFT WRONG PART W K NONE W INADEQUATE Q C ININSP/MAINT 1 AUS 448 (AUS) CRANKSHAFT GEAR INCORRECT PART. GEAR WAS NOT COMPLETELY MESHING WITH THE OIL PUMP DRIVE GEAR. PN 13S19648 FITTED INSTEAD OF CORRECT PN 13S19647. SUSPECT ENGINE HAD BEEN CONVERTED FROM EITHER AN IO-540 OR TSIO-540 MODEL, BOTH OF WHICH USED THE FITTED GEAR. PERSONNEL/MAINTENANCE ERROR. UNAPPROVED PART. 1H72 3O3 O A17EU E295 5 CP920 20031110000242003111000024SO 2003 11 10 AUS20031060 120031016G8120NSN CLAMP PIPER PA31 PA31P 7103120SO LYC O541 TIGO541E1A 41539EA HARTZLHCC3Y HCC3YN GL TURBOCHARGER WRONG PART W O OTHER W INADEQUATE Q C NRNOT REPORTED 1 AUS (AUS) ENGINE EXHAUST TURBOCHARGER INTERCOOLER DUCT HOSE CLAMP INCORRECTLY TORQUED FOLLOWING MAINTENANCE. HOSE PARTED DURING FLIGHT. 1L72 3O3 O A8EA E19EA 5 CP25EA 20031110000252003111000025EA 2003 11 10 AUS20031061 220031020G7420 IGNITION LEAD GULSTM680 680FLP 0141610SW LYC O720 IO720B1B 41546EA HARTZLHCA3V HCA3VK2 GL RT ENGINE FAULTY W O OTHER E VIBRATION/BUFFET CRCRUISE 1 AUS (AUS) RT ENGINE NR 7 CYLINDER LOWER IGNITION LEAD DEFECTIVE AT SPARK PLUG END. 1H72 3O3 O 2A4 1E15 5 CP6EA 20031110000262003111000026EA 2003 11 10 AUS20031062 220031020G8540 SEAL PIPER PA31 PA31 7103102SO LYC O540 TIO540A2C 41532EA HARTZLHCE3Y HCE3YR2 GL DRIVESHAFT DAMAGED W O OTHER EK VIBRATION/BUFFET FLUID LOSS CRCRUISE 1 AUS (AUS) LT ENGINE HYDRAULIC PUMP DRIVESHAFT SEAL DAMAGED AND LEAKING. HYDRAULIC PUMP HAD BEEN CHANGED ON THE PREVIOUS DAY. 1L72 3O3 O A20SO E14EA 5 CP33EA 20031110000272003111000027 2003 11 10 AUS20031063 420031014G34254019700902 INDICATOR BAC 146 146100A 1500260EU LYC ALF502ALF502R5 41580NE COCKPIT FAILED W C ABORTED TAKEOFF O OTHER TOTAKEOFF 1 AUS (AUS) CAPTAINS ATTITUDE DIRECTION INDICATOR (ADI) FAILED. 2H74 4F4 FRTA49EU E6NE 20031110000282003111000028GL 2003 11 10 AUS20031064 320031017G6114E4715 HUB CESSNA188 A188B 2073005CE CONT O520 IO520D 17032SO MCAULY2A34C D2A34C98 GL PROPELLER CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 908 (AUS) PROPELLER HUB CRACKED IN THREADED AREA. FOUND DURING EDDY CURRENT INSPECTION IAW AD/PMC/47 AMDT1. 1L71 3O3 O A9CE E5CE 5 CP3EA 20031110000292003111000029NM 2003 11 10 AUS20031065 120031022G2612 WARNING SYSTEM BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU FIRE DETECTION OVERHEATED W O OTHER MBJOVER TEMP SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CRCRUISE 1 AUS (AUS) RT WING BODY OVERHEAT LIGHT ILLUMINATED. LIMITED INFORMATION PROVIDED. 2L72 4F4 FRTA16WE E21EU 20031110000302003111000030NE 2003 11 10 AUS20031066 220030321G7200PW123D ENGINE DHAV DHC8 DHC8202 2809007NM PWA 120 PW123D 52152NE HAMSTD14SF 14SF23 NE RIGHT LEAKING W O OTHER B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 AUS (AUS) RT ENGINE LEAKING OIL. OIL FUMES IN CABIN. INVESTIGATION AND BOROSCOPE INSPECTION FOUND OIL WETTING IN AREA OF INTERCOMPRESSOR CASE. ENGINE REMOVED. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20031110000312003111000031EU 2003 11 10 AUS20031067 120031015G571158221283 SPAR CAP REIMS 406 F406 7535723EU PWA PT6 PT6A112 52043NE MCAULY3G34C73GFR34C701 GL RTWING CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT WING MAIN SPAR LOWER SPAR CAP CORRODED. MICROBIOLOGICAL GROWTH FOUND ON INSIDE OF FUEL ACCESS PANELS 621BB AND 521BB AND 521CB. 1L72 3T3 TRTA54EU E4EA 5 CP60GL 20031110000322003111000032EU 2003 11 10 AUS20031068 120031010G304059885 ARM BAG JETSTMJETSTM3201 1500217EU GARRTTTPE331TPE33112UHR WP MCAULY4HFR344HFR34C653 NE WINDSHIELD WIPERCRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT WINDSHIELD WIPER PIVOT ARM LUG CRACKED FROM TOP RADIUS TO ATTACHMENT PIN HOLE. FOUND DURING INSPECTION IAW AD JETSTREAM 76AMDT1 AND SB 30-JA-95041. 2L72 4T4 TRTA56EU E4WE 6 C3PNE 20031110000332003111000033EU 2003 11 10 AUS20031069 120030916G6410AS355A12003106 BLADE SNIAS 350 AS350BA 8680817EU TMECA ARRIELARRIEL1B 6OO30NE TAIL ROTOR DEBONDED W O OTHER F FLT CONT AFFECTED CLCLIMB 1 AUS 41 (AUS) TAIL ROTOR BLADE TAB DEBONDED AND SEPARATED FROM BLADE CAUSING EXCESSIVE VIBRATION. TAIL ROTOR BLADE TRAILING EDGE DAMAGED. INVESTIGATION FOUND FAILURE WAS DUE TO INCORRECT SOLVENT USED DURING TAB BONDING PROCEDURE AT OVERHAUL. SECONDARY EFFECTS OF TAB LOSS WERE TAIL ROTOR GEARBOX FAILURE DUE TO ALUMINIUM ON THEOIL AND DAMAGED TAIL ROTOR DRIVE TRAIN. 1G71 3U3 UNCH9EU E19EU 20031110000352003111000035 2003 11 10 AUS20031070 420030729G3457 GPS CESSNA206 U206G 2073356CE CONT O520 IO520F 17032SO MCAULYD3A34 D3A34C404 GL COCKPIT MISINSTALLED W K NONE W INADEQUATE Q C ININSP/MAINT 1 AUS VARIOUS (AUS) AGPS AND RADIO TRANSCEIVER REMOVED AND GPS/COM FITTED. AUDIO PANEL REMOVED AND A DIFFERENT ITEM FITTED. SEVERAL DEFECTS FOUND ASSOCIATED WITH INSTALLATION. NO ENTRY IN LOG BOOK, NO WEIGHT AND BALANCE CHANGE, NO ELECTRICAL LOAD ANALYSIS NO E/O'S IN LOG BOOK INCORRECT COAXIAL CABLE FITTED IAW INSTALLATION MANUAL INCORRECT GPS ANTENNA IAW INSTALLATION MANUAL. NO ADHERENCE TO ACCEPTABLE METHODS 8. SEVERAL INCONSISTENCIES NOW WITH RADIO SYSTEM IE. LABELING WRONG, ABSENCE OF NOTCH FILTERS, SIDETONE ISSUES. NO EVIDENCE OF FLIGHT CHECKING (IAW CAO 108.34) OF MARKER BEACON PERSONNEL/MAINTENANCE ERROR. UNAPPROVED MAINTENANCE. 1H71 3O3 O A4CE E5CE 5 CP47GL 20031110000362003111000036 2003 11 10 AUS20031071 420030729G2210 CAPSULE CESSNA206 U206G 2073356CE CONT O520 IO520F 17032SO MCAULYD3A34 D3A34C404 GL AUTOPILOT SYSTEMMISINSTALLED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) AUTOPILOT ALTITUDE HOLD CAPSULE FITTED IN A DIFFERENT POSITION TO THAT STATED BY STC. PERSONNEL/MAINTENANCE ERROR. INCORRECT FIT. 1H71 3O3 O A4CE E5CE 5 CP47GL 20031110000372003111000037NM 2003 11 10 AUS20031072 120031023G2450675230450 CIRCUIT BREAKER BOEING727 7272J4 1384006NM PWA JT8 JT8D17 52049NE AC POWER FAILED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) PACK COOLING FAN CIRCUIT BREAKER (C) PHASE TERMINAL OVERHEATED. 2L73 4F4 FRTA3WE E2EA 20031110000382003111000038 2003 11 10 AUS20031073 420030929G3452007062270000 DIODE KING PAC CT4 CT4B GL CONT O360 IO360HB 17025SO HARTZLHCC2Y BHCC2YF1 GL ATC TRANSPONDER FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS DEDESCENT 1 AUS 6884 (AUS) TRANSPONDER DIODE FAILED. EVIDENCE OF MINOR BURNING ON CIRCUIT BOARD. 1L71 3O3 ORTA9PC E1CE 5 CP920 20031110000802003111000080NM 2003 11 10 AUS20031074 120031001G2910731840 POWER UNIT DHAV DHC8 DHC8202 2809007NM PWA 120 PW123D 52152NE HAMSTD14SF 14SF23 NE HYD SYS FAULTY W C ABORTED TAKEOFF KJ FLUID LOSS WARNING INDICATION TOTAKEOFF 1 AUS (AUS) NR 2 STANDBY POWER UNIT FAULTY. SUSPECT CAUSED BY AIR IN NR 2 HYDRAULIC SYSTEM. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20031110000822003111000082NM 2003 11 10 AUS20031075 120031013G7603S315A10819 CABLE BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU POWER LEVER WRONG PART W K NONE W INADEQUATE Q C ININSP/MAINT 1 AUS (AUS) RT ENGINE THRUST LEVER STIFF IN OPERATION. INVESTIGATION FOUND INCORRECT CABLE FITTED. CABLE WAS APPROXIMATELY 120MM (4.72IN)LONGER THAN THE CORRECT CABLE. FURTHER INSPECTION ALSO FOUND CABLE JAMMING ON THE INTERNAL TEFLON SURFACE. UNAPPROVED PART. PERSONNEL/MAINTENANCE ERROR. 2L72 4F4 FRTA16WE E21EU 20031110000832003111000083NM 2003 11 10 AUS20031076 120031024G2612 FIRE DETECTOR BOEING737 737376 NM GE CFM56 CFM56* 13802NE NR 1 ENGINE INOPERATIVE W O OTHER BJ SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CRCRUISE 1 AUS (AUS) NR 1 ENGINE FIRE DETECTOR SYSTEM INOPERATIVE. 2L72 4F4 FRTA16WE E2GL 20031110000852003111000085SW 2003 11 10 AUS20031077 120031022G5521440000164 RIB GULSTM500 500S 0141107SW LYC O540 IO540E1B5 41532EA HARTZLHCC3Y HCC3YR2 NE ELEVATOR CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT ELEVATOR FORWARD RIB CRACKED AT TORQUE TUBE OUTBOARD MOUNTING FLANGE. RIB CONTAINS TWO CRACKS FROM TOP AND BOTTOM ATTACHMENT RIVETS. 1H72 3O3 O 6A1 1E4 5 CP25EA 20031110000872003111000087SW 2003 11 10 AUS20031078 120030912G5521440000164 RIB GULSTM500 500S 0141107SW LYC O540 IO540E1B5 41532EA HARTZLHCC3Y HCC3YR2 NE ELEVATOR CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT ELEVATOR FORWARD RIB CRACKED AT TORQUE TUBE OUTBOARD MOUNTING FLANGE. RIB IS CRACKED IN TWO PLACES FROM TOP AND BOTTOM ATTACHMENT RIVETS. 1H72 3O3 O 6A1 1E4 5 CP25EA 20031110000882003111000088CE 2003 11 10 AUS20031079 120031028G5730512201120 PANEL CESSNA402 402C 207590RCE CONT O520 TSIO520VB 17040SO MCAULY3AF32C3AF32C505 GL WING DEBONDED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT LOWER WING PANEL DISBONDED. 1L72 3O3 O A7CE E8CE 5 CP22EA 20031110000892003111000089CE 2003 11 10 AUS20031080 120031028G573051220031 SKIN CESSNA402 402C 207590RCE CONT O520 TSIO520VB 17040SO MCAULY3AF32C3AF32C505 GL LT WING DEBONDED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT WING LEADING EDGE SKIN DISBONDED. 1L72 3O3 O A7CE E8CE 5 CP22EA 20031110000902003111000090CE 2003 11 10 AUS20031081 120031028G5730512200817 PANEL CESSNA402 402C 207590RCE CONT O520 TSIO520VB 17040SO MCAULY3AF32C3AF32C505 GL LT WING DEBONDED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT WING UPPER SKIN PANEL DISBONDED. 1L72 3O3 O A7CE E8CE 5 CP22EA 20031110000912003111000091CE 2003 11 10 AUS20031082 120031028G5730512200818 PANEL CESSNA402 402C 207590RCE CONT O520 TSIO520VB 17040SO MCAULY3AF32C3AF32C505 GL RT WING DEBONDED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT UPPER WING PANEL SKIN DISBONDED. 1L72 3O3 O A7CE E8CE 5 CP22EA 20031110000922003111000092CE 2003 11 10 AUS20031083 120031028G5711512204124 SPAR CAP CESSNA402 402C 207590RCE CONT O520 TSIO520VB 17040SO MCAULY3AF32C3AF32C505 GL RT WING CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT WING LOWER SPAR CAP CORRODED IN AREA IN FRONT OF AILERON. 1L72 3O3 O A7CE E8CE 5 CP22EA 20031110000942003111000094CE 2003 11 10 AUS20031084 120031028G5711512204123 SPAR CAP CESSNA402 402C 207590RCE CONT O520 TSIO520VB 17040SO MCAULY3AF32C3AF32C505 GL LT WING CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT WING LOWER SPAR CAP CORRODED IN AREA IN FRONT OF AILERON. 1L72 3O3 O A7CE E8CE 5 CP22EA 20031110000952003111000095CE 2003 11 10 AUS20031085 120031028G5711512204125 SUPPORT CESSNA402 402C 207590RCE CONT O520 TSIO520VB 17040SO MCAULY3AF32C3AF32C505 GL LT WING CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT WING SPAR SUPPORT CORRODED. 1L72 3O3 O A7CE E8CE 5 CP22EA 20031110000972003111000097CE 2003 11 10 AUS20031086 120031028G5730512201121 PANEL CESSNA402 402C 207590RCE CONT O520 TSIO520VB 17040SO MCAULY3AF32C3AF32C505 GL LT WING DEBONDED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT WING LOWER SKIN PANEL DISBONDED. 1L72 3O3 O A7CE E8CE 5 CP22EA 20031110000982003111000098SW 2003 11 10 AUS20031087 120031025G213110234010 CONTROLLER SWRNGNSA227 SA227* SW GARRTTTPE331TPE33112UHR WP MCAULY4HFR344HFR34C652 NE CABIN PRESSURE FAULTY W O OTHER O OTHER CRCRUISE 1 AUS 16222 (AUS) CABIN PRESSURE CONTROLLER FAULTY. 2L72 4T4 TRTA5SW E4WE 6 C3PNE 20031110000992003111000099SW 2003 11 10 AUS20031088 120031022G5311UNK FRAME SWRNGNSA227 SA227* SW GARRTTTPE331TPE33112UHR WP MCAULY4HFR344HFR34C652 NE FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 17536 (AUS) CABIN BELT FRAME CRACKED. FOUND DURING INSPECTION IAW SERVICE LETTER CC7-SL-036. 2L72 4T4 TRTA5SW E4WE 6 C3PNE 20031110001002003111000100CE 2003 11 10 AUS20031089 120031022G5741NAS15237 BOLT BEECH 36 A36 1151604CE CONT O520 IO520B 17032SO MCAULY2A36C 2A36C23 GL LT WING DAMAGED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT WING UPPER FORWARD ATTACHMENT BOLT THREADS DAMAGED. 1L71 3O3 O 3A15 E5CE 5 CP880 20031110001012003111000101NE 2003 11 10 AUS20031090 220031010G7230110109007 COMPRESSOR LYC T53 T5317A 41549NE TURBINE ENGINE UNSERVICEABLE W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) ENGINE COMPRESSOR SECTION CONTAINED COMPONENTS FROM AN ENGINE INVOLVED IN AN AIRCRAFT CRASH. ENGINE HAD BEEN ASSEMBLED FROM COMPONENTS FROM FIVE DIFFERENT ENGINES. NO HISTORY CARDS WERE SUPPLIED FOR THE COMPRESSOR MODULE BUT INVESTIGATION FOUND THAT THE MODULE WAS FROM AN ENGINE FITTED TO AN AIRCRAFT THAT HAD CRASHED. 4 U E17EA 20031110001032003111000103CE 2003 11 10 AUS20031091 120031013G2810C1560030101 CAP CESSNA206 U206F 2073333CE CONT O520 IO520F 17032SO MCAULY3A32C D3A32C90 GL FUEL STORAGE FAULTY W O OTHER K FLUID LOSS NRNOT REPORTED 1 AUS (AUS) FUEL CAP PLASTIC SPACER FAILED ALLOWING FUEL TO VENT FROM TANK CAUSING THE FUEL CELL TO COLLAPSE. 1H71 3O3 O A4CE E5CE 5 CP21EA 20031110001042003111000104EA 2003 11 10 AUS20031092 220031022G732225763562 FUEL CONTROL CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA MCAULY1C235 1C235LFA GL ENGINE CONTAMINATED W K NONE O OTHER ININSP/MAINT 1 AUS 195 (AUS) FUEL CONTROL UNIT IMPACT AIR CHAMBER CONTAMINATED WITH FUEL. 1H71 3O3 ONT3A12 1E10 5 NP12EA 20031110001052003111000105NM 2003 11 10 AUS20031093 120031027G5230AE352211 SHAFT BOEING727 727277 138408SNM PWA JT8 JT8D15 52051NE CARGO DOOR SHEARED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) MAIN CARGO DOOR FORWARD AND AFT ACTUATOR PIVOT SHAFTS SHEARED. SECONDARY DAMAGE CAUSED TO AFT ACTUATOR MAIN SUPPORTS. 2L73 4F4 FRTA3WE E2EA 20031110001072003111000107NM 2003 11 10 AUS20031094 120031018G3221 BOLT BOEING767 767338 1385151NM GE CF6 CF680C2* GL NLG LOOSE W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) NOSE LANDING GEAR TRUNNION DRUM LT STOP BOLT LOOSE AND RT STOPBOLT MISSING. 2L72 4F4 FRTA1NM E23EA 20031110001082003111000108NM 2003 11 10 AUS20031095 120031027G3240 BRAKE ASSY BOEING737 737376 NM GE CFM56 CFM563B1 13802NE MLG FAULTY W O OTHER O OTHER NRNOT REPORTED 1 AUS (AUS) AUTOBRAKE SYSTEM NOT ARMING. LIMITED INFORMATION PROVIDED. 2L72 4F4 FRTA16WE E2GL 20031110001092003111000109EA 2003 11 10 AUS20031096 220031021G8530 EXHAUST VALVE CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA MCAULY1C160 1C160DTM GL ENGINE SEPARATED W O OTHER E VIBRATION/BUFFET CLCLIMB 1 AUS (AUS) NR 4 CYLINDER EXHAUST VALVE HEAD SEPARATED FROM VALVE STEM. VALVEGUIDE LOOSE IN HEAD. 1H71 3O3 ONT3A12 E274 5 NP910 20031110001192003111000119EA 2003 11 10 AUS20031097 220031015G732225765362 FUEL CONTROL CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA MCAULY1C235 1C235LFA GL ENGINE FAULTY W O OTHER EY VIBRATION/BUFFET ENGINE STOPPAGE LDLANDING 1 AUS (AUS) FUEL CONTROL UNIT FAULTY. WORKSHOP INVESTIGATION COULD FIND NO FAULT. 1H71 3O3 ONT3A12 1E10 5 NP12EA 20031110001202003111000120GL 2003 11 10 AUS20031098 320030923G6114 HUB CESSNA182 182B 2072706CE CONT O470 O470R 17026SO MCAULY2A36C 2A36C29 GL PROPELLER WRONG PART W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) PROPELLER HUB FAULTY. DURING COMPLIANCE WITH AD/PMC/47 IT WAS FOUND THAT THE MOUNTING STUDS HAD BEEN INCORRECTLY SEALED. SILASTIC MATERIAL WAS USED FOR SEALING RATHER THAN THE CORRECT PROCEDURE AS INDICATED IN MFG SL 1993-17. THE HUB WAS ALSO INCORRECTLY STAMPED AS STILL BEING A GREASE FILLED HUB. PROPELLER PISTON ALSO CONTAINED A NON-APPROVED REPAIR. UNAPPROVED PROCEDURE. PERSONNEL/MAINTENANCE ERROR. 1H71 3O3 ONT3A13 E273 5 CP880 20031110001212003111000121 2003 11 10 AUS20031099 420031025G34256225045202 SYMBOL GENERATOR BOEING767 767238 1385114NM PWA JT9 JT9D7R4E 52054NE COCKPIT FAILED W O OTHER O OTHER DEDESCENT 1 AUS (AUS) LT AND RT EFIS SYMBOL GENERATORS FAILED. 2L72 4F4 FRTA1NM E3NE 20040106000852004010600085EA 2004 1 6 AUS20031100 220031030G7414DO52071 BEARING ROBSINR22 R22BETA 7640110NM LYC O360 O360J2A 41514EA MAGNETO LOOSE W C ABORTED TAKEOFF E VIBRATION/BUFFET TOTAKEOFF 1 AUS 6 (AUS) MAGNETO BEARING SPINNING IN HOUSING. SEE MDR 03/1101 FOR FURTHER INFORMATION. 1G71 3O3 O H10WE E286 20040106000862004010600086EA 2004 1 6 AUS20031101 220031030G7414B19912E BEARING ROBSINR22 R22BETA 7640110NM LYC O360 O360J2A 41514EA MAGNETO LOOSE W C ABORTED TAKEOFF E VIBRATION/BUFFET TOTAKEOFF 1 AUS 164 (AUS) MAGNETO BEARING SPINNING IN HOUSING. SEE MDR 03/1100 FOR FURTHER INFORMATION. 1G71 3O3 O H10WE E286 20040106000872004010600087SO 2004 1 6 AUS20031102 120031022G53439572402 MOUNT PIPER PA34 PA34200 7103405SO LYC O360 IO360C1E6 41514EA HARTZLHCC2Y HCC2YK2 GL MLG SEPARATED W O OTHER O OTHER LDLANDING 1 AUS (AUS) NOSE LANDING GEAR ACTUATOR MOUNT BRACKET RIVETS FAILED. SUSPECT CAUSED BY HEAVY LANDING AND SUBSTANDARD RIVETING. PERSONNEL/MAINTENANCE ERROR. 1L72 3O3 O A7SO 1E10 5 CP920 20040106000892004010600089EU 2004 1 6 AUS20031103 120031029G3244PL126 TIRE BAG JETSTMJETSTM3201 1500217EU GARRTTTPE331TPE33112UHR WP MCAULY4HFR344HFR34C653 NE MLG PUNCTURED W O OTHER O OTHER LDLANDING 1 AUS 230 (AUS) RT MLG TIRE PUNCTURED ON LANDING. 2L72 4T4 TRTA56EU E4WE 6 C3PNE 20040106000902004010600090EU 2004 1 6 AUS20031104 120030925G28229688411404 PUMP PILATSPC12 PC12 7090550EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL FUEL BOOST FAILED W K NONE O OTHER ININSP/MAINT 1 AUS 85011 (AUS) RT FUEL BOOST PUMP FAILED. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040106000922004010600092EU 2004 1 6 AUS20031105 120031008G29329738114306 SWITCH PILATSPC12 PC12 7090550EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL HYD PRESSURE FAILED W O OTHER KJ FLUID LOSS WARNING INDICATION CLCLIMB 1 AUS (AUS) HYDRAULIC PRESSURE SWITCH FAILED. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040106000982004010600098SW 2004 1 6 AUS20031106 120031026G2435230811530 ARMATURE LEARSIEGLER BELL 206 206L3 1182108SW ALLSN 250C 250C30 03013GL START GENERATOR FAULTY W O OTHER H ELECT. POWER LOSS-50 PC NRNOT REPORTED 1 AUS 94090 (AUS) STARTER-GENERATOR ARMATURE LOST MAGNETISM. 1G71 3U3 U H2SW E1GL 20040107000172004010700017EU 2004 1 7 AUS20031107 120031004G2434 GENERATOR PARTENP68 P68B 6780104EU LYC O360 IO360A1B6 41514EA HARTZLHCC2Y HCC2YK2 GL DC LT & RT FAILED W O OTHER HJ ELECT. POWER LOSS-50 PC WARNING INDICATION CRCRUISE 1 AUS (AUS) LT AND RT GENERATORS FAILED. 1H72 3O3 O A31EU 1E10 5 CP920 20040107000182004010700018CE 2004 1 7 AUS20031108 120031031G32601CH16 SWITCH CESSNA404 404CESSNA 2075901CE CONT O520 GTSIO520M 17032SO MCAULY3FF32 3FF32C501 GL MLG FAULTY W O OTHER N FALSE WARNING CLCLIMB 1 AUS (AUS) NOSE LANDING GEAR DOWN SWITCH FAULTY. 1L72 3O3 O A25CE E7CE 5 CP45GL 20040107000192004010700019CE 2004 1 7 AUS20031109 120031030G53133541003868 LONGERON BEECH 36 A36 1151604CE CONT O520 IO520B 17032SO MCAULY2A36C 2A36C23 GL FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT FUSELAGE LONGERON CRACKED IN AREA APPROXIMATELY 6.35MM (0.25IN) AFT OF FIREWALL. 1L71 3O3 O 3A15 E5CE 5 CP880 20040107000202004010700020CE 2004 1 7 AUS20031110 120031031G2912MS28775224 O-RING PUROLATOR CESSNA441 441 2076020CE GARRTTTPE331TPE331* 01514WP HARTZLHCB3T HCB3TN5 GL HYD FILTER DETERIORATED W K NONE K FLUID LOSS ININSP/MAINT 1 AUS NA (AUS) HYDRAULIC FILTER HOUSING O-RING SEAL DETERIORATED AND LEAKING. 1L72 3T3 TRTA28CE E2WE 6 CP15EA 20040107000212004010700021SO 2004 1 7 AUS20031111 120031028G321365319004 CYLINDER PIPER PA28 PA28140 7102802SO LYC O320 O320* 41508EA SNSNCH74DM M74DM EA MLG CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) MAIN LANDING GEAR STRUT CYLINDER CRACKED IN AREA OF TORQUE LINK ATTACHMENT LUGS AS INDICATED IN MFG SB 1131. 1L71 3O3 O 2A13 E274 5 NP88614 20040107000222004010700022SO 2004 1 7 AUS20031112 120031028G3213653194 CYLINDER PIPER PA28 PA28151 7102805SO LYC O360 O360A4M 41514EA SNSNCH76E 76EM8 EA MLG CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT AND RT MAIN LANDING GEAR STRUT CYLINDERS CRACKED IN AREA OF TORQUE LINK ATTACHMENT LUGS AS INDICATED IN MFG SB 1131. 1L71 3O3 O 2A13 E286 5 NP4EA 20040107000232004010700023NE 2004 1 7 AUS20031113 220031101G7323210949 GOVERNOR PILATSPC12 PC12 7090550EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL TURBINE FAILED W O OTHER E VIBRATION/BUFFET CLCLIMB 1 AUS 2026 (AUS) ENGINE OVERSPEED GOVERNOR FAULTY. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040107000522004010700052SW 2004 1 7 AUS20031114 120031024G5311 FRAME SWRNGNSA227 SA227AC 8780603SW GARRTTTPE331TPE33111U 01514WP ROTOL R321 R321482F8 GL FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FUSELAGE INTERCOSTAL FRAMES CRACKED AND TORN IN AREA UNDER FLOOR. INSP FOUND FOLLOWING OTHER DEFECTS: LT AND RT BOX BEAMS (USED FOR CENTER ISLE SEAT TRACK SUPPORT) WERE CRUMPLING AND BREAKING, CAN BE SEEN FOR MOST OF LENGTH OF BOX BEAMS. WORSE AFFECTED AREA, WERE REAR BOX BEAMS JUST FWD OF CARGO BY AREA FLOOR BETWEEN STN435.060, STN362.271.2. MOST SIGNIFICANT NEW PROBLEM HOWEVER, CRACKS ON INTERCOSTAL FRAMES TO MAIN HOOP FRAME ATTACHMENT. THESE WERE ALL ON LT SIDE FRAME AREA. 4 CRACKS ALL WAY THROUGH INTERCOSTAL WERE FOUND IN AREA BETWEEN STN422.271, STN332.271. SOME SMALL CRACKS ON INTERCOSTAL FRAMES WERE FOUND ON ANOTHER 3 FRAMES ALL ON LT SIDE. SUSPECT CAUSED BY OVERLOAD OF FR8.03111424- 2L72 4T4 TRTA8SW E4WE 6 CP61GL 20040107000532004010700053 2004 1 7 AUS20031115 420031103G3418 COMPUTER DHAV DHC8 DHC8202 2809007NM PWA 120 PW123D 52152NE HAMSTD14SF 14SF23 NE STALL WARNING MALFUNCTIONED W O OTHER N FALSE WARNING CLCLIMB 1 AUS (AUS) STALL WARNING SYSTEM FAULTY. THE FOLLOWING ITEMS WERE REPLACED:-1. FLAP POSITION INDICATOR PN 4428-150-80-10 2. RT STALL VANE 3. NR 2 STALL WARNING COMPUTER. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040107000542004010700054NM 2004 1 7 AUS20031116 120031030G2997 WIRE BOEING767 767338 1385151NM GE CF6 CF680C2* GL HYDRAULIC PUMP DAMAGED W O OTHER K FLUID LOSS NRNOT REPORTED 1 AUS (AUS) RT ELECTRICAL HYDRAULIC PUMP PHASE A' SPLICE DAMAGED. 2L72 4F4 FRTA1NM E23EA 20040107000552004010700055NM 2004 1 7 AUS20031117 120031103G3244161U00011 TIRE BOEING747 747438 NM RROYCERB211 RB211524G19 NE NR 6 WHEEL PUNCTURED W O OTHER J WARNING INDICATION CLCLIMB 1 AUS (AUS) NR 6 WHEEL TIRE PUNCTURED. 2L74 4F4 FRTA20WE E30NE 20040107000562004010700056SO 2004 1 7 AUS20031118 120031029G1430401269 BOLT PIPER PA34 PA34220T 7103420SO CONT O360 TSIO360RB 17025CE MCAULY3AF32C3AF32C* GL AILERON CONTROL LOOSE W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) AILERON CONTROL COLUMN IDLER SPROCKET BOLT LOW TORQUE. SUSPECT BOLTS LOOSENED DURING RIGGING AT MANUFACTURE AND NOT RETORQUED. 1L72 3O3 O A7SO E9CE 5 CP22EA 20040107000572004010700057SO 2004 1 7 AUS20031119 120031030G1430401269 BOLT PIPER PA34 PA34220T 7103420SO CONT O360 TSIO360RB 17025CE MCAULY3AF32C3AF32C* GL AILERON CONTROL LOOSE W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) AILERON CONTROL COLUMN IDLER SPROCKET BOLT LOW TORQUE. SUSPECTBOLTS LOOSENED DURING RIGGING AT MANUFACTURE AND NOT RETORQUED. 1L72 3O3 O A7SO E9CE 5 CP22EA 20040107000582004010700058SO 2004 1 7 AUS20031120 120031030G1430401269 BOLT PIPER PA34 PA34220T 7103420SO CONT O360 TSIO360RB 17025CE MCAULY3AF32C3AF32C* GL AILERON CONTROL LOOSE W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) AILERON CONTROL COLUMN IDLER SPROCKET BOLT LOW TORQUE. SUSPECT BOLTS LOOSENED DURING RIGGING AT MANUFACTURE AND NOT RETORQUED. PERSONNEL/MAINTENANCE ERROR. 1L72 3O3 O A7SO E9CE 5 CP22EA 20040107000592004010700059EU 2004 1 7 AUS20031121 120031106G324440140A TIRE REIMS 406 F406 7535723EU PWA PT6 PT6A112 52043NE MCAULY3G34C73GFR34C701 GL NLG DEFLATED W O OTHER F FLT CONT AFFECTED CLCLIMB 1 AUS (AUS) NOSE WHEEL TIRE DEFLATED. NO DAMAGE TO WHEEL RIM. NOSE WHEEL MUD GUARD MISSING. INVESTIGATION FOUND THE VALVE STEM SHEARED FROM THE TUBE. SUSPECT VALVE STEM FAILURE CAUSED BY FATIGUE AND AGING OF THE RUBBER AROUND THE VALVE BASE. 1L72 3T3 TRTA54EU E4EA 5 CP60GL 20040107000612004010700061NM 2004 1 7 AUS20031122 120031105G3411 PIVOT BOEING737 7377BX 13844D2NM GE CFM56 CFM563B1 13802NE PITOT/STATIC SYSOBSTRUCTED W O OTHER O OTHER NRNOT REPORTED 1 AUS (AUS) FIRST OFFICERS PITOT PROBE BLOCKED BY INSECT. 2L72 4F4 FRTA16WE E2GL 20040107000682004010700068NM 2004 1 7 AUS20031123 120031104G2751426EN98 SWITCH BOEING737 7374Q8 138447QNM CFMINTCFM56 CFM563C 13802EU TE FLAPS FAILED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) TE FLAP SWITCH S245 FAILED. 2L72 4F4 FRTA16WE E21EU 20040107000692004010700069NM 2004 1 7 AUS20031124 120031104G3246314801 WHEEL DHAV DHC8 DHC8315 2809010NM PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE MLG FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) DURING TIRE CHANGE MAINTENANCE ON THE WHEEL, THE NDT INSPECTION WAS NOT CARRIED OUT. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040107000702004010700070NM 2004 1 7 AUS20031125 120031103G291065445433036 PIPE BOEING737 737376 NM GE CFM56 CFM563B1 13802NE HYD SYSTEM CHAFED W K NONE K FLUID LOSS ININSP/MAINT 1 AUS (AUS) NOSE LANDING GEAR UP HYDRAULIC PIPE CHAFED AND LEAKING. LOSS OF HYDRAULIC FLUID. SPRAY OF HYDRAULIC FLUID CONTAMINATED E1-3 AVIONICS RACK CONNECTORS D4115P AND D4067P. 2L72 4F4 FRTA16WE E2GL 20040107000712004010700071NM 2004 1 7 AUS20031126 120031103G2520201136612258 SEAT BELT BOEING737 737800* NM GE CFM56 CFM56* 13802NE CABIN DAMAGED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) SEAT BELT BUCKLE PIVOT PIN SHEARED. 2L72 4F4 FRTA16WE E2GL 20040107000722004010700072EU 2004 1 7 AUS20031127 120031101G56101379628C402 WINDSHIELD BAG JETSTMJETSTM3201 1500217EU GARRTTTPE331TPE33112UHR WP MCAULY4HFR344HFR34C653 NE COCKPIT CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT WINDSHIELD CRACKED. 2L72 4T4 TRTA56EU E4WE 6 C3PNE 20040107000732004010700073 2004 1 7 AUS20031128 420031105G2565D31591478 SLIDE BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU R1 DOOR TWISTED W K NONE L NO TEST ININSP/MAINT 1 AUS (AUS) DOOR R1 ESCAPE SLIDE TWISTED DURING DEPLOYMENT. 2L72 4F4 FRTA16WE E21EU 20040107000752004010700075EA 2004 1 7 AUS20031129 220031021G7414LW13795 GEAR ROBSINR44 R44 7640120WP LYC O540 O540F1B5 41532EA MAGNETO DRIVE DAMAGED W O OTHER EY VIBRATION/BUFFET ENGINE STOPPAGE CRCRUISE 1 AUS 2170 (AUS) ENGINE FAILED. INITIAL INVESTIGATION REVEALED A FAILURE OF THE MAGNETO DRIVE SYSTEM. DURING AUTO ROTATION AND LANDING, ONE MAIN ROTOR BLADE CONTACTED THE TAILBOOM. FURTHER EXAMINATION FOUND THE CRANKSHAFT IDLER GEAR DAMAGED. SUSPECT CAUSED BY LOSS OF TORQUE ON THE STUD HOLDING THE CRANKSHAFT IDLER GEAR POSSIBLY CAUSED BY THREAD BEING STRIPPED DURING ASSEMBLY. 1G71 3O3 O H11NM E295 20040107000762004010700076NM 2004 1 7 AUS20031130 120031105G2597 WIRE BOEING737 737800* NM GE CFM56 CFM56* 13802NE COFFEEMAKER SEPARATED W O OTHER B SMOKE/FUMES/ODORS/SPARKS TXTAXI/GRND HDL 1 AUS (AUS) REAR GALLEY COFFEE MAKER FAULTY. SUSPECT INTERNAL SHORT CIRCUIT IN HOTPLATE SECTION. WIRING CLAMP SCREW AND WASHERS SEPARATED FROM HOTPLATE BASE. 2L72 4F4 FRTA16WE E2GL 20040107000772004010700077NM 2004 1 7 AUS20031131 120031106G276082950010123 TUBE DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE DRAG CONTROL CRACKED W O OTHER KJ FLUID LOSS WARNING INDICATION LDLANDING 1 AUS (AUS) LT OB ROLL SPOILER ACTUATOR HYDRAULIC LINE CRACKED AND LEAKING ON BEND RADIUS. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040126001132004012600113EU 2004 1 26 AUS20031132 120031105G771224045 PIN AEROSPAS365 AS365N2 8680815EU TMECA ARRIELARRIEL2B NE TORQUEMETER FAILED W O OTHER E VIBRATION/BUFFET TXTAXI/GRND HDL 1 AUS 564 (AUS) ENGINE TORQUEMETER PIN FAILED. PIN COULD NOT BE FOUND AND IT WAS SUSPECTED THAT THE PIN WAS SOMEWHERE IN THE ENGINE. ENGINE WAS REMOVED FOR REPAIR. 1G72 3U3 URTH10EU E00054EN 20040107000782004010700078NM 2004 1 7 AUS20031133 120031107G2720 CONTROL CABLE BOEING747 747438 NM RROYCERB211 RB211524G19 NE RUDDER BINDING W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RUDDER CONTROL SYSTEM BINDING AT RT PEDAL HALF TRAVEL. INVESTIGATION FOUND CONTROLS BINDING ON NR 4 DRIPSHIELD LOCATED IN FIRST CLASS CEILING AREA. 2L74 4F4 FRTA20WE E30NE 20040107000792004010700079NE 2004 1 7 AUS20031134 220031109G7230RB211524H COMPRESSOR BOEING767 767* NM RROYCERB211 RB211524* NE LT ENGINE DAMAGED W O OTHER EB VIBRATION/BUFFET SMOKE/FUMES/ODORS/SPARKS DEDESCENT 1 AUS 7866 (AUS) LT ENGINE HAD SPARKS AND FLAMES WITH EGT APPROXIMATELY 50 DEGREES HIGHER THAN THE RT ENGINE. BOROSCOPE INSPECTION OF THE HPC FOUND SIGNS OF DAMAGE TO FIRST AND SECOND STAGES. 2L72 4F4 FRTA1NM E12EU 20040107000802004010700080 2004 1 7 AUS20031135 420031107G6122DCFS29050T3 GOVERNOR CESSNA340 340CESSNA 2076404CE CONT O520 TSIO520K 17040SO MCAULY2AF34CD2AF34C71 GL PROPELLER CRACKED W O OTHER EK VIBRATION/BUFFET FLUID LOSS CLCLIMB 1 AUS 952 (AUS) LT PROPELLER GOVERNOR HEAD CRACKED. LOSS OF ENGINE OIL. 1L72 3O3 O 3A25 E8CE 5 CP5EA 20040107000902004010700090NM 2004 1 7 AUS20031137 120031111G278110608198 SWITCH BOEING727 7272J4 1384006NM PWA JT8 JT8D17 52049NE KRUEGER FLAP FAULTY W O OTHER N FALSE WARNING CLCLIMB 1 AUS (AUS) NR 5 LEADING EDGE KRUEGER FLAP POSITION SWITCH FAULTY. 2L73 4F4 FRTA3WE E2EA 20040108000072004010800007EU 2004 1 8 AUS20031138 120031107G2897MS154145 CIRCUIT BREAKER BAC 146 146100A 1500260EU LYC ALF502ALF502R5 41580NE FUEL BOOST PUMP BURNED OUT W O OTHER B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 AUS (AUS) LT INNER FUEL BOOST PUMP CIRCUIT BREAKER BURNED OUT. 2H74 4F4 FRTA49EU E6NE 20040108000482004010800048SW 2004 1 8 AUS20031141 120031030G6720206001059101 CONTROL ROD BELL 206 206B3 1181506SW ALLSN 250C 250C20B 03013GL TAIL ROTOR CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) TAIL ROTOR CONTROL TUBE SEVERELY CORRODED IN AREA UNDER FORWARD NYLATRON SLEEVE. INSPECTION FOUND CORROSION WAS BEYOND LIMITS AND WAS REPLACED. AIRCRAFT OPERATES IN A MARINE ENVIRONMENT. 1G71 3U3 U H2SW E4CE 20040108000492004010800049GL 2004 1 8 AUS20031142 120030506G2572552541 RACK AMTR VANS RV8 GL CONT O550 TSIO550B 17043SO MUHBR MTV MTV9* EU AUTOPILOT RACK FAULTY W O OTHER F FLT CONT AFFECTED CLCLIMB 1 AUS (AUS) AUTOPILOT RACK FAULTY. RACK WAS TOO LONG FOR COMPUTER AND THE PINS WOULD NOT MATE CORRECTLY. RACK WAS A NEW ITEM. 1L71 3O3 ONTEXPA1L71E5SO 5 CP24NE 20040108000502004010800050CE 2004 1 8 AUS20031143 120031016G27501460100708 CONTROL CABLE CESSNA337 T337G 2075726CE CONT O360 TSIO360C 17025SO MCAULY2AF34CD2AF34C303 GL TE FLAP FRAYED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT AND RT FLAP DOWN CABLES PN 1460100-7 AND PN 1460100-8 FRAYED WITH BROKEN STRANDS AROUND BELLCRANK ACTUATOR. 1H72 3O3 O A6CE E9CE 5 CP5EA 20040108000512004010800051EA 2004 1 8 AUS20031144 220031107G8520LW16586 TAPPET CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA MCAULY1C160 1C160DTM GL ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 200 (AUS) TAPPET INNER BODIES CRACKED (8OFF). 1H71 3O3 ONT3A12 E274 5 NP910 20040106000122004010600012EA 2004 1 6 AUS20031145 220031106G8520LW16586 TAPPET CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA MCAULY1C160 1C160DTM GL ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) TAPPET INNER BODIES CRACKED (8OFF). 1H71 3O3 ONT3A12 E274 5 NP910 20040107000122004010700012NE 2004 1 7 AUS20031146 220031112G7261AS3216119 RING DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE ENGINE OIL MISSING W K NONE K FLUID LOSS ININSP/MAINT 1 AUS (AUS) NR 2 ENGINE OIL TRANSFER TUBE FORWARD AND AFT RETAINING RINGS PNOAS3216-119 MISSING. TUBE RUNS BETWEEN REDUCTION GEARBOX AND SCAVENGE PUMP. PERSONNEL/MAINTENANCE ERROR. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040107000242004010700024NM 2004 1 7 AUS20031147 120031112G712065187226 FITTING BOEING727 727277 138408SNM PWA JT8 JT8D15 52051NE ENGINE MOUNT CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) NR 1 ENGINE FORWARD SUPPORT FITTING TOP SURFACE CORRODED IN AREA BETWEEN FITTING AND UPPER STRUT SKINS. FOUND DURING INSPECTION IAW AD/B727/151. 2L73 4F4 FRTA3WE E2EA 20040108000042004010800004EU 2004 1 8 AUS20031148 120031111G3411 PITOT TUBE BNORM BN2 BN2B20 1520302EU LYC O540 IO540K1B5 41532EA HARTZLHCC2Y HCC2YK2 GL PITOT/STATIC SYSCONTAMINATED W O OTHER S AFFECT SYSTEMS CLCLIMB 1 AUS (AUS) PITOT/STATIC SYSTEM CONTAMINATED WITH WATER. 1H72 3O3 O A17EU 1E4 5 CP920 20040108000052004010800005NM 2004 1 8 AUS20031149 120031112G3244161U00011 TIRE BOEING747 747438 NM RROYCERB211 RB211524G19 NE LT MLG DEFLATED W O OTHER O OTHER NRNOT REPORTED 1 AUS 921 (AUS) LT BODY LANDING GEAR NR 4 REAR TIRE FLAT. 2L74 4F4 FRTA20WE E30NE 20040108000062004010800006EA 2004 1 8 AUS20031150 220031113G732225765362 FUEL CONTROL CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA MCAULYIC235 IC235LFA7570EA ENGINE CONTAMINATED W K NONE OE OTHER VIBRATION/BUFFET ININSP/MAINT 1 AUS (AUS) FCU IMPACT DIAPHRAGM CHAMBER CONTAMINTED WITH FUEL/OIL. 1H71 3O3 ONT3A12 1E10 5 NP12EA 20040108000082004010800008SO 2004 1 8 AUS20031151 220031112G8520646311 PISTON CESSNA303 T303 2073820CE CONT O520 TSIO520AE 17040SO MCAULY3AF32C3AF32C506 GL ENGINE CRACKED W O OTHER E VIBRATION/BUFFET CRCRUISE 1 AUS (AUS) PISTON PN 646311 CRACKED IN BOSS. PISTON PIN PN 643846 BROKEN. 1L72 3O3 O A34CE E8CE 5 CP57GL 20040108000462004010800046GL 2004 1 8 AUS20031152 220031024G72306890550 ROTOR BELL 206 206B 1181511SW ALLSN 250C 250C20 03013GL COMPRESSOR DAMAGED W K NONE O OTHER ININSP/MAINT 1 AUS 1127 CAE831056 (AUS) COMPRESSOR ROTOR ASSEMBLY DAMAGED BY FOD. AIRCRAFT HAD BEEN REASSEMBLED FOLLOWING PAINTING WHICH INCLUDED WORK IN THE COMPRESSOR PLENUM AREA. 1G71 3U3 U H2SW E4CE 20040108000472004010800047NM 2004 1 8 AUS20031153 120031115G7920 B-NUT BOEING737 7377Q8 NM GE CFM56 CFM567B24 NE ENGINE OIL LOOSE W O OTHER KJ FLUID LOSS WARNING INDICATION CLCLIMB 1 AUS (AUS) NR 2 ENGINE REAR SUMP OIL PRESSURE LINE B-NUT LOOSE. LOOSE UNION IS LOCATED AT 6 O'CLOCK POSITION JUST OB OF THE ENGINE LUBRICATION UNIT. 2L72 4F4 FRTA16WE E00055EN 20040106000132004010600013NE 2004 1 6 AUS20031154 220031111G8530 CYLINDER DOUG DC3 DC3CS1C3G 3021458WP PWA R1830 R183092 52020NE HAMSTD23E 23E50 NE ENGINE FAILED W O OTHER E VIBRATION/BUFFET CRCRUISE 1 AUS (AUS) NR 12 CYLINDER FAILED. LIMITED INFORMATION PROVIDED. 2L72 4R4 R A669 5E4 6 CP603 20040107000092004010700009EU 2004 1 7 AUS20031155 120030829G2797 WIRE REIMS 406 F406 7535723EU PWA PT6 PT6A112 52043NE MCAULY3G34C73GFR34C701 GL TE FLAPS BROKEN W O OTHER F FLT CONT AFFECTED CLCLIMB 1 AUS (AUS) FLAP UP MICROSWITCH WIRE BROKEN. SWITCH IS LOCATED BEHINDFLAP SELECTOR. 1L72 3T3 TRTA54EU E4EA 5 CP60GL 20040107000102004010700010NE 2004 1 7 AUS20031156 220031114G73103035987 PIPE DHAV DHC8 DHC8202 2809007NM PWA 120 PW123D 52152NE HAMSTD14SF 14SF23 NE ENGINE FUEL LOOSE W O OTHER EKJVIBRATION/BUFFET FLUID LOSS WARNING INDICATION CLCLIMB 1 AUS (AUS) LT ENGINE FUEL PRESSURE PIPE ATTACHMENT NUT LOOSE AND LEAKING. ATTACHMENT NUT HAD BEEN LOOSENED DURING FUEL NOZZLE REPLACEMENT. THE NUT HAD NOT BEEN RETORQUED OR LOCKWIRED DURING REINSTALLATION. PERSONNEL/MAINTENANCE ERROR. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040107000112004010700011EA 2004 1 7 AUS20031157 220030827G8530 EXHAUST VALVE PIPER PA38 PA38112 7103812SO LYC O235 O235L2A 41505EA SNSNCH72C 72CK EA ENGINE SEPARATED W O OTHER E VIBRATION/BUFFET CRCRUISE 1 AUS (AUS) NR 2 CYLINDER EXHAUST VALVE HEAD SEPARATED FROM VALVE STEM. ENGINE HAD BEEN SITTING IDLE FOR AT LEAST 18 MONTHS AND HAD JUST BEEN RETURNED TO OPERATION. 1L71 3O3 O A18SO E223 5 NP9045 20040107000252004010700025NM 2004 1 7 AUS20031158 120031117G2611473054 SMOKE DETECTOR DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE CARGO BAY MALFUNCTIONED W O OTHER N FALSE WARNING CRCRUISE 1 AUS (AUS) BAGGAGE COMPARTMENT SMOKE DETECTOR FAULTY. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040108000022004010800002EU 2004 1 8 AUS20031159 120031116G2742 ACTUATOR AIRBUS330 A330202 3930316EU GE CF6 CF680 30025NE HORIZONTAL STAB INCORRECT W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) INCORRECT GREASE USED ON TRIM ABLE HORIZONTAL STABILIZER ACTUATOR (THSA). AEROSHELL 22 USED INSTEAD OF CORRECT AEROSHELL 33. USE OF INCORRECT GREASE MAKES AIRCRAFT NON COMPLIANT WITH AD/330/7.UNAPPROVED PART. PERSONNEL/MAINTENANCE ERROR. 2L72 4F4 FRTA46NM E13NE 20040107001142004010700114NM 2004 1 7 AUS20031160 120031003G5313 STRINGER BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) STRINGER CRACKED AT RIVET HOLE LOCATED FORWARD OF FRAME 328. CRACK LENGTH APPROXIMATELY 0.0254MM (0.1IN). FOUND DURING EDDY CURRENT INSPECTION. 2L72 4F4 FRTA16WE E21EU 20040108000032004010800003NM 2004 1 8 AUS20031161 120031003G5712 RIB BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU WING CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) WING RIB LOCATED AT WBL 135.5 CRACKED AT LOWER CUT-OUT FOR STR 1 ON RT SIDE. CRACK LENGTH 25.4MM (1IN). FOUND DURING EDDY CURRENT INSPECTION. 2L72 4F4 FRTA16WE E21EU 20040108000092004010800009EU 2004 1 8 AUS20031162 120031114G56109598110108 WINDSHIELD PILATSPC12 PC12 7090550EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL COCKPIT CRACKED W O OTHER O OTHER NRNOT REPORTED 1 AUS (AUS) COPILOT'S WINDSHIELD CRACKED IN OUTER LAYER. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040108000432004010800043EA 2004 1 8 AUS20031163 220031114G8520LW16586 TAPPET LYC O320 O320H2AD 41508EA ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) HYDRAULIC LIFTERS (2 OFF) CRACKED. TAPPETS WERE NEW ITEMS. 3 O E274 20040108000442004010800044EU 2004 1 8 AUS20031164 120031103G5711TB2011003100 SPAR SOCATATB20 TB20TRINIDAD8680695EU LYC O540 IO540C4D5 41532EA HARTZLHCC2Y HCC2YK1 GL LT & RT WING CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS 3969 (AUS) LT AND RT MAIN WING SPARS CORRODED ON REAR FACE. SPAR PN TB20-11-003-100 AND PN TB20-11-003-101. 1L71 3O3 ORTA51EU 1E4 5 CP920 20040108000452004010800045SO 2004 1 8 AUS20031165 120031023G28206390115 HOSE PIPER PA28 PA28140 7102802SO LYC O320 O320E2D 41508EA SNSNCH74DM M74DM EA FUEL DIST DETERIORATED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FUEL SUPPLY HOSE FROM TANK OUTER SECTION PERISHED. 1L71 3O3 O 2A13 E274 5 NP88614 20040106000152004010600015SO 2004 1 6 AUS20031166 120031023G28206390115 HOSE PIPER PA28 PA28140 7102802SO LYC O320 O320E2D 41508EA SNSNCH74DM M74DM EA AIRCRAFT FUEL DETERIORATED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FUEL SUPPLY HOSE FROM TANK OUTER SECTION PERISHED. 1L71 3O3 O 2A13 E274 5 NP88614 20040107000062004010700006NE 2004 1 7 AUS20031167 220031117G7200 ENGINE BOEING747 747438 NM RROYCERB211 RB211524G19 NE NR 2 FAILED W O OTHER J WARNING INDICATION NRNOT REPORTED 1 AUS 13988 CW15 (AUS) NR 2 ENGINE FAILURE. 2L74 4F4 FRTA20WE E30NE 20040107000072004010700007SO 2004 1 7 AUS20031168 120030525G28203038 HOSE PIPER PA31 PA31 7103102SO LYC O540 TIO540A2C 41532EA HARTZLHCE3Y HCE3YR2 GL FUEL SYSTEM DETERIORATED W K NONE O OTHER ININSP/MAINT 1 AUS NA (AUS) FUEL HOSE LOCATED BETWEEN FUEL SELECTOR AND FUEL BOWL PERISHED. 1L72 3O3 O A20SO E14EA 5 CP33EA 20040107000082004010700008SO 2004 1 7 AUS20031169 120031023G32406390117 HOSE PIPER PA28 PA28140 7102802SO LYC O320 O320E2D 41508EA SNSNCH74DM M74DM EA BRAKE ASSY DETERIORATED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT BRAKE HOSE OUTER COVERING DETERIORATED. 1L71 3O3 O 2A13 E274 5 NP88614 20040107000262004010700026SO 2004 1 7 AUS20031170 120031103G32136531904 CYLINDER PIPER PA28 PA28140 7102802SO LYC O320 O320E2D 41508EA SNSNCH74DM M74DM EA MLG CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) MAIN LANDING GEAR CYLINDER CRACKED IN LOWER SECTION OF TORQUE LINK ATTACHMENT LUG. 1L71 3O3 O 2A13 E274 5 NP88614 20040107001092004010700109SO 2004 1 7 AUS20031171 120030725G571278475006 RIB PIPER PA32 PA32R301 7103218SO LYC O540 IO540K1G5 41532EA HARTZLHCC2Y HCC2YK1 GL WING CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) WING RIB LOCATED AT WS 49.25 CRACKED. 1L71 3O3 O A3SO 1E4 5 CP920 20040107001102004010700110SO 2004 1 7 AUS20031172 120030725G571278475007 RIB PIPER PA32 PA32R301 7103218SO LYC O540 IO540K1G5 41532EA HARTZLHCC2Y HCC2YK1 GL WING CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) WING RIB LOCATED AT WS 49.25 CRACKED. 1L71 3O3 O A3SO 1E4 5 CP920 20040107001112004010700111SW 2004 1 7 AUS20031173 120031112G2910SS1009H000A110 HOSE SWRNGNSA227 SA227* SW GARRTTTPE331TPE33112UHR WP MCAULY4HFR344HFR34C652 NE HYD SYSTEM BURST W A UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 AUS (AUS) RT HYDRAULIC PUMP MAIN PRESSURE LINE FAILED. LOSS OF HYDRAULIC FLUID. BOTH HYDRAULIC PUMPS UNSERVICEABLE DUE TO LACK OF FLUID. 2L72 4T4 TRTA5SW E4WE 6 C3PNE 20040107001122004010700112SO 2004 1 7 AUS20031174 120031120G781040310010 EXHAUST PIPE PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2 GL ENGINE DAMAGED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT ENGINE EXHAUST SEGMENT, HOLE IN AREA TO THE REAR OF THE TURBOCHARGER. 1L72 3O3 O A20SO E14EA 5 CP33EA 20040108000102004010800010SO 2004 1 8 AUS20031175 120031120G81204773120000 SPRING GARRTT PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2 GL WASTEGATE BROKEN W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT ENGINE TURBOCHARGER WASTEGATE OPEN, ASSIST SPRING BROKEN. 1L72 3O3 O A20SO E14EA 5 CP33EA 20040108000372004010800037SO 2004 1 8 AUS20031176 220031119G8530 NUT CESSNA182 182Q 2072732CE CONT O470 O470U 17026SO MCAULY2A34C 2A34C203 GL ENGING CYLINDER LOOSE W K NONE O OTHER ININSP/MAINT 1 AUS 450 (AUS) CYLINDER HOLDDOWN STUD NUTS MISSING OR LOOSE. MISSING NUTS FOUND IN ENGINE COWL. 1H71 3O3 ONT3A13 E273 5 CP3EA 20040108000382004010800038SW 2004 1 8 AUS20031177 120031110G1430NAS660427 BOLT SWRNGNSA227 SA227AC 8780603SW GARRTTTPE331TPE33111U 01514WP ROTOL R321 R321482F8 GL MLG BROKEN W K NONE O OTHER CLCLIMB 1 AUS (AUS) RT MAIN LANDING GEAR UPLOCK ROLLER ATTACHMENT BOLT BROKEN. 2L72 4T4 TRTA8SW E4WE 6 CP61GL 20040106000172004010600017SW 2004 1 6 AUS20031178 120031111G3260602EN6026 SQUAT SWITCH SWRNGNSA227 SA227* SW GARRTTTPE331TFE33112UHR WP MCAULY4HFR344HFR34C652 NE MLG FAILED W O OTHER N FALSE WARNING CLCLIMB 1 AUS (AUS) LT MAIN LANDING GEAR SQUAT SWITCH FAILED. 2L72 4T4 TRTA5SW E4WE 6 C3PNE 20040107000042004010700004CE 2004 1 7 AUS20031179 120031114G3244277K081 TIRE CESSNA441 441 2076020CE GARRTTTPE331TPE3318 01514WP HARTZLHCB3T HCB3TN5 GL RT MLG DEFLATED W O OTHER O OTHER LDLANDING 1 AUS (AUS) RT MAIN LANDING GEAR TIRE, DEFLATED DURING LANDING ROLL. 1L72 3T4 TRTA28CE E4WE 6 CP15EA 20040107000052004010700005EA 2004 1 7 AUS20031180 220031112G8550 OIL SYSTEM PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2 GL ENGINE CONTAMINATED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) ENGINE OIL SYSTEM CONTAMINATED BY UNKNOWN NON-FERROUS ITEMS. CONTAMINATES WERE SIMILAR TO SMALL PEBBLES AND WERE APPROXIMATELY 5MM BY 5MM (0.196IN BY 0.196IN) IN SIZE. 1L72 3O3 O A20SO E14EA 5 CP33EA 20040107000272004010700027NM 2004 1 7 AUS20031181 120031113G28226072101 PUMP BOEING747 747438 NM RROYCERB211 RB211524G19 NE FUEL BOOST OBSTRUCTED W K NONE O OTHER ININSP/MAINT 1 AUS 26529 (AUS) FORWARD OVERBOARD/JETTISON PUMP INLET HOUSING AND INLET CHECK VALVE WORN BEYOND LIMITS. AFT OVERBOARD/JETTISON PUMP INLET CHECK VALVE DETACHED AND BLOCKING PUMP INLET. 2L74 4F4 FRTA20WE E30NE 20040107001012004010700101EU 2004 1 7 AUS20031182 120030715G2497121972 SPLICE BAC 146 146200A 1500266EU LYC ALF502ALF502R5 41580NE AC POWER DAMAGED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) IDG FEEDER CABLE INLINE SPLICE WAS PRE SB-24-85-01253A. PRE MOD SPLICES PN 12197/2 WERE FITTED INSTEAD OF PN 12198/2 SPLICES. 2H74 4F4 F A49EU E6NE 20040107001022004010700102EU 2004 1 7 AUS20031183 120031119G2434ALU8421R ALTERNATOR BNORM BN2 BN2B20 1520302EU LYC O540 IO540K1B5 41532EA HARTZLHCC2Y HCC2YK2 GL RIGHT FAILED W O OTHER HJ ELECT. POWER LOSS-50 PC WARNING INDICATION CLCLIMB 1 AUS (AUS) RT ALTERNATOR FAILED. 1H72 3O3 O A17EU 1E4 5 CP920 20040107001032004010700103CE 2004 1 7 AUS20031184 120031029G32438000016 SEAL CESSNA CESSNA310 310R 2074245CE CONT O520 IO520M 17032SO MCAULY3AF32C3AF32C87 GL MASTER CYLINDER WORN W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) BRAKE MASTER CYLINDER SEAL WORN. 1L72 3O3 O 3A10 E5CE 5 CP22EA 20040107001042004010700104EA 2004 1 7 AUS20031185 220031030G8530IO360L2A EXHAUST VALVE CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA MCAULYIC235 IC235LFA7570EA ENGINE BURNED W K NONE O OTHER ININSP/MAINT 1 AUS 1323 (AUS) EXHAUST VALVES ON ALL FOUR CYLINDER BURNED. CAUSED BY FAULTY SWAGING ON ENGINE INDUCTION PIPES WHICH ALLOWED LEAN MIXTURE TO CYLINDERS. 1H71 3O3 ONT3A12 1E10 5 NP12EA 20040108000112004010800011NE 2004 1 8 AUS20031186 320031116G6111L106LA0 BLADE SWRNGNSA227 SA227* SW GARRTTTPE331TPE33112UHR WP MCAULY4HFR344HFR34C652 NE PROPELLER UNSERVICEABLE W O OTHER E VIBRATION/BUFFET NRNOT REPORTED 1 AUS 4190 (AUS) LT ENGINE PROPELLER BLADE FAULTY. LIMITED INFORMATION PROVIDED. 2L72 4T4 TRTA5SW E4WE 6 C3PNE 20040108000362004010800036EU 2004 1 8 AUS20031187 120031123G21217881601 FAN FOKKERF27 F27MK50 EU PWA PWA120PW125B NE ROTOL R352 R3526123F1 GL AIR DISTRIBUTIONFAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CLCLIMB 1 AUS 24707 (AUS) LT RECIRCULATING FAN FAILED. 2H72 4T4 TRTA817 E20NE 6 CP16NG 20040106000192004010600019GL 2004 1 6 AUS20031188 320031113G6110660715001 PROPELLER FOKKERF27 F27MK50 EU PWA PWA120PW125B NE ROTOL R352 R3526123F1 GL LEFT DAMAGED W O OTHER F FLT CONT AFFECTED NRNOT REPORTED 1 AUS 5133 (AUS) LT PROPELLER FAULTY. LIMITED INFORMATION PROVIDED. 2H72 4T4 TRTA817 E20NE 6 CP16NG 20040106001792004010600179EU 2004 1 6 AUS20031189 120031115G3230F8553048401 LINE FOKKERF27 F27MK50 EU PWA PWA120PW125B NE ROTOL R352 R3526123F1 GL MLG FAILED W A UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CLCLIMB 1 AUS 2614 (AUS) LT MAIN LANDING GEAR UP LINE FAILED. LOSS OF HYDRAULIC FLUID. 2H72 4T4 TRTA817 E20NE 6 CP16NG 20040106001802004010600180NM 2004 1 6 AUS20031190 120031122G3397 CIRCUIT BOARD DHAV DHC8 DHC8103 1386005NM PWA PW121 PW121 52124NE HAMSTD14SF 14SF7 NE CABIN LIGHT FAILED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) DURING INSPECTION IAW AD/DHC-8/027 THE FOLLOWING WAS OBSERVED:- 1. RT ROW 2 PSU PCB SHOWS EVIDENCE OF OVERHEATING AT CONNECTIONS TO Q2.2. RT ROW 4 PSU PCB SHOWS EVIDENCE OF OVERHEATING AT CONNECTIONS TO J2.3. RT ROW 8 PSU PCB SHOWS EVIDENCE OF OVERHEATING AT CONNECTIONS TO J2. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040107000012004010700001 2004 1 7 AUS20031191 420031122G34212593996333 GYRO BELL 412 412 1182202SW PWA PT6T PT6T3B 52045NE ATTITUDE FAILED W O OTHER F FLT CONT AFFECTED CRCRUISE 1 AUS (AUS) COPILOT TARSYN GYRO FAILED. 1G72 4U4 U H4SW E22EA 20040107000282004010700028SW 2004 1 7 AUS20031192 120031110G2752 CASE SWRNGNSA227 SA227* SW GARRTTTPE331TPE33112UHR WP MCAULY4HFR344HFR34C652 NE TE FLAP ACTUATORCRACKED W O OTHER KJ FLUID LOSS WARNING INDICATION NRNOT REPORTED 1 AUS 11722 SC873B (AUS) LT FLAP ACTUATOR CASE CRACKED AND LEAKING. 2L72 4T4 TRTA5SW E4WE 6 C3PNE 20040107001052004010700105SO 2004 1 7 AUS20031193 120031116G3241426871 CONTROL UNIT EMB 120 EMB120 3260201SO PWA 118 PW118A NE HAMSTD14RF 14RF9 NE ANTISKID SYS UNSERVICEABLE W O OTHER O OTHER LDLANDING 1 AUS 3252 (AUS) ANTI-SKID SYSTEM CONTROL BOX FAILED. 2L72 4T4 TRTA31SO E20NE 6 CP11NE 20040107001062004010700106SO 2004 1 7 AUS20031194 120031116G2997W602004022 WIRE HARNESS EMB 120 EMB120 3260201SO PWA 118 PW118A NE HAMSTD14RF 14RF9 NE HYDRAULIC POWER WORN W O OTHER KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 AUS 23711 (AUS) RT HYDRAULIC SYSTEM LOOM WIRE W602-0040-22 CHAFING ON HYDRAULIC PIPE. LOOM RUNS FROM THE TOP OF THE RT REAR NACELLE TO THE TRAILING EDGE. 2L72 4T4 TRTA31SO E20NE 6 CP11NE 20040107001072004010700107NE 2004 1 7 AUS20031195 220031123G7230311489101 VALVE DHAV DHC8 DHC8202 2809007NM PWA 120 PW123D 52152NE HAMSTD14SF 14SF23 NE ENGINE FAULTY W O OTHER B SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 AUS (AUS) ENGINE P2.5/P3 SWITCHING VALVE STICKING INTERMITTENTLY ALLOWING OIL VAPOUR INTO THE AIR CONDITIONING SYSTEM. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040107001082004010700108NE 2004 1 7 AUS20031196 220031118G7230PCE123321 BEARING DHAV DHC8 DHC8202 2809007NM PWA 120 PW123D 52152NE HAMSTD14SF 14SF23 NE NR 4 FAULTY W O OTHER B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 AUS (AUS) BOROSCOPE INSPECTION OF LT ENGINE FOLLOWING FUMES IN THE AIR CONDITIONING SYSTEM FOUND OIL LEAKING IN THE NR 4 BEARING AREA. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040108000122004010800012CE 2004 1 8 AUS20031197 120031114G329751184122 DIODE CESSNA340 340CESSNA 2076404CE CONT O520 TSIO520K 17040SO MCAULY2AF34CD2AF34C71 GL MLG FAILED W O OTHER O OTHER LDLANDING 1 AUS (AUS) LANDING GEAR ELECTRICAL CIRCUIT DIODE FAILED. INVESTIGATION FOUND POWER WAS BACK FEEDING FROM THE PRESS TO TEST CIRCUIT. 1L72 3O3 O 3A25 E8CE 5 CP5EA 20040108000392004010800039EA 2004 1 8 AUS20031199 220030916G7414101630052R MAGNETO ROBSINR22 R22BETA 7640110NM LYC O320 O320B2C 41508EA ENGINE FAILED W K NONE O OTHER ININSP/MAINT 1 AUS 192 L1699939 (AUS) LT MAGNETO HOUSING FAILED ALLOWING MAGNETO SHAFT TO COCK TO ONE SIDE AND SEIZE CAUSING DAMAGE TO MAGNETO DRIVE GEAR. 1G71 3O3 O H10WE E274 20040108000402004010800040GL 2004 1 8 AUS20031200 120030921G5720 FLYING WIRE AMTR VANS RV8 GL ROTAX 912 ROTAX912 55555EU AMTR C8289 C8289 GL WING FAILED W O OTHER O OTHER NRNOT REPORTED 1 AUS (AUS) FLYING WIRE BROKEN. INVESTIGATION FOUND FLYING WIRES WERE UNDERSIZE. AIRCRAFT IS AMATEUR BUILT. PERSONNEL/MAINTENANCE ERROR. UNAPPROVED PART. 1L71 3O3 INTEXPA1L71EXPE3I 5 NEXPP5N 20040108000412004010800041EU 2004 1 8 AUS20031201 120031124G27219787314203 ACTUATOR PILATSPC12 PC12 7090550EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL RUDDER TAB CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS 343 (AUS) PITCH TRIM ACTUATOR TOP ATTACHMENT FITTING CORRODED. SUSPECTED INTERGRANNULAR TYPE CORROSION IS CAUSING THE SURFACE PROTECTIVE COATING TO LIFT. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040108000422004010800042CE 2004 1 8 AUS20031202 120031124G571104263071 SPAR CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA MCAULY1A103 1A103TCM GL RT WING CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT WING SPAR ANGLE CONTAINED INTERGRANNULAR CORROSION IN AREA WHERE IT PASSES THROUGH THE FUEL TANK CAVITY. 1H71 3O3 ONT3A19 E223 5 NP50GL 20040106000202004010600020EA 2004 1 6 AUS20031203 220031111G7414101630456R MAGNETO ROBSINR22 R22BETA 7640110NM LYC O320 O320B2C 41508EA ENGINE UNSERVICEABLE W K NONE O OTHER ININSP/MAINT 1 AUS 396 (AUS) RT MAGNETO HOUSING SEPARATING DUE TO LOOSE RETAINING SCREWS. INTERNAL INSPECTION ALSO FOUND THAT THE ROTATING MAGNET HAD CONTACTED THE HOUSING CAUSING DAMAGE TO BOTH ITEMS. 1G71 3O3 O H10WE E274 20040106001762004010600176CE 2004 1 6 AUS20031204 120031117G2797 WIRE CESSNA206 U206F 2073333CE CONT O520 IO520F 17032SO MCAULYD3A34 D3A34C404 GL AILERON CONTROL LOOSE W C ABORTED TAKEOFF F FLT CONT AFFECTED TOTAKEOFF 1 AUS (AUS) PILOT REPORTED AILERONS JAMMING AFTER TAKE OFF. THE JAMMING CONTINUED INTERMITTENTLY AND AFTER LANDING THE PILOT WAS ABLE TO DUPLICATE THE PROBLEM. IT WAS SUSPECTED THAT A LOOSE WIRE MAY HAVE BEEN FOULING WITH THE PULLEY ON THE PILOTS CONTROL YOKE. 1H71 3O3 O A4CE E5CE 5 CP47GL 20040106001772004010600177NM 2004 1 6 AUS20031205 120031125G5397 WIRE HARNESS BOEING747 747338 NM RROYCERB211 RB211524D41954555NE FUSELAGE WORN W K NONE B SMOKE/FUMES/ODORS/SPARKS ININSP/MAINT 1 AUS (AUS) WIRING LOOM LOCATED AT BS 1000 BEHIND OVERHEAD LOCKERS CHAFED THROUGH INSULATION BLANKET AND CONTACTED FUSELAGE FRAME CAUSING BURNING OF WIRES AND DAMAGE TO THE INSULATION BLANKET AND FRAME. AREA OF DAMAGE TO FRAME WAS APPROXIMATELY 4.762MM BY 2.381MM(0.185IN BY 0.0937IN). 2L72 4F4 FRTA20WE E12EU 20040106001782004010600178WP 2004 1 6 AUS20031206 120031124G6210C0162 BLADE ROBSINR44 R44 7640120WP LYC O540 O540F1B5 41532EA MAIN ROTOR DELAMINATED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) MAIN ROTOR BLADE UPPER SKIN SUSPECT DELAMINATED. DELAMINATED AREA STARTS APPROXIMATELY 381MM (15IN) IN FROM BLADE TIP TO 1295.4MM (51IN) FROM THE BLADE TIP AND 63.5MM (2.5IN) IN FROM THE LEADINGEDGE. FOUND DURING INSPECTION IAW AD/R44/18. 1G71 3O3 O H11NM E295 20040107000292004010700029NM 2004 1 7 AUS20031207 120031126G3233 EYEBOLT BOEING747 747438 NM RROYCERB211 RB211524G19 NE MLG ACTUATOR LOOSE W K NONE O OTHER ININSP/MAINT 1 AUS 54609 (AUS) RT WING LANDING GEAR RETRACTION ACTUATOR EYE END UNSCREWED BY APPROXIMATELY 12.7MM (0.5IN). 2L74 4F4 FRTA20WE E30NE 20040107000952004010700095SO 2004 1 7 AUS20031208 120031127G7810LW12437 EXHAUST DUCT PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2 GL ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT ENGINE EXHAUST TRANSITION CRACKED. 1L72 3O3 O A20SO E14EA 5 CP33EA 20040107000962004010700096EU 2004 1 7 AUS20031209 220031126G7310737M28500011 VALVE BOEING737 7374Q8 138447QNM CFMINTCFM56 CFM563C 13802EU ENGINE FUEL FAILED W O OTHER EK VIBRATION/BUFFET FLUID LOSS TXTAXI/GRND HDL 1 AUS (AUS) NR 1 ENGINE FUEL SHUTOFF VALVE FAULTY. 2L72 4F4 FRTA16WE E21EU 20040108000132004010800013SW 2004 1 8 AUS20031210 120031125G5710 STRUCTURE SWRNGNSA227 SA227* SW GARRTTTPE331TFE33112UHR WP RT WING BIRD STRIKE W O OTHER O OTHER NRNOT REPORTED 1 AUS 14147 (AUS) RT WING LEADING EDGE DAMAGED BY BIRDSTRIKE. 2L72 4T4 TRTA5SW E4WE 20040108000332004010800033NM 2004 1 8 AUS20031211 120031123G3810DR62B WATER HEATER BOEING767 767238 1385114NM PWA JT9 JT9D7R4E 52054NE GALLEY FAULTY W O OTHER B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 AUS (AUS) AFT GALLEY NR 1 WATER BOILER FAULTY. 2L72 4F4 FRTA1NM E3NE 20040108000342004010800034NM 2004 1 8 AUS20031212 120031127G2910DSC252B40124 HOSE DHAV DHC8 DHC8202 2809007NM PWA 120 PW123D 52152NE HAMSTD14SF 14SF23 NE HYD SYSTEM FAILED W O OTHER KJ FLUID LOSS WARNING INDICATION CLCLIMB 1 AUS 99999 (AUS) NOSE LANDING GEAR RETRACTION HOSE WALL FAILED. LOSS OF NR 2 HYDRAULIC SYSTEM FLUID. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040106000212004010600021NM 2004 1 6 AUS20031213 120031006G5312 BULKHEAD BOEING737 7373Q8 1384670NM CFMINTCFM56 CFM563C 13802EU FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FORWARD PRESSURE BULKHEAD CRACKED IN WEB LOCATED AT THE TOP INBOARD CORNER OF THE LOWER LT RADAR MOUNT. CRACK LENGTH APPROXIMATELY 9.525MM (0.375IN). FOUND DURING ULTRASONIC AND EDDY CURRENT INSPECTION IAW AD/B737/141. 2L72 4F4 FRTA16WE E21EU 20040227000012004022700001GL 2004 2 27 AUS20031214 120031027G510220BHB HOSE AMTR KAVAGHB400 GL PROPANE FIRE W O OTHER A FLAME/FIRE CRCRUISE 1 AUS 88 (AUS) VAPOUR PILOT LIGHT HOSE CAUGHT FIRE. DAMAGE TO HOSE MADE THE CAUSE OF THE FIRE DIFFICULT TO ASSESS BUT IT WAS SUSPECTED THAT THE HOSE HAD A SMALL HOLE OR SPLIT WHICH ALLOWED PROPANE GAS TO LEAK AND IGNITE. 1B00 EXPA1B00 20040107000022004010700002WP 2004 1 7 AUS20031215 120031016G6720C0311 PITCH CONTROL ROBSINR44 R44 7640120WP LYC O540 O540F1B5 41532EA TAIL ROTOR ROUGH W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) TAIL ROTOR PITCH CONTROL SYSTEM ROUGH IN OPERATION. FOUND DURING INSPECTION IAW AD/R44/17. 1G71 3O3 O H11NM E295 20040107000032004010700003SW 2004 1 7 AUS20031216 120031126G29102781032001 TUBE SWRNGNSA227 SA227AC 8780603SW GARRTTTPE331TPE33111U 01514WP ROTOL R321 R321482F8 GL HYD SYSTEM CRACKED W K NONE K FLUID LOSS ININSP/MAINT 1 AUS (AUS) LANDING GEAR HYDRAULIC TUBE CRACKED AND LEAKING IN BEND RADIUS. 2L72 4T4 TRTA8SW E4WE 6 CP61GL 20040107000302004010700030SO 2004 1 7 AUS20031217 220031125G8530639649 ROCKER PAC CT4 CT4B GL CONT O360 IO360HB 17025SO HARTZLHCC2Y BHCC2YF1 GL ENGINE CYLINDER DEFORMED W O OTHER EF VIBRATION/BUFFET FLT CONT AFFECTED CRCRUISE 1 AUS BT24032 (AUS) NR 4 CYLINDER INTAKE ROCKER DEFORMED. SUSPECT MANUFACTURING ERROR. ROCKER SHAFT RETENTION STUD BROKEN. 1L71 3O3 ORTA9PC E1CE 5 CP920 20040107000972004010700097CE 2004 1 7 AUS20031218 120031125G3233 CAP BEECH 1900 1900C 1154161CE PWA PT6 PT6A65B 52043EA HARTZLHCB4M HCB4MP3 GL ACTUATOR CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 18286 (AUS) NOSE LANDING GEAR ACTUATOR END CAP CRACKED. 2L72 4T4 TRTA24CE E4EA 6 CP56GL 20040107000982004010700098NE 2004 1 7 AUS20031219 220031128G7200 ENGINE SAAB SF340 SF340A 7850100EU GE CT7TP CT75A2 30030NE ROTOL R354 R3544123F13 NE RIGHT MALFUNCTIONED W C ABORTED TAKEOFF R PARTIAL RPM/PWR LOSS TOTAKEOFF 1 AUS (AUS) DURING TAKEOFF RT ENGINE POWER WOULD NOT INCREASE TO TAKEOFF SETTINGS. THE RT ENGINE INDICATIONS REMAINED AT 85 PERCENT TO 90 PERCENT TORQUE AND THE RT PROPELLER WAS REPORTED TO REDUCE TO 1100 RPM. ENGINE GROUND RUNS AND FUNCTIONAL CHECKS COULD NOT CONFIRM OR REPRODUCE THE FAULT. AIRCRAFT HAS OPERATED FOR SEVERAL FLIGHTS WITH NO FURTHER PROBLEMS. DEFECT NOT CONFIRMED. 2L72 4T4 TRTA52EU E8NE6 6 CP61GL 20040107000992004010700099NM 2004 1 7 AUS20031220 120031117G2436GC1010245DIII GCU DHAV DHC8 DHC8202 2809007NM PWA 120 PW123D 52152NE HAMSTD14SF 14SF23 NE DC SYSTEM FAULTY W O OTHER HJ ELECT. POWER LOSS-50 PC WARNING INDICATION CRCRUISE 1 AUS (AUS) NR 1 DC GENERATOR AND GCU SUSPECT FAULTY. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040107001002004010700100EA 2004 1 7 AUS20031221 220031128G7250 ENGINE BELL 412 412 1182202SW PWA PT6T PT6T3 52045EA NOISY W O OTHER O OTHER NRNOT REPORTED 1 AUS (AUS) ENGINE POWER SECTION REMOVED DUE TO UNKNOWN NOISE. 1G72 4U4 U H4SW E22EA 20040108000142004010800014NM 2004 1 8 AUS20031222 120031119G2912271T006812 FILTER BOEING767 767* NM RROYCERB211 RB211524* NE HYDRAULIC SYSTEMDAMAGED W O OTHER KJ FLUID LOSS WARNING INDICATION CLCLIMB 1 AUS (AUS) LT HYDRAULIC FLUID DISCHARGED THROUGH DELTA (P) FITTING IN HYDRAULIC PUMP PRESSURE MODULE. 2L72 4F4 FRTA1NM E12EU 20040108000292004010800029NM 2004 1 8 AUS20031223 120031201G3244445X16 TIRE BOEING737 737* NM GE CFM56 CFM567B24 NE LT MLG FAILED W O OTHER O OTHER TXTAXI/GRND HDL 1 AUS (AUS) LT LANDING GEAR NR 2 TIRE BLEW OUT DURING TAXI. 2L72 4F4 FRTA16WE E00055EN 20040108000302004010800030EU 2004 1 8 AUS20031224 120031128G29329738114306 PRESSURE SWITCH PILATSPC12 PC12 7090550EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL HYD SYSTEM INTERMITTENT W O OTHER KJ FLUID LOSS WARNING INDICATION CLCLIMB 1 AUS (AUS) HYDRAULIC PRESSURE SWITCH INTERMITTENT IN OPERATION. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040108000312004010800031WP 2004 1 8 AUS20031225 120031202G1430NAS660531 BOLT ROBSINR44 R44 7640120WP LYC O540 O540F1B5 41532EA M/R SWASHPLATE MISMANUFACTURED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) MAIN ROTOR SWASHPLATE LOWER BOLT DAMAGED. INVESTIGATION FOUND A FLAT SPOT ON THE BLADE SHANK. SUSPECT MANUFACTURING ERROR AS FLAT SPOT HAD BEEN CADMIUM PLATED. FOUND DURING INSPECTION IAW AD/R44/20. 1G71 3O3 O H11NM E295 20040108000322004010800032NM 2004 1 8 AUS20031226 120031129G282020C1444 CHECK VALVE BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU FUEL TANK CRACKED W O OTHER KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 AUS 2176 (AUS) CENTER FUEL TANK RT BOOST PUMP DISCHARGE CHECK VALVE BODY CRACKED. CRACK LENGTH APPROXIMATELY 31.75MM (1.25IN). 2L72 4F4 FRTA16WE E21EU 20040106000222004010600022NM 2004 1 6 AUS20031227 120031126G7830 PLATE BOEING767 767330 NM RROYCERB211 RB211524* NE THRUST REVERSER SEPARATED W O OTHER E VIBRATION/BUFFET LDLANDING 1 AUS (AUS) NR 1 ENGINE THRUST REVERSER CASCADE VANE BLANKING PLATE SEPARATED AND ENTERED ENGINE CAUSING DAMAGE TO FAN BLADES (12OFF) AND ACOUSTIC PANEL. 2L72 4F4 FRTA1NM E12EU 20040106001442004010600144NE 2004 1 6 AUS20031228 320031129G61118022531 COLLAR DHAV DHC8 DHC8315 2809010NM PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE PROPELLER BLADE SEPARATED W C ABORTED TAKEOFF D INFLIGHT SEPARATION TOTAKEOFF 1 AUS 88362723 (AUS) NR 1 PROPELLER NR 1 BLADE COLLAR SEPARATED FROM BLADE AND STRUCK THE NO3 BLADE CAUSING IMPACT DAMAGE TO THE LEADING EDGE. DEBRIS THEN STRUCK THE NR 5 LT CABIN WINDOW SURROUND STRUCTURE. INNER PANE OF THE WINDOW REMAINED INTACT. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040106001462004010600146CE 2004 1 6 AUS20031229 120031124G5412 FIREWALL CESSNA208 208 2073702CE PWA PT6 PT6A114 52043NE MCAULY3AF34C3GFR34C703 GL RT NACELLE DISTORTED W C ABORTED TAKEOFF O OTHER TOTAKEOFF 1 AUS (AUS) RT FIREWALL BUCKLED DUE TO ASSYMETRIC WASTER CONTACT DURING TAKEOFF IN GUSTY CONDITIONS. AIRCRAFT IS CONFIGURED AS AN AMPHIBIAN. 1H71 3T3 TNTA37CE E4EA 5 CP60GL 20040106001472004010600147NE 2004 1 6 AUS20031230 220030925G73210164448160 FUEL CONTROL SNIAS 350 AS350BA 8680817EU TMECA ARRIELARRIEL1B 6OO30NE ENGINE FAULTY W O OTHER E VIBRATION/BUFFET CRCRUISE 1 AUS A490B (AUS) FUEL CONTROL UNIT FAULTY. SUSPECT FUEL TEMPERATURE SENSOR FAILED. 1G71 3U3 UNCH9EU E19EU 20040107000312004010700031EU 2004 1 7 AUS20031231 120031203G32601EN1 SWITCH STBROSSD3 SD360 8100606EU PWA PT6 PT6A67R 52043NE HARTZLHCA6A HCA6A3 NE MLG CONTAMINATED W O OTHER N FALSE WARNING DEDESCENT 1 AUS (AUS) RT MAIN LANDING GEAR SWITCHES AND OPERATING MECHANISM CONTAMINATED WITH GREASE. 2H72 4T4 T A41EU E26NE 6 CP14NE 20040107000942004010700094EU 2004 1 7 AUS20031232 120030917G6210117150071 BLADE BOLKMS117 BK117B2 5626013EU LYC LTS101LTS101750B1 41560NE MAIN ROTOR CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) MAIN ROTOR BLADE CRACKED IN BLADE THIMBLE RADIUS AREA. FOUND DURING REMOVAL AND INSPECTION IAW KHI KSB-117-168. 1G72 3U3 UNCH13EU E5NE10 20040108000152004010800015EU 2004 1 8 AUS20031233 120030917G6210117150071 BLADE BOLKMS117 BK117B2 5626013EU LYC LTS101LTS101750B1 41560NE MAIN ROTOR CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) MAIN ROTOR BLADE CRACKED IN BLADE THIMBLE RADIUS AREA. FOUND DURING REMOVAL AND INSPECTION IAW KHI KSB-117-168. 1G72 3U3 UNCH13EU E5NE10 20040108000352004010800035NE 2004 1 8 AUS20031234 320031201G61118022532 COLLAR HAMSTD DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE PROPELLER BLADE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS 6568 8660457 (AUS) PROPELLER BLADE COLLAR ASSEMBLY CRACKED. FOUND DURING FLEET-WIDE INSPECTION FOLLOWING SEPARATION OF BLADE COLLAR ON ANOTHER AIRCRAFT. SEE MDR 03/1228. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040106000232004010600023EU 2004 1 6 AUS20031235 120031013G53111152015 FRAME GROB G115 G115 EU LYC O235 O235L2C 41505EA SNSNCH72C 72CK EA FUSELAGE FRACTURED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FORWARD FUSELAGE FRAME AND SUPPORTING CROSS BEAM FRACTURED. NOSE LANDING GEAR AFT ATTACHMENT FITTING IS ATTACHED TO THE FRAME. 1L71 3O3 ONTA57EU E223 5 NP9045 20040106001292004010600129NM 2004 1 6 AUS20031236 120031202G6320A0061 GEARBOX ROBSINR22 R22BETA 7640110NM LYC O320 O320B2C 41508EA MAIN ROTOR CONTAMINATED W O OTHER O OTHER NRNOT REPORTED 1 AUS (AUS) FOLLOWING STRANGE NOISES ON RUNDOWN THE MAIN ROTOR GEARBOX WAS INSPECTED. THE MAIN ROTOR GEARBOX AND CHIP DETECTOR WERE FOUND TO BE CONTAMINATED WITH METAL. CHIP DETECTOR DID NOT ILLUMINATE CHIP LIGHT BUT WAS TESTED SERVICEABLE. 1G71 3O3 O H10WE E274 20040106001312004010600131NM 2004 1 6 AUS20031237 120031127G5311 FRAME BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FUSELAGE FRAME AFT CHORD HOLES (3OFF) CRACKED. AFT WEB HOLE CRACKED. FOUND DURING EDDY CURRENT INSPECTION IAW MFG DRAWING737R53-154-01. 2L72 4F4 FRTA16WE E21EU 20040107000322004010700032NM 2004 1 7 AUS20031238 120031207G6310A1902 DRIVE BELT ROBSINR22 R22BETA 7640110NM LYC O360 O360J2A 41514EA ENGINE/XMSN DAMAGED W O OTHER BJ SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CRCRUISE 1 AUS (AUS) ENGINE TO TRANSMISSION DRIVE BELTS JUMPED FORWARD ONE GROOVE. SUSPECT FAULTY BELTS. 1G71 3O3 O H10WE E286 20040107000862004010700086CE 2004 1 7 AUS20031239 120031202G534324130023 ATTACH FITTING CESSNA172 172RG 2072438CE LYC O360 O360F1A6 41514EA MCAULY2D34C B2D34C220 GL MLG ACTUATOR CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) NOSE LANDING GEAR ACTUATOR ATTACHMENT FITTING CRACKED IN TWO PLACES. FITTING HAD BEEN MODIFIED IAW AD/C170/58, SEB93-8 AND SK172-142. 1H71 3O3 O 3A17 E286 5 CP7EA 20040107000872004010700087CE 2004 1 7 AUS20031240 120031112G5310 STRUCTURE CESSNA402 402C 207590RCE CONT O520 TSIO520VB 17040SO MCAULY3AF32C3AF32C93 GL FUSELAGE DETERIORATED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) AIRCRAFT STRUCTURE DETERIORATED. NUMEROUS DEFECTS FOUND DURING INSPECTION IAW AD/400/40. MAIN LANDING GEAR ACTUATOR COLLAR CRACKED AT UPPER BARREL NEAR WELD, FOUND USING MAGNETIC PARTICLE INSPECTION. ENGINE MOUNT BEAM IB MOUNT DOUBLER CRACKED. LOWER CARRY THROUGH FRONT SPAR CAP PNO 5211178 CRACKED. WING DISBOND DETECTED. WING FRONT SPAR LUG INSPECTION DEFECTS WERE FOUND ON ALLOWING ATTACHMENT FITTINGS PN 0822550-19, PN 0822550-20, PN0822550-21 AN D PN 0822550-22 DEFECTS FOUND USING NON-DESTRUCTIVE TESTING METHODS. 1L72 3O3 O A7CE E8CE 5 CP22EA 20040107000882004010700088NM 2004 1 7 AUS20031241 120031127G271082700563S001 CONTROL CABLE DHAV DHC8 DHC8315 2809010NM PWA PW120 PW123 NE HAMSTD14SF 14SF15 NE AILERONS INOPERATIVE W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT AND RT WING AILERON CONTROL CABLES INCORRECTLY ROUTED AT OUTBOARD CONTROL QUADRANTS ON BOTH WINGS UNDER PANELS 532AT AND 632AT. CABLES HAD NOT BEEN LOCATED IN THE QUADRANT GROOVE AND WERE OPERATING ON TOP OF THE QUADRANT CAUSING RUBBING ON THE QUADRANT CAUSING WEAR. THE WEAR WAS STILL WITHIN MAINTENANCE MANUAL LIMITS WHEN FOUND. PANELS HAD NOT BEEN LIFTED AND WERE NOT REQUIRED TO BE LIFTED SINCE NEW. MANUFACTURING ERROR. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040107000892004010700089SO 2004 1 7 AUS20031242 120031207G792110717C OIL COOLER AYRES S2 S2RT34NORMAL0970106SO GARRTTTPE331TPE331* 01514WP HARTZLHCB4T HCB4TN5 GL ENGINE SPLIT W O OTHER EK VIBRATION/BUFFET FLUID LOSS TXTAXI/GRND HDL 1 AUS (AUS) ENGINE OIL COOLER SPLIT ALONG WELD LOCATED AT THE OPPOSITE END TO THE FITTINGS. COMPLETE LOSS OF ENGINE OIL. 1L71 3T3 T A3SW E2WE 6 CP40EA 20040108000162004010800016NM 2004 1 8 AUS20031243 120031129G27316355B000103 MOTOR BOEING737 7377Q8 NM GE CFM56 CFM567B24 NE ELEVATOR TAB FAILED W K NONE FJ FLT CONT AFFECTED WARNING INDICATION CLCLIMB 1 AUS (AUS) STABILIZER TRIM MOTOR FAILED. 2L72 4F4 FRTA16WE E00055EN 20040108000252004010800025SW 2004 1 8 AUS20031244 120031205G7603 POWER LEVER SWRNGNSA227 SA227* SW GARRTTTPE331TFE33112UHR WP MCAULY4HFR344HFR34C652 NE LT ENGINE INCORRECT W O OTHER EJ VIBRATION/BUFFET WARNING INDICATION NRNOT REPORTED 1 AUS (AUS) LT ENGINE FUEL BYPASS LIGHT ILLUMINATED DURING TAKEOFF. EXTENSIVE INVESTIGATION COULD FIND NO CAUSE FOR THE DEFECT. ENGINE GROUND RUNS AND POWER CHECKS WERE OK. SUSPECT CAUSED BY INCORRECTLY SET SPEED LEVER. DEFECT NOT CONFIRMED. 2L72 4T4 TRTA5SW E4WE 6 C3PNE 20040108000262004010800026SO 2004 1 8 AUS20031245 120031203G243523080013 STARTER GEN EMB 120 EMB120 3260201SO PWA 118 PW118A NE HAMSTD14RF 14RF9 NE APU UNSERVICEABLE W K NONE B SMOKE/FUMES/ODORS/SPARKS ININSP/MAINT 1 AUS (AUS) APU STARTER-GENERATOR BRUSH COVER INSULATION NOT FITTED DURING OVERHAUL. BRUSH LEADS SHORTED TO FRAME AND CAUSED DAMAGE TO THE TEST BENCH LOAD RESISTOR. STARTER-GENERATOR HAD BEEN RETURNED FROM OVERHAUL AND WAS UNDERGOING BEDDING IN ON THE TEST RIG BEFORE FITMENT. PERSONNEL/MAINTENANCE ERROR. 2L72 4T4 TRTA31SO E20NE 6 CP11NE 20040106000242004010600024 2004 1 6 AUS20031246 420031128G22100106R2 SERVO BNORM BN2 BN2B20 1520302EU LYC O540 IO540K1B5 41532EA HARTZLHCC2Y HCC2YK2 GL AUTOPILOT SYSTEMFAILED W O OTHER F FLT CONT AFFECTED CLCLIMB 1 AUS (AUS) AUTOPILOT ROLL SERVO FAULTY. 1H72 3O3 O A17EU 1E4 5 CP920 20040106001482004010600148NM 2004 1 6 AUS20031247 120031206G272265C370539 PCU BOEING737 737* NM CFMINTCFM56 CFM563C 13802EU RUDDER ACTUATOR FAILED W O OTHER F FLT CONT AFFECTED LDLANDING 1 AUS (AUS) RUDDER PCU FAULTY CAUSING UNCOMMANDED RUDDER INPUT AFTER TOUCHDOWN. INPUT WAS TO THE RT FOR A SHORT PERIOD. 2L72 4F4 FRTA16WE E21EU 20040106001632004010600163EA 2004 1 6 AUS20031248 220031201G7322RSA5AD2 FCU CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA MCAULYIC235 IC235LFA7570EA FUEL CONTROL/RECCONTAMINATED W K NONE O OTHER ININSP/MAINT 1 AUS 1308 (AUS) FUEL CONTROL UNIT AIR REFERENCE CHAMBER CONTAMINATED WITH FUEL. 1H71 3O3 ONT3A12 1E10 5 NP12EA 20040106001652004010600165NE 2004 1 6 AUS20031249 220031202G7321324485318 FUEL CONTROL DHAV DHC8 DHC8202 2809007NM PWA 120 PW123D 52152NE HAMSTD14SF 14SF23 NE LT ENGINE FAILED W C ABORTED TAKEOFF E VIBRATION/BUFFET TOTAKEOFF 1 AUS 2486 (AUS) LT ENGINE MECHANICAL FUEL CONTROL FAILED. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040106001722004010600172CE 2004 1 6 AUS20031250 120031128G7120 CLAMP CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA MCAULY1A103 1A103TCM GL ENGINE MOUNT SPLIT W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) ENGINE MOUNT LOWER CLAMP SPLIT ON LT SIDE. 1H71 3O3 ONT3A19 E223 5 NP50GL 20040107000332004010700033 2004 1 7 AUS20031251 420031128G3497 CONNECTOR BNORM BN2 BN2B20 1520302EU LYC O540 IO540K1B5 41532EA HARTZLHCC2Y HCC2YK2 GL MAGNETIC COMPASSCORRODED W O OTHER O OTHER CLCLIMB 1 AUS (AUS) COMPASS FLUX DETECTOR CONNECTOR CORRODED. SEE MDR 03/1246 FOR ASSOCIATED DEFECT. 1H72 3O3 O A17EU 1E4 5 CP920 20040107000912004010700091CE 2004 1 7 AUS20031252 120030920G2434A139271 BRUSHES CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA MCAULY1A170 1A170E GL DC ALTERNATOR WORN W O OTHER H ELECT. POWER LOSS-50 PC TXTAXI/GRND HDL 1 AUS (AUS) ALTERNATOR BRUSHES BADLY WORN. ALTERNATOR FAILED CAUSING WIRING TO BURN AND FAILURE OF ALTERNATOR CONTROL UNIT AND CURRENT SENSOR AND FUSING OF THE ALTERNATOR FIELD CIRCUIT BREAKER. 1H71 3O3 ONT3A12 1E10 5 NP857 20040107000922004010700092NE 2004 1 7 AUS20031253 220031210G7297430121301 WIRE HARNESS BOLKMS117 BK117B2 5626013EU LYC LTS101LTS101750B1 41560NE POWERPLANT FAILED W O OTHER E VIBRATION/BUFFET DEDESCENT 1 AUS (AUS) NR 1 ENGINE WIRING HARNESS FAULTY. SUSPECT CAUSED BY WORN/DIRTY PINS IN CONNECTOR. INVESTIGATION TRACED FAULT TO N1 SPEED PICKUP ELECTRICAL CONNECTOR. 1G72 3U3 UNCH13EU E5NE10 20040107000932004010700093EA 2004 1 7 AUS20031254 220031205G7421REM37BY SPARK PLUG GROB G115 G115 EU LYC O235 O235H2C 41505EA SNSNCH72C 72CK EA ENGINE WORN W O OTHER O OTHER NRNOT REPORTED 1 AUS (AUS) SEVERAL SPARK PLUGS WORN/FOULED. 1L71 3O3 ONTA57EU E223 5 NP9045 20040108000172004010800017NM 2004 1 8 AUS20031255 120031201G332017501 BALLAST BOEING747 747338 NM RROYCERB211 RB211524D41954555NE SEAT 19 FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 AUS (AUS) LIGHTING BALLAST LOCATED AT SEAT 19JK FAILED. 2L72 4F4 FRTA20WE E12EU 20040108000222004010800022EA 2004 1 8 AUS20031256 220031210G853074230 VALVE GUIDE BEECH 76 76 1153005CE LYC O360 LO360A1G6 41514EA HARTZLHCM2Y HCM2YR GL NR 1 CYLINDER WORN W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) NR 1 CYLINDER EXHAUST VALVE AND VALVE GUIDE WORN EXCESSIVELY. VALVE NOT SEATING CORRECTLY. FOUND DURING INSPECTION IAW AD/ENG/4 AMDT8. 1L72 3O3 O A29CE 1E10 5 CP43GL 20040108000232004010800023SO 2004 1 8 AUS20031257 120031209G323042042 ARM PIPER PA31 PA31 7103102SO LYC O540 TIO540A2B 41532EA HARTZLHCE3Y HCE3YR2 GL LT MLG BROKEN W O OTHER O OTHER NRNOT REPORTED 1 AUS (AUS) LT MAIN LANDING GEAR RETRACTION ARM BROKEN. ASSOCIATED FORK AND ROD END BENT. DAMAGE ALSO TO DOWNLOCK HOOK AND ROD END ASSEMBLY. SUSPECT DOWNLOCK HOOK FAILED TO DISENGAGE. 1L72 3O3 O A20SO E14EA 5 CP33EA 20040108000242004010800024SO 2004 1 8 AUS20031258 120031130G5524MS21260 STUD PIPER PA32 PA32RT300T 7103216SO LYC O540 TIO540S1AD 41532EA HARTZLHCE3Y HCE3YR1 GL ELEVATOR CONTROLCORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT ELEVATOR FORWARD CONTROL CABLE FAILED. CABLE LOCKING STUD CORRODED. CONTROL WHEEL HAD BEEN RESTRAINED WITH SEAT BELT AND CABLE LOCK STUD FAILED DUE TO WIND GUSTS. 1L71 3O3 O A3SO E14EA 5 CP33EA 20040106000252004010600025NM 2004 1 6 AUS20031259 120031205G33201167008141 CONNECTOR BOEING747 747438 NM RROYCERB211 RB211524G19 NE CABIN FAILED W K NONE O OTHER ININSP/MAINT 1 AUS 9902056827 (AUS) OVERHEAD ELECTRONICS UNIT (OEU) J1 HARNESS SEIZED AND FUSED INTO OEU CONNECTOR AT SEAT 37HJK. 2L74 4F4 FRTA20WE E30NE 20040106001172004010600117NE 2004 1 6 AUS20031260 220031206G7200 ENGINE BOEING737 73776N 13844CHNM GE CFM56 CFM567B24 NE NR 1 BIRD INGESTION W C ABORTED TAKEOFF EC VIBRATION/BUFFET F.O.D. TOTAKEOFF 1 AUS (AUS) NR 1 ENGINE BIRDSTRIKE. INVESTIGATION FOUND BIRD REMAINS BUT NO EVIDENCE OF DAMAGE. 2L72 4F4 FRTA16WE E00055EN 20040106001192004010600119NM 2004 1 6 AUS20031261 120031018G5330 SKIN BOEING747 74748E 2FOR NM GE CF6 CF680C2* GL FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FUSELAGE SKIN CRACKED IN UPPER FORWARD CORNER OF LOWER AFT CARGO DOOR CUTOUT FASTENER HOLE. CRACK WAS FOUND IN NR 1 FASTENER HOLE AT THE 6 O'CLOCK POSITION WITH A LENGTH GREATER THAN 1.01MM (0.040IN). FOUND DURING INSPECTION IAW AD/B747/293 AND EI 747-053-017R01. 2L72 4F4 FRTA20WE E23EA 20040106001202004010600120EU 2004 1 6 AUS20031262 120031201G27507445B VALVE BAG JETSTMJETSTM3201 1500217EU GARRTTTPE331TPE33112UA 01514WP MCAULY4HFR344HFR34C653 NE T/E FLAP FAULTY W C ABORTED TAKEOFF F FLT CONT AFFECTED TOTAKEOFF 1 AUS LK29 (AUS) FLAP EMERGENCY RELEASE VALVE OPERATED (POPPED). 2L72 4T4 TRTA56EU E4WE 6 C3PNE 20040106001222004010600122EA 2004 1 6 AUS20031263 220031202G732225765362 INJECTOR CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA MCAULY1A170 1A170E GL ENGINE FUEL FAILED W O OTHER E VIBRATION/BUFFET LDLANDING 1 AUS (AUS) ENGINE FUEL INJECTOR SYSTEM FAULTY. LIMITED INFORMATION PROVIDED. 1H71 3O3 ONT3A12 1E10 5 NP857 20040107000372004010700037SW 2004 1 7 AUS20031264 120031214G2731DL5040M6 ACTUATOR SWRNGNSA227 SA227AC 8780603SW GARRTTTPE331TPE33111U 01514WP ROTOL R321 R321482F8 GL ELEVATOR TAB FAULTY W O OTHER FJ FLT CONT AFFECTED WARNING INDICATION CLCLIMB 1 AUS 6510 (AUS) ELEVATOR PITCH TRIM ACTUATOR FAULTY. SUSPECT ACTUATOR BINDING INTERNALLY. 2L72 4T4 TRTA8SW E4WE 6 CP61GL 20040107000832004010700083 2004 1 7 AUS20031265 420031205G34165934PM3 ALTIMETER BNORM BN2 BN2A21 1520221EU LYC O540 IO540K1B5 41532EA HARTZLHCC2Y HCC2YK2 GL COCKPIT OUT OF ADJUST W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) ALTIMETER OUT OF CALIBRATION. 1H72 3O3 O A17EU 1E4 5 CP920 20040107000842004010700084NM 2004 1 7 AUS20031266 120031205G3411 PIPE BOEING747 747438 NM RROYCERB211 RB211524G19 NE PITOT/STATIC SYSLEAKING W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT AUXILIARY PITOT SYSTEM PIPE CHAFED AND LEAKING IN AREA LOCATED AT STN 1880 ABOVE SEAT 63DEFG. 2L74 4F4 FRTA20WE E30NE 20040107000852004010700085CE 2004 1 7 AUS20031267 120031210G5730 SKIN BEECH 36 A36 1151604CE CONT O520 IO520B 17032SO MCAULY2A36C 2A36C23 GL RT WING DAMAGED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FOLLOWING REMOVAL OF THE LT WING THE UPPER SKIN AND INNER RIB FLANGE WAS FOUND TO BE GROUND AWAY TO THE EXTENT THAT THE RIVET EDGE DISTANCE WAS COMPROMISED. SOME RIVETS ALSO EXHIBIT GRINDINGMARKS. THE RT WING WAS THEN REMOVED AND INSPECTED AND FOUND TO BE IN A SIMILAR CONDITION. PERSONNEL/MAINTENANCE ERROR. 1L71 3O3 O 3A15 E5CE 5 CP880 20040108000192004010800019CE 2004 1 8 AUS20031269 120031201G3222AN431 BOLT CESSNA182 182P 2075816CE CONT O470 O470R 17026SO MCAULY2A34C 2A34C203 GL NLG BENT W O OTHER O OTHER CRCRUISE 1 AUS (AUS) NLG UPPER TORQUE LINK UPPER BOLT TO STEERING COLLAR SEVERELY BENT AND ALMOST SHEARED. INVESTIGATION ALSO FOUND THE STRUT UNDER EXTENDED DUE TO BEING OVERFILLED WITH OIL AND UNDER INFLATED WITH AIR. 1H71 3O3 ONTTA13 E273 5 CP3EA 20040108000202004010800020CE 2004 1 8 AUS20031270 120031215G323399101363 ACTUATOR CESSNA402 402C 207590RCE CONT O520 TSIO520VB 17040SO MCAULY3AF32C3AF32C505 GL RT MLG MALFUNCTIONED W O OTHER J WARNING INDICATION LDLANDING 1 AUS 68 (AUS) RT MAIN LANDING GEAR ACTUATOR FAULTY. 1L72 3O3 O A7CE E8CE 5 CP22EA 20040108000212004010800021EA 2004 1 8 AUS20031271 220031117G73101776698 HOSE PIPER PA31 PA31 7103102SO LYC O540 TIO540A2C 41532EA HARTZLHCE2Y HCE2YK2 GL FUEL PRESSURE LEAKING W O OTHER K FLUID LOSS CRCRUISE 1 AUS (AUS) FUEL PRESSURE GAUGE SENSOR HOSE LEAKING IN AREA BEHIND INSTRUMENT PANEL. 1L72 3O3 O A20SO E14EA 5 CP9EA 20040106000262004010600026NM 2004 1 6 AUS20031272 120031202G3020 DOOR BOEING747 747438 NM RROYCERB211 RB211524G19 NE NR 4 NACELLE MISSING W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) NR 4 ENGINE NACELLE ANTI-ICE PRESSURE RELIEF BLOWOUT DOOR MISSING. 2L74 4F4 FRTA20WE E30NE 20040106001252004010600125EU 2004 1 6 AUS20031273 120031215G5610 DRAIN LINE FOKKERF28 F28MK0100 4990807EU RROYCETAY TAY65015 54557NE WINDOW FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CLCLIMB 1 AUS (AUS) DRAIN TUBE CONNECTION LOCATED BELOW WINDSCREEN FAILED ALLOWING WATER TO LEAK ONTO AND CONTAMINATE LANDING GEAR LOCK HANDLE SOLENOID. 2L72 4F4 FRT E25NE 20040107000382004010700038SW 2004 1 7 AUS20031274 120031216G75008961153 GASKET GULSTM690TP 690 0141720SW GARRTTTPE331TPE3315251K NM HARTZLHCB3T HCB3TN5 GL BLEED AIR FAILED W O OTHER EBJVIBRATION/BUFFET SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CLCLIMB 1 AUS (AUS) RT ENGINE BLEED AIR LINE ATTACHMENT GASKET BLEW OUT ALLOWING HOTGAS TO BLOW ONTO ADJACENT FIRE WARNING DETECTOR. 1H72 3T4 T 2A4 E2WE 6 CP15EA 20040107000822004010700082CE 2004 1 7 AUS20031275 120031211G2910 VALVE CESSNA404 404CESSNA 2075901CE CONT O520 GTSIO520M 17032SO MCAULY3FF32 3FF32C501 GL HYD SYSTEM CONTAMINATED W O OTHER J WARNING INDICATION LDLANDING 1 AUS (AUS) HYDRAULIC SYSTEM UNLOADING VALVE CONTAINED DEBRIS UNDER THE VALVE SEAT CAUSING THE VALVE TO REMAIN PARTIALLY OPEN AND PREVENTING THE CORRECT HYDRAULIC PRESSURE FROM BEING REACHED. 1L72 3O3 O A25CE E7CE 5 CP45GL 20040108000182004010800018EA 2004 1 8 AUS20031276 220031218G8550 SEAL GULSTM500 500S 0141107SW LYC O540 IO540E1B5 41532EA HARTZLHCC3Y HCC3YR2 NE OIL FILTER DAMAGED W O OTHER KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 AUS (AUS) RT ENGINE OIL FILTER SEAL DAMAGED AND LEAKING. SUSPECT SEAL DAMAGED DURING INSTALLATION. PERSONNEL/MAINTENANCE ERROR. 1H72 3O3 O 6A1 1E4 5 CP25EA 20040108000272004010800027 2004 1 8 AUS20031277 420031211G341640187592 COUNTER DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE ALTIMETER SEIZED W K NONE O OTHER ININSP/MAINT 1 AUS 77110459 (AUS) ALTITUDE INDICATOR BARO COUNTER SEIZED. FOUND DURING INSPECTION IAW AD/INST/9 AMDT6. DURING TESTING SEVERAL LIGHTING LAMPS WERE FOUND TO BE BLOWN AND THE DRIVE MOTOR WAS ROUGH IN OPERATION. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040108000282004010800028SO 2004 1 8 AUS20031278 120031218G571162054001 SPAR PIPER PA28 PA28180 7102808SO LYC O360 O360A4A 41514EA SNSNCH76E 76EM8 EA RT WING CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS 8720 (AUS) RT WING REAR SPAR CORRODED. FOUND DURING INSPECTION IAW AD/PA28/40A. 1L71 3O3 O 2A13 E286 5 NP4EA 20040106000272004010600027 2004 1 6 AUS20031279 420031210G34177000700975 ADC DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE COCKPIT OUT OF ADJUST W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) AIR DATA COMPUTER (ADC) OUT OF CALIBRATION AT ALL ALTITUDES. FOUND DURING INSPECTION IAW AD/INST9 AMDT6. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040106001142004010600114SO 2004 1 6 AUS20031280 120031218G571162054000 SPAR PIPER PA28 PA28180 7102808SO LYC O360 O360A4A 41514EA SNSNCH76E 76EM8 EA WING CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS 8720 (AUS) LT WING REAR SPAR CORRODED. FOUND DURING INSPECTION IAW AD/PA28/40A. 1L71 3O3 O 2A13 E286 5 NP4EA 20040106001162004010600116SO 2004 1 6 AUS20031281 120031218G53206241100 CHANNEL PIPER PA28 PA28180 7102808SO LYC O360 O360A4A 41514EA SNSNCH76E 76EM8 EA FUSELAGE CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS 8720 (AUS) LOWER REAR FUSELAGE CENTER CHANNEL SECTION CONTAINED DISSIMILAR METAL CORROSION ON BOTH SIDES IN AREA OF REAR SPAR ATTACHMENT. FOUND DURING INSPECTION IAW AD/PA28/40A AND PIPER SERVICE BULLETIN NR 977. 1L71 3O3 O 2A13 E286 5 NP4EA 20040107000392004010700039NM 2004 1 7 AUS20031282 120031213G2597 WIRE BOEING747 747438 NM RROYCERB211 RB211524G19 NE CHILLER DAMAGED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) UPPER DECK CHILLER WIRES W8599-006-10, W8599-005-10 AND W8599-006-10 CHAFED. 2L74 4F4 FRTA20WE E30NE 20040107000812004010700081 2004 1 7 AUS20031283 420031212G341670007641 POTENTIOMETER DHAV DHC8 DHC8* NM PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE ALTIMETER FAILED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) ALTITUDE INDICATOR POTENTIOMETER UNSERVICEABLE. FOUND DURING INSPECTION IAW AD/INST9 AMDT6. SEVERAL LIGHTING LAMPS ALSO FOUND TO HAVE FAILED. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040329000852004032900085EU 2004 3 29 AUS20031284 120031216G3260867501 SENSOR FOKKERF28 F28MK0100 4990807EU RROYCETAY TAY65015 54557NE MLG INDICATOR FAILED W O OTHER N FALSE WARNING CLCLIMB 1 AUS (AUS) LT LANDING GEAR UPLOCK SENSOR FAILED. SEE ALSO MDR 03/1273 FOR ASSOCIATED DEFECT. 2L72 4F4 FRT E25NE 20040329000862004032900086NE 2004 3 29 AUS20031285 220031204G7200 ENGINE BAC 146 146200A 1500266EU LYC ALF502ALF502R5 41580NE NR 3 FAILED W O OTHER EJ VIBRATION/BUFFET WARNING INDICATION CLCLIMB 1 AUS (AUS) NR 3 ENGINE FAILED. 2H74 4F4 F A49EU E6NE 20040329000872004032900087EU 2004 3 29 AUS20031286 120031222G3020S230SST CLAMP FOKKERF28 F28MK0100 4990807EU RROYCETAY TAY65015 54557NE ANTI ICE VALVE WRONG PART W K NONE W INADEQUATE Q C ININSP/MAINT 1 AUS 16544 (AUS) ENGINE ANTI-ICE VALVE PIPE PN 1159P41706-7 WORN AND BROKEN BY CLAMP. CLAMP WAS INCORRECT PART PN S230SST (CORRECT CLAMP PN GC500BV04CTN). THE TEFLON SLEEVE ON THE CLAMP HAD WORN AWAY RESULTING IN METAL TO METAL CONTACT BETWEEN THE CLAMP AND PIPE WHICH WAS CHAFED TO THE POINT OF FAILURE. UNAPPROVED PART. PERSONNEL/MAINTENANCE ERROR. 2L72 4F4 FRT E25NE 20040329000882004032900088NM 2004 3 29 AUS20031287 120031206G7312G726681 ELEMENT DHAV DHC8 DHC8202 2809007NM PWA 120 PW123D 52152NE HAMSTD14SF 14SF23 NE FUEL HEATER FAULTY W O OTHER EK VIBRATION/BUFFET FLUID LOSS CRCRUISE 1 AUS (AUS) NR 1 ENGINE FUEL HEATER THERMAL ELEMENT FAULTY. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040329000892004032900089NM 2004 3 29 AUS20031288 120031218G291082970009199 PIPE DHAV DHC8 DHC8315 2809010NM PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE HYD SYSTEM UNSERVICEABLE W K NONE K FLUID LOSS ININSP/MAINT 1 AUS 99999 (AUS) RT MAIN LANDING GEAR HYDRAULIC UP' PIPE LEAKING. INVESTIGATION FOUND A CRACK IN THE SIDEWALL OF THE PIPE LOCATED AT A BEND RADIUS. SUSPECT THE BEND RADIUS WAS DEFORMED DURING FIT AT MANUFACTURE. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040329000902004032900090NM 2004 3 29 AUS20031289 120031210G7697BACC63CC1415SN CONNECTOR BOEING737 7377Q8 1384418NM GE CFM56 CFM567B24 NE ENGINE CONTROLS LOOSE W C ABORTED TAKEOFF E VIBRATION/BUFFET TOTAKEOFF 1 AUS (AUS) ENGINE CONNECTOR D11286 NOT CONNECTED. CONNECTOR WAS SITTING ON TOP OF THE RECEPTACLE. 2L72 4F4 FRTA16WE E00055EN 20040329000912004032900091EU 2004 3 29 AUS20031290 120031214G2197P3802B WIRE FOKKERF28 F28MK0100 4990807EU RROYCETAY TAY65015 54557NE AIR CONDITIONINGDAMAGED W K NONE O OTHER ININSP/MAINT 1 AUS 17418 (AUS) FORWARD AVIONICS BAY WIRING DAMAGED. EFIS FAN CIRCUIT BREAKER FAILED AND COULD NOT BE RESET. 2L72 4F4 FRT E25NE 20040329000922004032900092NM 2004 3 29 AUS20031291 120031215G2910AN81510D COUPLING DHAV DHC8 DHC8315 2809010NM PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE HYDRAULIC SYSTEMUNSERVICEABLE W O OTHER KJ FLUID LOSS WARNING INDICATION LDLANDING 1 AUS 99999 (AUS) NR 2 HYDRAULIC SYSTEM PRESSURE FILTER MANIFOLD UNION FRACTURED. SUSPECT UNION FAILED DUE TO OVERTORQUING DURING INSTALLATION. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040329000932004032900093NE 2004 3 29 AUS20031292 120031226G26127630607902104 FIRE DETECTOR SKRSKYS76 S76C 8143008NE TMECA ARRIELARRIEL1S 60030NE NR 2 ENGINE FAULTY W O OTHER EBJVIBRATION/BUFFET SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CRCRUISE 1 AUS 6868 (AUS) NR 2 ENGINE BAY FIRE DETECTOR FAULTY. 1G72 3U3 UNCH1NE E19EU 20040329000942004032900094NE 2004 3 29 AUS20031293 220031224G7200200304018 ENGINE BAC 146 146200A 1500266EU LYC ALF502ALF502R5 41580NE NR 2 FAILED W O OTHER YJ ENGINE STOPPAGE WARNING INDICATION CRCRUISE 1 AUS (AUS) NR 2 ENGINE UNCOMMANDED SHUTDOWN. 2H74 4F4 F A49EU E6NE 20040329000532004032900053NE 2004 3 29 AUS20031294 220031230G7200 ENGINE SAAB SF340 340B 7860101EU GE CT7TP CT79B 30030NE ROTOL R375 R3754123F21 NE RIGHT MAKING METAL W O OTHER EK VIBRATION/BUFFET FLUID LOSS CLCLIMB 1 AUS (AUS) RT ENGINE OIL SYSTEM FAULTY. LOW OIL PRESSURE AND OIL TEMPERATURE HIGH. INVESTIGATION FOUND A SMALL METAL SLIVER ON THE POWER UNIT CHIP DETECTOR WHICH HAD NOT ACTIVATED THE INDICATOR. THE FRONT COMPRESSOR SEAL WAS ALSO FOUND TO BE LEAKING. DURING ENGINE GROUND RUN THE CHIP INDICATOR ILLUMINATED AND THE DETECTOR WAS FOUND TO HAVE A NUMBER OF CONTAMINANTS ON IT. THE ENGINE WAS REPLACED. SUSPECT FAILURE OF COMPRESSOR SCAVENGE PUMP. 2L72 4T4 TRTA52EU E8NE 6 CP17NE 20040329000622004032900062CE 2004 3 29 AUS20031295 120031223G52101144000301 SEAL BEECH 1900 1900C 1154161CE PWA PT6 PT6A65B 52043EA HARTZLHCB4M HCB4MP3 GL CABIN DOOR SPLIT W O OTHER O OTHER CLCLIMB 1 AUS (AUS) CABIN DOOR SEAL SPLIT ALONG TOP SECTION. LENGTH OF SPLIT APPROXIMATELY 50MM (1.96IN). 2L72 4T4 TRTA24CE E4EA 6 CP56GL 20040329000632004032900063CE 2004 3 29 AUS20031296 120031128G28203034 HOSE CESSNA337 337G 2075730CE CONT O360 IO360G 17025SO MCAULY2AF34CD2AF34C306 GL FUEL SYSTEM DETERIORATED W O OTHER K FLUID LOSS TXTAXI/GRND HDL 1 AUS (AUS) REAR ENGINE FUEL PRESSURE HOSE LOCATED BETWEEN FIREWALL AND FUEL MANIFOLD DETERIORATED AND LEAKING ONTO LT EXHAUST STACK. 1H72 3O3 O A6CE E1CE 5 CP5EA 20040329000642004032900064NM 2004 3 29 AUS20031297 120031229G3260841005 PSEU DHAV DHC8 DHC8103 1386005NM PWA PW121 PW121 52124NE HAMSTD14SF 14SF7 NE RT MLG FAULTY W O OTHER N FALSE WARNING CLCLIMB 1 AUS (AUS) RT MAIN LANDING GEAR DOOR PROXIMITY SENSE ELECTRONIC UNIT (PSEU) FAULTY. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040329000652004032900065SW 2004 3 29 AUS20031298 120030926G3213ED12758 CLEVIS GULSTM500 500S 0141107SW LYC O540 IO540E1B5 41532EA HARTZLHCC3Y HCC3YR2 NE MLG CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) MAIN LANDING GEAR CLEVIS CRACKED. FOUND USING MAGNETIC PARTICLE INSPECTION AND VISUAL TECHNIQUES. 1H72 3O3 O 6A1 1E4 5 CP25EA 20040329000662004032900066NE 2004 3 29 AUS20031299 220031229G7210 GEARBOX BELL 412 412 1182202SW PWA PT6T PT6T3B 52045NE ENGINE CONTAMINATED W O OTHER EJ VIBRATION/BUFFET WARNING INDICATION CRCRUISE 1 AUS 3322 CPGB2272 (AUS) ENGINE COMBINING GEARBOX METAL CONTAMINATION. 1G72 4U4 U H4SW E22EA 20040329000672004032900067NM 2004 3 29 AUS20031300 120031217G32463006202 WHEEL DHAV DHC8 DHC8202 2809007NM PWA 120 PW123D 52152NE HAMSTD14SF 14SF23 NE MLG FAILED W O OTHER O OTHER TXTAXI/GRND HDL 1 AUS 131 (AUS) NR 1 MAIN WHEEL FAILED AT IB WHEEL RIM. APPROXIMATELY HALF OF THE RIM (180 DEGREE ARC) HAD FAILED AND BROKEN AWAY. TIRE DEFLATED AND ADJACENT BRAKE UNIT SUFFERED DAMAGE AT THE HOSE FITTING. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040329000682004032900068CE 2004 3 29 AUS20031301 120031229G3230084012515 ROD CESSNA 310R CESSNA310 310R 2074245CE CONT O520 IO520M 17032SO MCAULY3AF32C3AF32C* GL MLG FRACTURED W O OTHER O OTHER LDLANDING 1 AUS (AUS) RT MAIN LANDING GEAR AFT PUSH/PULL ROD ASSEMBLY FRACTURED. 1L72 3O3 O 3A10 E5CE 5 CP22EA 20040329000692004032900069CE 2004 3 29 AUS20031302 120031208G2434ES4118 BRUSH BLOCK CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA MCAULY1C160 1C160DTM GL DC GENERATOR WORN W O OTHER H ELECT. POWER LOSS-50 PC CRCRUISE 1 AUS 1469 5112030 (AUS) ALTERNATOR GROUND BRUSH COMPLETELY WORN AWAY. SLIP RING DAMAGED BY WORN BRUSH. 1H71 3O3 ONT3A12 E274 5 NP910 20040329000702004032900070CE 2004 3 29 AUS20031303 120031228G5311VARIOUS FRAME BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FUSELAGE FRAMES CRACKED AT FRAME CUTOUTS. FRAME LOCATED AT FS 286.75. 1L72 4T4 T A24CE E4EA 6 CP15EA 20040329000712004032900071NM 2004 3 29 AUS20031304 120031220G2822 IMPELLER BOEING767 767338 1385151NM GE CF6 CF680C2* GL BOOST PUMP BROKEN W K NONE O OTHER ININSP/MAINT 1 AUS 2706 0655 (AUS) LT CENTER AUXILIARY FUEL TANK OVERRIDE PUMP SEIZED. INVESTIGATION FOUND PART OF THE IMPELLER BROKEN AND JAMMED IN THE PUMP CASING. 2L72 4F4 FRTA1NM E23EA 20040329000742004032900074CE 2004 3 29 AUS20031305 120031215G2434ES4118 BRUSHES CESSNA206 U206G 2073356CE CONT O520 IO520F 17032SO MCAULY3A32C D3A32C90 GL DC GENERATOR WORN W K NONE O OTHER ININSP/MAINT 1 AUS 125 D052304 (AUS) ALTERNATOR GROUND BRUSH ALMOST WORN AWAY. POSITIVE BRUSH WAS HARDLY WORN. 1H71 3O3 O A4CE E5CE 5 CP21EA 20040329000752004032900075NM 2004 3 29 AUS20031306 120031230G56105893543130 WINDSHIELD BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU COCKPIT CRACKED W O OTHER O OTHER DEDESCENT 1 AUS (AUS) FIRST OFFICERS NR 1 WINDOW CRACKED IN OUTER PANE. CRACKING APPEARS TO ORIGINATE FROM DELAMINATION AT TOP LT AREA OF WINDOW. 2L72 4F4 FRTA16WE E21EU 20040329000762004032900076NM 2004 3 29 AUS20031307 120031222G7830RB211524H THRUST REVERSER BOEING767 767* NM RROYCERB211 RB211524* NE ENGINE FAULTY W O OTHER EJ VIBRATION/BUFFET WARNING INDICATION CLCLIMB 1 AUS (AUS) ENGINE THRUST REVERSER FAULTY. LIMITED INFORMATION PROVIDED. 2L72 4F4 FRTA1NM E12EU 20040329000772004032900077CE 2004 3 29 AUS20031308 120031218G2434ES4118 BRUSH BLOCK CESSNA182 182A 2072704CE CONT O470 O470R 17026SO MCAULY2A34C 2A34C66 GL DC GENERATOR WORN W K NONE O OTHER ININSP/MAINT 1 AUS 237 A032173 (AUS) ALTERNATOR BRUSHES WORN UNEVENLY. GROUND BRUSH WORN COMPLETELY AWAY WHILE THE POSITIVE BRUSH APPEARED IN NEAR NEW CONDITION. 1H71 3O3 ONT3A13 E273 5 CP3EA 20040329000782004032900078CE 2004 3 29 AUS20031309 120031218G57120823400110 BULKHEAD CESSNA310 310R 2074245CE CONT O520 IO520M 17032SO AMTR C8289 C8289 GL RT WING CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT WING TIP TANK REAR ATTACHMENT BULKHEAD CRACKED. 1L72 3O3 O 3A10 E5CE 5 NEXPP5N 20040329000792004032900079EA 2004 3 29 AUS20031310 220031215G8520SL13521 BEARING PIPER PA28 PA28R201 7102816SO LYC O360 IO360C1C6 41514EA MCAULY2D34C B2D34C213 GL CONNECTING ROD DELAMINATED W K NONE O OTHER ININSP/MAINT 1 AUS 376 L1887951A (AUS) CONNECTING ROD BIG END BEARING DELAMINATED. 1L71 3O3 O 2A13 1E10 5 CP7EA 20040329000802004032900080GL 2004 3 29 AUS20031311 220031227G7200 ENGINE BOEING747 747438 NM GE CF6 CF680C2* GL NR 3 FAILED W E ENGINE SHUTDOWN EJ VIBRATION/BUFFET WARNING INDICATION CRCRUISE 1 AUS (AUS) NR 3 ENGINE FAILED. SUSPECT HAIL INGESTION. 2L74 4F4 FRTA20WE E23EA 20040329000812004032900081NE 2004 3 29 AUS20031312 320031103G61118175981 SEAL HAMSTD DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE PROPELLER BLADE DAMAGED W O OTHER E VIBRATION/BUFFET CRCRUISE 1 AUS 881235 (AUS) RT PROPELLER BLADE SEAL TORN ALONG OUTER SIDE. LENGTH OF TEAR APPROXIMATELY 38.1MM (1.5IN). PROPELLER HUB LEAKING OIL. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040329000822004032900082WP 2004 3 29 AUS20031313 220031216G723031070515 SEAL CESSNA441 441 2076020CE GARRTTTPE331TPE3318 01514WP HARTZLHCB3T HCB3TN5 GL COMPRESSOR LEAKING W O OTHER KB FLUID LOSS SMOKE/FUMES/ODORS/SPARKS TOTAKEOFF 1 AUS 1386 P31229 (AUS) RT ENGINE COMPRESSOR SEAL SUSPECT FAULTY. LEAKING OIL CAUSED SMOKE IN COCKPIT. 1L72 3T4 TRTA28CE E4WE 6 CP15EA 20040329000832004032900083EA 2004 3 29 AUS20031314 220031219G7322RSA5AD1 FUEL CONTROL CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA MCAULYIC235 IC235LFA7570EA ENGINE CONTAMINATED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FUEL CONTROL UNIT AIR CHAMBER CONTAMINATED BY FUEL. 1H71 3O3 ONT3A12 1E10 5 NP12EA 20040329000842004032900084NM 2004 3 29 AUS20031315 120031218G3411 PITOT HEAD BOEING737 7377BX 13844D2NM GE CFM56 CFM567B24 NE PITOT/STATIC SYSCONTAMINATED W O OTHER O OTHER TOTAKEOFF 1 AUS (AUS) LT PITOT PROBE CONTAMINATED BY MUD FROM SUSPECTED WASP NEST. 2L72 4F4 FRTA16WE E00055EN 20040329001042004032900104NM 2004 3 29 AUS20031316 120031219G3411 PITOT TUBE BOEING737 737800* NM GE CFM56 CFM56* 13802NE PITOT/STATIC SYSCONTAMINATED W O OTHER O OTHER CLCLIMB 1 AUS (AUS) LT ELEVATOR FEEL SYSTEM PITOT TUBE CONTAMINATED WITH MUD FROM WASPS. 2L72 4F4 FRTA16WE E2GL 20040329001052004032900105CE 2004 3 29 AUS20031318 120031128G275014601007 CONTROL CABLE CESSNA337 337H 2075732CE CONT O360 IO360G 17025SO MCAULY2AF34CD2AF34C310 GL TE FLAPS FRAYED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) IB FLAP CABLE CONTAINED BROKEN WIRES LOCATED AT TIGHT BEND AROUND THE BELLCRANK. APPROXIMATELY 50 PERCENT OF THE WIRES WERE BROKEN. INSPECTION CARRIED OUT IN RESPONSE TO MFG ALERT. 1H72 3O3 O A6CE E1CE 5 CP5EA 20040329001062004032900106NM 2004 3 29 AUS20031319 120031127G2822609891002 PUMP BOEING737 7377Q8 1384418NM GE CFM56 CFM56* 13802NE FUEL BOOST FAILED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) ELECTRIC FUEL PUMP FAILED INSPECTION IAW AD/737/198/BORO. FOUND USING BOROSCOPE AND X-RAY INSPECTION. 2L72 4F4 FRTA16WE E2GL 20040329001072004032900107CE 2004 3 29 AUS20031320 120031215G5320 STRAP BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) EMERGENCY EXIT DOOR CUTOUT FRAME STRAP AT FS187.375 CRACKED APPROXIMATELY 50 PERCENT THROUGH. CRACK LENGTH APPROXIMATELY 25.4MM(1IN). 1L72 4T4 T A24CE E4EA 6 CP15EA 20040329001082004032900108SO 2004 3 29 AUS20031321 120031215G5500 STRUCTURE PIPER PA28 PA28140 7102802SO LYC O320 O320* 41508EA AMTR C8289 C8289 GL STABILIZER CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) STABILIZER STRUCTURE CORRODED. 1L71 3O3 O 2A13 E274 5 NEXPP5N 20040429000022004042900002CE 2004 4 29 AUS20031322 120031216G32335721319 ROD CESSNA CESSNA414 414 2075908CE ACTUATOR STICKING W O OTHER O OTHER LDLANDING 1 AUS 50 231 (AUS) MAIN LANDING GEAR ACTUATOR FAULTY. INVESTIGATION FOUND CHROME CHIPPING AWAY FROM THE EDGE OF THE LOCK GROOVE CAUSING THE LOCK RETAINING RING TO STICK. 1L72 3O RTA7CE 20040330001202004033000120SW 2004 3 30 AUS20031323 120031126G54142735112026 SKIN SWRNGNSA227 SA227* SW GARRTTTPE331TPE33112UHR WP MCAULY4HFR344HFR34C652 NE RT NACELLE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT ENGINE IB NACELLE SKIN CRACKED. STRINGER AND FORMER ALSO CRACKED. 2L72 4T4 TRTA5SW E4WE 6 C3PNE 20040330001212004033000121CE 2004 3 30 AUS20031324 120031218G2434D0FF10300JR ALTERNATOR CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA MCAULY1C160 1C160DTM GL DC SYSTEM FAULTY W O OTHER H ELECT. POWER LOSS-50 PC CRCRUISE 1 AUS 1925 (AUS) ALTERNATOR SUSPECT FAULTY. ALTERNATOR BENCH TESTED OK, BUT REPLACED DUE TO HIGH HOURS. FAULT HAS NOT REOCCURRED SINCE. 1H71 3O3 ONT3A12 E274 5 NP910 20040330001222004033000122NM 2004 3 30 AUS20031325 120031227G2422S282T0044 INVERTER BOEING767 767338 1385151NM GE CF6 CF680C2* GL AC SYSTEM FAULTY W O OTHER H ELECT. POWER LOSS-50 PC APAPPROACH 1 AUS (AUS) STANDBY INVERTER SUSPECT FAULTY. 2L72 4F4 FRTA1NM E23EA 20040330001232004033000123NM 2004 3 30 AUS20031326 120031231G7830 BLOCKER DOOR RROYCE BOEING747 747438 NM RROYCERB211 RB211524G19 NE THRUST REVERSER DAMAGED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) NR 3 ENGINE THRUST REVERSER NR 1 BLOCKER DOOR BREAKING UP. A 25.4MM BY 304.8MM (1IN BY 12IN) PORTION OF ONE EDGE HAD SEPARATED. 2L74 4F4 FRTA20WE E30NE 20040330001242004033000124NM 2004 3 30 AUS20031327 120031228G5610 WINDOW BOEING767 767338 1385151NM GE CF6 CF680C2* GL COCKPIT OUT OF ADJUST W O OTHER O OTHER CRCRUISE 1 AUS (AUS) CAPTAINS NR 2 WINDOW OUT OF ADJUSTMENT. 2L72 4F4 FRTA1NM E23EA 20040330001322004033000132NM 2004 3 30 AUS20031328 120031230G3411 LINE BOEING767 767338 1385151NM GE CF6 CF680C2* GL PITOT/STATIC SYSWORN W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) AUXILIARY PITOT SYSTEM LEAKING. LEAK TRACED TO PITOT LINE RUBBING ON TIE ROD BRACKET AT STN 410 RBL 50 WL300. 2L72 4F4 FRTA1NM E23EA 20040330001332004033000133 2004 3 30 AUS20031329 420031229G34316225221120 RECEIVER BOEING767 767* NM RROYCERB211 RB211524* NE LOCALIZER/VOR SYFAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 AUS 7938 1817 (AUS) LT INSTRUMENT LANDING SYSTEM (ILS) RECEIVER FAILED. LT ILS CIRCUIT BREAKER TRIPPED. 2L72 4F4 FRTA1NM E12EU 20040330001342004033000134CE 2004 3 30 AUS20031330 120031229G5522 SKIN CESSNA207 207 2073602CE CONT O520 IO520F 17032SO MCAULYD3A34 D3A34C404 GL ELEVATOR LOOSE W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT ELEVATOR RIVETS FAILED ALLOWING LOWER ELEVATOR SKIN TO BECOME LOOSE AT THE IB TRAILING EDGE. INVESTIGATION FOUND SIMILAR PROBLEMS WITH THE RIVETS ALONG THE LEADING EDGE. THE RIVETS WERE .0937 INCH POP RIVETS. INSPECTION OF THE RT ELEVATOR FOUND THE SAME PROBLEMS. SUSPECT SKIN HAD BEEN REPLACED SOME YEARS AGO. 1H71 3O3 O A16CE E5CE 5 CP47GL 20040330001352004033000135CE 2004 3 30 AUS20031331 120030902G2910P40791 SHUTOFF VALVE LEAR 45 45LEAR 5170805CE GARRTTTFE731TFE7312 01518WP HYD SYSTEM FAULTY W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) LT ENGINE FIREWALL MOUNTED HYDRAULIC FIREWALL SHUTOFF VALVE FAULTY. VALVE WOULD NOT FULLY CLOSE WHEN THE FIRE SWITCH WAS OPERATED WHICH ALLOWED HYDRAULIC FLUID TO LEAK PAST THE VALVE. 2L72 4F4 FRTT00008WIE6WE 20040330001362004033000136GL 2004 3 30 AUS20031332 220031227G7230 BLADE BOEING747 747438 NM GE CF6 CF680C2* GL COMPRESSOR FAILED W O OTHER EF VIBRATION/BUFFET FLT CONT AFFECTED CLCLIMB 1 AUS (AUS) ENGINE VIBRATION AFTER TAKEOFF. BOROSCOPE INSPECTION FOUND FOURTH STAGE HPC BLADE FAILED. 2L74 4F4 FRTA20WE E23EA 20040330001372004033000137EU 2004 3 30 AUS20031333 120031215G541568120251 FITTING PARTENP68 P68B 6780104EU LYC O360 IO360A1B6 41514EA HARTZLHCC2Y HCC2YK2 GL NACELLE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) ENGINE MOUNT FITTINGS PN 68-1.2025-1 AND PN 68-1.2025-2 CRACKED AROUND RIVET HOLES. 1H72 3O3 O A31EU 1E10 5 CP920 20040330001382004033000138EU 2004 3 30 AUS20031334 120031215G571168140093 DOUBLER PARTENP68 P68B 6780104EU LYC O360 IO360A1B6 41514EA HARTZLHCC2Y HCC2YK2 GL WING SPAR CORRODED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) WING SPAR DOUBLERS PN 68-1.4009-3 AND PN 68-1.4009-4 CONTAINED A SMALL AMOUNT OF CORROSION. DOUBLERS ARE LOCATED IN AREA BEHIND ENGINES AND ENGINE FIREWALLS. 1H72 3O3 O A31EU 1E10 5 CP920 20040330001392004033000139EU 2004 3 30 AUS20031335 120031229G32425011830 BRAKE ASSY FOKKERF28 F28MK0100 4990807EU RROYCETAY TAY65015 54557NE MLG BROKEN W O OTHER O OTHER LDLANDING 1 AUS 3059 (AUS) NR 1 BRAKE ASSEMBLY FAILED. INSPECTION FOUND THAT THE PISTONS HAD HOLED THE CARBON DISK PRESSURE PLATE CAUSING IT TO DELAMINATE AND THEN ALLOW THE PISTONS TO CONTACT THE FIRST ROTATING DISK R1 CAUSING SEVERE WEAR TO R1 AND THE PISTONS. 2L72 4F4 FRT E25NE 20040330001402004033000140CE 2004 3 30 AUS20031336 120031220G32429540666 HOUSING BEECH 18 D18S 1151004CE PWA R985 R985AN14B 52008NE HARTZLHCB3Z HCB3Z302 GL BRAKE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT MAIN LANDING GEAR BRAKE HOUSING CRACKED ON MOUNT FLANGE. 1L72 3R3 R A765 5E1 5 CP907 20040330001412004033000141NM 2004 3 30 AUS20031337 120031228G3242 PISTON BOEING767 767338 1385151NM GE CF6 CF680C2* GL BRAKE JAMMED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) NR 2 FRONT MAIN BRAKE ASSEMBLY PISTON JAMMED AND ROTORS DISINTEGRATING. 2L72 4F4 FRTA1NM E23EA 20040330001422004033000142EU 2004 3 30 AUS20031338 120031222G6510350A34021006 DRIVE SHAFT SNIAS 350 AS350B 8680801EU TMECA ARRIELARRIEL1B 6OO30NE TAIL ROTOR DEBONDED W K NONE O OTHER ININSP/MAINT 1 AUS 5087 (AUS) TAIL ROTOR DRIVESHAFT FORWARD SPLINED END DEBONDED AND RIVETS WORKING. 1G71 3U3 U H9EU E19EU 20040330001442004033000144NM 2004 3 30 AUS20031339 120031227G3246 BOLT BOEING737 737476 NM CFMINTCFM56 CFM563C 13802EU WHEEL SHEARED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) RT MAIN LANDING GEAR OUTBOARD WHEEL TIE BOLT SHEARED IN THREADED SECTION. 2L72 4F4 FRTA16WE E21EU 20040330001592004033000159NM 2004 3 30 AUS20031340 120031220G5330 SKIN BOEING747 747438 NM RROYCERB211 RB211524G19 NE FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) FUSELAGE SKIN CRACKED AT FORWARD UPPER CORNER OF AFT CARGO DOOR CUTOUT. FOUND DURING INSPECTION IAW EI 747-053-0170R1 AND AD/B747/293. 2L74 4F4 FRTA20WE E30NE 20040330001602004033000160EU 2004 3 30 AUS20031341 120031222G3242AHA1899 TORQUE TUBE DUNLOP BAG JETSTMJETSTM4112 EU BRAKE CRACKED W K NONE O OTHER ININSP/MAINT 1 AUS RM199 (AUS) BRAKE ASSEMBLY TORQUE TUBE CRACKED. CRACK LENGTH 3.175MM(0.125IN). FOUND DURING MAGNETIC PARTICLE INSPECTION (MPI). 1L72 4T RTA196 20040330001612004033000161 2004 3 30 AUS20031342 420031212G34104066192901X DISPLAY BAG BAE146BAE146300A 1500267EU LYC ALF502ALF502R5 41580NE FLIGHT ENVIRONMEWRONG PART W K NONE O OTHER ININSP/MAINT 1 AUS (AUS) ELECTRONIC DISPLAY UNIT (EDU) WAS INCORRECT PART. MANUFACTURERS AME PLATE WAS IN RED WHICH INDICATED THAT IT WAS AN ENGINEERING EVALUATION UNIT. THE AIRWORTHY UNITS HAVE A BLACK NAMEPLATE. AND CARRY THE PN 4066192-901. PERSONNEL/MAINTENANCE ERROR. UNAPPROVED PART. 2H74 4F4 FRTA49EU E6NE 20040330001622004033000162 2004 3 30 AUS20031343 420031028G34604082260937 CONTROL PANEL BOEING737 737* NM GE CFM56 CFM567B24 NE FLT MANAGEMENT FAILED W O OTHER F FLT CONT AFFECTED DEDESCENT 1 AUS (AUS) MODE CONTROL PANEL (MCP) FAILED. INVESTIGATION FOUND THE FAULT IN U14 ON MICROPROCESSOR CCA A10. 2L72 4F4 FRTA16WE E00055EN 20030805000342003080500034SO 2003 8 5 B30R2003003 220030602G8530655465A4 CYLINDER CESSNA210 T210L 2073449CE CONT O550 IO550* SO HARTZLHCJ3Y PHCJ3YF1 GL ENGINE CRACKED B B30RK NONE O OTHER ININSP/MAINT 1 SW03732JF309 50 21061543 821007 A48936A DURING ANNUAL ENGINE INSPECTION A MECHANIC NOTED BLUE FUEL STAIN IN THE AREA OF THE NR 1 CYLINDER FUEL DRAIN PORT. BLUE FUEL STAIN WAS REMOVED AND ENGINE FUEL SYSTEM WAS PRESSURIZED. AT THIS TIME FUEL STARTED TO DRIP FROM IN BETWEEN THE FIRST TWO COOLING FINS NEXT TO THE DRAIN PORT. FURTHER INSPECTION OF THE COOLING FIN AREA WITH A BORESCOPE REVEALED TWO HOLES IN THE CYLINDER CASTING WITH A CRACK IN BETWEEN HOLES. 1H71 3O3 O 3A21 E3SO 5 CP36EA 20031230000292003123000029EU 2003 12 30 B30R20031120 120031211G5414 SKIN SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE COWL DOOR DELAMINATED B B30RK NONE O OTHER ININSP/MAINT 1 SW035204X1378 100 3099 9570 DURING 100 HOUR INSPECTION, IT WAS DISCOVERED THAT THE INNER FIBERGLASS SKIN OF THE UPPER AFT SECTION OF THE ENGINE COWLING HAD DISBONDED FROM THE HONEYCOMB STRUCTURE OF THE COWLING. PRYROPEL INSULATION WAS TO BE INSTALLED WHILE THE AIRCRAFT WAS IN INSPECTION AND THE COWLING WAS REMOVED TO FACILITATE THIS MAINTENANCE. REPAIRS TO BE MADE TO COWLING IAW MANUFACTURER'S REPAIR PROCEDURES. THEN PRYROPEL WILL BE INSTALLED IAW SOW-03-087. 1G71 3U3 U H9EU E19EU 20030918001272003091800127CE 2003 9 18 B30R20033010 120030604G55201016200111 HINGE FITTING BEECH 200 A200 1152921CE PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL ELEVATOR CORRODED B B30RK NONE O OTHER ININSP/MAINT 1 SW037074G BC17 DURING A 14 DAY CORROSION INSP, MECH NOTED PAINT BLISTERING AROUND RIGHT ELEVATOR HINGE FITTING MOUNTING HARDWARE. REMOVAL OF PAINT BLISTERS FROM HINGE FITTING REVEALED INTERGRANULAR CORROSION. HINGE FITTING WAS REMOVED AND CORRODED AREA WAS CLEANED. AT THIS TIME IT WAS NOTED THAT CORROSION DAMAGE WAS BEYOND A SERVICABLE LIMIT. AT FACILITY, WE OPERATE 3 OF THESE AGING AIRCRAFT. WE HAVE FOUND SAME PARTS CORRODED ON MOST RECENT CORROSION INSP OF OUR 2 OTHER AIRCRAFT. THIS AIRCRAFT WAS REPAINTED 2 YEARS AGO. DUE TO TYPE AND NATURE OF THIS CORROSION, WE ADVISE THAT OPERATORS PAY ATTENTION TO DETAIL FOR CORROSION ON THE HORIZONTAL AND VERTICAL STABILIZERS AND THERE FLIGHT CONTROL SUFACES. 1L72 4T4 T A24CE E4EA 6 CP15EA 20030918001282003091800128CE 2003 9 18 B30R20033011 120030604G55201016200121 HINGE BRACKET BEECH 200 A200 1152921CE PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL ELEVATOR DAMAGED B B30RK NONE O OTHER ININSP/MAINT 1 SW037074G BC17 DURING A 14 DAY CORROSION INSPECTION, MECHANIC NOTED PAINT BLISTERING ON THE RIGHT INBOARD ELEVATOR HINGE BRACKET. REMOVAL OF THE PAINT BLISTERS FROM HINGE BRACKET REVEALED INTERGRANULAR CORROSION. THE HINGE BRACKET WAS REMOVED AND CORRODED AREA WAS CLEANED. AT THIS TIME IT WAS NOTED THAT THE CORROSION DAMAGE WAS BEYOND A SERVICABLE LIMIT. AT OUR FACILITY, WE OPERATE 3 OF THESE AGING AIRCRAFT. THIS AIRCRAFT WAS REPAINTED 2 YEARS AGO. DUE TO THE TYPE AND NATURE OF THIS CORROSION, WE ADVISE THAT THE OPERATORS OF THE PAY ATTENTION TO DETAIL FOR CORROSION ON THE HORIZONTAL AND VERTICAL STABILZERS AND THEIR FLIGHT CONTROL SURFACES. 1L72 4T4 T A24CE E4EA 6 CP15EA 20031113000692003111300069CE 2003 11 13 B30R20033017 120030925G2897652635537 WIRE HARNESS CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE FUEL PUMP CHAFED B B30RK NONE O OTHER ININSP/MAINT 1 SW0326621 5500593 IN TROUBLESHOOTING A SUBMERGED FUEL BOOST PUMP CIRCUIT BREAKER POPPING, MAINTENANCE TECHNICIANS DISCOVERED THE FUEL BOOST PUMP ELECTRICAL HARNESS HAD CHAFFED THROUGH THE BUNDLE INSULATION AND WAS ARCING ON ALUMINUM FUEL LINE P/N 6526355-37 INSIDE THE WET WING. THE POTENTIAL FOR FUEL VAPOR IGNITION AND AN EXPLOSION. 1L72 4F4 F A22CE E1NE 20031113000682003111300068CE 2003 11 13 B30R20033018 120030925G2897 WIRE CESSNA500 550 2076604CE FUEL BOOST ARCED B B30RK NONE B SMOKE/FUMES/ODORS/SPARKS ININSP/MAINT 1 SW0326494 5500605 IN TROUBLESHOOTING A SUBMERGED FUEL BOOST PUMP CIRCUIT BREAKER POPPING, MAINTENANCE TECHNICIANS DISCOVERED THE FUEL BOOST PUMP ELECTRICAL HARNESSES HAD CHAFED THROUGH THE BUNDLE INSULATION AND WAS ARCING ON ALUMINUM FUEL LINES P/N 6526355-37 INSIDE BOTH THE LEFT AND RIGHT WET WING. THE POTENTIAL FOR FUEL VAPOR IGNITION COULD HAVE CAUSED AN EXPLOSION. 1L72 4F A22CE 20030428000222003042800022CE 2003 4 28 B3OR20030001 120030319G716021095011 ALT AIR DOOR CESSNA210 T210N 2073456CE CONT O520 TSIO520* 17040SO ENGINE SEPARATED B B3ORA UNSCHED LANDING D INFLIGHT SEPARATION CLCLIMB 1 SW035515Y930 21064233 289125R ON CLIMB OUT, ENG BEGAN TO RUN ROUGH, DROPPING 300 RPM. DURING GROUND RUN UP, MAG CHECK AT 1700 RPM SHOWED NO PROBLEM. RUN UP TO PWR AND ENG RAN FINE, THEN DROPPED 300 RPM AND RAN ROUGH. MAINT REMOVED ALL SPARK PLUGS AND FOUND LEAD FOULED. CLEANED AND FIRE CHECK SPARK PLUGS. CHANGED IGN LEADS, BOTH MAGS AND ALL SPARK PLUGS, SUSPECT BURN MARKS AT LEADS TO HARNESS. AIR INTAKE DUCT ALTERNATE AIR DOOR WAS FOUND TO BE UNHINGED AND FOUND HINGE PIN AND DOOR LAYING IN DUCT. NO SPRING WAS FOUND. ALL CYL WERE BOROSCOPED. NR 5 CYLINDER WAS FOUND TO HAVE IMPACT MARKS ON TOP OF PISTON, HEAD AND INTAKE VALVE SEAT. NR 5 CYL WAS REPLACED. INTAKE DOOR SPRING HAD ENTERED CYLINDER AND EXITED EXHAUST VALVE, IT WAS NEVER FOUND. 1H71 3O3 O 3A21 E8CE 20030430001002003043000100SO 2003 4 30 B3OR2003002 220030429G855065217122 DIPSTICK CESSNA210 T210N 2073456CE CONT O550 IO550* SO ZONE 400 BROKEN B B3ORO OTHER O OTHER NRNOT REPORTED 1 SW036621A340 100 21063559 821022R AFTER THE SECOND GROUND RUN, AND DURING A PRE-RUN CHECK FOR A THIRD GROUND RUN, A MECHANIC REMOVED THE OIL FILLER CAP/DIPSTICK AND DISCOVERED THAT THE DIPSTICK HAD BROKEN OFF FROM THE OIL FILLER CAP. THE OIL WAS DRAINED FROM THE ENGINE, AND A BORESCOPE WAS USED TO DETERMINE THAT THE DIPSTICK HAD BEEN BROKEN INTO NUMEROUS PARTS.ONE PART OF THE DIPSTICK WAS RECOVERED FROM THE OIL DRAIN HOLE AND IT WAS ABOUT ONE INCH LONG AND BENT IN A 90 DEGREE ANGLE. THE OIL FILTER WAS REMOVED, CUT OPEN, AND THE FILTER CONTAINED A LARGE AMOUNT OF METAL FLAKES. THE OIL REMAINING IN THE FILTER CAN LOOKED LIKE METALLIC PAINT.THE MECHANIC SAID HE HAD NO PROBLEM WITH INSTALLING THE OIL CAP/DIPSTICK BACK INTO THE ENGINE PRIOR TO THE S1H71 3O3 O 3A21 E3SO 20030805000372003080500037CE 2003 8 5 B3OR2003004 120030605G27301016100191 PITCH HORN BEECH 200 C12C 1152903CE ELEVATOR CORRODED B B3ORK NONE O OTHER ININSP/MAINT 1 SW03724761411225 BC26 DURING A 15 DAY CORROSION INSPECTION, A MECHANIC NOTICED "PAINT BUBBLING" ON THE LT ELEVATOR CONTROL PITCH HORN. UPON FURTHER INVESTIGATION BY SCRAPING-OFF THE PAINT BUBBLE, PITTING CORROSION WAS FOUND. AN ATTEMPT WAS MADE TO CLEAN AND TREAT THE PITTED AREA, BUT IT WAS FOUND THAT THE PITS WERE TOO DEEP INTO THE METAL. A NEW PITCH HORN WAS ORDERED AND THE AFFECTED PART WAS REPLACED. 1L72 4T A24CE 20030805000392003080500039CE 2003 8 5 B3OR2003005 120030605G55201016200111 HINGE BRACKET BEECH 200 A200 1152921CE ZONE 300 CORRODED B B3ORK NONE O OTHER ININSP/MAINT 1 SW0372476 35 BC26 MECHANIC NOTICED (PAINT BUBBLING) ON LT OB ELEVATOR HINGE .UPON FURTHER INVESTIGATION BY SCRAPING-OFF THE PAINT BUBBLE, CORROSION WAS FOUND. AN ATTEMPT WAS MADE TO CLEAN AND TREAT AREA, BUT IT WAS FOUND THAT MORE YOU TRIED TO CLEAN CORROSION, MORE METAL WAS BEING REMOVED IN PROCESS. FLAKING OF CORROSION WAS TOO DEEP INTO METAL OF HINGE BRACKET. A NEW HINGE BRACKET WAS ORDERED AND PART WAS REPLACED. HAVE FOUND IT DIFFICULT TO SPOT THESE (BUBBLED PAINT) AREAS. WHEN AREAS ARE SPOTTED, WE SCRAPE-OFF SOME OF PAINT AND RESULT IS SAME, CORROSION AND FLAKING. REPLACEMENT OF PART. IT IS ADVISED THAT OPERATORS OF A/C PAY PARTICULAR ATTENTION TO ELEVATOR HINGE BRACKETS AT THEIR NEXT PERIODIC MAINTENANCE INSP. 1L72 4T A24CE 20030805000402003080500040CE 2003 8 5 B3OR2003006 120030605G55201016200131 HINGE BRACKET BEECH 200 A200 1152921CE ELEVATOR CORRODED B B3ORK NONE O OTHER ININSP/MAINT 1 SW037247Y 40 BC03 MECH NOTICED (PAINT BUBBLING) ON LT AND RT, MIDDLE ELEVATOR HINGE. FURTHER INVESTIGATION BY SCRAPEING-OFF PAINT BUBBLE, CORROSION WAS FOUND. ATTEMPT WAS MADE TO CLEAN AND TREAT AREA, FOUND THAT MORE YOU TRIED TO CLEAN CORROSION, MORE METAL WAS BEING REMOVED IN PROCESS. FLAKING, CORROSION WAS TOO DEEP INTO METAL OF HINGE BRACKET. NEW HINGE BRACKET WAS ORDERED AND AFFECTED PART WAS REPLACED. A/C WAS RE-PAINTED OVER TWO YEARS AGO. WE HAVE FOUND IT DIFFICULT TO SPOT THESE (BUBBLED PAINT) AREAS. REPLACEMENT OF AFFECTED PART. IT IS ADVISED THAT OPERATORS OF AIRCRAFT PAY PARTICULAR ATTENTION ELEVATOR HINGE BRACKETS AT THEIR NEXT MAINT INSP. 1L72 4T A24CE 20030805000412003080500041CE 2003 8 5 B3OR2003007 120030605G55201016200121 HINGE BRACKET BEECH 200 A200 1152921CE ELEVATOR CORRODED B B3ORK NONE O OTHER ININSP/MAINT 1 SW0372476 25 BC26 DURING CORR INSP, MECH NOTICED "PAINT BUBBLING" ON LT, IB ELEV HINGE BRACKET. FURTHER INVESTIGATION BY SCRAPING-OFF PAINT BUBBLE, CORR WAS FOUND. ATTEMPT WAS MADE TO CLEAN AND TREAT AREA, BUT FOUND THAT MORE YOU CLEANED CORROSION, MORE METAL WAS BEING REMOVED IN PROCESS. FLAKING, CORR WAS TOO DEEP INTO METAL OF HINGE BRKT. HINGE BRKT WAS ORDERED AND AFFECTED PART WAS REPLACED. A/C ARE KEPT OUTSIDE, THIS IS REASON FOR CORROSION INSP CYCLE. A/C WAS RE-PAINTED OVER TWO YEARS AGO. WE HAVE FOUND IT DIFFICULT TO SPOT THESE "BUBBLED PAINT" AREAS, WHEN AREAS ARE SPOTTED, SCRAPE-OFF SOME PAINT AND RESULT IS SAME, CORR AND FLAKING. RESULT IS REPLACEMENT OF AFFECTED PART. CORR FOUND ON THESE HINGE BRKT. 1L72 4T A24CE 20030805000422003080500042CE 2003 8 5 B3OR2003008 120030605G554010164001413 HINGE BEECH 200 A200 1152921CE HINGE CORRODED B B3ORK NONE O OTHER ININSP/MAINT 1 SW037247Y 40 BC03 DURING A 15 DAY CORROSION INSP, MECH NOTICED "PAINT BUBBLEING" ON MIDDLE RUDDER HINGE BRACKET. UPON INVESTIGATION, CORROSION FOUND. ATTEMPT WAS MADE TO CLEAN & TREAT AREA, BUT FOUND THAT MORE METAL WAS BEING REMOVED IN THE PROCESS. FLAKING, CORROSION WAS TOO DEEP INTO METAL OF THE HINGE BRACKET. A NEW HINGE BRACKET WAS ORDERED AND THE AFFECTED PART WAS REPLACED. AS A NOTE, THE AIRCRAFT ARE KEPT OUTSIDE FOR THE MAJORITY OF THE TIME, THIS IS THE REASON FOR THE 15 DAY CORROSION INSPECTION CYCLE. AIRCRAFT RE-PAINTED 2 YEARS AGO. FOUND IT DIFFICULT TO SPOT "BUBBLED PAINT" AREAS, WHEN AREAS ARE SPOTTED, SCRAPE-OFF SOME OF PAINT & RESULT IS SAME, CORROSION & FLAKING. RESULT IS REPLACEMENT OF AFFECTED PART. 1L72 4T A24CE 20030805000432003080500043CE 2003 8 5 B3OR2003009 120030605G554010164001411 HINGE BRACKET BEECH 200 A200 1152921CE RUDDER CORRODED B B3ORK NONE O OTHER ININSP/MAINT 1 SW037247Y 40 BC03 MECH NOTICED (PAINT BUBBLING) ON, UPPER RUDDER HINGE BRACKET. ON INVESTIGATION, CORROSION WAS FOUND. FLAKING, CORROSION WAS TOO DEEP INTO METAL OF HINGE BRACKET. NEW HINGE BRACKET WAS ORDERED AND AFFECTED PART WAS REPLACED. WE HAVE FOUND IT DIFFICULT TO SPOT THESE (BUBBLED PAINT) AREAS, WHEN AREAS ARE SPOTTED, WE SCRAPE-OFF SOME OF PAINT AND RESULT IS SAME, CORROSION AND FLAKING. RESULT IS REPLACEMENT OF AFFECTED PART. IT IS ADVISED THAT OPERATORS OF A/C PAY PARTICULAR ATTENTION TO RUDDER AND ELEVATOR HINGE BRACKETS AT THEIR NEXT PERIODIC MAINT INSPECTION. CORROSION FOUND ON THESE HINGE BRACKETS HAS BEEN DISCOVERED IN ADDITION TO HINGE BRACKET CORROSION. 1L72 4T A24CE 20031113000702003111300070NE 2003 11 13 B3OR20031119 220031104G7270310863201 DUCT CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE ENGINE CRACKED B B3ORK NONE O OTHER ININSP/MAINT 1 SW03264962481 2481 5500607 PCE71520 DURING A PHASE 3 AND 4 INSPECTION, IT WAS DISCOVERED THAT THE FORWARD INNER BY-PASS DUCT HAD A CRACK. THE CRACK WAS LOCATED AT THE 6 O'CLOCK POSITION AND WAS ABOUT AND INCH-AND-A-HALF LONG. THE DUCT WAS REMOVED AND A NEW FORWARD INNER BY-PASS DUCT WAS INSTALLED. 1L72 4F4 F A22CE E1NE 20030918001262003091800126CE 2003 9 18 B3OR20033012 120030804G57531011200561 FLAP TRACK BEECH 200 A200 1152921CE PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL ZONE 600 CORRODED B B3ORK NONE O OTHER ININSP/MAINT 1 SW037247Y1360775 BC03 DURING A 14 DAY CORROSION INSPECTION THE RIGHT HAND INBORAD FLAP TRACK WAS FOUND TO HAVE DEEP EXIFOLLIATION FLAKING CORROSION ON THE INBOARD SIDE OF THE TRACK.THE FLAKING WAS SEVERE ENOUGH TO CAUSE SEVERAL LAYERS OF FLAKES TO BE PRESENT. THE PART WAS REMOVED AND A NEW FLAP TRACK WAS INSTALLED.THIS AIRCRAFT WAS REPAINTED IN 1999, AND HAS BEEN KEPT, FOR THE MOST PART, OUTSIDE DUE TO LACK OF HANGER SPACE. 1L72 4T4 T A24CE E4EA 6 CP15EA 20030918001292003091800129CE 2003 9 18 B3OR20033013 120030804G575310111001613 FLAP TRACK BEECH 200 A200 1152921CE PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL TE FLAP CORRODED B B3ORK NONE O OTHER ININSP/MAINT 1 SW037247Y1360775 BC03 DURING A 14 DAY CORROSION INSPECTION THE RIGHT HAND OUTBOARD FLAP TRACK WAS FOUND TO HAVE EXIFOLIATION FLAKING CORROSION ON THE FLAP TRACK. THE FLAKING WAS SEVERE ENOUGH TO CAUSE BUBBLING PAINT AND FLAKING METAL TO BE PRESENT. THE PART WAS REMOVED AND A NEW FLAP TRACK WAS INSTALLED. THIS AIRCRAFT WAS REPAINTED IN 1999, AND HAS BEEN KEPT, FOR THE MOST PART, OUTSIDE DUE TO THE LACK OF HANGER SPACE. 1L72 4T4 T A24CE E4EA 6 CP15EA 20030918001302003091800130CE 2003 9 18 B3OR20033014 120030804G57531011100171 FLAP TRACK BEECH 200 A200 1152921CE PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL TE FLAP CORRODED B B3ORK NONE O OTHER ININSP/MAINT 1 SW037247Y1360775 BC03 DURING A 14 DAY CORROSION INSPECTION THE LEFT OUTBOARD FLAP TACK WAS FOUND TO HAVE EXIFOLIATION FLAKING CORROSION ON THE FLAP TRACK. THE FLAKING WAS SEVERE ENOUGH TO CAUSE SEVERAL LAYERS OF FLAKING METAL TO BE PRESENT. THE PART WAS REMOVED AND A NEW FLAP TRACK WAS INSTALLED. THIS AIRCRAFT WAS REPAINTED IN 1999 AND, FOR THE MOST PART, HAS BEEN KEPT OUTSIDE DUE TO LACK OF HANGER SPACE. 1L72 4T4 T A24CE E4EA 6 CP15EA 20030918001312003091800131CE 2003 9 18 B3OR20033015 120030728G321312411023 STRUT CESSNA210 T210N 2073456CE CONT O550 IO550* SO HARTZLHCJ3Y PHCJ3YR2 GL RT MLG CORRODED B B3ORO OTHER O OTHER ININSP/MAINT 1 SW036621A5671 50 21063559 DURING AN ANNUAL INSPECTION, THE RT MAIN LANDING GEAR SPRING HAD BUBBLING PAINT IN THE AREA WHERE THE SPRING CONNECTS TO THE AXEL ASSEMBLY. THE SPRING WAS REMOVED AND THE AXEL ASSEMBLY WAS REMOVED. THE SPRING WAS FOUND TO HAVE SEVERE PITTING CORROSION ON THE BOTTOM END WHERE IT ATTACHES TO THE AXEL ASSEMBLY. A NEW SPRING WAS ORDERED AND IT WAS REPLACED. IT IS SUSPECT THAT THE SPRING BEING STEEL AND THE AXEL HOUSING BEING ALLUMINUM IT CAUSED DISSIMLER METAL CORROSION AND PITTING. 1H71 3O3 O 3A21 E3SO 5 CP36EA 20030918001322003091800132CE 2003 9 18 B3OR20033016 120030728G321312411024 STRUT CESSNA210 T210N 2073456CE CONT O550 IO550* SO HARTZLHCJ3Y PHCJ3YF2 GL MLG CORRODED B B3ORO OTHER O OTHER ININSP/MAINT 1 SW036621A5671 50 21063559 DURING AN ANNUAL INSPECTION, THE LEFT MAIN LANDING GEAR SPRING HAD BUBBLING PAINT IN THE AREA WHERE THE SPRING CONNECTS TO THE AXEL ASSEMBLY. THE SPRING WAS REMOVED AND THE AXEL ASSEMBLY WAS REMOVED. THE SPRING WAS FOUND TO HAVE SEVERE PITTING CORROSION ON THE BOTTOM END WHERE IT ATTACHES TO THE AXEL ASSEMBLY. A NEW SPRING WAS ORDERED AND IT WAS REPLACED. IT IS SUSPECT THAT THE SPRING BEING STEEL AND THE AXEL HOUSING BEING ALLUMINUM IT CAUSED DISSIMLER METAL CORROSION AND PITTING. 1H71 3O3 O 3A21 E3SO 5 CP36EA 20030106001442003010600144 2003 1 6 BAQA082775 420030103G3416396005241 ENCODER AEROSPSA365 SA365N 8680669EU ALTIMETER INACCURATE H BAQAO OTHER O OTHER NRNOT REPORTED 1 FS01199SM 6396 ALTIMETER ENCODING INACCURATE. REPLACED WITH SERVICEABLE UNIT. 1G72 3U H10EU 20030224000172003022400017EU 2003 2 24 BAQA084020 120030122G6700117132811 CONTROL ROD BOLKMS117 BK117B1 5626012EU ROTOR HEAD WORN H BAQAO OTHER O OTHER NRNOT REPORTED 1 FS01945ME5952 7235 BEARINGS WORN. REPLACED WITH SERVICEABLE ROD. 1G72 3U H13EU 20030423000742003042300074EU 2003 4 23 BAQA084034 120030127G54121176623541 FIREWALL BOLKMS117 BK117B1 5626012EU ENGINE BAY CRACKED E BAQAO OTHER O OTHER NRNOT REPORTED 1 FS01945ME6018 7235 FIREWALL CRACKED ON LOWER CORNER. REPLACED WITH SERVICEABLE UNIT. 1G72 3U H13EU 20030224000182003022400018 2003 2 24 BAQA084038 420030127G3442071015190101 RADAR UROCOPEC135 EC135T1 5620026EU WX RADAR SYS INOPERATIVE H BAQAO OTHER O OTHER NRNOT REPORTED 1 FS01522ME963 0144 WEATHER RADAR INOPERATIVE. REPLACED WITH SERVICEABLE UNIT. 1G72 3U H88EU 20030224000192003022400019EU 2003 2 24 BAQA084043 120030128G2430171BS1011 BATTERY BOLKMSBK117 BK117C1 5626025EU MAIN WORN H BAQAO OTHER O OTHER NRNOT REPORTED 1 FS01117NC391 7517 INTERMITTENT CHARGE OF BATTERY. NO CHARGE LIGHT ON. REPLACED WITH SERVICEABLE UNIT. 1G72 3U NCH13EU 20030203000862003020300086EU 2003 2 3 BAQA084057 120030130G6730L673M40A1001 ACTUATOR UROCOPEC135 EC135P1 8680990EU TAIL ROTOR LEAKING H BAQAO OTHER O OTHER NRNOT REPORTED 1 FS01135ME1351 0009 LEAKING AT SPLIT LINE OF TRIANGULAR PLATE ON BOTTOM SIDE OF ACTUATOR. REPLACED WITH SERVICEABLE UNIT. 1G72 3U O H88EU 20030203000922003020300092EU 2003 2 3 BAQA084063 120030130G641011731743 BLADE BOLKMS117 BK117A3 5626015EU TAIL ROTOR OUT OF BALANCE H BAQAO OTHER O OTHER NRNOT REPORTED 1 FS01911NH 7030 BLADES WOULD NOT BALANCE. REPLACED WITH SERVICEABLE UNITS S/N 413 AND 414. 1G72 3U H13EU 20030224000212003022400021EU 2003 2 24 BAQA084080 120030204G6520 STUD BOLKMS117 BK117B1 5626012EU GEARBOX LOOSE H BAQAO OTHER O OTHER NRNOT REPORTED 1 FS01945ME4107 7235 STUD ON GEARBOX MOUNT IS WORKING LOOSE. REPLACED WITH SERVICEABLE UNIT. 1G72 3U H13EU 20030423000882003042300088 2003 4 23 BAQA084838 420030227G2210117884141 CONTROL UNIT BOLKMS117 BK117B1 5626012EU LYC LTS101LTS101600A 41560NE CSAS INOPERATIVE E BAQAO OTHER O OTHER NRNOT REPORTED 1 EA03213AE 7219 YAW CSAS WILL NOT COME ON LINE. REPLACED WITH SERVICEABLE UNIT. 1G72 3U3 U H13EU E5NE 20030423000462003042300046 2003 4 23 BAQA085101 420030306G3421109290 GYRO BOLKMS117 BK117A1 5626010EU LYC LTS101LTS101750B1 41560NE COCKPIT MALFUNCTIONED E BAQAO OTHER J WARNING INDICATION NRNOT REPORTED 1 EA03300CP2430 7249 RATE GYRO LIGHT ILLUMINATED IN FLIGHT AND DECOUPLED. REPLACED WITH SERVICEABLE UNIT. 1G72 3U3 U H13EU E5NE10 20030410002332003041000233EU 2003 4 10 BAQA085817 120030325G5330L633M2010101 MOUNT UROCOPEC135 EC135T1 5620026EU TRANSMISSION LEAKING E BAQAO OTHER K FLUID LOSS NRNOT REPORTED 1 EA03511ME 0143 LEAKING. PIN NOT STICKING OUT UNDER A LOAD. REPLACED WITH SERVICEABLE UNIT. 1G72 3U H88EU 20030423000862003042300086 2003 4 23 BAQA085828 420030327G3414C6610630106 INDICATOR CESSNA500 560CESSNA 2076750CE PWA JT15 JT15D5 52112NE AIRSPEED OUT OF ADJUST E BAQAO OTHER O OTHER NRNOT REPORTED 1 EA03560H 3178 0017 AIRSPEED INDICATOR OUT OF CALIBRATION. LEAK. REPLACED WITH SERVICEABLE UNIT. 2L72 4F4 FRTA22CE E25EA 20030509001152003050900115EU 2003 5 9 BAQA085906 120030403G2913L290M20A1014 PUMP UROCOPEC135 EC135P1 8680990EU PWA PW206 PW206A NE HYD SYS LEAKING E BAQAO OTHER K FLUID LOSS NRNOT REPORTED 1 FS01601FH231 0069 EXCHANGE. HYDRAULIC PUMP, LEAKING. REPLACED WITH SERVICEABLE UNIT. 1G72 3U3 UO H88EU E42NE 20030423000922003042300092 2003 4 23 BAQA085907 420030403G3422501121001 GYRO AGUSTAA109 A109E 0260119EU COCKPIT INOPERATIVE H BAQAO OTHER O OTHER NRNOT REPORTED 1 FS017YL 571 11502 VERTICAL GYRO IS INOPERABLE. CAUSES ADI INDICATION FAILURE. REPLACED WITH SERVICEABLE UNIT. 4/8/03 1G72 3U RTH7EU 20030414000712003041400071EU 2003 4 14 BAQA085911 120030404G6520741C000005 ACTUATOR BOLKMS117 BK117A1 5626010EU TAIL ROTOR LEAKING E BAQAO OTHER K FLUID LOSS NRNOT REPORTED 1 EA03300CP2430 7249 TAIL ROTOR ACTUATOR LEAKING. CLEVIS WORN. WAITING FOR UNIT TO COME IN FROM AEC. CORE UNIT WAS OUR ASSET OFF OF 7249 SINCE 7249 USED A RECENT REPAIRED UNIT REPAIRED FOR 7099 (NO UNIT ON 7099). 7099 NEEDED ONE IMMEDIATELY, PURCHASED ONE FOR 7099 AS AN EXCHANGE. 7249'S CORE GOES BACK AS AN EXCHANGE TO AEC. 1G72 3U H13EU 20030423000652003042300065 2003 4 23 BAQA085912 420030404G221041600297006 MODULE UROCOPEC135 EC135T1 5620026EU TMECA ARRIUSARRIUS2B1 NE TRIM ACTUATOR FAILED E BAQAO OTHER J WARNING INDICATION NRNOT REPORTED 1 EA03533ME472 132 GIVING P/R SAS LIGHT AND ACTUATION W/A CORRESPONDING (P) ON PFD. HARD CARD ENCLOSED. REPLACED WITH SERVICEABLE UNIT. 1G72 3U3 U H88EU E34NE 20030423000632003042300063EU 2003 4 23 BAQA085925 120030407G6720 SHAFT UROCOPEC135 EC135T1 5620026EU ACTUATOR WORN H BAQAO OTHER O OTHER NRNOT REPORTED 1 EA03511ME136 149 0143 INTERMITTENT YAW LIGHT AND SHAFT WORN. REPLACED WITH SERVICEABLE UNIT. 1G72 3U H88EU 20030423000802003042300080EU 2003 4 23 BAQA085927 120030407G6510365A12002002 BLADE AEROSPAS365 AS365N2 8680815EU TAIL ROTOR CRACKED H BAQAO OTHER O OTHER NRNOT REPORTED 1 FS01915ME2174 6417 TAIL ROTOR BLADE HAS A CRACK NEAR CUFF. REPLACED WITH SERVICEABLE UNIT. 1G72 3U RTH10EU 20030423000812003042300081EU 2003 4 23 BAQA085929 120030408G212119A2772 BLOWER BOLKMS117 BK117A1 5626010EU AIR DISTRIBUTIONINOPERATIVE H BAQAO OTHER O OTHER NRNOT REPORTED 1 FS01955ME728 7243 BLOWER WILL NOT COME ON. ONE CORE BEING SENT BACK. REPLACED WITH SERVICEABLE UNIT. 1G72 3U H13EU 20030423000902003042300090 2003 4 23 BAQA085935 420030408G344278805191703 INDICATOR BOLKMS117 BK117A1 5626010EU WX RADAR SYS DAMAGED H BAQAO OTHER O OTHER NRNOT REPORTED 1 FS01967LS251 7067 UPPER LEFT PUSH BUTTON RECESSED. REPLACED WITH SERVICEABE UNIT. 1G72 3U H13EU 20030414000652003041400065EU 2003 4 14 BAQA085938 120030409G7722L316M30C1003 INDICATOR UROCOPEC135 EC135P1 8680990EU TOT INACCURATE H BAQAO OTHER O OTHER NRNOT REPORTED 1 FS01601FH19 0069 NR 1 TOT READS 800 WHEN ENGINE IS COLD. NO HARD CARD AVAILABLE. REPLACED WITH SERVICEABLE UNIT. 1G72 3U O H88EU 20030414000552003041400055EU 2003 4 14 BAQA085940 120030409G5312L713M1051101 FIREWALL UROCOPEC135 EC135T1 5620026EU FUSELAGE CRACKED H BAQAO OTHER O OTHER NRNOT REPORTED 1 FS01575ME1633 0157 FIREWALL CRACKED. REPLACED WITH SERVICEABLE UNIT. 1G72 3U H88EU 20030509001132003050900113EU 2003 5 9 BAQA086237 120030422G6210L621M1010054 STUD UROCOPEC135 EC135P1 8680990EU PWA PW206 PW206A NE M/R BLADE BROKEN E BAQAO OTHER O OTHER NRNOT REPORTED 1 EA03601FH2722 0069 WEIGHT STUD BROKE AT CUTTER KEY HOLE. BLADE INSTALLED BUT NEVER FLOWN. MECHANIC WENT TO ADJUST WEIGHT AND FOUND THE STUD BROKE. BLADE SENT TO BE REPAIRED UNDER PO NR. REINSTALLED RENTAL BLADE S/N 928. 1G72 3U3 UO H88EU E42NE 20030509001172003050900117EU 2003 5 9 BAQA086254 120030424G243245043006 BATTERY UROCOPEC135 EC135T1 5620026EU TMECA ARRIUSARRIUS2B1 NE MASTER FAILED E BAQAO OTHER O OTHER NRNOT REPORTED 1 EA03554ME25 0154 BATTERY UNIT FAILED SELF TEST AT INSTALLATION. AIRCRAFT WOULD NOT CRANK-(BATTERY DISCONNECT). REPLACED WITH SERVICEABLE UNIT. 1G72 3U3 U H88EU E34NE 20030509001182003050900118EU 2003 5 9 BAQA086255 120030424G243245043006 BATTERY UROCOPEC135 EC135T1 5620026EU TMECA ARRIUSARRIUS2B1 NE MASTER FAILED E BAQAO OTHER O OTHER NRNOT REPORTED 1 EA03554ME25 0154 BATTERY UNIT FAILED SELF TEST AT INSTALLATION. AIRCRAFT WOULD NOT CRANK (BATTERY DISCONNECT). HARD CARD ENCLOSED. REPLACED WITH SERVICEABLE UNIT. 1G72 3U3 U H88EU E34NE 20030604002172003060400217NE 2003 6 4 BAQA086309 220030501G7297430121302 WIRE HARNESS BOLKMS117 BK117A3 5626015EU LYC LTS101LTS101650B1 41560NE ENGINE FAILED B BAQRO OTHER O OTHER NRNOT REPORTED 1 FS01117UB 7062 N1 GUAGE WOULD NOT SPOOL WITH THIS HARNESS. REPLACED WITH SERVICEABLE UNIT. 1G72 3U3 U H13EU E5NE 20030528000452003052800045EU 2003 5 28 BAQA086332 120030506G6220E1T302301 ADAPTER AEROSPSA365 SA365N 8680669EU FREQUENCY TORN H BAQAO OTHER O OTHER NRNOT REPORTED 1 FS01199SM667 6396 FREQUENCY ADAPTER TORN BEYOND LIMITS. REPLACED WITH SERVICEABLE SET. 1G72 3U H10EU 20030605001522003060500152 2003 6 5 BAQA086380 420030512G3442MI585200 RADAR BEECH 100 100BEECH 1152916CE COCKPIT INOPERATIVE E BAQAO OTHER O OTHER NRNOT REPORTED 1 FS01777GS B241 RADAR INOPERATIVE. REPLACED WITH SERVICEABLE UNIT. 1L72 3T A14CE 20030605001532003060500153 2003 6 5 BAQA086396 420030512G3442MI585202 PEDESTAL BEECH 100 100BEECH 1152916CE ANTENNA DAMAGED E BAQAO OTHER O OTHER NRNOT REPORTED 1 FS01777GS B241 NEGATOR SPRING. REPLACED WITH SERVICEABLE UNIT. 1L72 3T A14CE 20030528000472003052800047EU 2003 5 28 BAQA086406 120030514G2140JBS8803 HEATER UROCOPEC135 EC135T1 5620026EU CABIN MALFUNCTIONED H BAQAO OTHER O OTHER NRNOT REPORTED 1 FS01533ME271 132 HEATER MALFUCTIONED, TEMPERATURE WILL NOT REGULATE. REPLACED WITH SERVICEABLE UNIT. 1G72 3U H88EU 20030617003282003061700328EU 2003 6 17 BAQA086465 120030520G79315338100 TRANSDUCER AEROSPAS365 AS365N2 8680815EU OIL PRESSURE MALFUNCTIONED H BAQAO OTHER N FALSE WARNING NRNOT REPORTED 1 FS01915ME 6417 PRESSURE DROPPED TO YELLOW AT IDLE. REPLACED WITH SERVICEABLE UNIT. 1G72 3U RTH10EU 20030807001222003080700122SW 2003 8 7 BAQA086745 120030527G2820430201407 LINE BELL 222 222U 1182140SW FUEL SYS LEAKING H BAQAO OTHER K FLUID LOSS NRNOT REPORTED 1 FS01223HX 47511 PUMP LEAKED FUEL BADLY FROM BOTH ENDS WHEN INSTALLED. NEVER PUT INTO SERVICE. 8130 AND HISTORICAL RECORD CARD ENCLOSED. REMOVED FROM ENGINE LE47204. REPLACED WITH SERVICEABLE UNIT. 1G72 3U H9SW 20030618000172003061800017EU 2003 6 18 BAQA087114 120030613G245045023500 ELECTRICAL BOX UROCOPEC135 EC135P1 8680990EU INOPERATIVE H BAQAO OTHER O OTHER NRNOT REPORTED 1 FS01577LF2045 0140 AIR CONDITIONER. INOPERATIVE. REPLACED WITH SERVICEABLE UNIT. 1G72 3U O H88EU 20031230000452003123000045CE 2003 12 30 BHA01RS 120031128G561010243008513 WINDOW BEECH 58 58P 1152744CE COCKPIT DEPARTED B O OTHER D INFLIGHT SEPARATION CRCRUISE 1 NM046047S 58 TJ37 WHILE IN FLIGHT, PILOTS LEFT SIDE WINDOW CRACKED AND DEPARTED AIRCRAFT. AIRCRAFT LANDED WITHOUT FURTHER INCIDENT. 1L72 3O A23CE 20031230000382003123000038 2003 12 30 BHA02RS 420031128G8300 CASE GARRTT CASA C212 C212 2410200EU GARRTTTPE331TPE33110 01514WP GEARBOX CRACKED B K NONE K FLUID LOSS ININSP/MAINT 1 NM04117BH 838 908169820 171 P37036 DURING ROUTINE INSPECTION, CRACK IN ACCESSORY GEARBOX WAS NOTED. CRACK WAS LOCATED AT RT SIDE ENGINE MOUNT PAD. UPON ENGINE REMOVAL, CRACK WAS FOUND TO BE ALMOST COMPLETELY THROUGH ENGINE MOUNT PAD AREA. 2H72 4T4 T A43EU E4WE 20041027000962004102700096CE 2004 10 27 BJ82004F00000 120031023G212150041 MOTOR BEECH 200 200BEECH 1152920CE PWA PT6 PT6* 52043EA BLOWER FAILED B O OTHER O OTHER NRNOT REPORTED 1 EA2393ZC BB654 PILOT REPORT SMELLING SMOKE IN COCKPIT. LANDED SAFELY. UPON INVESTIGATION FOUND FWD EVAPORATOR MOTOR HAD A BURN SMELL. REPLACED, OPS CHS GOOD. NO CHAPTER 4 OR 5 TIME ITEMS OR EVAPORATOR BLOWER ASSY OR INSPECTION OF BRUSHES. 1L72 4T3 T A24CE E2NE 20030106000322003010600032NM 2003 1 6 BLAI200200001 120030103G571441513017R RIB UNIVAR415 415D 0420306NM CENTER WING CORRODED H K NONE O OTHER ININSP/MAINT 1 SO11999972120 2620 DURING REFURBISHMENT OF THE WING CENTER SECTION WING WALKWAY BOXES, AN INSPECTION WAS CONDUCTED TO COMPLY WITH AD 2002-26-02. LOWER SKINS OF THE WALKWAY BOXES HAD BEEN REMOVED TO PROVIDE ACCESS FOR REFURBISHMENT, THIS PROVIDED UNIMPEDED ACCESS TO THE ENTIRE CENTER SECTION. CORROSION WAS FOUND ON THE RIGHT SIDE INBOARD REAR FORMER RIB LOCATED BEHIND THE REAR SPAR. CORROSION HAD SEVERELY DAMAGED THE RIB BEYOND AC43-4A CRITERIA REQUIRING REPLACEMENT. NEW RIB WAS PURCHASED AND INSTALLED. NO OTHER CORROSION WAS FOUND IN THE CENTER SECTION. THE ENTIRE CENTER SECTION WAS CLEANED AND PRIMED PRIOR TO REINSTALLATION OF LOWER SKIN. 1L71 3O A787 20031114000072003111400007CE 2003 11 14 BR549 120031029G76034576101000V1700 ATTACH BOLT LEAR 45 45LEAR 5170805CE GARRTTTFE731TFE731* 01518WP THROTTLE CABLE CORRODED C K NONE W INADEQUATE Q C ININSP/MAINT 1 SO09222MW866 110 UPON REPLACEMENT OF THRUST LEVER MODULE FOUND BOTH BOLTS ATTACHING THROTTLE CABLE CLEVIS TO THROTTLE MODULE CORRODED IN A HANK AREA WHERE BOLT PASSES THROUGH ROD END BEARINGS. HAD TO DRIVE BOLTS OUT WITH PUNCH TO REMOVE. UPON REMOVAL FOUND BOTH BOLTS DRY WITH NO VISIBLE LUBRICATION. ONE BOLT PITTED IN SHANK AREA. ORDERED TWO NEW BOLTS FROM MANUFACTURER AND FOUND THAT NEITHER ORIGINAL BOLT WAS CORRECT SHANK LENGTH WHEN COMPARED WITH NEW BOLTS. 2L72 4F4 FRTT00008WIE6WE 20031114000142003111400014CE 2003 11 14 BR550 120031029G760366274010000007 ACTUATOR LEAR 45 45LEAR 5170805CE GARRTTTFE731TFE731* 01518WP 2NDARY TRIM SYS FAILED C K NONE W INADEQUATE Q C ININSP/MAINT 1 SO09222MW4 4 110 UNIT CAUSED FAILURE OF SECONDARY TRIM SYSTEM AFTER 4.7 HOURS OF OPERATION. 2L72 4F4 FRTT00008WIE6WE 20030212000542003021200054CE 2003 2 12 CA030114004 120030109G712095510171 MOUNT CESSNA172 172L 2072432CE LYC O320 O320E2D 41508EA ENGINE CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA 10164 (CAN) ONE CRACK FOUND AT ONE TOP DYNAFOCAL WELD TO TUBE, FOUR CRACKS FOUND AT CROSS TUBE BETWEEN LOWER LEGS AT WELDED AREAS. ALL CRACKS FOUND DURING DYE-PENETRANT INSPECTION CARRIED OUT IN ACCORDANCE WITH CESSNA'S CONTINUING AIRWORTHINESS PROGRAM, CAP 71-20-00. MOUNT IS OLDER STYLE, LACKING WELDED FINGER-PATCH REINFORCEMENTS FOUND ON LATER MODELS AT CROSS-TUBE WELDS. CRACKS REPAIRED AND MOUNT RETURNED TO SERVICE. 1H71 3O3 ONT3A12 E274 20030203000312003020300031CE 2003 2 3 CA030114006 120030113G2133 LINE BEECH 100 A100 1152915CE PWA PT6 PT6A28 EA OUTFLOW VALVE FROZEN W D RETURN TO BLOCK J WARNING INDICATION TXTAXI/GRND HDL 1 CA (CAN) OUTFLOW VALVE SUCTION LINE WAS FROZEN CAUSING AIRCRAFT TO PRESSURIZE ON THE GROUND. COULD NOT BE CONTROLLED BY CONTROLLER. LINE WAS BLOWN OUT AND SYSTEM CHECKED SERVICIBLE AS PER MANUFACTURER. 1L72 3T4 T A14CE E4EA 20030203000322003020300032SO 2003 2 3 CA030114007 120030102G53124521504 BULKHEAD PIPER PA31T PA31T 7103124SO PWA PT6 PT6A28 EA FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 17198 (CAN) DURING SHEDULED MAINTENANCE DISCOVERED FLEXING UNDER THE DOOR SNUBBER ATTACH BRACKET WHEN OPENING AND CLOSING THE CABIN DOOR. INSPECTION REVEALED CRACKING IN BULKHEAD AND SKIN AT FS 215 REPAIRS CARRIED OUT IAW REPAIR DESIGN CERTIFICATE C-RA02-425/D. 1L72 3T4 T A8EA E4EA 20030212000582003021200058CE 2003 2 12 CA030115005 120030115G531004118684 DOOR FRAME CESSNA150 150L 2071826CE CONT O200 O200A 17020SO FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 19600 (CAN) DOOR POST SKIN EXTERIOR FOUND 0.5 INCH CRACK AT THE CENTRE OF THE CURVE CUTOUT AT THE FORWARD UPPER DOOR ON THE FUSELAGE. 1H71 3O3 O 3A19 E252 20030203000352003020300035CE 2003 2 3 CA030115006 120030114G78101099500001 EXHAUST STACK BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING ROUTINE INSPECTION THE ANTI ICE BOSS ON THE LT EXHAUST STACK P/N 1099500001 WAS FOUND BROKEN OFF WITH THE ANTI ICE FLEX TUBE. THE FLEX TUBE WAS ALSO CRACKED AROUND THE THE LOWER ELBOW. 1L72 3T4 TRT3A20 E4EA 20030212000642003021200064EU 2003 2 12 CA030116006 120030103G324223203500 BRAKE DISC PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL MLG CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DUE TO PREVIOUS BRAKE FAILURES WE NOW DISSASSEMBLE AND INSPECT THE BRAKE ASSY. AT 900 HRS. ON INSPECTION OF THIS ASSY. WE FOUND THE INSIDE ROTOR DISK CRACKED IN 2 PLACES. WEAR PINS INDICATED BRAKE ASSY AT LESS THAN HALF LIFE. CRACKS STARTED AT RELIEF HOLE AND PROCEEDED OUTWARD. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030212000662003021200066CE 2003 2 12 CA030117001 120030115G3710 CHECK VALVE CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA VACUUM SYSTEM UNSERVICEABLE W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE VACUUM SYSTEM CHECK VALVE MANIFOLD WAS DETERMINED TO BE UNSERVICEABLE DUE TO LEAKS PAST THE CHECK VALVE DISC. THIS FINDING WAS DETERMINED BY FOLLOWING THE INSPECTION CRITERIA CONTAINED IN CESSNA SB02-37-04. THE PART WAS REMOVED FROM SERVICE AND A REPLACEMENT PART WAS ORDERED. 1H71 3O3 ONT3A12 1E10 20030212000672003021200067CE 2003 2 12 CA030117002 120030116G3710 CHECK VALVE CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA VACUUM SYSTEM UNSERVICEABLE W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE VACUUM SYSTEM CHECK VALVE MANIFOLD WAS DETERMINED TO BE UNSERVICEABLE DUE TO LEAKS PAST THE CHECK VALVE DISC. THIS FINDING WAS DETERMINED BY FOLLOWING THE INSPECTION CRITERIA CONTAINED IN CESSNA SB 02-37-04. THE PART WAS REMOVED FROM SERVICE AND A REPLACEMENT PART WAS ORDERED. 1H71 3O3 ONT3A12 1E10 20030203000642003020300064CE 2003 2 3 CA030117005 120030116G3010130936P8D1000 LINE BEECH BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA DEICE SYS COLLAPSED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE TUBING THAT SUPPLIES PNUEMATIC PRESSURE TO THE DEICER BOOTS WAS FOUND COLLAPSED. THIS TUBE IS LOCATED UNDER THE HEAT REGISTER IN THE AFT BAGGAGE COMPARTMENT. IT APPEARS THE TUBING WAS WARM AND COLLAPSED DURING THE DEICE BOOT CYCLE. THE HEATER DUCT SHOWS NO SIGN OF LEAKAGE. DAMAGED AREA IS 1 1/4 INCH LONG. REF. ' FIRE AND ICE AVIATION SAFTEY, OCT 2002 PG 25 'KING AIR HEATER DISSABLES DEICE SYSTEM FOR TURBO PROP EMPANNAGE' 1L72 3T4 TRT3A20 E4EA 20060612003692006061200369EU 2006 6 12 CA030117006 120030116G2910AE707910 HOSE AIRBUS320 A320231 3930325EU IAE V2500 V2500A1 NE HYD SYSTEM CHAFED W BA EMER. DESCENT UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CLCLIMB 1 CA 2909029090 HYDRAULIC HOSE FOUND CHAFFED THROUGH ON ENGINE 1 GREEN HYDRAULIC SYSTEM PUMP PRESSURE TRANSDUCER. REF. 29-11-49-80A TUBES INSTL-HYDRAULIC, V2500, ENGINE 1, ZONE 400/ITEM 310. 2L72 4F4 FRTA28NM E311NE 20030210000842003021000084EA 2003 2 10 CA030119002 120030112G5610 WINDSHIELD PPG NP13932110 CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE WINDSHIELD W A UNSCHED LANDING O OTHER CRCRUISE 1 CA 22172 94144H7006 (CAN) RIGHT WINDSHIELD CRACKED DURING FLIGHT. DIVERTED FLIGHT TO HAMBURG.RIGHT WINDSHIELD REPLACED PER AMM. 2L72 4F4 FRTA21EA E15NE 20030210000852003021000085NE 2003 2 10 CA030119004 220030109G73216078T55P13 FCU GE 6078T55P13 CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE FCU W E ENGINE SHUTDOWN X ENGINE FLAMEOUT DEDESCENT 1 CA WYG96536 (CAN) 60 MILES FROM SAVANNAH, ON DESCENT FROM FL230 TO FL110, CREW REPORTED SLOW RH ENGINE. FLAMEOUT ON DESCENT AT 330 KTS AT 3200 FEET/MIN DESCENT. THE INFORMATION THAT FOLLOWS WAS TAKEN FROM AIRCRAFT DEFECT LOG BEGIN QUOTE:DEFECT: ON DESCENT RIGHT ENGINE FLAMED OUT, RIGHT ENG LOW OIL PRESSURE CAS MESSAGE DISPLAYED.ACTION: REMOVED AND REPLACED #2 FCU IAW 73-21-00.OP CK PERFORMED.NO DEFECTS NOTED. OP & LEAK CK GOOD. FUEL FILTER REPLACED, RIG CHECKED, TANKS SUMPED, NO DEFECTS NOTED. 2L72 4F4 FRTA21EA E15NE 20060612003702006061200370EA 2006 6 12 CA030119007 120030107G5610NP1393216 WINDSHIELD CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE COCKPIT CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA 6898 PERFORMED TECH FERRY FLIGHT AC FERRY FLIGHT APPROVAL AND REPLACED WINDSHIELD ACC AMM 56-11-01. 2L72 4F4 FRTA21EA E15NE 20060612004192006061200419NM 2006 6 12 CA030120005 120030109G213080053258 CONTROL PANEL BOEING727 727223 1384074NM PWA JT8 JT8D15A 52051NE CABIN PRESSURE FLUCTUATES W A UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 CA AT FLIGHT LEVEL 25,000 FT, IT WAS OBSERVED CABIN PRESSURE WAS CLIMBING 1,000 FT - 2,000 FT PER MINUTE. AIRCRAFT RETURNED TO BASE WITHOUT INCIDENT. CABIN PRESSURE CONTROL PANEL REPLACED AND CHECKED SERVICEABLE IAW WITH MM 21-30-00. NO FURTHER INCIDENT DURING SUBSEQUENT FLIGHT. 2L73 4F4 F A3WE E2EA 20060612004202006061200420CE 2006 6 12 CA030120006 120030116G2421DOFF10300F ALTERNATOR CESSNA150 150 2071802CE CONT O200 O200A 17020SO FAILED W K NONE O OTHER ININSP/MAINT 1 CA ON OVERHAUL OF THE ALTERNATOR THE RECTIFIER P/N ES4113, BRUSH P/N E4118, AND BEARING P/N ES4104. ALL THESE PART NUMBERS ARE NON-APPROVED. ALTERNATOR BUILD UP CARRIED OUT WITH APPROVED PARTS. 1H71 3O3 ONT3A19 E252 20030210000862003021000086EU 2003 2 10 CA030120011 120030117G3310 WIRE PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL WIRE W O OTHER O OTHER ININSP/MAINT 1 CA (CAN) WHILE REPLACING L.H. ALTIMETER, AN ARC/BURN MARKWAS NOTED ON THE EADI MOUNTING TRAY. WIRE # L52N-22 WAS FOUND TO HAVE CHAFFED THROUGH.NO PROBLEMS TO THE GPWS LIGHTING HAD BEEN REPORTEDWIRE WAS REPAIRED AND LOOM RESECURED. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030213000022003021300002EU 2003 2 13 CA030121001 120030116G32309738114306 PRESSURE SWITCH PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL MLG INTERMITTENT W O OTHER J WARNING INDICATION APAPPROACH 1 CA (CAN) PILOT REPORTED GEAR WOULD NOT LOCK WHEN SELECTED DOWN THE EMERGENCY HAND PUMP WAS USED TO LOCK GEAR AND INDICTION WORKED AND LANDING WAS UNEVENTFUL.MAINTENANCE AT THE BASE DID GEAR FUNCTIONAL TEST AND IT FUNCTIONED NORMAL, THE PRESSURE SWITCH CANNON PLUG WAS CLEANED.WHEN AIRCRAFT RETURNED TO BASE THE SYSTEM WAS FUNCTIONAL TESTED AGAIN AND WATER STAINS WERE OBSERVED IN THE HYDRAULIC AREA.ALL ELECTRICAL CONNECTORS WERE CLEANED AND TREATED WITH PRODUCT RECOMMENDED BY AIRCRAFT MANUFACTURE. THE PRESSURE SWITCH WAS REMOVED AND CLEANED AND FUNCTIONAL TESTED WITH NITROGEN. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030210000872003021000087CE 2003 2 10 CA030121004 120030121G243515872694 DRIVE SHAFT BENDIX 66082019 LEAR 35 35LEAR 5170600CE GARRTTTFE731TFE73122B 01518WP ON SHEARED W A UNSCHED LANDING H ELECT. POWER LOSS-50 PC CRCRUISE 1 CA 1271 (CAN) WHILE ON CRUISE,A/C LOST ELECTRICAL POWER FROM THE R/H ENGINE. A/C RETURNED TO BASE. UPON INSPECTION,FOUND DRIVE SHAFT ON DC GENERATOR HAD SHEARED.DC GENERATOR REPLACED,GROUND RUN CARRIED OUT FOUND STILL UNSERVICEABLE. UPON FUTHERTROUBLESHOOTING FOUND CURRENT LIMITER HAD BLOWN. CURRENT LIMITER REPLACED. 2L72 4F4 F A10CE E6WE 20030210000882003021000088NM 2003 2 10 CA030121007 120030109G2780 BEARING BOEING737 7372T5 1384474NM PWA JT8 JT8D17 52049NE AUX TRACK W K NONE J WARNING INDICATION APAPPROACH 1 CA (CAN) LOG SNAG - ON FLAP SELECTION TO ONE UNIT, LE FLAP TRANSIT LIGHT REMAINED ON. NO. 4 SLAT REMAINED AMBER. ALL OTHERS GREEN. ON SELECTION OF FLAP 10, NO. 4 WENT GREEN FULL EXTEND WITH OTHER LE DEVICES.THE MAINTENANCE MECHANICS DISCOVERED THE NO. 4 LE SLAT OUTBOARD AUX TRACK ROLLER BEARING AND ATTACH BOLT HAD DEPARTED AND WERE FOUND IN THE LOWER PART OF THE L/E.THIS CAUSED THE SLAT ASSEMBLY TO SKEW UPON EXTENSION AND TRIGGER THE TRANSIT INDICATION.THE ROLLER BEARING ATTACH BOLT CASTELLATED NUT COTTER PIN, WAS FOUND SHEARED AND A PORTION OF THE PIN WAS FOUND IN THE AREA.THE ROLLER BEARING AND ATTACH BOLT WERE REPLACED AND THE SYSTEM CHECKED SERVICEABLE. 2L72 4F4 FRTA16WE E2EA 20030210000892003021000089CE 2003 2 10 CA030122003 120030117G711026520227 SHROUD CESSNA 2652022208 CESSNA208 208B 2073701CE PWA PT6 PT6A114A 52043NE MCAULY3AF34C3GFR34C703 GL OUTBOARD CRACKED W O OTHER O OTHER ININSP/MAINT 1 CA (CAN) CRACK IN LOWER RIGHT COWLING APPROXIMATELY AT STN 50 WHERE SHROUD PN 2652022-7 OUTBOARD MEETS HAT SECTION STRINGER REPAIRED IN ACCORDANCE WITH SIRM 51-76-00 FIG 802, PAGE 803. 1H71 3T3 T A37CE E4EA 5 CP60GL 20030210000912003021000091NM 2003 2 10 CA030122006 120030120G291082970010401 HYDRAULIC LINE DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE HYDRAULIC LINE LEAKING W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) CREW REPORTED HYDRAULIC FLUID LEAKING FROM NO. 1 NACELLE. MAINTENACE FOUND NO.2 SYSTEM MLG DOWN PRESSURE HYDRAULIC LINE LEAKING.IPC REF 29-10-00 FIG.20 ITEM 25. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030210000922003021000092EA 2003 2 10 CA030123001 120030117G5610NP1393226 WINDOW PPG NP1393226 CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE WINDOW CRACKED W K NONE O OTHER LDLANDING 1 CA 00004H7000 (CAN) RH SIDE WINDOW CRACKED ON LANDING. WINDOW ASSY REPLACED. 2L72 4F4 FRTA21EA E15NE 20030210000932003021000093EA 2003 2 10 CA030123002 120030116G5610NP1393222 WINDOW PPG NP1393222 CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE WINDOW CRACKED W K NONE O OTHER APAPPROACH 1 CA 16752 97101H4237 (CAN) SHORTLY BEFORE LANDING, THE RIGHT WINDOW CRACKED. CRACK FURTHER PROGRESS ON TOUCH DOWN. AIRPLANE FERRIED. RIGHT WINDOW REPLACED. 2L72 4F4 FRTA21EA E15NE 20060612004222006061200422EA 2006 6 12 CA030123005 220030120G8530383B NUT PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA CYLINDER DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA DURING AIRCRAFT SCHEDULED INSPECTION EVENT, MAINTENANCE PERSONNEL FOUND A CYLINDER BASE NUT LODGED IN THE OIL PUMP SCAVENGE SCREEN ORIFICE. THE NUT WAS TOO BIG IN SIZE TO BE REMOVED FROM ENGINE; THEREFORE ENGINE ACCESSORY CASE, OIL PAN AND THREE (3) CYLINDERS WERE REMOVED. THE NUT WAS RETRIEVED, AND THE ENGINE WAS INSPECTED INTERNALLY. IT WAS CONCLUDED THAT THE NUT WAS LEFT IN THE ENGINE BY MISTAKE BY THE OVERHAUL FACILITY. THE ENGINE HAS A TOTAL OF 330 HRS TSO. THE ENGINE WAS REASSEMBLED AND RETURNED TO SERVICE. 1L72 3O3 O A20SO E14EA 20030210000942003021000094CE 2003 2 10 CA030123009 120030120G561010138402518 WINDSHIELD BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCD4N3HCD4N3A GL OUTER PANE CRACKED W A UNSCHED LANDING D INFLIGHT SEPARATION CRCRUISE 1 CA (CAN) AFTER DEPARTURE THE WINSHIELD HEAT WAS SELECTED ON AT 1500 FEET. AFTER LEVELING AT CRUISE ALTITUDE OF 16,000 FT THE CREW HEARD A POPPING NOISE AND NOTED THAT THE RIGHT WINDSHIELD HAD CRACKED IN THE OUTER PANE. THE CRACK WENT FROM TOP TO BOTTOM AND WAS APPROXIMATELY IN THE CENTER OF THE WINDSHIELD. ABNORMAL PROCEDURES AS PER THE AFM WERE FOLLOWED AND THE AIRCRAFT LANDING WAS UNEVENTFUL. MAINTENANCE REPLACED THE WINDSHIELD WITH AN OVERHAULED ASSEMBLY. NO SPECIFIC CAUSE OF THE WINDSIELD CRACKING WAS DETERMINED. 1L72 4T4 T A24CE E4EA 5 CSTC 20060612004242006061200424GL 2006 6 12 CA030124002 220030122G7310 UNION BELL 206 206L4 1182110SW ALLSN 250C 250C30P 03013GL GOVERNOR OBSTRUCTED W O OTHER O OTHER TXTAXI/GRND HDL 1 CA 3 DIFFICULTY TO START ENGINE. UNION FITTING OBSTRUCTED WITH METALLIC PARTICLES. 1G71 3U3 UNCH2SW E1GL 20030213000212003021300021 2003 2 13 CA030124004 420030123G6122 SHAFT PIPER PA46 PA46500TP 7104622SO PWA PT6 PT6A42 52043NE PROP GOVERNOR SHEARED W E ENGINE SHUTDOWN RE PARTIAL RPM/PWR LOSS VIBRATION/BUFFET TXTAXI/GRND HDL 1 CA (CAN) AT ENGINE START UP, THE PROPELLER WOULD NOT COME OUT OF FEATHER. INSPECTION REVEALED A SHEARED CONSTANT SPEED PROPELLER GOVERNOR SHAFT. 1L71 3O4 TRTA25SO E4EA 20030213000242003021300024EA 2003 2 13 CA030127004 220030113G8520LW15916 CRANKSHAFT LYC O320 O320H2AD 41508EA ENGINE CORRODED W K NONE O OTHER ININSP/MAINT 1 CA L364376T (CAN) CORROSION FOUND UNDERNEATH URETHABOND COATING APPLIED IN ACCORDANCE WITH SB 505B, SB 530A AND AD 998-02-08. URETHABOND COATING IS APPLIED TO PREVENT CORROSION, BUT AS IN MOST CASES, IT DID NOT. 3 O E274 20030213000252003021300025CE 2003 2 13 CA030127005 120030125G32602MD31AX287 SWITCH BEECH 90 65A90 1152908CE PWA PT6 PT6A20 52043EA MLG SELECTOR BROKEN W O OTHER J WARNING INDICATION APAPPROACH 1 CA (CAN) ON APPROACH , THE LANDING GEAR WAS SELECTED DOWN, BUT THE GEAR DID NOT EXTEND. FIVE ATTEMPTS WERE MADE TO EXTEND THE GEAR NORMALLY AND NO JOY. THE GEAR WAS EXTENDED USING THE EMERGENCY EXTENSION SYSTEM. THE PILOT NOTED THAT IT WAS DIFFICULT TO EXTEND. THE EMERGENCY SERVICES WERE ACTIVATED AND A LOWFLY PAST WAS CARRIED OUT TO ENSURE THE GEAR WAS DOWN. THE AIRCRAFT LANDED SUCCESSFULLY. ON INVESTIGATION, ONE OF THE SWITCHES WAS FOUND TO BE FAULTY IN THE LANDING GEAR SELECTOR ASSY. THE GEAR ALSO EXTENDED NORMALLY WHEN USING THE EMERGENCY EXTENSION. THE OAT WAS AROUND -35C. 1L72 3T3 T 3A20 E4EA 20030326000522003032600052CE 2003 3 26 CA030129001 120030122G7713 LINE CESSNA421 421B 2076014CE CONT O520 GTSIO520H 17032SO MANIFOLD BLOCKED W C ABORTED TAKEOFF N FALSE WARNING TOTAKEOFF 1 CA (CAN) ON GROUND WARM UP AND RUN ALL WAS NORMAL, ON TAKEOFF RT MANIFOLD STAYED AT 28.5 INCHES, ALL OTHER INDICATIONS AND ENGINE FUNCTIONS NORMAL. TAKEOFF ABORTED AND AIRCRAFT RETURNED TO HANGAR. MANIFOLD LINE FOUND BLOCK IN WING SECTION BETWEEN WING AND A/F. MOISTURE REMOVED TESTED FOUND SERVICEABLE. NOTE OUTSIDE AIR TEMP AT -29 DEGREES C AND ACFT WAS IN HANGAR PRIOR TO FLIGHT. 1L72 3O3 O A7CE E7CE 20030213000312003021300031 2003 2 13 CA030129004 420030129G3497RG223 COAX BEECH 200 B200 1152922CE PWA PT6 PT6A42 52043NE INSTRUMENTS UNSERVICEABLE W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) DURING AIRCRAFT IMPORTATION INSPECTION INTO CANADA, AVIONICS CHECKS NOTED WEAK NAVIGATION, COMMS, G/S RECEPTION. TROUBLESHOOTING FOUND THAT THE COAXIAL CABLE INSTALLED FOR THE ENTIRE AIRCRAFT, NAVIGATION, AND COMMUNICATIONS SYSTEMS HAD A MANUFACTURING DEFECT FROM DAY ONE OF INSTALLATION. THE INNER CORE OF TO CABLE DOES NOT RUN IN THE CENTER OF THE INSULATOR. THE CORE TOUCHES THE SHIELDING IN MULTIPLE LOCATIONS OF THE CABLE CAUSING SHORTS IN THE CABLE. INFORMATION ON CABLE AS FOLLOWS: M17/167-00001. MIL-C-17. 07145, AA-4649 1L72 4T4 T A24CE E4EA 20030213000322003021300032CE 2003 2 13 CA030129005 120030127G57519913000011 SKIN BEECH 100 100BEECH 1152916CE PWA PT6 PT6A28 EA RT AILERON CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) A 1.5 CENTIMETER CRACK FOUND RADIATING FROM A RIVET ON SECOND RIB FROM INBOARD EDGE AND LAST RIVET HOLE BEFORE THE TRAILING EDGE. ANOTHER .5 CENTIMETER CRACK IN SKIN FOUND RADIATING FROM THE SECOND RIVET FROM THE TRAILING EDGE ON THE THIRD RIB. THE CRACKS WERE DIFFICULT TO SEE BUT WERE INDICATED BY THE PAINT.THE SKIN HAD BEEN REPLACED AND HAD 870.2 HOURS SINCE NEW. BEECHCRAFT IS BEEN CONTACTED TO DISCUSS ANY WARRANTY OPTIONS. 1L72 3T4 T A14CE E4EA 20030213000342003021300034CE 2003 2 13 CA030130002 120030128G61203022852 SEAL RING BEECH 1900 1900C 1154161CE PWA PT6 PT6A65B 52043EA R GEARBOX STUCK W ED ENGINE SHUTDOWN RETURN TO BLOCK J WARNING INDICATION TXTAXI/GRND HDL 1 CA (CAN) AFTER ENGINE START, THE TORQUE READING INDICATED APPROX 3000 FT/LBS. POWER INCREASES OR DECREASES HAD LITTLE EFFECT. TROUBLESHOOTING WAS PERFORMED. A TORQUE INDICATION SYSTEM CALIBRATION TESTER WAS CONNECTED AND INDICATION WAS NORMAL. A TEST GAUGE WAS CONNECTED TO THE TORQUEMETER OIL LINE AND CONFIRMED A HIGH READING USING THE STARTER TO SPOOL. A SERVICE REP SUGGESTED THAT THE TORQUEMETER PISTON INSIDE THE RGB MAY BE HUNG UP. THIS CAN BE CAUSED BY THE TEFLON RINGS ON THE METER PISTON STICKING BEFORE THEY ARE WORN IN. SUGGESTED TO BLOW LOW PRESSURE AIR INTO THE OIL LINE IN THE RGB WHILE ROCKING THE PROP BACK AND FORTH. THIS PROCEDURE RECTIFIED THE PROBLEM AND ALL INDICATIONS HAVE BEEN NORMAL. 2L72 4T4 TRTA24CE E4EA 20030213000362003021300036CE 2003 2 13 CA030130007 120030127G32601003810061 DOWNLOCK SWITCH BEECH 100 A100 1152915CE PWA PT6 PT6A28 EA HARTZLHCB3T HCB3TN3 GL LT MLG FAILED W L ABORTED APPROACH N FALSE WARNING LDLANDING 1 CA (CAN) WHILE ON APPROACH THE PILOT SELECTED GEAR DOWN AND THE LT GEAR INDICATION DID NOT ILLUMINATE. THE GEAR WAS CYCLED WITH NO CHANGE. THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE REPLACED THE LEFT GEAR DOWNLOCK INDICATOR SWITCH AND SYSTEM WAS TESTED SERVICABLE 1L72 3T4 T A14CE E4EA 6 CP15EA 20060619001522006061900152EA 2006 6 19 CA030130008 120030126G321310195101 CYLINDER DHAV DHC8 DHC8311 1386006EA PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE MLG CORRODED W O OTHER O OTHER NRNOT REPORTED 1 CA 1245512455 AFTER A VERY COLD OPERATION DAY, A/C TOWED TO HANGAR. DURING INSPECTION, MECH FOUND LT MLG WITH NO CHROME PORTION VISIBLE AND AREA WET. LT MLG INNER CYLINDER REMOVED TO GAIN ACCESS FOR INSPECTION AND SEAL REPLACEMENT. FOUND LWR INNER CYLINDER WHERE LOWER BEARING SEATS SHOWING SOME CORROSION AND PITTING IAW MESSIER DOWTY MANUAL THIS AREA HAS A VERY LOW DAMAGE TOLERANCE THAT HAS BEEN EXCEEDED. SO OUTER CYLINDER REPLACED. QUALITY ASSURANCE INVESTIGATION C/OUT AND FOUND THAT THIS GEAR ASSY HAS LESS THEN AFT OF IS TIME BEFORE O/H AND NOTHING INTO BOMBARDIER MX PROGRAM REQUIRE INSPECTION INTO THIS AREA OR ANY TYPE OF FLUID REPLACEMENT. THINK THAT LOWER INNER PORTION OF MLG STRUT IS EXPOSED TO WATER (HUMIDITY) T2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030213000372003021300037EA 2003 2 13 CA030131001 120030122G2730C2T29A TORQUE TUBE DHAV DHC2 DHC2MK1 2800102EA PWA R985 R985AN14B 52008NE ELEVATOR MISREPAIRED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) PART WAS ACTUALLY REMOVED FROM STOCK FOR INSTALLATION ON A/C, BUT WOULD NOT FIT. IT WAS TAGGED AS 'USED SERVICEABLE'. IT APPEARS AS IF THE END LEVER HAD BEEN HOME MADE AND WELDED ON TO THE TUBE. ALSO PREVIOUSLY WORN ATTACHING HOLES HAD BEEN ' REPAIRED' BY THE WELDING OF WASHERS TO THE LEVERS. THE MECHANIC TRYING TO INSTALL THE UNIT REJECTED IT. 1H71 3R3 R A806 5E1 20030213000382003021300038EA 2003 2 13 CA030131002 220030124G8520LW17031 CRANKSHAFT LYC O320 O320D2J 41508EA ENGINE CORRODED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) CORROSION FOUND UNDERNEATH URETHABOND COATING APPLIED IN ACCORDANCE WITH SB 505B, SB 530A, & AD 98-9 3 O E274 20030326000562003032600056EA 2003 3 26 CA030131006 120030122G27306009230053 FEEL UNIT CNDAIRCL604 CL604 1900301EA GE CF34 CF343B1 NE PITCH ROUGH W O OTHER F FLT CONT AFFECTED TOTAKEOFF 1 CA (CAN) CREW STATED THAT ON TAKEOFF, EXCESSIVE FORCE ( AS COMPARED TO NORMAL TAKEOFF FORCE) WAS REQUIRED TO PULL THE YOKE BACK FOR TAKEOFF. CREW STATED THAT THE REQUIRED FORCE WAS SUCH THAT THEY CONSIDERED ABORTING TAKEOFF, BUT DID NOT. CREW ALSO NOTED THAT THE FORCE HAD A BREAKAWAY POINT, IN THAT PULLING THE YOKE BACK WAS DIFFICULT FOR A PERIOD OF TIME, THEN SEEMED TO SPRING FREE AND BECAME NORMAL. SUBSEQUENT TROUBLESHOOTING ON THE GROUND LED THE MAINTENACE CREW TO USE THE PITCH DISCONNECT MECHANISM AND ISOLATE THE PITCH FEEL SIMULATOR (PFS). IT WAS FOUND THAT THE LEFT PFS HAD SOME ROUGHNESS AND JERKINESS. BOTH LT AND RT PFS UNITS WERE REPLACED. 2L72 4F4 FRTA21EA E15NE 20030326000592003032600059CE 2003 3 26 CA030203004 120030129G801110357487242 STARTER CESSNA421 421C 2076016CE CONT O520 GTSIO520L 17032SO MCAULY3FF32 3FF32C501 GL ENGINE INTERMITTENT W E ENGINE SHUTDOWN E VIBRATION/BUFFET CLCLIMB 1 CA (CAN) FLIGHT CREW REPORTED THAT THE RIGHT HAND ENGINE WOULD INTERMITTENTLY 'SHUDDER'. THE FLIGHT CREW SECURED THE ENGINE AND THE AIRCRAFT RETURNED TO BASE UNEVENTFULLY. A DETAILED INSPECTION OF THE ENGINE AND IGNITION SYSTEM REVEALED THAT THE STARTING VIBRATOR WAS INTERMITTENTLY ACTIVATING. ACTIVATION OF THE STARTER VIBRATOR GROUNDS THE PRIMARY POINTS IN THE MAGNETOS AND UTILIZES THE SECONDARY POINTS IN THE LEFT HAND MAGNETO TO ADVANCE THE TIMING FOR STARTING. THERE HAVE BEEN NO FURTHER REPORTED INSTANCES OF MALFUNCTION SINCE THE STARTING VIBRATOR WAS REPLACED. 1L72 3O3 O A7CE E7CE 5 CP45GL 20030213000442003021300044CE 2003 2 13 CA030204013 120030204G5520115610010125 SPLINE ADAPTER BEECH 100 A100 1152915CE PWA PT6 PT6A28 EA ELEVATORS CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) UPON A RECENT INSPECTION REQUESTED BY THE REGIONAL PMI IT WAS DISCOVERED THAT THE TRAILING EDGE SPLINES ON BOTH PORT AND STARBOARD ELEVATORS WERE CRACKED. THE ELEVATOR TRAILING EDGE SPLINES ARE PRESENTLY BEING CLOSELY MONITORED AND WILL BE REPLACED IN THE NEAR FUTURE. 1L72 3T4 T A14CE E4EA 20050427003082005042700308NE 2005 4 27 CA030204016 120030128G32127625101104011 FLOAT SKRSKYS76 S76A 8143006NE ALLSN 250C 250C30S 03013GL MLG DEPLOYED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA 760065 (CAN) PRE-TAKE OFF CHECKS WERE COMPLETED FOR FLIGHT. AC WAS TURNED INTO WIND AND TAXIED FORWARD TO STRAIGHTEN OUT NOSE WHEEL. ONCE DONE THE TOE BRAKES WERE APPLIED BY THE COPILOT AND THE PILOT BECAUSE THE AC WAS ROLLING FORWARD. IMMEDIATELY, FLOATS WERE ACTIVATED. NEITHER PILOT RECALLS PRESSING FLOAT ACTIVATION BUTTON ON EITHER CYCLIC. AC WAS THEN FLOWN WITH THE FLOATS ( ALL FOUR ) DEPLOYED. THE FLOATS WERE DEFLATED AND REMOVED FROM THE AIRCRAFT. THE FLOAT SYSTEM (4 FLOAT BAGS, 4 FLOAT BOTTLES AND 4 SQUIBS ) WERE REMOVED FROM ANOTHER AIRCRAFT AND INSTALLED ONTO THIS AIRCRAFT IAW THE MM. A WIRING CONTINUITY CHECK OF ENTIRE FLOAT SYS WAS PERFORMED AN NO FAULT WAS FOUND. THE AIRCRAFT WAS RETURNED TO SERVICE. 1G72 3U3 U H1NE E1GL 20030213000482003021300048EU 2003 2 13 CA030205003 120030126G2752952D1005 PDU PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL TE FLAPS FAILED W O OTHER FJ FLT CONT AFFECTED WARNING INDICATION LDLANDING 1 CA (CAN) FLAPS FAILED TO EXTEND ON APPROACH INTO PE. A/C LANDED AND FLAP SYSTEM INSPECTED, FLAP POWER DRIVE UNIT FOUND FAULTY PN 952D1005. UNIT REPLACED AND FLAP O SET CARRIED OUT. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030213000492003021300049EU 2003 2 13 CA030205005 120030121G27529787320307 ACTUATOR PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL TE FLAPS FROZEN W O OTHER FJ FLT CONT AFFECTED WARNING INDICATION APAPPROACH 1 CA (CAN) ON APPROACH, FLAPS WERE SELECTED AND C/B FOR FLAPS POPPED. A/C LANDED AND SYSTEM WAS RESET AND TRIED AGAIN, C/B POPPED AGAIN. UPON INVESTIGATION IT WAS FOUND THAT SEVERAL OF THE FLAP ACTUATORS WERE FROZEN. WHEN SYSTEM WAS WARMED EVERYTHING WORKED PROPERLY. ACTUATORS WERE REMOVED AND NEW ONES INSTALLED WITH IMPROVED SEALS INCORPORATED IN THEM. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030210000952003021000095EA 2003 2 10 CA030206001 120030129G5610NP1393222 WINDOW PPG NP1393222 CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE WINDOW CRACKED W K NONE O OTHER CRCRUISE 1 CA 12304 96262H7317 (CAN) RIGHT WINDOW CRACKED ALONG WITH MESSAGE R WINDOW HEAT (C).RIGHT WINDOW AND RIGHT WINDOW HEAT CONTROLLER REPLACED AND AIRCRAFT RETURNED TO SERVICE. 2L72 4F4 FRTA21EA E15NE 20030213000532003021300053SO 2003 2 13 CA030206003 120030129G2434 FIELD WIRE PRESTOLITE PIPER PA31 PA31310 7103103SO LYC O540 TIO540A2B 41532EA ALTERNATOR CHAFED W A UNSCHED LANDING HJ ELECT. POWER LOSS-50 PC WARNING INDICATION CLCLIMB 1 CA (CAN) ON TAKEOFF THE TWO ALTERNATOR LIGHTS CAME ON, THE PILOT RETURNED TO THE AIRPORT. THE LIGHTS EXTINGUISHED AND THEN HE CARRIED OUT A GROUND RUN, EVERYTHING WAS BACK TO NORMAL. A SECOND TAKEOFF WAS CARRIED OUT, THE PROBLEM RETURNED. THE AUXILIARY CONTROL BOX WAS GROUND CHECKED SERVICEABLE, HOWEVER, WE NOTICED THAT THE VOLTMETER WAS HIGH. WE CARRIED OUT A GROUND RUN WITH AN INDEPENDENT VOLTMETER, WE DETERMINED THAT THE LT ALTERNATOR WAS CHARGING AT FULL CAPACITY (30VDC), AND IT WAS ENGAGING THE OVER VOLTAGE RELAY. WE DISCOVERED THAT THE NEGATIVE FIELD GROUND WAS WORN AND IT WAS TOUCHING THE CHARGING GROUND, CAUSING THE ALTERNATOR TO CHARGE AT ITS MAXIMUM. 1L71 3O3 ORTA20SO E14EA 20030327001912003032700191EA 2003 3 27 CA030211003 220030204G8530 VALVE GUIDE SUPAC CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA MCAULY1C160 1C160DTM GL CYLINDER STUCK W A UNSCHED LANDING ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS DEDESCENT 1 CA (CAN) IN CRUISE FLIGHT ENGINE STARTED TO RUN ROUGH AND UNABLE TO MAINTAIN POWER ABOVE 1800 RPM. PILOT LANDED WITHOUT PROBLEMS. ON INVESTIGATION NOTICED NR 2 CYLINDER EXHAUST VALVE STUCK OPEN ALSO NOTICED VALVE TAPPET BODY CRACKED. ENGINE WAS REMOVED FOR REPAIR. TAPPET BODY P/N SL72877 1H71 3O3 ONT3A12 E274 5 NP910 20030327001932003032700193WP 2003 3 27 CA030211006 120030205G7500369H8407 TUBE HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL BLEED AIR LEAKING W EA ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION NRNOT REPORTED 1 CA (CAN) HARD TO START ENGINE. FIRST START OF DAY, CAUSED HUNG STARTS AT 50-55 PERCENT N1. NO TOT INCREASE WHEN HEATER VALVE OPENED. SERVICEABLE HOSE INSTALLED. 1G71 3U3 U H3WE E4CE 20030327001982003032700198CE 2003 3 27 CA030211011 120030204G551111562001025 RIB BEECH 100 100BEECH 1152916CE PWA PT6 PT6A28 EA HORIZONTAL STAB CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 19698 B45 (CAN) THE HORIZONTAL STABILIZER WAS REMOVED FOR ROUTINE MAINTENANCE. UPON INSPECTION OF THE LT AND RT NR 1 LEADING EDGE RIBS IT WAS NOTED THAT THE LT RIB WAS CRACKED ALONG LOWER FORWARD RADIUS FOR APPROXIMATELY TWO INCHES. THIS AREA IS DIFFICULT TO INSPECT WITH HORIZONTAL STABILIZER INSTALLED AS THE NR 1 RIB IS IN CLOSE PROXIMITY TO THE AIRCRAFT EMPENAGE AND BEHIND AN AIR SEAL. 1L72 3T4 T A14CE E4EA 20030328000022003032800002EA 2003 3 28 CA030212005 120030131G2710 SEAL CNDAIRCL604 CL604 1900301EA GE CF34 CF343B1 NE RT AILERON SHAFTLEAKING W K NONE K FLUID LOSS NRNOT REPORTED 1 CA (CAN) EVIDENCE OF HYDRAULIC FLUID LEAKING FROM PCU SHAFT SEAL AREA.SUSPECT LEAKING IS WORSE AT ALTITUDE ORIN EXTREME COLD CONDITIONS. 2L72 4F4 FRTA21EA E15NE 20030328000082003032800008SO 2003 3 28 CA030214002 120030128G1100753690 PLACARD PIPER PA32 PA32300 7103212SO LYC O540 IO540K1A5 41532EA ENGINE MISMARKED W O OTHER W INADEQUATE Q C NRNOT REPORTED 1 CA (CAN) ENGINE MAGNETO TIMING DIFFERS FROM ENGINE DATA PLATE VERSES AIRFRAME SERVICE MANUAL. ENGINE DATA PLATE CALLS FOR 20 DEGREES BTC AND THE AIRFRAME MANUAL SAYS 25 DEGREES BTC. THERE ARE SEVERAL LYCOMING SBS REGARDING ENGINE DAMAGE FROM INCORRECT TIMING. WE CONTACTED BOTH THE ENGINE MANUFACTURER AND THEAIRFRAME MANUFACTURER, ATTACHED IS THE REPLY FROM THE AIRFRAME MANUFACTURER. THEY WILL CHANGE THE S RVICE MANUAL. 1L71 3O3 O A3SO 1E4 20030328000132003032800013NM 2003 3 28 CA030214007 120030213G5210PACMKP23SFS428 BEARING BOEING757 757236 1384971NM RROYCERB211 RB211535E4 54555NE R1 CABIN DOOR CORRODED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING OPERATION OF THE DOOR R1, IT WAS NOTED THAT A SLIGHT PUSH WAS REQUIRED TO CLOSE THE DOOR. DURING A SCHEDULE MAINTENANCE (S-01) CHECK, MTCE FOUND THE DOOR MECHANISM CAM FOLLOWER CRANK ASSY BEARING BADLY CORRODED. 2L72 4F4 FRTA2NM E12EU 20030328000142003032800014CE 2003 3 28 CA030214008 120030212G3340 SWITCH CARLINGSWTCH CESSNA182 182Q 2072732CE CONT O470 O470U 17026SO MCAULY2A34C C2A34C204 GL LANDING LIGHT SPARKS W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA (CAN) SMOKE WAS SEEN COMING FROM THE NAV LIGHT SWITCH. THE SWITCH FELL OUT AND SPARKS WERE SEEN INSIDE THEOPENING. THE SPARKING STOPPED AFTER APPROXIMATELY 30 SECONDS. THE FAULT WAS CONFERMED BY MAINTENANC E. NO OTHER DAMAGE WAS EVIDENT. SWITCH IS TO BE REPLACED. 1H71 3O3 ONT3A13 E273 5 CP3EA 20030429001432003042900143EU 2003 4 29 CA030214011 120030130G2997E0052R10865NF WIRE AIRBUS310 A310304 3930339EU GE CF6 CF680C2A5 NE NR 2 ENGINE BURNED W K NONE O OTHER ININSP/MAINT 1 CA 695452 (CAN) ENGINE NR 2, HYDRAULIC FIRE SHUTOFF VALVE, CIRCUIT BREAKER 558 POPPING AND WILL NOT RESET. INSPECTION FOUND WIRING DAMAGED (P/N'S: 2912-5006, 2912-5007 AND 29-5003)(BURNT OVER 12INCHES)FROMCONNECTOR OF THE NR 2 ENGINE FIRE SHUTOFF VALVE (YELLOW SYSTEM), FUNCTIONAL IDENTIFICATION NUMBER: 2GD. THE WIRING WAS REPAIRED IAW AMM 20-43-10 AND THE CONNECTOR REPLACED IAW AMM 20-53-20. A FUNCTIONAL CHECK WAS C/OUT I.A.W. AMM 29-10-00. A FLEET CAMPAIGN WAS INITIATED. 2L72 4F4 FRTA35EU E13NE 20030328000222003032800022CE 2003 3 28 CA030218008 120030211G27200400107104 CONTROL CABLE CESSNA140 140 2071602CE CONT O200 O200A 17020SO MCAULY1A101 1A101DCM GL RUDDER CORRODED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) 2 CABLES FOUND CORRODED AND FRAYED AT FUSELAGE STA. 20.5. BOTTOM OF FORWARD LANDING GEAR BULKHEAD. DEFECT WAS FOUND ON CABLES BECAUSE THEY HAD TO BE REMOVED FOR MAJOR STRUCTURAL REPAIRS. THOSE CABLES RUN ON PULLIES ATTACHED TO THE BULKHEAD AT THE VERY BOTTOM OF THE FUSELAGE. VERY HARD TO DETECT UNLESS CABLES ARE REMOVED. FUSELAGE BOTTOM USUALLY VERY DIRTY IN THAT AREA WHERE WATER AND MUD ACCUMULATE. 1H71 3O3 ONCA768 E252 5 NP918 20030415000072003041500007CE 2003 4 15 CA030218009 120030209G7921636900 OIL COOLER CESSNA402 402B 207590PCE CONT O520 TSIO520E 17040SO MCAULY3AF32C3AF32C87 GL ENGINE OIL CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) WE DISCOVERED CRACKS DEVELOPING AROUND WELDS ON THE ATTACHING POINTS OF THE OIL COOLER. INSTALLATION PROCEDURE INCLUDING TORQUE, AND ALL THE ATTACHING HARDWARE, WERE CORRECTLY FOLLOWED. 1L72 3O3 O A7CE E8CE 5 CP22EA 20030401000472003040100047 2003 4 1 CA030218010 420030213G6122697072003 GOVERNOR BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA OVERSPEED FAILED W E ENGINE SHUTDOWN E VIBRATION/BUFFET APAPPROACH 1 CA (CAN) CAUTION LIGHT FOR NR 2 AC GENERATOR ON AFTER ENGINE START. CHECKLIST CONSULTED AND GENERATOR RESET WITH SUCCESS. AFTER TAKEOFF POWERPLANT MESSAGE ON ED, CHECKLIST CONSULTED AND NORMAL ENGINE INDICATIONS OBSERVED, FLIGHT CONTINUED TO NEXT BASE. ON APPROACH, AT 500-300 FT TORQUE ON NR 2 ENGINE, STARTED TO FLUCTUATE AND A SOUND SIMILAR TO OVERSPEED GOVERNOR TEST WAS OBSERVED. AIRCRAFT YAW TO THE RIGHT WAS FELT, ENGINE INSTRUMENT WAS MONITORED WHILE POWER LEVER ON ENGINE NR 2 WAS REDUCED TO FLIGHT IDLE, POWER WAS ADDED TO THE NR 1 ENGINE. ENGINE NR 2 WAS FEATHERED AND SHUTDOWN. AN UNEVENTFUL LANDING WAS PERFORMED. OVERSPEED GOVERNOR/PUMP REPLACED. 2H72 4T4 TRTA13NM E00062EN 20030429001442003042900144 2003 4 29 CA030218011 420030211G8300 GEARBOX PWA PT6 PT6A41 52043EA ACCESORY FAILED W EA ENGINE SHUTDOWN UNSCHED LANDING R PARTIAL RPM/PWR LOSS CRCRUISE 1 CA 8129 (CAN) ENGINE SUFFERED AN IFSD AND WAS REMOVED AND RETURNED FOR INVESTIGATION. CUSTOMER SUSPECTED AN AGB BALL LOCK FAILURE. ENGINE WAS FOUND TO HAVE SIGNIFICANT DAMAGE INSIDE THE AGB WITH MANY GEARSHAFTS & MUTILATED TEETH & INPUT DRIVE FLANGED BEARING COMPLETELY DESTROYED. 4 T E4EA 20030401000482003040100048CE 2003 4 1 CA030218012 120030217G3350TB1 TERMINAL BLOCK LEAR 55 55LEAR 5170702CE ALIDSGTFE731TFE7313AR WP EMERGENCY LIGHTSOVERHEATED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) MFG DESIGN FLAW, INSTRUMENT LIGHTING SYS WAS DISCOVERED WHEN NEW AIR DATA DISPLAY UNIT WAS INSTALLED FOR RVSM UPGRADE. SYMPTOM WAS ADDU LIGHT WOULD GO INTO NIGHT MODE (VERY DIM) WHEN EMER BATT PACK WAS TURNED ON. PACK IS KEPT ON IN FLIGHT TO RUN STANDBY GYRO. PROBLEM WAS THAT IN NON-EMER MODE, EMERGENCY PACK WAS POWERING WHOLE 5 VOLT INSTRUMENT LIGHTING BUS VIA RELAY K2 AND CR4 ON TB1 IN CIRCUIT BOARD UR-1. 2.2 AMP DRAW THROUGH CR4 WOULD CAUSE IT TO OVERHEAT BUT IN TURN DROP VOLTAGE LOW ENOUGH THAT LAMP LIGHTING WAS TOO DIM TO BE NOTICED. PROBLEM WENT UN-NOTICED UNTIL RVSM MOD WAS DONE. MFG WAS NOTIFIED OF PROBLEM, SENT WIRING MOD TO SYS. 2L72 4F4 F A10CE E6WE 20030415000092003041500009CE 2003 4 15 CA030218013 120030214G56101013840252 WINDSHIELD BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA COCKPIT CRACKED W BA EMER. DESCENT UNSCHED LANDING O OTHER CRCRUISE 1 CA (CAN) PILOTS WINDOW CRACKED IN FLIGHT 1L72 4T4 T A24CE E4EA 20030415000102003041500010EU 2003 4 15 CA030219002 120030218G30205302412123 HOSE PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL ANTI ICE SYS LEAKING W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) EXHAUST STAINING WAS NOTED COMING FROM LT INTAKE LIP DE-ICE AREA. SUBJECT HOSE (SEAL)WAS FOUND TOBE LEAKING WHERE THE LT PIPE COMES DOWN FROM THE EXHAUST STACK AND JOINS WITH THE LIP DEICE PART.HOSE REPLACED WITH NEW. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030415000112003041500011CE 2003 4 15 CA030219004 120030219G3213504100077 PISTON CESSNA310 310L 2074230CE CONT O470 IO470VO 17026SO MLG CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) DURING COMPLETE REMOVAL AND NDT OF ALL LANDING GEAR PARTS BOTH LT & RT MAIN GEAR PISTON AND AXLE ASSEMBLIES (P/N S 5041000-77 & 5041000-76 RESPECTIVELY) WERE FOUND CRACKED AT THE SMALLER OF THE TWO TORQUE LINK ATTACH LUGS.THE RT WAS REPLACED WITH A USED SERVICEABLE UNIT, HOWEVER 10 USED LT UNITS WERE TESTED AND FAILED PRIOR TO FINDING A SERVICEABLE USED ONE TO INSTALL. WE FEEL FINDING A GOOD USED RT UNIT ON THE FIRST TRY WAS JUST A STROKE OF LUCK. 1L72 3O3 O 3A10 3E1 20030415000132003041500013CE 2003 4 15 CA030220003 120030120G531210143002115 BULKHEAD BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA FUSELAGE CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA 2015220152 (CAN) CREW REPORTED ON LAST LEG TO AIRPORT, LOW PRESSURIZATION OF 3.2 PSI. DURING TROUBLESHOOTING FOUND A CRACK FOUR INCHES LONG ON BULKHEAD. LOCATION - CENTER OF FUSELAGE AT STATION 227.125. 1L72 4T4 T A24CE E4EA 20030415000042003041500004CE 2003 4 15 CA030220004 120030128G27801013800005 CONTROL CABLE BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCD4N3HCD4N3A GL LE FLAPS SHEARED W O OTHER F FLT CONT AFFECTED APAPPROACH 1 CA (CAN) ON APPROACH AIRCRAFT FLAP ASYMMETRY TRIPPED. ON INSPECTION OF FLAP SYSTEM THE L/H OUTBOARD FLAP CABLE DRIVE AT MOTOR FOUND SHEARED. NEW OUTBOARD L/H FLAP CABLE INSTALLED (P/N 101-380000-5). FLAP SYSTEM FUNCTION TEST CARRIED OUT. TESTED OK. 1L72 4T4 T A24CE E4EA 5 CSTC 20030415000052003041500005CE 2003 4 15 CA030220008 120030220G2710051010532 CONTROL CABLE CESSNA185 A185E 2072818CE CONT O520 TSIO520T 17040SO AILERON FRAYED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) AILERON DIRECT CABLE FRAYED AT NYLON PULLEYS IN CABIN ROOF AREA 1H71 3O3 O 3A24 E8CE 20030415000142003041500014 2003 4 15 CA030221004 420030113G61228210007 GOVERNOR BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL PROPELLER INOPERATIVE W O OTHER E VIBRATION/BUFFET CRCRUISE 1 CA (CAN) ON RETURN FLIGHT PILOTS REPORT THAT RT PROPLLER RPM STAYED AT 2100. THEY WERE NOT ABLE TO GOVERN PROPELLER SPEED. AFTER LANDING MAINTENACE CHECKED THE SYSTEM AND DETERMINED THAT REPLACEMENT OF PROP. GOVERNOR WAS REQUIRED. AFTER REPLACEMENT WITH A SERVICABLE PART, FUNCTION CHECK WAS COMPLETED AND OPERATION WAS NORMAL. 1L72 4T4 T A24CE E4EA 6 CP15EA 20030415000012003041500001CE 2003 4 15 CA030221006 120030218G5510504400317 CHANNEL BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA HORIZONTAL STAB CHAFED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) UPPER ELEVATOR CABLE P/N NAS304-34-0753 FOUND INCORRECTLY ROUTED. INSTEAD OF PASSING THROUGH THE LIGHTNING HOLES IN AFT BOX STRUCTURE P/N50-440031-7, THE CABLE WAS ROUTED ABOVE THE STRUCTURE. THIS CAUSED THE ELEVATOR CABLE TO CUT INTO THE CHANNEL ASSY. WHEN FOUNDTHE CABLE HAD SAWN INTO THE EDGE OF THE CHANNEL. THE ELEVATOR BELLCRANK HAD BEEN REPLACED 84HRS PREVIOUSLY. 1L72 3T4 TRT3A20 E4EA 20030415000022003041500002CE 2003 4 15 CA030221007 120030220G5520556555026 ARM CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE COUNTER WEIGHT CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) DURING ROUTINE MAINTENANCE INSPECTION OF THE CONTROL COLUMN, A CRACK WAS FOUND IN THE BOB WEIGHT ARMNEAR THE HOLE WHERE THE ARM IS ATTACHED TO THE ELEVATOR TORQUE TUBE. BOB WEIGHT ARM REPLACED. 1L72 4F4 F A22CE E1NE 20030415000062003041500006CE 2003 4 15 CA030221009 120030220G243523080025 BEARING CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE STARTER GEN FAILED W O OTHER E VIBRATION/BUFFET CRCRUISE 1 CA (CAN) AT FLIGHT LEVEL 33,000 FT A POPPING SOUND FOLLOWED BY ENGINE VIBRATIONS WAS EXPERIENCED. RT POWER LEVER RETARDED SLOWLY AND VIBRATION LEVEL SOFTENED,BUT, STILL NOTICEABLE, ALL ENGINE PARAMETERS WERE NORMAL AND STEADY. AT 73 PERCENT ON DECENT THRU 29000 FT A STRONG VIBRATION BEGAN. THE RT LEVER SET TO 67 PERCENT THE VIBRATION WAS STILL NOTICEABLE. AT 9,000 FT THE POWER LEVER WAS RETARDED TO 58 PERCENT. LANDED AND SHUTDOWN ENGINE. NR 2 STARTER GENERATOR REMOVED DUE TO BEARING FAILURE. 1L72 4F4 F A22CE E1NE 20030415000152003041500015EU 2003 4 15 CA030224002 120030224G2897 WIRE PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL BOOST PUMP CHAFED W K NONE O OTHER ININSP/MAINT 1 CA B4673 (CAN) A FUEL BOOST PUMP WAS REPLACED FOR ITS SCHEDULED OVERHAUL REPLACEMENT AT 3500 HOURS.A WIRE WAS FOUND CHAFED TO BARE WIRE THROUGH ROUGHLY MIDWAY OF THE MANUFACTURER SUPPLIED HARNESS. THIS COULD HAVE THE POTENTIAL TO IGNITE THE FUEL TANK IF SPARKS WERE PRESENT. DUE TO THE LENGTH OF WIRE, IT IS POSSIBLE FOR THE HARNESS TO RUB ON A COUPLE OF DIFFERENT PLACES, IE: BONDING STRAP, RIB, TOP OF PUMP. PILATUS WAS CONTACTED WITH THE PROBLEM AND WE REQUESTED A MEANS TO PROTECT THE HARNESS. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030414000922003041400092SO 2003 4 14 CA030227001 220030224G74146310 FLANGE BEECH 95 95B55 1152729CE CONT O470 IO470L 17026SO MAGNETO FAILED W O OTHER R PARTIAL RPM/PWR LOSS NRNOT REPORTED 1 CA (CAN) UPON PREFLIGHT RUN-UP, PILOT NOTICED RT MAGNETO ON NR 1 ENGINE WAS NOT FUNCTIONING. UPON INSPECTION BY MAINTENANCE, THE MAGNETO WAS FOUND DETACHED FROM ENGINE WITH THE MOUNTING FLANGE BROKEN AND STILL ATTACHED TO THE ENGINE. MAGNETO WAS REPLACED WITH NO FURTHER PROBLEMS. 1L72 3O3 ORT3A16 3E1 20030414000952003041400095CE 2003 4 14 CA030227005 120030227G275014601007 CONTROL CABLE CESSNA337 337G 2075730CE CONT O360 IO360GB 17025SO MCAULY2AF34CD2AF34C306 GL TE FLAPS FRAYED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) DURING 100 HR INSPECTION THE INBOARD RIGHT HAND FLAP CABLE WAS INSPECTED FOR WEAR IN THE AREA OF THE INBOARD FLAP BELLCRANK. CABLE WAS FOUND FRAYED APPROX. 1 INCH FROM CABLE END ATTACH FITTING.CABLE R EPLACED. 1H72 3O3 O A6CE E1CE 5 CP5EA 20030414000962003041400096SO 2003 4 14 CA030227006 120030220G3297 WIRE HARNESS PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA RT MLG DAMAGED W O OTHER N FALSE WARNING NRNOT REPORTED 1 CA (CAN) A/C DID NOT HAVE A RIGHT GEAR DOWN & LOCKED INDICATION APPROACHING AIRPORT. SEVERAL ATTEMPTS TO RECYCLE THE GEAR HAD NO EFFECT. ALL OTHER INDICATIONS AND GEAR OPERATION APPEARED NORMAL. A/C OVERFLEWAIRPORT FOR PRECAUTIONARY REASONS. LANDING WAS UNEVENTFUL. A BROKEN WIRE WAS FOUND IN THE MAIN WIRING BUNDLE ON THE RIGHT MAIN GEAR. THE WIRE COMPLETED THE RT GEAR DOWN & LOCKED INDICATION CIRCUIT. 1L72 3O3 O A20SO E14EA 20030414000972003041400097CE 2003 4 14 CA030228001 120030228G551007321014 HINGE CESSNA185 A185F 2072821CE CONT O550 IO550D 17042SO MCAULYD3A34 D3A34C401 GL STABILIZER CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) DURING ROUTINE SCHEDULED MAINTENANCE, IT WAS DISCOVERED THAT THE REINFORCEMENTS - STABILIZER HINGE WERE CRACKED. P/N 0732101-4 REPLACED WITH NEW PARTS. 1H71 3O3 O 3A24 E3SO 5 CP47GL 20030414001002003041400100SW 2003 4 14 CA030228004 120030221G5312222031506103A FITTING BELL 222 222U 1182140SW LYC LTS101LTS101750C1 41560NE BULKHEAD CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) UPON A THREE HUNDRED HOUR INSPECTION 270 BULKHEAD FITTING 222-031-506-103A WAS FOUND CRACKED. TO REPAIR INCORPORATION OF TB 222U-94-72. 1G72 3U3 U H9SW E5NE 20030414001012003041400101CE 2003 4 14 CA030228007 120030226G5312071111224 BULKHEAD CESSNA180 180 2072602CE CONT O470 O470K 17026SO MCAULY2A34C 2A34C66 GL FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING ANNUAL INSPECTION, IT WAS DICOVERED THE BULKHEAD HAD A SUBSTANDARD REPAIR AT REAR FLOAT FITTING ATTACHMENT BRACKETS. PREVIOUS REPAIR REMOVED TO FACILITATE NEW REPAIR. BULKHEAD WAS FOUND TO BE CRACKED BEYOND REPAIR WITH A TOTAL OF 4 CRACKS WITHIN A 8 INCH AREA. CRACKS WERE FOUND IN FLANGE AND WEB. AREA IS SOMEWHAT DIFFICULT TO INSPECT DUE TO FLOOR SKIN COVERING. BULKHEAD IS BEING REPLACED WITH NEW. 1H71 3O3 ONC5A6 E273 5 CP3EA 20030414001042003041400104CE 2003 4 14 CA030228010 120030221G7820175400122 MUFFLER CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA MCAULY1C160 1C160CTM GL EXHAUST SYS CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) RT MUFFLER END PLATE CRACKED BEHIND RT FORWARD EXHAUST INLET (NR 1 CYLINDER). NOT LEAKING INTO HEAT MUFFLER. BARREL ALSO BULGED FORWARD SIDE NEAR OUTLET (USUAL PLACE). BOTH DAMAGES MAY HAVE BEEN CAUSED BY AFTER FIRING IN MUFFLER. MUFFLER HAS BEEN PREVIOUSLY REPAIRED ON OPPOSITE ENDPLATE. CRACK PROBABLY DUE TO METAL FATIGUE AND AGE. 1H71 3O3 ONT3A12 E274 5 NP910 20030414001052003041400105CE 2003 4 14 CA030228011 120030219G3320PWFLC28 POWER SUPPLY BEECH 100 A100 1152915CE PWA PT6 PT6A28 EA CABIN SHORTED W FA ACTIVATE FIRE EXT. UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CLCLIMB 1 CA (CAN) DURING CLIMB, SMOKE WAS NOTICED IN THE CABIN AREA. CABIN FIRE EXTINGUISHER WAS DISCHARGED IN GENERALAREA OF SMOKE. NO OPEN FLAMES WERE NOTICED. AFTER LANDING MAINTENANCE INVESTIGATED AND FOUND THAT T HE SOLID STATE POWER SUPPLY FOR AN OVERHEAD FLOURESCENT LIGHT HAD HAD AN INTERNAL SHORT. THERE WAS NO DAMAGE TO ADJACENT STRUCTURE INSULATION OR WIRING. POWER SUPPLY WAS REPLACED WITH NEW PART. SYSTEMWORKED NORMALLY. 1L72 3T4 T A14CE E4EA 20030414001072003041400107SO 2003 4 14 CA030228015 120030225G3230OAS29305 POWERPACK PIPER PA31 PA31 7103102SO LYC O540 TIO540A2C 41532EA MLG UNSERVICEABLE W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) UPON TAKEOFF FROM AIRPORT, MLG SELECTED UP, BUT THE INTRANSIT LIGHT DID NOT GO OFF. MLG WAS CYCLED WITH DOWN AND LOCKED INDICATING EACH TIME, BUT INTRANSIT REMAINING ON DURING GEAR UP SELECTION. A FLY-BY WAS PERFORMED, NOTING THE LT MLG DOOR OPEN, LT MLG HANGING ABOUT 45 DEGREES, AND RT MLG DOOR OPEN. A/C RETURNED TO AIRPORT, MLG WAS SELECTED DOWN WITH DOWN AND LOCKED INDICATIONS AND LANDED. HYD SYS PRESSURES WERE CHECKED & FOUND TO BE WEAK, HYD POWER PACK WAS REPLACED WITH AN OVERHAUL UNIT, MULTIPLE GEAR SWINGS WERE PERFORMED AND THE AIRCRAFT WAS GROUND RUN AND HYD PRESSURES WERE CHECKED SERVICEABLE. THE AIRCRAFT SUBSEQUENTLY PERFORMED A TEST FLT WITHOUT GEAR TROUBLES. 1L72 3O3 O A20SO E14EA 20030414001102003041400110EA 2003 4 14 CA030305001 220030304G7414M3100 IMPULSE COUPLING ZLIN 242 Z242L 9970204EU LYC O360 AEIO360A1B6 41514EA MAGNETO LOOSE W K NONE O OTHER ININSP/MAINT 1 CA (CAN) AS A RESULT OF PREVIOUS IMPULSE COUPLING FAILURES, WE IMPLEMENTED AN IMPULSE COUPLING INSPECTION EVERY 100 HRS. UPON INSPECTION OF THIS IMPULSE COUPLING WE FOUND THE HUB VERY LOOSE, BOTH PAWL RIVETS LOOSE, AND THE PAWL GAPS EXCEEDED THE MAXIMUM ALLOWED BY SLICK SB1-98. PAWL GAPS WERE IN EXCESS OF .170 INCH. MAX ALLOWABLE IS .150 INCH. HAD THIS IMPULSE COUPLING FAILED IT WOULD HAVE DAMAGED AND CONTAMINATED THE ENGINE. 1L71 3O3 O0 A76EU 1E10 20030414001112003041400111EA 2003 4 14 CA030305002 220030227G7414M3100 IMPULSE COUPLINGSLICK 4372 ZLIN 242 Z242L 9970204EU LYC O360 AEIO360A1B6 41514EA MAGNETO LOOSE W K NONE O OTHER ININSP/MAINT 1 CA 00052906 (CAN) DUE TO PREVIOUS IMPULSE COUPLING FAILURES, WE IMPLEMENTED AN IMPULSE COUPLING INSPECTION EVERY 100 HRS. THIS IMPULSE COUPLING WAS FOUND TO HAVE A LOOSE PAWL RIVET. SLICK SB1-98 WAS CARRIED OUT AND THE PAWL GAPS WERE FOUND TO BE WITHIN LIMITS, AND THE T-155 RIVET GAUGE SHOWED NO WEAR. THE IMPULSE CO UPLING WAS REPLACED WITH A NEW ONE. 1L71 3O3 O0 A76EU 1E10 20030414001142003041400114CE 2003 4 14 CA030305005 120030227G612335821511 CONNECTOR BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3I NE AUTOFEATHER SYS CRACKED W O OTHER N FALSE WARNING DEDESCENT 1 CA 10024 (CAN) CREW REPORTED THAT AUTOFEATHER DISABLE LIGHT WOULD ILLUMINATE DURING CLIMB AND DECENT PORTIONS OF FLIGHT. MAINTENANCE DID NUMEROUS ATTEMPTS TO DUPLICATE WITH SYSTEM PARTS BEING REPLACED FOR TROUBLESHOOTING PURPOSES. TEST FLIGHTS WHERE COMPLETED WITH THE DEFECT ALSO NOT DUPLICATED. THE PRINTED CIRCUIT BOARD CONNECTOR WAS FOUND TO HAVE A HAIRLINE CRACK AND WAS REPLACED. THE AIRCRAFT HAS FLOWN APPROX. 7 DAYS WITHOUT REOCCURENCE. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20030414001172003041400117GL 2003 4 14 CA030305008 320030217G6111D3A36C435A PROPELLER CESSNA210 2105 2073404CE CONT O470 IO470S 17026SO MCAULY2A34C D2A34C58 GL BLADE ANGLES FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) FACTORY NEW PROPELLER STC SA00920CH. ONLY OBTAIN 2300 RPM STATIC, SHOULD BE 2600 RPM. FOUND BLADE LOW END STOPS INCORRECTLY SET.- PROP RETURNED TO OBTAIN NEEDED 2600 RPM. ERROR IN ENGINEERING APPROVAL AT MCCAULEY INCORRECT BLADE ANGLES. 1H71 3O3 O 3A21 3E1 5 CP3EA 20030414001212003041400121CE 2003 4 14 CA030306002 120030304G32456006 TUBE CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA MLG WHEEL TORN W O OTHER O OTHER LDLANDING 1 CA (CAN) A/C LANDED AND PILOT TAXIED OFF THE RUNWAY. 20 TO 30 FEET ON TAXIWAY AND A/C BECAME IMPOSSIBLE TO TAXI. FOUND LEFT MAIN WHEEL FLAT.WHEEL DISASEMBLED AND FOUND TUBE WITH TEAR APPROX 1/4 INCH LONG ON THECENTER OF THE TUBE ALONG THE MOLDING RIBS. 1H71 3O3 ONT3A12 E274 20030414000872003041400087EA 2003 4 14 CA030306004 120030228G5510C2TP57 SPAR DHAV DHC2 DHC2MK1 2800102EA PWA R985 R98539 52008NE HORIZONTAL STAB CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) INSPECTION CARRIED OUT AS PER SB 2/47 REV 'D' AD CR-91-42.TAILPLANE SPAR FOUND CRACKED LT SIDE TOP UNDER LT PICK-UP BRACKET C2TP159. MODS 2/436, 2/466, 2/758 HAD ALREADY BEEN INCORPORATED.AIRCRAFTTTSN 10127.3 HOURS. 1H71 3R3 R A806 5E1 20030409000122003040900012CE 2003 4 9 CA030311008 120030305G3250 BUNGEE CYLINDER BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL NLG STEERING FAILED W O OTHER S AFFECT SYSTEMS TXTAXI/GRND HDL 1 CA (CAN) NOSE GEAR STEERING FAILED DURING TAXI . THE CREW EXPERIENCED A (THUMP) IN THE RUDDER / STEERING SYSTEM. AFTER THE (THUMP) THE CREW WAS UNABLE TO TAXI THE AIRCRAFT IN A STRAIGHT LINE. INSPECTION REVEALED THAT THE NOSE GEAR STEERING SPRING BUNGEE ASSEMBLY HAD FAILED. FAILURE OCURRED IN THE SPRING CLIP RETAINING SLOT AREA. SB 2220 DEALS WITH THIS ISSUE. THIS OPERATORSHALL INITIATE ADDITIONAL INSPECTIONS TO PREVENT REPEAT OCCURENCES. 1L72 4T4 T A24CE E4EA 6 CP15EA 20030409000132003040900013CE 2003 4 9 CA030311017 120030307G561010138402523 WINDSHIELD BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL COCKPIT CRACKED W A UNSCHED LANDING O OTHER CRCRUISE 1 CA (CAN) IN CRUISE THE PILOTS NOTICED A CRACK APPEARED ON THE RIGHT SIDE OF THE PILOTS FRONT WINDOW. MORE CRACKS APPEARED ON DESCENT INTO AIRPORT. ON INSPECTION THE CRACKS WERE FOUND TO BE IN THE OUTSIDE NON-STRUCTURAL GLASS. THE WINDOW WAS REPLACED. 1L72 4T4 T A24CE E4EA 6 CP15EA 20030409000142003040900014CE 2003 4 9 CA030311018 120030308G32301153800025 MOTOR BEECH 100 A100 1152915CE PWA PT6 PT6A28 EA HARTZLHCB4T HCB4TN3 GL MLG INTERMITTENT W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) LANDING GEAR STOPPED APROXIMATELY HALF WAY UP. CIRCUIT BREAKER IN THE FLOOR HAD POPPED. CIRCUIT BREAKER WAS RESET AND GEAR WAS SELECTED DOWN AND AIRCRAFT LANDED WITHOUT INCIDENT. MOTOR WAS REPLACED AND SWINGS CARRIED OUT IAW MANUFACTURER. 1L72 3T4 T A14CE E4EA 6 CP40EA 20030409000152003040900015EU 2003 4 9 CA030312001 120030221G2913704A33690004 BELT SNIAS 350 AS350BA 8680817EU TMECA ARRIELARRIEL1B 6OO30NE HYD PUMP BROKEN W C ABORTED TAKEOFF J WARNING INDICATION TOTAKEOFF 1 CA (CAN) BELT BROKE BEFORE TAKE OFF. FOUND TO HAVE BROKEN AT THE SEAM. PULLEY AND PUMP WERE CHANGED AT THE SAME TIME AS THE BELT. IT WAS NOTED THIS TIME, AS IN OTHER TIMES THAT THE BELT WAS TENSIONED TO THE MAX IN ORDER TO PUT THE PULLEY BOLTS IN. 1G71 3U3 UNCH9EU E19EU 20030409000162003040900016EU 2003 4 9 CA030312002 120030305G2913704A33690004 BELT SNIAS 350 AS350BA 8680817EU TMECA ARRIELARRIEL1B 6OO30NE HYD PUMP BROKEN W C ABORTED TAKEOFF FJ FLT CONT AFFECTED WARNING INDICATION TOTAKEOFF 1 CA (CAN) AFTER THE PILOT PERFORMED HIS HYD PRESSURE TEST, (HYDRAULIC PRESSURE) LIGHT CAME ON. ON DI THE NIGHT BEFORE AND ON THE DAY OF INCIDENT, THE BELT. 1G71 3U3 UNCH9EU E19EU 20030409000172003040900017EU 2003 4 9 CA030312003 120030226G2913704A33690004 BELT SNIAS 350 AS350D 8680803EU LYC LTS101LTS101600A2 41560NE HYD PUMP BROKEN W O OTHER F FLT CONT AFFECTED APAPPROACH 1 CA (CAN) ON DESCENT FOR THE BASE, THE CAUTION HORN AS WELL AS (HYDRAULIC PRESSURE) LIGHT CAME ON. A/C LANDED WITHOUT INCIDENT. UPON INSPECTION, HYDRAULIC PUMP BELT WAS FOUND BROKEN, LAYING ON THE TRANSMISSION DECK. THE BELT WAS BROKEN AT THE JOINT. 1G71 3U3 U H9EU E5NE 20030409000182003040900018EA 2003 4 9 CA030312005 120030228G5610NP1393325 WINDOW CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE COCKPIT CRACKED W O OTHER O OTHER DEDESCENT 1 CA (CAN) FLIGHTDECK LT SIDE WINDOW CRACKED. WINDOW ASSEMBLY REPLACED. 2L72 4F4 FRTA21EA EOOO63EN 20030409000192003040900019EA 2003 4 9 CA030312006 120030307G5610NP1393226 WINDOW CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE COCKPIT CRACKED W O OTHER O OTHER CRCRUISE 1 CA (CAN) AT FL340, CO-PILOTS WINDOW CRACKED. TWO CRACKS OF AROUND 30CM IN AFT PORTION OF WINDOW. DURING APPROACH, WINDOW CRACK FURTHER EXTEND TOTALLY FROM FRONT TO REAR. FOUND MIDDLE AND INNER PLY CRACKED. WINDOW REPLACED. 2L72 4F4 FRTA21EA EOOO63EN 20030409000202003040900020EA 2003 4 9 CA030312007 120030308G5610NP1393226 WINDOW CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE COCKPIT CRACKED W K NONE D INFLIGHT SEPARATION DEDESCENT 1 CA 13433 (CAN) AIRCRAFT 7169 TAT = 13433.6 HOURS F/O SIDE WINDOW CRACKED AND ARCING ON DESCENT. OUTER PANE CRACKED.ROAD TRIP CREW DESPATCHED. REMOVED AND REPLACED RT SIDE WINDOW (ORIGINAL EQUIPMENT). RETURNED TO SERVICE. 2L72 4F4 FRTA21EA E15NE 20030409000212003040900021EA 2003 4 9 CA030312008 120030214G2710600911787 CONTROL CABLE CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE AILERON FAILED W O OTHER F FLT CONT AFFECTED APAPPROACH 1 CA (CAN) AILERON CONTROL JAM. ACTION QRH ESTABLISHED THAT PILOT SIDE WAS OPERATING CHANNEL. CONTROL ON CO-PILOT AILERON, FULL CONTROL FOR AILERON UP. AILERON MOTION FROM APPROX NEUTRAL AND DOWN NON EXISTENT. CONTROL ON CAPTAIN SIDE WAS FULL AND FREE. FOUND RT AILERON QUADRANT AT RT WHEEL WELL, LOWER CONTROL CABLE GUARD PIN LOW CLEARANCE WITH QUADRANT. DAMAGE AT TIP OF THAT GUARD PIN, WHICH WAS MISORIENTED, WAS STOPPING THE MOTION WHEN TRYING TO MOVE AILERON DOWN. NEW GUARD PIN INSTALLED IAW DWG 600-91014 AND BAPS 164-001. NO DAMAGE WAS FOUND AND INTEGRITY OF AILERON CONTROL SYS WAS CARRIED OUT ON THE RT SIDE, EVERYTHING CHECKED SERVICEABLE. AIRCRAFT WAS RELEASE FOR FLIGHT. NO FURTHER ACTION REQUIRED. 2L72 4F4 FRTA21EA E15NE 20030409000222003040900022EA 2003 4 9 CA030312009 120030309G5610NP1393211 WINDOW CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE COCKPIT CRACKED W A UNSCHED LANDING D INFLIGHT SEPARATION CRCRUISE 1 CA 15823 (CAN) AIRCRAFT TAT = 15823.8 HOURS.FLIGHT 5788. CAPTAIN'S SIDE WINDOW CRACKED IN CRUISE FLIGHT. DECLARED AN EMERGENCY AND LANDED. REMOVED AND REPLACED SIDE WINDOW. 2L72 4F4 FRTA21EA E15NE 20030429001482003042900148SO 2003 4 29 CA030313003 120030308G75005842281H5210 REGULATOR VALVE PIPER PA31T PA31T2 7103127SO PWA PT6 PT6A135 52043NE ENGINE MALFUNCTIONED W O OTHER H ELECT. POWER LOSS-50 PC APAPPROACH 1 CA (CAN) ON APPROACH, THE CREW NOTICED MULTIPLE AVIONICS FAILURES. BOTH VOR SIGNAL STRENGTHS VERY WEAK, NR 1 COMM INOP, MOST NAVIGATION EQUIPMENT INOP. THE PNEUMATIC PRESSURE WAS NOTED AS BEING AT 21 PSI, WHEN IT SHOULD HAVE BEEN AT 18 PSI. THE PNEUMATIC REGULATOR VALVE HAD FAILED. THIS FAILURE CAUSED HOT AIR TO BE RELEASED AT THE PRESSURE RELIEF VALVE WHICH IS LOCATED IN CLOSE PROXIMITY TO AN ANTENNA COAXIAL CABLE BUNDLE. THE HOT AIR HARDENED & DAMAGED THE CABLES, CAUSING THE AVIONICS FAILURES MENTIONED ABOVE. 1L72 3T4 TRTA8EA E4EA 20030429001492003042900149SW 2003 4 29 CA030313004 120030311G52102720063907 RECEPTACLE SWRNGNSA226 SA226TC 8780404SW GARRTTTPE331TPE33110UA 01514WP PAX DOOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 15106 (CAN) DURING DOOR REPAIR, INSPECTION OF LATCHING MECH ON FUSELAGE WAS CARRIED OUT. RECEPTICLE CRACKS WERE NOTICED VISUALLY ON 6 OF 7 RECEPTICLES. LATCHING RECEPTICLE CONTAINS AN ECCENTRIC FITTING SITS IN RECEPTICLE TO ADJUST FOR ALIGNMENT OF CABIN DOOR WHEN CLOSED. CRACKS IN RECEPTICLES CAN`T BE SEEN IF ECCENTRICS ARE INSTALLED. THESE RECEPTICLES ARE ALL ALUMINUM EXCEPT FOR NR 7 WHICH IS LOCATED AT TOP OF FUSELAGE THAT ONE IS STEEL. NR 7 RECEPTICLE ALSO DOESN`T REQUIRE AN ECCENTRIC FITTING. RECEPTICLES WERE REMOVED FROM A A/C PREVIOUSLY REMOVED FROM SERVICE & SENT FOR NDT INSPECTION PRIOR TO INSTALLATION. WERE ALSO ALL CRACKED SIMILAR TO ONES REMOVED FROM AIRCRAFT. 2L72 4T4 TRTA8SW E4WE 20030429001502003042900150NM 2003 4 29 CA030313005 120030226G2121732591 FAN BOEING767 767383 1385214NM GE CF6 CF680C2B6F 30025NE COCKPIT FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 CA (CAN) SMOKE IN COCKPIT, DISSAPATED AFTER LANDING WITH A STATUS MESSAGE 'FWD EQ EXH FAN' AND FOUND C/B H21 LWR EQUIPEMENT PANEL 'FWD EXH EQUIP COOL FAN' POPPED 2L72 4F4 FRTA1NM E13NE 20030429001512003042900151 2003 4 29 CA030314001 420030313G34178220372145 COMPUTER CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE ADC FAILED W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) DIS-DURING CLIMB OUT CREW NOTED CAPT/FO ALT GO BLANK. CREW ELECTED TO RETURN TO AIRPORT. NOTE ON THEWAY TO AIRPORT SYSTEM CAME BACK ON LINE. CREW CONTINUED TO AIRPORT TO HAVE MTX CHECK OUT SYSTEM. A/C LANDED SAFELY NO FURTHER INCIDENTS WERE REPORTED. FOUND NR 1 ADC COMPUTER INTERNAL FAILURE. RAI'D THE NO.1 ADC AND OPS CHECK GOOD. 2L72 4F4 FRTA21EA EOOO63EN 20030429001522003042900152EA 2003 4 29 CA030314002 120030309G5610NP139H6850 WINDSHIELD CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE COCKPIT CRACKED W O OTHER O OTHER APAPPROACH 1 CA (CAN) CREW NOTED THE CAPTAIN'S SIDE WINDOW HAD CRACKED. MAINTENANCE REMOVED AND REPLACED THE CAPTAIN'S SIDE WINDOW WITH SERVICEABLE UNIT. 2L72 4F4 FRTA21EA EOOO63EN 20030429001532003042900153EA 2003 4 29 CA030314005 120030212G301073010033147 LINE DHAV DHC7 DHC7102 2802708EA PWA PT6 PT6A50 52043EA HAMSTD24PF 24PF305 GL DE-ICE SYS CHAFED W O OTHER O OTHER NRNOT REPORTED 1 CA 28861 (CAN) DURING TROUBLESHOOTING A DE-ICE SNAG, ( NR 1 ENG DE-ICE BOOT WILL NOT INFLATE ) IT WAS FOUND THAT THE DE-ICE LINE P/N 73010033-147 HAD BEEN CHAFFING ON A HYDRAULIC LINE. THIS LINE IS LOCATED UNDER PANEL 419AT (NR 1 ENG BATMAN PANEL). THE LINE IS HIDDEN UNDER NUMEROUS OTHER LINES AND IT IS VERY DIFFICULT TO SEE / NOTICE THE CHAFFING. WE HAVE CHECK AN OTHER AIRCRAFT AND HAD TO USE A BORESCOPE TO CONFIRM IF THE LINES WERE TOUCHING EACH OTHER. THE LINE WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE.SEE ATTACHED PICTURES. 2H74 4T4 T A20EA E4EA 6 CP1NE 20030429001552003042900155CE 2003 4 29 CA030317004 120030313G212119A6002 MOTOR CESSNA210 210R 2073458CE CONT O520 IO520L 17032SO MCAULYD3A34 D3A34C404 GL FAN WORN W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA (CAN) PILOT REPORTED DURING CRUISE A ODOUR AND NOISE IN COCKPIT. A SLIGHT AMOUNT OF SMOKE WAS NOTICED IN WINDSHIELD AREA. PILOT PULLED CIRCUIT BREAKER FOR AVIONICS FAN AND NOISE STOPPED.PILOT RETURNED TO BASE AS PRECAUTION. SMELL DISSIPATED DURING RETURN TO BASE. BEARINGS ON MOTOR SHAFT FOUND TO BE WORN,CAUSING FAN TO RUB ON HOUSING. 1H71 3O3 ORT3A21 E5CE 5 CP47GL 20030429001562003042900156CE 2003 4 29 CA030317007 120030311G5751991300009 SKIN BEECH 100 100BEECH 1152916CE PWA PT6 PT6A28 EA LT AILERON CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA 22426 (CAN) 1/2 INCH CRACK ON TOP SKIN OF LT AILERON FROM TRIM TAB OPENING FAR OUTBOARD CORNER TO FIRST RIVET. 1L72 3T4 T A14CE E4EA 20030415000242003041500024CE 2003 4 15 CA030317008 120030307G6120HCB4MP3 PROPELLER BEECH 300 300BEECH 1152930CE PWA PT6 PT6A60A 52043NE HARTZLHCB4M HCB4MP3 GL FAILED W O OTHER O OTHER LDLANDING 1 CA FWA2327 (CAN) ON LANDING ON A CLEARED RUNWAY WITH SNOW & ICY PATCHES, SKY CLEAR & WIND CALM, PILOT HAD DIFFICULTY CONTROLLING A/C. AS A/C SLOWED DOWN RUDDER CONTROL BECAME INEFFECTIVE CAUSING A/C TO DRIFT INTO RT SNOW BANK. UPON INVESTIGATING LT PROP, FOUND IN A FINE PITCH POSITION & BLADES WERE BENT BACK 90 DEGREES FROM DIRECTION OF ROTATION. RT PROP BLADES WERE FOUND TO BE 180 DEGREES FROM FEATHERED POSITION & WERE BENT BACK IN DIRECTION OF ROTATION.PROPS WILL BE REMOVED AND FORWARDED TO A PROP OVERHAUL FACILITY WHERE RT PROPELLER WILL BE DISASSEMBLED AND INSPECTED TO SEE IF AN INTERNAL FAILURE RESULTED IN BLADES GOING INTO THIS POSITION CAUSING THE AIRCRAFT TO LOOSE DIRECTIONAL CONTROL. 2L72 4T4 T A24CE E4EA 6 CP56GL 20030429001572003042900157CE 2003 4 29 CA030317009 120030314G27315052447413 TUBE BEECH BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA CLEVIS BROKEN W A UNSCHED LANDING I FLT. ATTITUDE INST. CRCRUISE 1 CA (CAN) AT FLIGHT LEVEL 220, FLIGHT CREW HEARD A LOUD BANG AND EXPERIENCED SIGNIFICANT AIRFRAME VIBRATION. THE A/C CLIMBED APPROXIMATELY 200FT BEFORE CREW WERE ABLE TO STOP ASCENT. EMERGENCY DECLARED, UNSCHEDULED LANDING CARRIED OUT. MAINTENANCE CREW FOUND THE LT ELEVATOR TRIM CONTROL TUBE FAILED. 1L72 3T4 TRT3A20 E4EA 20030429001582003042900158CE 2003 4 29 CA030317010 120030303G323035175A BRUSHES BEECH 58 58 1152740CE CONT O550 IO550C SO MLG MOTOR BROKEN W O OTHER J WARNING INDICATION APAPPROACH 1 CA (CAN) DURING LANDING, MLG SELECTED DOWN & NOTHING HAPPENED. CIRCUIT BREAKER TRIPPED. STARTED A MANUAL EMERGENCY MLG EXTEND MANUAL MLG EXTEND HANDLE ENGAGED, STUDENT COULDN`T MOVE ACT. AFTER SEVERAL ATTEMPTS & 2 STUDENTS MANAGED TO TURN ACT HANDLE. AFTER 1ST TURN HANDLE BECAME EASY TO MOVE. GEAR LOWERED SUCCESSFULLY & A/C LANDED. INSPECTION OF MLG ACT SYS, MLG MOTOR FOUND U/S WITH ONE BAD BRUSH. ACT WAS STIFF IN FULL UP POSITION. BOTH MOTOR & ACT REPLACED. PARTS SENT FOR INSPECT & REPAIR. 1L72 3O3 O 3A16 E3SO 20030429001592003042900159CE 2003 4 29 CA030318002 120030317G27315061001736 TRIM TAB BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA ELEVATOR FRETTED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) SPECIAL INSPECTION CARRIED OUT AS PER CAMPAIGN 681-27-30-015 WHICH MANDATES INSPECTION OF THE ELEVATOR CONTROL TUBE ATTACHMENT TO TRIM TAB. RT TRIM TAB , BUSHING WAS FOUND NOT SEATED ALL THE WAY INTO THE TRIM TAB HORN. THE OUTBOARD SIDE OF THE HORN HAD EXCESSIVE FRETTING FROM CONTROL ROD FORK END. 1L72 3T4 TRT3A20 E4EA 20030429001602003042900160EA 2003 4 29 CA030318009 120030304G2730C2T7A TORQUE TUBE DHAV DHC2 DHC2MK1 2800102EA PWA R985 R985AN14B 52008NE ELEVATOR WORN W O OTHER O OTHER NRNOT REPORTED 1 CA 21878 (CAN) THE ELEVATOR TORQUE TUBE LOWER CABLE ATTACH POINT WAS FOUND TO BE ELONGATED. THE PART WAS SENT OUT TO BE REPAIRED. 1H71 3R3 R A806 5E1 20030429001612003042900161CE 2003 4 29 CA030318010 120030228G32456006 TUBE CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA MLG WHEEL TORN W O OTHER O OTHER LDLANDING 1 CA (CAN) ON LANDING THE A/C STARTED TO YAW LEFT. THE TIRE ON LT MAIN SIDE WAS FLAT AND VERY LOOSE ON THE RIM. ON LANDING THE BRAKES WERE NOT OVERLY USED. (PILOT REPORT)WHEEL ASSEMBLY DISASEMBLE AND FOUND TUBE WITH TEAR APPROX 1/4 INCH LONG ON THE CENTER OF THE TUBE ALONG MOLDING RIBS. 1H71 3O3 ONT3A12 E274 20030415000332003041500033CE 2003 4 15 CA030318011 120030318G8011 DRIVE GEAR CESSNA150 150L 2071826CE CONT O200 O200A 17020SO STARTER WORN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING 50 HR INSPECTION, OIL FILTER ELEMENT WAS INSPECTED. STEEL PARTICLES WERE FOUND. NR 2 & 4 CYLINDERS WERE REMOVED FOR EXAMINATION OF CAMSHAFT & FOLLOWERS. NO FAULT FOUND. REMOVED THE TCM LIGHTWEIGHT STARTER, THE DRIVE GEAR WAS FOUND TO BE EXCESSIVELY WORN. FURTHER INVESTIGATION REVEALED THAT BOTH MAGNETO DRIVE GEARS WERE ALSO DAMAGED. THE CAM & IDLER GEARS WERE INSPECTED & NO DAMAGE OR WEAR WAS FOUND. I SUGGEST THAT THE STARTER GEAR WAS THE CAUSE OF THE WEAR TO THE MAGNETO DRIVE GEARS DUE TO METAL PARTICLES FALLING FROM THE STARTER DRIVE DOWN ONTO THE GEARS BELOW & BEING DRIVEN IN BETWEEN THE OTHERGEARS. IT WOULD SEEM THAT THE OTHER GEARS ARE A HARDER MATERIAL & THAT IS WHY THEY REMAINED UNDAMAG ED.1H71 3O3 O 3A19 E252 20030429001622003042900162CE 2003 4 29 CA030318015 120030311G324565010 TUBE CESSNA310 310R 2074245CE CONT O520 IO520M 17032SO MLG WHEEL TORN W O OTHER O OTHER TXTAXI/GRND HDL 1 CA (CAN) A/C LANDED WITH NO PROBLEM, TAXIED TO RAMP AND PILOT NOTICE A LOT OF DRAG ON RT MAIN HEEL DISESSEMBLED AND FOUND TUBE WITH TWO TEARS APPROX 1/4 INCH. 1L72 3O3 O 3A10 E5CE 20030429001632003042900163CE 2003 4 29 CA030318016 120030306G32971003810061 WIRE HARNESS BEECH 100 100BEECH 1152916CE PWA PT6 PT6A28 EA DOWNLOCK SWITCH FAILED W O OTHER O OTHER APAPPROACH 1 CA (CAN) UPON APPROACH , MLG WAS SELECTED DOWN FOR LANDING. AFTER EXTENSION IT WAS NOTED THAT THE RT MAIN WAS NOT INDICATING THAT IT WAS DOWN AND LOCKED. THE GEAR WAS CYCLED SEVERAL TIMES WITH NO CHANGE IN DOWN AND LOCKED INDICATION PROBLEM. FLT CREW PERFORMED EMERGENCY MLG EXTENSION & DECLARED AN IN-FLT EMERGENCY AND A/C WAS LANDED SAFELY. A/C WAS PLACED ON JACKS AND INDICATION SYSTEM INSPECTED. FAULT WAS LOCATED IN THE RT DOWNLOCK SWITCH WIRING HARNESS WHERE IT BENDS AT MLG ASSEMBLY AND DRAG LEG INTERSECTION. A BROKEN WIRE WAS LOCATED FROM THE DOWNLOCK SWITCH AND REPAIRED. MLG SYSTEM WAS GROUND-CHECKED SERVICEABLE WITH SEVERAL MLG EXTENSION AND RETRACTIONS, AND THE A/C WAS RELEASED FOR RETURN TO SERVICE. 1L72 3T4 T A14CE E4EA 20030429001642003042900164CE 2003 4 29 CA030318017 120030316G29101013880175 HOSE BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HYD SYSTEM CUT W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) DURING A WALK AROUND, THE CREW NOTICED HYDRAULIC FLUID IN THE RT MAIN GEAR AREA.MAINTENANCE FOUND THAT THE RETRACT LINE HAD BEEN CUT CLOSE TO THE IDENTIFICATION CLAMP. THE CUT OCCURED NEAR THE CLAMP WHICH MAY INDICATE A CYCLIC FAILURE WITH THE CLAMP BEING THE EDGE APPLYING PRESSURE THROUGH THE WEIGHT ON-WEIGHT OFF MOTION. THE HOSE WAS REPLACED, GEAR CYCLED AND THE AIRCRAFT RELEASED. 2L72 4T4 TRTA24CE E26NE 20030415000382003041500038SW 2003 4 15 CA030318019 120030318G6220407010105101 STUD BELL 407 407 1182206SW ALLSN 250C 250C47B GL M/R HEAD CRACKED E O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) TYPICAL CRACK FOUND AT OVERHAUL OF MAIN ROTOR HEAD. 1G71 3U3 UO H2SW E1GL 20030429001652003042900165SO 2003 4 29 CA030319001 120030317G324565010 TUBE PIPER PA31 PA31 7103102SO LYC O540 TIO540A2B 41532EA MLG WHEEL TORN W O OTHER O OTHER TXTAXI/GRND HDL 1 CA (CAN) A/C LANDED WITH NO PROBLEM, TAXIED TO RAMP AND PILOT NOTICE A LOT OF DRAG ON RT MAIN WHEEL. ASSEMBLY DISASSEMBLED AND FOUND TUBE WITH TWO TARE APPROX 1/4 INCH LONG ABOUT 6 TO 7 INCHES APART. THE TWO TEARS ARE ALONG THE OUTBOARD DIAMETER OF THE TUBE. TIRE INSPECTED FOR ANY FOREIGN OBJECTS AND NONE FOUND. 1L72 3O3 O A20SO E14EA 20030429001662003042900166EA 2003 4 29 CA030319004 120030319G2820525GG12D FLAPPER VALVE DHAV DHC2 DHC2MK1 2800102EA PWA R985 R985AN14B 52008NE FUEL SYSTEM DETERIORATED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ON ANNUAL INPSECTION, THIS FUEL CHECK VALVE WAS REMOVED FROM AIRCRAFT FOR INSPECTION. WE HAD TROUBLE DISMANTLING THE VALVE AS CORROSION HAD STARTED TO FUSE THE PARTS TOGETHER. ONCE DISMANTLED THE RUBBER SEAL ON THE INTERNAL FLAPPER VALVE WAS FOUND TO BE IN POOR CONDITION, AND WHEN TOUCHED WITH A SCREWDRIVER IT CRUMBLED APART. THE CURE DATE STAMPED ON THE OUTSIDE OF THE VALVE WAS DATED IN 1955. FAILURE OF THIS VALVE IN COULD CAUSE THE HAND WOBBLE PUMP IN THE AIRCRAFT TO BECOME INEFFECTIVE. 1H71 3R3 R A806 5E1 20030415000392003041500039SO 2003 4 15 CA030319006 120030317G7810557584 CLAMP PIPER PIPER PA31 PA31 7103102SO LYC O540 TIO540A2B 41532EA TAIL PIPE BROKEN W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) THE MULTI SEGMENTED CLAMP WAS FOUND TO HAVE FLANGES BROKEN OFF THREE OF THE SEGMENTS. FORTUNATELY, THE REMAINING SEGMENT HELD THE TAILPIPE IN PLACE. 1L72 3O3 O A20SO E14EA 20030429001682003042900168EA 2003 4 29 CA030320001 120030318G301073010033147 LINE DHAV DHC7 DHC7102 2802708EA PWA PT6 PT6A50 52043EA HAMSTD24PF 24PF305 GL DE-ICE SYS CHAFED W O OTHER O OTHER NRNOT REPORTED 1 CA 32910 (CAN) AFTER FINDING THIS LINE CHAFED ON AN OTHER AIRCRAFT WE COMPLETED A SPECIAL INSPECTION. WE FOUND THAT THE DE-ICE LINE HAD BEEN CHAFING ON A HYDRAULIC LINE. THIS LINE IS LOCATED UNDER PANEL 419AT (NR 1 ENG BATMAN PANEL). THE LINE IS HIDDEN UNDER NUMEROUS OTHER LINES AND IT IS VERY DIFFICULT TO SEE / NOTICE THE CHAFFING. WE HAD TO USE A BORESCOPE TO CONFIRM IF THE LINES WERE TOUCHING EACH OTHER. THE LINE WILL BE REMOVED AND REPLACED. 2H74 4T4 T A20EA E4EA 6 CP1NE 20030429001692003042900169CE 2003 4 29 CA030320002 120030319G32421338932 STATOR CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE BRAKE ASSY BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) AIRCRAFT RETURNED FROM TRIP MARCH 17 / 03 WITH A SNAG IN THE LOGBOOK ( 2016B)- BRAKES ARE GRABBING WHEN APPLIED, NOTICEABLE AT LOW SPEEDS AND DURING GROUND TURNS. A/C WHEEL AND BRAKE ASSY'S REMOVED AND DISMANTLED FOR INSPECTION.BRAKE ASSY S/N 1649 HAD A BROKEN STATOR, BRAKE ASSY 2662 HAD STATORS WORN TO LIMITS.BOTH BRAKE ASSY WERE REPLACED AND A/C RETURNED TO SERVICE. BRAKE ASSY'S WERE INSTALLED AT ACTT 521 7 / TOTAL LANDINGS OF 5881. THE STATORS ON S/N 1649 HAD TOTAL LNDGS OF 649 PRIOR TO FAILURE.THE STATORS ON S/N 2662 HAD821 LANDINGS PRIOR TO REPLACEMENT. 1L72 4F4 F A22CE E1NE 20030415000402003041500040SO 2003 4 15 CA030320003 220030314G8530641917 CYLINDER HEAD CESSNA150 150L 2071826CE CONT O200 O200A 17020SO MCAULY1A101 1A101HCM GL ENGINE CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) CRACK IN ALUMINUM HEAD RUNNING UNDER TOP SPARKPLUG HOLE. CRACK DOES NOT EXTEND INTO COMBUSTION CHAMBER - NO LEAKAGE FOUND DURING PRESSURE TEST. CYLINDER REMOVED AND REPLACED WITH RECONDITIONED UNIT. 1H71 3O3 O 3A19 E252 5 NP918 20030429001702003042900170CE 2003 4 29 CA030321001 120030319G2721 ACTUATOR CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE RUDDER TRIM FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING THE DAILY INSPECTION THE NUT SECURING THE RUDDER TRIM TABACTUATOR UPPER BOLT WAS NOTICED MISSING. THE NUT SECURING THE LOWER BOLT WAS LOOSE WITH NO COTTER PIN INSTALLED. 5.7 HOURS HAD ELAPSEDSINCE THE PHASE 1 THRU 4 INSPECTION. THE UPPER AND LOWER BOLTS ARE NORMALLY REMOVED AT THE PHASE1 THRU 4, TO ENABLE ACTUATOR ROD LUBRICATION. THE INSTALLED ACTUATOR HAD A PREVIOUS MODIFIICATION WHICH INCORPORATED A GREASE FITTING, THE REQUIREMENT FOR DISSAEMBLY WAS NOT NECESSARY. THE AME WHO CARRIED OUT THE LUBRICATION TASK, HAD MADE A LOD BOOK ENTRY STATING THAT A INDEPENDANT CHECK WAS REQUIRED FOR BOTH SUBJECT BOLTS, BUT, THE ENTRY HAD BEEN CROSSED OUT AND NOTED AS 'ENTERED IN ERROR' AFTER THE AME HAD NOTI1L72 4F4 F A22CE E1NE 20030429001712003042900171EU 2003 4 29 CA030321002 120030320G2910A27180210009000 TUBE AIRBUS310 A310300 3930305EU GE CF6 CF680C2A5 NE HYD SYSTEM DAMAGED W O OTHER KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 CA (CAN) DURING FLIGHT HYDRAULIC RESERVOIR LOW LEVEL APPEARED ON GREEN SYSTEM. AFTER INVESTIGATION A PIN HOLE WAS FOUND ON THE LT WING SPOILER PRESSURE TUBE. TUBE ASSY WAS REPLACED AS M/M AND SYSTEM SERVICED AIRCRAFT WAS RETURNED TO SERVICE. CAUSE OF FAILURE IS UNKNOWN . LINE WAS ROUTED TO ENGINEERING FOR ANALYSIS . SUSPECT INTERNAL EROSION 2L72 4F4 FRTA35EU E13NE 20030429001722003042900172NM 2003 4 29 CA030321003 120030309G3297471515 WIRE HARNESS BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA MLG FAULTY W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) AFTER TAKE OFF LANDING GEAR WOULD NOT RETREACT. A/C RETURN TO FIELD NLG HARNESS FOUND TO BE FAULTY, REPLACED, A/C SERVICEABLE. 2H72 4T4 TRTA13NM E00062EN 20030415000432003041500043EA 2003 4 15 CA030321004 220030320G7414 SHAFT SLICK BEECH 95 D95A 1153408CE LYC O360 IO360B1B 41514EA MAGNETO CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA 01021635 (CAN) RT ENGINE WOULD NOT START. DURING TROUBLESHOOTING THE MAGNETO WAS REPLACED. DURING THE INSPECTION OF THE MAGNETO, IT WAS NOTICED THAT THE MAGNETO SHAFT WAS CRACKED AT THE POINT WHERE THE PHENOLIC CAM FOR THE POINTS IS INSERTED INTO THE SHAFT. ALSO EXCESSIVE WEAR WAS NOTICED ON THE CAM. WE DON'T SUSPECT THE CRACK IN THE SHAFT AFFECTED THE OPERATION OF THE MAGNETO EVEN WITH THE CRACK IN THE SHAFT. 1L72 3O3 O 3A16 1E10 20030415000452003041500045CE 2003 4 15 CA030321007 120030321G55235061001735 BUSHING BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA ELEVATOR TRIM CORRODED W O OTHER O OTHER NRNOT REPORTED 1 CA 5523 (CAN) DURING INVESTIGATION OF ELEVATOR TRIM TAB CLEVIS , BUSHINGS FOUND CORRODED AND SEIZED ON ONE SIDE/ NEW BUSHINGS AND BOLTS ON ORDER. A/C GROUNDED 1L72 3T4 TRT3A20 E4EA 20030415000462003041500046CE 2003 4 15 CA030321008 120030321G55235061001735 BUSHING BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA ELEVATOR TRIM CORRODED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) DURING INVESTIGATION OF ELEVATOR TRIM TAB CLEVIS , BUSHINGS P/N 50-524024-1 FOUND LIGHTLY CORRODED AND LIGHT WEAR. NEW BUSHINGS AND BOLTS ON ORDER. A/C GROUNDED 1L72 3T4 TRT3A20 E4EA 20030415000472003041500047CE 2003 4 15 CA030321009 120030321G55235061001735 BUSHING BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA ELEVATOR TRIM CORRODED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) DURING INVESTIGATION OF ELEVATOR TRIM TAB CLEVIS , BUSHINGS P/N 50-524024-1 AND P/N 90-610010-5 FOUND LIGHTLY CORRODED AND PARTIALY SEIZED . BOLT AND NUTWERE FOUND INSTALLED CORRECTLY WITH THE CORRECT TORQUE. NEW BUSHINGS AND BOLTS ON ORDER. A/C GROUNDED 1L72 3T4 TRT3A20 E4EA 20030415000482003041500048CE 2003 4 15 CA030321010 120030319G5712052323178 RIB CESSNA185 A185F 2072821CE CONT O520 IO520D 17032SO MCAULY2A34C D2A34C58 GL FLAP TRACK CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING 200 HR INSPECTION THE INBOARD FLAP TRACK BRACKETS FOR THE CLOSING SKIN WHERE FOUND CRACKED. DURING REPLACEMENT OF THESE BRACKETS IT WAS DISCOVERED THAT THE LOWER CORNER OF THE RIBS WHERE ALSO CRACKED. BOTH INBOARD AND OUTBOARD RIBS ON THE FELT INBOARD FLAP TRACK WHERE FOUND CRACKED AND THE INBOARD RIB ON THE RT INBOARD FLAP TRACK WAS FOUND CRACKED. CRACKS MOST LIKLY CAUSED FROM REPEATED CYCLES AND OR HIGH FLAP EXTENSION SPEEDS. NOTEON THIS AIRCRAFT THE LOWER FLAP SKINS WHERE ALSO CHANGED DURING THIS INSPECTION DUE TO CRACKS IN THETRAILING EDGE SKINS. 1H71 3O3 O 3A24 E5CE 5 CP3EA 20050427003092005042700309NM 2005 4 27 CA030321011 120030226G2740 CONTROL UNIT BOEING737 737217 1384464NM PWA JT8 JT8D17 52049NE RUDDER MISOVERHAULED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) UNSCHEDULED REMOVAL OF RUDDER PCU, OCCURRED ON FEB 25/26/2003 WAS IN RESPONSE TO A REQUEST FROM MATERIAL SERVICES BASED ON A FAA UNAPPROVED PARTS NOTIFICATION NR 2001-0089 DATED AUG 12,2002. SUSPECT PCU P/N 1U1150-3 S/N 737 WAS LISTED IN THE NOTIFICATION. REMOVAL OF RUDDER PCU P/N 1U1150-3 S/N 0737 DOES CROSS REFERENCE TO FTN ZKMZP8 AND DOES INDICATE THAT IT WAS INSTALLED, BUT HISTORY INDICATES UNIT WAS REPAIRED ON MARCH 13,2000. FTN HISTORY INDICATES THAT UNIT WAS INSTALLED ON AC ON MARCH 21, 2000 UNTIL PRESENT DATE. FAA NOTICE INDICATES THAT SUSPECT UNITS WERE IMPROPERLY O/H JANUARY 3-8 2001. SHOP REPORT ESTABLISHED THAT PART HAD MFG CODES. PRESUMING THAT PART LISTED ON FAA LISTING HAS BE FORGED. 2L72 4F4 F A16WE E2EA 20030429001742003042900174NM 2003 4 29 CA030321013 120030303G243503600923 BEARING LUCAS DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE STARTER GEN FAILED W H DEACTIVATE SYST/CIRCUITS J WARNING INDICATION CRCRUISE 1 CA 1067 (CAN) GENERATOR CAUTION LIGHT ILLUMINATED DURING FLIGHT.UPON DISASSEMBLY FOUND COMMUTATOR END BEARING HAD FAILED. BEARING FELL APART DURING DISASSEMBLY. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030415000502003041500050NE 2003 4 15 CA030324002 320030317G6110 BEARING RACE BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3I NE PROP BLADE CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) PROP REMOVED DUE TO EXCESSIVE BLADE RADIAL PLUS END PLAY. UPON DISASSEMBLY 2 OPPOSING BLADE BEARING WERE FOUND TO BE CRACKED. HUB FORWARDED TO HARTZELL FOR EVALUATION OF DAMAGE. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20030415000512003041500051CE 2003 4 15 CA030324003 120030310G325059420011 BELLCRANK CESSNA310 310Q 2074242CE CONT O470 IO470VO 17026SO MCAULY3AF32C3AF32C87 GL NLG STEERING CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) UPON INSPECTION, FOUND STEERING BELLCRANK CRACKED IN RADIUS, SEVERAL LOCATIONS. NOTE: THE NEW BELLCRANK INSTALLED IS A HEAVIER UNIT. 1L72 3O3 O 3A10 3E1 5 CP22EA 20030415000532003041500053SO 2003 4 15 CA030324005 120030320G5540 TORQUE TUBE PIPER PA31T PA31T 7103124SO PWA PT6 PT6A28 EA RUDDER CORRODED W O OTHER O OTHER NRNOT REPORTED 1 CA 12087 (CAN) DURING INSPECTION OF THE RUDDER TORQUE TUBE ASSY FOR CORROSION IAW PIPER SERVICE BULLETIN 1105 IT WAS DETERMINED THAT THE TORQUE TUBE HAD EXTERNAL CORROSION. THE TUBE WAS REMOVED TO ASESS THE AMOUNT OF CORROSION AND IF IT COULD BE REMOVED AND TREATED. THE AMOUNT OF EXTERNAL SURFACE CORROSION WAS MINIMAL.THE INSIDE OF THE TORQUE TUBE WAS INSPECTED WITH A BOROSCOPE WHICH IS NOT CALLED FOR IN THE SERVICE BULLETIN AND WAS FOUND SEVERELY CORRODED. PIPER AIRCRAFT WAS NOTIFIED AND THE TORQUE TUBE WAS REPLACED WITH NEW.THE OWNER HAS POSSESION OF THE CORRODED TORQUE TUBE. 1L72 3T4 T A8EA E4EA 20030415000542003041500054EU 2003 4 15 CA030324008 120030313G2742 ACTUATOR PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL PITCH TRIM SEIZED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) FLIGHT CREW HAD A AUTOPILOT DISCONNECT IN CRUISE FLIGHT THEY SHUT DOWN AUTOPILOT SYSTEM AND CONTINUED FLIGHT HOME. MAINTENANCE TESTED AUTOPILOT SYSTEM AFTER RESETTING C/B AND SYSTEM WORKED AS PER M/M.THEY THEN CARRIED OUT THE TEST ON THE HORIZONTAL STAB TRIM, WHEN THEY GOT TO THE PROCEDURE TO TESTTHE ALTERNATE TRIM THEY FOUND IT TO BE U/S. FURTHER INSPECTION REVEALED THAT THE SECONDARY MOTOR WAS SEIZED. A REPLACEMENT UNIT WAS INSTALLED AND TESTED SERVICEABLE.PITCH TRIMACTUATOR HAD 808.7 HR S AND 890 CYCLES. THIS IS THE SECOND FAILURE WE HAVE HAD ON THESE UNITS WITH LESS THAN 1000 HRS. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030415000552003041500055EA 2003 4 15 CA030325005 220030314G7414 RIVET SLICK ZLIN 242 Z242L 9970204EU LYC O360 AEIO360A1B6 41514EA IMPULSE COUPLINGLOOSE W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DUE TO PREVIOUS IMPULSE COUPLING FAILURES, WE HAVE IMPLEMENTED AN INSPECTION OF THE IMPULSE COUPLING EVERY 100 HOURS. THIS IMPULSE COUPLING HAD A LOOSE RIVET ON ONE OF THE PAWLS. IF THE RIVET WAS TO SHEAR THERE WOULD BE SIGNIFICANT DAMAGE TO THE ENGINE. 1L71 3O3 O0 A76EU 1E10 20030415000562003041500056CE 2003 4 15 CA030325006 120030318G7810 BRACKET CESSNA208 208B 2073701CE PWA PT6 PT6A114A 52043NE MCAULY3AF34C3GFR34C703 GL EXHAUST CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) REGULAR INSPECTION REVEALED A CRACKED EXHAUST SUPPORT BRACKET, THE BRACKET WAS REPLACED AND AIRCRAFTWAS RETURNED TO SERVICE 1H71 3T3 T A37CE E4EA 5 CP60GL 20030415000572003041500057SO 2003 4 15 CA030325007 220030312G8530 CYLINDER CONT O550 IO550F 17042SO ENGINE WORN W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) ON INSPECTION OF 2 CYLINDERS, 1ST CYLINDER MEASUREMENT OF THE BARREL OF THE CYLINDER VARIES FROM 5.252' AT THE ENTRANCE OF THE CYLINDER AND 5.255' AT THE BOTTOM. MAXIMUM LIMITS ARE 5.256 INCHES. WE DISCOVERED A 'STEP' (SEE PHOTO) AT THE BOTTOM 0.008 DEEP. THIS 'STEP' WAS FORMED BY WHERE THE RINGS STOPPED THEIR TRAVEL. THE EXHAUST VALVE WAS WORN 0.005 ON THESTEM.2ND CYLINDER - THE CYLINDER BARREL MEASUREMENT VARIED FROM 5.252 TO 5.259. WE SURPASS THE ALLOWABLE LIMITS ESTABLISHED BY THE MANUFACTURER (5.256). THE EXHAUST VALVE WAS WORN 0.007 ON THE STEM A ND IT ALSO HAD A 0.008 'STEP' AT THE BOTTOM OF THE CYLINDER. 3 O E3SO 20030415000582003041500058GL 2003 4 15 CA030325012 320030319G6140 CONNECTOR PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL CSU SHORTED W A UNSCHED LANDING N FALSE WARNING CRCRUISE 1 CA (CAN) DURING FLIGHT, PILOT REPORTED THAT NP RPM INDICATION WAS FLUCTUATING. NP WOULD DROP TO AROUND 1620 FOR A FEW SECONDS & THEN IT WOULD RETURN TO IT'S CONSTANT SPEED RANGE OF AROUND 1700. FLUCTUATIONS LASTED FOR ABOUT 20 MINUTES. TORQUE & FUEL FLOW WERE CONSTANT & NO SURGING WAS FELT BY PILOT. PILOT LANDED AT NEAREST AIRPORT. NP INDICATION SYS WAS INSPECTED, & RPM CONNECTOR CLEANED ON CSU. A/C WAS GROUND RUN AND NP INDICATIONS WERE NORMAL AND CONSTANT. A/C RETURNED TO BASE. RETURN FLT, & FURTHER INVESTIGATIONS & GROUNDS RUNS AT BASE, NP SYSTEM FUNCTIONED NORMALLY. AFTER 22 HOURS OF FLIGHT OPERATION, PROBLEM HAS NOT RETURNED. BELIEVE THE PROBLEM WAS RPM CONNECTOR ON CSU, SINCE OTHER PC-12 ENGINE CONNECTORS 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030415000592003041500059CE 2003 4 15 CA030326001 120030325G5523906100105 BUSHING RAYTHN BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA CONTROL ROD SEIZED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) BUSHING INSERTED INTO ELEVATOR TRIM TAB HORNS, BOTH LT AND RT FOUND TO BE INCORRECTLY INSTALLED. BUSHING WAS NOT INSERTED FAR ENOUGH INTO THE HORN. THIS CAUSED THE CLEVIS FORK END TO CLAMP THE OUTER BUSHING AND HORN TAB INSTEAD OF THE INNER BUSHING. THE INNER BUSHING HAD TO BE DRIVEN OUT WITH A HAMMER AND PUNCH. ONCE REMOVED AND MEASURED, THE INNER BUSHING DIMENSION WAS FOUND TO BE THE SAME SIZE AS THE OUTER BUSHING. THIS LEAVES A ZERO CLEARANCE FIT WHICH DOESNOT ALLOW A FREE BEARING MOVEMENT. 1L72 3T4 TRT3A20 E4EA 20030415000602003041500060CE 2003 4 15 CA030326002 120030321G273150524161606 ACTUATOR BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA ELEVATOR TRIM LOOSE W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) DURING ELEVATOR TRIM TAB FREE PLAY CHECK THE LT ELEVATOR TRIM TAB ACTUATOR WAS FOUND TO HAVE EXCESSIVE PLAY. MEASURED .031 1L72 3T4 TRT3A20 E4EA 20030415000612003041500061CE 2003 4 15 CA030326003 120030325G5523905240241 BUSHING BEECH 90 C90 1152913CE PWA PT6 PT6A21 52043EA ELEVATOR TRIM SEIZED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) LT & RT ELEVATOR TRIM HORN INNER BUSHINGS HAD TO BE DRIVEN OUT OF INNER BUSHINGS WITH HAMMER AND PUNCH. ONCE REMOVED & MEASURED, INNER BUSHING DIMENSION WAS FOUND TO BE THE SAME AS OUTER BUSHING INNER DIAMETER. THERE WAS NO CORROSION BETWEEN THE 2 BUSHINGS. THIS LEFT A 0 CLEARANCE FIT NOT ALLOWING FREE BEARING MOVEMENT. NEW OUTER & INNER BUSHINGS WERE RECEIVED. NEW OUTER BUSHINGS HAVE A MEASURED INNER DIAMETER .3735. REMOVED OUTER BUSHING. ID WAS MEASURED AT .3750. BUSHINGS HAVE BEEN INSTALLED IN ELEVATOR TRIM HORN & INNER BUSHING NOW FREELY ROTATE WITHIN OUTER BUSHING. LT BUSHING LOCATED IN END OF THE ELEVATOR TRIM TAB ACTUATOR ALSO REQUIRED FORCEFUL REMOVAL DUE TO CORROSION. RT SLID OUT FREELY. 1L72 3T4 T 3A20 E4EA 20030415000652003041500065CE 2003 4 15 CA030327001 120030326G71609091010017 TUBE BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA ANTI ICE SYS CRACKED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) ENGINE INTAKE ANTI-ICE TUBES REPLACED AS PER BEECH SB 71-3142. NEW TUBES FOUND CRACKED AT SECOND INSPECTION AFTER SB COMPLIANCE. 1L72 3T4 TRT3A20 E4EA 20030415000752003041500075EA 2003 4 15 CA030328001 220030311G8520LW17071 CRANKSHAFT CESSNA172 172P 2072436CE LYC O320 O320D2J 41508EA MCAULY1C160 1C160DTM GL ENGINE CORRODED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) UPON INSPECTION FOR AD 98-02-08 INTERNAL CORROSION. LIGHT SURFACE CORROSION WAS FOUND, WHEN LOG BOOKS CHECKED IT WAS FOUND THAT LYCOMING HAD SIGNED OFF SB530 WHICH A COATING THAT TERMINATES INSP. LYCOMING HAS BEEN CONTACTED AND CORRECTING THE PROBLEM. THIS PROBLEM WAS FOUND DUE AN ERROR IN OUR TRACKING SYSTEM WHICH SHOWED AD 98-02-08 STILL AS A 5 YEAR INSP. NOTE THE CORROSION FOUND DID NOT REQUIRE THE CRANKSHAFT TO BE REPLACED 1H71 3O3 ONT3A12 E274 5 NP910 20030415000862003041500086CE 2003 4 15 CA030331003 120030328G32450923150 TUBE CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA WHEEL TORN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ON WALK AROUND PILOT NOTICE RT MAIN TIRE FLAT. WHEEL ASSEMBLY REMOVED AND TUBE INSPECTED, TWO TEAR APPROX 1/4 INCH AND APPROX 7 INCHES APART FOUND ON OUTBOARD CENTER SEAM. MICHELIN WAS CONTACTED AND THE FOUR PREVIOUS TUBES WERE SENT TO MICHELIN FOR MORE INSPECTION. TIRE WAS INSPECTED FOR FOREIGN OBJECT AND NO PROBLEM FOUND. 1H71 3O3 ONT3A12 E274 20030415000872003041500087SW 2003 4 15 CA030331005 120030331G2810512681 TANK AIRTRCAT802 AT802 0390305SW FUEL CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING INSPECTION A CRACK WAS DISCOVERED ON THE FUEL HEADER TANK END PLATE. THE HEADER TANK WAS REMOVED AND REPLACED WITH A NEW PART. AIRCRAFT WAS RETURNED TO SERVICE. 1L71 3T NCA19SW 20030415000882003041500088NE 2003 4 15 CA030331006 220030308G7321 LINE SKRSKYS64 S64E 8142604NE PWA JFTD12JFTD12A4A 52047NE P3 SENSING FROZEN W EA ENGINE SHUTDOWN UNSCHED LANDING RJ PARTIAL RPM/PWR LOSS WARNING INDICATION HOHOVERING 1 CA (CAN) A/C WAS COVERED IN SNOW AND ICE & REQUIRED EXTENSIVE PREHEATING. ENGS WERE STARTED & NR 1 ENG TOOK LONGER TO LIGHT OFF. ONCE ALL WAS IN GREEN, A/C LIFTED OFF. APPROX. 10 MINS INTO 1ST CYCLE, CREW NOTICED ENGS WERE UNMATCHED. ATTEMPTED TO MATCH THEM USING BEEPER TRIM FOR EACH ENG, UNSUCCESSFUL. ATTEMPT TO THROTTLE BACK FAILED BECAUSE THROTTLE LEVERS FROZEN. LOGS RELEASED & NR 1 ENG SURGED, OVERSPEED PROTECTION SHUT ENG DOWN. WITH ENG SHUTDOWN, ABLE TO GET VERTICAL BOUNCE UNDER CONTROL. NR 1 ENG WAS SECURED & A/C RETURNED & LANDED. INSPECTION OF ENG AND ITS CONTROL LINKAGES REVEALED ICE IN ENG P3 SENSE LINE & AN N2 BEEP MOTOR INOP. BEEP MOTOR REPLACED. ENG FCU WAS REPLACED AND ENG GROUND RUN. 2G72 4U4 U H4EA E15EA 20030415000892003041500089SO 2003 4 15 CA030331007 220030320G8530 EXHAUST VALVE CESSNA150 150H 2071818CE CONT O200 O200A 17020SO MCAULY1A101 1A101DCM GL ENGINE STUCK W K NONE O OTHER ININSP/MAINT 1 CA (CAN) PILOT REPORT OF INTERMITTENT ENGINE ROUGH RUNNING. NR 4 EXHAUST VALVE FOUND STICKY. GUIDE AND STEM CLEANED. GROUND RUN SATISFACTORY. 1H71 3O3 O 3A19 E252 5 NP918 20030415000902003041500090CE 2003 4 15 CA030331008 120030309G2434DOFF10300B ALTERNATOR CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA MCAULY1C160 1C160DTM GL ENGINE FAILED W A UNSCHED LANDING H ELECT. POWER LOSS-50 PC LDLANDING 1 CA (CAN) ALTERNATOR FAILURE IN FLIGHT,ELECTRICAL FAILURE 1H71 3O3 ONT3A12 E274 5 NP910 20030415000912003041500091 2003 4 15 CA030331009 420030331G2562 G SWITCH ELT FAILED W K NONE L NO TEST ININSP/MAINT 1 CA 408797 (CAN) DURING RECERTIFICATION TESTING THE G SWITCH WAS FOUND FAILED, UNIT RETURNED TO MANUFACTURER FOR REPAIR 20030415000922003041500092 2003 4 15 CA030331010 420030331G2562 G SWITCH POINTER ELT FAILED W K NONE L NO TEST ININSP/MAINT 1 CA 408816 (CAN) DURING ANNUAL RECERTIFICATION G SWITCH FAILED TO OPERATE - UNIT RETURNED TO MANUFACTURER FOR REPAIR. 20030415000932003041500093 2003 4 15 CA030331011 420030331G2562 G SWITCH POINTER ELT FAILED W K NONE L NO TEST ININSP/MAINT 1 CA 408870 (CAN) DURING ANNUAL RECERTIFICATION G SWITCH FAILED TOP OPERATE - UNIT RETURNED TO MANUFACTURER FOR REPAIR 20030415000942003041500094SO 2003 4 15 CA030401001 120030331G32101742002 TUBE PIPER PA23 PA23250 7102308SO LYC O540 TIO540C1A 41532EA MLG CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THREE CRACKS WERE FOUND ON THE RT MLG OUTBOARD TUBE ASSEMBLY OF THE DRAG LINK FITTING SUPPORT. THE CRACKS ARE LOCATED AROUND THE LOWER MOUNTING BOLT HOLE OF THE TUBE ASSEMBLY. AFTER REMOVAL OF THE DRAG LINK SUPPORT ASSEMBLY, THE FORWARD SUPPORT FITTING WAS FOUND WITH TWO CRACKS ALONG THE EACH SIDE OF THE CASTING SEAM TO THEMOUNTING BOLT HOLE. 1L72 3O3 O 1A10 E14EA 20030415000952003041500095 2003 4 15 CA030401003 420030331G34226226163002 GYRO BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA COCKPIT FAILED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) NR 2 HSI COMPASS CARD FAILES TO DISPLAY TRUE COMPASS HEADING WITH NO FLAG IN VIEW. WHEN FAILED THE NR 2 HSI COMPASS CARD CANNOT BE SLEWED IN EITHER SLAVE OR FREE MODES, AND IS FROZEN ON ONE BEARING. THE PAIRED CROSS SIDE RMI REMAINES SERVICEABLE AND CAN BE SLEWED IN BOTH FREE AND SLAVE MODE. NO WARNING FLAGS OCCUR ON ANY SYSTEM. NR 2 HEADING SYSTEM IS COUPLED TO P/N 331A-3G HSI. APPARENT FAILURE IS A LACK OF 26 VAC SUPPLY FROM PIN 31 OF THE DGS-65 TO NR 2 HSI. REPLACEMENT OF DGS-65 GYRO CLEARS THE FAULT.THE SAFETY CONCERN IS THE LACK OF A HDG WARNING FLAG ON NR 2 HSI WHEN FAULT OCCURES. 1L72 3T4 TRT3A20 E4EA 20030415000962003041500096CE 2003 4 15 CA030401004 120030401G5511043200115 SPAR CESSNA150 150L 2071826CE CONT O200 O200A 17020SO HORIZONTAL STAB CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 19406 (CAN) ON INSPECTION 0432001-15 SPAR REINFORCEMENT FOUND CRACKED AFTER DISASSEMBLEY LT & RT SPARS ALSO FOUND CRACKED. REASSEMBLED WITH NEW PARTS INCLUDING NEW STYLE BRACKET. AIRCRAFT RETURNED TO SERVICE. 1H71 3O3 O 3A19 E252 20030415000982003041500098 2003 4 15 CA030401008 420030401G2562 G SWITCH POINTER ELT FAILED W K NONE O OTHER ININSP/MAINT 1 CA 408078 (CAN) DURING ANNUAL RECERTIFICATION G SWITCH FAILED TO OPERATE - UNIT RETURNED TO MANUFACTURER FOR REPAIR 20030415000992003041500099 2003 4 15 CA030401009 420030401G2562 G SWITCH POINTER ELT FAILED W K NONE L NO TEST ININSP/MAINT 1 CA 408884 (CAN) DURING ANNUAL RECERTIFICATION G SWITCH FAILED TO OPERATE - UNIT RETURNED TO MANUFACTURER FOR REPAIR 20030415001002003041500100 2003 4 15 CA030401010 420030401G2562 G SWITCH POINTER ELT FAILED W K NONE L NO TEST ININSP/MAINT 1 CA 408387 (CAN) DURING ANNUAL RECERTIFICATION G SWITCH FAILED TO OPERATE - UNIT RETURNED TO MANUFACTURER FOR REPAIR 20030415001012003041500101 2003 4 15 CA030401011 420030401G2562 G SWITCH POINTER ELT FAILED W K NONE L NO TEST ININSP/MAINT 1 CA 409263 (CAN) DURING ANNUAL RECERTIFICATION G SWITCH FAILED TO OPERATE - UNIT RETURNED TO MANUFACTURER FOR REPAIR 20030611000442003061100044EA 2003 6 11 CA030403004 120030312G5753601R145011 SKIN CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE TE FLAP DELAMINATED W K NONE O OTHER ININSP/MAINT 1 CA 10121 (CAN) CREW REPORTED (LEFT OUTBOARD FLAP UPPER PANEL HAS 6 INCH DELAMINATION). OUTBOARD FLAP UPPER SKIN FOUND TO HAVE 2 CRACKS NEAR INBOARD END BEGINNING AT LEADING EDGE OF SKIN PANEL. 2L72 4F4 FRTA21EA E15NE 20030415001042003041500104SO 2003 4 15 CA030404002 120030404G1430NAS464P427 BOLT PIPER PA44 PA44180 7104402SO NLG DRAG LINK SHEARED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) CENTER NOSE GEAR DRAG LINK BOLT FOUND SHEARED BUT STILL IN PLACE DURING 100 HR. INSPECTION. 1L72 3O A19S0 20030429001772003042900177SW 2003 4 29 CA030404007 120030325G53207033012 STRAP AIRTRCAT400 AT401 0390204SW ORENDAOE600AOE600A NE FUSELAGE BROKEN W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) UPON PERFORMING THE SCHEDULED 200 HOUR INSTALLATION INSPECTION, THE HOSE STRAP WAS FOUND TO BE BROKEN NEAR THE MOUNTING BOLT HOLE. THE BROKEN HOSE STRAP WAS REPLACED. INVESTIGATION INTO THE CAUSE, AND FORMULATION OF CORRECTIVE ACTION CONTINUES. MORE DETAIL TO FOLLOW. 1L71 3R3 V A17SW E0006A 20030506002542003050600254EA 2003 5 6 CA030406001 120030402G212092E204 CHECK VALVE CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE BULKHEAD DAMAGED W B EMER. DESCENT W INADEQUATE Q C CRCRUISE 1 CA 16373 (CAN) FLT CREW REPORTED LOSS OF PRESSURIZATION AT FL330, CABIN RATE INCREASED AT 2000/3000 FT PER MIN.EMERGENCY DESCENT PERFORMED PER QRH.AIRCRAFT LANDED WITHOUT FUTHER INCIDENT.MTCE FOUND A DUCT BLOWN OFF THE LEFT WATER SEPARATOR AND THE LT BULKHEAD CHECK VALVE DAMAGED. THE DUCT WAS REINSTALLED ON THE WATER SEPARATOR, THE LH BULKHEAD CHECK VALVE WAS REPLACED AND AIRCRAFT WAS RETURNED TO SERVICE. 2L72 4F4 FRTA21EA E15NE 20030507000082003050700008CE 2003 5 7 CA030407001 120030402G324453716 TIRE MCAULY CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA NLG BLISTERED W O OTHER O OTHER TXTAXI/GRND HDL 1 CA (CAN) DURING GROUND HANDLING IT WAS NOTICED THAT A CHUNK OF RUBBER FROM THE SIDE WALL OF THE NOSE WHEEL TIRE WAS MISSING. IT SEAMED THAT THE RUBBER HAD BISTERED AND HAD BURST. NOSE WHEEL TIRE WAS REPLACED. 1H71 3O3 ONT3A12 E274 20030507000102003050700010EU 2003 5 7 CA030407003 120030227G2435 STARTER GEN BAG JETSTMJETSTM3107 1500215EU GARRTTTPE331TPE33110UG 01514WP ROTOL R333 R333482F12 GL ENGINE FAILED W O OTHER H ELECT. POWER LOSS-50 PC TXTAXI/GRND HDL 1 CA (CAN) AFTER START THE GENERATOR WOULD NOT COME ON LINE. TESTING REVEALED A FAILED TERMINAL END ON THE FIELD WIRE INSIDE THE GENERATOR. 2L72 4T4 TRTBA15CAA E4WE 6 CP61GL 20030429001822003042900182CE 2003 4 29 CA030407008 120030403G3260MS250413 SOCKET BEECH 100 100BEECH 1152916CE PWA PT6 PT6A28 EA HARTZLHCB3T HCB3TN3 GL MLG INDICATOR INTERMITTENT W L ABORTED APPROACH P NO WARNING INDICATION APAPPROACH 1 CA 11701 (CAN) FLIGHT CREW COULD NOT GET A LT GREEN GEAR LOCKED INDICATION ON APPROACH. UPON APPROACH LT MAIN GEAR GREEN INDICATOR ILLUMINATED. ALL GEAR RIGGING INSPECTED AND TESTED IAW M/M WITH NO DEFECTS NOTED. FOUND THE LT MAIN INDICATOR LIGHT SOCKET TO HAVE ITERMITTENT CONTACT ON PIN NR 2. REMAINDER OF WIRE INSPECTED AND TESTED FROM INDICATOR TO DOWNLOCK SWITCH WITH NO OTHER DEFECTS NOTED. AIRCRAFT RELEASED PENDING SATISFACTORY TEST FLIGHT. CREW REPORTS NO FURTHER PROBLEMS. 1L72 3T4 T A14CE E4EA 6 CP15EA 20030507000152003050700015CE 2003 5 7 CA030408001 120030403G323466710 CONTROL VALVE CESSNA500 500CESSNA 2076602CE PWA JD15 JT15D1A NE LANDING GEAR MALFUNCTIONED W O OTHER J WARNING INDICATION APAPPROACH 1 CA (CAN) CESSNA 500 ON APPROACH, GEAR DID NOT EXTEND SO MANUAL GEAR EXTENSTION PROCEDURE CARRIED OUT. AIRCRAFT LANDED NORMALY. INSPECTED AIRCRAFT UNABLE TO DUPLICATE SNAG. SO CHANGED LANDING GEAR CONTROL VALVE AS A PRECAUTION. 1L72 4F4 F A22CE E25EA 20030429001832003042900183CE 2003 4 29 CA030408002 120030403G2720115524067 SPRING BEECH 100 100BEECH 1152916CE PWA PT6 PT6A28 EA HARTZLHCB3T HCB3TN3 GL RUDDER RETURN BROKEN W K NONE O OTHER ININSP/MAINT 1 CA 14260 (CAN) PILOT REPORTED NOSE STEERING SEEMED SLOPPY ON TAXI AND RUDDER STIFF AFTER 70 KIAS ON TAKEOFF. REMOVED TAILCONE AND FOUND BOTH RUDDER RETURN SPRINGS BROKEN WITH THE LEFT HAND SPRING BINDING ON THE ELEVATOR SUPPORT ARM. REPLACED SPRINGS AND OPERATION NORMAL. 1L72 3T4 T A14CE E4EA 6 CP15EA 20030429001842003042900184CE 2003 4 29 CA030408004 120030408G3020909100991317 TUBE BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA HARTZLHCB3T HCB3TN3 GL ANTI-ICE SYS CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) DURING RT ENGINE CHANGE, THE LOWER COWL WAS REMOVED AND BOTH ENGINE INTAKE ANTI-ICE FLEX TUBES WERE FOUND CRACKED. BOTH TUBES (P/N 90-910099-13 AND 90-910099-17) WERE CRACKED GREATER THAN 50 PERCENT OF THERE CIRCUMFERENCE. THERE WAS NO EVIDENCE OF ANY EXHAUST LEAK INSIDE THE COWLING. (TUBE P/N 90-910099-13) TSN110-2 HRS. P/N 90-910099-17 WAS 307.1 TSN. BOTH TUBES HAVE BEEN REPLACED. 1L72 3T4 TRT3A20 E4EA 6 CP15EA 20030507000242003050700024CE 2003 5 7 CA030408005 120030312G571205230301 RIB CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA MCAULY1C160 1C160DTM GL LT WING CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 16746 (CAN) ROUTINE INSPECTION FOUND CRACKS IN LEFT NOSE RIB AT STATION 100.00 OF WING. THE RIB WAS CRACKED THROUGH LIGHTENING HOLE TO UPPER BEND RELIEF. RIGHT SIDE AT 100.00 WAS ALSO SHOWING CRACKS FROM RIVET HOLES AND FROM THE BEND RELIEF TOWARD THE LIGHTENING HOLE.BOTH RIBS WERE REPLACED. NO OTHER RIBS AFFECT ED. PLANE BELONGS TO A FLYING SCHOOL WHERE OUT OF THE 7 OPERATED 4 SHOWED SIGNS OF CRACKS ON BOTH OREITHER SIDE.TIME ON AIRCRAFT RANGE FROM 9500 TO 16746.1 HRS. 1H71 3O3 ONT3A12 E274 5 NP910 20030429001852003042900185CE 2003 4 29 CA030408006 120030408G5520115610010125 SPLINE ADAPTER BEECH 100 B100 1152919CE ELEVATOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING ROUTINE MAINTENANCE, ELEVATORS WERE REMOVED FOR SB 2145 ON ELEVATOR TORQUE TUBE. AFTER REVIEWING SERVICE DIFFICULTY ADVISORY AV-2003-01 FOR BEECH A100, WE FOUND SAME CRACKES ON THE RIGHT ELEVATOR ON OUR B100. AFTER DISASSEMBLE AT LOCAL SHEET METAL SHOP WE WERE INFORMED THAT THERE WERE 17 CRACKS AND ONE CRACK WAS COMPLETLY THROUGH THE SPLINE.THE TRANSPORT OFFICE WAS NOTIFIED AND THEY REQUESTED PICTURES. 1L72 4T A14CE 20030507000352003050700035CE 2003 5 7 CA030409004 120030407G534324130023 FITTING CESSNA172 172RG 2072438CE LYC O360 O360F1A6 41514EA MCAULY2D34C B2D34C220 GL FUSELAGE CRACKED I K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING SCHEDULED INSPECTION OF THE AIRCRAFT AND LANDING GEAR IT WAS NOTICED THAT THE FITTING WHICH ACCEPTS THE NOSE GEAR ACTUATOR ASSEMBLY WAS CRACKED. THE TWO CRACKS WERE LOCATED JUST OUTBOARD OF THEACTUATOR MOUNTING BOSSES AND EXTEND BACK FROM THE FORWARD EDGE TO THE FIRST INBOARD FASTENER HOLE.THE AFFECTED PART WAS REMOVED AND REPLACED WITH A NEW PART. 1H71 3O3 O 3A17 E286 5 CP7EA 20030429001862003042900186SO 2003 4 29 CA030409005 220030131G8520643989 CRANKCASE CESSNA210 P210N 2073454CE CONT O520 TSIO520AF 17040SO MCAULYD3A34 D3A34C402 GL ENGINE DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) AT INSPECTION A SMALL AMOUNT OF ALUMINIUM WAS FOUND IN THE OIL FILTER. CYLINDERS WERE REMOVED FROM THE ENGINE TO INVESTIGATE THE SOURCE OF THE FILTER CONTAMINATION. IT WAS FOUND THAT THE NR 2 MAIN BEARING HAD SHIFTED FORWARD AND WAS LOOSE CAUSING WEAR IN THE CRANKCASE NR 2 MAIN BEARING SUPPORT. 1H71 3O3 O 3A21 E8CE 5 CP47GL 20030429001872003042900187SO 2003 4 29 CA030409006 120030407G3220AN721 BOLT PIPER PA18 PA18150 7101828SO LYC O320 O320A2B 41508EA SNSNCH74D 74DM EA TAILWHEEL ASSY SHEARED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) GROUND CREW WAS MOVING THE AIRCRAFT ON RAMP AND RAN TAILWHEEL OF AIRCRAFT OVER SMALL ICE RIDGE IN ORDER TO GAIN ACCESS TO POSITION FOR PARKING. JOLT FROM THE WHEEL JUMPING ICE RIDGE RESULTED IN COLLAPSE OF THE TAILWHEEL ASSEMBLY FROM THE LEAF SPRING ASSEMBLY. INSPECTION REVEALED THAT ATTACHING BOLT HAD SHEARED AND ALLOWED THIS CONDITION TO OCCUR. FURTHER INVESTIGATION BY MAINTENANCE REVEALED THAT THE BOLT HAD LIKELY BEEN PARTIALLY SHEARED FOR SOME TIME AND GONE UNDETECTED HOWEVER, THE BRIEF JOLT FROM THE GROUND HANDLING INCIDENT WAS ENOUGH TO COMPLETELY SEVERE THE BOLT ITSELF. THE ROOT CONDITION IS DUE TO REPEATED LANDINGS IN THE FLIGHT TRAINING ENVIRONMENT WITH THIS AIRCRAFT. BOLT WAS REPLACED. 1H71 3O3 O 1A2 E274 5 NP88614 20030429001882003042900188EU 2003 4 29 CA030409007 120030407G213390231570381 OUTFLOW VALVE AIRBUS320 A320212 3930322EU CFMINTCFM56 CFM565A3 NE CABIN PRESSURE INOPERATIVE W B EMER. DESCENT J WARNING INDICATION CRCRUISE 1 CA (CAN) ON POSITIONING FLIGHT, IN CRUISE AT 37 000, ECAM WARNING CABIN SAFETY VALVE OPEN, FOLLOWED BY CABIN PRESSURE EXCESSIVE, CABIN ALTITUDE . FLIGHT CREW PERFORMED EMERGENCY DECENT AND DIVERTED. ON LANDING, OUTFLOW VALVE HAD TO BE OPENED MANUALLY TO DEPRESSURIZE AIRCRAFT. OUTFLOW VALVE REPLACED AND SYSTEM CHECKED SERVICEABLE. 2L72 4F4 FRTA28NM E29NE 20030507000362003050700036SO 2003 5 7 CA030409008 120030403G29101159P20518 TUBE GULSTMG1159 G1159A 3970109SO RROYCESPEY SPEY5118 54523EU HYD SYSTEM CHAFED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) HUDRAULIC TUBES WERE FOUND TO BE CHAFFED BEYOND LIMITS DURING THE PYLON INTERIOR SCHEDULE INSPECTION. BOTH LEFT & RIGHT TUBES SHOWED DAMAGE IN NEARLY IDENTICAL SPOTS, CAUSED BYCHAFFING ON A ELECTRICALWIRE THAT HAD BEEN CLAMPPED NOT PROPERLY. THE WIRE SHOWED NO SIGNS OF DAMAGE. BOTH TUBES WERE REPLACED. 2L72 4F4 F A12EA E2EU 20030507000372003050700037CE 2003 5 7 CA030409011 120030325G3010 PICCOLO TUBE CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE RT ENGINE CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) A RIGHT ENGINE INLET FOUND CRACKED WHERE INLET INTO PICOLO TUBE FOR LIP HEAT IS MOUNTED. CRACK RADIATES UPWARD ABOUT 4 INCHES. NEW INLET INSTALLED. TEST 1L72 4F4 F A22CE E1NE 20030429001912003042900191SO 2003 4 29 CA030409014 120030408G27106210200 BELLCRANK PIPER PA28 PA28160 7102806SO LYC O320 O320D2A 41508EA SNSNCH74D 74DM EA LT WING CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) FOUND BRACKET CRACKED FOR A LENGTH OF ABOUT 2 CENTIMETERS JUST BELOW FORWARD BOLT HOLE. DEFECT CAN ONLY BE SEEN WITH INSPECTION MIRROR FROM OUTBOARD INSPECTION HOLE. 1L71 3O3 O 2A13 E274 5 NP88614 20030429001922003042900192SO 2003 4 29 CA030409015 120030403G3230 DOWNLOCK PIPER PA23 PA23250 7102308SO LYC O540 IO540C4B5 41532EA HARTZLHCE2Y HCE2YR2 GL MLG STIFF W O OTHER LR NO TEST PARTIAL RPM/PWR LOSS CRCRUISE 1 CA (CAN) ONCE THE PILOT SELECTED LANDING GEAR UP, THE GEAR DID NOT RETRACT. WE DISCOVERED THAT THE DOWN LOCK MECHANISM WAS HARD TO MANEUVER, AFTER LUBRICATION AND CLEANING WE CARRIED OUT GEAR RETRACTION. SYSTEM SERVICEABLE. 1L72 3O3 O 1A10 1E4 5 CP9EA 20030429001972003042900197CE 2003 4 29 CA030410002 120030409G27315052442034 HINGE BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA HARTZLHCB3T HCB3TN3 GL ELEVATOR CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) DURING UNSCHEDULED INSPECTION OF THE TAIL. THE ENGINEER CHECKED FOR PLAY IN THE ELEVATOR HORN BEARINGS P/N MS27645-5. UPON CLOSER EXAMINATION THE ENGINEER NOTICED A CRACK IN THE BEARING HOUSING AREA OF P/N 50-524420-4. AFTER REMOVAL OF THE BEARING FROM THE LT BEARING HOUSING P/N 50-524420-3 CORROSION WAS FOUND. NEW PARTS WERE ORDERED TO CORRECT DEFECT. 1L72 3T4 TRT3A20 E4EA 6 CP15EA 20030429001982003042900198CE 2003 4 29 CA030410003 120030409G30209091009913 TUBE BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA HARTZLHCB3T HCB3TN3 GL ANTI ICE SYS CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) THE COWLINGS WERE REMOVED FROM THE AIRCRAFT FOR SCHEDULED OIL CHANGE. VISUAL INSPECTION CARRIED OUT ON COWLING PRIOR TO REINSTALLATION IDENTIFIED ONE CRACKED COWL ANTI-ICE BLEED AIR TUBE. NEW PARTS WERE INSTALLED. . A FLEET CAMPAIGN INSPECTION IS ONGOING, WITH INSPECTION DUE THE NEXT TIME THE COWL IS REMOVED FOR MAINTENANCE. AVERAGE PART LIFE IS LESS THAN 200 HRS. AFTER INSTALLATION. 1L72 3T4 TRT3A20 E4EA 6 CP15EA 20030507000642003050700064CE 2003 5 7 CA030410005 120030327G554105331531 RIB CESSNA172 172P 2072436CE LYC O320 O320D2J 41508EA RUDDER CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA 13866 (CAN) REPOSITIONED RUBBER AND REPLACED CRACKED RIB. 1H71 3O3 ONT3A12 E274 20030507000662003050700066EU 2003 5 7 CA030410007 120030410G3260973303311 PROXIMITY SWITCH PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL MLG FAILED W A UNSCHED LANDING N FALSE WARNING CLCLIMB 1 CA (CAN) AFTER TAKE-OFF THE CREW HAD AN INTRANSITT LIGHT AND A DOWN LOCK LIGHT ON NOSE GEAR. GEAR WAS FUNCTIONING NORMALLY. FOUND THE NOSE GEAR DOWN LOCK PROX. SWITCH STUCK IN THE LOCK INDICATION POSITION. REPLACED SWITCH, RIGGED, FUNCTION TESTED GEAR THROUGH SEVERAL SWINGS AND NO FURTHER DEFECTS NOTED. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030507000682003050700068EA 2003 5 7 CA030411003 220030410G7421URHB37E SPARK PLUG PIPER PA32 PA32300 7103212SO LYC O540 TIO540* 41532EA HARTZLHCC2Y HCC2YK1 GL ENGINE BROKEN W A UNSCHED LANDING RE PARTIAL RPM/PWR LOSS VIBRATION/BUFFET CLCLIMB 1 CA (CAN) SPARK PLUG SEPARATED IN HALF AND BURNT HOLE IN TOP COWLING. 1L71 3O3 O A3SO E14EA 5 CP920 20030507000902003050700090CE 2003 5 7 CA030414004 120030411G533007133343 SKIN CESSNA182 182S 2072701CE LYC O540 IO540AB1A5 EA MCAULY3D36C B3D36C431 GL FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) FUSELAGE SKIN PANEL UNDER REFUELING STEP NOTED HAVING A BULGE AREA UNDER TOP REAR MOUNTING BOLT AREA. SKIN MOVEMENT ALSO WAS EVIDENT WHEN WEIGHT WAS APPLIED TO THE STEP. DETAIL INSPECTION OF AREA FOUND BOTH THE FUSELAGE SKIN AND BULKHEAD WHERE THE STEP IS MOUNTED HAS MULTIPLE CRACKS. 1H71 3O3 ONT3A13 1E4 5 C 20030507000912003050700091CE 2003 5 7 CA030414005 120030411G5330 SKIN CESSNA182 182S 2072701CE LYC O540 IO540AB1A5 EA MCAULY3D36C B3D36C431 GL FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) FUSELAGE SKIN PANEL UNDER REFUELING STEPS NOTED HAVING A BULGE AREA AROUND MOUNTING BOLT. SKIN MOVEMENT ALSO WAS EVIDENT WHEN WEIGHT WAS APPLIED TO THE STEP. DETAIL INSPECTION OF AREA FOUND BOTH THE FUSELAGE SKIN AND BULKHEAD WHERE THE STEPS ARE MOUNTED HAS MULTIPLE CRACKS. 1H71 3O3 ONT3A13 1E4 5 C 20030530001002003053000100CE 2003 5 30 CA030414006 120030411G531207137879 BULKHEAD CESSNA182 182S 2072701CE LYC O540 IO540AB1A5 EA MCAULY3D36C B3D36C431 GL FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) FUSELAGE SKIN PANEL UNDER REFUELING STEPS NOTED HAVING A BULGE AREA AROUND MOUNTING BOLT. SKIN MOVEMENT ALSO WAS EVIDENT WHEN WEIGHT WAS APPLIED TO THE STEP. DETAIL INSPECTION OF AREA FOUND BOTH THE FUSELAGE SKIN AND BULKHEAD WHERE THE STEP IS MOUNTED HAS MULTIPLE CRACKS. 1H71 3O3 ONT3A13 1E4 5 C 20030530001012003053000101EA 2003 5 30 CA030415002 220030409G73212525098 HOUSING HONEYWELL PWA PT6 PT6* 52043EA FUEL CONTROL DAMAGED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA A7264 (CAN) FACE OF BODY MACHINED DOWN. WALL THICKNESS AS SHOWN IN PICTURE SHOULD BE BETWEEN .0962 FT TO .0862 FT. FOUND AT .0625 FT. BODY NOT IAW OEM DRAWING REQUIREMENTS. REWORK NOT APPROVED BY OEM. MAIN BODY P/N2525098, S/N 106. 3 T E2NE 20030507001072003050700107NE 2003 5 7 CA030416005 120030416G6520SB8208102 SEAL SKRSKYS76 S76 8143010NE T/R GEARBOX LEAKING W O OTHER K FLUID LOSS NRNOT REPORTED 1 CA (CAN) NEW SEALS HAVE BEEN FOUND TO BE LEAKING FROM NEW. THESE ARE A NEW P/N RELEASED BY SIKORSKY AND SEVERAL CUSTOMER COMPLAINTS HAVE BEEN RECEIVED. NEW SEALS FOUND IN THE MAIN GEARBOX HAVE ALSO LEAKED UPON TEST OR SUBSEQUENT FIELD USE. 1G72 3U H1NE 20030507001082003050700108CE 2003 5 7 CA030417001 120030407G3297 CIRCUIT BREAKER BEECH 18 D18S 1151004CE PWA R985 R985AN14B 52008NE MLG FAILED W O OTHER O OTHER LDLANDING 1 CA (CAN) UPON SELECTING THE LANDING GEAR UP THE LANDING GEAR MOTOR WAS UNDER EXCESSIVE STRAIN DUE TO THE LANDING GEAR GUIDE BEING VERY DIRTY AND THE CIRCUIT BREAKER POPPED. THE PILOT SELECTED FREE FALL ASSIST TO LOCK THE GRAR DOWN. CIRCUIT BREAKER WAS REPLACED, IT HAD 494.6 HOURS IN SERVICE. 1L72 3R3 R A765 5E1 20030507001192003050700119NE 2003 5 7 CA030417009 220030416G8520 BEARING DOUG A26 A26BSHIELDS 3020504WP PWA R2800 R280079 52026NE ENGINE FAILED W E ENGINE SHUTDOWN O OTHER CRCRUISE 1 CA (CAN) DURING A LOCAL TRAINING FLIGHT THE RT OIL TEMP WAS NOTICED TO BE ON THE RISE. THE OIL COOLER WAS OPENED HOWEVER THE TEMP CONTINUED TO RISE. A SHORT TIME LATER THE OIL PRESSURE BEGAN TO DROP ACCOMPANIED BY BLACK SMOKE FROM EXHAUST. ENGINE WAS SHUT DOWN AND THE AIRCRAFT MADE A SINGLE ENGINE LANDING AT RED DEER WITHOUT INCIDENT. THE ENGINE APPEARS TO HAVE A MAIN BEARING FAILURE. 2M72 4R4 R L34 5E8 20030530001072003053000107NM 2003 5 30 CA030417011 120030415G2710 PCU BOEING737 7372T5 1384474NM PWA JT8 JT8D17 52049NE AILERON INOPERATIVE W O OTHER K FLUID LOSS NRNOT REPORTED 1 CA (CAN) AFTER PUSHBACK AND START, FLAP 2 SELECTED AND HYDRAULIC SYSTEM A LOW PRESSURE ILLUMINATED AND HYD QTY GUAGE DECREASED TO ZERO. MAINTENANCE FOUND THE A SYSTEM AILERON POWER CONTROL UNIT (PCU) FILTER BOWL HAD FRACTURED RESULTING IN LOSS OF HYD PRESS/FLUID. FURTHER INFO INCLUDING THE UNIT PART NUMBER AND S/N WILL FOLLOW AFTER SHOP REPORT IS RECEIVED. 2L72 4F4 FRTA16WE E2EA 20030507001362003050700136EU 2003 5 7 CA030421001 120030416G3230AE7060322 HOSE AIRBUS310 A310304 3930339EU GE CF6 CF680C2A5 NE HYD SYSTEM RUPTURED W O OTHER K FLUID LOSS APAPPROACH 1 CA (CAN) ON FINAL APPROACH WHEN GEAR SELECTEDDOWNGREEN HYDRAULIC SYSTEM QUANTITY DROPPED TO NEARLY ZERO .DURING INVESTIGATION FOUND THE HYDRAULIC DOWN LINE RUPTURED AT THE UPPER RIGHT HAND MAIN LANDING GEAR SWIVEL AREA. LINE WAS REPLACED AND SYSTEM TESTED SERVICEABLE. A CAMPAIGN HAS BEEN INITIATED TO REPLACE ALL FLEX HYDRAULIC LINES AT THE UPPER MAIN LANDING GEAR TRUNNION AREA AT NEXT A CHECK VISIT ON ALL A-310 AIRCRAFT. ALSO NEW LINES WILL BE A TIME CONTROL ITEM. 2L72 4F4 FRTA35EU E13NE 20030507001372003050700137EA 2003 5 7 CA030421002 220030411G7322 SCREW MARVELSCHEBX CESSNA172 172P 2072436CE LYC O320 O320D2J 41508EA CARBURETOR MISSING W O OTHER Y ENGINE STOPPAGE LDLANDING 1 CA 75104001 (CAN) PILOT FIRST NOTICED PROBLEM WHEN TURNED OFF RUNWAY AFTER LANDING. REPORTED ENGINE WILL NOT CONTINUE TO RUN BELOW 1200 RPM. MAINTENANCE FOUND IDLE MIXTURE SCREW MISSING FROM CARBURETOR. OPERATION OK WHEN PART REPLACED. 1H71 3O3 ONT3A12 E274 20030507001382003050700138CE 2003 5 7 CA030421003 120030421G2750C145350 MOTOR CESSNA208 208B 2073701CE PWA PT6 PT6A114A 52043NE MCAULY3AF34C3GFR34C703 GL FLAP SYSTEM SEPARATED W O OTHER F FLT CONT AFFECTED APAPPROACH 1 CA (CAN) ON APPROACH WHEN FLAPS WERE SELECTED FROM FLAPS 10 TO FLAPS 20 THE PILOT HEARS A LOUD BANG AND FLAPS RAPIDLY RETRACTED BACK TO FLAPS 10. PILOT LANDED THE AIRCRAFT IN THIS CONFIGURATION. MAINTENANCE FOUND THE FLAP TRANSMISSION TO HAVE BROKEN FREE OF THE STRUCTURE. AN INSPECTION WAS CARRIED OUT ON THE FLAPS & FLAP TRACKS FOR ANY ITEM THAT MAY HAVE CAUSED THE FLAPS TO JAM. NO FAULTS WERE FOUND.THE AIRCRAFT IS CURRENTLY OUT OF SERVICE WHILE REPAIRS ARE CARRIED OUT TO THE DAMAGED FLAP TRANSMISSION SURPORT ASSEMBLY. MAINTENANCE HAS BEEN UNABLE TO DETERMINE WHAT CAUSED THIS FAULT. DUE TO PREVIOUS PROBLEMS WITH THE FLAP SYSTEM ON THE C208 CARAVAN MAINTENANCE SUSPECTS A FAILURE OF THE FLAP MOTOR ASSEMBLY. 1H71 3T3 T A37CE E4EA 5 CP60GL 20030507001422003050700142SO 2003 5 7 CA030421007 120030420G27314536700 BEVEL GEAR PIPER PA31T PA31T 7103124SO PWA PT6 PT6A28 EA ELEVATOR TRIM BROKEN W O OTHER F FLT CONT AFFECTED DEDESCENT 1 CA 18055 (CAN) PILOT REPORTED JAMMING ELEVATOR TRIM CONTROL BETWEEN 2 TO 4 DEGREES DOWN POSITION. THE WHEEL WOULD RELEASE IF WORKED BACK AND FORTH. UPON INSPECTION, ONE OF THE BEVEL GEARS INSIDE THE ELEVATOR TRIM INDICATOR BOX WAS FOUND TO HAVE TWO BROKEN TEETH. 1L72 3T4 T A8EA E4EA 20030520000072003052000007EU 2003 5 20 CA030422001 120030414G2897 WIRE CRANEXXXXXXX PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL BOOST PUMP CHAFED W K NONE O OTHER ININSP/MAINT 1 CA B5091B5087 (CAN) AIRCRAFT WAS INSPECTED DUE TO FINDINGS ON PREVIUOS AIRCRAFT IN OUR FLEET. BOTH THE LT AND RT AIRFRAME FUEL BOOST PUMPS WERE FOUND WITH CHAFED WIRES IN THE HARNESS. A VERY CLOSE VISUAL INSPECTION WAS NEEDED TO FIND THE DAMAGE.PILATUS HAS BEEN CONTACTED AGAIN TO STRESS THE IMPORTANCE OF A RECOMENDATION TO REPAIR, EVEN IF ONLY TEMPORARY. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030520000092003052000009EU 2003 5 20 CA030422003 120030415G2432TAS203 HEATER PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL BATTERY BURNED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) A SECTION OF THIS HEATING ELEMENT BURNED OUT SCORCHING THE PAINT ON THE BATTERY. THE BURNED AREA ON THE ELEMENT IS 5MM X 22CM. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030602000342003060200034CE 2003 6 2 CA030423002 120030408G2430S159060L CIRCUIT BREAKER CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA ALTERNATOR FAILED W H DEACTIVATE SYST/CIRCUITS HB ELECT. POWER LOSS-50 PC SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA 11636 (CAN) THE PILOT WAS DOING NIGHT TRAINING LOCALLY WHEN HE NOTICED THE LOW VOLTAGE INDICATOR LIT AND THE AMMETER SHOWING A DISCHARGE. HE FOUND THE ALTERNATOR CIRCUIT BREAKER TRIPPED.THE BREAKER WAS RESET WHICH RESULTED IN SOME SMOKE AND SPARKS FROM UNDER THE PANEL. THE LOW VOLTAGE INDICATOR WAS STILL LIT AND THE AMMETER STILL SHOWING DISCHARGE.THE PILOT SHUT DOWN THE ALTERNATOR SYSTEM AND RETURNED UNEVENTFULLY TO THE AIRPORT. INVESTIGATION REVEALED THE ALTERNATOR CIRCUIT BREAKER FAILED IN THE CLOSED POSITION.CIRCUIT BREAKER REPLACED IN ACCORDANCE WITH CESSNA SERVICE LETTER SE76-15. 1H71 3O3 ONT3A12 E274 20030602000352003060200035NM 2003 6 2 CA030423003 120030416G3242214665 BRAKE ASSY DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE MLG CRACKED W O OTHER K FLUID LOSS ININSP/MAINT 1 CA 24203 (CAN) BRAKE UNIT WAS INSTALLED ON AIRCRAFT FOR 233:40 SINCE ITS LAST OVERHAUL IT WAS REMOVED FROM THE AIRCRAFT ON APR 16/03 DUE TO IT LEAKING, ONCE AT THE SHOP IT WAS STRIPPED AND CLEANED AND SENT FOR NDT WORK. THE TECHNICIAN FOUND THE NR 1 PISTON BOSS CRACKED IN THE BOTTOM OF THE PISTON CYLINDER BORE. OUR OVERHAUL POLICY ON THE BRAKE UNITS ARE ON THE THIRD SHOP VISIT THE CASTING IS SENT FOR NDT TESTING THIS UNIT HAD ONLY 233 HRS SINCE THAT WAS LAST ACCOMPLISHED. BECAUSE OF THE LOCATION AND LENGTH OF THE CRACK IT WAS DECIDED TO SCRAP OUT THE UNIT. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030602000402003060200040CE 2003 6 2 CA030423004 120030320G55110432001646 RIB CESSNA150 150M 2071830CE CONT O200 O200A 17020SO MCAULY1A102 1A102OCM GL HORIZONTAL STAB CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) LEADING EDGE RIB ASSEMBLIES ARE VERY 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.I HAVE INCLUDED TWO PHOTOS. ONE OF THE PHOTOS SHOWS A NEW PART AND WERE THE LOCATION OF THE CRACKS HAVE BEEN(ALONG THE TABS: UPPER AND LOWER).WE BELIEVE THE RIBS ARE CRACKING DUE TO IMPROPER GROUND HANDLING.THE PRACTICE OF PUSHING THE AIRCRAFTS TAIL DOWN BY ITS SPAR IN ORDER TO ROTATE THE AIRCRAFT IN POSITION MAY BE DAMAGING THESE RIBS. BOTH RIBS WERE REPLACED WITH NEW.THE TAIL SURFACES WERE REMOVED AND REINSTALLED. 1H71 3O3 O 3A19 E252 5 NP918 20030602000412003060200041SO 2003 6 2 CA030423005 220030418G8520AEC648029 PISTON BEECH 95 95B55 1152729CE CONT O470 IO470L 17026SO ENGINE BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) RT ENGINE OIL PRESSURE PROBLEMS WERE NOTICED DURING ENGINE RUN-UP. NR 2 CYLINDER PISTON WAS F OUND CRACKED AND THE LOWER SKIRT OF PISTON FOUND IN OIL PAN. CYLINDERS WERE REMOVED & ENGINE INSPECTED. REMOVAL OF CYLINDERS & PISTONS REVEALED OTHER CRACKED PISTON SKIRTS THAT HAD NOT YET FAILED. WE SUSPECT THAT THIS IS A BAD BATCH OF PISTONS AND ANY ECI CYLINDERS AND PISTONS ARE BEING REPLACED. THE AIRCRAFT IS STILL UNDERGOING MAINTENANCE TO INVESTIGATE THE PROBLEM WITH THESE CYLINDERS AND PISTONS. 1L72 3O3 ORT3A16 3E1 20030602000542003060200054 2003 6 2 CA030423007 420030417G256205118204 LANYARD CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA ELT CHAFED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING A ROUTINE INSPECTION IT WAS NOTICED THAT THE LANYARD CABLE WHICH LINKS THE ELT SUPPORT BRACKET TO THE ELT ANTENNA SUPPORT BRACKET HAS ENOUGH SLACK IN ITS LENGTH THAT IT RUBS AGAINST THE FUSELAGE (EMPENNAGE) SKIN. THE LANYARD APPEARS TO BE STEEL, AND THE SKIN HAS A SMALL WERE MARK ON THE INSIDE AREA MIDWAY BETWEEN THE ELT AND ANTENNA. (MONOCOQUE SKIN)WE INSTALLED A PIECE OF SPIRAL WRAP AROUND THE LANYARD BECAUSE WE COULD NOT REPOSITION NOR CHANGE THE LENGTH. THE LANYARD STILL RUBS UP AGAINST THE SKIN BUT IS NO LONGER WEARING A HOLE IN THE SKIN. 1H71 3O3 ONT3A12 1E10 20030602000662003060200066EA 2003 6 2 CA030424005 220030414G7414ES1068255511 MAGNETO CESSNA177 177B 2073708CE LYC O360 O360A1F6 41514EA MCAULY2D34C B2D34C208 GL MAGNETO MISOVERHAULED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) MAGNETO FAILED ON LT PORTION (DUAL MAG) ON RUN UP. MAGNETO WAS REMOVED AND EXAMINED, BUT NO OBVIOUS DAMAGE OR FAILURE WAS EVIDENT. AS THE PART ONLY HAD 72.5 HOURS SINCE ENGINE WAS OVERHAULED. REPAIRED THE MAGNETO. WHEN I RECEIVED THE MAGNETO BACK AFTER REPAIR, I BENCH TESTED IT AND DISCOVERED THAT THE SPARK WAS WEAK AND NOT OCCURRING AT THE PROPER TIME. UPON FURTHER INVESTIGATION I DISCOVERED THAT THE MAGNETO ROTOR WAS NOT TIMED CORRECTLY TO THE DISTRIBUTOR GEARS. I RETIMED THE MAGNETO ROTOR TO THE DISTRIBUTOR GEARS, RETESTED ON THE BENCH AND NOW THE MAGNETO FUNCTIONS PROPERLY. 1H71 3O3 O A13CE E286 5 CP7EA 20030702001032003070200103CE 2003 7 2 CA030424007 120030328G2140H11D59 NOZZLE JANITROL BEECH 90 B90 1152912CE PWA PT6 PT6A20 52043EA HARTZLHCB3T HCB3TN3 GL HEATER LEAKING W D RETURN TO BLOCK B SMOKE/FUMES/ODORS/SPARKS TXTAXI/GRND HDL 1 CA (CAN) HEATER UNSERVICEABLE, LEAK FOUND ON HEAD ASSY. PARTS INSTALLED, NOZZEL, GASKETS, ELEC GROUND, ELEC WASHERS, GASKET HEAD, IGN, IGN UNIT, VALVE, BRUSH KIT, FILTER, VENT BLOWER MOTOR O/H. HEATER, SMOKY BLACK, PARTS INSTALLED, REG VALVE, VALVE, IGN, EXHAUST BLK SMOKE, REMOVED HEATER FOR LEAK CHECK, NO LEAK ON COMBUSTION TUBE, REMOVE HEAD ON TUBE FOR INSP, FUEL NOZZLE, INSP FOR SPRAY PATTERN, NOZZLE INSTALLED. 1 GALLON, REINSTALL NOZZLE, 1 GALLON. HEATER REINSTALLED IN A/C, HEATER TEST, WORKING NORMALLY. 1L72 3T3 T 3A20 E4EA 6 CP15EA 20030702001042003070200104GL 2003 7 2 CA030425004 220030425G723023004538 BEARING ALLSN 250C 250C* GL ENGINE DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) NUT FOR NR 1 BEARING HAVE, ON SEVERAL OCCASIONS, BEEN RECEIVED NEW WITH DAMAGED BLACK NYLON (ZYTEL) MATERIAL AT TOP OF NUT. THERE IS THE POTENTIAL FOR LEAKS THROUGH THIS MATERIAL. THREE RECENT SHIPMENTS (TOTALLING OVER 100 NUTS) HAVE BEEN FOUND WITH DAMAGE TO THIS SEALING MATERIAL. 3 U E4CE 20030609001632003060900163CE 2003 6 9 CA030425005 120030306G7797501A RESISTOR BEECH 200 B200 1152922CE PWA PT6 PT6A42 52043NE INDICATOR LOOSE W D RETURN TO BLOCK O OTHER TXTAXI/GRND HDL 1 CA 1259812598 (CAN) CREW REPORTED TOTAL LOSS OF ENGINE TEMPERATURE INDICATION DURING TAXI OPERATIONS. ALL TROUBLESHOOTING PROCEDURES WERE FOLLOWED IN THE ENGINE AND AIRFRAME MANUFACTURER'S MAINTENANCE MANUALS. AIRFRAME WIRING HARNESS WAS CONNECTED TO MULTIMETER FOR TESTS. OPEN CIRCUIT WAS NOTED TO EXIST THROUGH THE BALANCE RESISTOR. INTERNAL INSPECTION OF THE RESISTOR REVEALED A LOOSE, SOLDERED CONNECTION. SYSTEM TESTED WITHIN LIMITS. ENGINE RUNS CARRIED OUT AND SYSTEM OPERATED NORMALLY. 1L72 4T4 T A24CE E4EA 20030609001642003060900164CE 2003 6 9 CA030425006 120030414G2434DOFF10300J ALTERNATOR CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA ENGINE FAILED W O OTHER H ELECT. POWER LOSS-50 PC CRCRUISE 1 CA (CAN) WHILE AIRCRAFT WAS RETURNING TO AIRPORT, THE PILOT NOTICED AN ELECTRICAL FAILURE, AND RADIO QUIT. CONTINUED APPROACH AND LANDING. 1H71 3O3 ONT3A12 E274 20030609001652003060900165NM 2003 6 9 CA030425010 120030331G2897NA WIRE BOEING737 73776N 13844CHNM CFMINTCFM567CFM567B22 13802NE FUEL BOOST PUMP BURNED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) MAINTENANCE FOUND NR 2 MAIN AFT FUEL LOW PRESSURE LIGHT ILLUMINATED DURING OVERNIGHT MAINTENANCE. SYSTEM INSPECTED, RELATED CIRCUIT BREAKER FOUND POPPED. AIRCRAFT RELEASED UNDER MEL 28-1-1. MAINTENANCE REPLACED NR 2 AFT FUEL BOOST PUMP - SYSTEM DID NOT FUNCTION CHECK SERVICEABLE. FURTHER INVESTIGATION FOUND A BROKEN AND BURNED WIRE IN THE THREE WIRE BUNDLES GOING TO CONNECTOR D74 FROM THE AFT BOOST PUMP. THE REPORTED PROBLEM IS ADDRESSED BY SERVICE BULLETIN 737-28A1188 RELEASED MAR. 06/03. WESTJET COMPLETED SB FEB.27/03. MAINT REPAIRED WIRING, PLUG D74 WIRE IAW MM 20-10-11. SYSTEM GROUND CHECKED SERVICEABLE & RETURNED TO SERVICE WITH NO FURTHER INCIDENTS TO REPORT. 2L72 4F4 FRTA16WE E00055EN 20030703000342003070300034EA 2003 7 3 CA030426001 120030419G2133 OUTFLOW VALVE CNDAIRCL600 CL6002D24 EA GE CF34 CF343B1 NE CABIN PRESSURE MALFUNCTIONED W B EMER. DESCENT J WARNING INDICATION CRCRUISE 1 CA (CAN) AIRCRAFT HAS RECEIVED A REPORT WHICH WE FEEL IS A REPORTABLE EVENT. THE CABIN ALTITUDE STARTED TO FLUCTUATE ERRACTICALLY AND BEGAN CLIMBING UNCONTROLLABLY. THE O2 MASK DROPPED AND COMMENCED EMERGENCY DESCENT TO MINIMUM SAFE ALTITUDE. THE LANDING WAS UNEVENTFUL AND ALL PASSENGERS WERE DEPLANED AT THE GATE WITHOUT FURTHER EVENT. 2L72 4F4 FRTA21EA E15NE 20030609001662003060900166CE 2003 6 9 CA030427001 120030426G251005142132 LOCK CESSNA182 182S 2072701CE LYC O540 IO540AB1A5 EA MCAULY3D36C B3D36C431 GL SEAT CYLINDER COLLAPSED W O OTHER O OTHER DEDESCENT 1 CA (CAN) PILOT WAS PRACTICING A FORCED LANDING AND WAS ON FINAL APPROACH WITH FULL FLAPS, NO POWER AND A LOT OF TRIM TO PRODUCE A 70KT GLIDE. AS FULL THROTTLE WAS APPLIED AND ABORTED LANDING AT 500 FT, THERECLINABLE SEAT BACK COLLAPSED. THE PILOT MANAGED TO USE THE ELECTRIC TRIM TO BACK OFF THE TRIM AND REGAIN CONTROL. THE SEAT BACK WAS RECLINED BACK TO THE UPRIGHT POSITION FOR AN UNEVENTFUL LANDING.THE PROBLEM COULD NOT BE REPEATED ON THE GROUND, INSPECTION COULD NOT REVEAL ANY OBVIOUS SIGN FOR THE CAUSE OF THE FAILURE. THE SEAT RECLINE CYLINDER LOCK ASSY WAS REPLACED AS A PRECAUTION. 1H71 3O3 ONT3A13 1E4 5 C 20030609001672003060900167CE 2003 6 9 CA030428004 120030428G2160NYLC9871 ACTUATOR BEECH 100 B100 1152919CE BLEED SYSTEM FAILED W O OTHER O OTHER CRCRUISE 1 CA (CAN) CREW WAS UNABLE TO COOL THE CABIN TEMPERATURE DURING THE FLIGHT. BOTH THE AUTO AND MANUAL MODE SYSTEM WAS USED WITHOUT SUCCESS. FOUND THE LT BLEED AIR BYPASS VALVE/ACTUATOR STUCK IN THE FULL HOT POSITION.UNIT REPLACED WITH AN OVERHAULED UNIT AND SYSTEM TESTED OK. 1L72 4T A14CE 20030609001682003060900168 2003 6 9 CA030428005 420030428G34189754421421 SWITCH PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL AOA FAILED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) ROUGH & STICKING OPERATION OF THE VANE WAS NOTED. ASSY REPLACED WITH NEW, FUNCTION TESTS SATISFACTORY. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030609001692003060900169CE 2003 6 9 CA030428006 120030428G2612 FIRE LOOP BEECH 100 B100 1152919CE RT ENGINE MALFUNCTIONED W FA ACTIVATE FIRE EXT. UNSCHED LANDING N FALSE WARNING CLCLIMB 1 CA (CAN) DURING CLIMB AFTER TAKE OFF, THE RT FIRE WARNING LIGHT CAME ON, THE PILOT CONDUCTED AN ENGINE SHUT DOWN AND USED THE FIRE BOTTLE AND RETURN TO THE MAIN BASE AS PER FLIGHT MANUAL CHECKLIST . UPON INVESTIGATION, NO FIRE WAS FOUND, ALL THREE FIRE SENSORS DETECTORS WERE INSPECTED, WIRING INSPECTED AND NO FAULTS WERE FOUND. THE FIRE BOTTLE WAS RESERVICED AND REINSTALLED AND SYSTEM WAS TESTED PER THE MAINTENANCE MANUAL, OK. THE FIRE WARNING WAS CAUSED BY THE EARLY MORNING SUN LIGHT WHICH SHINED INTO COWL OPENINGS CAUSING A FALSE WARNING. 1L72 4T A14CE 20030609001702003060900170CE 2003 6 9 CA030429001 120030429G2612302158 FIRE DETECTOR BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA ENGINE MALFUNCTIONED W A UNSCHED LANDING N FALSE WARNING CLCLIMB 1 CA (CAN) WHILE CLIMBING THROUGH 1500 FT, LT ENGINE FIRE WARNING LIGHT ILLUMINATED INTERMITTENTLY WITH NO APPARENT SIGNS OF FIRE, HEAT OR CHANGE IN ENGINE PARAMETERS. THE AIRCRAFT RETURNED TO BASE FOR LANDING AND THE LIGHT EXTINGUISHED AND STAYED OUT ON FINAL APPROACH. INSPECTION OF FIRE DETECTION SYSTEM BY MAINTENANCE DETERMINED THAT THE LIGHT WAS SET OFF BY THE PRESENCE OF MOISTURE IN THE FIRE DETECTOR WIRING CONNECTOR. THE MOISTURE WAS EXPELLED AND THE SYSTEM TESTED SERVICEABLE. 1L72 4T4 T A24CE E4EA 20030611000522003061100052EU 2003 6 11 CA030429002 120030331G6230350A37118322 BEARING SNIAS 350 AS350BA 8680817EU TMECA ARRIELARRIEL1B 6OO30NE M/R SHAFT BROKEN W K NONE O OTHER ININSP/MAINT 1 CA M1004 (CAN) COMPONENT REMOVED FOR METAL CONTAMINATION. DURING DISASSEMBLY FOR INVESTIGATION BEARING LOCK FOUND BROKEN INTO MULTIPLE FRAGMENTS. THIS CAUSED EXTENSIVE DAMAGE TO EPICYCLIC AND REDUCTION GEARBOX ASSEMBLIES. POSSSIBLE CAUSE IS INCORRECT BEARING PRELOAD DURING ASSEMBLY. 1G71 3U3 UNCH9EU E19EU 20030611000532003061100053SO 2003 6 11 CA030430004 220030430G8530625859CP CYLINDER BEECH 35 M35 1151526CE CONT O470 IO470C 17026SO MCAULY2A36C 2A36C23 GL ENGINE CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) NR 4 CYLINDER, ON INVESTIGATION DURING LEAK, DOWN TEST NOTED LOW COMPRESSION AND LEAKAGE IN EXHAUST PORT. CYLINDER REMOVED AND CRACK FOUND IN EXHAUST PORT. THIS ENGINE TYPE NOTED FOR HIGH CYLINDER FAILURE RATE. CYLINDER SCRAPPED. 1L71 3O3 O 3A15 E273 5 CP880 20030611000542003061100054CE 2003 6 11 CA030430005 120030430G3020S123017 WIRE CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA CARB HEAT CONTROBROKEN W O OTHER E VIBRATION/BUFFET DEDESCENT 1 CA (CAN) CARB HEAT CONTROL WIRE BROKE AT PIVOT BOLT AT AIRBOX ARM. NO VISIBLE DAMAGE, BOLT MAY HAVE BEEN OVERTIGHT AND NICKED WIRE. NO WEAR ON CONTROL OTHERWISE, CABLE WIRE AND SHEATH ADJUSTED AND WIRE REATTACHED (EXTRA LENGTH AVAILABLE FOR ADJUSTMENT). AIRCRAFT RETURNED TO SERVICE.FAILURE POSSIBLY DUE TO ROUGH OPERATION BY STUDENT. 1H71 3O3 ONT3A12 E274 20030609001712003060900171CE 2003 6 9 CA030430007 120030430G3221NAS755006 BUSHING CESSNA208 208B 2073701CE PWA PT6 PT6A114A 52043NE MCAULY3AF34C3GFR34C703 GL NLG MISSING W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) DURING THE COURSE OF COMPLIANCE WITH A ROUTINE PHASE 6 INSPECTION ON THE NLG OF THIS (A SHORT-TERM LEASE) AIRCRAFT, MAINTENANCE FOUND NLG BEARING BLOCK WAS MISSING THE TWO BUSHINGS THAT GUIDE AND SUPPORT NLG DRAG BRACE FORK ATTACHMENT BOLTS. THESE BOLTS WERE OVERTORQUED, DAMAGING FORK BEARINGS, CLIPS AND GOUGING OUT THE BEARING BLOCK BUSHING BORES. ON REPLACEMENT OF THE BEARING BLOCK, BOLT WAS FOUND TO BE CRACKED IN TWO PLACES. THE POSSIBILITY EXISTS OF PUSHING FORK BEARINGS THRU THE FORK AND INTO THE BEARING BLOCK BUSHING BORES THUS RENDERING THE FORK UNSTABLE WHICH COULD SEPARATE FROM THE BEARING BLOCK UNDER LOAD, AND CAUSE A NOSE GEAR COLLAPSE. 1H71 3T3 T A37CE E4EA 5 CP60GL 20030609001742003060900174CE 2003 6 9 CA030501001 120030501G3230MC815AS1 CONTROLLER BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA MLG STUCK W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) FOLLOWING A NORMAL TAKE-OFF, GEAR WAS SELECTED UP AT WHICH TIME THE FLT CREW HEARD A LOUD GRINDING NOISE DURING THE FINAL PHASE OF GEAR UP CYCLE. GEAR WAS RESELECTED DOWN AND THERE WAS NO MOVEMENT OR MOTOR NOISES. FLT CREW COMPLETED A MANUAL GEAR EXTENSION, THREE GREEN LIGHTS OBSERVED. ANUNEVENTFUL LANDING WAS COMPLETED. FURTHER INVESTIGATION BY MAINTENANCE FOUND THAT LANDING GEAR MOTOR CONTROLLER HAD FAILED IN GEAR UP POSITION, NOT STOPPING WHEN THE GEAR WAS UP, ONLY STOPPING WHEN THE MOTOR COULD NOT LONGER MOVE THE GEAR AND POPPED ITS CIRCUIT BREAKER. MAINTENANCE REPLACEDTHE CONTROLLER AND COMPLETED GEAR SWINGS ALL SWINGS WERE NORMAL. 1L72 4T4 T A24CE E4EA 20030609001772003060900177NM 2003 6 9 CA030501004 120030428G291082950010269 LINE DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE HYD SYSTEM LEAKING W O OTHER K FLUID LOSS NRNOT REPORTED 1 CA (CAN) CREW REPORTED A FLUID LEAK FROM THE RT WING INBOARD SPOILER PCU. MAINTENANCE FOUND LIFT DUMP HYDRAULIC LINE FROM RT WING SPOILER ACTUATOR LEAKING FROM A PIN HOLE AT THE MAIN ELBOW ON THE OUTBOARD PART OF THE LINE. AFTT: 32777 HRS CYCLES: 36996 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030520001592003052000159NM 2003 5 20 CA030505002 120030504G5610NP1653114 WINDOW AIRBUSA319 A319114 3930350NM CFMINTCFM56 CFM565A3 NE COCKPIT CRACKED W A UNSCHED LANDING O OTHER CRCRUISE 1 CA (CAN) AT FL 370 FO,S FRONT WIND SCREEN OUTER PANE SUDDENLY CRACKED. SPIDER WEB PATTERN WITH MULTITUDE FRACTURES.DECENDED TO FL 230. DELTA P AT 5.0. DIVERTED TO DUE FUEL. REPLACED FO,S WINDSHIELD AND WINDOW HEAT CONTROLLER AS PER AMM 56-11-11. WINDOW OPERATION CHECKED SERVICEABLE. 2L72 4F4 FRTA28NM E29NE 20030520001602003052000160NM 2003 5 20 CA030505003 120030503G561065C343482 WINDOW BOEING737 7372T7 1384482NM PWA JT8 JT8D17 52049NE COCKPIT CRACKED W O OTHER O OTHER CRCRUISE 1 CA (CAN) F/O,S NR 1 WINDOW OUTER (POSS MIDDLE) PANE CRACKED AT 31000 WINDOW SLOWLY DELAMINATED AND AFTER WE TURNED HEAT OFF WINDOW CRACKED. WINDOW REPALCED AS PER AMM. 2L72 4F4 FRTA16WE E2EA 20030520001622003052000162SO 2003 5 20 CA030505005 120030501G273041734078 CONTROL CABLE PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL ELEVATOR BROKEN W O OTHER F FLT CONT AFFECTED TXTAXI/GRND HDL 1 CA (CAN) AFT ELEVATOR TRIM CABLE LOCATED AT AUTOPILOT SERVO SNAPPED. 1L72 3O3 O A20SO E14EA 5 CP33EA 20030507000012003050700001CE 2003 5 7 CA030505006 120030505G53301211650 SKIN CESSNA206 U206G 2073356CE CONT O520 IO520F 17032SO MCAULYD3A34 D3A34C404 GL FUSELAGE CORRODED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) THE AIRCRAFT HAS A BLACK MATERIAL BONDED TO THE AIRCRAFT BELLY SKIN INTERIOR TO PREVENT OIL CANNING.SEVERE CORROSION WAS FOUND BETWEEN THE BONDED MATERIAL AND THE SKIN. IN SOME AREAS THE CORROSION EXTENDED TO A DEPTH EQUAL TO HALF OF THE SKINS .032 THICKNESS. THE SKIN WAS REPLACED. OTHER SKIN AREAS ALSO REQUIRED REMOVAL OF THE BLACK MATERIAL AND REMOVAL OF SURFACE CORROSION CARRIED OUT. A REVIEW OF THE AIRCRAFT IPC COULD NOT FIND THIS ITEM. THIS UNKNOWN BLACK MATERIAL WAS CHECKED WITH A MULTI-METER AND FOUND TO BE CONDUCTIVE SUGGESTING THAT WITH THE PRESENCE OF MOISTURE ELECTROLYTIC CORROSION COULD RESULT. 1H71 3O3 O A4CE E5CE 5 CP47GL 20030602000242003060200024CE 2003 6 2 CA030506001 120030428G323250450014 ACTUATOR CESSNA310 310L 2074230CE CONT O470 IO470VO 17026SO HARTZLHCJ3Y PHCJ3YF2 GL MLG DOOR CRACKED W O OTHER J WARNING INDICATION APAPPROACH 1 CA (CAN) AT 160 KTS DID NOT GET DOWN LOCKED IND ON RT MAIN. GEAR WAS SEL UP, TOP OF TRAVEL, GRINDING NOISE WAS HEARD. GEAR SELECT WAS PLACED IN NEUTRAL, GEAR WAS HAND-CRANKED DOWN, A/C LANDED. RT MAIN GEAR DOOR WAS OPEN ABOUT 6 IN FROM NORMAL CLOSED GEAR DOWN POSITION. WELD HOLDING GEAR DOOR ATTACH ARM TO MAIN GEAR DOOR ACT ASSY SHAFT WAS BROKEN ALLOWING ARM TO SLIP ON SHAFT. DURING GEAR UP SEL, DETERMINED THAT TIRE STRUCK, RE-LOCATED ARM AND MOTOR, NOT HAVING ANY IND TO SHUT OFF AS LIMIT SWITCHES ARE LOCATED ON GEAR ACT, KEPT GOING CAUSING DAMAGE TO OUTPUT GEAR, GEARBOX GEAR. EXCESSIVE WIND FORCE WAS APPLIED TO DOOR, BREAKING WELD. LT MAIN GEAR DOOR ACT ARM HAS BEEN REMOVED FOR NDT. 1L72 3O3 O 3A10 3E1 5 CP36EA 20030530001062003053000106CE 2003 5 30 CA030506002 120030429G8011MZ2399S ARMATURE PRESTOLITE CESSNA172 172N 2072434CE LYC O360 O360A4A 41514EA SNSNCH76E 76EM8S5 EA STARTER BROKEN W O OTHER O OTHER NRNOT REPORTED 1 CA 2K000682 (CAN) UPON INITIAL START OF DAY, STARTER MADE GRINDING NOISE.UPON REMOVAL AND DISASSEMBLY OF STARTER. IT WAS VISUALLY EVIDENT THE GEAR ON THE ARMATURE WAS MISSING 4 TEETH AND THE GEAR AT THE BASE OF THE BENDI X WAS MISSING ONE TOOTH. THE FLYWHEEL WAS INSPECTED SERVICEABLE, THE STARTER WAS REPLACED WITH AN OVERHAUL UNIT AND THE ENG WAS GROUND RUN SATISFACTORY. 1H71 3O3 ONT3A12 E286 5 NP4EA 20030707000112003070700011EA 2003 7 7 CA030506004 120030413G24202CM70D6A GENERATOR CNDAIRCL215 CL2151A10 1900320EA ELECTRICAL FAILED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) TWO GENERATORS HAD 8130 FORMS STATING THAT GENERATORS HAD BEEN OVERHAULED AND TESTED. AFTER A GROUND GENERATOR FIRE DURING INITIAL RUNUP ON THE FIRST UNIT, THE SECOND GENERATOR THAT HAD BEEN INSTALLED ON ANOTHER AIRCRAFT BUT NOT RUN YET WAS REMOVED FOR INVESTIGATION. COMPANY OVERHAUL SHOP INSPECTED THE INTERNAL PARTS OF THE REMAINING GENERATOR AND FOUND EVERYTHING CLEAN EXCEPT THAT THE BRUSHES WERE BRAND NEW AND HAD NOT BEEN RUN IN AT ALL. UPON 5 MINUTES OF TESTING WITH A CURRENT ON TO WEARING THE BRUSHES, THE GENERATOR STARTED MAKING STRANGE NOISES AND BEGAN SMOKING. TEST WAS HALTED. GENERATORS SENT BACK TO SUPPLIER FOR INVESTIGATION AND CREDIT. 2H72 4R RTA14EA 20030822000952003082200095EA 2003 8 22 CA030506005 120030201G32131606042 TRUNNION CNDAIRCL215 CL2151A10 1900320EA MLG WORN W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) THE REAR TRUNNION WAS TO BE OVERHAULED BY COMPANY. COMPANY O/H SHOP AME RECOGNIZED THAT THE CURRENT PLATING PROCESS ON THE PART WAS INCORRECT (COPPER). THE PART WAS SENT TO PLATING COMPANY FOR NICKEL/CHROME PLATING. STRIPPING OF PART REVEAL ED EXCESSIVE ETCHING, PITTING, AND A PREVIOUS UNAPPROVED WELD REPAIR. PLATING COMPANY CALLED US FOR INSTRUCTIONS. WE ADVISED THEM TO RETURN THE PART. STORES ANDTHE OVERHAUL SHOP NOTIFIED TO DESTROY PART TO MAKE IT UNUSABLE ONCE RETURNED. 2H72 4R RTA14EA 20030707000132003070700013CE 2003 7 7 CA030506006 120030314G2797 WIRE BEECH 95 95 1153402CE TE FLAP MOTOR FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE AME INSTALLED THE COMPONENT (OVERHAULED JAN/02) DURING 2002-2003 WINTER MAINTENANCE. A FUNCTION CHECK OF THE UNIT REVEALED INTERMITTENT INDICATIONS. REMOVAL OF THE UNIT REVEALED THAT THERE WAS A BROKEN WIRE INTERNALLY. A PREVIOUSLY UNDISCOVERED CRACK IN THE GEARBOX HOUSING WAS ALSO DETECTED. THIS UNIT HAD 0 TSO. COMPANY NOTIFIED OF POOR WORKMANSHIP. 1L72 3O 3A16 20030530001102003053000110EU 2003 5 30 CA030507003 120030110G3150 DISPLAY PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL COCKPIT MALFUNCTIONED W H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 CA 6313 (CAN) THE CREW REPORTED ON ROUTE THAT THE DE-ICE FAIL LIGHT WAS ON BUT ALL SYSTEMS WERE WORKING PROPERLY. UPON LANDING THE LIGHT REMAINED ON WITH ALL SYSTEMS OFF , ONLY THE BATTERY TURNED ON. THE BATTERYWAS CYCLED OFF THEN ON TO ATTEMPT TO CLEAR THE SNAG.AFTER ABOUT 2 MINUTES OF BATTERY POWER ON, SMOKE AND ELECTRICAL BURNING SMELL APPEARED. THE BATTERY POWER WAS TURNED OFF AND THE BURNING DISSIPATED. MAINTENANCE FOUND THE CAWS PANEL AND CAWS COMPUTER COOKED, REPLACED BOTH UNITS AND NO FURTHER PROBLEMS ENCOUNTERED. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030530001132003053000113CE 2003 5 30 CA030507007 120030402G2720505243263 PEDAL BEECH 95 95B55 1152729CE CONT O470 IO470L 17026SO RUDDER BROKEN W K NONE O OTHER ININSP/MAINT 1 CA 10509 (CAN) DURING AN OPERATIONAL CHECK OF CONTROLS DURING MAINTENANCE, LT RUDDER PEDAL FRACTURED AT ITS ATTACHMENT POINT FROM WEAR. OBLONG WEAR WAS NOTED IN ATTACHMENT AREA. WEAR WAS NOT READILY NOTICED DUE TO ATTACHEMENT DESIGN AND ATTACHMENT TO BRAKE MASTER CYLINDER. REMOVAL OF ATTACHING HARDWARE OF PEDAL NEEDED TO CHECK FOR WEAR. OTHER COMPANY B55 AIRCRAFT CHECKED FOR WEAR AND FOUND WORN. PARTS REPLACED AS NECCESSARY. 1L72 3O3 ORT3A16 3E1 20030530001142003053000114EU 2003 5 30 CA030508001 120030507G2897 WIRE PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL BOOST PUMP CHAFED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DUE TO PREVIOUS FIND OF FUEL BOOST PUMP WITH A CHAFED WIRING HARNESS, THE BOOST PUMPS WERE REMOVED FOR PRECAUTIONARY INSPECTION. CHAFED WIRES ON HARNESS WERE FOUND ON THERIGHT SIDE PUMP. LT PUMP WAS OLD STYLE PUMP STILL INSTALLED WITH HARNESS COMING OUT THE TOP OF THE PUMP. PUMP HAD 1 848.4 HOURS PUMP WAS REPLACED AND AIRCRAFT RETURNED TO SERVICE 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030530001162003053000116CE 2003 5 30 CA030508003 120030506G32339981005765 ACTUATOR BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA MLG DAMAGED W O OTHER O OTHER CLCLIMB 1 CA (CAN) ACTUATOR WAS INSTALLED AFTER HAVING OTHER GEAR PROBLEMS. WHEN GEAR WAS SELECTED UP INFLIGHT THE GEAR MOVED 1/4 OF THE WAY BEFORE THE CLUTCH IN THE GEARBOX BEGAN SLIPPING & CONTINUED TO SLIP UNTIL CIRCUIT BREAKER POPPED. FIRST TIME THIS HAPPENED SUSPECTED MOTOR & CIRCUIT BREAKER BECAUSE WE DID NOT KNOW THAT THE CLUTCH WAS SLIPPING, AFTER REPLACING THE MOTOR & CB, GEAR REPEATED SAME PROBLEM. ON 2ND ATTEMPT, NOTED GEARBOX CLUTCH WAS SLIPPING DURING RETRACTION IN FLIGHT. DECIDED TO REPLACE GEARBOX. WITH GEARBOX DISCONNECTED IT WAS NOTED THAT RT GEAR ACTUATOR WAS HARDER TO TURN THAN NORMAL IT ALSO HAD A DRY SOUNDING BACKLASH NOISE COMING FROM INPUT GEAR WHEN TORQUE TUBE IS ROCKED BACK AND FORTH. 1L72 4T4 T A24CE E4EA 20030530001172003053000117EA 2003 5 30 CA030508004 220030508G7414M3100 RIVET SLICK ZLIN 242 Z242L 9970204EU LYC O360 AEIO360A1B6 41514EA IMPULSE COUPLINGLOOSE W K NONE O OTHER ININSP/MAINT 1 CA 98040711 (CAN) DUE TO OTHER IMPULSE COUPLING FAILURES, AT EVERY 100 HR INSPECTION, THE LT MAGNETO IS REMOVED AND THE IMPULSE COUPLING IS INSPECTED. THIS IMPULSE COUPLING HAD A LOOSE RIVET THAT HOLDS ONE OF THE PAWLS IN PLACE. HAD THE RIVET FAILED THE PAWL WOULD CONTAMINATE THE ENGINE WITH METAL. THE 100 HR INSPECTION INTERVAL WILL CONTINUE ON THE LT MAGNETO. 1L71 3O3 O0 A76EU 1E10 20030530001182003053000118EU 2003 5 30 CA030509001 120030508G29119738114306 ACCUMULATOR PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL HYD SYSTEM LEAKING W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) DISCOVERED FAULT WAS WITH MLG HYD SYS PRESSURE SWITCH. REPLACED DUE TO LEAK FROM ACCUMULATOR SIDE OF HYD SYS THROUGH A VENT HOLE IN SIDE OF BODY OF SWITCH. THIS DEPLETES NITROGEN IN ACCUMULATOR, WITH LESS AIR IN ACCUMULATOR, LANDING GEAR HYDR SYS MOTOR/PUMP WOULD RUN CONSTANTLY. PRESSURE SWITCH CONTROLS RELAY THAT CONTROLS HYD MOTOR/PUMP OPERATION. RELAY'S OTHER CONTACTS CONTROL HYD INTERLOCK RELAY TO PREVENT OPERATION OF VAPOR CYCLE COOLING SYS & LANDING GEAR HYDR SYS FROM OPERATING AT SAME TIME. NO INDICTION OF ANY DEFECT WITH LANDING GEAR SYS ,NO WARNING LIGHTS IN COCKPIT. UPON REPLACEMENT OF PRESSURE SWITCH AND LANDING GEAR HYD SYS RESERVICING ALL SYSTEMS OPERATED NORMALLY. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030617000442003061700044GL 2003 6 17 CA030509002 220030423G721023059576 SHIM ALLSN 23035179 ALLSN 250C 250C30 03013GL GEARBOX MISSING W K NONE O OTHER ININSP/MAINT 1 CA CAG90752 (CAN) A GEARBOX WAS DISASSEMBLED FOR INSPECTION DUE TO REPORT OF LOW OIL PRESSURE. 4 OF 8 SMALL SCREWS USED TO RETAIN A REPAIR SHIM WERE FOUND MISSING. THE REPAIR SHIM WAS LOCATED UNDER THE TORQUEMETER AND JOURNAL FLANGED SUPPORT. REPAIR SHIM WAS LIKELY USED FOR DIMENSIONAL RESTORATION OF THE TORQUEMETER SUPPORT PAD FEATURE OF THE GEARBOX COVER. 3 OF THE MISSING SCREWS AND A WASHER WERE LATER FOUND TRAPPED IN THE SCREEN OF THE SCAVENGE OIL TRANSFER TUBE AND SCREEN ASSY, WHICH IS LOCATED JUST UPSTREAM OF THE SCAVENGE OIL INLET OF THE OIL PUMP.THE FOURTH MISSING SCREWWAS LATER FOUND ON AN INTERNAL SURFACE OF THE GEARBOX COVER. 3 U E1GL 20030602000252003060200025CE 2003 6 2 CA030512001 120030501G2750SM50D7 RELAY BEECH 99 B99 1154004CE PWA PT6 PT6A28 EA TE FLAPS INTERMITTENT W A UNSCHED LANDING F FLT CONT AFFECTED CLCLIMB 1 CA (CAN) FLAPS WERE SELECTED FROM THE 15 DEGREE POSITION AND WOULD NOT MOVE UP OR DOWN. DYNAMIC BRAKE RELAY WAS FOUND TO WORK IF TAPPED. RELAY REPLACED AND AIRCRAFT RETURNED TO SERVICE. 1L72 3T4 T A14CE E4EA 20030602000362003060200036WP 2003 6 2 CA030512002 220030512G7250310170318 BUSHING 310170318 GARRTTTPE331TPE33110UA 01514WP ENGINE WRONG PART W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) UPON ATTEMPTING TO INSTALL TWO BUSHINGS ON THE TORSION SHAFT FOR THE ENGINE IT WAS NOTICED THAT THE TWO BUSHINGS HAVING THE SAME PART NUMBER HAD A DIFFERENT WALL THICKNESS AND INSIDE DIAMETER. THE SAME PART NUMBER WAS STAMPED ON EACH BUSHING. THE REMAINDER OF THE BUSHINGS WERE CHECKED AND A TOTAL OFTHREE BUSHINGS WERE FOUND WITH THE SAME PROBLEM (TOO THIN OF A WALL). BUSHINGS WERE REMOVED FROM STOCK AND PLACED IN QUARENTINE. 4 T E4WE 20030602000372003060200037GL 2003 6 2 CA030513001 120030509G2434654358 BRACKET CIRRUSSR SR20 05628AJGL CONT O360 IO360E 17025SO HARTZLHCJ2Y BHCJ2YF1 GL ALTERNATOR MOUNTCRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) FORWARD ALTERNATOR MOUNTING BRACKET CRACKED. THE CRACK IS LOCATED ON THE BOTTOM SIDE OF THE FORWARD ALTERNATOR MOUNTING HOLE. 1L71 3O3 ONTA00009CHE1CE 5 CP37EA 20030602000262003060200026WP 2003 6 2 CA030514003 120030427G6300C0511 ACTUATOR ROBSINR44 R44 7640120WP LYC O540 O540F1B5 41532EA MAIN ROTOR FAILED W E ENGINE SHUTDOWN J WARNING INDICATION NRNOT REPORTED 1 CA (CAN) MAIN ROTOR ACTUATOR ENGAGEMENT WAS OVER 90 SECONDS. ACTUATOR REMOVED AND SENT FOR OVERHAUL. 1G71 3O3 O H11NM E295 20030602000282003060200028CE 2003 6 2 CA030514004 120030428G5312504100491 FLANGE BEECH 100 100BEECH 1152916CE PWA PT6 PT6A28 EA BULKHEAD CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) CRACK ON BULKHEAD FLANGE APPROX. .7500 LONG CRACK. NOSE COMPARTMENT AREA, NOSE WHEEL STEERING IDLER SHAFT SUPPORT INTERCOSTAL BULKHEAD. 1L72 3T4 T A14CE E4EA 20030602000302003060200030EA 2003 6 2 CA030514007 220030422G7414ES10384585 BREAKER POINTS BENDIX CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA MCAULY1C160 1C160DTM GL MAGNETO WORN W A UNSCHED LANDING RJ PARTIAL RPM/PWR LOSS WARNING INDICATION CRCRUISE 1 CA 33440 (CAN) WHILE IN CRUISE AIRCRAFT EXPERIENCED A DROP IN ENGINE RPM TO APPROXIMATELY 1900 RPM. WHILE HEADING TO NEAREST AIRPORT, A MAGNETO CHECK DETERMINED RIGHT MAGNETO TO BE COMPLETELY DEAD. AFTER LANDING & PULLING POWER BACK, THEN ENGINE QUIT AND COULD NOT BE RESTARTED. MAGNETO WAS REMOVED AND FOUND THAT POINTS WERE NOT OPENING AT ALL DUE TO THE EXCESSIVE WEAR OF THE NYLON/PLASTIC. MAGNETO REPLACED WITH SPARE AND ENGINE RAN NORMALLY. 1H71 3O3 ONT3A12 E274 5 NP910 20030602000312003060200031GL 2003 6 2 CA030514009 320030424G619730600003 WIRE HARNESS PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL PROPELLER SHORTED W O OTHER J WARNING INDICATION CRCRUISE 1 CA (CAN) WHILE IN FLIGHT, THE (DE-ICE CAUTION) AMBER CAUTION LIGHT ILLUMINATED AND THE GREEN (PROP DE-ICE) WAS FLASHING. AFTER INVESTIGATING THE PROBLEM. THE WIRE THAT WAS PROVIDING HEAT TO THE DE-ICE WAS ALREADY REPLACED. 2 BARE HEATING WIRES ON INTERIOR OF DE-ICER BUNDLES WERE TOUCHING CAUSING A SHORT, THE CAUTION LIGHTS THEN WOULD ILLUMINATE. ONCE WIRE BUNDLE (3E2360-4) WAS REPLACED, THE SYSTEM WORKED CORRECTLY. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030602000522003060200052CE 2003 6 2 CA030514010 120030510G2810261601741 RESERVOIR CESSNA208 208B 2073701CE PWA PT6 PT6A114A 52043NE MCAULY3AF34C3GFR34C703 GL FUEL SYSTEM CRACKED W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) POST FLIGHT INSPECTION REVEALED FUEL DRIPPING FROM THE RESERVOIR AREA ON THE BELLY OF THE AIRCRAFT. AFTER REMOVING THE ACCESS PANEL FUEL WAS SEEN TO BE SEEPING FORM THE UPPER SURFACE OF THE RESERVOIR . AFTER REMOVING THE RESERVOIR A SMALL CRACK WAS VISIBLE ON THE TOP SURFACE. 1H71 3T3 T A37CE E4EA 5 CP60GL 20030602000322003060200032CE 2003 6 2 CA030514012 120030507G8011Z4214 STARTER CESSNA150 150M 2071830CE CONT O200 O200A 17020SO MCAULY1A102 1A102OCM GL ENGINE BLOCKED W O OTHER H ELECT. POWER LOSS-50 PC NRNOT REPORTED 1 CA (CAN) ON ENGINE START UP, PILOT NOTICED THAT THE PROP WAS NOT TURNING. AFTER INVESTIGATION WE DISCOVERED THAT THE STARTER WAS DEFECTIVE. 1H71 3O3 O 3A19 E252 5 NP918 20030602000332003060200033EA 2003 6 2 CA030514013 220030425G852011F20022S3 CRANKCASE PIPER PA31 PA31 7103102SO LYC O540 TIO540A2B 41532EA HARTZLHCE3Y HCE3YR2A GL ENGINE LEAKING W O OTHER K FLUID LOSS NRNOT REPORTED 1 CA (CAN) DURING A 50 HOUR INSPECTION, THE ENGINEERS NOTICED AN OIL LEAK. THEY CLEANED THE ENGINE AND SPRAYED IT WITH A DEVELOPER. AFTER PERFORMING A GROUND RUN ON THE ENGINE, A CRACK WAS DISCOVERED IN THE CRANKCASE. THIS CRACK WAS ABOUT 6 INCHES LONG AND LOCATED ON THE RIGHT SIDE OF THE ENGINE, UNDER THE NR1 CYLINDER. THE ENGINE WAS REMOVED FOR REPAIR. 1L72 3O3 O A20SO E14EA 5 CP33EA 20030611000562003061100056EA 2003 6 11 CA030514017 120030404G492038004883 APU CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE FIRE W F ACTIVATE FIRE EXT. A FLAME/FIRE TXTAXI/GRND HDL 1 CA (CAN) APPROXIMATELY 5 MINUTES AFTER SHUTTING DOWN APU (ENGINES OFF NO GROUND POWER), DECIDED TO OPEN APU DOOR TO HELP COOL APU DOWN PRIOR TO LCV CHANGE. 2 MINUTES LATER, MAITNENANCE NOTICED THAT SMOKE AND FLAMES WERE COMING OUT OF THE APU INTAKE. MECHANIC RUSHED TO COCKPIT, CLOSED APU DOOR AND MANUALLY DISCHARGED FIRE BOTTLE. SHORTLY AFTER NOTICED THAT FLAMES WERE NOW COMING OUT OF APU EXHAUST. MAITNENANCE THEN DISCHARGED TWO PORTABLE FIRE EXTINGUISHERS INTO APU EXHAUST UNTIL FIRE WAS EXTINGUISHED. MAINTENANCE THEN NOTIFIED THE FIRE DEPARTMENT HOWEVER NO FURTHER ACTION WAS REQUIRED. THE APU WAS REPLACED AND SENT TO MFG FOR INVESTIGATION. NOTE: THIS APU HAD RECENTLY BEEN INSTALLED ON A/C. 2L72 4F4 FRTA21EA E15NE 20030611000582003061100058NM 2003 6 11 CA030515001 120030226G3260473901 DOWNLOCK SENSOR BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA NLG DAMAGED W O OTHER N FALSE WARNING CLCLIMB 1 CA (CAN) NOSE GEAR UNSAFE (AMBER NLG, RED NLG & AMBER TRANSIENT LIGHT IN HANDLE) DURING CLIMB AND CRZ, MAX SPEED 210 KTS. AFTER GEAR DOWN SELECTION, NOSE GEAR INDICATE UNSAFE, NORMAL LANDING PERFORMED AFTER ALTERNATE GEAR SELECTION AND SAFE INDICATING. NOSE LANDING GEAR DOWNLOCK PROXIMITY SENSORS NR 1 AND NR 2 REPLACED . DAMAGES TO NOSE LANDING GEAR FWD DOORS REPAIRED. LANDING GEAR RETRACTION/EXTENSION CHECK PERFORMED WITHOUT ANY REMARKS. CONCLUSION THE NOSE GEAR UNSAFE CONDITION WAS MOST PROBABLY CAUSED DUE BREAKAGE OF THE NR 1 LOCK SENSOR WIRING. 2H72 4T4 TRTA13NM E00062EN 20030611000592003061100059CE 2003 6 11 CA030515003 120030509G2720300433113 BELLCRANK CESSNA120 120 2071402CE CONT C85 C8512F 17008SO MCAULY1A90 1A90* GL RUDDER CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING INVESTIGATION THE RUDDER BELLCRANK WAS FOUND CRACKED. 1H71 3O3 O A768 E233 5 NP842 20030611000602003061100060CE 2003 6 11 CA030515004 120030514G282050921620235 TUBE BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA HARTZLHCB3T HCB3TN3 GL FUEL SYS GROOVED W O OTHER W INADEQUATE Q C NRNOT REPORTED 1 CA (CAN) THIS AC HAS CLEVELAND BRAKE STC INSTALLED. DURING MAIN GEAR RETRACTION AND EXTENSION LT MAIN GEAR FORWARD HYD BRAKE UNIT CONTACTED MAIN FUEL SUPPLY TUBE AND DAMAGED TUBE BY ERODING A TWO-INCH LONG BY ONE-QUARTER INCH WIDE GROOVE IN TUBE WALL. THIS FUEL TUBE IS MAIN SUPPLY LINE FROM NACELLE TANK BOOST PUMP TO FIREWALL SHUTOFF VALVE AND APPEARED TO BE IMPROPERLY POSITIONED FOR ADEQUATE CLEARANCE. PERFORATION OF TUBE WALL WOULD RESULT IN TOTAL FUEL LOSS FROM LT WING FROM A PRESSURIZED LEAK. POTENTIAL SAFETY ISSUES ARE RISK OF FIRE, LOSS OF ENGINE POWER AND POSSIBLE CONTROL DIFFICULTY RESULTING FROM A 1000 LB FUEL IMBALANCE. TUBE WAS REPLACED WITH A SERVICEABLE UNIT CORRECTLY POSITIONED FOR CLEARANCE. 1L72 3T4 TRT3A20 E4EA 6 CP15EA 20030707000122003070700012NE 2003 7 7 CA030515007 220030513G7261 ENGINE CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE NR 1 OVERSERVICED W A UNSCHED LANDING WB INADEQUATE Q C SMOKE/FUMES/ODORS/SPARKS CLCLIMB 1 CA (CAN) SMOKE/FUMES DETECTED IN FLT COMPARTMENT & CABIN, TOILET SMOKE WARNING ACTIVATED, QRH DRILL ACTIONED, PAN DECLARED, SMOKE CLEARED, RETURN, LANDED SAFELY. MAINT CARRIED OUT AN INSP & CONCLUDED THAT SMOKE/FUMES WERE RELATED TO NR 1 ENGINE HAVING BEEN OVERSERVICED WITH ENGINE OIL, OIL HAS BEEN OBSERVED DRIPPING FROM GANG DRAINS OF ENG & ALSO SOME WETTING OF NR 1 CARBON SEAL (FAN). A/C HAS BEEN FLIGHT TESTED & ODOR OF ENGINE OIL COULD BE DETECTED IN CABIN AND COCKPIT, ESPECIALLY WHEN NR 1 PACK WAS UTILIZED. NO VISIBLE FUMES/SMOKE & NO ALARM TRIGGERED DURING FLIGHT TEST, MAINT PERFORMED A COMPRESSOR WASH & CLEANED NR 1 PACK ECS DUCTING. A/C RETURNED TO SERVICE & HAD NO REOCCURRENCE. 2L72 4F4 FRTA21EA E15NE 20030611000642003061100064CE 2003 6 11 CA030516002 120030514G6120640789 CIRCUIT BOARD BEECH 1900 1900C 1154161CE PWA PT6 PT6A65B 52043EA HARTZLHCB4M HCB4MP3 GL AUTOFEATHER SYS INOPERATIVE W CD ABORTED TAKEOFF RETURN TO BLOCK J WARNING INDICATION TOTAKEOFF 1 CA (CAN) DURING TAKE-OFF ROLL, PILOT NOTICED THAT AUTO-FEATHER SYSTEM DID NOT ILLUMINATE TO IDENTIFY ARM FUNCTION. PILOT INITIATED REJECTED TAKE-OFF, ADVISED ATC & SUBSEQUENTLY RETURNED TO AIRPORT. MAINTENANCE WAS CONTACTED TO INSPECT AND TROUBLESHOOT AUTO FEATHER SYSTEM MALFUNCTION. WE WERE INFORMED BY THE AMO THAT THE MALFUNCTION OF THE AUTO FEATHER INDICATION SYSTEM WAS RECTIFIED BY THE REPLACEMENT OF THE PRINTED CIRCUIT BOARD NR 119 REFERENCED AS P/N 112-364021-5. AIRCRAFT RUNS WERE COMPLIED WITH AND THE AIRCRAFT WAS RETURNED TO SERVICE. THERE HAS BEEN NO REOCCURRENCE OF THIS DISCREPANCY. 2L72 4T4 TRTA24CE E4EA 6 CP56GL 20030715000072003071500007CE 2003 7 15 CA030517001 120030517G2810 FUEL CELL BEECH 95 95B55 1152729CE CONT O470 IO470L 17026SO CONTAMINATED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING CREW WALK AROUND & ACTUATION WATER DRAINS, CREWS CONSISTENTLY FIND WATER EVEN IF COMPLETELY DRAINED ON PREVIOUS FLIGHT. AIRCRAFT INSPECTED AND ALL FUELCAPS COMPLETELY RESEALED AND SEAL SEATS CLEANED. ALL FUEL BLADDERS INTERNALLY I NSPECTED AND FOUND MULTIPLE LARGE WRINKLES TRAPPING WATER SLUGS. ALL BLADDERS DRAINED. DURING INSPECTION IT WAS NOTED THAT THERE IS NO POSSIBLE WAY TO FLATTEN THE BOTTOM OF EACH BLADDER. THE BLADDERS ARE ALL PHYSICALLY LARGER THAN THE WING SECTIONS THAT THEY LIVE IN. RAYTHEON TECH SUPPORT NOTIFIED AND THEY RESPONDED BY TELLING US THAT ALL OF THE BARON A/C ARE LIKE THAT. RECOMMENDED TO JUST CLEAN OUT THE WATER AND MAKE SURE FUEL CAPS SEAL PROPERLY. ALL TANKS RESEALED. 1L72 3O3 ORT3A16 3E1 20030617000112003061700011CE 2003 6 17 CA030517002 120030517G2720 RUDDER CESSNA150 150G 2071816CE CONT O200 O200A 17020SO VERTICAL STAB BINDING W K NONE O OTHER ININSP/MAINT 1 CA (CAN) INCORPORATION OF AD 2000-20R1 (CESSNA S/B SEB01-1) RESULTS IN BINDING BETWEEN NEW STOP BOLTS AND RUDDER STRUCTURE DUE TO THE INCREASED SIZE OF THE STOP BOLTS. BINDING WAS NOT APPARENT UNLESS PRESSURE WAS APPLIED TO BOTH RUDDER PEDALS. 1H71 3O3 O 3A19 E252 20030609001882003060900188EA 2003 6 9 CA030518001 120030518G7603 GEARBOX CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE THROTTLE CONTROLDEFECTIVE W O OTHER XJ ENGINE FLAMEOUT WARNING INDICATION DEDESCENT 1 CA (CAN) WHEN PILOT RETARDED THROTTLE AT TOP OF DESCENT, LT ENGINE FLAMED OUT. UNEVENTFUL SINGLE ENGINE LANDING. TROUBLE SHOOTING REVEALED THROTTLE CONTROL GEARBOX DEFECTIVE. 2L72 4F4 FRTA21EA E15NE 20030609001892003060900189EA 2003 6 9 CA030518002 120030404G7603 GEARBOX CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE THROTTLE MALFUNCTIONED W O OTHER YJ ENGINE STOPPAGE WARNING INDICATION DEDESCENT 1 CA (CAN) THE RT ENGINE FLAMED OUT DURING DESCENT, WHEN THROTTLES WERE RETARDED TO IDLE, RT ENGINE CONTINUEDTO SPOOL DOWN ( TOP OF DESCENT ). TRIED RE-LIGHT ACCORDING QRH : N2 STAGNATION AT 40 PERCENT AND HIGH ITT, ABORTED ENGINE START AND PERFORMED UNEVENTFULL SINGLE ENGINE LANDING IN VIE.FOUND THROTTLE CONTROL GEARBOX MALFUNCTION, WITH WORN TEETH. OBSERVED SEVERE BACKLASH IN MOVMENT , 30 ROTATION WITHOUT OUTPUTON SHAFT, FLIGHT CREW REPORTED STICKY THROTTLE LEVER DURING FLIGHT 2L72 4F4 FRTA21EA E15NE 20030822000942003082200094EA 2003 8 22 CA030519001 220030518G7310LW120980100 TUBE PIPER PA31 PA31 7103102SO LYC O540 TIO540A2C 41532EA HARTZLHCE3Y HCE3YR2A GL FUEL MANIFOLD BROKEN W BE EMER. DESCENT ENGINE SHUTDOWN E VIBRATION/BUFFET CLCLIMB 1 CA (CAN) TUBE ASSEMBLY FOUND BROKEN AT THE INTAKE OF THE FUEL INJECTOR WHICH CAUSED LOSS OF POWER DURING CLIMB. 1L72 3O3 O A20SO E14EA 5 CP33EA 20030530000932003053000093EU 2003 5 30 CA030521004 220030519G8530 INTAKE VALVE DIAMONDA20 DA20A1 2990000GL ROTAX 912 ROTAX912 55555EU HOFMANHOV352HOV352F NE CYLINDER SEPARATED W A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CRCRUISE 1 CA (CAN) KATANA DA20A1 WAS ON A ROUTINE TRAINING FLIGHT WHEN THE CREW BECAME SUDDENLY AWARE OF A SIGNIFICANT ENGINE POWER LOSS AND WERE FORCED INTO MAKING AN UNSCHEDULED LANDING IN A FARMERS FIELD. THE AIRCRAFT LANDED SAFELY AND WAS LATER DISMANTLED AS NECESSARY AND TRAILORED BACK TO ITS BASE OF OPERATION. FURTHER INVESTIGATION REVEALED THAT THE NR 3 CYLINDER INTAKE VALVE HAD SEPARATED AND CAUSED SIGNIFICANT DAMAGE TO THE CYLINDER HEAD AND PISTON. THE VALVE ENDED UP WEDGED PERPENDICULAR IN ITS SEAT AND THE VALVE SPRING RETAINER WAS FOUND SEPARATED AS WELL. THE ENGINE HAS BEEN REMOVED FROM THE AIRCRAFT FOR FURTHER ASSESSMENT AND REPAIR. 1L71 3O3 INTTA4CH EXPE3I 5 CTP5BO 20030530000942003053000094EU 2003 5 30 CA030521005 120030518G324221600 BRAKE ASSY AIRBUSA319 A319112 3930323EU CFMINTCFM565CFM565B6 13802NE MLG FIRE W O OTHER A FLAME/FIRE NRNOT REPORTED 1 CA (CAN) FLAMES OBSERVED COMING FROM LT WHEEL OUTERSIDE BRAKE. AFTER A LONG TAXI, LOW WEIGHT, SINGLE ENG, THE BRAKE GOT TO 440 C , AFTER PARKING AT THE GTE, FIRE WAS PUT OUT BY AC EMPL. WITH AC FIRE EXTING. REMOVED M/W & BRAKE ASSY'S. VISUAL INSPECTION OF LT MAIN GEAR & AXLE CARRIED OUT, NIL FAULT FOUND. AREA CLEANED OF RESIDUAL FIRE EXT. AGENT. NEW BRAKE AND MAIN WHEEL INSTALLED. 2L72 4F4 FRTA28NM E37NE 20030530000952003053000095CE 2003 5 30 CA030521006 120030521G2750S3782 BRACKET CESSNA185 A185F 2072821CE CONT O520 IO520D 17032SO HARTZLHCC3Y HCC3YF1 GL FLAP PULLEY WRONG PART W K NONE O OTHER ININSP/MAINT 1 CA (CAN) FLAP CABLE IN LT WING AT FLAP PULLEY BRACKET FALL OF THE PULLEY BECAUSE OF THE WRONG SIZE OF PULLEY, PULLEY AND BOLT SHOULD BE USE ON A/C S/N 185-0238 AND ON. 1H71 3O3 O 3A24 E5CE 5 CP25EA 20030530000962003053000096NE 2003 5 30 CA030521007 220030516G8530114651 EXHAUST ROCKER DOUG DC3 DC3CS1C3G 3021458WP PWA R1830 R183092 52020NE HAMSTD23E 23E50 NE CYLINDER CRACKED W O OTHER E VIBRATION/BUFFET CRCRUISE 1 CA (CAN) DURING CRUISE THE CREW NOTICED A SLIGHT VIBRATION IN THE LT ENGINE. UPON LANDING A VISUAL INSPECTION WAS CARRIED OUT AND THE NR 11 CYLINDER WAS FOUND TO BE CRACKED FORE AND AFT ALONG THE EXHAUST ROCKER COVER, FROM THE EAR BACK TO THE ROCKER SHAFT. CYLINDER WAS REPLACED WITH AN O/H UNIT AND THE ENGINE WAS GROUND RUN SERVICEABLE. 2L72 4R4 R A669 5E4 6 CP603 20030530000972003053000097CE 2003 5 30 CA030521008 120030515G32440773450 TIRE CESSNA402 402B 207590PCE CONT O520 TSIO520AE 17040SO MCAULY3AF32C3AF32C87 GL RT MLG BLOWN W O OTHER O OTHER LDLANDING 1 CA (CAN) ON LANDING THE RT MAIN WHEEL BLEW. A/C WAS STOPPED SAFELY ON THE RUNWAY AND THEN TOWED OFF ONTO THE NEAREST TAXIWAY. AFTER THE RIM WAS INSPECTED AND THE TIRE REPLACED THE A/C WAS DISPATCHED FOR THE NEXT FLIGHT. 1L72 3O3 O A7CE E8CE 5 CP22EA 20030617000722003061700072NE 2003 6 17 CA030522001 220030505G7532HTE4500019 VALVE AIRBUS330 A330243 3930330EU RROYCERB211 RB211TRENT77 NE ENGINE BROKEN W K NONE O OTHER ININSP/MAINT 1 CA 1806918069 (CAN) DURING THE SCHEDULE REMOVAL OF THE ENGINE S/N 41063 THE NON-RETURN IP CHECK VALVE WAS FOUND BROKEN AT THE HINGE BOLT. SPRING AND WASHER WAS ALSO MISSING. VALVE WAS REPLACED AND ENGINE REPAIR SHOP WAS ADVISED. 2L72 4F4 FRTA46NM E39NE 20030530000982003053000098EU 2003 5 30 CA030522002 120030520G52402242277501 ACCESS DOOR AIRBUS310 A310300 3930305EU GE CF6 CF680C2* GL OIL SYSTEM BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) AIRCRAFT ARRIVED AT THE STATION WITH THE RT ENGINE OIL TANK ACCESS DOOR HALF PORTION BROKEN OFF ANDMISSING. NEW DOOR WAS INSTALLED. FAN COWL WAS SLIGHTLY DAMAGED BY THE DOOR STRIKING. DAMAGE WAS CONSIDERED ACCEPTABLE AS PER AMM. SUSPECT THAT OIL TANK ACCESS DOOR WAS NOT PROPERLY CLOSED AT PREVIOUS STATION. 2L72 4F4 FRTA35EU E23EA 20030530000992003053000099EU 2003 5 30 CA030523003 120030517G5610NP1653115 WINDSHIELD AIRBUS320 A320211 3930320EU CFMINTCFM56 CFM565A1 NE COCKPIT BROKEN W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) CAPTAINS WINDSHIELD SHATTERED AT 11000 FT. REPLACED THE WINDSHIELD AND HEAT CONTROLLER. HEAT CONTROLLER TOTAL OF WINDSHIELD 8477 HRS TIME SINCE INST 203 HRS. 2L72 4F4 FRTA28NM E29NE 20030702000562003070200056EA 2003 7 2 CA030523004 220030312G8520 CRANKCASE PIPER PA31 PA31350 7103110SO LYC O540 LTIO540J2BD 41533EA HARTZLHCE3Y HCE3YR2A GL ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) AT INSPECTION OIL LEAKAGE WAS OBSERVED FROM RIGHT ENGINE. AFTER CLEAN UP AND FURTHER INVESTIGATION A 1.25 FT CRACK WAS FOUND STARTING AT A CRANK CASE SEAM BOLT CLOSE TO THE STARTER AREA. AIRCRAFT WAS GROUNDED AND AN OVERHAULED ENGINE INSTALLED. 1L72 3O3 O A20SO E14EA 5 CP33EA 20030703000702003070300070CE 2003 7 3 CA030523005 120030521G323050452112 FORK CESSNA402 402B 207590PCE CONT O520 TSIO520AE 17040SO MCAULY3AF32C3AF32C87 GL NLG SHEARED W O OTHER J WARNING INDICATION CLCLIMB 1 CA (CAN) PILOT REPORTS GEAR WOULD NOT RETRACT ON TAKE OFF. HE ELECTED TO LEAVE DOWN FOR FLIGHT MAINTAINING PROPER SPEED.ON LANDING TRUCKS WERE REQUESTED BUT NO EMERGENCY DECLARED. LANDING WAS UNEVENTFUL. WHEN MAINTENANCE INSPECTED GEAR THEY FOUND ADJUSTING FORK SHEARED AT THE FIRST THREAD. MAINTENANCE TRIED TO USE THE SAME PART OFF ANOTHER A/C WHICH WAS IN OUR HANGER FOR MAINTENANCE, BUT FOUND IT CRACKED IN THE SAME PLACE. NEW PART INSTALLED RIGGED AND GEAR SWING CARRIED OUT AND RELEASED FOR FURTHER FLIGHT. 1L72 3O3 O A7CE E8CE 5 CP22EA 20030703000712003070300071EU 2003 7 3 CA030526001 120030523G7820 BAFFLE ZLIN 242 Z242L 9970204EU LYC O360 AEIO360A1B6 41514EA MUFFLER BROKEN W K NONE O OTHER ININSP/MAINT 1 CA L2514551A (CAN) DUE TO FINDING A BROKEN INTERNAL BAFFLE INSIDE THE NR 1 EXHAUST SILENCER, WE INITIATED AN INTERNAL INSPECTION OF THE SILENCER EVERY 100 HR INSPECTION INTERVAL. THIS BAFFLE WAS FOUND TO BE COMPLETELY BROKEN. THE EXHAUST SILENCER WAS REPLACED WITH A REPAIRED UNIT. IT IS BELIEVED THAT A BACKFIRE UPON STARTUP IS THE CAUSE OF THE BAFFLE DAMAGE AND HEATING AND COOLING OF THE EXHAUST SYSTEM. THE STUDENTS ARE REMINDED TO NOT OVER PRIME THE ENGINES AT START UP. 1L71 3O3 O0 A76EU 1E10 20030715000092003071500009EU 2003 7 15 CA030526003 120030521G5312 PRESSURE PANEL BAC 146 146200A 1500266EU LYC ALF502ALF502R5 41580NE FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 3715337153 (CAN) DURING COMPANY SPECIAL FLEET INSPECTION 13 INCH CRACK DISCOVERED IN THE WHEEL WELL UPPER PRESSURE SKIN ALONG AIRCRAFT CENTER LINE AT EDGE OF STRINGER BETWEEN FRAME 29 TO 32. MANUFACTURER CONTACTED. DAMAGE REPAIRED AS PER BAE REPAIR INSTRUCTION HC532H9018. 2H74 4F4 F A49EU E6NE 20030715000102003071500010EU 2003 7 15 CA030526004 120030521G5311 PRESSURE PANEL BAC 146 146200A 1500266EU LYC ALF502ALF502R5 41580NE FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 3686636866 (CAN) DURING COMPANY SPECIAL FLEET INSPECTION 20 INCH CRACK DISCOVERED IN THE WHEEL WELL UPPER PRESSURE SKIN ALONG AIRCRAFT CENTER LINE AT EDGE OF STRINGER BETWEEN FRAMES 29 TO 32. MANUFACTURE CONTACTED. DAMAGE REPAIRED AS PER BAE REPAIR INSTRU CTION HC532H9018. 2H74 4F4 F A49EU E6NE 20030702000572003070200057EA 2003 7 2 CA030526008 120030521G3246L812148 BEARING DHAV DHC8 DHC8311 1386006EA PWA PW120 PW123 NE HAMSTD14SF 14SF15 NE WHEEL SPALLED W D RETURN TO BLOCK B SMOKE/FUMES/ODORS/SPARKS TXTAXI/GRND HDL 1 CA (CAN) DURING TAXI OUT, FLT ATTENDANT REPORT SPARKS FROM NR 2 (IB LT ) MLG WHEEL ASSY. AIRCRAFT RETURNED TO THE GATE, NEAR GATE AREA NOTICED WHEEL HUB CAP. CREW CONFIRMS THAT DURING WALKAROUND PRIOR TO TAXI WHEEL ASSEMBLY APPREARED NORMAL AND HUB CAP ON WHEEL. AFTER TAXING BACK TO GATE NR 2 WHEEL ASSEMBLY MISSING HUB CAP , RETAINING NUT & SAFETY HARDWARE STILL INTACT/INSTALLED. INVESTIGATION FOUND BOTH BEARINGS FAILED P/N L812148 CODE FY AND P/N L713049 CODE JT . DUE TO THE SEVERE HEAT DAMAGE NOTICED TO THE BEARINGS AND MOLTEN MATERIAL, A PRESUMPTION IS MADE THAT THE WHEEL BEARINGS PROBABLY FAILED DURING THE PREVIOUS LANDING. WHEEL ASSEMBLY HAD 249 CYCLES SINCE LAST SHOP VISIT , BEARING TIMES UNKNOWN. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030703000542003070300054CE 2003 7 3 CA030526010 120030414G7722MS3505929 SWITCH CESSNA441 441 2076020CE GARRTTTPE331TPE33110 01514WP EGT LIMITER INTERMITTENT W O OTHER E VIBRATION/BUFFET CRCRUISE 1 CA (CAN) RT ENGINE EGT LIMITER NOT WORKING, REVERTED TO MANUAL, TTL. SWITCH P/N MS35059-29 WAS FAULTY. SWITCH P/N MS35059-29 WAS TAKEN APART AND FOUND TO BE CONTAMINATED. THE SWITCHES LOCATED BELOW FOUL WEATHER WINDOW WHICH MAY HAVE BEEN LT OPEN ON THE GROUND, OR CONTAMINATION MAY HAVE RESULTED FROM A SPILT DRINK. 1L72 3T4 TRTA28CE E4WE 20030703000552003070300055SW 2003 7 3 CA030526011 120030505G5511206020120011 SPAR BELL 206 206B 1181511SW ALLSN 250C 250C20 03013GL HORIZONTAL STAB CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) CRACK FOUND ON INBOARD PORTION OF SPAR RUNNING LONGITUDINALLY. 1G71 3U3 U H2SW E4CE 20030703000562003070300056NE 2003 7 3 CA030526012 220030305G7250 ENGINE SNIAS 350 AS350BA 8680817EU TMECA ARRIELARRIEL1B 6OO30NE FOD W K NONE O OTHER ININSP/MAINT 1 CA 10369 (CAN) ENGINE DOESN'T CRANK. COMPRESSOR APPEARED LOCKED. STARTER & FCU REMOVED. COMPRESSOR STILL LOCKED. WHILE TRYING TO ROTATE COMPRESSOR BY HAND IT EVENTUALLY FREED UP A BIT. IT WOULD ROTATE 1 AND 1/2 TURNS THEN LOCK UP. SUSPECTED FOD IN THE COMPRESSOR. ENGINE WAS REMOVED. IT WOULD ROTATE FREELY IN A HORIZONTAL POSITION BUT LOCK UP IF TILTED FORWARD. MODULES 2/3 WERE REMOVED & SENT FOR INSPECTION. AFTER INSPECTION COWLING & SAND FILTER INSTALLATION, FOUND POSSIBLE EVIDENCE OF A MISSING TIE RAP WHICH SECURED WIRING HARNESS FOR P2 SOLENOID ON SAND FILTER. TIE RAP MAY HAVE CHAFED & EVENTUALLY BROKE & WAS INGESTED. 1G71 3U3 UNCH9EU E19EU 20030715000012003071500001EA 2003 7 15 CA030527001 320030521G6114 HUB BOEING75 A75N1 1380134CE CONT R670 R670* 17016SO SNSNCHW96JB W96JB EA PROPELLER CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) PROPELLER WAS FOUND TO BE CRACKED BETWEEN LAMINATIONS, INSIDE THE INTERNAL HUB. MANUFACTURER INDICATES THIS MAY HAVE BEEN CAUSED BY MOISTURE CONTENT FLUCTUATIONS, WHICH WOULD CAUSE INCONSISTANT PROP TORQUE SETTINGS.THERE WAS NO EVIDENCE OF A LOOSE PROP. PROP WAS ALSO QUITE OLD. REPLACED WITH NEW. 1Q71 3R3 R A743 E162 5 NP170 20030702000582003070200058SW 2003 7 2 CA030527005 120030526G21102784142007 LINE SWRNGNSA226 SA226TC 8780404SW GARRTTTPE331TPE33110UA 01514WP BLEED AIR BROKEN W O OTHER J WARNING INDICATION CRCRUISE 1 CA 31322 (CAN) FLIGHT CREW COMPLAINED OF PRESSURIZATION PROBLEMS. THE CABIN DIFFERENTIAL WAS LOWER THAN NORMAL. UPON INSPECTION OF THE RT WING AIR CONDITIONING SYSTEM THE FLEXABLE ACCORDION STYLE BLEED AIR LINE FROM THE HEAT EXCHANGER/COOLING TURBINE ASSY WAS FOUND BROKEN IN HALF IN TWO PLACES. NO WING OVERHEAT WARNING INDICATIONS WERE WITNESSED BY THE FLIGHT CREW OR ANY HEAT DAMAGE FOUND IN WING. NOTHING FOUND IN OR AROUND THE AREA OF THE LINE WOULD HAVE CAUSED THE DAMAGE TO THE LINE.WE SUSPECT THAT FATIGUE IS THE CAUSE DUE TO YEARS OF HEAT AND VIBRATION. 2L72 4T4 TRTA8SW E4WE 20030703000512003070300051NE 2003 7 3 CA030527006 220030512G8530 SPARK PLUG DOUG B26 B26C 3200524WP PWA R2800 R280079 52026NE HAMSTD23E 23E50 NE CYLINDER HEAD LOOSE W E ENGINE SHUTDOWN E VIBRATION/BUFFET CRCRUISE 1 CA (CAN) DURING A TEST FLIGHT AFTER AN ENGINE CHANGE THE LT ENGINE BEGAN TO RUN ROUGH AT CRUISE POWER SETTINGS. AS A PRECAUTION, THE ENGINE WAS SHUT DOWN AND SECURED. AIRCRAFT LANDED WITHOUT INCIDENT. INVESTIGATION FOUND ONE SPARK PLUG BECAME LOOSE AND BACKED OUT OF CYLINDER HEAD. ALL OTHER SPARK PLUGS FOUND TO BE SECURE. MAINTENANCE CREW BRIEFED. 2M72 4R4 R L34 5E8 6 CP603 20030703000522003070300052EA 2003 7 3 CA030527007 220030526G7314 BOLT ROBSINR44 R44 7640120WP LYC O540 O540F1B5 41532EA FUEL PUMP LOOSE W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) DURING THE FIRST 100 HR INSPECTION THE BOLTS HOLDING THE BOTTOM COVER TO THE PUMP BODY WERE FOUND LOOSE BY SEVERAL TURNS. BOLTS WERE TIGHTENED AND TORQUE SEAL WAS ADDED TO MAKE VISUAL INDICATION OF MOVEMENT. THIS INSTALLATION WOULD BE BETTER SERVED WITH BOLTS THAT WOULD ALLOW FOR LOCKWIRE. 1G71 3O3 O H11NM E295 20030715000022003071500002EU 2003 7 15 CA030527008 120030527G6730 SERVO SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE M/R HYD SYS FAILED W A UNSCHED LANDING FJ FLT CONT AFFECTED WARNING INDICATION HOHOVERING 1 CA (CAN) RESISTANCE IN CYCLIC STICK LT INPUT. FLIGHT CONTROL SYSTEM INSPECTED. CYCLIC STICK FRICTION STACK UP CHECKED OK. ALL FLIGHT CONTROLS UP TO THE SERVOS CHECK OK. M/R PITCH LINKS DISCONNECTED OK. SERVO AC 67244 SWAPPED AND PROBLEM WENT TO OPPOSITE SIDE RT. AT GROUND IDLE SIGNIFICANT RESISTANCE FELT. RESISTANCE NOT AS SEVERE AT FLIGHT IDLE. SERVO AIR BLEEDS CHECKED OK. NEW HYD. FILTER INSTALLED. PROBLEM STILL THERE. REPLACEMENT SERVO REQUESTED 1G71 3U3 U H9EU E19EU 20030617000322003061700032EU 2003 6 17 CA030527010 120030516G3411PC1245 STATIC LINE PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL NR 2 SYSTEM FAILED W O OTHER N FALSE WARNING CRCRUISE 1 CA (CAN) AIRCRAFT WAS AT CRUISE FLIGHT (28,000 FT) & AUTOPILOT BEGAN TO CLIMB. AUTOPILOT WAS DISENGAGED AND AIRCRAFT LEVELED OFF. NR 1 ALTIMETER AND AIRSPEED BEGAN TO RAPIDLY MOVE TO ZERO. CREW DESCENDED AND LANDED AT NEXT AVAILABLE AIRPORT AS NR 2 SYSTEM FUNCTIONED NORMALLY. AIRCRAFT WAS FLOWN VFR BACK TO MAINTENANCE BASE WHERE NR 1 STATIC LINE WAS FOUND PULLED OUT OF TEE FITTING IN CABIN SIDEWALL. LINE WAS TOO SHORT AND HAD BEEN FORCED INTO PLACE. LINE REPLACED AND REINSTALLED AND TESTED. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030702000592003070200059EA 2003 7 2 CA030527011 120030429G2731 PIN DHAV DHC6 DHC6300 2802606EA PWA PT6 PT6A27 52043EA HARTZLHCB3T HCB3TN3 GL ELEVATOR CONTROLLOOSE W O OTHER I FLT. ATTITUDE INST. LDLANDING 1 CA (CAN) PILOT REPORTED THAT HE RAN OUT OF NOSE DOWN ELEVATOR TRIM WITH FLAPS 30 DEGREES. INSPECTED FLAP TRIM INTERCONNECT AND FOUND NO FAULTS. INSPECTED ELEVATOR TRIM AND FOUND THAT NOSE DOWN TRIM WAS LIMITED BY A STOP IN THE COCKPIT TRIM WHEEL. FOUND THAT PIN THAT RIDES IN GROOVE IN TRIM WHEEL & DRIVES TRIM POSITION INDICATOR HAD POPPED OUT AND INTO NEXT GROOVE. REPOSITIONED IN APPROPRATE LOCATION & OPS CHECK OK. RERIGGED POSITION INDICATOR AND TEST FLEW AIRCRAFT, OPS NORMAL. 1H72 3T4 TRTA9EA E4EA 6 CP15EA 20030703000662003070300066EU 2003 7 3 CA030527012 120030512G6730SC5083 SERVO SNIAS 350 AS350B 8680801EU TMECA ARRIELARRIEL1B 6OO30NE LT HYD SYS FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING HYD TEST CYCLIC WENT HARD OVER LT WITHOUT CONTROL INPUT. WHEN HYD FLUID WAS WARM HARD OVER WAS LESS NOTICEABLE. WHEN HYD SYSTEM PRESSURE WAS DUMPED, CYCLIC WENT HARD OVER LT. HYD SERVO REPLACED, AIRCRAFT WAS RETURNED TO SERVICE. 1G71 3U3 U H9EU E19EU 20030703000672003070300067GL 2003 7 3 CA030527013 220030508G7323 DRIVE GEAR BELL 206 206B 1181511SW ALLSN 250C 250C20B 03013GL GOVERNOR SHAFT DISCONNECTED W A UNSCHED LANDING W INADEQUATE Q C CRCRUISE 1 CA (CAN) THE EXPOXY HOLDING THE SAFETY CLIP IN PLACE CAME UNBONDED, THEREFORE ALLOWING THE CLIP TO MOVE THUS ALLOWING THE DRIVE GEAR TO DISCONNECT FROM THE SHAFT. 1G71 3U3 U H2SW E4CE 20030703000682003070300068EU 2003 7 3 CA030527014 120030526G53021172213201 SPLICE BOLKMS117 BK117B1 5626012EU LYC LTS101LTS101750B1 41560NE TAILBOOM CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) CRACK ORIGINATING FROM TOOLING HOLE AND PROGRESSING UP VERTICAL AND ACROSS HORIZONTAL LEG OF SPLICE. SPLICE IS LOCATED ON LT FORWARD SECTION OF TAILBOOM ATTACH STRUCTURE. 1G72 3U3 U H13EU E5NE10 20030703000692003070300069EU 2003 7 3 CA030527015 120030526G53101172213202 SPLICE BOLKMS117 BK117B1 5626012EU LYC LTS101LTS101750B1 41560NE FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) CRACK ORIGINATING AT TOOLING HOLE AND PROGRESSING HORIZONTALY ACROSS LOWER FLANGE. 1G72 3U3 U H13EU E5NE10 20030715000032003071500003 2003 7 15 CA030527016 420030506G3497K22A24 WIRE HARNESS PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL STALL WARING SHORTED W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) STALL WARNING NR 1 C/B POPPED WITH A PUSHER CAUTION JUST AFTER TAKE-OFF.AIRCRAFT RETURNED TO BASE. C/B COULD NOT BE RE-SET. POWER WIRE TO TORQUE TRANSDUCER (KA22A24) FOUND SHORTED FORWARD OF THE OF THE LT EXHAUST STACK, BURNING WIRE AND TIE WRAP. WIRE AND SHIELDING REPAIRED. SYTEM FUNCTION TESTED SATISFACTORY 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030617000212003061700021CE 2003 6 17 CA030528001 120030521G3710212CW PUMP CESSNA206 U206B 2073322CE CONT O520 IO520F 17032SO MCAULY3A32C D3A32C90 GL VACUUM SYS FAILED W O OTHER HJ ELECT. POWER LOSS-50 PC WARNING INDICATION DEDESCENT 1 CA (CAN) FAILURE OF VACUUM AIR PUMP ON DESCENT DURING UFR OPERATIONS. VANE FAILURE, DRIVE SHEARED. 1H71 3O3 O A4CE E5CE 5 CP21EA 20030702000602003070200060WP 2003 7 2 CA030528002 220030512G720030728001 ENGINE AMD FALC50FALCON50MYST2730106EU GARRTTTFE731TFE7313 01518WP NR 1 BIRD INGESTION W EA ENGINE SHUTDOWN UNSCHED LANDING CKJF.O.D. FLUID LOSS WARNING INDICATION CRCRUISE 1 CA (CAN) IN CRUISE FLIGHT AT 33 K FT, DAYTIME, CLEAR SKY, NR 1 ENGINE FUEL OIL PRESSURE LIGHT FLICKERED AND FLUCTUATING OIL PRESSURE WAS CONFIRMED ON GUAGE. NR 1 ENGINE WAS SHUTDOWN AND AIRCRAFT DIVERTED FOR REPAIRS. REPACED 2 FAN BLADES, CORE INLET STATOR AND CRACKED OIL PRESSURE LINE. ENGINE BORESCOPED, GROUND RUN AND VIBRATION SURVEY C/W SATISFACTORY AND ENGINE RETURNED TO SERVICE 2003, MAY 15. SUSPECT BIRD STRIKE OCCURRED ON PREVIOUS TAKEOFF BUT NOT NOTICED BY FLIGHT CREW. 2L73 4F4 F A46EU E6WE 20030703000362003070300036NM 2003 7 3 CA030528003 120030525G3234 SELECTOR VALVE BOEING737 7372T2 1384491NM PWA JT8 JT8D17 52049NE MLG FAULTY W O OTHER O OTHER APAPPROACH 1 CA (CAN) ON APPROACH THE CREW REPORTED THE NOSE GEAR DID NOT UNLOCK OR EXTEND ON THE INITIAL EXTENSION ATTEMPT. THE GEAR HANDLE WAS RECYCLED AND THE NOSE GEAR CAME DOWN NORMALLY. IT WAS DECIDED TO OPERATE THE AIRCRAFT UNDER A FLIGHT PERMIT (FERRY PERMIT) FOR TROUBLESHOOTING. RECTIFICATION UPON ARRIVAL INTO MAINTENANCE CONDUCTED SEVERAL GEAR SWINGS ALONG WITH RIGGING AND ROUTING CHECKS OF THE LANDING GEAR CONTROL SYSTEM.THE FAULT COULD NOT BE DUPLICATED. DUE TO THE HISTORY ASSOCIATED WITH THE DEFECT, IT WAS DECIDED TO REPLACE LANDING GEAR SELECTOR VALVE FOR TROUBLESHOOTING. 2L72 4F4 FRTA16WE E2EA 20030715000042003071500004SW 2003 7 15 CA030528004 120030513G5347206031103043 SEAT TRACK BELL 206 206B 1181511SW ALLSN 250C 250C20B 03013GL FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) 8 INCH CRACK RUNNING LONGITUDINALLY IN BEND OF ANGLE. TOP FORWARD CORNER OF AFT CABIN SEAT STRUCTURE. 1G71 3U3 U H2SW E4CE 20030715000052003071500005SW 2003 7 15 CA030528005 120030512G5302206032308103S FRAME BELL 206 206L1 1182107SW ALLSN 250C 250C28 03013GL FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) CRACK FOUND IN AFT FUSELAGE FRAME. CRACK APPROXIMATELY .3750 INCH IN LENGTH LOCATED ABOVE UPPER RT TAILBOOM ATTACH BOLT MOUNTING BOLT HOLE. FOUND DURING 1200 HR TAILBOOM INSPECTION AND ONLY VISIBLE WITH 10X POWER GLASS. FRAME REPLACED WITH NEW. 1G71 3U3 U H2SW E1GL 20030715000062003071500006SW 2003 7 15 CA030528006 120030408G6320206040532005 CASE BELL BELL 206 206L1 1182107SW ALLSN 250C 250C28B 03013GL TRANSMISSION CRACKED W K NONE O OTHER ININSP/MAINT 1 CA BMC00527 (CAN) 1 SPLINE, ADJACENT TO 3 REWORKED SPLINES HAS SUSPECTED CRACK, IMPACT DAMAGE AND CORROSION PITTING OVER 40 PERCENT LENGTH OF SPLINE. 2ND ADJACENT SPLINE, ALSO HAS SUSPECTED CRACK AND CORROSION PITTING. CRACKS NOT IDENTIFIED ON INITIAL OH NDI ( FPI). UPPER CASE SCRAPPED. 1G71 3U3 U H2SW E1GL 20030617000222003061700022CE 2003 6 17 CA030528007 120030520G8011PM2401H STARTER CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA ENGINE FAILED W O OTHER O OTHER TXTAXI/GRND HDL 1 CA (CAN) STARTER FAILED AFTER MINIMAL USE. 1H71 3O3 ONT3A12 1E10 20030702000622003070200062EU 2003 7 2 CA030528010 120030423G5312 PRESSURE PANEL BAC 146 146200A 1500266EU LYC ALF502ALF502R5 41580NE MLG WW CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 3214432144 (CAN) DURING A 'C' CHECK INSPECTION A 13 INCH CRACK DISCOVERED IN THE WHEEL WELL UPPER PRESSURE SKIN ALONG AIRCRAFT CENTER LINE AT EDGE OF STRINGER BETWEEN FRAMES 29 TO FRAME 32. MANUFACTURER CONTACTED. DAMAGE REPAIRED IAW MFG REPAIR INSTRUCTION HC532H9018. 2H74 4F4 F A49EU E6NE 20030703000382003070300038SO 2003 7 3 CA030528011 120030502G5330 SKIN EMB 120 EMB120ER 3260203SO PWA 118 PW118 NE HAMSTD14RF 14RF9 NE FUSELAGE LIGHTNING STRIKEW O OTHER O OTHER NRNOT REPORTED 1 CA 1748517485 (CAN) DAMAGE CAUSE TO AIRCRAFT AND EQUIPMENT DUE TO LIGHTNING STRIKE. MFG RECOGNIZED THE LOWER FUSELAGE COMPOSITE PANELS ATTACHING THE ROTARY BEACON DO NOT HAVE ADEQUATE BONDING AND A SERVICE BULLETIN IS UNDER EVALUATION TO PROVIDE AN APPROPRIATE BONDING. 2L72 4T4 TRTA31SO E20NE 6 CP11NE 20030703000392003070300039CE 2003 7 3 CA030528012 120030519G32440316138 WHEEL CESSNA560 560XL 2076702CE PWA 545 PW545A NE NLG UNBONDED W C ABORTED TAKEOFF E VIBRATION/BUFFET TOTAKEOFF 1 CA (CAN) AT LIFT OFF PILOT HEARD AND FELT STRONG VIBRATIONS ON THE NOSE WHEEL. HE DECLARED AN EMERGENCY AND RETURNED TO BASE. DURING THE INVESTIGATION FOUND NOSE WHEEL OUT OF BALANCE. NOSE WHEEL ASSY WAS STRIPPED MAY 27/03 AND FOUND BALANCE PATCH GLUED TO TIRE UNBONDED WHICH CAUSE THE VIBRATION, THE PATCH WEIGHT IS 1 OUNCE. 2L72 4F4 FRTA22CE E00059EN 20030703000402003070300040 2003 7 3 CA030528013 420030527G2565101656305 SLIDE BOEING767 767333 1385301NM GE CF6 CF680C2B6F 30025NE LT WING DEPLOYED W O OTHER W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) LT O/H WING CHUTE WAS ACCIDENTALLY DEPLOYED BY FLT OPS DURING A TRAINING SESSION. THE CHUTE DID NOT DEPLOY COMPLETELY. THE LOWER SECTION OF THE CHUTE WAS PREVENTED FROM COMPLETE DEPLOYMENT BY THE IB SIDE. CONFIRMED, OPERATOR NEVER CHANGED OR REMOVED THIS CHUTE, IT'S A NEW AIRCRAFT SINCE 2001 CHUTE MFR DATE 03/01 PACK DATE 06/15/01. 2L72 4F4 FRTA1NM E13NE 20030822000932003082200093NE 2003 8 22 CA030528014 220030512G74219550168760 IGNITER SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE ENGINE FAILED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) GENERAL INFORMATION LETTER NR 02-01 (FEB18, 2002), SERVICE LETTER 2171/02/ARL1/66 (FEB12, 2002), AND SERVICE LETTER 2223/03/ARL/173 (APRIL02, 2003), THESE PART NUMBER IGNITERS ARE FAILING IN SERVICE, USUALLY CAUSING EXTENSIVE ENGINE DAMAGE (WITH FIRST HAND KNOWLEDGE OF THIS). IT IS MFG RECOMMENDATION THAT THESE IGNITERS BE REMOVED FROM SERVICE TO PREVENT THIS ENGINE DAMAGE FROM OCCURING, AND THEY HAVE BEEN REPLACING THEM ON WARRANTY. ON THE ENGINE LISTED ABOVE, RECEIVED NEW FROM MFG FEBRUARY 2003, THESE PART NUMBER IGNITERS WERE FOUND TO BE INSTALLED DURING A ROUTINE VISUAL EXAMINATION OF THE ENGINE TECHNICAL LOGS. THEY WERE REMOVED PRIOR TO FURTHER FLIGHT AND RE PLACEMENT IGNITERS INSTALLED. 1G71 3U3 U H9EU E19EU 20030721000492003072100049SO 2003 7 21 CA030528015 120030528G1430MS24665143 COTTER PIN CURTISC46 C46FAIRLIFT SO PWA R2800 R2800* 52026NE FUSELAGE MISMANUFACTURED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) THE COTTER PINS RECIEVED FROM AIRCRAFT PARTS INTERNATIONAL ARE FAULTY AROUND THE HEAD. THE COTTER PINS ARE MANUFACTURED BY WESTERN WIRE. WE RECIEVED THEM IN MARCH 2003. WHEN I CALLED THE SUPPLIER AND EXCHANGED LOT NUMBERS, HE HAD A DIFFERENT LOT NUMBER OF COTTER PINS THAT DID THE SAME THING, BREAK AT THE LOOP. 2L72 4R4 R 3A2 5E8 20030617000512003061700051EA 2003 6 17 CA030529001 220030430G852013F17786 CRANKSHAFT PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA ENGINE BROKEN W EO ENGINE SHUTDOWN OTHER YJ ENGINE STOPPAGE WARNING INDICATION CRCRUISE 1 CA (CAN) DURING CRUISE FLIGHT, THE RT ENGINE STOPPED. THE PILOTS TRIED TO RESTART THE ENGINE WITHOUT SUCCESS. WHILE SEARCHING THE CAUSE OF THE ENGINE STOPPAGE, WE DISCOVERED THAT THE VALVES WERE NOT WORKING. WE REMOVED THE ENGINE AND SENT IT FOR OVERHAUL, ON DISASSEMBLY THEY FOUND THE CRANKSHAFT BROKEN. ACCORDING TO THE OVERHAUL FACILITY DETONATION WOULD HAVE CAUSED THE CRACK. THE ENGINE WAS REPAIRED AND REINSTALLED. 1L72 3O3 O A20SO E14EA 20030617000532003061700053SO 2003 6 17 CA030529003 120030523G5730 STITCHING PIPER PA18 PA18150 7101828SO LYC O320 O320A2B 41508EA RT WING RIBS BROKEN W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) RIB STICHING BROKEN MOST RIBS RT WING RECORDS. ONLY GO BACK TO 1978 NO RECORD OF REPLACEMENT AT THAT TIME. FABRIC TESTED GOOD. (WING RESTITCHED.) 1H71 3O3 O 1A2 E274 20030702000632003070200063WP 2003 7 2 CA030529004 120030526G5270H2028B SWITCH DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE PAX DOOR DIRTY W A UNSCHED LANDING N FALSE WARNING CRCRUISE 1 CA (CAN) WHILE IN CRUISE THE AFT CABIN DOOR OPEN LIGHT ILLUMINATED. AIRCRAFT RETURNED TO AIRPORT FOR INVESTIGATION. DOOR FRAME AND SEAL CHECKED, NO DEFECT. DOOR SWITCH INSPECTED AND CLEANED. AIRCRAFT RETURNED TO SERVICE. 2L72 4F4 FRTA6WE E9NE 20030703000312003070300031EA 2003 7 3 CA030529005 220030323G7200 ENGINE PWA PT6 PT6A28 EA FAILED W O OTHER Y ENGINE STOPPAGE NRNOT REPORTED 1 CA (CAN) ENG WAS REMOVED FROM WING AFTER A/C (ON LANDING) SKIDDED OFF END OF RUNWAY INTO MUD. ENG BEEN SENT FOR SUDDEN STOPPAGE. ENG WAS DAMAGED IN ACCIDENT. MOST SERIOUS DAMAGE WAS FOUND IN PWR SEC BUT BROKEN FUEL PUMP MNTG FLANGE INDICATES THAT GG SEC HAD SOME SERIOUS LOADS/STRESS. ENG MOSTLY PWR SEC WAS DAMAGED DURING INCIDENT. ENERGY OF IMPACT WAS REALIZED ON EXHAUST DUCT THROUGH ITS OUTER SKIN DEFORMATION WHILE OTHER POWER SEC INTERNAL COMPONENTS WERE NOT DAMAGED DESPITE FACT THAT PT SECTION WAS MOVED REARWARD INTO HOT SECTION. ALL POWER, HOT SECTION ELEMENTS, EXCEPT EXHAUST DUCT, WERE REPAIRABLE. GG SECTION DID NOT HAVE NOTICEABLE DAMAGE ATTRIBUTED TO INCIDENT. UNSERVICEABLE PARTS WERE REPLACED. 4 T E4EA 20030703000322003070300032EA 2003 7 3 CA030529006 220030323G7200 ENGINE PWA PT6 PT6A28 EA FAILED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) ENGINE WAS REMOVED FROM WING AFTER A/C (ON LANDING) SKIDDED OFF END OF RUNWAY INTO MUD. ENGINE HAS BEEN SENT FOR SUDDEN STOPPAGE INVESTIGATION AND REPAIR. ENGINE WAS DAMAGED IN ACCIDENT. MOST SERIOUS DAMAGE WAS FOUND IN POWER SECTION BUT BROKEN FUEL PUMP MOUNTING FLANGE INDICATED THAT GG SECTION HAD SOME SERIOUS LOADS/STRESS. ENERGY OF IMPACT WAS REALIZED ON EXHAUST DUCT THROUGH ITS OUTER SKIN DEFORMATION WHILE OTHER POWER SECTION INTERNAL COMPONENTS WERE NOT DAMAGED DESPITE FACT PT SECTION WAS MOVED REARWARD IN TOWARDS THE HOT SECTION. ALL POWER AND HOT SECTION ELEMENTS EXCEPT EXHUAST DUCT WERE REPAIRABLE. ENGINE WAS REPAIRED IAW MM, LIGHT OVERHAUL SECTION. 4 T E4EA 20030703000332003070300033SW 2003 7 3 CA030530001 120030526G6330212030104101 LINK BELL 212030104101BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA XMSN MOUNT BROKEN W O OTHER D INFLIGHT SEPARATION CRCRUISE 1 CA (CAN) AFTER THE FLIGHT AN INSPECTION OF THE AIRCRAFT IT WAS DETERMINED THAT PART OF THE LIFT LINK HAD BROKEN OFF NEAR THE UPPER STAKED BEARING BOSS. THE CAUSE OF THE BROKEN PIECE UNDETERMINED AT THIS TIME, INVESTIGATION IS ON GOING. 1G71 4U4 U H4SW E22EA 20030702000642003070200064NM 2003 7 2 CA030530004 120030501G5522 SKIN AIRBUSA319 A319114 3930350NM GE CFM56 CFM565A 13802NE RT ELEVATOR INOPERATIVE W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THIS WAS A PREVIOUS INSPECTON CALLED ON A320 FLEET. THIS IS AN UNSCEDULED INSPECTION OF THE LT ELEVATOR SURFACE ON THE A319. THE INSPECTION ON THE A320 FLEET WAS 55-1024 THE ELEVATOR IN QUESTION WAS DECLARED BER (BEYOND ECONOMICAL REPAIR) AND HAD TO BE REPLACED. AIRCRAFT TOTAL TIME 17,948. NOTE: SAME AS A 320 EXCEPT THE 319 DOES NOT HAVE THE AD APPLIED TO IT. 2L72 4F4 FRTA28NM E29NE 20030703000372003070300037NM 2003 7 3 CA030530005 120030528G275185711423101 BRACKET DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE TORQUE SENSOR BROKEN W O OTHER F FLT CONT AFFECTED LDLANDING 1 CA (CAN) AT THE END OF THE LANDING ROLL THE FLAPS WERE SELECTED UP. FLAPS TRAVELLED TO APPROX 5 DEG AND STOPPED. FLAP DRIVE ANNUN ILLUMINATED, FLAPS WOULD NOT MOVE UP OR DOWN. MAINT WAS DISPATCHED AND DISCOVERED SECONDARY FLAP DRIVE CABLE INTO LT FLAP TORQUE SENSOR, SHEARED. LT FLAP TORQUE SENSOR BRACKET WAS FOUND BROKEN THROUGH ON TOP FOLD AND CRACKED ALONG LOWER FOLD. SOME MINOR LOOM DAMAGE OCCURED DUE TO THRASHING OF ADRIFT DRIVE CABLE. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030702000982003070200098GL 2003 7 2 CA030530006 320030526G6114D4883 NUT MCAULY BEECH 95 95B55 1152729CE CONT O470 IO470L 17026SO MCAULY2AF34C2AF34C55 GL PROPELLER CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 780950 (CAN) CUSTOMER COMPLAINED OF SPINNER CRACKING. OVER HAULED BOTH PROPS AS A PRECAUTIONERY. CHECKED PROP BEFORE DISASSEMBLY. TRACK, ANGLES, BALANCE WITHIN SPEC. FOUND HUB CRACKED IN THREADS. MATE TO PROBLEM PROPELLER. 1 CRACKED BLADE NUT. 1L72 3O3 ORT3A16 3E1 5 CP5EA 20030703000242003070300024NE 2003 7 3 CA030530010 220030519G7321430128807 FUEL CONTROL SNIAS 350 AS350D 8680803EU LYC LTS101LTS101600A3 41560NE ENGINE FAILED W O OTHER E VIBRATION/BUFFET TXTAXI/GRND HDL 1 CA (CAN) NO FUEL COMING OUT THE FUEL CONTROL UNIT. IT HAPPENED ON THE FIRST START ATTEMPT, IN THE MORNING. INTERNAL FAILURE OF FCU SUSPECTED, SINCE ALL FUEL LINES HAVE BEEN BLED FROM AIR. PREVIOUS FLIGHTS HAD NOT REVEALED ANY FLUCTUATIONS OR PARAMETERS PROBLEMS. FCU HAS BEEN REPLACED ON 22 MAY 2003. AND STARTS WERE AS NORMAL AS IT SHOULD. THEN, INTERNAL FCU FAILURE WILL HAVE TO BE INVESTIGATED BY THE OVERHAUL FACILITY OR MANUFACTURER. 1G71 3U3 U H9EU E5NE 20030703000252003070300025EA 2003 7 3 CA030530011 120030515G5610601R3303311 WINDOW CNDAIRCL600 CL6002B19 1900309EA COCKPIT BROKEN W A UNSCHED LANDING O OTHER DEDESCENT 1 CA (CAN) DURING THE FIRST PRODUCTION FLIGHT TEST AT 8,000 FT/250 KTS AND APPROXIMATELY 2.5 PSID IN DESCENT. THE LT SIDE WINDOW SHATTERED. 2L72 4F RTA21EA 20030702000992003070200099EU 2003 7 2 CA030530012 120030527G6320 GEARBOX BOLKMS117 BK117B1 5626012EU LYC LTS101LTS101750B1 41560NE MAIN ROTOR MAKING METAL W A UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 CA (CAN) MAIN TRANSMISSION CHIP LIGHT IN CRUISE, CHIP DETECTORS PULSED UNSUCCESSFULLY, PILOTS LANDED A/C. CHIP DETECTORS INSPECTED AND FOUND .1 FT X .05 FT FERROUS CHIP WITH SEVERAL FERROUS FLAKES. FILTERS INSPECTED, FOUND CONTAMINATED WITH FERROUS FLAKES. TRANSMISSION REMOVED FOR REPAIR. 1G72 3U3 U H13EU E5NE10 20030702000652003070200065EA 2003 7 2 CA030530014 120030528G2613GG670801021 LOOP CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE BLEED SENSING FAILED W A UNSCHED LANDING W INADEQUATE Q C CLCLIMB 1 CA (CAN) CREW EXPERIENCED A LT BLEED DUCT WARNING MSG ON CLIMB OUT THRU 23,000 FT. LT PACK WENT OFF LINE & APPROX. 30 SECONDS LATER, RT PACK WENT OFF LINE. CREW WERE UNABLE TO RESET THIS CONDITION IN AIR. AC DIVERTED. TROUBLESHOOTING, MAINT LT BLEED LOOP B HIGH PRESS OUTPUT(MT138) FOUND FAILED/OPEN CIRCUIT. LT BLEED LOOP ACM (MT140) FOUND TOUCHING BLEED DUCT IN TWO AREAS. A BLEED LEAK WAS FOUND BETWEEN LT ACM & PRE-COOLER. LOSS OF PRESS IS BELIEVED TO BE DUE TO LT BLEED DUCT WARNING WHICH REMAINED CONSTANT FOR MORE THAT 30 SECONDS RESULTING IN AUTOMATIC CLOSING OF L AND R ENGINE BLEED SOURCES.FOLLOWING REPLACEMENT OF FAILED LOOPS & RECTIFICATION OF LEAK, AC FLT TESTED & DECLARED SERVICEABLE. 2L72 4F4 FRTA21EA EOOO63EN 20030703000222003070300022CE 2003 7 3 CA030602001 120030530G275214601007 CONTROL CABLE CESSNA337 337G 2075730CE CONT O360 IO360G 17025SO MCAULY2AF34CD2AF34C306 GL FLAP ACTUATOR DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) AFTER RECEIVING SDR ALERT AL-2003-05 AN INSPECTION WAS CARRIED OUT ON OUR 337G. TWO CABLES ON BOTH SIDES WERE FOUND DAMAGED. THE DAMAGE WAS LOCATED EXACTLY IN THE SAME LOCATION AS MENTION IN THE ALERT IE AROUND THE SHARP BEND OF THE BELLCRANK. ALL CABLES HAD TO BE REMOVED TO SEE THE DAMAGE.HAD THEY NOT THE DAMAGE WOULD OF WENT UNNOTICED. BOTH SETS OF CABLES WERE REPLACED WITH SERVICEABLE UNITS. 1H72 3O3 O A6CE E1CE 5 CP5EA 20030703000212003070300021EU 2003 7 3 CA030602005 120030523G1430LN93556X32 BOLT BO105 BOLKMS105 BO105C 5626005EU ALLSN 250C 250C20B 03013GL HYD PACK INCORRECT W K NONE O OTHER ININSP/MAINT 1 CA (CAN) WHILE COMPLYING WITH FLEET CAMPAIGN NOTICE 351-73-20-12 IT WAS FOUND THAT THE BOLT CONNECTING THE TWO NR 2 GOVERNOR CABLES TOO THE HYD PACK WAS TOO SHORT, ONLY ONE THREAD WAS SHOWING THROUGH THE ANCHOR NUT. A NEW BOLT WAS INSTALLED AND THE AIRCRAFT WAS RETURNED TO SERVICE. 1G72 3U3 U H3EU E4CE 20030703000352003070300035CE 2003 7 3 CA030602008 120030527G30009091009913 LINE BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA HARTZLHCB3T HCB3TN3 GL ANTI ICE SYS CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) DURING INSPECTION THE LT AND RT ENGINE SHORT ANTI-ICE FLEX TUBES WERE FOUND TO BE CRACKED. THERE WAS NO EVIDENCE OF AN EXHAUST LEAK INSIDE THE COWLING. THE TUBES WERE CRACKED APPROX. HALF OF THEIR CIRCUMFERENCE. CRACKED TUBES WERE REPLACED. LT TUBE TTSN 351 HOURS. RT TUBE TTSN 44 HOURS. 1L72 3T4 TRT3A20 E4EA 6 CP15EA 20030703000082003070300008NM 2003 7 3 CA030602010 120030529G324050841 SHUTTLE VALVE DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE BRAKE SYSTEM BROKEN W O OTHER KJ FLUID LOSS WARNING INDICATION CLCLIMB 1 CA (CAN) NUMBER ONE BRAKE ASSY WAS LEAKING AT PISTON (DUE TO AN O-RING PROBLEM). THE NR 1 SHUTTLE VALVE WAS NOT OPERATING PROPERLY CAUSING NR 2 HYDRAULIC SYSTEM QUANTITY DROP TO ZERO AND NR 1 HYD SYSTEM DROP TO 1 QUART CAUSING MANY SYSTEM FAILURE. THAT PROBLEM IS KNOWN BY THE MANUFACTURER AND A SB EXIST TO CORRECT THE PROBLEM. AN AD IS ALSO IN A DRAFT PROCESS. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030703000092003070300009 2003 7 3 CA030603005 420030602G231124700032 AUDIO PANEL CESSNA172 172RG 2072438CE LYC O360 O360F1A6 41514EA MCAULY2D34C B2D34C220 GL UHF SYSTEM MISINSTALLED W O OTHER W INADEQUATE Q C NRNOT REPORTED 1 CA (CAN) CREW REPORTED BOTH VOR SYSTEMS WERE NOT FUNCTIONING COMPLETELY. VOR AUDIO SIGNAL COULD BE PICKED UP AND TO/FROM FLAG WORKED. INDICATOR NEEDLES WOULD NOT DEVIATE FROM CENTER. COMPONENTS FAILED TO DETERMINE SOURCE OF PROBLEM. A/C WAS SENT TO FACILITY WHERE THEY DETERMINED THAT AUDIO PANEL DID NOT HAVE RELAYS INSTALLED FOR AUTOPILOT. IT WOULD APPEAR THAT AUDIO PANEL WAS DIFFERENT FOR A/C WITH FACTORY INSTALLED AUTOPILOTS. AUDIO PANEL DOES NOT LOOK DIFFERENT FROM FRONT, NO DISTINGUISHING PLACARDS TO WARN THAT UNIT IS FOR AUTOPILOT EQUIPPED MODELS ONLY. ALSO, NONE OF THE UNITS WE TRIED WERE SERIALIZED. RESULT WAS THAT PROPER AUDIO PANEL WAS INSTALLED FOR A/C & ALL RELATED SYSTEMS CHECKED SERVICEABLE. 1H71 3O3 O 3A17 E286 5 CP7EA 20030703000102003070300010CE 2003 7 3 CA030603006 120030529G32421338932 STATOR CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE BRAKE ASSY BROKEN W O OTHER O OTHER TXTAXI/GRND HDL 1 CA (CAN) A/C WAS TAXIING TO POSITION TO PARK ON APRON WHEN IT HAD AN UNCOMMANDED BRAKING ACTION ON LT SIDE OF A/C. FLIGHT CREW SHUT DOWN AS NORMAL AND INVESTIGATED PROBLEM. UPON VIEWING LT BRAKE, NOTICED PIECES OF BRAKE STICKING OUT AND REASON FOR BRAKE TO JAM. ENG FLEW UP WITH PARTS, FOUND PIECES WERE PARTS OF IB STATOR. BRAKE WAS CHANGED, NO OTHER DAMAGE TO A/C WAS NOTED. UPON INVEST OF BRAKE ASSY, IT WAS NOTED THAT IB STATOR BROKE INTO 4 PIECES. SOME PIECES HAD JAMMED BETWEEN TORQUE PLATE ASSY, LINING CARRIER ASSY (ROTOR), CAUSING BRAKE TO JAM AND ALSO CAUSING DAMAGE TO TORQUE PLATE ASSY. BRAKE UNIT WAS STAMPED WITH 'SB' INDICATING COMPLIANCE WITH SB550-32-41 AND STATOR WAS STAMPED WITH 'CHGC' AFTER PN. 1L72 4F4 F A22CE E1NE 20030703000112003070300011CE 2003 7 3 CA030603007 120030528G323008421022 BELLCRANK CESSNA310 T310P 2074240CE CONT O520 TSIO520B 17040SO MCAULY3AF32C3AF32C87 GL NLG WW BROKEN W O OTHER O OTHER CLCLIMB 1 CA (CAN) WHEN GEAR WAS SELECTED UP AFTER TAKE OFF A LOUD SNAP WAS HEARD THE RED GEAR LIGHT WAS ON. WHEN GEAR WAS SELECTED DOWN THE 3 GREEN GEAR LIGHTS WAS OBTAINED. THE AIRCRAFT LANDED WITHOUT FURTHER INCIDENT. FOUND BROKEN IDLER BELLCRANK. MAINTENANCE IS CHECKING RIGGING AND ANY OTHER CAUSES. 1L72 3O3 O 3A10 E8CE 5 CP22EA 20030702000752003070200075SW 2003 7 2 CA030603009 120030131G5310205030712037 ANGLE BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) CRACK IS IN ANGLE ONLY, NOT FITTING. 1G71 4U4 U H4SW E22EA 20030703000122003070300012SW 2003 7 3 CA030603010 120030131G5302212030156047 BULKHEAD BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA TAILBOOM CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) TAIL BOOM ATTACH BULKHEAD AT STA 243.937, P/N 212030156047. CRACK UNDER 1 INCH LENGTH. BULKHEAD REPLACED WITH NEW. 1G71 4U4 U H4SW E22EA 20030703000132003070300013CE 2003 7 3 CA030603011 120030529G2752503801536 DRIVE GEAR BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA HARTZLHCB3T HCB3TN3 GL FLAP ACTUATOR FAILED W A UNSCHED LANDING F FLT CONT AFFECTED CLCLIMB 1 CA (CAN) DURING TRAINING FLIGHT, CREW WAS PERFORMING (TOUCH AND GO). AFTER TAKEOFF, CREW RETRACTED FLAPS AND SYS C/B POPPED. INDICATIONS REVEALED THAT RT FLAPS HAD A STAGGER. CREW DECIDED TO DO A FLAPLESS LANDING. ON GROUND FLAP EXT REVEALED THAT TARGET FLAP (RT IB) REMAINED UP WHILE OTHER THREE CAME DOWN. FLAP MOTOR RAN TILL C/B POPPED. INVESTIGATION REVEALED THAT LOCK PIN RETAINING NUT ON 90 DEGREE DR ADAPTER, ON FLAP ACT (RT IB), FOR TARGET FLAP HAD BACKED OFF AND PIN GOT DISENGAGED FROM JACK GROOVE. 90 DEGREE DR HSG MOVED AWAY FROM JACK AND ALLOWED BEVEL GEAR TO DISENGAGE. 90 DEGREE DR ADAPTER ON RT IB ACTUATOR WAS REPLACED. A FLEET WIDE INSPECTION WAS CARRIED OUT FOR SECURITY OF NUT IN QUESTION. 1L72 3T4 TRT3A20 E4EA 6 CP15EA 20030703000142003070300014EA 2003 7 3 CA030603012 120030602G2421755469B IDG CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE AC GENERATOR MAKING METAL W A UNSCHED LANDING H ELECT. POWER LOSS-50 PC CRCRUISE 1 CA (CAN) IDG 2 CAUTION MSG POSTED WHILE IN CRUISE. LT ENGINE GENERATOR ALREADY DEFERRED. AIRCRAFT DIVERTED, DECLARED AN EMERGENCY AND LANDED WITHOUT FURTHER INCIDENT. MTCE REPLACED IDG NR 2 AND OPS CHECKED SERVICEABLE. LEFT ENGINE GENERATOR REMAINED DEFERRED. AIRCRAFT RETURNED TO SERVICE. 2L72 4F4 FRTA21EA E15NE 20030703000182003070300018 2003 7 3 CA030603013 420030529G22156288713001 DOWEL PIN CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE SERVO CONTROL SHEARED W O OTHER D INFLIGHT SEPARATION APAPPROACH 1 CA (CAN) PILOT REPORTED THAT WHEN AUTOPILOT WAS DISCONNECTED ON APPROACH ELEVATOR CONTROL WAS VERY HEAVY. PILOT ASKED CO-PILOT TO CONFIRM. BOTH WERE IN AGREEMENT THAT AIRCRAFT WAS VERY HEAVY ON THE PITCH CONTROL. AN UNEVENTFUL LANDING WAS COMPLETED WITH BOTH PILOTS FLYING AIRCRAFT DUE TO HEAVINESS OF CONTROLS. ONCE ON GROUND, IT WAS AGAIN CONFIRMED THAT ELEVATOR CONTROL FELT HEAVY. NOISE COULD BE HEARD WHEN ELEVATOR CONTROL WAS MOVED. NOISE WAS ISOLATED TO ELEVATOR AUTO PILOT SERVO, WITH SERVO MOTOR REMOVED CAPSTAN DRIVE GEAR DOWELS (QTY 6) WERE FOUND SHEARED. THE ELEVATOR SERVO MOUNT WAS REPLACED AND THE ELEVATOR CONTROL SYSTEM INSPECTION WAS COMPLETED FROM NOSE TO TAIL WITHOUT ANY OTHER ANOMALY FOUND. 2L72 4F4 FRTA21EA E15NE 20030617000552003061700055EA 2003 6 17 CA030604001 220030601G8530 VALVE CESSNA177 177RG 2073709CE LYC O360 IO360A1B6 41514EA MCAULY2D34C B2D34C207 GL CYLINDER HEAD BROKEN W A UNSCHED LANDING E VIBRATION/BUFFET CLCLIMB 1 CA (CAN) PILOT REPORTED HEARING A BANG DURING CLIMB, FOLLOWING BY PARTIAL POWER LOSS AND VIBRATION WAS FELT. AN EMERGENCY WAS DECLARED AND AIRCRAFT RETURN FOR AN UNEVENTFUL LANDING. INITIAL INVESTIGATION REVEALED NR 3 CYLINDER HAS A VALVE HEAD SEPARATED AND IS STICKING OUT OF BOTTOM SPARK PLUG HOLE AREA. FURTHER DETAIL WILL BE SUBMITTED UPON ENGINE TEARDOWN. 1H71 3O3 O A20CE 1E10 5 CP7EA 20030702000762003070200076CE 2003 7 2 CA030604002 120030520G7830AE1009195G0130 HOSE ROHR CESSNA500 560CESSNA 2076750CE PWA JT15 JT15D1 52060NE THRUST REVERSER RUPTURED W O OTHER K FLUID LOSS ININSP/MAINT 1 CA 3688 (CAN) WHILE PREPARING TO REFUEL THE AIRCRAFT, PILOT NOTED A LARGE QUANTITY OF HYDRAULIC FLUID ON THE RT ENGINE/THRUST REVERSER AREA. THE AFT HYDRAULIC HOSE CONNECTING THE TAIL ROTOR TO THE PYLON HAD BURST AT APPROXIMATELY MID LENGTH. (THIS IS THE AREA WHERE THE HOSE MAKES A 90 DEGREES TURN.) THE CREW HAD NO INDICATION OF THE PROBLEM DURING LANDING AND TAXI. 2L72 4F4 FRTA22CE E1NE 20030703000152003070300015CE 2003 7 3 CA030604003 120030517G323399810057652 ACTUATOR BEECH 100 A100 1152915CE PWA PT6 PT6A28 EA HARTZLHCB3T HCB3TN3 GL MLG DAMAGED W O OTHER J WARNING INDICATION DEDESCENT 1 CA (CAN) INSPECTION OF LT MAIN LANDING GEAR ACTUATOR P3 99-810057-652 S NR 89-1002 FOLLOWING THE OCCURENCE REVEALED THAT THE ACME THREADS IN THE ACTUATOR WERE STRIPED. THE UNIT WAS REPLACED WITH AN OVERHAULED ACTUATOR AS WAS THE RIGHT HAND ACTUATOR AS A PRECAUTIONARY MEASURE. 1L72 3T4 T A14CE E4EA 6 CP15EA 20030703000162003070300016CE 2003 7 3 CA030604004 120030520G575350160020 BUSHING BEECH B300 B300B350C CE PWA PT6 PT6A60A 52043NE HARTZLHCB4M HCB4MP3 GL TE FLAP SEIZED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE AIRCRAFT WAS ON A 1ST PHASE 200 HOUR INSPECTION DURING WHICH A VISUAL AND OPERATIONAL CHECK OF THE FLAPS WAS MADE. AT THIS TIME IT WAS NOTICE THAT THE FLAPS DID NOT OPERATE SMOOTHLY. A CLOSER LOOK AND REMOVAL OF THE FLAPS REVEALED THAT BUSHINGS PN 50-160020 WAS SEIZED IN BOTH INBOARD AND OUTBOARD FLAPS BOTH SIDES. THE FLAPS WERE VERY DIFFICULT TO REMOVE AS ALL THE HARDWARE WAS SEIZED IN THE BUSHINGS. 2L72 4T4 TRTA24CE E4EA 6 CP56GL 20030703000172003070300017NE 2003 7 3 CA030604005 220030528G8520519589 INSERT PWA R2800 CA3 52026NE ENGINE CADE BLEW OUT W EA ENGINE SHUTDOWN UNSCHED LANDING BKESMOKE/FUMES/ODORS/SPARKS FLUID LOSS VIBRATION/BUFFET CRCRUISE 1 CA (CAN) IN FLIGHT, NOSE CASE PLUG INSERT BLEW OUT PUMPING ENGINE OIL OVERBOARD. ENGINE WAS SMOKING AND OIL STREAMING NECESSITATED ENGINE SHUT DOWN, PROP FEATHER, AND AIRCRAFT RETURNING TO AIRPORT. NOSE CASE REPLACED WITH A SERVICEABLE UNIT. 4 R E231 20030703000062003070300006GL 2003 7 3 CA030604006 320030522G6111FC84754 BLADE PIPER PA31 PA31 7103102SO LYC O540 TIO540A2B 41532EA HARTZLHCE2Y HCE2YR2 GL PROPELLER CORRODED W O OTHER P NO WARNING INDICATION ININSP/MAINT 1 CA (CAN) PROPELLER RECEIVED ON 22 MAY 2003, MODEL HC-E2YK-2B/FC847504 REMOVED FOR INSPECTION DUE TO EXCESSIVE ROTATIONAL BLADE MOVEMENT. A DECISION WAS MADE TO OVERHAUL THE PROPELLER. VISUAL INSPECTION ON ONE BLADE REVEALED EXCESSIVE CORROSION AT THE BLADE BEARING AREA. BLADE KNOB OF BLADE WAS WORN BEYOND LIMITS, BEARINGS CORRODED, PITCH CHANGE FORK AND BLOCKS WORN. ALL OTHER PARTS SUCH AS HUB ASSEMBLY, CYLINDER, PISTON, ETC. FOUND TO BE IN NORMAL CONDITION. BLADE FAILURE MOST LIKELY WOULD HAVE OCCURRED IN THE NEAR FUTURE DUE TO BLADE KNOB FAILURE OR CORROSION ON BLADE SHANK RADIUS AREA. 1L72 3O3 O A20SO E14EA 5 CP9EA 20030617000572003061700057EA 2003 6 17 CA030604007 220030526G732210S135 CARBURETOR CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA MCAULY1C160 1C160DTM GL ENGINE FAILED W E ENGINE SHUTDOWN E VIBRATION/BUFFET DEDESCENT 1 CA (CAN) ACCELERATER DISCHARGE TUBE IN THE CARBURETOR VENTURI BROKE OFF, IT WAS SUCKED UPTO THE THROTTLE PLATE AND APPARENTLY JAMMED THE THROTTLE AT 2,00 RPM. PILOT COULD NOT ADJUST POWER UP OR DOWN. THE AIRCRAFT WAS FLOWN TO THE AIRPORT, ENGINE WAS SHUT DOWN AND A GLIDE TO LANDING WAS EXECUTED. AFTER TOUCHDOWN ENGINESTARTED AND RAN NORMALLY. IT APPEARS THE DISCHARGE TUBE FELL DOWN INTO THE INTA KE AIR BOXWHEN THE ENGINE WAS SHUT DOWN DUE TO NO AIRFLOW IN THE VENTURI. THIS ALLOWED THE THROTTLE PLATE TO WORK NORMALLY FOR THE TAXI. THE TUBE WAS FOUND LYING IN THE AIRBOX BY THE CARB AT FLAPPER. 1H71 3O3 ONT3A12 E274 5 NP910 20030702000772003070200077GL 2003 7 2 CA030604008 320030604G6114A2202 BEARING HARTZL HARTZLHCE3Y HCE3YR2A GL PROPELLER WORN W O OTHER O OTHER NRNOT REPORTED 1 CA DJ11708A (CAN) UPON DISASSEMBLIED OF THE PROPELLER IT WAS NOTED THAT ALL THREE OF THE INBOARD THRUST RACES WERE BADLY DENTED. IT WAS ALSO NOTED THAT THE PC ROD WAS WORN THROUGH THE HARD CHROME SURFACE.THE BEARINGS, ROD, BALLS, AND ALL THE OTHER NECESSARY PARTS WERE REPLACED AND THE REPAIR WAS COMPLETED. BEARINGS P/N A2202, PITCH CHANGE ROD PN B2491-4S 5 CP33EA 20030702001122003070200112CE 2003 7 2 CA030604009 120030507G2720505243263 RUDDER PEDAL BEECH 95 95B55 1152729CE CONT O470 IO470L 17026SO HARTZLHCA3V PHCA3VF2 GL COCKPIT WORN W O OTHER O OTHER TXTAXI/GRND HDL 1 CA (CAN) AFTER FINDING A BROKEN RUDDER PEDAL, AN INSPECTION WAS CARRIED OUT ON THE OTHER A/C. ON ONE OF THE AIRCRAFT, THE ATTACHMENT POINT FOR THE RUDDER PEDAL WAS FOUND EXCESSIVELY WORN IN THE SAME LOCATION AS THE BROKEN PEDAL FOUND ON THE OTHER AIRCRAFT. INSPECTING THIS ATTACHMENT PROPERLY CAN BE ACCOMPLISHED BY REMOVING THE ATTACHMENT HARDWARE AND INSPECTING THE PIVOT POINTS. THE DESIGN OF THE RUDDER PEDAL AND ITS ATTACHEMENT TO THE BRAKE MASTER CYLINDER CAUSES THE PERSON INSPECTING THE PEDAL TO ASSUME THAT THERE IS NOT ANY WEAR. 1L72 3O3 ORT3A16 3E1 5 CP6EA 20030702001132003070200113NM 2003 7 2 CA030605001 120030521G5330 SKIN BOEING737 737201 1384454NM PWA JT8 JT8D9A 52048NE FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) CRACK FOUND LT SIDE OF FUSELAGE FORWARD UPPER CORNER OF WINDOW NR 4 AT BODY STATION 420 AND STRINGER NR 11 LT RECTIFICATION: HIGH FREQUENCY EDDY CURRENT CARRIED OUT IAW SRM 53-30-3 IN REPAIR AREA AT LT FUSELAGE AS 420 STR 11 LT, (NO CRACKS DETECTED). SKIN REPAIRED IAW B737 SRM 2L72 4F4 F A16WE E2EA 20030703000072003070300007CE 2003 7 3 CA030605003 120030526G801108504691 CONTACTOR CESSNA310 310R 2074245CE CONT O520 IO520MB 17032SO MCAULY3AF32C3AF32C87 GL STARTER ARCED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ELECTRICAL SYSTEM FAILED. LT STARTER RELAY STUCK IN ON POSITION DURING START. STARTER ROTATED TILL BATTERY WAS RUN OUT AS IT WAS A HIGH LOAD. SERVICEABLE RELAY WAS INSTALLED, A NEW BATTERY AND OVERHAULED STARTER WERE INSTALLED, WIRING WAS CHECKED. PROBLEM WAS CORRECTED. 1L72 3O3 O 3A10 E5CE 5 CP22EA 20030617000592003061700059EA 2003 6 17 CA030605004 220030304G8520 CONNECTING ROD BNORM BN2 BN2B21 7080221EU LYC O540 IO540K1B5 41532EA NR4 CYLINDER FRACTURED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE CAUSE OF THE ENGINE FAILURE WOULD BE DUE TO NR 4 CONNECTING ROD BOLTS FRACTURING AT THE CRANKSHAFT JOURNAL. WITH THIS HAPPENING IT BECOMES DISCONNECTED & COMPLETELY DESTROYES THE CRANKCASE IN THATAREA AND PUSHES THE NR 4 CYLINDER OFF OF IT'S BASES PULLING AND STRIPPING ALL OF THE CYLINDER STUDS. 1H72 3O3 O A17EU 1E4 20030702000782003070200078CE 2003 7 2 CA030605005 120030526G7603 SPRING CESSNA441 441 2076020CE GARRTTTPE331TPE33110 01514WP ENGINE CONTROL BROKEN W C ABORTED TAKEOFF O OTHER TOTAKEOFF 1 CA (CAN) ON TAKEOFF ROLE AIRCRAFT LT ENGINE ONLY DEVELOPED 1,000 LBS TORQUE. AIRCRAFT RETURNED TO HANGAR. MAINT RAN AIRCRAFT IN MANUAL MODE & AIRCRAFT DEVELOPED POWER. AFTER TROUBLE SHOOTING MAINTENANCE FOUND O-SPRING BROKE IN THE THROTTLE QUADRANT AND FELL INTO THE THROTTLE POT SENDING A FALSE READING TO THE COMPUTER LIMITING TORQUE. 1L72 3T4 TRTA28CE E4WE 20030703000022003070300002EA 2003 7 3 CA030605006 220030529G8520LW15272 CRANKCASE CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA ENGINE CRACKED W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) OIL LEAK DISCOVERED AT 100 HOUR INSPECTION. NR 3 CYLINDER REMOVED UPON INSPECTION OF CRANK CASE FOUND 2 CRACKS AT AFT 2 STUDS OF CYLINDER NR 3. OWNER NOTIFIED, ENGINE TO BE REMOVED. 1H71 3O3 ONT3A12 E274 20030703000032003070300003EA 2003 7 3 CA030605007 220030513G8530893742C CYLINDER DOUG DC3 R4D8 3021474WP WRIGHTR1820 R182080 67020EA HAMSTD23E 23E50 NE ENGINE PERFORATED W C ABORTED TAKEOFF K FLUID LOSS TOTAKEOFF 1 CA (CAN) AIRCRAFT NR 1 ENGINE RAN ROUGH ON TAKEOFF. COME BACK TO BASE ON REDUCED POWER. DIFFERENTIAL COMPRESSION CHECK INDICATED (0) ON NR 4 CYLINDER. FOUND ALUMINIUM IN OILFILTER. SUSPECT PISTON FAILURE. REMOVED ENGINE FOR OVERHAUL. 2L72 4R4 R 6A2 E259 6 CP603 20030703000042003070300004 2003 7 3 CA030605008 420030524G61221A2G5 GOVERNOR DHAV DHC2 DHC2MK1 2800102EA PWA R985 R985AN14B 52008NE HAMSTD2D 2D30 NE PROPELLER FAILED W C ABORTED TAKEOFF E VIBRATION/BUFFET TOTAKEOFF 1 CA (CAN) PROPELLER MOVED TO LOW RPM POSITION AS POWER WAS APPLIED FOR TAKEOFF, TAKEOFF WAS ABORTED AND AIRCRAFT TAXIED BACK TO DOCK. PROPELLER GOVERNOR REPLACED WITH OVERHAULED UNIT, MAIN OIL FILTER INSPECTED AND FOUND CLEAN. AIRCRAFT GROUND RUN AND HIGH SPEED WATER RUN COMPLETED SATISFACTORY, PROPELLER FUNCTION FOUND NORMAL. REMOVED GOVERNOR INSPECTED FOR METAL CONTAMINATION, NONE FOUND. GOVERNOR SENT TO HOPE AERO PROPELLER FOR INSPECTION AND OVERHAUL. 1H71 3R3 R A806 5E1 5 CP206 20030617000602003061700060CE 2003 6 17 CA030605009 120030527G29102607003453 TUBE LEAR 35 35A 5170602CE HYD SYSTEM LEAKING W LJ ABORTED APPROACH DUMP FUEL KJ FLUID LOSS WARNING INDICATION APAPPROACH 1 CA (CAN) ON FINAL, CREW SELECTED GEAR DOWN, GEAR UNLOCKED AND FAILED TO EXTEND, NO HYDRAULIC PRESSURE, AIRCRAFT DIVERTED TO QUEBEC AIRPORT, GEAR EMERGENCY EXTENDED, AIRCRAFT LANDED WITH NO FURTHER PROBLEM.FOUND LT ENGINE HYDRAULIC PUMP FUSELAGE LINE HAD A CHAFED HOLE FROM THE END ON A SCREW HOLDING A CLAMP. LINE REPLACED SYSTEM BLEED AND SERVICE, FOUND LT ENGINE HYDRAULIC PUMP FAILED, (SUSPECT RAN DRY), PUMP REPLACED, ALL HYDRAULIC SYSTEM CHECK SERVICEABLE, PRESSURE FILTER REPLACED. AIRCRAFT RETURNED TO SERVICE. 2L72 4F A10CE 20030702000792003070200079WP 2003 7 2 CA030605010 120030529G6210369A10045 PIN DOUG HUGHES369 369D 4470706WP ALLSN 250C 250C20 03013GL M/R HEAD BROKEN W O OTHER O OTHER NRNOT REPORTED 1 CA 0980 (CAN) UPON POST FLIGHT INSPECTION BLADE PIN FOUND TO BE BROKEN WHERE THREAD MEETS THE PIN. 1G71 3U3 U H3WE E4CE 20030703000052003070300005 2003 7 3 CA030605011 420030602G25624520130 BATTERY PACK PIPER PA44 PA44180 7104402SO LYC O360 O360A1H 41514EA HARTZLHCC2Y HCC2YR2 GL ELT CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) WHILE CHANGING A BATTERY PACK IN AN ELT, THE CASING WAS NOTICED TO BE CRACKED ATTHE SCREW HOLES. IF THE BATTERIES HAD LEAKED THE ACID COULD LEAK ON TO THE BATTERY TRAY & THE AIRCRAFT SURROUNDING STRUCTURE. THIS HAS HAPPENED TWICE BEFORE. WE HAVE AN INSPECTION INTERVAL OF 50 HRS. ON THE BATTERY TRAY AND ELT MOUNTING. 1L72 3O3 O A19S0 E286 5 CP920 20030702001082003070200108EU 2003 7 2 CA030605012 120030604G7603LN93556X32 BOLT BOLKMS105 BO105S 5626006EU ALLSN 250C 250C20 03013GL N2 LEVER OVERSIZED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING INSPECTION TO COMPLY WITH AIRCRAFT SERVICES CAMPAIGN NOTICE THE BOLT CONNECTING THE N2 CONTROL CABLES TO THE N2 LEVER ASSEMBLY WAS FOUND TO BE TOO LONG. THE EXTRA LENGTH HAD BEEN COMPENSATED FOR WITH THE USE OF EXTRA WASHERS UNDER THE BOLT HEAD. INCORRECT BOLT WAS REMOVED & CORRECT BOLT INSTALLED AND TORQUE SEAL APPLIED TO THE END OF THE BOLT TO NUT-PLATE CONNECTION. 1G72 3U3 U H3EU E4CE 20030617000622003061700062EU 2003 6 17 CA030605013 120030530G7603LN93556X32 BOLT BOLKMS105 BO105C 5626005EU ALLSN 250C 250C20B 03013GL N2 LEVER LOOSE W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING INSPECTION TO COMPLY WITH AIRCRAFT SERVICES CAMPAIGN NOTICE 351-73-20-12 THE BOLT CONNECTING THE N2 CONTROL CABLES TO THE N2 LEVER ASSEMBLY WAS FOUND TO HAVE A LOW DRAG TORQUE IN THE NUT-PLATE.A NEW BOLT WAS INSTALLED & DRAG TORQUE WAS DETERMINED TO BE ACCEPTABLE. 1G72 3U3 U H3EU E4CE 20030702000802003070200080CE 2003 7 2 CA030605014 120030604G2750656517543 SWITCH CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE TE FLAPS SYS OUT OF RIG W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) THE FLAP SYSTEM SECONDARY SWITCHES LOCATED IN THE AFT CABIN WERE FOUND TO BE SEVERELY OUT OF RIG. THIS ALLOWED THE FLAP BELL CRANKS TO OVER TRAVEL CONTACTING THE WING STRUCTURE DURING FLAP OPERATION. NO STRUCTURAL DAMAGE WAS FOUND. SYSTEM RERIGGED & CHECKED SERVICEABLE. 1L72 4F4 F A22CE E1NE 20030702001072003070200107WP 2003 7 2 CA030605015 220030529G7321 FUEL CONTROL LEAR 35 35A 5170602CE GARRTTTFE731TFE73122B 01518WP ENGINE INOPERATIVE W O OTHER E VIBRATION/BUFFET ININSP/MAINT 1 CA (CAN) WHEN TESTING MANUAL MODE (COMPUTER OFF) THERE WAS NO ENGINE POWER RESPONSE TO POWER LEVER INPUTS. FCU REPLACED, PROBLEM SOLVED. 2L72 4F4 F A10CE E6WE 20030702001092003070200109GL 2003 7 2 CA030605016 320030527G6110B1894 NUT HARTZL DHAV DHC2 DHC2MK1 2800102EA PWA R985 R985AN14B 52008NE HARTZLHCB3R HCB3R304 GL PROPELLER CRACKED W K NONE O OTHER ININSP/MAINT 1 CA CX41 (CAN) PROP WAS REMOVED DURING ENGINE REPAIRS, NUT HOLDING PROP TO CRANKSHAFT WAS FOUND CRACKED. NUT WAS CRACKED FROM NOTCH FOR INSTALL/REMOVAL TOOL TO HOLE FOR LOCKING CLIP. NUT WAS REPLACED WITH OVERHAULED UNIT AND PROP WAS REINSTALED & AIRCRAFT RETURNED TO SERVICE. 1H71 3R3 R A806 5E1 5 CP28EA 20030617000682003061700068NE 2003 6 17 CA030605019 220030530G8550 ENGINE GRUMAVG21 G21A 3951204SO PWA R985 R985* 52008NE MAKING METAL W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING REGULAR MAINTENANCE INSPECTION METAL WAS FOUND IN THE OIL SCREEN IN SUFFICIENT QUANTITY TO WARRANT ENGINE REMOVAL. 1H72 3R3 R TC654 5E1 20030702000812003070200081GL 2003 7 2 CA030606001 320030529G6114 BOLT PIPER PA31 PA31 7103102SO LYC O540 TIO540A2B 41532EA HARTZLHCE2Y HCE2YR2 GL PROPELLER FAILED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) DURING LAST THREE PROPELLER OVERHAULS THESE BOLTS ARE REPLACED WITH NEW AS REQUIRED. THE LAST TWO INSTALLS WERE NOT IN COMPLIANCE WITH SL 508. THESE WERE ONLY BY CHANCE NOTICED BY THE MAINTENANCE CO-ORDINATOR (NOT AME). THE PREVIOUS ONE WAS NOT NOTICED AND WAS RELEASED FOR SERVICE AND DESTROYED THE PROP SPINNER. THIS IS 100 PERCENT RECURRING FOR US. SPINNER IS NOT NORMALLY INSTALLED BY PROPELLER OVERHAUL COMPANY. RECOMMENDED AT THE NEXT 100 HR INSPECTION. 1L72 3O3 O A20SO E14EA 5 CP9EA 20030702001102003070200110 2003 7 2 CA030606002 420030529G2210 CLAMP PIPER PA31 PA31 7103102SO LYC O540 TIO540A2B 41532EA HARTZLHCE2Y HCE2YR2 GL PITCH SERVO JAMMED W O OTHER F FLT CONT AFFECTED TXTAXI/GRND HDL 1 CA (CAN) AUTO PILOT BRIDLE CABLE CLAMP (PITCH) JAMS AGAINST EACH OTHER AT OR NEAR FULL UP (NOSE UP) CONTROL MOVEMENT. THIS IS A RECURRING PROBLEM. THIS HAS ALSO HAPPENED YEARS AGO WITH OLD EDO-AIR (ALTIMATIC III A/P). THESE CLAMPS ARE NEWER STYLE (MANDITORY BY AD) OLD CLAMPS DID NOT CAUSE PROBLEM. STEC DRAWING 76891 DOES NOT CLEARLY WARN OF THIS POTENTIAL PROBLEM. MFG DOES NOT WARN OF THIS PROBLEM DURING SETTING CABLE TENSION. MISSED BY (3) DUAL INSPECTIONS. 1L72 3O3 O A20SO E14EA 5 CP9EA 20030702001052003070200105SO 2003 7 2 CA030606003 120030530G2730 CABLE PIPER PA31 PA31 7103102SO LYC O540 TIO540A2B 41532EA HARTZLHCE2Y HCE2YR2 GL PITCH SERVO JAMMED W O OTHER F FLT CONT AFFECTED NRNOT REPORTED 1 CA (CAN) AUTO PILOT PITCH SERVO BRIDLE CABLE TO ELEVATOR MAIN CONTROL CABLE CLAMPS ERRONEOUSLY INSTALLED CAUSING PITCH CONTROL JAMMING AT FULL ELEVATOR UP EXTENSION. 1L72 3O3 O A20SO E14EA 5 CP9EA 20030702000822003070200082CE 2003 7 2 CA030606004 120030605G28201200106253 LINE CESSNA206 TU206G 2073357CE CONT O520 TSIO520M 17040SO MCAULYD3A34 D3A34C402 GL FUEL SYSTEM SEVERED W O OTHER K FLUID LOSS NRNOT REPORTED 1 CA (CAN) DURING THE LAST OPS 4 INSPECTION, SEB 95-6, RUBBER FUEL HOSE INSPECTION AND REPLACEMENT WAS ACCOMPLISHED. SUBSEQUENT INSPECTION REVEILED THAT THE FUEL PRIMER LINE FROM THE MANIFOLD TO THE PRIMER T FITTING ROUTED NEAR THE ALTERNATOR PULLEY FOUND BROKEN IN TWO AND THE TEE FITTING CHAFED ON THE ALTERNATOR PULLEY. AIR TIME SINCE INSPECTION /MODIFICATION WAS 19.1 HOURS. THE ABSENCE OF CLAMPS AT THE TEE FITTING TO THE INTAKE MANIFOLD AND THE INCREASED STIFFNESS OF THE NEW LINES CAUSED INCREASED STRESS ON THE RIGID PRIMER LINE LEAD TO THE RIGID LINE FAILURE. A NEW RIGID LINE AND FITTINGS WERE INSTALLED AND THE TEE FITTING CLAMPED AS DESCRIBED IN THE MAINTENANCE MANUAL AND IPC. 1H71 3O3 O A4CE E8CE 5 CP47GL 20030702001112003070200111CE 2003 7 2 CA030606005 120030606G7931 WIRE BEECH 99 99A 1154003CE PWA PT6 PT6A28 EA HARTZLHCB3T HCB3TN3 GL OIL PRESS XMTER FAILED W D RETURN TO BLOCK N FALSE WARNING TXTAXI/GRND HDL 1 CA (CAN) PORT ENGINE OIL PRESSURE. ON TAXI OUT, PILOTS NOTICED OIL LIGHT FLASHING. THEY SHUT DOWN THE ENGINE AND TAXIED BACK TO THE TERMINAL, CALLED MAINTENANCE. THEY CHECKED THE WIRES ON THE OIL PRESSURE TRANSMITTER, STARTED UP THE ENGINE AND ALL INDICATIONS WERE NORMAL. THEY FERRIED THE AIRCRAFT BACK, WHERE MAINTENANCE REPAIRED A WIRE TO THE OIL PRESSURE TRANSMITTER. 1L72 3T4 T A14CE E4EA 6 CP15EA 20030703000192003070300019EA 2003 7 3 CA030606006 120030530G3010600800398 PICCOLO TUBE CNDAIRCL600 CL600* EA PICCOLO TUBE MISMARKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) WHILE CARRYING OUT SB 600-0718 INSPECTION OF PICOLO TUBES AND DUCTS FOR CORRECT ALIGNMENT IT WAS FOUND THAT THE RT OUTBOARD PICCOLO TUBE BLEED HOLES WERE IMPROPERLY POSITIONED AS IDENTIFIED IN THE SB. THE PICCOLO TUBE WAS REMOVED AND IT WAS FOUND THAT THE TUBE HAD BEEN MANUFACTURED FOR A LT INSTALLATION AND IDENTIFIED AS A RT TUBE BY PART NUMBER AND ORINTATION LABLE. A CORRECTLY IDENTIFIED & MANUFACTURED TUBE WAS INSTALLED AND THE AIRCRAFT WAS RETURNED TO SERVICE. 2L72 4F RTA21EA 20030703000202003070300020EA 2003 7 3 CA030606007 220030523G8520LW12163 CRANKSHAFT PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) CRACKS FOUND IN THRUST AREA OF CRANKSHAFT CAUSED BY EXCESSIVE END CLEARANCE OF CRANKSHAFT (IN CRANKCASE). 1L72 3O3 O A20SO E14EA 5 CP33EA 20030702000832003070200083EA 2003 7 2 CA030606008 220030527G852079027 CRANKSHAFT PIPER PA31 PA31 7103102SO LYC O540 TIO540A2B 41532EA HARTZLHCE3Y HCE3YR2A GL CRANKSHAFT FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) COUNTERWEIGHT BLADE BUSHINGS AND BORE WORN (LOOSE) BEYOND REPAIRABLE LIMITS. PROP GOVERNOR GEAR P/N 70389 HAD FAILED. 1L72 3O3 O A20SO E14EA 5 CP33EA 20030702000842003070200084NE 2003 7 2 CA030606009 220030527G73203036640 FLOW DIVIDER PWA PT6 PT6A42 52043NE ENGINE WRONG PART W E ENGINE SHUTDOWN N FALSE WARNING CRCRUISE 1 CA 93753 (CAN) ENG WAS SHUTOFF IN FLT FOLLOWING HIGH T-5 OCCURRENCE. NO DAMAGE EXTERNALLY & ONLY DAMAGE FOUND INTERNALLY RUBBING CONTACT BETWEEN COMP TURBINE BLADE TIPS & CT SHROUD SEG. NO EVIDENCE OF OVERTEMP, OR ANY BUILD ERRORS IN THE ENG. FLOW DIVIDER HAS WRONGLY IDENTIFIED BODY INSTALLED, THIS ERROR HAS CAUSED DIFFICULTIES IN STARTING AND IN FLT INCIDENT. IN-FLT PROBLEMS OF THIS ENG CAUSED BY FLOW DIVIDER. WRONG BODY BEING INSTALLED ALLOWED OUTLET TO POUR A LOT OF FUEL THROUGH IT. ENG WAS POURING FUEL OUT OF THE FLOW DIVIDER, MADE ENG RUN VERY LEAN IN FUEL & NOT ABLE TO PRODUCE ENOUGH ENERGY TO PROPERLY ACCELERATE DURING THE START CYCLE, LEADING TO ELEVATED TEMP WITH CT BLADE TIP RUB. 4 T E4EA 20030702000852003070200085CE 2003 7 2 CA030606010 120030606G2780 CONTROL CABLE CESSNA337 337A 2075704CE CONT O360 IO360D 17025SO MCAULY2AF34CD2AF34C59 GL TE FLAP FRAYED W F ACTIVATE FIRE EXT. F FLT CONT AFFECTED NRNOT REPORTED 1 CA (CAN) INSPECTION OF FLAP CABLES IAW SERVICE DIFFICULTY ALERT NR AL-2003-05, FOUND THREE FRAYED CABLE ENDS, ONE AT OUTBOARD BELLCRANK. 1H72 3O3 O A6CE E1CE 5 CP5EA 20030703000412003070300041NM 2003 7 3 CA030609001 120030605G2612 FIRE DETECTOR BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU NR 2 ENGINE DEFECTIVE W F ACTIVATE FIRE EXT. N FALSE WARNING TXTAXI/GRND HDL 1 CA (CAN) A/C WAS AT GATE, NR 2 ENGINE ALREADY RUNNING. DURING NR 1 ENGINE START FLIGHT CREW ENCOUNTERED A FIRE WARNING. THE CREW FIRED BOTH FIRE BOTTLES AND CONDUCTED AN EMERGENCY EVACUATION OF THE AIRCRAFT. IT HAS BEEN DETERMINED THAT THE WARNING WAS OF A NUISANCE NATURE AND NO ACTUAL FIRE OCCURRED. INITIAL INVESTIGATION CARRIED OUT BY ENGINEERS PEC FIRE LOOP REPLACEMENT CURED DEFECT. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20030702000862003070200086EA 2003 7 2 CA030609002 120030527G5730CVR67 SEAL DHAV DHC7 DHC7102 2802708EA PWA PT6 PT6A50 52043EA HAMSTD24PF 24PF305 GL ACCESS PANEL SWOLLEN W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) WHILE REMOVING FUEL LIDS TO ACCESS FUEL TANKS FOR SNAG RECERTIFICATION FOLLOWING MAJOR INSPECTION, IT WAS NOTICED THAT THE NEW LIGHTNING SEAL P/N CVR 67 THAT WAS INSTALLED IN THE LAST WEEK OR TWO HAD SWOLLEN ALMOST 50 PERCENT LARGER THEN ITS NORMAL SIZE AND THE MATERIAL HAD SOFTEN FROM EXPOSURE TO JET FUEL. THE SEAL WAS ALSO DISLODGED AND HANGING OFF THE LADDER PLATES. WE TESTED OUR STOCK AND FOUND THAT ONLY ONE BATCH OF THE CVR 67 IS AFFECTED BY FUEL REMOVED THIS BATCH FROM OUR STOCK AND REPLACED THE SEAL ON THE AIRCRAFT. WE ARE ALSO GOING TO REPLACE THE SEAL ON ONE OTHER AIRCRAFT THAT WAS ISSUED THIS SEAL FROM THE SAME BATCH NR. 2H74 4T4 T A20EA E4EA 6 CP1NE 20030703000502003070300050EA 2003 7 3 CA030609003 120030606G79303034081 CHIP DETECTOR DHAV DHC6 DHC6300 2802606EA PWA PT6 PT6A34 52043EA HARTZLHCB3T HCB3TN3 GL ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING INSPECTION OF MAGNETIC PLUG, A STRESS CRACK WAS FOUND AT THE BASE OF THE PLUG. UNIT WAS REMOVED FROM SERVICE. 1H72 3T4 TRTA9EA E4EA 6 CP15EA 20030703000722003070300072CE 2003 7 3 CA030609004 120030528G2910570383 PRESSURE SWITCH BEECH 200 B200C 1152924CE PWA PT6 PT6A42 52043NE HARTZLHCD4N3HCD4N3A GL HYD SYSTEM FAILED W A UNSCHED LANDING H ELECT. POWER LOSS-50 PC CLCLIMB 1 CA (CAN) AIRCRAFT FLEW UNEVENTFUL. UPON TAKEOFF, THE CREW SELECTED GEAR UP. THE NOSE AND RT MAIN GEAR BEGAN TO RETRACT. THE LT MAIN GEAR REMAINED DOWN AND LOCKED. CREW SELECTED GEAR DOWN AND RETURNED TO 3 GREEN. ONCE AGAIN, CREW SELECTED GEAR UP. GEAR DID NOT MOVE. CREW LANDED. AIRCRAFT THEN FERRIED BACK. TROUBLESHOOTING DETERMINED POWERPACK PRESSURE SWITCH HAD FAILED OPEN. SWITCH REPLACED, LANDING GEAR FUNCTION CHECKED NORMAL. 1L72 4T4 T A24CE E4EA 5 CSTC 20030718001012003071800101NE 2003 7 18 CA030609005 220030602G7230586982 VALVE SKRSKYS64 S64E 8142604NE PWA JFTD12JFTD12A4A 52047NE DUMP FAILED W EA ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION DEDESCENT 1 CA (CAN) A/C PICKED UP A 15,000 LB LOAD OF LOGS. PILOT MADE A LT PEDAL TURN TO DEPART FROM LOGGING CUT BLOCK & LOWERED COLLECTIVE TO DESCEND TO LOG LANDING. CREW HEAR A SWOOSH SOUND AT WHICH TIME NR 2 ENG N1 UNDER-SPEED WARNING SOUNDED & WARNING LIGHTS ILLUMINATED INDICATING A SOFT STALL CONDITION. CREW EXECUTED AN IN-FLT SHUTDOWN & MOTORING OF SUBJECT ENGINE TO PREVENT AN OVER-TEMPERATURE CONDITION. WITH NR 2 ENG SHUTDOWN PROCEDURES COMPLETED A/C CONTINUED TO LOG LANDING & RELEASED ITS LOAD & RETURNED TO SERVICE AREA & MADE AN UNEVENTFUL SINGLE ENG LANDING. COMPLETE INSP OF ENG & ITS RELATED CONTROL LINKAGES REVEALED NOTHING ABNORMAL. ENG FUEL FILTER WAS INSPECTED FOR CONTAM. 2G72 4U4 U H4EA E15EA 20030703000732003070300073NE 2003 7 3 CA030609006 220030607G8550 ENGINE GRUMAVG21 G21A 3951204SO PWA R985 R985AN14B 52008NE HARTZLHCB3R HCB3R302 GL RIGHT CONTAMINATED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING REGULARLY SCHEDULED MAINTENANCE, METAL WAS FOUND IN THE OIL SCREEN OF THE RT ENGINE IN SUFFICIENT QUANTITY TO NECESSITATE ENGINE REMOVAL. 1H72 3R3 R TC654 5E1 5 CP28EA 20030703000742003070300074SO 2003 7 3 CA030609007 220030526G85604066109025 TURBOCHARGER CESSNA401 401 207590CCE CONT O520 TSIO520E 17040SO MCAULY3AF32C3AF32C505 GL ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING AN INSPECTION, THE COLD SIDE OF THE TURBOCHARGER TURBINE WAS FOUND TO BE RUBBING WHEN SPUN BY HAND. THE TURBOCHARGER WAS REMOVED. A CRACK WAS FOUND CLOSE TO THE TAIL PIPE ATTACH FLANGE. THE CRACK HAD SWELLED, CAUSING THE TURBO HOUSING TO COME INTO CONTACT WITH THE HOT-SIDE TURBINE. THE TURBO WAS REPLACED. 1L72 3O3 O A7CE E8CE 5 CP22EA 20030703000752003070300075SO 2003 7 3 CA030609008 120030609G3250AN3H7A BOLT PIPER PA31T PA31T 7103124SO PWA PT6 PT6A28 EA HARTZLHCB3T HCB3TN3 GL NLG STEERING SHEARED W O OTHER O OTHER DEDESCENT 1 CA (CAN) AFTER GEAR WAS SELECTED DOWN AND THE CREW HAD THREE GREEN LIGHTS, THE PILOT NOTICED THAT THE NOSE WHEEL WAS NOT CENTERED. THE PILOT WAS ADVISED TO KEEP THE WEIGHT OFF OF THE NOSE WHEEL AS MUCH AS POSSIBLE AND LANDED THE AIRCRAFT SAFELY WITHOUT INCIDENT. UPON INSPECTION, THE THREE AN3 BOLTS HOLDING THE STEERING ARM TO THE NOSE GEAR CYLINDER WERE FOUND TO BE SHEARED. A 1200 HR REPLACEMENT INTERVAL HAS NOW BEEN ADDED TO THIS OPERATOR'S MAINTENANCE TRACKING SYSTEM. 1L72 3T4 T A8EA E4EA 6 CP15EA 20030703000762003070300076EA 2003 7 3 CA030609009 120030528G5523C2T29A TORQUE TUBE DHAV DHC2 DHC2MK1 2800102EA PWA R985 R985AN14B 52008NE HAMSTD2D 2D30 NE LT ELEVATOR BROKEN W O OTHER DF INFLIGHT SEPARATION FLT CONT AFFECTED CRCRUISE 1 CA 13672 (CAN) LT ARM WHICH CONNECTS LT ELEVATOR TRIM TAB CONTROL ROD TO TORQUE TUBE BROKEN, COMPLETELY OFF. NOTE: THIS ASSEMBLY IS OF PRE-MOD, NATURE AND PROBABLY BROKE DUE TO MISHANDLING. POST MOD ARM HAS A REINFORCING GUSSET WHICH SUBSTANTIALLY IMPROVES STRENGTH/RIGIDITY. 1H71 3R3 R A806 5E1 5 CP206 20030707000012003070700001 2003 7 7 CA030609010 420030514G3418601R591541 VANE CNDAIRCL600 CL6002B19 1900309EA AOA OUT OF TOLERANCEW O OTHER L NO TEST CRCRUISE 1 CA (CAN) WHILE DOING THE CLEAN STALL TEST, THE SHAKER FIRED 2 KNOTS ABOVE THE CALCULATED VALUE. THEN, WHILE SLOWING THRU 2 KNOTS BELOW THE SHAKER, THE AIRCRAFT STARTED BUFFETING AND DEVELOPED A PRONOUNCED ROLLTO THE LEFT. THE PUSHER ACTIVATED 3 KNOTS ABOVE THE CALCULATED VALUE, BUT THE ANGLES AT THE PUSHER SHOWED 14.5 & 14.6. AIRCRAFT RETURNED WITHOUT FURTHER OCCURRENCES. UPON ARRIVAL, THE LT AND RT AOA VANES NUL ADJUST WERE FOUND OUT OF TOLERANCES AT 0.7/0.6 INSTEAD OF 0.8 IAW FTP601R2731U. VANES WERE ADJUSTED IAW FTP601R2731U AND AIRCRAFT RETURNED TO FLIGHT WITHOUT FURTHER OCCURRENCES. 2L72 4F RTA21EA 20030707000022003070700002SO 2003 7 7 CA030609011 120030520G2121 MOTOR PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL FAN ODOR W H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS DEDESCENT 1 CA (CAN) THE PILOTS DETECTED A BURNING ODOR WHILE THE AIRCRAFT WAS IN DESCENT. AFTER ELIMINATING SYSTEMS, THE PILOTS CAME TO THE CONCLUSION THAT IT WAS THE GROUND FAN. AFTER DISASSEMBLY & INSPECTION WE DID NOT FIND ANYTHING ABNORMAL. WE THINK THAT THE ODOR ORIGINATED FROM DUST IN THE MOTOR OF THE FAN. THE GROUND FAN WAS UTILIZED FOR THE FIRST TIME THIS SUMMER, ITS USE IS FOR WHEN IT IS HOT OUTSIDE. 1L72 3O3 O A20SO E14EA 5 CP33EA 20030703000422003070300042EA 2003 7 3 CA030609012 220030602G8530 ENGINE CESSNA150 152 2071835CE LYC O235 O235N2C 41505EA MCAULY1A103 1A103TCM GL FAILED W O OTHER O OTHER LDLANDING 1 CA (CAN) DURING LANDING AFTER PASSING THE RUNWAY THRESHOLD ENGINE BROUGHT TO IDLE CAUSING IT TO STOP AND PROP TO WINDMILL. AFTER LANDING PILOT TAXIED WITH REMAINING SPEED OFF THE RUNWAY. (RESTARTING WAS UNSUCCESSFUL). PLANE WAS TOWED TO THE RAMP. NOTE: 164 HOURS LT FOR ENGINE OVERHAUL, 2 CYLINDERS FOUND LOW COMPRESSOR, ENGINE REMOVED FOR OVERHAUL. 1H71 3O3 ONT3A19 E223 5 NP50GL 20030703000432003070300043NE 2003 7 3 CA030609014 220030609G7323 SCREEN BENDIX BOLKMS117 BK117A1 5626010EU LYC LTS101LTS101750B1 41560NE PT GOVERNOR LOOSE W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA 85030104 (CAN) RECEIVING INSPECTION, POST REPAIR, REVEALED A LOOSE SCREEN IN THE PG FITTING. THIS FITTING HAD BEEN REPLACED DURING THE REPAIR PROCESS. UNIT RETURNED TO MFG REPAIR STATION. 1G72 3U3 U H13EU E5NE10 20030703000442003070300044CE 2003 7 3 CA030610001 120030609G57536525115 RIB CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE TE FLAPS WORN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING PHASE 5 INSPECTION SEVERAL FLAP RIB EXTENSIONS WERE FOUND WORN BY THE RIVETS SECURING THE FLAP TRACKS TO THE WING. THE CENTER HINGE INBOARD AND OUTBOARD EXTENSIONS ON THE LT FLAP AND THE INBOARD ON THE RT FLAP WERE WORN BEYOND LIMITS AND REPLACED. THE OTHERS WERE BLENDED IAW AIRCRAFT SERVICES AS SB -851-0082 AND RETURNED TO SERVICE. 1L72 4F4 F A22CE E1NE 20030703000452003070300045NE 2003 7 3 CA030610002 120030605G6410S611730101045 BLADE SKRSKYS61 S61N 8142104NE GE CT58 CT581402 30011NE TAIL ROTOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 14200 (CAN) DURING A DAILY INSPECTION A CRACK WAS FOUND IN THE INBOARD SIDE OF THE TRAILING EDGE POCKET. THE CRACK STARTED AT THE TRAILING EDGE AND PROPAGATED FORWARD APPROXIMATELY 70MM. (2.75 INCHES) 2G72 4U4 U 1H15 1E3 20030703000472003070300047SO 2003 7 3 CA030610004 120030603G3230455180 CONDUIT 455180 PIPER PA30 PA30 7103002SO LYC O320 IO320B1A 41508EA HARTZLHCE2Y HCE2YL2 GL MLG FAILED W O OTHER O OTHER LDLANDING 1 CA (CAN) RT MAIN GEAR CONDUIT FLEXIBLE OUTER SLEEVE MOVED WITH INNER CABLE EXPOSING 11.0 INCHES OF INNER CABLE. INNER CABLE LOOPED OUT OF EXPOSED AREA. NOW WITH CABLE BEING BENT RT GEAR COULD NOT OVER CENTER FOR DOWN AND LOCKED. 1L72 3O3 O A1EA 1E12 5 CP9EA 20030703000482003070300048CE 2003 7 3 CA030610005 120030606G2711130909B38 BOLT BEECH 1015210391 BEECH 200 B200 1152922CE PWA PT6 PT6A42 52043NE HARTZLHCE4N HCE4N3 NE LT AILERON LOOSE W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) UPON INSPECTION THE TRIM TAB ACTUATOR WAS FOUND TO HAVE 2 BOLTS, P/N 130909B38, LOOSE. THE ACTUATOR SHOWED NO INDICATIONS OF DAMAGE OR MALFUNCTION, TRIM TAB FREE PLAY INSPECTION WAS WELL WITHIN TOLERANCE. BOLTS WERE TORQUED AND ANTI SABATOGE LAQUER WAS INSTALLED. THERE WAS NO EVIDENCE OF THE PART BEING REMOVED AND WAS MOST LIKELY THAT WAY SINCE THE AIRCRAFT LEFT THE FACTORY. 1L72 4T4 T A24CE E4EA 5 CP10NE 20030703000492003070300049CE 2003 7 3 CA030610006 120030603G36101H7512 REGULATOR BEECH 200 B200 1152922CE PWA PT6 PT6A42 52043NE HARTZLHCE4N HCE4N3 NE PNEUMATIC SYS FAILED W A UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 CA (CAN) PNEUMATIC REGULATOR FAILURE IN CRUISE FLIGHT OCCURRED. PILOTS HAD TWO BLEED AIR FAIL LIGHTS, LEFT AND RIGHT, AND ALSO NOTED LOSS OF SUCTION AND PNEUMATIC PRESSURES CONFORMING LIGHT INDICATION. PILOTS RETURNED TO BASE. UPON INSPECTION THE REGULATOR FOUND TO HAVE TOTALLY FAILED. THIS TYPE OF REGULATOR HAS A SAFETY WHERE BY IT SHOULD REGULATE TO 20 PSI UPON FAILURE OF THE NORMAL 18 PSI REGULATION. THE PART WAS REPLACED WITH AN OVERHAULED UNIT, TESTED AND FOUND TO OPERATE PROPERLY. 1L72 4T4 T A24CE E4EA 5 CP10NE 20030702001002003070200100CE 2003 7 2 CA030610007 120030603G27521295210511 ACTUATOR BEECH 200 B200 1152922CE PWA PT6 PT6A42 52043NE HARTZLHCE4N HCE4N3 NE TE FLAPS MISINSTALLED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) FLAP ACTUATOR WAS FOUND TO HAVE BEEN INSTALLED INCORRECTLY WITH LUBRICANT VENT HOLE DOWN WHICH RESULTS IN LOSS OF LUBRICANT. ACTUATOR WAS REMOVED AND FOUND TO BE UNSERVICEABLE DUE TO HAVING TOO MUCH END PLAY. THE ACTUATOR WAS SENT FOR REPAIR, RE-INSTALLED AND RIGGED. THIS WAS CAUSED BY THE OVERHAULER NOT ASSEMBLING THE ACTUATOR CORRECTLY AND THE INSTALLER NOT NOTICING POSITION OF THE VENT HOLE ON INSTALLATION. THE LUBE ON THIS ACTUATOR HAD BEEN DONE 572 HOURS AND 660 CYCLES EARLIER. 1L72 4T4 T A24CE E4EA 5 CP10NE 20030702001012003070200101NE 2003 7 2 CA030610008 220030610G74219550175400 IGNITER SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE ENGINE BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ON INSPECTION IT WAS DISCOVERED THE INSULATOR HAD BROKEN FREE AND HAD SLID DOWN THE CENTER ELECTRODE ABOUT .3750. COULD POSSIBLY HAVE GONE THROUGH THE GAS PATH OF ENGINE HAD IT NOT BEEN DISCOVERED. 1G71 3U3 U H9EU E19EU 20030702001022003070200102CE 2003 7 2 CA030610009 120030606G5620 WINDOW BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3I NE FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING A ROUTINE CABIN WINDOW INSPECTION MAINTENANCE FOUND A SMALL CRACK IN WINDOW SURROUND STRUCTURE OF A LT CABIN WINDOW BETWEEN STA 303.25 AND 318.25. THE CRACK MEASURED O.800 INCHES IN LENGTH, PASSED 1/4 INCH PAST A FASTENER, AND WAS 3/4 INCH FROM THE WINDOW EDGE. THE WINDOW SURROUND STRUCTURE WAS REPAIRED IAW RRB/0 809-03 AND THE AIRCRAFT WAS RETURNED TO SERVICE. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20030703000572003070300057WP 2003 7 3 CA030610010 220030609G73218978017 FUEL CONTROL SWRNGNSA226 SA226TC 8780404SW GARRTTTPE331TPE33110UA 01514WP HARTZLHCE4N HCE4N3 NE ENGINE INOPERATIVE W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) UPON PERFORMING A GROUND RUN FOR AN ENGINE REPLACEMENT AND UPON THE APPLICATION OF FULL POWER THE ENGINE RESPONSE WAS GOOD, BUT IN ATTEMPT TO DECREASE ENGINE POWER THE ENGINE WOULD NOT RESPOND TO THROTTLE INPUTS. IT WAS APPROXIMATELY 30 SECOND TO A MINUTE BEFORE THE ENGINE POWER STARTED TO DECREASE TO NORMAL IDLE SPEED. INSPECTION OF ENGINE AND RIGGING REVEALED NO PROBLEMS. THE FUEL CONTROL UNIT WAS REPLACED AND A GROUND RUN CARRIED OUT WITHOUT THE RECURRENCE OF THE DEFECT. 2L72 4T4 TRTA8SW E4WE 5 CP10NE 20030703000582003070300058SW 2003 7 3 CA030610011 120030607G530220403082506 SPAR BELL 204 204B 1181404SW LYC T53 T5311B 41549NE TAILBOOM CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 19119 (CAN) ENGINEER OPENED TAIL ROTOR DRIVESHAFT COVER TO CHANGE COUPLINGS AND FOUND A CRACK HAD DEVELOPED IN THE VERTICAL FIN SPAR. STARTING AT THE TOP LIGHTENING HOLE AND GOING LT TO THE OUTER EDGE OF THE SPARE. OUTER LT SKIN WAS ALSO CRACKED APPROX. SIX INCHES. TAILBOOM WAS REPLACED 1G71 4U4 U H1SW E1EA 20030703000592003070300059EU 2003 7 3 CA030611001 220030609G8560139379 LINE BRAERO748 HS7482A 4231001EU RROYCEDART DART5342 EU ROTOL R4304 R2124304 EU FITTING BROKEN W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) UPON RETURN OF AIRCRAFT TO BASE, MAINTENANCE FOUND OIL LEAKING FROM AROUND RT GEARBOX AREA. INVESTIGATION FOUNG THE OIL SUPPLY LINE FROM GEARBOX TO SUPERCHARGER HAD SHEARED OFF AT THE SUPERCHARGER. THE LINE IS A FLEXIBLE FLUID LINE AND THE NUT PORTION ALONG WITH THE FLARE STAYED ATTACHED TO THE SUPERCHARGER. THE BREAK OCCURED JUST BEHIND THE NUT PORTION. DUE TO THE LOW OIL LEVEL NOTED IN THE GEARBOX, THE GEARBOX & SUPERCHARGER WERE REPLACED. OPERATOR WILL NOW SELF IMPOSE A RETIREMENT LIFE TO THIS HOSE ASSEMBLY 2L72 3T4 T A24EU A196 6 CP899 20030718001002003071800100NM 2003 7 18 CA030611002 120030609G2710654476114 PCU BOEING737 737281 138448PNM PWA JT8 JT8D17 52049NE AILERON BROKEN W O OTHER K FLUID LOSS LDLANDING 1 CA (CAN) DURING LANDING THROUGH APPROXIMATELY 60 KNOTS, AIRCRAFT EXPERIENCED A COMPLETE LOSS OF 'A' SYSTEM HYDRAULICS. (NOTE: 'A' PUMPS ON WITH LOW PRESSURE LIGHTS ILLUMINATED - MAX 1.5 MINUTES) MAINTENANCE INSPECTION REVEALED POSITION NR 1 LOWER AILERON PCU FILTER HOUSING COMPLETELY CRACK AROUND CIRCUMFERENCE OF HOUSING (DETACHED FROM UNIT). MAINTENANCE REPLACED PCU PER MM 27-11-71, LEAK CHECK AND ADJUSTMENT TEST OF AILERON ACTUATOR COMPLETE. NO LEAKS TO REPORT.AIRCRAFT RETURNED TO SERVICE WITH NO FURTHER INCIDENTS TO REPORT. 2L72 4F4 F A16WE E2EA 20030721000082003072100008EU 2003 7 21 CA030611003 120030610G7830 THRUST REVERSER AIRBUSA340 A340313 EU CFMINTCFM56 CFM565C4 13802NE NR 3 & 4 ENG CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) OPERATOR HAS IDENTIFIED CRACKS IN BOTH THE NR 3 AND 4 IN-BOARD THRUST REVERSER HALF, J-RINGS, ON AIRCRAFT 904. THE CRACKS ARE THE SUBJECT OF AD 2003-108 (B), BUT OPERATOR HAS NOT COMMENCED THE AD INSPECTION AS IT IS ONLY DUE BEFORE 6666 FC OR WITHIN 2166 FC FROM THE AD EFFECTIVE DATE OF MARCH 29,2003. OPERATOR IMMEDIATELY ADVISED AIRBUS OF THE FINDINGS AND AIRBUS INDICATED THAT NO APPROVED REPAIRS CURRENTLY EXIST AND THE REVERSER HALVES WILL REQUIRE REPLACEMENT. OPERATOR IS CURRENTLY INTHE PROCESS OF OBTAININGTWO REPLACEMENT REVERSER HALVES. 2L74 4F4 FRTA197 E37NE 20030822001102003082200110SO 2003 8 22 CA030611004 120030611G7120PEP6295 RING GULSTMG1159 G1159 3953505SO RROYCESPEY SPEY5118 54523EU TRUNNION CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 10190 (CAN) TIME SHOWN ABOVE IS ENGINE TIME. PART IS OVERHAULED AT ENGINE INSTALLATION. THE TRUNNION ASSEMBLY ATTACHED TO THE FORWARD ENGINE MOUNTING BEAM LINK, ATTACHING ENGINE TO AIRCRAFT, WAS RECEIVED AT RRC WITH ENGINE 8841 FOR REVISION. THE RING NUT LOCKING TRUNNION PEP6295 WAS FOUND CRACKED 360 DEGREE DURING THE NDT INSPECTION. THE FLANGE TRUNNION PEP 6553 WHICH IS A SEPARATE ITEM WAS FOUND SWAGED INSIDE THE LOCKING RING NUT. INSPECTION OF ASSEMBLY HAS DETERMINED THAT INCORRECT ASSEMBLY OF COMPONENTS HAS CAUSED THE COMPONENTS TO CRACK DUE TO AN OVER TORQUE APPLIED BY THE OPERATOR INSTALLING THE ENGINE ON THE AIRCRAFT. 2L72 4F4 FRTA12EA E2EU 20030822001112003082200111CE 2003 8 22 CA030611005 120030605G270116001041 SPRING CESSNA188 A188B 2073005CE CONT O550 IO550D 17042SO HARTZLHCC3Y HCC3YF1 GL CONTROL COLLUMN BROKEN W A UNSCHED LANDING F FLT CONT AFFECTED CRCRUISE 1 CA (CAN) THE SPRING (P/N 1600104-1) THAT RETRACTS THE CONTROL LOCK (P/N 1613195-1) IN FLIGHT FAILED AND ALLOWED THE CONTROL LOCK ASSEMBLY TO EXTEND AND SUBSEQUENTLY PARTIALLY JAM THE CONTROL STICK. THE PILOT WAS ABLE TO DISENGAGE THE LOCK ASSEMBLY WHICH HAD JAMMED THE CONTROL STICK AND RETURNED TO BASE WITHOUT FURTHER INCIDENT. 1L71 3O3 O A9CE E3SO 5 CP25EA 20030703000602003070300060CE 2003 7 3 CA030612001 120030611G5270 SWITCH BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL PAX DOOR INOPERATIVE W O OTHER N FALSE WARNING APAPPROACH 1 CA (CAN) ON APPROACH, WHILE DESCENDING THROUGH 8000 FT THE CREW NOTED ILLUMINATION OF THE CABIN DOOR WARNING LIGHT. THE BLEEDS WERE TURNED OFF AND THE CABIN DEPRESSURIZED. JUST PRIOR TO LANDING THE LIGHT EXTINGUISHED. UPON EXITING THE AIRCRAFT, THE CREW VERIFIED THAT THE DOOR WAS INDEED IN THE CLOSED AND LOCKED POSITION AND THAT ALL VISUAL LOCK INDICATORS ON THE DOOR WERE SHOWING A GREEN/LOCKED INDICATION. MAINTENANCE INSPECTION DETERMINED THAT THE CABIN DOOR CLOSED SWITCH MOUNTED ON THE FORWARD LOWER DOOR FRAME WAS JUST BARELY BEING MADE. THE SWITCH WAS ADJUSTED FOR PROPER OVER TRAVEL AND THE DOOR WARNING SYSTEM VERIFIED FOR CORRECT OPERATION. IN ADDITION THE DOOR LATCHING MECHANISM AND STRUCTURE WAS INSPECTED. 1L72 4T4 T A24CE E4EA 6 CP15EA 20030718000582003071800058EU 2003 7 18 CA030612002 120030610G793111346AA TRANSMITTER AMD FALC20FALCON20C5 2730107EU GE CF700 CF7002D2 30010NE OIL PRESSURE MALFUNCTIONED W C ABORTED TAKEOFF J WARNING INDICATION TOTAKEOFF 1 CA (CAN) ON JUNE 10, 2003 DURING TAKE-OFF ROLL OF OUR FALCON 20 A/C, PILOT NOTICED A DECREASE IN OIL PRESSURE INDICATION WHILE ADVANCING LT ENGINE THROTTLE. PILOT INITIATED REJECTED TAKE-OFF. FLT CREW ADVISED ATC. RETURNED TO MAINT FACILITY. MAINT CONFIRMED THAT OIL PRESSURE TRANSMITTER WAS DEFECTIVE. REPLACED WITH SERVICEABLE COMPONENT ACCOMPLISHED & ENG RUN COMPLIED WITH, ALL INDICATIONS NORMAL. A/C RELEASED, COMPLETE CHECK FLT WAS COMPLETED SATISFACTORY WITH NO ABNORMALITIES. MAINT HAS ADVISED US OF THE FOLLOWING; AFTER REMOVAL AND VISUAL INSPECTION OF DEFECTIVE OIL PRESSURE TRANSMITTER,RESIDUAL TRACES OF THREAD TAPE USED ON AN TYPE FITTINGS WAS FOUND, WHICH CAUSED THE FALSE INDICATION. 2L72 4F4 FRTA7EU E7EA 20030703000612003070300061CE 2003 7 3 CA030612003 120030531G55201016100191 TORQUE TUBE BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL ELEVATOR CORRODED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) DURING A SCHEDULED FLEET CAMPAIGN INSPECTION OF THE ELEVATOR TORQUE TUBE FOR ANY EVIDENCE OF CORROSION, THERE WAS MINOR CORROSION DETECTED ON THE LT ELEVATOR TORQUE TUBE FLANGE BETWEEN MOUNTING BOLT HOLES. THE TUBE WAS REPLACED. A SPECIAL INSPECTION IN ADDITION TO THE MANUFACTURERS INSPECTION PROGRAM HAS BEEN INITIATED, CALLING UP A DETAILED VISUAL OF THIS AREA EVERY 6 MONTHS. 1L72 4T4 T A24CE E4EA 6 CP15EA 20030703000622003070300062EU 2003 7 3 CA030612004 120030608G7931 TRANSDUCER SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE ENG OIL PRESSUREINOPERATIVE W O OTHER N FALSE WARNING CRCRUISE 1 CA (CAN) DURING CRUISE FLIGHT THE PILOT NOTICED ENG OIL PRESSURE DROP OFF TO ZERO THEN INDICATED 9 BARS ON THE PRESSURE GAUGE. PILOT RETURNED TO POINT OF DEPARTURE. TROUBLE SHOOTING FOUND THE TRANSDUCER TO BE UNSERVICEABLE. 1G71 3U3 U H9EU E19EU 20030703000632003070300063GL 2003 7 3 CA030612005 220030612G724023034114 CASE BELL 206 206L 1181522SW ALLSN 250C 250C20R2 GL COMBUST CHAMBER CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA 12789 (CAN) ROUTINE INSPECTON AND CHANGING FUEL NOZZLE IT WAS SUSPECTED THAT THERE WAS A CRACK ALONG THE WELD WHERE THE FUEL NOZZLE ADAPTER IS ATTATCHED TO THE END OF OUTER COMBUSTION CASE. ON CLOSER INSPECTION IT WAS NOTED THAT THE CRACK COVERED OVER HALF OF THE WELDED AREA. THE CASE WAS REMOVED AND ANOTHER CASE WAS INSTALLED. 1G71 3U3 U H2SW E4CE 20030703000642003070300064GL 2003 7 3 CA030612006 220030612G724023034114 CASE BELL 206 206L 1181522SW ALLSN 250C 250C20R2 GL COMBUST CHAMBER CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) AFTER INPSECTION WITH THE ENGINE RUNNING A LEAK CHECK WAS CARRIED OUT BY PLACING A HAND IN AREA OF THE FUEL NOZZLE AND AIR WAS FELT. THE ENGINE WAS SHUT DOWN AND A CLOSE INSPECTION WAS CARRIED OUT IN THE AREA OF WHERE THE NOZZLE ADAPTER PLATE IS WELDED TO THE COMBUSTION CASE. THE CRACK EXTENDED AROUND APPROXIMATLY HALF OF THE WELD. A SERVICABLE CASE WAS INSTALLED AND THE HELICOPTER WAS RETURNED TO SERVICE. 1G71 3U3 U H2SW E4CE 20030703000652003070300065GL 2003 7 3 CA030612007 220030611G75302305714 CASE ALLSN BELL 206 206B 1181511SW ALLSN 250C 250C20 03013GL COMPRESSOR BROKEN W E ENGINE SHUTDOWN D INFLIGHT SEPARATION TXTAXI/GRND HDL 1 CA CAC37734 (CAN) COMPRESSOR STALL ON START UP. PLASTIC WAS FOUND PROTRUDING FROM START BLEED VALVE. AFTER REMOVING BLEED VALVE, A 1.25 X 2 X .056 INCH PIECE OF PLASTIC WAS REMOVED, WHICH WHICH APPARENTLY HAD BROKEN FREE FROM THE BLEED AIR CHAMBER THAT SURROUNDS THE COMPRESSOR CASE ASSY. 1G71 3U3 U H2SW E4CE 20030718000722003071800072EA 2003 7 18 CA030612008 120030609G5610601R3303312 WINDOW CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE COCKPIT CRACKED W O OTHER O OTHER APAPPROACH 1 CA (CAN) CO-PILOT'S WINDOW CRACKED ON APPROACH. WINDOW WAS REPLACED AND AIRCRAFT DECLARED SERVICEABLE. 2L72 4F4 FRTA21EA E15NE 20030718000742003071800074SO 2003 7 18 CA030613001 120030611G2752B120344 TUBE MOOG 1159SCC2121 GULSTMG1159 G1159A 3970109SO RROYCESPEY SPEY5118 54523EU TE FLAPS SHEARED W O OTHER O OTHER NRNOT REPORTED 1 CA 98195 (CAN) AFTER REMOVING THE FLAPS TO REPAIR THE D TRACK WEB IAW AIRCRAFT SERVICE CHANGE 318B. THE LT OUTBOARD FLAP ACTUATOR SCREWJACK BALL RETURN TUBE COVER WAS FOUND SHEARED OFF (SUSPECT IMPROPER INSTALLATION). REPAIRED IAW CUSTOMER BULLETIN NR 99. 2L72 4F4 F A12EA E2EU 20030721000182003072100018SO 2003 7 21 CA030613003 120030610G32446006 TIRE PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL NLG DAMAGED W C ABORTED TAKEOFF D INFLIGHT SEPARATION TOTAKEOFF 1 CA (CAN) ON TAKEOFF ROLL THE PILOT NOTICE A VIBRATION IN THE AIRFRAME, THEN ABORTED TAKEOFF AND TAXIED TO THE NEAREST TAXIWAY AND NOTIFIED MAINTENANCE. UPON ARRIVAL MAINTENANCE NOTICED THE NOSE WHEEL WAS FLAT. THE NOSE WHEEL WAS DAMAGED TOO MUCH TO BE ABLE TO DETERMINE WHAT CAUSED THE FLAT TIRE. 1L72 3O3 O A20SO E14EA 5 CP33EA 20030822001062003082200106EA 2003 8 22 CA030613004 120030611G2720C2CF1777A MOUNT DHAV DHC2 DHC2MK1 2800102EA PWA R985 R985AN14B 52008NE HAMSTD2D 2D30 NE RUDDER PEDAL CRACKED W D RETURN TO BLOCK F FLT CONT AFFECTED TXTAXI/GRND HDL 1 CA (CAN) DURING TAKE OFF RUDDER PEDAL MOUNT ASSY PN C2CF1777A CRACKED AT BASE OF OPERATING LEVER WELD ALLOWING THE RT RUDDER PEDAL TO DROP TO THE FLOOR, RUDDER CONTROL WAS LOST AND THE TAKE OFF ABORTED. UPON EXAMINATION OF THE AFFECTED PARTS IT WAS NOTED THAT THE WELD HAD SEPARATED CLEANLY FROM THE TUBE AND ALL WELD FILLER MATERIAL REMAINED ON THE OPERATING LEVER HALF, INDICATING POSSIBLE POOR PENETRATION OF THE ORIGINAL WELD. THIS TORQUE TUBE IS DIFFICULT TO INSPECT AT THE WELD LOCATION UNLESS THE FOOT WELL PANEL IS REMOVED TO ENABLE VIEWING FROM ABOVE. TH E SUBMITTER HAS INCORPORATED A SPECIAL IN DETAIL INSPECTION OF THE AFFECTED PART/WELD ON A REPEATATIVE BASIS. 1H71 3R3 R A806 5E1 5 CP206 20030822001072003082200107EA 2003 8 22 CA030613005 120030605G5753 RIB DHAV DHC6 DHC6300 2802606EA PWA PT6 PT6A27 52043EA HARTZLHCB3T HCB3TN3 GL TE FLAP WORN W K NONE O OTHER ININSP/MAINT 1 CA 29987 (CAN) EXCESSIVE LOOSENESS BETWEEN THE TWO HALVES OF THE FLAP AT THE CENTER HINGE ARM POSITION. THE RIBS ON EITHER SIDE OF THE HINGE ARM ARE ASSEMBLED TO THE ARM BY THE USE OF MS20470AD5-24 SOLID RIVETS. IT WOULD APPEAR THAT THERE HAS BEEN SOME WORKING BETWEEN THE RIVET HEADS AND THE RIBS WHICH HAS CAUSED WEARING OF THE RIB AROUND THE RIVET HOLES. 1H72 3T4 TRTA9EA E4EA 6 CP15EA 20030822001082003082200108SW 2003 8 22 CA030613006 120030307G6320206040532005 CASE BELL BELL 206 206L3 1182108SW ALLSN 250C 250C30P 03013GL TRANSMISSION MISMANUFACTURED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA BMC51561 (CAN) TRANSMISSION RECEIVED FOR 1,500 HOUR INSPECTION. TOP CASE REMOVED AND 10 TEETH FROM THE INVOLUTE SPLINES WERE BROKEN WHICH IS NOT IN ITSELF AN UNUSUAL OCCURRENCE. WHEN A NEW REPLACEMENT WAS OBTAINED FROM BELL THE LOCKWIRE HOLES FOR THE FILLER CAP AND CHIP PLUG HAD NOT BEEN DRILLED. A SECOND CASE WAS ACQUIRED FROM BELL AND IT WAS CORRECTLY DRILLED. 1G71 3U3 U H2SW E1GL 20030902000022003090200002EA 2003 9 2 CA030613007 120030609G5511C2TP57 SPAR DHAV DHC2 DHC2MK1 2800102EA PWA R985 R985AN14B 52008NE HAMSTD2D 2D30 NE HORIZONTAL STAB CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) COMPLETED CF-91-42, SB 2/47 REV.C ON POST MOD 2/758 STABILIZER. NO CRACK WAS INITIALLY DETECTED. ALTHOUGH IT IS NOT REQUIRED BY THE AD, BRACKETS C2TP159A AND C2TP160A WERE REMOVED FOR DETAILED VISUAL INSPECTION OF THE SPAR. THE SPAR WAS FOUND CRACKED UNDER THE RT BRACKET (C2TP160A) APPROXIMATELY .2500 INCHES ABOVE THE TOP BRACKET BOLT HOLE. THE GUSSET PLATE C2TP171 WAS ALSO CRACKED DIRECTLY BEHIND THE SPAR CRACK. THESE CRACKS ARE LOCATED PARALLEL TO AND DIRECTLY IN FRONT OF THE RADIUS OF WASHER PLATE P/N C2TP177. BOTH CRACKS ARE APPROXIMATELY .2500 - .6258 INCHES LONG. 1H71 3R3 R A806 5E1 5 CP206 20030718000592003071800059EA 2003 7 18 CA030613008 220030612G72613024566 BYPASS VALVE BEECH 99 99A 1154003CE PWA PT6 PT6A28 EA HARTZLHCB3T HCB3TN3 GL OIL FILTER WORN W E ENGINE SHUTDOWN KJ FLUID LOSS WARNING INDICATION CLCLIMB 1 CA (CAN) LT ENG OIL PRESSURE DROPPED FROM NORMAL 92 P.S.I. TO APPROX 60 P.S.I. PILOT REDUCED POWER TO 1100 LBS OF TORQUE. TORQUE STARTED TO FLUCTUATE AND OIL PRESS CONTINUED TO DROP TO 50 P.S.I., PILOT FEATHERED AND SHUT DOWN ENG. DECLARING AN EMERGENCY AND LANDED WITHOUT FURTHER INCIDENT. UPON INSP OF ENG, OIL WAS FOUND L EAKING OUT OF ENG INTAKE. AFTER SOME TROUBLESHOOTING AND DISCUSSION WITH A TECH, IT WAS DECIDED TO REMOVE OIL FILTER HSG, REPLACE O RINGS AND LAP CHECK VALVE SEAT, ON OUTSIDE OF HSG. AS FURTHER PRECAUTION, MAIN OIL FILTER AND CHIP DETECTOR WERE REMOVED, INSPECTED, CLEANED AND REINSTALLED. NO METAL PARTICLES WERE FOUND. ENGINE WAS TOPPED UP WITH OIL AND ENGINE RUNS COMPLETED SERVICEABLE. 1L72 3T4 T A14CE E4EA 6 CP15EA 20030721000192003072100019SW 2003 7 21 CA030613009 120030525G6320212040054007 CASE BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA M/R GEARBOX BROKEN W K NONE O OTHER ININSP/MAINT 1 CA 11290 (CAN) WHILE CARRYING OUT A DAILY CHECK ON THE AIRCRAFT THE ENGINEER NOTICED THAT THE ONE EAR OF THE LIFT LINK SUPPORT ON THE TRANSMISSION SUPPORT CASE WAS BROKEN OFF. THE TRANSMISSION SUPPORT CASE WAS REPLACED 1G71 4U4 U H4SW E22EA 20030908001622003090800162GL 2003 9 8 CA030615001 120030615G3240 CONTROL CABLE AMTR AVRO LANCASTER10 GL PCKARD224 224 SO HAMSTD23E 23EX583 NE CONTROL COLUMN STRETCHED W O OTHER F FLT CONT AFFECTED TXTAXI/GRND HDL 1 CA (CAN) AIRCRAFT DEPARTED TAXIWAY AFTER PILOT EXPERIENCED PARTIAL BRAKE LOSS WHILE RETURNING TO THE RAMP AFTER LANDING. DISCOVERED A STRETCHED PILOT'S CONTROL CABLE TO BRAKE PROPORTIONING VALVE, WHICH IN TURN LOWERED THE AIR PRESSURE AVAILABLE TO WHEELS. 2H74 4V4 VRCEXPA2M74EXP4V 6 CEXPP6C 20030902000032003090200003EA 2003 9 2 CA030616001 220030613G850075414 SUPPORT BRACKET PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2 GL ENGINE BROKEN W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) FUEL MANIFOLD SUPPORT BRACKET BREAKS AT BEND RADIUS-BELIEVE DUE TO STRESS INDUCED AT MANUFACTURE. BRACKET BROKE 4 TIMES:1. AT 208.4 TTSNEACH TIME BRACKET REPLACED WITH NEW 2. AT 96.0 TTSN 3. AT 86.0 TTSN 4. AT 16.3 TTSN ON INSPECTION OF NEW BRACKETS WE FOUND DEEP IMPRESSIONS AT BEND RADIUS(INSIDE)FROM TOOLING- ALSO BEND IS SO SHARP THAT CRACKS ARE STARTING ON THE OUTSIDE OF BEND RADIUS. REPORTED FINDINGS TO SUPPLIER. 1L72 3O3 O A20SO E14EA 5 CP33EA 20030902000042003090200004SW 2003 9 2 CA030616002 120030616G275219023 CABLE BBAVIA8 8GCBC 1220803SW LYC O360 O360C2E 41514EA MCAULY1A200 1A200* GL FLAP CONTROLS FRAYED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) CABLE IS FRAYED AT UPPER ALUMINUM PULLEY. 1H71 3O3 O A21CE E286 5 NP874 20030902000052003090200005SW 2003 9 2 CA030616003 120030616G32207147061 FRAME BBAVIA8 8GCBC 1220803SW LYC O360 O360C2A 41514EA MCAULY1A200 1A200* GL TAIL SPRING BROKEN W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) FRAME TUBE WAS BROKEN OFF ON BOTH SIDES OF TAIL SPRING FWD ATTACH BUSHING. 1H71 3O3 O A21CE E286 5 NP874 20030718000602003071800060EA 2003 7 18 CA030616004 120030613G3234574205A SOLENOID DHAV DHC7 DHC7102 2802708EA PWA PT6 PT6A50 52043EA HAMSTD24PF 24PF305 GL SELECTOR VALVE FAILED W O OTHER J WARNING INDICATION APAPPROACH 1 CA 35478 189 (CAN) ON APPROACH THE LANDING GEAR WAS SELECTED DOWN ALL THREE GEAR STAYED UP AND LOCKED. AN EMERGENCY GEAR EXTENSION WAS COMPLETED AND THE AIRCRAFT LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE JACKED THE AIRCRAFT AND ATTEMPTED TO COMPLETE GEAR SWINGS WHEN THEY SELECTED GEAR UP THERE WAS NO RESPONSE. MAINTENANCE FOUND THAT THE LANDING GEAR SELECTOR VALVE SOLENOID DID NOT MAKE ANY NOISE WHEN THE GEAR SELECTOR WAS UP OR DOWN. THE LANDING GEAR SELECTOR VALVE SOLENOID WAS REPLACED AND THE GEAR SWUNG WITHOUT FURTHER INCIDENT. 2H74 4T4 T A20EA E4EA 6 CP1NE 20030718000612003071800061SW 2003 7 18 CA030617001 120030616G5302206031329003 ATTACH FITTING BELL 206 206L 1181522SW ALLSN 250C 250C20B 03013GL TAILBOOM CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING MAJOR INSPECTION THE TAILBOOM ATTACH FITTING UPPER LT FUSELAGE SIDE WAS FOUND CRACKED AT THE UPPER AFT RIVET HOLE. 1G71 3U3 U H2SW E4CE 20030718000622003071800062EU 2003 7 18 CA030617002 120030520G5531350A14111925 RIB AEROSPAS355 AS355F1 8680810EU ALLSN 250C 250C20F 03013GL VERTICAL STAB CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING ROUTINE INSPECTION OF THE UPPER VERTICAL FIN ATTACHMENT FRAME, AME DISCOVERED RIB TO BE CRACKED. RIB REPLACED AS PER REPAIR MANUAL AND A/C RETURNED TO SERVICE. 1G72 3U3 U H11EU E4CE 20030721000202003072100020SW 2003 7 21 CA030617003 120030514G6320 FITTING BELL 206 206B 1181511SW ALLSN 250C 250C20B 03013GL MAIN ROTOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) SENT IN FOR OVERHAUL, DUE TO BEARING CHANGE NDT INSPECTION FOUND A 1 INCH CRACK AT BASE OF BEARING LUG TO BASE OF FRAME NEXT TO PIN. 1G71 3U3 U H2SW E4CE 20030908001642003090800164NM 2003 9 8 CA030618001 120030613G5610 WINDOW BOEING737 73776N 13844CHNM CFMINTCFM567CFM567B22 13802NE COCKPIT BIRD STRIKE W C ABORTED TAKEOFF C F.O.D. TOTAKEOFF 1 CA (CAN) CREW REPORTS A SEAGULL STRUCK THE CO-PILOT'S R1 WINDOW AT ABOUT 100 KNOTS WHEN DEPARTED. TAKE-OFF WAS REJECTED RESULTING IN A 'HIGH ENERGY STOP'. AIRCRAFT TAXIED BACK TO THE RAMP WITH NO FURTHER INCIDENTS TO REPORT. MAINTENANCE INSPECTED THE AIRCRAFT, HIGH ENERGY STOP INSPECTION PER MM. ONE FAULT FOUND, MELTED SUBSTANCE ON NR 2 BRAKE (RUNWAY ASHPHALT) - MAINTENANCE R EPLACED NR 2 BRAKE ASSEMBLY.BIRD STRIKE INSPECTION COMPLETE PER MM. BIRD REMAINS REMOVED FROM R1 WINDOW AREA - NO FURTHER FAULTS FOUND. AIRCRAFT RETURNED TO SERVICE WITH NO FURTHER INCIDENTS TO REPORT. 2L72 4F4 FRTA16WE E00055EN 20030822000982003082200098CE 2003 8 22 CA030618002 120030617G324695440263 WHEEL LEAR 35 35A 5170602CE GARRTTTFE731TFE73122B 01518WP MLG CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) AT OVERHAUL THE INNER WHEEL HALF WAS FOUND TO BE CRACKED AT ONE CORNER RADIUS OF EACH BRAKE DISC KEYWAY. THE CRACKS EMINATED FROM A MACHINED NOTCH IN THE RADIUS OF THE CORNERS. THE OPPOSITE CORNER OF EACH KEYWAY WAS SMOOTH. 2L72 4F4 F A10CE E6WE 20030718000632003071800063NM 2003 7 18 CA030618003 120030617G3260858601 PROXIMITY SENSOR DHAV DHC8 DHC8301 1386003NM PWA PW120 PW123 NE HAMSTD14SF 14SF15 NE MLG FAILED W O OTHER N FALSE WARNING APAPPROACH 1 CA 2621026210 (CAN) DURING SELECTION OF GEAR DOWN ON APPROACH, THE GEAR FAILED TO EXTEND. THREE RED GEAR LIGHTS ILLUMINATED, AMBER WARNING LIGHT IN SELECTOR HANDLE ILLUMINATED, GEAR DOORS DID NOT OPEN. AIRCRAFT RETURNED TO ORIGINATING AIRPORT, ALTERNATE GEAR EXTENSION USED, GEAR EXTENDED AND AIRCRAFT LANDED NORMALLY. PSEU SHOWING FAULT CODES 53 & 55 (INTERNAL CARD FAILURES). LANDING GEAR PROXIMITY CONTROL BOX (PSEU) REPLACED. GEAR SWINGS CARRIED OUT . AIRCRAFT RETURNED TO SERVICE , NO FURTHER FAULTS. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030721000212003072100021CE 2003 7 21 CA030618004 120030616G32469544008 LINER GOODYEAR LEAR 35 35A 5170602CE GARRTTTFE731TFE73122B 01518WP KEYWAY BENT W O OTHER O OTHER NRNOT REPORTED 1 CA MAY772454 (CAN) ONE OF TWO MS20427-4C7 RIVETS THAT HOLD THE KEYWAY LINER ON THE INNER WHEEL HALF FAILED ALLOWING THE CENTRIFUGAL FORCE OF THE SPINNING WHEEL TO BEND THE LINER OUTWARD UNTIL IT CONTACTED THE LOWER TORQUE LINK, DAMAGING IT AND ALSO CUTTING THE SIDEWALL OF THE TIRE. A SIMILAR INCIDENT OCCURED EARLIER ON ANOTHER LEAR 35 THAT RESULTED IN DAMAGE TO THE GEAR LEG. THE DAMAGED PARTS IN BOTH CASES HAD TO BE REPLACEDTHE RIVETS ARE OFTEN FOUND LOOSE AND REPLACED AT WHEEL OVERHAUL. A COMPANY PROCEDURE BULLETIN HAS NOW BEEN ISSUED TO INSPECT THE LINER RIVETS FOR LOOSENESS AT EACH 50 CYCLE BRAKE WEAR CHECK. 2L72 4F4 F A10CE E6WE 20030821000852003082100085EU 2003 8 21 CA030618005 120030613G2450LHA4B6101 SWITCH LUCAS LHA4B6101 STBROSSD3 SD360 8100606EU PWA PT6 PT6A65AR 52043NE MASTER JAMMED W O OTHER H ELECT. POWER LOSS-50 PC ININSP/MAINT 1 CA (CAN) THIS SWITCH SWITCHES POWER FROM EXTERNAL TO OFF AND TO INTERNAL POWER. THE SWITCH JAMMED AND IT WAS PHYSICALLY IMPOSSIBLE TO MOVE THE SWITCH TO THE OFF POSITION. 2H72 4T4 T A41EU E4EA 20030821000882003082100088EU 2003 8 21 CA030618006 120030613G5210500221XXX321 SPRING STBROSSD3 SD360 8100606EU PWA PT6 PT6A65AR 52043NE PAX DOOR BROKEN W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) THIS PART IS THE STRUT THAT LOCKS THE MAIN CABIN DOOR IN THE OPEN POSITION. THE INTERNAL SPRING FAILED CAUSING THE DOOR TO COME TO A SUDDEN STOP WHEN FULLY OPEN. THIS CAUSES STRESS ON THE LOCKING STRUT AND DOOR FRAME. 2H72 4T4 T A41EU E4EA 20030718000642003071800064WP 2003 7 18 CA030618007 120030618G5511369D23623 SPAR HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL HORIZONTAL STAB CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 009991878 (CAN) DURING 100 HR INSPECTION SMOKING RIVETS WERE OBSERVED ON THE BOTTOM CENTER DOUBLER OF THE HORIZONTAL STABILIZER. INVESTIGATION REVEALED SPAR CRACK IN WEB AND LOWER FLANGE. HORIZONTAL STAB WAS REMOVED AND SENT OUT FOR SPAR REPLACEMENT. 1G71 3U3 U H3WE E4CE 20030721000222003072100022WP 2003 7 21 CA030618008 220030617G73218974573 BYPASS VALVE BAG JETSTMJETSTM3212 1500217EU GARRTTTPE331TPE33110UG 01514WP MCAULY4HFR344HFR34C652 NE ENGINE INTERMITTENT W EA ENGINE SHUTDOWN UNSCHED LANDING X ENGINE FLAMEOUT CLCLIMB 1 CA (CAN) ON TAKE OFF, BOTH ENGS PRODUCED NORM TAKE OFF PWR AT 400 FT AGL, CAPT CALLED FOR CLIMB PWR, RT ENG POWER REDUCED TO 30 PERCENT TORQUE. A/C RETURNED TO LAND WITH RT ENG SHUTDOWN & RT PROP FEATHERED. MAINT RECEIVED A/C WITH RT PROP FEATHERED. PROP WAS UNFEATHERED & VARIOUS FUEL CONTROL & SHUT OFF COMPONENTS CHECKED FOR PROPER OP. NO FAULTS FOUND. GRD RUNS CARRIED OUT. NO FAULTS FOUND. A FLT TEST REQUESTED & CARRIED OUT, NO FAULTS FOUND. A/C RELEASED FOR SERVICE. 4 FLTS LATER, PILOT REPORTED TORQUE TEMP LIMITING SYS TEST PRODUCING ABNORMAL LARGE DROPS IN TORQUE, TEMPS & FUEL FLOW. SYS IS ACTIVE DURING TAKE OFF & ITS PURPOSE IS TO PREVENT DAMAGING ENG WITH EXCESSIVE TORQUES OR TEMPS. 2L72 4T4 TRTBA15CAA E4WE 6 C3PNE 20030821000912003082100091NE 2003 8 21 CA030619001 220030527G7261UL39099 BEARING BOEING757 757200 1384950NM RROYCERB211 RB211535* NE NR 1 ENGINE FRACTURED W O OTHER K FLUID LOSS NRNOT REPORTED 1 CA 13434 (CAN) HIGH OIL CONSUMPTION AIRCRAFT N752NA, NR 1 ENGINE 31652 HAD CONSUMED APPROX. 17 QUARTS OF OIL AFTER 5.5 HR FLT FROM OKLAND TO MIAMI, 18 MAY 2003. ENGINE IS AT RRC FOR REPAIR, DURINGDISMANTLING OF MODULE 5, THE HP/IPT OIL VENT TUBE WAS FOUND FRACTURED AT WELD JOINT. ROLLS-ROYCE FRS 5585 REPLACES DAMAGED TUBE. 2L72 4F4 FRTA2NM E12EU 20030821000932003082100093CE 2003 8 21 CA030619002 120030617G3230MS24171D1 RELAY BEECH 1900 1900C 1154161CE PWA PT6 PT6A65B 52043EA MLG FAILED W O OTHER O OTHER APAPPROACH 1 CA (CAN) WHEN THE LANDING GEAR WAS SELECTED DOWN ON APPROACH THE GEAR FAILED TO EXTEND. A MANUAL EXTENSION WAS CARRIED OUT. MAINT JACKED THE AIRCRAFT AND SELECTEDGEAR UP AND THE GEAR AGAIN WOULD NOT MOVE. TROUBLESHOOTING FOUND THAT THE ABOVE RELAY WAS EXTREMELY HOT AND NOT FUNCTIONING. THE RELAY WAS REPLACED, SEVERAL GEAR SWINGS WERE CARRIED OUT AND THE AIRCRAFT WAS RETURNED TO SERVICE. 2L72 4T4 TRTA24CE E4EA 20030821000952003082100095EU 2003 8 21 CA030619003 120030617G3020SM600BA CIRCUIT BREAKER STBROSSD3 SD360 8100606EU PWA PT6 PT6A65AR 52043NE INTAKE HEATER FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 CA (CAN) PILOT TURNED ON MASTER SWITCH AT BEGINNING OF DAY AND GROUND HANDLERS NOTICED SMOKE COMING FROM THE RT ENGINE INTAKE LIP HEATER. THE MASTER WAS SHUT OFF BUT EXTENSIVE DAMAGE HAD ALREADY OCCUREDTO THE INTAKE LIP HEATER. IT WAS FOUND THAT THE ABOVE REMOTE CONTROL CIRCUIT BREAKER HAD PERMANENTLY CLOSED CONTACTS WHICH IN TURN CAUSED THE INTAKE LIP HEAT TO REMAIN ON. INTAKE LIP HEATER AND CIRCUIT BREAKER WERE REPLACED AND AIRCRAFT RETURNED TO SERVICE 2H72 4T4 T A41EU E4EA 20030821000962003082100096EA 2003 8 21 CA030619004 120030616G3260N864808 PSEU CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE MLG FAILED W O OTHER N FALSE WARNING APAPPROACH 1 CA (CAN) ON GEAR DOWN SELECTION, GEAR DISAGREE MESSAGE DISPLAYED. POSITION SENSOR ELECTRONICS UNIT REPLACED AND CHECKED SERVICABLE. 2L72 4F4 FRTA21EA E15NE 20030718000652003071800065SO 2003 7 18 CA030619005 120030612G323042042000 PIVOT PIPER PA31T PA31T 7103124SO PWA PT6 PT6A28 EA HARTZLHCB3T HCB3TN3 GL MLG CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING SCHEDULED INSPECTION, A CRACK WAS FOUND ON THE INSIDE RADIUS OF THE LT MLG ACTUATOR PIVOT ARM. 1L72 3T4 T A8EA E4EA 6 CP15EA 20030721000232003072100023EU 2003 7 21 CA030619006 120030616G3250Z4242390000 CABLE ZLIN 242 Z242L 9970204EU LYC O360 AEIO360A1B6 41514EA NLG STEERING BROKEN W D RETURN TO BLOCK O OTHER TXTAXI/GRND HDL 1 CA (CAN) WHILE TAXIING AN AIRCRAFT THE STUDENT PILOT NOTICED THAT THE NOSE WHEEL STEERING WAS NOT RESPONDING WITH TURNS TO THE RT. MAINTENANCE WAS NOTIFIED AND IT WAS FOUND THAT THE RT NOSE GEAR STEERING CABLE WAS BROKEN AT THE AFT END OF THE CABLE WHERE THE ATTACH BOLT GOES THROUGH THE THIMBLE. THE CABLE WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. IF THE AIRCRAFT IS NOT ROLLING WHEN NOSE WHEEL STEERING IS ACTIVATED IT PUTS STRESS ON THE NLG STEERING SYSTEM. THIS SYSTEM DOES NOT AFFECT RUDDER MOVEMENT. 1L71 3O3 O0 A76EU 1E10 20030821000982003082100098NM 2003 8 21 CA030619007 120030619G32228800 STRUT DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE NLG WORN W K NONE O OTHER ININSP/MAINT 1 CA 22169 (CAN) WHILE PERFORMING DEHAV TASK CARD 3220/02 VISUAL INSPECTION OF NLG ASSY GREASE FITTINGS ON NLG TRAILING ARM TO SHOCK STRUT PISTON LINK ASSY. FOUND GREASE FITTINGS MISSING AND LINK WORN ON DISASSEMBLY.THE FOLLOWING PARTS HAD SUSTAINED EXTENSIVE DAMAGE: PIN P/N 8871-1 DIAMETER HAD BEEN REDUCED ON ONE SIDE BY .151 INCHES, DIAMETER OF PIN MEASURED 1.186. LINK ASSY LOWER BORE WORN OVAL DIMENSIONS 1.311 X 1.381.TRAILING ARM WORN BETWEEN BUSHING LUGS .162. LINK BUSHING PN 8885-3 ONLY APPROX 1/3 REMAINED. TRAILING ARM LINK PIN BUSHINGS PN 8806-7 PITTED AND SCORED. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030718000662003071800066NM 2003 7 18 CA030620001 120030618G291082960010115 LINE DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE HYD SYSTEM CRACKED W O OTHER KJ FLUID LOSS WARNING INDICATION APAPPROACH 1 CA 34525 (CAN) A HYDRAULIC LINE FROM THE NR 2 HYD SYS THAT FEEDS THE RUDDER PRESSURE REGULATOR DEVELOPED A HAIRLINE CRACK IN THE TAIL SECTION. . THE NR 2 SYSTEM HYDRAULIC QUANTITY DEPLETED TO BELOW MINIMUM. AN EMERGENCY LANDING GEAR EXTENSION WAS CARRIED OUT AND THE AIRCRAFT LANDED WITHOUT FURTHER INCIDENT. A FLEXIBLE HYDRAULIC LINE WAS INSTALLED TEMPORARILY AS DETAILED IN MAINTENANCE MANUAL CHAPTER 20-50-52. NR 2 HYDRAULIC PUMP WAS REPLACED AS A PRECAUTION, GEAR SWINGS CARRIED OUT AND THE AIRCRAFT RETURNED TO SERVICE. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030721000242003072100024SW 2003 7 21 CA030620002 120030618G532027200637 RECEPTACLE SWRNGNSA226 SA226TC 8780404SW GARRTTTPE331TPE33110UA 01514WP DOOR FRAME CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 23728 (CAN) WHILE CARRYING OUT SERVICE LETTER 226-SL-027, WHICH CALLS FOR INSPECTION OF THE ALL DOOR LATCH RECEPTICLES, WE FOUND 3 CRACKED ON PASSENGER DOOR FRAME & 2 CRACKED ON THE AFT CARGO DOOR FRAME. ONE RECEPTICAL WAS CRACKED ALMOST IN HALF WHILE OTHERS SMALL AND DIFFICULT TO SEE. THE ECCENTRIC BUSHING WHICH MOUNTS IN THE RECEPTICAL MUST BE REMOVED TO SEE THE CRACKS. CRACKED RECEPTICLES WERE DISCOVERED IN ANOTHER METRO II IN THE FLEET THIS SERVICE LETTER IS NOT MANDATORY. 2L72 4T4 TRTA8SW E4WE 20030821001012003082100101EA 2003 8 21 CA030620003 120030615G7110AC35500 RING ASSEMBLY DHAV DHC3 DHC3 2800202EA WSK ASZ62 ASZ62IRM18 NE COWL CRACKED W BA EMER. DESCENT UNSCHED LANDING D INFLIGHT SEPARATION CRCRUISE 1 CA (CAN) NOSE COWLING PARTIALLY SEPARATED FROM ENGINE CAUSING THE TOP AND RT SEGMENTS OF COWL TO CONTACT THE PROP. AFTER LANDING THE COWL RING WAS INSPECTED AND 5 OF THE 9 ATTACH LUGS HAD FAILED AND 2 OF THE LUGS HAD THE VIBRATION ISOLATORS PULLED THROUGH. THE FAILURE OF THE LUGS WAS PROGRESSIVE IN NATURE AND SHOULD HAVE BEEN VISABLE DURING DAILY AND ROUTINE INSPECTIONS. 1H71 3R3 R A815 E10NE 20030821001032003082100103WP 2003 8 21 CA030620005 120030620G2910 VALVE CVAC 340 340CVAC 242270AWP ALLSN 501D 501D13D 03004GL HYD SYSTEM FAILED W O OTHER KJ FLUID LOSS WARNING INDICATION APAPPROACH 1 CA (CAN) DURING APPROACH INTO YELLOW, HYD SYSTEM FAILURE. MANUAL GEAR EXTENTION CARRIED OUTAND A/C LANDED WITH OUT DIFFICULTY. LT GEAR BLOW BACK VALVE FOUND FAILED (CAP BURST), REPLACED IAW MM AND A/C RETURNED TO SERVICE 2L72 4R4 T 6A6 E282 20030718000672003071800067NM 2003 7 18 CA030620006 120030619G2910 LINE BOEING737 737242C 1384478NM PWA JT8 JT8D9A 52048NE HYD SYSTEM MISINSTALLED W A UNSCHED LANDING WJ INADEQUATE Q C WARNING INDICATION CLCLIMB 1 CA (CAN) FLT CREW REPORTED THAT NLG UNLOCKED BUT FAILED TO RETRACT. SUBSEQUENT GEAR SELECTS WERE UNSUCCESSFUL UNTIL SPEED REDUCED. GEAR DID RETRACT AT 160 KNOTS IAS, VERY SLOW, RETURN TO YEG. THIS ANOMALY DATES BACK TO 06/4/03, WHEN SKI ACTUATOR ROBBED TO SERVICE ANOTHER A/C. REPLACING SKI ACTUATOR, FLEX LINES LEADING TO ACTUATOR WERE INSTALLED INCORRECTLY. INSTALLATION RESULTED IN FLEXIBLE HYD LINES BECOMING CRIMPED DURING GEAR RETRACTION. CULMINATING ON 06/17/03 WHEN NLG REPORTED SLOW TO RETRACT. LINES FOUND TO INSTALLED INCORRECTLY AT TIME. LINES WERE CORRECTLY INSTALLED & AIRCRAFT DISPATCHED. HOWEVER SNAG RETURNED ON JUNE 19, CAUSING AIR RETURN, MAINT UNABLE TO CONFIRM THE FAULT DURING GEAR SWINGS. 2L72 4F4 F A16WE E2EA 20030721000252003072100025NE 2003 7 21 CA030623001 220030618G8530 CYLINDER CNDAIRCL215 CL2151A10 1900320EA PWA R2800 CA3 52026NE ENGINE CRACKED W E ENGINE SHUTDOWN J WARNING INDICATION NRNOT REPORTED 1 CA (CAN) AFTER A SCOOPING RUN THE CREW NOTICED A 30 DROP IN THE BMEP ON THE LT ENGINE. LOAD WAS DROPPED AND A/C CLIMBED TO 2500 FT AND EXECUTED A PRECAUTIONARY ENGINE SHUT DOWN. THE A/C FLEW TO BASE WHERE IT LANDED UNEVENTFULLY. THE NR 5 CYLINDER WAS CRACKED. CYLINDER WAS REPLACED & A/C RETURNED TO SERVICE. 2H72 4R4 RRTA14EA E231 20030821001052003082100105NM 2003 8 21 CA030623003 120030622G3260841005 PSEU DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE MLG FAILED W O OTHER J WARNING INDICATION APAPPROACH 1 CA 21563 (CAN) DURING GEAR DOWN SELECTION , NO 'GREEN' INDICATION FOR NLG , GEAR CYLED, ALTERNATE GEAR EXTENSION SELECTED. SYS RESET AND NORMAL GEAR DOWN SELECTED , ALTERNATE AND NORMAL GEAR INDICATION BOTH SHOWED 'GREEN' INDICATION. NORMAL LANDING. MAINTENANCE REPLACED PSEU , GEAR SWINGS CARRIED OUT WITH NO FAULTS. AIRCRAFT RETURNED TO SERVICE. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030821001072003082100107CE 2003 8 21 CA030623004 120030613G30209091010017 DUCT BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA ANTI-ICE SYSTEM CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) WHILE CARRYING OUT A COMPANY CAMPAIGN NOTICE TO INSPECT ENGINE INLET ANTI-ICE DUCTS FOR CRACKS, BOTH ENGINE SHORT LT DUCTS WERE FOUND CRACKED. ONE DUCT WAS CRACKED ON ONE END AND THE OTHER WAS CRACKED AT BOTH ELBOW ENDS. THE DUCTS HAD ACCUMULATED 191.5 HOURS SINCE INSTALLATION AS PART OF SB 71-3142. BOTH ENGINE RT LONG DUCTS HAD ALSO BEEN REPLACED SINCE SB 71-3142 INSTALLATION. THE POST SB PARTS HAVE A HIGHER FAILURE RATE THAN THE UNITS THEY ARE REPLACING. 1L72 3T4 TRT3A20 E4EA 20030718000682003071800068EA 2003 7 18 CA030624001 120030618G3232NAS620434D BOLT CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE NLG DOOR ACT CORRODED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ROLLER BEARING WITH NLG DOORS FULLY CLOSED SHOULD FALL WITHIN ITS MECHANICAL CAM-LOCK WHEN FUNCTIONING NORMALLY. WHEN HYDS ARE REMOVED, RETRACT ACTUATOR WILL RELAX AND CAM-LOCKED ROLLER BEARING WILL KEEP NLG DOOR FULLY CLOSED, PREVENTING FROM FALLING 'OPEN'. IF PIVOT BOLT BECOMES CORRODED AND RESTRICTS MOVEMENT OF ITS SPRING-LOADED PIVOT LEVER. ROLLER BEARING CAN HANG-UP AND NOT FALL INTO ITS CAM-LOCK SLOT. WHEN HYDRAULICS ARE REMOVED AND DOOR RETRACT ACTUATOR RELAXES, DOORS WILL DROP OPEN. 2L72 4F4 FRTA21EA E15NE 20030822000962003082200096NM 2003 8 22 CA030624003 120030412G213092148C010101 MODULE BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA CABIN PRESSURE FAILED W A UNSCHED LANDING W INADEQUATE Q C CLCLIMB 1 CA (CAN) DURING CLIMB, PILOT OBSERVED DIFF PRESS WENT FROM 4,5 TO 0 & RATE WENT TO A 1500 FPM DESCEND. PILOT MONITORED INSTRUMENTS CLOSELY & SHORTLY DIFF PRESS WENT BACK TO NORMAL & RATE CLIMBED NORMAL 5-600 FPM. AT ALL TIMES CABIN ALT WAS STEADY ON 4200 FT. LEVELING OFF AT FL 180, FELT A CLICKING IN OUR EARS & CA CALLED & SAID THEY FELT SAME WAY. STARTED A NORMAL DESCEND TO FL100 & CONTINUED FLT TOP CPH AT FL100. BEFORE LEVELING OF AT FL100, A LOUD WHISTELING NOISE IN A/C. MADE DESCEND INBOUND TO BASE & DECIDED TO DUMP CABIN PRESSURE ON APPROACH & LAND DEPRESSURIZED. CHECKED FOR FAULTS. FAIL TO CABIN INDICATION MODULE RECORDED. CIM REPLACED ACCORDING AMM. CABIN PRESS TEST PERFORMED WITHOUT REMARKS. 2H72 4T4 TRTA13NM E00062EN 20030821001102003082100110NM 2003 8 21 CA030624004 120030506G3230 SQUAT SWITCH BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA NLG FAILED W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) AFTER LANDING GEAR WAS SELECTED UP, LANDING GEAR WAS STILL DOWN INDICATING 3 GREEN AND 3 RED LIGHTS. TRIED TO RECYCLE THE GEAR ONCE WITHOUT SUCCESS. RETURNED FOR A NORMAL LANDING. PASSENGERS WHERE BRIEFED IN THE AIR AND ON GROUND. HARNESS ASSY WOW SWITCH ON NOSE WHEEL CENTERING REPLACED. 2H72 4T4 TRTA13NM E00062EN 20030821001162003082100116SW 2003 8 21 CA030625001 120030623G2913MS219266 ELBOW VICKER BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA HYD PUMP CRACKED W O OTHER K FLUID LOSS NRNOT REPORTED 1 CA MX326593 (CAN) A HYD LEAK WAS FOUND DURING A GROUND RUN TO CHECK FOR LEAKS AFTER MINOR MAINTENANCE. THE ENGINEER NOTICED HYD FLUID DRIPPING FROM AN ELBOW FITTING ON THE NR 1 HYD PUMP. THE FITTING AND LINE B-NUT WERE CHECKED AND FOUND SECURE. THE FITTING WAS REMOVED AND UPON FURTHER INSPECTION A CRACK WAS FOUND. THE AIRCRAFT WAS REMOVED FROM SERVICE AND A REPLACEMENT PART ORDERED. 1G71 4U4 U H4SW E22EA 20030821001182003082100118NM 2003 8 21 CA030625002 120030526G3297471515 WIRE HARNESS BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA NLG WOW DAMAGED W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) GEAR UP SELECTION WAS UNSUCCESSFUL. 3 GREEN & 3 RED LIGHTS AT THE SAME TIME. GEAR RECYCLED BUT WITHOUT SUCCESS. WE RETURNED FOR A NORMAL LANDING (NO EMERGENCY DECLARED). CABIN AND PAX BRIEFED AND DEBRIEFED. INVESTIGATION/ACTION HARNESS ASSEMBLY WOW SWITCH ON NOSE WHEEL CENTERING REPLACED. 2H72 4T4 TRTA13NM E00062EN 20030718000692003071800069NM 2003 7 18 CA030625003 120030519G3297 WIRE BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA WOW SWITCH SHORTED W A UNSCHED LANDING N FALSE WARNING CLCLIMB 1 CA (CAN) AFTER TAKEOFF, WOW CAUTION CAME ON AFTER SELECTING GEAR UP. ALL OTHER INDICATIONS NORMAL. QRH PERFORMED AND A/C LANDED AFTER CONSULTING TCC. TROUBLESHOOTING WIRES TO LT GEAR WOW NR 2 SENSOR WAS FOUND SHORTED. SENSOR ASSEMBLY REPLACED ACCORDING AMM TASK 32-61-00. 2H72 4T4 TRTA13NM E00062EN 20030718000702003071800070CE 2003 7 18 CA030625004 120030625G321366422172 STRUT CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE NLG PUNCTURED W O OTHER K FLUID LOSS NRNOT REPORTED 1 CA (CAN) PILOT REPORTED THAT THE NOSE OLEO WAS BOTTOMING OUT WHILE TAXING THE AIRCRAFT. WHEN ATTEMPTING TO SERVICE THE AIRSIDE OF THE OLEO IT WAS DISCOVERED THAT OIL WAS PRESENT AT THE AIR VALVE. THE STRUT WAS DISASSEMBLED TO VERIFY IF ANY DAMAGE HAD OCCURRED TO THE ISOLATION PISTON PACKINGS. THE AME FOUND THAT THE METERING PIN HAD PUNCTURED THE TOP OF THE ISOLATOR PISTON. THE DAMAGED PARTS WERE REPLACED & THE AIRCRAFT RETURNED TO SERVICE. 1L72 4F4 F A22CE E1NE 20030718000712003071800071 2003 7 18 CA030625005 420030610G3416 INDICATOR DHAV DHC8 DHC8315 2809010NM PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE ALTIMETER INCORRECT W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) STANDBY ALTIMETER WAS FOUND TO HAVE THE INCORRECT FACE INSTALLED. PART NUMBER INDICATES THE ALTIMETER IS METRIC SELECTABLE RANGE IS METRIC HOWEVER FACE OF ALTIMER STATES INCHES OF MERCURY RATHER THAN MILLIBARS. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030721000272003072100027SO 2003 7 21 CA030625006 120030625G7332486439 TRANSMITTER PIPER PA38 PA38112 7103812SO LYC O235 O235L2C 41505EA FUEL PRESSURE FAILED W A UNSCHED LANDING N FALSE WARNING CRCRUISE 1 CA (CAN) DURING FLT, PILOT NOTICED THE FUEL PRESSURE INDICATION DROP TO ZERO, WITHOUT ANY CHANGE IN ENGINE FUNCTION. THE PILOT CUT SHORT HIS LOCAL FLT, & RETURNED TO THE AIRPORT. THE FUEL PRESSURE TRANSDUCER WAS REPLACED WITH ANOTHER NEW TRANSDUCER, AND THE PRESSURE INDICATION RETURNED TO NORMAL. FURTHER TO THIS, THESE TRANSDUCERS ARE FAILING AT AN ALARMING RATE. EVEN A DISTRIBUTOR OF THESE PRODUCTS ADMITS THAT THEY ARE A DISPOSABLE ITEM. 1L71 3O3 O A18SO E223 20030721001042003072100104NM 2003 7 21 CA030625007 120030618G2721682015 SWITCH DHAV DHC8 DHC8315 2809010NM PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE RUDDER FAILED W O OTHER H ELECT. POWER LOSS-50 PC CLCLIMB 1 CA (CAN) DURING CLIMB ALTITUDE PASSING 3,000 FT, PILOT PUT RUDDER TRIM SWITCH TO A/C LT DIRECTION. HEARD STRANGE SOUND & RUDDER TRIM CONTINUED MOVING TO A/C LT DIRECTION UNTIL FULL LT DIRECTION. TRIED TO PUT SWITCH TO RT DIRECTION BUT COULDN`T CONTROL A/C WITH USING RUDDER TRIM SWITCH. RUDDER TRIM WAS STILL FULL LT. PUSHED RUDDER PEDAL TO RT DIRECTION TO MAINTAIN A/C ATTITUDE & DECREASED AIR SPEED TO 160KT ANOTHER FLT. TOO HARD TO CONTROL A/C ATTITUDE WITH MANUAL RUDDER IN AIRSPEED 220 KT. IN CRUSE, ATTEMPTED CIRCUIT BREAKER (RUDDER TRIM ACTUATOR) RECYCLED IAW WITH AOM , BUT CONDITION DID NOT RECOVER. LANDED AT DESTINATION. ROTOARY SWITCH REPLACED. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030721001052003072100105NM 2003 7 21 CA030625008 120030620G32208600113 ACTUATOR DHAV DHC8 DHC8301 1386003NM PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE NLG STEERING LEAKING W O OTHER K FLUID LOSS LDLANDING 1 CA 15728 (CAN) PILOT COMPLAINED OF NLG WHEEL SHIMMY ON LANDING. DURING INVEST FOUND EXCESSIVE PLAY IN NLG STEERING ACTUATOR & TELESCOPIC LINKS. A/C BROUGHT TO HANGER & PLACED ON JACKS. FOUND THAT WHEN YOU MOVE NOSE WHEELS LT & RT STEERING ACTUATOR MOVING FORE & AFT. ATTACH BOLTS FOR CENTERING SPRING WERE ALSO LOOSE & ASSY WAS MOVING FORE & AFT. DUE TO MOVEMENT OF ACTUATOR, INPUT END GLAND NUT OF ACTUATOR WOULD OPEN UP CAUSING A HYD LEAK. STEERING ACTUATOR TRANSFER TUBE REMOVED & FOUND DAMAGED IN CENTRE OF TUBE. A SERVICEABLE TUBE, STEERING ACTUATOR, TELESCOPIC LINKS & CENTERING SPRING WHERE FITTED TO A/C. DURING CHECKS FOUND STEERING LIMIT SWITCH U/S. SWITCH REPLACED. CHECKS CARRIED OUT WITH NO DEFECTS. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030821001192003082100119CE 2003 8 21 CA030626001 120030624G5220651125619 SEAL CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE ESCAPE HATCH DAMAGED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) IN PREPARATION FOR A PHASE 5 INSPECTION MAINTENANCE TECHNICIANS HAD DIFFICULTY REMOVING THE EMERGENCY EXIT DOOR. UPON REMOVAL IT WAS NOTED THAT THE DOOR SEAL HAD SOME FORM OF LUBRICANT ON IT THAT CAUSED THE SEAL TO STICK TO THE FRAME. THE AIRCRAFT MAINTENANCE MANUAL DOES NOT INDICATE ANY REQUIREMENT FOR IN SERVICE SEAL LUBRICATION. SUBSEQUENT REINSTALLATION AFTER CLEANING THE SEAL POSED NO DIFFICULTY. 1L72 4F4 F A22CE E1NE 20030718000752003071800075EA 2003 7 18 CA030626003 220030613G8520LW18840 CAMSHAFT ZLIN 242 Z242L 9970204EU LYC O360 AEIO360A1B6 41514EA MUHBR MTV MTV9* EU ENGINE SPALLED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE ENGINE WAS SENT IN FOR A PROP STRIKE INSPECTION. AFTER DISASSEMBLY THE CAMSHAFT WAS FOUND TO HAVE AN UNACCEPTABLE AMOUNT OF SPALLING ON THE NR 1 EXHAUST LOBE AND ON BOTH INTAKE LOBES. THE CAM AND LIFTERS WERE REPLACED WITH A MFG FACTORY NEW KIT. 1L71 3O3 O0 A76EU 1E10 5 CP24NE 20030721000292003072100029CE 2003 7 21 CA030626004 120030619G2435230850041 STARTER GEN CESSNA525 525 2076601CE WILINTFJ44 FJ441A GL ENGINE FAILED W H DEACTIVATE SYST/CIRCUITS J WARNING INDICATION CLCLIMB 1 CA (CAN) LT GENERATOR WENT OFF LINE IN FLIGHT. AFTER LANDING WE TRIED TO START THE LT ENGINE AND NO RESPONSE,THE LT STARTER GENERATOR WAS CHANGE WITH AN OVERHAUL UNIT. THE LT GENERATOR WAS DUE FOR OVERHAUL AT 2049 HOURS. 1L72 4F4 FRTA1WI E3GL 20030821001212003082100121EA 2003 8 21 CA030626005 220030612G8520LW18840 CAMSHAFT ZLIN 242 Z242L 9970204EU LYC O360 AEIO360A1B6 41514EA ENGINE SPALLED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE ENGINE WAS SENT FOR INSPECTION DUE TO METAL CONTAMINATION. AFTER DISASSEMBLY THE CAMSHAFT WAS FOUND TO HAVE SPALLING ON ALL THE LOBES, THE INTAKE LOBES BEING THE WORST. THIS SPALLING WAS THE CAUSE OF THE METAL CONTAMINATION. THE CAMSHAFT WAS REPLACED WITH A FACTORY NEW KIT. 1L71 3O3 O0 A76EU 1E10 20030821001232003082100123EA 2003 8 21 CA030626006 220030613G8520LW18840 CAMSHAFT ZLIN 242 Z242L 9970204EU LYC O360 AEIO360A1B6 41514EA ENGINE WORN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE ENGINE WAS SENT IN FOR CAMSHAFT CHANGE DUE TO CAMSHAFT FAILURE. THE CAMSHAFT WAS FOUND TO HAVE SEVERE WEAR ON THE NR 1 & 2 INTAKE LOBE. REPLACED WITH A FACTORY NEW CAMSHAFT. 1L71 3O3 O0 A76EU 1E10 20030718000762003071800076EA 2003 7 18 CA030626007 220030612G8520LW18840 CAMSHAFT ZLIN 242 Z242L 9970204EU LYC O360 AEIO360A1B6 41514EA MUHBR MTV MTV9* EU ENGINE SPALLED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE ENGINE WAS SENT IN FOR INSPECTION DUE TO METAL CONTAMINATION. TWO PROBLEMS WERE DISCOVERED. FIRST, THE CONNETING ROD CAPS WERE CONTACTING THE OPPOSING PISTON SKIRTS, THE CAPS WERE FOUND TO BE APPROXIMATELY .020 THICKER THAN SEVERAL OTHERS MEASURED. THE SECOND PROBLEM FOUND WAS SPALLING ON MOST OF THE CAMSHAFT LOBES. BOTH THESE PROBLEMS CONTRIBUTED TO THE METAL CONTAMINATION. THE CYLINDERS, PISTONS A ND CAMSHAFT WERE ALL REPLACED WITH FACTORY NEW PARTS. 1L71 3O3 O0 A76EU 1E10 5 CP24NE 20030721000302003072100030SO 2003 7 21 CA030626008 220030619G8520646476 BEAM IO520MB CONT O520 IO520MB 17032SO CON ROD BENT W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) THE MAIN BEAM ON THE NR 2 & 6 CONNECTING RODS WERE BENT. NR 5 WAS THE MOST SEVERE. POSSIBLE CAUSE IS HYD LOCKING. 3 O E5CE 20030721000922003072100092SO 2003 7 21 CA030626009 220030626G8530 CYLINDER HEAD CESSNA150 150M 2071830CE CONT O200 O200A 17020SO ENGINE WORN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ON INSPECTION FINE BRONZE PARTICLES FOUND IN OIL FILTER & SCREEN. FURTHER INVESTIGATION REVEALED ROCKER ARM BUSHINGS WORN. ALSO CYLINDER HEAD BOSSES WORN. THE ROCKER SHAFTS ON THESE NEW STYLE CYLINDERS ARE HELD IN PLACE WITH SET SCREWS WHICH SEEM TO LOOSEN OFF. WE HAVE ALSO TRIED LOCTITE BUT IT SEEMS WITH NO SUCCESS. SUGGEST THAT ANY ONE WITH THESE NEW CYLINDERS CHECK THEM ASAP. 1H71 3O3 O 3A19 E252 20030721000932003072100093NM 2003 7 21 CA030627001 120030626G2710BACC13AP6E2858 CONTROL CABLE BOEING727 727225 1384077NM PWA JT8 JT8D15A 52051NE RT INBD. AILERONCHAFED W O OTHER F FLT CONT AFFECTED NRNOT REPORTED 1 CA (CAN) DURING A ROUTINE MAINTENANCE INSPECTION, IT WAS OBSERVED THAT THE RT INBOARD AILERON CABLE ASSY WAS CHAFED AND WORN AT THE CABLE GUIDE. THE CABLE WAS REMOVED & NEW CABLE INSTALLED IAW MM 27-10-71. ADJUSTMENT AND FUNCTIONAL CHECK CARRIED OUT SERVICEABLE IAW MM 27-10-0.AIRCRAFT RETURNED TO SERVICE. 2L73 4F4 F A3WE E2EA 20030718000772003071800077CE 2003 7 18 CA030627002 120030602G2510 INSULATION CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE HEADLINER BURNED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING AN INSPECTION ON THE AIRCRAFT, THE COCKPIT HEADLINER WAS REMOVED TO ACCESS THE G-SWITCH FOR A FUNCTIONAL CHECK. ONCE THE HEADLINER PANEL WAS REMOVED A SECTION OF INSULATION THAT WAS NEXT TO THE MAP LIGHT FOR THE CO-PILOT WAS FOUND SCORCHED AND BRITTLE FROM CONTACT WITH THE BACK OF THE LIGHT ASSEMBLY. THE INSULATION WAS REMOVED AND THE PANEL REINSTALLED AND THE AIRCRAFT WAS RETURNED TO SERVICE. 1L72 4F4 F A22CE E1NE 20030721000312003072100031CE 2003 7 21 CA030627003 120030620G7120 MOUNT CESSNA182 182J 2072722CE CONT O520 IO520D 17032SO MCAULY3A32C D3A32C90 GL ENGINE CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) ENGINE MOUNT CRACKED AT SUPPORT PADS. REINFORCED TO CARRY 10520 ENGINE AS PER P-PONK STC SA461NW ON JULY 96. MOUNT REPLACED WITH NEW MOUNT PN 4402. NO VIBRATION TO DATE. 1H71 3O3 ONT3A13 E5CE 5 CP21EA 20030721000942003072100094NE 2003 7 21 CA030627004 220030605G8530 EXHAUST VALVE DOUG B26 B26C 3200524WP PWA R2800 R280079 52026NE CYLINDER FAILED W E ENGINE SHUTDOWN KB FLUID LOSS SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA (CAN) DURING CRUISE FLIGHT OIL WAS NOTICED COMING FROM THE RT ENGINE. THE ENGINE WAS SHUTDOWN AND LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE EXHAUST VALVE ON NR 5 CYLINDER HAD FAILED. 2M72 4R4 R L34 5E8 20030721000952003072100095GL 2003 7 21 CA030627005 220030605G7323 GOVERNOR BELL 206 206B 1181511SW ALLSN 250C 250C20B 03013GL ENGINE FAILED W O OTHER W INADEQUATE Q C DEDESCENT 1 CA (CAN) WHEN AIRCRAFT APPLIED POWER, GOVERNOR WOULD DROOP BUT WOULD RECOVER WITH A SLIGHT DELAY BUT WHEN AIRCRAFT DESCENDED AND GOVERNOR WOULD OVERSPEED IT WOULD NOT GOVERN AND DECREASE RPM AS WOULD BE NORMAL. TIME SINCE LAST REPAIR 114.8 HRS. 1G71 3U3 U H2SW E4CE 20030721001012003072100101SO 2003 7 21 CA030627007 220030609G853021153 SCREW CESSNA150 150M 2071830CE CONT O200 O200A 17020SO CYLINDER HEAD LOOSE W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) ROCKER SHAFT SET SCREW BECAME LOOSE AFTER 148.1 HRS OF OPERATION AND WORE THE ROCKER SHAFT BOSS IN CYLINDER HEAT MAKING THE CYLINDER UNSERVICEABLE. 1H71 3O3 O 3A19 E252 20030821001282003082100128CE 2003 8 21 CA030627010 120030623G78101019100751 PLATE BEECH 200 B200 1152922CE PWA PT6 PT6A42 52043NE EXHAUST SEAL LEAKING W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING SCHEDULED INSPECTION, FOUND EXHAUST SEAL PLATE FROM LT ENGINE OUTBOARD EXHAUST STACK TO THE HEATED ENGINE INTAKE ANTI-ICE LIP WITH ONE BOLT MISSING AND THE REMAINING BOLTS LOOSE. THE RESULTING EXHAUST LEAK HAS CAUSED SOOT TO BUILDUP ON THE ENGINE CASES. THIS HAS CAUSED AND HIDDEN SEVERE CORROSION PITTING ON THE REDUCTION GEARBOX (RGB) CASE AND SOME BOLTS AT ENGINE FLANGE 'B'. THIS COROSSION IS BEYOND ALLOWABLE LIMITS FOR A LOCAL FIELD REPAIR PER THE PWC ENGINE MM AND WILL REQUIRE REPLACEMENT OF THE RGB CASE. 1L72 4T4 T A24CE E4EA 20030721000892003072100089SW 2003 7 21 CA030627011 120030617G7120206069105101 MOUNT BELL 206 206L3 1182108SW ALLSN 250C 250C30P 03013GL ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING A 100 HR INSPECTION, THE ENGINEER PERFORMING A VISUAL INSPECTION OF THE ENGINE MOUNTS FOUND A CRACK ON THE LOWER PORTION OF THE STRUT 1. 1G71 3U3 U H2SW E1GL 20030721000322003072100032EA 2003 7 21 CA030627014 220030620G853071381 EXHAUST VALVE STOLAMRC3 RC3 3080203NM LYC O480 GO480G2D6 41527EA NR 2 CYLINDER BROKEN W A UNSCHED LANDING E VIBRATION/BUFFET CLCLIMB 1 CA (CAN) ON INITIAL CLIMB OUT, SUDDEN VIBRATION OCCURRED. AIRCRAFT LANDED SAFELY. INVESTIGATION REVEALED FAILURE OF THE 7/16 INCH ZERO STEM EXHAUST VALVE IN CYLINDER NR 2. 1H71 3O3 ORCA769 E275 20030721000752003072100075CE 2003 7 21 CA030627015 120030429G282005001183 LINE CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA FUEL SYSTEM CHAFED W O OTHER O OTHER NRNOT REPORTED 1 CA 14293 (CAN) ABOVE FUEL LINE WAS FOUND CHAFED DURING 200 HR INSPECTION. IT WAS DETERMINED THIS WAS CAUSED FROM RUBBING ON STEERING ROD MOUNT. THIS WOULD BE VERY DIFFICULT TO SEE BUT CLOSE INSPECTION SHOULD BE CARRIED OUT. 1H71 3O3 ONT3A12 E274 20030721000762003072100076SO 2003 7 21 CA030627016 120030502G32302176000 ATTACH FITTING PIPER PA30 PA30 7103002SO LYC O320 IO320B1A 41508EA MLG BROKEN W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) GEAR WOULD NO EXTEND WHEN SELECTED DOWN. EMERGENCY GEAR EXTENSION CARRIED OUT. LUG WAS FOUND BROKEN. THIS RESULTED IN JAMMING OF THE RETRACTION MECHANISM. THIS PART SHOULD BE INSPECTED FOR CRACKS AT INSPECTION. ALSO ATTENTION SHOULD BE PAID TO THIS AREA AFTER HARD LANDINGS, GEAR UP LANDING OR ANY TIME THE GEAR HAS BEEN EXTENDED ABOVE ANY EXTENSION AIRSPEED. 1L72 3O3 O A1EA 1E12 20030721000772003072100077GL 2003 7 21 CA030627017 120030627G27302053840204 STOP DIAMONDA20 DA20A1 2990000GL ELEVATOR BROKEN W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) THE ELEVATOR STOP WAS FOUND BROKEN OFF THE RT ELEVATOR HINGE BLOCK. EXTENSIVE CORROSION WAS FOUND IN THE AREA OF THE FAILURE. THE AIRCRAFT WAS OPERATED FOR FOUR YEARS ON THE CALIFORNIA COAST. IT IS UNCLEARIF THE SALT RICH ENVIRONMENT CONTRIBUTED TO THE CORROSION AND SUBSEQUENT FAILURE. 1L71 3O NTTA4CH 20030721000882003072100088NM 2003 7 21 CA030627018 120030627G2782 ACTUATOR BOEING727 72722C 138400FNM PWA JT8 JT8D7B 52053NE SLAT FAILED W C ABORTED TAKEOFF KJ FLUID LOSS WARNING INDICATION TOTAKEOFF 1 CA (CAN) 'A' SYSTEM HYDRAULIC FAILURE T/O ABORTED AND A/C RETURNED TO BLOCKS. NR 6 SLAT ACTUATOR FOUND FAILED.REPLACED ACT AND A SYSTEM PUMP CASE DRAIN FILTERS INSPECTED/REPLACED. NO CONTAMINATION FOUND. AIRCRAFT RETURNED TO SERVICE. 2L73 4F4 F A3WE E2EA 20030718000802003071800080EA 2003 7 18 CA030628001 120030626G2497MS24171D1 RELAY DHAV DHC6 DHC6300 2802606EA PWA PT6 PT6A27 52043EA HARTZLHCB3T HCB3TN3 GL ELECTRICAL SHORTED W H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA (CAN) DURING FLT, CREW SMELLED ELECTRICAL BURNING ODOR. SYS SYSTEMATICALLY SHUT DOWN INCLUDING, AVIONICS & AIRCRAFT MASTER, ODOR DISSIPATED. ALL RADIOS WERE SWITCHED OFF IN AN ATTEMPT TO SECURE OPERATION OF ONE RADIO FOR COMMS. A/C & AVIONICS MASTER WERE SWITCHED ON WITH AN IMMEDIATE RETURN OF ODOR. A/C AVIONICS MASTER WAS AGAIN ISOLATED & ODOR DISSIPATED. A/C MASTER WAS TURNED ON TO ESTABLISH BASIC A/C SYSTEMS WITH A RETURN OF ODOR. A/C RECOVERED TO MAIN MAINTENANCE BASE WITHOUT FURTHER INCIDENT. UPON INVESTIGATION IT WAS REVEALED THAT POWER TERMINAL OF THE NR 1 AVIONICS RELAY HAD SHORTED TO GROUND. AT THIS TIME THE CAUSE OF THE SHORT IS UNKNOWN. 1H72 3T4 TRTA9EA E4EA 6 CP15EA 20030718000812003071800081NM 2003 7 18 CA030630001 120030629G5755MB543DDFS464 BEARING DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE SPOILER SEIZED W K NONE O OTHER ININSP/MAINT 1 CA 3174031740 1205 (CAN) BEARING FOUND SEIZED DURING 'D' CHECK INSPECTION AT SUMMING LEVER WHERE FEEDBACKARM ATTACHES. THIS CAUSES THE FEEDBACK ARM TO TWIST AND BIND INCREASING FRICTIO N TO THE POINT WHERE NEAR FULL TRAVEL, THE SPOILER CLUTCH WILL DISENGAGE. ROLL SPOILER ACTUATOR (RT IB) REPLACED AND CHECKED, SERVICEABLE. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030718000822003071800082EU 2003 7 18 CA030630002 120030630G24379755084910 DISPLAY PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL GEN 1 AMP/VOLT INTERMITTENT W K NONE O OTHER ININSP/MAINT 1 CA (CAN) GEN 1 AMP/VOLT DISPLAY WENT BLANK. ALL OTHER GEN 1 INDICATIONS NORMAL. ASSY REPLACED WITH SERVICEABLE UNIT. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20031017000112003101700011CE 2003 10 17 CA030702001 120030626G1430S346151 BOLT CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE QUALITY CONTROL WRONG PART W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) BOLTS ORDERED FROM CESSNA AIRCRAFT COMPANY UNDER PROPRIETARY PN S346151 WERE RECEIVED AND DETERMINED TO BE INCORRECT. THE ORIGINAL BOLTS REMOVED FROM THE ENGINE MOUNT INSTALLATION WERE STAMPED WITH PN NAS464P864. REPLACEMENT BOLTS ORDERED FROM CESSNA UNDER PN S346151 WERE RECEIVED AND FOUND STAMPED WITH P/N NAS6208-64D AND PHYSICAL INSPECTION SHOWED THAT THEY WERE .125 LONGER THAN THE ORIGINALS. CESSNA CITATION CUSTOMER SUPPORT OFFICE WAS CONTACTED TO DETERMINE IF THE BOLTS WOULD BE ACCEPTABLE TO INSTALL WITH THE ADDITION OF EXTRA WASHERS. CESSNA ENGINEERS CONSULTED ENGINEERING DRAWING PN 6550000 AND DETERMINED THAT PN NAS464P864 WAS THE ONLY CORRECT PN. CESSNA ENGINEERING ADVISED THAT THEY WOULD CONTACT1L72 4F4 F A22CE E1NE 20030721000332003072100033NE 2003 7 21 CA030702002 220030618G7321 FCU SKRSKYS64 S64E 8142604NE PWA JFTD12JFTD12A4A 52047NE ENGINE MALFUNCTIONED W EA ENGINE SHUTDOWN UNSCHED LANDING RJ PARTIAL RPM/PWR LOSS WARNING INDICATION HOHOVERING 1 CA (CAN) A/C HAD JUST DROPPED A 15,000 LB LOAD OF LOGS AT LOG LANDING IN AN UP HILL YARD. PILOT MADE A LT PEDAL TURN TO DEPART LOG LANDING. COLLECTIVE LOWERED TO DESCEND BACK DOWN TO CUT BLOCK, NR 2 ENG N1 UNDER-SPEED WARNING SOUNDED & WITH WARNING LIGHTS, INDICATING SOFT STALL. CREW EXECUTED AN IN-FLIGHT SHUTDOWN & MOTORING OF ENG TO PREVENT OVER-TEMP. NR 2 ENG SHUTDOWN COMPLET, A/C RETURNED TO SERVICE AREA & MADE A SINGLE ENG LANDING. COMPLETE INSP OF ENG & CONTROL LINKS REVEALED NOTHING ABNORMAL. ENG FUEL FILTER INSP FOR CONTAM, NONE FOUND. ENG FUEL PRESSURIZING & DUMP VALVE CHANGED. FCU ALSO CHANGED AS A PRECAUTION. ENG RESTARTED & GROUND-RUN, ALL PARAMETERS FOUND TO BE ACCEPTABLE & A/C RELEASED FOR FLT. 2G72 4U4 U H4EA E15EA 20030721000862003072100086CE 2003 7 21 CA030702003 120030622G2612302158 FIRE DETECTOR BEECH 200 B200 1152922CE PWA PT6 PT6A42 52043NE HARTZLHCD4N3HCD4N3A GL RT ENGINE MALFUNCTIONED W A UNSCHED LANDING N FALSE WARNING CLCLIMB 1 CA (CAN) AFTER TAKEOFF AIRCRAFT CLIMBED OUT, AND A RT ENGINE FIRE WARNING LIGHT CAME ON. COULD NOT SEE SMOKE, ENGINE FUNCTIONED NORMAL.. RETURNED TO MAINTENANCE FACILITY. 1L72 4T4 T A24CE E4EA 5 CSTC 20030721000872003072100087SW 2003 7 21 CA030702004 120030626G612089741016 GOVERNOR SWRNGNSA227 SA227AC 8780603SW GARRTTTPE331TPE33111U 01514WP ROTOL R321 R321482F8 GL PROPELLER FAILED W C ABORTED TAKEOFF J WARNING INDICATION TOTAKEOFF 1 CA (CAN) ON TAKEOFF ROLL LT ENGINE DID NOT PRODUCE TORQUE FOR TAKEOFF (PROP PARTIALLY CAME OFF LOCKS). ABORTED TAKEOFF. RETURNED TO MAINTENANCE FACILITY. 2L72 4T4 TRTA8SW E4WE 6 CP61GL 20030721000902003072100090CE 2003 7 21 CA030702005 120030616G553004311481 FITTING CESSNA150 150M 2071830CE CONT O200 O200A 17020SO MCAULY1A102 1A102OCM GL VERTICAL STAB CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA 11807 (CAN) DURING PREFLIGHT INSPECTION PILOT NOTICED CRACK, PARALLEL ALONG 90 DEGREES ANGLE. 1H71 3O3 O 3A19 E252 5 NP918 20030718000832003071800083EA 2003 7 18 CA030703001 220030529G855020008A OIL COOLER ROBSINR22 R22BETA 7640110NM LYC O320 O320B2C 41508EA ENGINE LEAKING W O OTHER K FLUID LOSS CRCRUISE 1 CA (CAN) AT START AFTER LAST DAILY FLIGHT NOTED SMALL POOL OF OIL ON LANDING PAD. ALSO NOTICED .7500 INCHES CRACK ALONG CASTING WELD. ONLY LASTED SHORT TIME, ORDERED BRAND NEW COOLER. WILL STROBE FAN AND TAIL ROTOR AFTER INSTALL TO CHECK FOR VIBRATION. 1G71 3O3 O H10WE E274 20030721000342003072100034CE 2003 7 21 CA030703002 120030620G712005510171 MOUNT CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA ENGINE BROKEN W O OTHER O OTHER NRNOT REPORTED 1 CA 10212 (CAN) LOWER CROSS TUBE FOUND BROKEN AT WELD ON LT SIDE. 1H71 3O3 ONT3A12 E274 20030721001022003072100102EU 2003 7 21 CA030703003 120030623G6730SC5083 SERVO SNIAS 350 AS350B 8680801EU TMECA ARRIELARRIEL1B 6OO30NE RT HYD SYS FAILED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) PROBLEM RETURNED WITH AIRCRAFT. HYD HAND OVER LT DURING HYD TEST. SWAPPED LATERAL SERVO'S LT TO RT AND RT TO LT. DURING TEST CYCLE WENT HAND OVER RT. THE OPPOSITE SERVO (LT HYDRAULIC SERVO) FROM PREVIOUS SDR WAS REPLACED. PROBLEM WENT AWAY. HYD SERVO IS BEING SENT TO EUROCOPTER CANADA FOR TESTING. EUROCOPTER TECH REP. FOR TESTING/TROUBLESHOOTING. 1G71 3U3 U H9EU E19EU 20030721001032003072100103CE 2003 7 21 CA030703004 120030624G5697PQ020JE004 WIRE HARNESS CESSNA750 750 2076810CE ALLSN AE3007AE3007C GL RT CARGO BAY SHORTED W H DEACTIVATE SYST/CIRCUITS J WARNING INDICATION CRCRUISE 1 CA (CAN) RT WINDSHIELD HEAT INOPERATIVE ON ENGINE INDICIATING AND CREW ALERT SYSTEM POPPED. SB HK062 AC POWER TO RT WINDSHIELD. WIRE BUNDLE PQ020 AND JE004 TOUCHING AND HEAT SHRINK FAILURE CAUSING SB HK 062 TO POP.REPLACED HEAT SHRINK PROBLEM ELIMINATED. 2L72 4J4 FRTT00007WITE6CH 20030721000742003072100074CE 2003 7 21 CA030703005 120030623G3411IMP44PN HOSE CESSNA180 180H 2072618CE CONT O470 O470R 17026SO MCAULY2A34C 2A34C203 GL STATIC SYS FAILED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) NYLON STATIC HOSE CATCHING ON LT CONTROL COLUMN UNIVERSAL JOINT ATTACH BOLT. STATIC HOSE NOT TIED OFF PROPERLY, WHICH RESTRICTED FORWARD MOVEMENT OF CONTROL WHEEL. 1H71 3O3 O 5A6 E273 5 CP3EA 20030721000352003072100035EA 2003 7 21 CA030703007 220030625G8530LW13623 PISTON CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA ENGINE FAILED W BA EMER. DESCENT UNSCHED LANDING EY VIBRATION/BUFFET ENGINE STOPPAGE CRCRUISE 1 CA (CAN) NR 3 CYLINDER PISTON EXPERIENCED FAILURE OF ITS ALUMINUM SIDE DURING CRUISE FLIGHT, RESULTING IN ENGINE POWER LOSS AND ROUGH OPERATION. PISTON FAILURE CAUSED PRESSURE FROM COMBUSTION TO ENTER THE CRANKCASE. THIS RESULTED IN THE CRANKCASE BECOMING PRESSURIZED FORCING THE ENGINE OIL TO BE DUMPED OVERBOARD THROUGH THE CRANKCASE BREATHER TUBE. OIL PRESSURE WAS EVENTUALLY LOSS RESULTING IN AN ENGINE STOPPAGE IN FLIGHT. EMERGENCY LANDING ISSUED WITH NO FURTHER DAMAGE. 1H71 3O3 ONT3A19 E223 20030721000672003072100067CE 2003 7 21 CA030703008 120030624G5313101406335 STRINGER BEECH 200 B200 1152922CE PWA PT6 PT6A42 52043NE HARTZLHCD4N3HCD4N3A GL FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) 600 HR INSPECTION REVEALED 2 CRACKED STRINGERS (NR 9 RT HYD TSB 2472 REV.II.) 1L72 4T4 T A24CE E4EA 5 CSTC 20030721000682003072100068CE 2003 7 21 CA030703009 120030624G54121019100383 BULKHEAD BEECH 200 B200 1152922CE PWA PT6 PT6A42 52043NE HARTZLHCD4N3HCD4N3A GL NACELLE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) NACELLE BULKHEAD CRACKED FROM LOWER RT BOLT HOLE TO EDGE OF BULKHEAD. NEW BULKHEAD INSTALLED ON BOTH NACELLES. PROBLEM ATTRIBUTED TO AIRCRAFT AGE AND NUMBER OFCYCLES. 1L72 4T4 T A24CE E4EA 5 CSTC 20030821001312003082100131CE 2003 8 21 CA030703010 120030627G533005411212 SKIN CESSNA182 182B 2072706CE FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) AIRCRAFT IS USED FOR PARACHUTE OPERATIONS AND DOES MANY CYCLES. ON INSPECTION FOUND VISIBLE CRACK ABOUT 1 INCH LONG AT REAR OF GEAR CUT OUT. 1H71 3O NT3A13 20030721000692003072100069SO 2003 7 21 CA030703011 220030410G8520 CRANKCASE CESSNA402 402C 207590RCE CONT O520 TSIO520VB 17040SO ENGINE CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) DURING INSPECTION A CRACK WAS DISCOVERED. 1L72 3O3 O A7CE E8CE 20030721000702003072100070SO 2003 7 21 CA030703012 220030514G8520 CRANKCASE CESSNA402 402C 207590RCE CONT O520 TSIO520VB 17040SO ENGINE CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) CRACK DISCOVERED ON THE CRANKCASE. THE CRACK WAS IN THE SAME AREA AS A PREVIOUS WELD REPAIR.THE ENGINE WAS REPAIRED (NEW CRANKCASE AND NEW CRANKSHAFT). DURING THE REPAIR THE COUNTERWEIGHT PINS WERE FOUND CORRODED. 1L72 3O3 O A7CE E8CE 20030718000842003071800084EA 2003 7 18 CA030703013 220030618G8500H10360D1A ENGINE HUGHES269 269C 4470504WP LYC O360 HIO360D1A 41514EA NACELLE FLAMED OUT W BA EMER. DESCENT UNSCHED LANDING DE INFLIGHT SEPARATION VIBRATION/BUFFET CRCRUISE 1 CA (CAN) SUDDEN ENGINE FLAMES AND A CONTINUOUS LOSS OF SUBSTANTIAL POWER. EMERGENCY LANDING CARRIED OUT. THE ENGINE IS UNDER INVESTIGATION BY TSB. ADDITIONAL REPORT TO FOLLOW. 1G71 3O3 O 4H12 1E10 20030721000362003072100036EA 2003 7 21 CA030703014 220030609G8550STD213 SEAL CESSNA206 T206H 2073303CE LYC O540 TIO540AJ1A EA ENGINE LEAKING W O OTHER K FLUID LOSS NRNOT REPORTED 1 CA (CAN) FOLLOWING A FLIGHT TEST THAT WAS CARRIED OUT AFTER ENGINE INSTALLATION. THE PILOT NOTICED AN EXCESSIVE OIL LEAK. THE ENGINE HAD RETURNED FROM OVERHAUL. FURTHER INVESTIGATION REVEALED THAT OIL SEAL WAS NOT INSTALLED. AN EMPTY SPACE WAS CREATED BECAUSE THAT SEAL WAS MISSING, CREATING AN EXCESSIVE OIL LEAK. 1H71 3O3 ORTA4CE E14EA 20030721000712003072100071CE 2003 7 21 CA030703015 120030618G3060P5855B5W DEICE SYSTEM CESSNA402 402CESSNA 207590KCE CONT O520 TSIO520E 17040SO PROP BLADE DAMAGED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) AFTER FLT THE PILOT NOTICED THAT THERE WAS A DE-ICE PAD MISSING ON THE LEFT PROP. WHILE WE WERE INSPECTING THE PROP, WE NOTICED THAT THE GLUE USED TO GLUE THE DE-ICE PAD HAD NOT DRIED OR HARDENED. THE BLADE HAD ONLY 91.1 HOURS AND IT ARRIVED FROM OVERHAUL. A TECHNICIAN FROM THAT OVERHAUL FACILITY ADVISED US THAT WE SHOULD ROLL ALL OTHER PROP DE-ICE PADS TO ENSURE THAT THEY ARE PROPERLY GLUED. 1L72 3O3 O A7CE E8CE 20030721000722003072100072SO 2003 7 21 CA030703016 120030615G3230 O-RING PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA NLG FAILED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) AIRCRAFT JACKED UP, GEAR SWUNG. NOSE GEAR SLOWER IN RETRACTION. FOUND NOSE GEAR RAM O-RINGS FLAT. REMOVED, REPAIRED, REINSTALLED. AIRCRAFT OK. 1L72 3O3 O A20SO E14EA 20030721000912003072100091SO 2003 7 21 CA030703017 220030701G8530654004 EXHAUST VALVE CESSNA150 150M 2071830CE CONT O200 O200A 17020SO ENGINE CORRODED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) UPON INSTALLATION OF CYLINDERS AFTER OVERHAUL OF CRANKCASE THE EXHUAST VALVE IN ONE CYLINDER WAS NOTICED TO BE BADLY CORRODED AND ERODED AT THE NECK OF THE VALVE.ALL OTHER EXHAUST VALVES WERE INSPECTED SERVICEABLE AND THE ONE WILL BE REPLACED. IT SHOULD BE NOTED THAT WHEN INSTALLED, EVEN WITH A BOROSCOPE THIS AREA CAN NOT BE INSPECTED. 1H71 3O3 O 3A19 E252 20030821001342003082100134EU 2003 8 21 CA030704002 120030627G2120783108505 SLEEVE ISRAEL1125 ASTRASPX 4500205EU A/C DUCT DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING ROUTINE A-CHECK A DAMAGED SLEEVE WAS FOUND ON THE AIR CONDITIONING DUCT FROM THE COOLING TURBINE TO THE WATER SEPERATOR UNIT. THE DUCT HAD A 1 CM DIAMETER HOLE IN THE SIDE WALL ALLOWING THE AIR TO DUMP UNDER THE BAGGAGE FLOOR. NO ADDITIONAL DAMAGE TO ANYTHING IN THE AREA WAS NOTED. 2L72 4F RTA16NM 20030721000372003072100037CE 2003 7 21 CA030704003 120030623G8011 MOTOR CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA STARTER BURNED W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CLCLIMB 1 CA (CAN) ENGINE STARTER MOTOR WAS BURNED, 1H71 3O3 ONT3A12 1E10 20030721000512003072100051NM 2003 7 21 CA030704004 120030703G33403008375 LIGHT BOEING737 737275 1384485NM PWA JT8 JT8D9A 52048NE ANTI COLLISION FAILED W AG UNSCHED LANDING O2 MASK DEPLOYED W INADEQUATE Q C CLCLIMB 1 CA (CAN) WHILE CLIMING THROUGH 23,000 FT. THEY EXPERIENCED A RAPID DEPRESSURIZATION, LOSS OF CABIN PRESSURE (O2 MASKS WERE DONNED BY FLT CREW). CREW MANUALLY CLOSED OUTFLOW VALVE HOWEVER AIRCRAFT WOULD NOT PRESSURIZE. CREW REQUESTED DESCENT AND RETURN TO BASE - NO EMERGENCY WAS DECLARED. AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE INSPECTION REVEALED THE UPPER BEACON ASSEMBLY LIGHT MISSING - NO DAMAGE IN HOLE OR AIRFRAME. ASSEMBLY REPLACED AND AIRCRAFT GROUND CHECKED SERVICEABLE. AIRCRAFT RETURNED TO SERVICE WITH NO FURTHER INCIDENTS TO REPORT. NOTE: PART HISTORY SHOWS UPPER ANTI COLLISION LIGHT ASSEMBLY REPLACED APRIL 17/03 DURING 'C1-3 CHECK' AT 3RD PARTY VENDOR PER NON ROUTINE FORM. 2L72 4F4 F A16WE E2EA 20030721000522003072100052NE 2003 7 21 CA030704006 220030624G7250 ENGINE PWA PT6 PT6A67D NE FAILED W K NONE O OTHER ININSP/MAINT 1 CA 15655 (CAN) RUBBING SOUNDS COMING FROM POWER TURBINE AREA CAUSED BY CONTACT BETWEEN FACE OF 2ND STAGE POWER TURBINE DISK, SEAL & COVER OF PT SHAFT HOUSING ASSY. CONTACT AROSE BECAUSE TEE HEAD LUGS SECURING SEAL & COVER TO PT SHAFT HOUSING FRETTED THROUGH FLANGE RELEASING SEAL AND COVER, ALLOWING SEAL TO MOVE REARWARDS & CONTACT FACE OF PT 2 DISK. ALL OF SLOTS IN PT SHAFT HOUSING ASSY HAVE HEAVY FRETTING WEAR, EITHER COMPLETELY THROUGH OR ALMOST COMPLETELY THROUGH FLANGE. THIS MEANS THAT 4 RIVETS WHICH BROKE, RELEASING TEE HEADED LUGS, FAILED TOWARDS END OF PROCESS. RIVET FAILURE WAS A RESULT OF WEAR & FRETTING & WAS NOT CAUSE OF IT. 4 T E26NE 20030721000532003072100053NE 2003 7 21 CA030707001 220030620G7230 GAS GENERATOR PWA JT15 JT15D4 52112NE ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) COMPLETE ENG OVERHAUL. AT DISASSEMBLY DISCOVERED THAT IMPELLER HAD THREE VANES WITH SECTIONS OF INDUCER DAMAGED. IT APPEARS THAT 3 PORTIONS OF LIBERATED MATERIAL FROM IMPELLER WERE RESULT OF IMPELLER FAILURE, PROBABLY DUE TO FATIGUE RESULTING FROM BLADE VIBRATION INDUCED STRESSES. MATERIAL WAS LIBERATED FROM IMPELLER ENTERED INTO THE COMBUSTION SECTION OF ENGINE THROUGH THE DIFFUSER TUBES OF THE GAS GENERATOR. REMAINS OF TWO OF THREE LIBERATED PIECES WERE TRAPPED BETWEEN SMALL EXIT DUCT & COMBUSTION LINER. ONE LIBERATED PIECE, APPEARS TO HAVE ENTERED THROUGH COMBUSTION LINER & INTO GAS PATH. HP TURBINE INGESTED IMPELLER MATERIAL CAUSING HEAVY DAMAGE TO HP TURBINE BLADES. 4 F E1NE 20030718000862003071800086SW 2003 7 18 CA030707002 120030707G275019023 CONTROL CABLE BBAVIA8 8GCBC 1220803SW LYC O360 O360C2E 41514EA MCAULY1A200 1A200* GL TE FLAPS FRAYED W K NONE O OTHER ININSP/MAINT 1 CA (CAN)TE FLAP CABLE FRAYED AT UPPER RT PULLEY. 1H71 3O3 O A21CE E286 5 NP874 20030721000642003072100064NE 2003 7 21 CA030707004 220030526G72009606080705 BEARING SNIAS 350 AS350B 8680801EU TMECA ARRIELARRIEL1B 6OO30NE ENGINE DESTROYED W A UNSCHED LANDING JD WARNING INDICATION INFLIGHT SEPARATION CRCRUISE 1 CA (CAN) AIRCRAFT WAS FLYING AND HAD A CHIP LIGHT. PILOT LANDED IMMEDIATELY. ON SHUT DOWNHE HEARD LOTS OF NOISE COMING FROM THE ENGINE. CHECKED IS CHIP PLUG AND FOUND L OTS OF METAL. AIRCRAFT WAS GROUNDED AND LEFT ON SITE. RENTAL ENGINE WAS INSTALLED. ENGINE WAS TRANSPORTED TO TROIS-RIVIERES FOR INVESTIGATION. MODULE 4 WAS REMOVED AND REPLACED AND ENGINE REINSTALLED. 1G71 3U3 U H9EU E19EU 20030721000652003072100065NE 2003 7 21 CA030707005 220030706G7200 MODULE SNIAS 350 AS350BA 8680817EU TMECA ARRIELARRIEL1B 6OO30NE ENGINE DAMAGED W B EMER. DESCENT D INFLIGHT SEPARATION CLCLIMB 1 CA (CAN) AIRCRAFT WAS TAKING OFF AND CLIMBING. HE WAS ABOUT 40 FT INTO THE AIR AND HEARD A LOUD BANG. LANDED IMMEDIATELY. THE ENGINE WAS SHUT DOWN. THE AIRCRAFT WAS GROUNDED. ENGINEER SENT TO THE LOCATION FOR INVESTIGATION. THE INSPECTION REVEAL POSSIBLE DAMAGE OF MODULE 2 AND 3. 1G71 3U3 UNCH9EU E19EU 20030821001362003082100136EA 2003 8 21 CA030707006 120030701G273183963 ACTUATOR CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE HORIZONTAL STAB FAILED W A UNSCHED LANDING F FLT CONT AFFECTED CRCRUISE 1 CA (CAN) FLIGHT CREW REPORTED ' STAB CHANNEL NR 1 FAIL' MESSAGE DURING CRUISE. RESET OK BUT FAIL MESSAGE AGAIN DURING MANUAL TRIM. TROUBLE SHOOTING DISCOVERED MOTOR ON NR 1 HORIZONTAL STAB TRIMACTUATOR HAD FAILED. TRIM UNIT AND MOTOR CONTROL UNIT WERE ALSO REPLACED 2L72 4F4 FRTA21EA E15NE 20030721000662003072100066SO 2003 7 21 CA030708001 120030702G5200 DOOR PIPER PA42 PA42 7104202SO PWA PT6 PT6A41 52043EA WING LOCKER BUCKLED W O OTHER D INFLIGHT SEPARATION DEDESCENT 1 CA 12400 (CAN) ON DESCENT AT 8500 FT, LT WING LOCKER DOOR BUCKLED UP IN MIDDLE APPROX 4-5 INCHES, THEN CAME LOOSE FROM DOOR PIN AND POPPED OPEN & STARTED FLAPPING. AIRCRAFT SPEED WAS REDUCED TO 140 KTS & AIRCRAFT LANDING WAS UNEVENTFUL. DETERMINED THAT WING LOCKER WAS PRESSURIZING IN FLT & WAS INCREASED ON THE DESCENT BY SPEED. IT WAS FOUND THAT THERE WERE SOME HOLES IN THE FORWARD END OF LOCKER & SEALEANT ON THE LOCKER SKIN SEAMES HAD DETERIORATED AND FALLEN OUT ALLOWING HIGH PRESSURE AIR FROM THE FLAP WELL TO ENTER THE LOCKER AREA. HOLES WERE PLUGGED & SEAMS RESEALED AND THE LOCKER WAS PRESSURE CHECKED FOR LEAKAGE AND FOUND SERVICEABLE. 1L72 4T4 T A23SO E4EA 20030821001382003082100138 2003 8 21 CA030708002 420030505G22101394T1007Z INDICATOR CESSNA441 441 2076020CE TURN COORDINATORFAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) BEARINGS VERY NOISY AND ROUGH. BUT INSTRUMENT OPERATING NORMALLY. 1L72 3T RTA28CE 20030821001392003082100139CE 2003 8 21 CA030708003 120030514G5220CM3838296 SEAL CESSNA441 441 2076020CE ESCAPE HATCH CUT W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ESCAPE HATCH LEAKING RAIN WATER WHEN AIRCRAFT SITTING ON GROUND. THE RUBBER SEAL WAS CUT BY THE LIP ON THE SEAL RETAINER WHICH IS LOCATED ON FUSELAGE DOOR STRIKER. 1L72 3T RTA28CE 20030821001422003082100142CE 2003 8 21 CA030708004 120030623G2823 SEAL CESSNA441 441 2076020CE VALVE ASSEMBLY LEAKING W O OTHER K FLUID LOSS NRNOT REPORTED 1 CA (CAN) FIREWALL FUEL SHUT OFF VALVE FOUND TO BE LEAKING FUEL EXTERNALLY PAST HARDENED O-RING SEALS. INTERNAL LEAKAGE CAUSED BY INCORRECT SEALS WHICH HAD GONE SOFT LIKE PUTTY AND WERE BREAKING UP. 1L72 3T RTA28CE 20030821001452003082100145CE 2003 8 21 CA030708005 120030624G2823 O-RING CESSNA441 441 2076020CE VALVE ASSEMBLY LEAKING W O OTHER K FLUID LOSS NRNOT REPORTED 1 CA (CAN) FIREWALL FUEL SHUT OFF VALVE FOUND TO BE LEAKING FUEL EXTERNALLY PAST HARDENED O-RING SEALS. INTERNAL LEAKAGE CAUSED BY INCORRECT SEALS WHICH HAD GONE SOFT LIKE PUTTY AND WERE BREAKING UP. 1L72 3T RTA28CE 20030721000442003072100044SW 2003 7 21 CA030708007 120030415G561041373 WINDOW BBAVIA7 7GCBC 1220601SW LYC O320 O320A2D 41508EA COCKPIT DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE ONLY EXPLANATION WE HAVE FOR THIS BURNED AREA COMES FROM THE FEW TIMES THIS AIRCRAFT HAS BEEN PARKED OUTSIDE, OR DURING FLIGHT. IT MIGHT SOUND CRAZY, BUT SUNLIGHT MUST HIT THE GLASS AT THE RIGHT PERFECT ANGLE, BUNDLE THE LIGHT LIKE A MAGNIFYING GLASS AND THEN HIT THE VINYL BEFORE AIRCRAFT WAS REBUILT IN 1996. 1H71 3O3 ONCA759 E274 20030721000452003072100045SW 2003 7 21 CA030708008 120030501G6510204040603009 HANGER ASSY BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA TAIL ROTOR CORRODED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) DEFECTS FOUND DURING ROUTINE INSPECTION/LUBRICATION. PROBLEM MAY HAVE EXISTED ATPRIOR INSPECTIONS BUT NOT DISCOVERED. 4 INNER, 4 OUTER COUPLINGS REPLACED. CORROSION PITS/SPALLING WERE ON SEVERAL TEETH OF EACH COUPLING. 1G71 4U4 U H4SW E22EA 20030821001462003082100146SW 2003 8 21 CA030708009 120030501G6400212001053005 CONTROL ARM BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA FAIRLEAD CHAFED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) CONTROL TUBE AT PRIOR MAINTENANCE EVENT WAS INSTALLED BACKWARDS (180 DEGREES OUT). TUBE HAD NYLATRON SLEEVES BUT REVERSED POSITION CAUSED WEAR AT AFT FAIRLEAD. TUBE WORN 0.013. TUBE WALL THICKNESS IS 0.035. PART REPLACED. 1G71 4U4 U H4SW E22EA 20030721000462003072100046SW 2003 7 21 CA030708010 120030515G6520209011710005 SHAFT BELL BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA PITCH CHANGE STRIPPED W O OTHER W INADEQUATE Q C NRNOT REPORTED 1 CA AHT50649 (CAN) DURING ATTEMPTED DISASSEMBLY, WE WERE UNABLE TO REMOVE THREADED SLEEVE PN 209011719003. FOUND INCORRECT HARDWARE STARKUP (WASHER PN 212010714003 MISSING). PRESUME SLEEVE BOTTOMED OUT, NUT MS14145L8 ALSO, AND HENCE THREADS STRIPPED ON TORQUE UP. HAD TO HACKSAW END OF SHAFT OFF TO REMOVE. PART REPLACED. 1G71 4U4 U H4SW E22EA 20030718000882003071800088SW 2003 7 18 CA030708011 120030515G6300212060724033 TUBE BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA CONTROL TUBE CHAFED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) CONTROL TUBE CHAFING IS 0.017 INCH DEEP. TUBE IS STEEL ALLOY. TUBE CHAFED FROM CONTACT WITH FIREWALL BOOT/ALUMINUM FLANGE. TUBE REPLACED. 1G71 4U4 U H4SW E22EA 20030718000892003071800089SW 2003 7 18 CA030708012 120030624G65103272H DISC PACK BELL 206 206B 1181511SW ALLSN 250C 250C20B 03013GL TAIL ROTOR CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) SIGNIFICANT FRETTING AT BOLT HOLE/CLAMP UP AREA. TWO DISKS CRACKED AT BOLT HOLE. PART REPLACED. (FORWARD POSITION) 1G71 3U3 U H2SW E4CE 20030718000902003071800090SW 2003 7 18 CA030708013 120030701G291070012J22OW234 LINE BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA HYDRAULIC SYS RUPTURED W A UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION NRNOT REPORTED 1 CA (CAN) THE PILOT REPORTED A NOISE (FROM AN UNLOADED HYDRAULIC PUMP) FOLLOWED BY THE ODOR OF HYD FLUID. HYDRAULIC PRESSURE ON SYSTEM NUMBER 2 DROPPED TO ZERO. THE PILOT INITIATED AN UNSCHEDULED LANDINGTO INVESTIGATE THE PROBLEM. AFTER LANDING A CHAFED HYD LINE FROM THE NUMBER 2 HYDRAULIC PUMP WAS DISCOVERED. THE LINE WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 1G71 4U4 U H4SW E22EA 20030721000472003072100047NM 2003 7 21 CA030709001 120030709G323011972 SOLENOID DHAV DHC8 DHC8301 1386003NM PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE MLG MALFUNCTIONED W L ABORTED APPROACH J WARNING INDICATION APAPPROACH 1 CA (CAN) IN FLT DURING APPROACH, THE LANDING GEAR WAS SELECTED THE DOWN/EXTEND POSITION WITH NO SUBSEQUENT INDICATIONS THAT EXTENSION HAD OCCURRED. ONLY INDICATION WAS ILLUMINATION OF 3 RED, LT NOSE RT, MISMATCH ADVISORY LIGHTS ON LANDING GEAR SELECTOR PANEL. AFTER CONSULTING WITH ENGINEERING AN ALTERNATE EXTENSION CARRIED OUT WITH NO FURTHER INCIDENCE. INVESTIGATION CARRIED OUT TO DETERMINE CAUSE OF LANDING GEAR FAILURE. A RESISTANCE CHECK ON BOTH THE SOLENOIDS ON LANDING GEAR SELECTOR VALVE (1 FOR EXTEND & 1 FOR RETRACT COMMAND) FOUND THAT SOLENOID COIL A, HAD A RESISTANCE TWICE THAT OF TOLERANCE GIVEN IN CMM CH 32-30-10. SOLENOID SELECTOR VALVE REPLACED. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030721000482003072100048EA 2003 7 21 CA030709002 220030703G7322193F0004D0330 SENSE LINE PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA RT ENGINE FAILED W EA ENGINE SHUTDOWN UNSCHED LANDING N FALSE WARNING CLCLIMB 1 CA (CAN) IN CLIMB THROUGH 8,500 FT, RT ENG MANIFOLD PRESSURE DROPPED BACK TO 20 INCHES MANIFOLD PRESSURE, FROM CLIMB POWER SETTING OF 40 INCHES MANIFOLD PRESSURE & 2,400 RPM WITH MIXTURE FULL RICH. PILOT DID A CAUSE CHECK WITH NO RESULTS. PILOT SECURED ENGINE & DIVERTED TO CLOSEST SUITABLE AIR FIELD. A/C LANDED WITHOUT FURTHER PROBLEMS. ON INSPECTION OF ENGINE, MANIFOLD SENSE LINE THAT RUNS FROM DIFFERENTIAL CONTROLLER TO MANIFOLD HAD BROKEN OFF AT DIFFERENTIAL END. THIS WOULD MAKE ENG RUN VERY RICH AND MAKE IT LOOK LIKE ENG HAD QUIT. THIS IS A KNOWN PROBLEM AREA THAT WAS INSPECTED 20 HOURS PREVIOUS BEFORE THE FAILURE, WITH NO FAULT DETECTED. WE ARE NOW PUTTING AN IN HOUSE 200 HR REPLACEMENT ON THIS HOSE. 1L72 3O3 O A20SO E14EA 20030821001502003082100150SW 2003 8 21 CA030709006 120030702G6510327211 COUPLING BELL 206 206B 1181511SW T/R DRIVESHAFT FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ON DAILY INSPECTION OF AIRCRAFT FORWARD THOMAS COUPLING ATTACHMENT BOLT FOUND LOOSE. FORWARD T/R DRIVESHAFT REMOVED AND DISASSEMBLED. FORWARD DISC PACK (THOMAS COUPLING) SCRAPPED DUE TO FRETTING DAMAGE AS WELL AS ATTACHING BOLT. ALL HARDWARE INSPECTED FOR SERVICE ABLILITY. ALL HARDWARE FOUND NOT TORQUE SEALED AS PER BHT TORQUE CHECK PROCEDURE. 10- 25 HR TORQUE CHECK TO BE COMPLETED AS PER BHT MM TO INSURE BOLT TORQUE. MORE DETAILED DAILY INSPECTION SHOULD BE COMPLETED. PROPER MAINTENANCE PROCEDURES SHOULD BE FOLLOWED. 1G71 3U H2SW 20030718000932003071800093EU 2003 7 18 CA030709007 120030628G6220LB412311 THRUST BEARING SNIAS 350 AS350BA 8680817EU TMECA ARRIELARRIEL1B 6OO30NE SPHERICAL DAMAGED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) ELASTOMER SEPARATION. 1G71 3U3 UNCH9EU E19EU 20030718000942003071800094WP 2003 7 18 CA030709008 220030707G7321 SPLINE ADAPTER WOODWARD SWRNGNSA226 SA226TC 8780404SW GARRTTTPE331TPE33110UA 01514WP FUEL CONTROL FAILED W E ENGINE SHUTDOWN XEJENGINE FLAMEOUT VIBRATION/BUFFET WARNING INDICATION TXTAXI/GRND HDL 1 CA 2007677 (CAN) CREW STARTED ENG & NOTICED ENG WAS SLOW TO ACCELERATE TO IDLE. ONCE AT IDLE (70 PERCENT) ENGINE SLOWLY INCREASED TO APPROXIMATLY 80 PERCENT WITHOUT INPUT FROM CREW. IN AN ATTEMPT TO REDUCE ENG POWER, WAS NO RESPONSE TO ENG CONTROL INPUTS BY CREW. ENG SHUTDOWN & MAINT CONTACTED. UPON INSP BY MAINT, FCU DRIVE FOUND SEIZED & SHAFT SHEARED OFF. FCU REPLACED & ENG FUNCTION NORMAL DURING ENG RUN. UPON REASEARCHING RECORDS ON THIS FCU, IT WAS DETERMINED THAT THIS FCU WAS REPAIRED SEVERAL TIMES SINCE OVERHAUL. OVERHAUL WAS COMPLETED JULY 7, 2000 & REMOVED FOR REPAIR JANUARY 15, 2002 AT 1418.8 HRS TSO & THEN AGAIN ON OCTOBER 31, 2002 AT 2168.3 HRS TSO. FAILURE OF THIS FCU OCCURED 141 HRS SINCE THE LAST REPAIR. 2L72 4T4 TRTA8SW E4WE 20030821001512003082100151SO 2003 8 21 CA030709009 120030616G21504633600 CLUTCH YORK PIPER PA31 PA31P 7103120SO LYC O541 TIGO541E1A 41539EA AIR CONDITIONER UNSERVICEABLE W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE RIVETS ON THE AIR CONDITIONING CLUTCH ASSEMBLY FAILED. THIS ALLOWED TWO OF THE THREE BRACKETS THAT CONNECT THE OUTER RING TO THE INNER CORE, EACH ABOUT 2.25 1L72 3O3 O A8EA E19EA 20030718000952003071800095WP 2003 7 18 CA030709010 120030628G534095K0300305 ATTACH FITTING HUGHES369 369E 4470707WP ALLSN 250C 250C20B 03013GL FUSELAGE MISINSTALLED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) EXTERNAL PLATFORM AND COUNTERWEIGHT INSTALLATION MODIFICATION OF STRUT ATTACH FITTING IS DAMAGING UPPER CORNER OF HELICOPTER ROOF STRUCTURE AND THUS REQUIRES INSTALLATION OF NEW HARDWARE PN 95K0300-063 & 95K0300-065. 1G71 3U3 U H3WE E4CE 20030718000962003071800096EA 2003 7 18 CA030710001 220030410G8530SA10204 EXHAUST VALVE PIPER PA28 PA28180 7102808SO LYC O360 O360A4A 41514EA MCAULY1A170 1A170* GL NR 2 CYLINDER SEPARATED W A UNSCHED LANDING E VIBRATION/BUFFET CRCRUISE 1 CA (CAN) DURING A TRAINING FLIGHT POWER WAS ADVANCED, THE ENGINE LOST POWER AT THIS POINT AND STARTED TO VIBRATE. THE AIRCRAFT IMMEDIATELY RETURNED TO THE AIRPORT AND LANDED SAFELY WITHOUT FURTHER INCIDENT. UPON INSPECTION OF THE ENGINE IT WAS DETERMINED THAT THE HEAD OF THE EXHAUST VALVE ON NR 2 CYLINDER HAD SEPARATED FROM THE STEM. BECAUSE OF INTERNAL DAMAGE TO THE CYLINDER IT WAS CONSIDERED UNSERVICEABLE, AND A COMPLETE NEW CYLINDER ASSEMBLY PN TBN12-OCA WAS INSTALLED. THE ENGINE WAS TEST RUN AND THE AIRCRAFT RETURNED TO SERVICE. 1L71 3O3 O 2A13 E286 5 NP857 20030718000972003071800097SW 2003 7 18 CA030710002 120030606G6410212010750105FM BLADE BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA TAIL ROTOR FAILED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) VOID IN S.S. LEADING EDGE STRIP OUTBOARD BLADE TIP JUNCTION OF BLADE SKIN. VOID AREA APPROXIMATELY 0.175 INCH CHORDWISE X 0.375 INCH SPANWISE. BLADE REMOVED AND SENT FOR REPAIR. SN A-7719. 1G71 4U4 U H4SW E22EA 20030718000982003071800098EA 2003 7 18 CA030710003 220030606G7414106006141 MAGNETO ROBSINR22 R22BETA 7640110NM LYC O320 O320B2C 41508EA ENGINE FAILED W A UNSCHED LANDING D INFLIGHT SEPARATION CRCRUISE 1 CA (CAN) INTERMITTENT ROUGH RUNNING ENGINE IN FLIGHT. MAGNETO'S CHANGED EARLY FOR 500 HR INSPECTION. ON REMOVAL FROM ENGINE, SUBJECT MAGNETO NOTED TO HAVE EXCESSIVE END PLAY ON GEARSHAFT. OVERHAUL VENDOR CONFIRMED END PLAY, OIL THROUGH OUT ASSEMBLY, BEARING BORE IN DISTRIBUTOR BLOCK HOUSING WAS OVERSIZE. CONTACT ASSEMBLY'S WORN BEYOND LIMITS. UNIT OVERHAULED. 1G71 3O3 O H10WE E274 20030908001662003090800166CE 2003 9 8 CA030710004 120030709G5220 SEAL CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE EMERGENCY EXIT DIRTY W K NONE O OTHER ININSP/MAINT 1 CA (CAN) CAMPAIGN NOTICE 851-52-20-020 TO INSPECT THE EMERGENCY EXIT FOR STICKING CARRIED OUT. THE EMERGENCY EXIT OF AIRCRAFT WAS INITIALLY DIFFICULT TO OPEN. THE SEAL WAS CLEANED AND INSPECTED AND FOUND SERVICEABLE. THE EMERGENCY EXIT WAS REINSTALLED AND FUNCTION CHECKED NORMALLY. 1L72 4F4 F A22CE E1NE 20030821001532003082100153SW 2003 8 21 CA030711001 120030710G3297120 WIRE SWRNGNSA226 SA226TC 8780404SW GARRTTTPE331TPE33110UA 01514WP RT MAIN GEAR BROKEN W L ABORTED APPROACH N FALSE WARNING APAPPROACH 1 CA 23747 (CAN) ON LANDING THE RT MAIN DID NOT INDICATE GREEN SO THE PILOT DIVERTED TO A MAJOR CENTER WHERE THE TOWER CONFIRMED THE GEAR WAS DOWN AND HE LANDED WITHOUT INCIDENT. THE GROUND WIRE TO THE RT INBOARD ACTUATOR SWITCH WAS FOUND TO BE BROKEN IN THE SERVICE LOOP TO THE SWITCH. THERE WERE SIGNS THAT THE WIRE MAY HAVE BEEN PINCHED AT THE POINT OF BREAKAGE SOMETIME IN THE PAST. 2L72 4T4 TRTA8SW E4WE 20030821001542003082100154CE 2003 8 21 CA030711002 120030623G551007126153 BULKHEAD CESSNA182 182P 2075816CE CONT O470 O470S 17026SO MCAULY2A34C 2A34C66 GL HORIZONTAL STAB CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 41111 (CAN) BULKHEAD WAS CRACKED UNDER ANCHOR DOUBLER AT TOP LT HORIZONTAL STABILIZER ATTACH BOLT. 1H71 3O3 ONTTA13 E273 5 CP3EA 20030821001562003082100156NE 2003 8 21 CA030711003 220030708G8530127145 STUD PWA DOUG DC4 C54GDC 3021534WP PWA R2000 D5 52023NE CYLINDER BROKEN W E ENGINE SHUTDOWN KE FLUID LOSS VIBRATION/BUFFET CRCRUISE 1 CA SO712 (CAN) DURING CRUISE IT WAS NOTICED THAT THERE WAS A SLIGHT SHAKE AND DEVELOPED AN OIL LEAK, A PRECAUTIONARY SHUT DOWN WAS CARRIED OUT AND PROP FEATHERED, UPON INSPECTION IT WAS FOUND THAT THE LOWERS STUDS WERE BROKEN ON THE CYLINDER ASSEMBLY. CURRENTLY AN INVESTIGATION INVOLVING THE OVERHAUL FACILITY IS BEING CARRIED OUT. THE STUDS WERE REPLACED ALONG WITH THE CYLINDER ASSEMBLY. 2L74 4R4 R A762 E230 20030821001582003082100158NE 2003 8 21 CA030711004 220030708G8530127145 STUD PWA DOUG DC4 C54GDC 3021534WP PWA R2000 D5 52023NE CYLINDER BROKEN W E ENGINE SHUTDOWN K FLUID LOSS CRCRUISE 1 CA SO712 (CAN) AN OIL LEAK WAS OBSERVED IN CRUISE AND A PRECAUTIOARY SHUT DOWN WAS CARRIED OUT. UPON INSPECTION IT WAS FOUND THAT THE LOWER STUDS WERE BROKE, THEY WERE REPLACED ALONG WITH THE CYLINDER. 2L74 4R4 R A762 E230 20030718000992003071800099EA 2003 7 18 CA030711005 120030702G5740VALC3W1005 STRUT DHAV DHC3 DHC3 2800202EA PWA PT6 PT6A34 52043EA HARTZLHCB3T HCB3TN3 GL LT WING CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 3070 (CAN) DURING A ROUTINE DAILY INSPECTION A 7 INCH CRACK ON THE UPPER SURFACE OF THE LT LOWER WING STRUT IN THE TRAILING EDGE SKIN WAS OBSERVED. 4.2 HOURS OUT OF A 100 HR INSPECTION. THE STRUT WAS GIVEN TO A DAR, WHO IS CONDUCTING AN INVESTIGATION. THE REPORT SHALL BE FORWARDED TO THIS SDR WHEN RECEIVED. 1H71 3R4 T A815 E4EA 6 CP15EA 20030821001662003082100166EA 2003 8 21 CA030713001 120030629G2997MS220733 CIRCUIT BREAKER CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE HYD SYSTEM FAILED W D RETURN TO BLOCK H ELECT. POWER LOSS-50 PC TXTAXI/GRND HDL 1 CA (CAN) WHILE TAXIING THE FIRST OFFICER NOTICED AN ODOUR AND THE CAPTAIN VERIFIED PRESENCE OF SMOKE AT CIRCUIT BREAKER PANEL NR 2. THE SMOKE STOPPED WHEN THE CREW REACHED OVER AND PULLED CIRCUIT BREAKER CBP2-G13. THE PROBLEM WAS FINALLY SOLVED WITH THE REPLACEMENT OF CIRCUIT BREAKERS CBP2-G13 & -G14 AND HYDRAULIC RESERVOIR NR 1. 2L72 4F4 FRTA21EA E15NE 20030821001672003082100167EA 2003 8 21 CA030713002 120030629G5610NP1393215 WINDSHIELD CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE COCKPIT FAILED W A UNSCHED LANDING D INFLIGHT SEPARATION CLCLIMB 1 CA (CAN) CAPTAIN'S WINDSHIELD SHATTERED ON CLIMBOUT (RECEIVED A LT WINDSHIELD HEAT CAUTION ABOUT 15 SECONDS PRIOR TO IT SHATTERING). UNEVENTFULL LANDING PERFORMED. REPLACED LT WINDSHIELD AND HEAT CONTROLLER. AIRCRAFT RETURNED TO SERVICE.CONTROLLER PN 16591, SN 1660, 2L72 4F4 FRTA21EA E15NE 20030821001862003082100186EA 2003 8 21 CA030713003 120030629G5210601R3197411 LEVER CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE PAX DOOR BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) REPORTED THAT ON THE PAX DOOR BOTH THE FWD AND AFT SWIVEL LEVERS (601R3197411) HAD FAILED ALLOWING THE DOOR TO FREEFALL. MAINTENANCE FOUND THE SUPPORT WHEEL LEVER BENT AND THE DOOR SKIN DISTORTEDAND WITH INTERNAL STRUCTURAL DAMAGE. REPLACED THE SUPPORT WHEEL, BOTH SWIVEL ASSEMBLIES AND DAMAGED DOOR SIDE SKINS. AIRCRAFT RETURNED TO SERVICE. 2L72 4F4 FRTA21EA E15NE 20030821001892003082100189SW 2003 8 21 CA030714001 120030708G57512734027001 COUNTERWEIGHT SWRNGNSA226 SA226TC 8780404SW GARRTTTPE331TPE33110UA 01514WP LT AILERON TORN W K NONE O OTHER ININSP/MAINT 1 CA 23729 (CAN) PILOT DISCOVERED ON HIS POST FLIGHT WALKAROUND THAT THE LT AILERON COUNTERWIEGHTWAS HANGING DOWN ON THE INBOARD END OF THE AILERON. THE AILERON WAS REMOVED AND THE BALANCE WEIGHT WAS FOUND TO HAVE TORN OUT OF THE INBOARD BOLT HOLE. THE DAMAGED PART OF THE WEIGHT WAS CUT OFF AND AILERON BALANCED CHECK IAW SA226TC SRM AND FOUND TO BE WITHIN LIMITS. THE BALANCE WEIGHTS WHERE THEN SECURED WITH PRO SEAL.THE MATERIAL FOR THE BALANCE WEIGHT IS QUITE SOFT AND TENDS TO DROOP WITH TIME. WE HAVE CHECKED OTHER AIRCRAFT AND FOUND SOME WEIGHTS TO BE SLIGHTLY DROOPING. 2L72 4T4 TRTA8SW E4WE 20030821001902003082100190EA 2003 8 21 CA030714002 120030712G24212CM70D2 GENERATOR CNDAIRCL215 CL2151A10 1900320EA PWA R2800 CA3 52026NE ENGINE BURNED W A UNSCHED LANDING H ELECT. POWER LOSS-50 PC CLCLIMB 1 CA (CAN) AFTER DEPARTING FOR A FIRE SUPPRESION MISSION, THE RT ENGINE DRIVEN GENERATOR FAILED. THE AIRCRAFT RETURNED TO BASE FOR MAINTENANCE. ACCESS TO THE ENGINE DRIVEN GENERATOR REVEALED A SMALL GENERATOR FIRE. A HAND HELD EXTINGUISHER WAS DISCHARGED PUTTING OUT THE FIRE. CAUSE OF THE FAILURE IS UNKNOWN BUT A GENERATOR BEARING FAILURE IS SUSPECTED. GENERATOR, WIRING HARNESS, SCAT HOSE AND FIRE SLEEVE/OIL VENT LINE DESTROYED/DAMAGED. 2H72 4R4 RRTA14EA E231 20030821001912003082100191EA 2003 8 21 CA030715001 220030714G7314LW15473 PUMP ROBSINR44 R44 7640120WP LYC O540 O540F1B5 41532EA FUEL SYSTEM LOOSE W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING 100 HR INSPECTION THE BOLTS (ON THE ENGINE DRIVEN FUEL PUMP) HOLDING THE BOTTOM COVER TO THE PUMP BODY WERE FOUND LOOSE. BOLTS WERE TIGHTENED AND TORQUE SEAL WAS APPLIED TO MAKE VISUAL INDICATION OF MOVEMENT. THIS INSTALLATION WOULD BE BETTER SERVED WITH BOLTS THAT WOULD ALLOW LOCKWIRE. THIS IS THE SECOND TIME THAT THESE BOLTS HAVE BEEN FOUND LOOSE AT INSPECTION. AIRCRAFT MANUFACTURER HAS BEEN CONTACTED REGARDING THIS PROBLEM. 1G71 3O3 O H11NM E295 20030821001922003082100192 2003 8 21 CA030715002 420030715G2215 SERVO CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE AUTOPILOT DEFECTIVE W A UNSCHED LANDING F FLT CONT AFFECTED APAPPROACH 1 CA (CAN) PILOT YOKE BINDING DURING APPROACH. USING PITCH DISCONNECT HANDLE, COPILOT YOKE FELT NORMAL. FORCE FELT LIGHTER AS FLAPS EXTENDED. AUTOPILOT DISCONNECTED TO VERIFY A FLAP INDICATION AT A LOWER ALT & GREATER THAN NORM FORCE REQUIRED TO MOVE YOKE FORWARD. CONTROLS RELAXED TO FEEL CONTROLLABILITY, AN ABRASIVE NOISE HEARD. FORCE REQUIRED TO MOVE CONTROLS WERE LIGHTER THAN NORM. APPROACH COMPLETED. AUTOPILOT SERVO MECHANISM FOR ELEVATOR HAS BEEN REMOVED & REPLACED & A/C RETURNED TO SERVICE. AUTOPILOT SERVO RETURNED TO COLLINS FOR INVEST THAT REVEALED A PIECE OF ADHESIVE STUCK BETWEEN DIAPHRAGM & GEARSHAFT. IT WAS DETERMINED THAT AN EXCESSIVE AMOUNT OF ADHESIVE DURING ASSY PROCESS OF SHAFT CAUSED INCIDENT. 2L72 4F4 FRTA21EA EOOO63EN 20030821001932003082100193NE 2003 8 21 CA030716001 220030710G7250311963101 DEFLECTOR CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE TURBINE SECTION CRACKED W O OTHER E VIBRATION/BUFFET NRNOT REPORTED 1 CA (CAN) TECHNICIANS FOUND CRACKED AND MISSING PIECES OF DIFFUSER DEFLECTOR SEGMENTS DURING AN ENGINE INTERNAL BORESCOPE INSPECTION. AFTER INVESTIGATION IT WAS FOUND THAT THE STARTER GENERATOR HAD BEEN REMOVED IN MARCH 2003 FOR CAUSING HIGH FREQUENCY VIBRATIONS. PRATT & WHITNEY BELIEVES THAT THE STARTER GENERATOR VIBRATION WAS THE CAUSE OF THE DAMAGE TO THE DIFFUSER DEFLECTOR SEGMENTS. 1L72 4F4 F A22CE E1NE 20030821001942003082100194SW 2003 8 21 CA030716002 120030716G272012364 CONTROL CABLE BBAVIA8 8GCBC 1220803SW LYC O360 O360C2E 41514EA RUDDER FRAYED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) LT AND RT RUDDER CABLES FRAYED AT FUSELAGE PULLEYS WITH RUDDER NEUTRAL. 1H71 3O3 O A21CE E286 20030821001952003082100195NM 2003 8 21 CA030716003 120030711G291365449617 HOUSING BOEING737 7372H4 138448CNM PWA JT8 JT8D9A 52048NE HYD PUMP CRACKED W D RETURN TO BLOCK KJ FLUID LOSS WARNING INDICATION TXTAXI/GRND HDL 1 CA (CAN) FLIGHT CREW REPORTS ON TAXI OUT OF YVR AIRCRAFT LOST 'A' SYSTEM HYDRAULICS AND NR 1 'A' PUMP LOW PRESSURE WARNING LIGHT ILLUMINATED. AIRCRAFT RETURNED TO GATE UNDER ITS OWN POWER. MAINTENANCE INSPECTION REVEALED THE NR 8 GROUND SPOILER ACTUATOR PISTON HAD POPPED OUT OF HOUSING AND THE CASING WAS ENTIRELY CRACKED AROUND THE HOUSING. COMPONENT WAS REPLACED AND SYSTEM GROUND CHECKED SERVICEABLE. AIRCRAFT RETURNED TO SERVICE WITH NO FURTHER INCIDENTS TO REPORT. 2L72 4F4 F A16WE E2EA 20030821001962003082100196EU 2003 8 21 CA030716004 120030710G2822 WIRE HARNESS CRANEXXXXXXX PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL FUEL BOOST PUMP NICKED W K NONE O OTHER ININSP/MAINT 1 CA B5009A (CAN) WHILE PERFORMING PILATUS S/B 28-011,INSPECTION OF BOOST PUMP WIRES, SOME DAMAGE IN THE FORM OF A SMALL NICK WAS NOTED APPROX 7 INCHES FOR THE PUMP BODY. THE INSULATION APPEARED TO BE DAMAGED THROUGH TO THE CONDUCTOR. THE PUMP ASSY WAS REPLACED WITH AN OVERHAULED UNIT. RECORDS INDICATE THAT THESE PUMPS HAVE NEVER BEEN REMOVED AS THEY WERE MOD 'A' PUMPS SINCE NEW. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030821001972003082100197CE 2003 8 21 CA030716005 120030710G3233 ACTUATOR BEECH 99 99 1154002CE PWA PT6 PT6A28 EA MLG FRACTURED W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) RT GEAR WOULD NOT RETRACT ON TAKE OFF.AIRCRAFT RETURNED TO BLOCKS AND RT MAIN GEAR ACTUATOR RELACED. RAM WAS FRACTURED ON THE FIRST THREAD OF RAM TO HOLD PISTON IN PLACE. 1L72 3T4 T A14CE E4EA 20030821001982003082100198EA 2003 8 21 CA030716006 120030713G5740VALC3W1005 STRUT DHAV DHC3 DHC3 2800202EA PWA PT6 PT6A34 52043EA LT WING CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) CRACKED TRAILING EDGE SKIN APROX 9 INCHES LONG AT LOWER END OF STRUT ON THE BOTTOM SIDE. 1H71 3R4 T A815 E4EA 20030821001992003082100199NE 2003 8 21 CA030716007 220030625G7200 ENGINE BOEING234 234 1385049EA LYC AL5512AL5512 41581NE NR 2 FAILED W A UNSCHED LANDING BY SMOKE/FUMES/ODORS/SPARKS ENGINE STOPPAGE NRNOT REPORTED 1 CA (CAN) LOUD BANG, SMOKE, NR 2 ENGINE STOPPED. AIRCRAFT RETURNED TO BASE SINGLE ENGINE. SMALL PIECES OF ENGINE FOUND CONTAINED IN NACELLE THAT APPEAR TO HAVE BEEN EJECTED THROUGH BLEED BAND. ENGINE RETURNED TO OVERHAUL SHOP FOR INVESTIGATION AND REPAIR. THIRD THROUGH SEVENTH STAGE OF COMPRESSOR FAILED. 2G72 4U4 U H9EA E4NE 20030821002002003082100200CE 2003 8 21 CA030717001 120030715G37101013202661 LINE BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA VACUUM REGULATORCHAFED W O OTHER D INFLIGHT SEPARATION NRNOT REPORTED 1 CA (CAN) DURING A MAINTENANCE GROUND RUN, AND FOLLOWING THE START OF THE RT ENGINE, A HISSING SOUND WAS NOTICED EMITTING FROM BEHIND THE INSTRUMENT PANEL. AFTER FURTHER INVESTIGATION IF WAS FOUND THAT THE INSTRUMENT AIR TUBE HAD BEEN CHAFING ON THE UPPER CORNER OF THE RADIO RACK. THE TUBE IS USED TO JOIN THE VACUUM REGULATOR TO THE LT SIDE OF THE FORWARD BULKHEAD TO THE MANIFOLD LOCATED IN THE COCKPIT BEHIND THE INSTRUMENT PANEL ON THE RT SIDE. 1L72 3T4 TRT3A20 E4EA 20030821002012003082100201NM 2003 8 21 CA030717002 120030714G2910 LINE DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE MLG LEAKING W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING INSPECTION FOR MINOR HYDRAULIC LEAK FROM THE NR 2 NACELLE , SERVERAL HYDRAULIC LINES WERE REMOVED FOR INSPECTION . CHAFE DAMAGE WAS FOUND ON THE NR 2 NACELLE OUTBOARD MAIN LANDING GEAR FRAME , AND ON SOME STAINLESS STEEL HYDRAULIC LINES. ALL CHAFED LINES REPLACED WITH NEW , FRAME DAMAGE TEMPORARY REPAIRED BY BLENDING AS ALLOWED BY BOMBARDIER REPAIR DRAWING ISSUED FOR THIS DAMAGE. AIRCRAFT REASSEMBLED AND RETURNED TO SERVICE. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030821002032003082100203CE 2003 8 21 CA030717003 120030716G2434DOFF10300J ALTERNATOR CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA ENGINE FAILED W D RETURN TO BLOCK H ELECT. POWER LOSS-50 PC TXTAXI/GRND HDL 1 CA (CAN) PILOT REPORTED ELECTRICAL FAILURE DURING TAXI. INVESTIGATION FOUND ALTERNATOR HAD A LOOSE HOUSING. ALL LOCKING TABS WERE SECURE ON THRU BOLTS THAT HOLD THE FORWARD AND AFT CASE HALVES TOGETHER, YET THECASE WAS CLEARLY LOOSE AND THE TWO SECTIONS FRETTING AGAINST EACH OTHER.AS MUCH AS .125 IN. CLEARANCE WAS FOUND DESPITE APPEARANCE THAT ATTACHEMENT BOLTS HAD BEEN LOCKED TIGHT. ALTERNATOR EXCHANGED FOR NEW PART. 1H71 3O3 ONT3A12 E274 20030821002042003082100204EA 2003 8 21 CA030717004 220030715G7311156E00512D0240 OIL COOLER PIPER PA31T PA31T 7103124SO PWA PT6 PT6A28 EA ENGINE LEAKING W E ENGINE SHUTDOWN KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 CA (CAN) PILOT NOTICED OIL LEAKING FROM REAR COWL AREA DURING CRUISE FLT. ENGINE WAS INTENTIONALLY SHUT DOWN & SECURED WHEN OIL PRESSURE FLUCTUATED AND FELL TO APPROX. 50 PSI (YELLOW INDICATION STATUS). MAINTENANCE CLEANED ENGINE AND ADDED 5 QUARTS OIL PRIOR TO GROUND RUN. OIL LEAK SOURCE DETERMINED TO BE THE ENGINE OIL COOLER INLET HOSE. EXTERIOR INSPECTION OF THE HOSE SHOWED NO DISCREPANCIES. HOSE REMOVED FROM ENGINE AND FIRE SLEEVE REMOVED FOR FURTHER HOSE INSPECTION. STEEL BRAID WAS INTACT AND SHOWED SUBTLE KINK NEAR WHERE THE INNER BEND RADI WOULD HAVE BEEN AT INSTALLATION. INTERNAL HOSE RUPTURE LIKELY CAUSED BY INSTALLATION STRES S NOT VISIBLE UNDER FIRE SLEEVE. HOSE TTSN 390 HOURS. 1L72 3T4 T A8EA E4EA 20030821002062003082100206NE 2003 8 21 CA030718001 220030715G7421AA725 IGNITER BOEING727 727225 1384077NM PWA JT8 JT8D15A 52051NE ENGINE FAULTY W E ENGINE SHUTDOWN AJ FLAME/FIRE WARNING INDICATION NRNOT REPORTED 1 CA (CAN) DURING START OF NR 3 ENGINE, IT WAS OBSERVED THERE WAS NO EGT. START WAS ABORTED & OBSERVED ALL PARAMETERS. MAINT INSPECTED AREA & REQUESTED ANOTHER START. NR 3 ENGINE STARTED & OBSERVED RAPID EGT RISE & ENG START ABORTED. MAINT INFORMED FLT DECK THAT THERE WAS A NR 3 ENG TAIL FIRE. FLT CREW NOTIFIED ATC. AN AIR START UNIT WAS USED TO START A/C AS APU WAS INOP. FUEL HAD DRIPPED ONTO AIR HOSE & CAUGHT FIRE. ASU SHUTDOWN IMMEDIATELY BEFORE FLT CREW COULD CARRY OUT EMERGENCY PROCEDURES FOR ENG TAIL FIRE. BOTH ASU AIR HOSE & TAIL FIRE WAS EXTINGUISHED SUCCESSFULLY BY MAINT. NR 3 ENGINE IGNITOR ASSY REPLACED & CHECKED SERVICEABLE IAW MM 74-00 PAGES 601-608. NO FURTHER INCIDENT. 2L73 4F4 F A3WE E2EA 20030821002072003082100207CE 2003 8 21 CA030718002 120030716G3246101800259 WHEEL BEECH 200 B200 1152922CE PWA PT6 PT6A42 52043NE MLG CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) DURING WHEEL OVERHAUL THE NDT FACILITY DISCOVERED 3 CRACKS IN THE OUTER-HALF OF THE WHEEL ASSEMBLY. CRACKING WAS IN THE WEB AREA BETWEEN THE BEARING BOSS AND THE BEAD SEAT FLANGE. THE INBOARD HALF WAS NOT DAMAGED. OUTBOARD WHEEL HALF SCRAPPED AND REPLACED WITH NEW. 1L72 4T4 T A24CE E4EA 20031020001582003102000158WP 2003 10 20 CA030718003 120030718G3250 ACTUATOR CVAC 440 440 2422902WP ALLSN 501D 501D13D 03004GL NLG STEERING MISOVERHAULED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) RECIEVED ACTUATOR THROUGH OUR SUPPLIER. UPON INSTALLATION, FOUND IT BINDING. REMOVED IT AND FOUND THAT TWO SEPERATE CABLES THIS UNIT HAS WERE GOING THROUGH THE SAME PULLEY WHICH LEFT THE OTHER PULLEY NOT IN USE AND BINDING THE UNIT AS WELL AS DAMAGING THE CABLES. THE UNIT HAD A OVERHAULED TAG ON IT AND WAS SUPPOSED TO BE TESTED BUT I DON'T THINK IT COULD HAVE BEEN TESTED PROPERLY GIVEN THE WAY THE CABLES WERE RUN. 2L72 4R4 T 6A6 E282 20030821002082003082100208GL 2003 8 21 CA030718004 220030718G725023074538 SHAFT EMB 145 EMB145 3260210SO ALLSN AE300 AE3007A GL LP TURBINE DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ENGINE CAE 312387 IS AT ROLLS ROYCE CANADA FOR REPAIR DUE TO VIBRATION. DURING INSPECTION OF THE LP TURBINE ASSEMBLY IT WAS DISCOVERED THAT THE LP TURBINE SHAFT (23074538) HAD A SEVERE RUB AND HEAT DISCOLORATION ON THE OUTSIDE DIAMETER, LOC ATED IN THE AREA OF THE HP TURBINE SLEEVE (23056160) ALSO RUBBED AT FOUR LOCATION. THE SLEEVE IS ASSEMBLED INSIDE THE HP T/SHAFT (23069441). THIS UNUSUAL CONDITION WAS NOTED FOR THE SECOND TIME AT RRC, THE LP T/SHAFT IS A CRITICAL PART. 2L72 4F4 FRTT00011ATTE6CH 20030821002092003082100209EA 2003 8 21 CA030718005 120030714G5610NP1393226 WINDOW CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE COCKPIT CRACKED W B EMER. DESCENT O OTHER CRCRUISE 1 CA 15617 (CAN) FLIGHT AT FL220, THE EXTERNAL PLY OF THE RT WINDOW CRACKED. THE FLIGHT CREW DID AN EMERGENCY DESCENT AND DEPLOYED THE OXYGEN MASK IN THE CABIN. 2L72 4F4 FRTA21EA E15NE 20030821002102003082100210CE 2003 8 21 CA030721001 120030716G2821710C4X DRAIN BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA FUEL FILTER LEAKING W A UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 CA (CAN) ABOUT ONE HOUR INTO THE FLT, THE CREW NOTED THAT FUEL WAS LEAKING OUT THE LEFT AFT NACELLE FUEL DRAIN VALVE. ONCE ON THE GROUND INSPECTION OF THE VALVE DETERMINED THAT THE VALVE CENTER BODY HAD SEPERATED FROM THE HOUSING, RESULTING IN THE LEAK. THE BODY IS CRIMPED INTO THE HOUSING DURING MANUFACTURE OF THE VALVE ANDTHE CRIMP APPEARS TO HAVE FAILED. OTHER VALVES IN THE SYSTEM WERE INSPECTED WITH NO DEFECTS NOTED. A FLEET CAMPAIGN IS INITIATED TO REPLACE ALL THE VALVES. RAYTHEON WAS CONTACTED AND ADVISES THAT THERE WERE PROBLEMS IN THE PAST, WITH A BEECH COMMIQUE 97-001 AND COMM NR 38 BEING ISSUED IN 1997 AND 1982 RESPECTIVELY TO REVIEW THIS ISSUE. 1L72 4T4 T A24CE E4EA 20030821002122003082100212SW 2003 8 21 CA030722002 120030708G275019023 CONTROL CABLE BBAVIA8 8GCBC 1220803SW LYC O360 O360C2E 41514EA TE FLAP FRAYED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) CABLE FOUND FRAYED AT THE PULLEY PN 1-2395.THE AREA TENDS TO BE A HIGH WEAR BECAUSE OF THE SIZE OF PULLEY AND IS MONITORED CLOSELY AT ALL INSPECTIONS. FAILURES HAVE OCCURED IN THE PAST WITH THIS COMPANY. 1H71 3O3 O A21CE E286 20030821002132003082100213NE 2003 8 21 CA030722003 220030425G7261 PUMP CNDAIRCL600 CL600* EA LYC ALF502ALF502L 41580NE RT ENGINE OIL FLUCTUATES W E ENGINE SHUTDOWN YJ ENGINE STOPPAGE WARNING INDICATION CRCRUISE 1 CA (CAN) DURING CRUISE, THE RT ENGINE OIL PRESSURE STARTED FLUCTUATING WITH HIGH VIBESMASTER CAUTION. CREW SHUT DOWN RIGHT ENGINE AND AN UNEVENTFUL LANDING WAS MADE. PAX CONTINUED ON CHARTERED AIRCRAFT. POSTFLIGHT TROUBLESHOOTING REVEALED A DEFECTIVE OIL PUMP AND METAL CONTAMINATION. THE ENGINE WAS REMOVED. A LOANER ENGINE WAS INSTALLED AND THE AIRCRAFT WAS TURNED TO SERVICE. 2L72 4F4 FRTA21EA E6NE 20030821002142003082100214GL 2003 8 21 CA030722004 220030721G7323252466715 GOVERNOR HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL TURBINE FAILED W O OTHER J WARNING INDICATION APAPPROACH 1 CA (CAN) PILOT WAS IN CRUISE FLIGHT & SET UP FOR HIS APPROACH FOR LANDING AND THE ENGINE DECELLED BACK TO IDLE.THE ROTOR RPM DECAYED AND HE ENTERED AN AUTOROTATION AND LANDED WITHOUT FURTHER INCEDENT. WHEN ON THE GROUND WE TRIED TO MOVE THE THROTTLE TO FULL OPEN AND THE ENGINE WOULD ALMOST QUIT.THE GOVERNOR WAS CHANGED AND THE AIRCRAFT OPERATED NORMALLY. 1G71 3U3 U H3WE E4CE 20030902000122003090200012SW 2003 9 2 CA030722005 120030722G523027200631 BUSHING SWRNGNSA226 SA226TC 8780404SW GARRTTTPE331TPE33110UA 01514WP HARTZLHCE4N HCE4N3 NE RECEPTICLE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 33541 (CAN) DURING COMPLETION OF MFG SERVICE LETTER 226-SL-027 INSPECTION OF CABIN AND CARGO DOOR CLICK CLACK BUSHING RECEPTICLES FOR CRACKS, THE NR 3 CABIN DOOR RECEPTICLE WAS FOUND CRACKED IAW THE SERVICE LETTER. THE RECEPTICLE WAS REPLACED. ALL OTHER RECEPTICLES WERE FOUND IN GOOD CONDITION. 2L72 4T4 TRTA8SW E4WE 5 CP10NE 20030902000132003090200013SW 2003 9 2 CA030723001 120030723G272012364 CABLE BBAVIA8 8GCBC 1220803SW LYC O360 O360C2E 41514EA MCAULY1A200 1A200* GL RUDDER CONTROL FRAYED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) LT & RT CABLES FRAYED AT CABIN PULLEYS. CABLES ARE STAINLESS STEEL AND REPLACED WITH GALVANIZED. 1H71 3O3 O A21CE E286 5 NP874 20030821002152003082100215SO 2003 8 21 CA030723002 120030722G3234554401 CONTROL CABLE PIPER PA31 PA31350 7103110SO LYC O540 LTIO540J2BD 41533EA MLG SELECTOR FRAYED W O OTHER O OTHER LDLANDING 1 CA (CAN) PILOT SELECTED LANDING GEAR AND NOTICED GEAR SELECTOR WAS STICKY, HE CARRIED OUT HIS LANDING WITH NO TROUBLE. MAINT WAS NOTIFIED AND AFTER FURTHER INSPECTION FOUND THAT GEAR SELECTOR CABLE HAD FRAYED INTERNALLY. 1L72 3O3 O A20SO E14EA 20030821002162003082100216EA 2003 8 21 CA030723003 120030721G2720C6CFM12106 RUDDER PEDAL DHAV DHC6 DHC6300 2802606EA PWA PT6 PT6A27 52043EA COCKPIT BROKEN W D RETURN TO BLOCK O OTHER TXTAXI/GRND HDL 1 CA (CAN) THE CAPTAIN'S RUDDER PEDAL BROKE OFF THE AXLE WHEN APPLYING THE BRAKES TO RELEASE THE PARKING BRAKE. WHEN EXAMINING THE PEDAL A DARKENED AREA IN THE AREA OF THE BREAK IS VISIBLE INDICATING IT WAS PREVIOUSLY CRACKED PRIOR TO THE FAILURE. THE RUDDER PEDAL WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. AN EXAMINATION OF 5 OTHER AIRCRAFT IN THE FLEET SHOWED NO DISCREPENCIES. 1H72 3T4 TRTA9EA E4EA 20030821002172003082100217CE 2003 8 21 CA030723004 120030716G2421ES4145 ROTOR CESSNA177 177B 2073708CE LYC O360 O360A1F6 41514EA MCAULY2D34C B2D34C202 GL ALTERNATOR WORN W O OTHER H ELECT. POWER LOSS-50 PC NRNOT REPORTED 1 CA (CAN) ALTERNATOR WAS REMOVED AT 225.9 HRS BECAUSE OF DECREASING OUTPUT & VOLTAGE AS ELECTRICAL LOAD WAS APPLIED. ON DISASSEMBLY, TWO DEFECTS WERE FOUND. THE ROTOR SHAFT BEARING JOURNAL AT THE DRIVE END WAS FOUND LOOSE TO THE BEARING BY ABOUT .080 INCHES, ALLOWING THE ROTOR TO RUB ON THE STATOR STACKS.THE BEARING WAS ALSO SLIGHTLY WORN ON THE INSIDE BORE.ESSENTIALLY THE SHAFT MATERIAL WAS WORN AWAY. OTHER DEFECT LIKELY CAUSED OUTPUT SNAG. THREE POWER OUTPUT WIRES CONNECTING STATOR TO RECTIFIER ASSEMBLY WERE CHAFED & HAD BEEN SHORTING AGAINST INSIDE OF REAR HOUSING. THERE WAS NO SLEEVING OR SILICONE ADHESIVE TO PROTECT AGAINST CHAFING. 1H71 3O3 O A13CE E286 5 CP7EA 20030908001672003090800167EA 2003 9 8 CA030723005 120030719G6123C6NE10473 SWITCH DHAV DHC6 DHC6200 2802620EA PWA PT6 PT6A20 52043EA HARTZLHCB3T HCB3TN3 GL NR 1 ENGINE MISINSTALLED W A UNSCHED LANDING WJ INADEQUATE Q C WARNING INDICATION CLCLIMB 1 CA (CAN) NR 1 ENGINE, BETA BACK-UP SYSTEM, STEADY BLUE LIGHT ILLUMINATED IN CRUISE. FAULT FOUND TO BE KLIXON SPRING PN KX5, DRILLED MOUNTING HOLES NOT LINING UP WITH SWITCH KX511. 1H72 3T3 TRTA9EA E4EA 6 CP15EA 20030908001692003090800169EU 2003 9 8 CA030723006 120030720G783073M200S035 WEB AIRBUS330 A330322 3930325EU PWA 4168 PW4168 NE TORQUE BOX TORN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ON ARRIVAL, MAINTENANCE NOTICED APPROXIMATELY 18 INCHES OF METAL PROTRUDING INTO THE AIR STREAM OF NR 1 ENGINE INBOARD THRUST REVERSER, JUST FORWARD OF THE CASCA DE VANES. FURTHER INVESTIGATION REVEALEDTHE DAMAGE TO BE THAT THE TORQUE-BOX FLOW WEB PANEL HAD SEPARATED FROM THE TORQUE-BOX FLOW WEB. MFG HAVE RECOMMENDED REPLACEMENT OF FLOW WEB PANEL. 2L72 4F4 FRTA46NM E36NE 20030821002252003082100225EU 2003 8 21 CA030724001 120030707G2550121433 SOLENOID BOLKMS105 BO105C 5626005EU ALLSN 250C 250C20B 03013GL CARGO HOOK SHORTED W H DEACTIVATE SYST/CIRCUITS H ELECT. POWER LOSS-50 PC HOHOVERING 1 CA (CAN) WHEN CARGO HOOK ELECTRICAL RELEASE IS ACTIVATED THE SYSTEM CIRCUIT BREAKER OPENS. FOUND ELECTRICAL SOLENOID INTERNALLY SHORTED. 1G72 3U3 U H3EU E4CE 20030821002262003082100226EA 2003 8 21 CA030724002 120030721G24326104789 BATTERY PACK CNDAIRCL601 CL6012A12 1900303EA EMERGENCY LIGHTOVERHEATED W O OTHER MH OVER TEMP ELECT. POWER LOSS-50 PC NRNOT REPORTED 1 CA (CAN) THE BATTERY ASSEMBLY FOR NR 4 EMERGENCY LIGHTING POWER SUPPLY WAS REMOVED FOR BENCH CHECK. THE ASSEMBLY WAS INSPECTED AND FOUND THAT THE CELL TABS HAD BEEN OVERHEATED, INSULATION HAD BEEN MELTED OFF AND THE PLASTIC ENCLOSURE WAS ALSO DAMAGED. AN OPERATIONAL CHECK OF THE EMERGENCY LIGHTING SYSTEM & POWER SUPPLIES WAS CARRIED OUT AND FOUND SERVICEABLE. 2L72 4F RTA21AE 20030821002282003082100228CE 2003 8 21 CA030724003 120030717G3210681316 SEAL CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE MLG DAMAGED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) BOTH MAIN LANDING GEAR WHEEL ASSEMBLIES WERE INSTALLED WITH THE INBOARD WHEEL BEARING SEAL INSTALLED ON THE INCORRECT SIDE OF THE SNAP RING. THE MAIN WHEEL INSTALLATION BUILD-UP OUT OF SEQUENCE WITH THE BUILD-UP SHOWN IN THE COMPONENT MAINTENANCE MANUAL. 1L72 4F4 F A22CE E1NE 20030821002292003082100229CE 2003 8 21 CA030724004 120030717G2697 WIRE CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE OVERHEAT DETECT BROKEN W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) DUCT OVERHEAT SENSOR WIRE PN W84C20 WAS FOUND BARE & BROKEN UNDER DUCT COUPLING CLAMP. THE ELECTRICAL CIRCUIT WAS COMPLETED THROUGH THE CLAMP AND DID NOT SHORT TO GROUND BECAUSE IT WAS ISOLATED BY THE SILICONE RUBBER COUPLING. 1L72 4F4 F A22CE E1NE 20030821002302003082100230CE 2003 8 21 CA030724005 120030723G322266412005 AXLE CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE MLG CORRODED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) DURING A PHASE 1-5 INSPECTION OF THE MAIN LANDING GEAR THE AXLE EXPANSION PLUG PN 5514350 WAS FOUND CORRODED. UPON REMOVAL OF THE PLUG CORROSION WAS FOUND ON THE AXLE BORE APPROXIMATELY 1.5 INCHES FROM THE END. 1L72 4F4 F A22CE E1NE 20030821002422003082100242CE 2003 8 21 CA030724006 120030723G7120310239001 PAD CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE UPPER MOUNT CORRODED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) DUE TO LEAKING GASKET AT BLEED AIR SUPPLY TUBE FOR INLET VANE ANTI-ICING THE FORWARD FACE OF THE UPPER LT ENGINE MOUNT PAD HAS CORRODED. 1L72 4F4 F A22CE E1NE 20030822000012003082200001SO 2003 8 22 CA030724007 120030722G8120 SHAFT GARRTT PIPER PA31 PA31325 7103105SO LYC O540 LTIO540F2BD 41533EA TURBOCHARGER SHEARED W EA ENGINE SHUTDOWN UNSCHED LANDING A FLAME/FIRE CLCLIMB 1 CA YC001309 (CAN) AFTER TAKEOFF, PILOT NOTICED A LOSS OF MANIFOLD PRESS ON RT ENG. RETURNED TO AIRPORT. SAW FLAMES, SHUTDOWN & FEATHERED PROP. LANDING UNEVENTFUL. DURING TAXI & AFTER STOP, ENG CONTINUED TO SMOKE. DURING INSPECT, OIL COVERED EXHAUST & TURBOCHARGER. COMPRESSOR OF TURBOCHARGER DAMAGED. BLADES BROKEN, CURLED BACK & NICKED. COMPRESSOR LOOSE IN HOUSING & DAMAGE APPEARS TO BE CAUSED BY BLADE CONTACT. INSPECT TURBINE. TURBINE WAS MISSING, DEPARTED A/C THROUGH EXHAUST. DUE TO SHAFT FAILURE, OIL BEING PUMPED PAST SEAL INTO INDUCTION SYS & CAUSING SMOKE, OIL BURNED IN CYLINDERS. TURBOCHARGER REMOVED & DISASSEMBLED FOR INSPECT. OIL PASSAGES TO BEARING WERE CLEAR. BUSHINGS LOOK LIKE THEY PILED UP & SHAFT TWISTED. 1L72 3O3 O A20SO E14EA 20030822000022003082200002EA 2003 8 22 CA030725001 120030414G5751 COUNTERWEIGHT DHAV DHC2 DHC2MK1 2800102EA PWA R985 R985AN14B 52008NE AILERON LOOSE W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) RT AILERON BALANCE WEIGHT ARM RIVETS FOUND LOOSE 1H71 3R3 R A806 5E1 20030822000032003082200003EU 2003 8 22 CA030725002 120030724G324215907400 DISK CLEVELAND PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL BRAKE ASSY CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA 1099 (CAN) WHILE CHANGING THE RT MAIN TIRE, THE OUTBOARD DISK WAS FOUND CRACKED. SINCE THE BRAKE WEAR INDICATORS WERE FAR FROM THEIR MAXIMUM LIFE INDICATION, THIS COULD BE CONSIDERED PREMATURE FAILURE. NOTE:THERE HAD BEEN A NOISE COMING FROM THE BRAKE DURING TOWING. THE BRAKE UNIT HAD BEEN INSPECTED WITH THE WHEEL OFF, BUT NO DEFECTS HAD BEEN NOTED. ONLY FULL DISASSEMBLY OF THE BRAKE UNIT ITSELF MAY HAVE FOUND THE CRACKS EARLIER. BRAKE UNIT WAS REPLACED WITH A SERVICEABLE UNIT 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030822000042003082200004NE 2003 8 22 CA030725003 220030708G7200 PLANETARY GEAR CESSNA208 208B 2073701CE PWA PT6 PT6A114A 52043NE MCAULY3AF34C3GFR34C703 GL ENGINE FRACTURED W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA 10279 (CAN) DURING CLIMB, CREW NOTED CHIP DETECTOR LIGHT ILLUMINATED. CREW RETURNED TO DEPARTURE AIRPORT. MAINTENANCE FOUND ENGINE MAKING A GRINDING NOISE AND FELT SOME DISTRESS IN THE POWER SECTION WHEN ROTATED. ENGINE WAS REMOVED FOR INVESTIGATION. DURING TEARDOWN, THE 1ST STAGE PLANETARY GEAR WAS FOUND MISSING ONE TOOTH. FURTHER SPALLING WAS FOUND ON THE SUN GEAR. THE DAMAGED COMPONENTS ARE BEING REPLACED. ENGINE WAS 4222.0 HRS/5454 CYCLES TSO. 1H71 3T3 T A37CE E4EA 5 CP60GL 20030822000052003082200005SW 2003 8 22 CA030725004 120030724G6230407040036107 BEARING BELL BELL 407 407 1182206SW ALLSN 250C 250C47B GL M/R MAST SPALLED W K NONE O OTHER ININSP/MAINT 1 CA 53168 (CAN) MAST REMOVED BECAUSE OF METAL CONTAMINATION, ROLLER FOUND SPALLED. 1G71 3U3 UO H2SW E1GL 20030822000062003082200006NE 2003 8 22 CA030725005 120030721G792123063372 SEAL ALLSN SKRSKYS76 S76A 8143006NE ALLSN 250C 250C30S 03013GL ACCESSORY G/B TORN W K NONE K FLUID LOSS ININSP/MAINT 1 CA CAG90348 (CAN) SHORTLY AFTER INSTALLATION OF A REPAIRED ENGINE (40.5 HRS TSR), OIL COOLER BLOWER SEAL FAILED CAUSING SUBSTANTIAL LEAK FROM ACCESSORY GEARBOX. UPON REMOVAL OF SEAL, AME DISCOVERED A TORN SEAL LIP. IT WAS ALSO DETERMINED THAT INSTEAD OF ONE SPRING, (OR NONE FOR SEALS MODIFIED BY CEB 72-3260), THE SEAL CONTAINED TWO SPRINGS AROUND THE LIP. SEAL REPLACED, A/C RETURNED TO SERVICE. 1G72 3U3 U H1NE E1GL 20030908001712003090800171EA 2003 9 8 CA030726002 120030515G2720C2CF697 SPRING DHAV DHC2 DHC2MK1 2800102EA PWA R985 R985AN14B 52008NE PEDAL ATTACH DAMAGED W K NONE F FLT CONT AFFECTED ININSP/MAINT 1 CA (CAN) SPRING PEDAL ATTACH REPLACE. 1H71 3R3 R A806 5E1 20030822000102003082200010CE 2003 8 22 CA030726006 120030305G5751 RIVET CESSNA206 U206F 2073333CE CONT O550 IO550F 17042SO AILERON HINGE LOOSE W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) LOOSE RIVETS ON BOTH WINGS AT AILERON HINGE BRACKET REPLACED. 1H71 3O3 O A4CE E3SO 20030822000112003082200011WP 2003 8 22 CA030728001 120030724G6210500P2100101 BLADE HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL MAIN ROTOR CRACKED W O OTHER O OTHER LDLANDING 1 CA (CAN) ON LANDING PILOT NOTICED DEFECT IN WHITE ROTOR BLADE. BLADE FOUND CRACKED ON UNDERSIDE SKIN FROM TRAILING EDGE TO SPAR 17 INCHES FROM BLADE ROOT. REMAINING BLADES INSPECTED NO DEFECTS FOUND. 1G71 3U3 U H3WE E4CE 20030908001782003090800178EU 2003 9 8 CA030728002 120030727G5312 PRESSURE PANEL BAC 146 146200A 1500266EU LYC ALF502ALF502R5 41580NE MLG WW CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 3625236252 (CAN) DURING GROUND PRESSURIZATION RUN FOR T/S. VISUAL INSPECTION FOUND 12 INCH CRACK IN UPPER WHEEL WELL PRESSURE SKIN ALONG AIRCRAFT CENTER LINE AT EDGE OF STRINGER BETWEEN FRAMES 29 TO FRAME 32. AIRCRAFT WAS PREVIOUSLY SUBJECT TO A COMPANY SPECIAL INSPECTION FOR THIS PROBLEM ON OTHER SIMILAR AIRCRAFT IN OPERATORS FLEET ON MAY 24/2003 AND NO REPORTED DISCREPANCIES FOUND. AIRCRAFT REPAIRED AS PER BAE REPAIR INSTRUCTION HC532H9018. AIRCRAFT RETURNED TO SERVICE. 2H74 4F4 F A49EU E6NE 20030908001792003090800179 2003 9 8 CA030728003 420030728G3197 WIRE HARNESS GROB G115 G115C 1660303EU LYC O320 O320D1A 41508EA INSTRUMENT PANELFAILED W C ABORTED TAKEOFF B SMOKE/FUMES/ODORS/SPARKS TOTAKEOFF 1 CA (CAN) A WIRE BUNDLE BEHIND THE RT INSTRUMENT PANEL HAD CHAFED ON A SCREW SECURING A FACTORY INSTALLED BLANKING PLATE. THE NUT APPEARS TO HAVE BECOME LODGED IN THE CASING SECURING THE WIRE BUNDLE ALLOWING THE SCREW TO CHAFE THROUGH THE INSULATION ON TWO WIRES. THE SCREW WAS OBSERVED TO FLASH WHITE AND THE INSTRUMENT PANEL SHOWS SIGNS OF HEAT DAMAGE AROUND THE SCREW HOLE. 1L71 3O3 ONTA57EU E274 20030908001822003090800182GL 2003 9 8 CA030729001 320030723G6110C83811 CLAMP HARTZLHCA3V PHCA3VF2 GL PROPELLER CORRODED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) PROP WAS SENT IN TO US FOR AD 2003-13-17. PROP INSPECTION WAS NOT REQUIRED BY S/N, BUT IN THE AD THEY RECOMMENDED THAT ANY PROP THAT HAD BEEN OVERHAULED BY T&W BE INSPECTED IAW PARAGRAPH H. UPON DISASSEMBLY & VISUAL INSPECTION OF PARTS, FOUND TWO OF C838-11 CLAMPS WERE CORRODED BEYOND REPAIR & NEEDED PLATING. ALL THREE OF A971 BEARINGS CORRODED & DENTED BEYOND REPAIR. B854 CYLINDER ALSO FOUND TO BE CORRODED ON INTERNAL SURFACE & NEEDS REPLACEMENT. 5 CP6EA 20030822000122003082200012EA 2003 8 22 CA030729002 120030708G5610NP1393212 WINDSHIELD CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE COCKPIT CRACKED W A UNSCHED LANDING O OTHER CLCLIMB 1 CA (CAN) DURING CLIMB, RT WINDSHIELD CRACKED. RETURNED TO DEPARTURE AIRPORT. FOLLOWING THE WINDSHIELD REPLACEMENT, THE AIRCRAFT RETURNED TO SERVICE. 2L72 4F4 FRTA21EA E15NE 20030822000182003082200018NE 2003 8 22 CA030729003 220030724G7200 ENGINE CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE LEFT SHUTDOWN W E ENGINE SHUTDOWN EY VIBRATION/BUFFET ENGINE STOPPAGE CLCLIMB 1 CA 807603 (CAN) LT ENGINE SHUT ITSELF DOWN WITH SMALL VIB AND OIL PRESSURE WARNING. MTCE REPORTED CHIP DETECTOR WAS CONTAMINATED AND SOME DEBRIS WAS IN THE TAILPIPE. FOLLOWING LT ENGINE REPLACEMENT, THE AIRCRAFT RETURNED TO SERVICE. 2L72 4F4 FRTA21EA E15NE 20030822000212003082200021EA 2003 8 22 CA030729004 120030716G3320BC10065003 LIGHT CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE CABIN BURNED W K NONE B SMOKE/FUMES/ODORS/SPARKS ININSP/MAINT 1 CA (CAN) GALLEY LIGHTING FIXTURE OVERHEATED: NO SNAGS FOUND IN REVIEW OF SPRING & SUMMER 2003 AMTAK RECORDS WITH REFERENCE TO GALLEY LIGTHING FIXTURE ISSUES. NO LIGHT FIXTURES PURCHASED OR CONSUMED DURING THE PAST 2 YEARS. LIGHT BULB INSTALLED IN GALLEY LIGHTING AREA AS WELL AS ALL CABIN LIGHTING ON CRJ. LIGHTING FIXTURE FOUND ONLY IN GALLEY AREA. 2L72 4F4 FRTA21EA E15NE 20030822000232003082200023SO 2003 8 22 CA030729005 120030708G324216413601 BRAKE DISC CLEVELAND MAULE MX7 MX7235 5460180SO MLG WHEEL FAILED W O OTHER O OTHER TXTAXI/GRND HDL 1 CA (CAN) BRAKE DISC BROKE AWAY AT ALL THREE MOUNTING HOLES CAUSING RT BRAKE TO FAIL IN THE TAXI MODE. AIRCRAFT VEERED OFF TAXIWAY AND STOPPED ON GRASS. NO OTHER DAMAGE TO AIRCRAFT. WHEEL BOLTS APPEARED TO HAVE BEEN SLIGHTLY LOOSE, SOME CHAFING EVIDENT. WHEEL INSPECTED, NEW DISC AND BOLTS INSTALLED. 1H71 3O NC3A23 20030822000252003082200025EA 2003 8 22 CA030729006 220030726G8520 ROD CAP PIPER PA31 PA31350 7103110SO LYC O540 LTIO540J2BD 41533EA ENGINE BROKEN W EA ENGINE SHUTDOWN UNSCHED LANDING E VIBRATION/BUFFET CRCRUISE 1 CA (CAN) DURING CRUISE THE PILOT NOTICED A SLIGHT VIBRATION IN LT ENGINE AND A STRANGE NOISE THEN HE NOTICED OIL COMING OUT OF THE ENGINE COWL. THE ENGINE WAS SHUT DOWN AND PROP FEATHERED AND THEN LANDED AT THE NEAREST AIRPORT WITH NO FURTHER PROBLEMS. INSPECTION OF THE ENGINE REVEILED THAT NR 1 CONNECTING ROD HAB BROKEN AND PUNCTURED THE CASE IN THREE DIFFERENT LOCATIONS. WE ARE STILL WAITING TO HEAR FROM THE ENGINE SHOP FOR THE CAUSE OF THE BREAKAGE. 1L72 3O3 O A20SO E14EA 20030822000292003082200029CE 2003 8 22 CA030729007 120030723G243523047004 STARTER GEN CESSNA441 441 2076020CE GARRTTTPE331TPE3311 01514WP ENGINE FAILED W O OTHER EH VIBRATION/BUFFET ELECT. POWER LOSS-50 PC CLCLIMB 1 CA (CAN) STARTER GENERATOR HAD INTERNAL FAILURE CAUSING AN ELECTRICAL SHORT CIRCUIT TO GROUND, CAUSING THE BUSS TIE TO LT BUSS CURRENT LIMITER TO BLOW, THUS CAUSING TO LT BUSS TO LOOSE ELECTRICAL POWER, NO PILOTS INSTRUMENTS. NO POWER TO OPERATE CONTROL CIRCUITS FOR FLAPS ON MLG (GEAR WAS BLOWN DOWN WITH N2). NO POWER TO OPERATE ENGINE ELECTRIC CONTROL, REVERTING TO MANUAL, THUS NO REVERSE FOR LANDING. 1L72 3T3 TRTA28CE E3WE 20030822000362003082200036GL 2003 8 22 CA030729008 320030722G6114A2202 BEARING BLANCA17 1731ATC 1220437GL LYC O540 IO540K1E5 41532EA HARTZLHCC3Y HCC3YR GL PROPELLER CRACKED W K NONE O OTHER ININSP/MAINT 1 CA DY40 (CAN) SEVERAL SMALL CRACKS WERE FOUND ALONG THE BALL TRACK OF THE INBOARD RACE OF THE A2202 BEARING. THE BEARINGS WERE REPLACED AND THE PROPELLER WAS OVERHAULED. 1L71 3O3 O A18CE 1E4 5 CP25EA 20030822000382003082200038EA 2003 8 22 CA030729009 220030526G7322MA45PA CARBURETOR CESSNA172 172L 2072432CE LYC O320 O320E2D 41508EA ENGINE FAILED W B EMER. DESCENT RJ PARTIAL RPM/PWR LOSS WARNING INDICATION CLCLIMB 1 CA (CAN) AIRCRAFT ENGINE LOST POWER IN A CLIMB, LEVELLING OUT RESTORED POWER, ANY ATTEMPT TO CLIMB RESULTED IN PARTIAL POWER LOSS. AT 231.2 HOURS THE CARB WAS REMOVED AND REPAIRED. THE FLOAT BOWL THREADS WERE STRIPPED OUT, A USED SERVICEABLE FLOAT BOWL WAS INSTALLED. I SUSPECT THE FLOAT LEVER SETTING IS INCORRECT. IN THE PAST 2 YEARS I HAVE SENT BACK 4 MAGS, 2 STARTERS AND ANOTHER CARBURETOR TO THIS COMPANY THAT WERE FRESH OUT OF OVERHAUL AND HAVE FAILED. 1H71 3O3 ONT3A12 E274 20030822000412003082200041NM 2003 8 22 CA030729010 120030727G2612UK CONNECTOR BOEING737 7372H4 138448CNM PWA JT8 JT8D9A 52048NE NR 2 ENGINE CONTAMINATED W EF ENGINE SHUTDOWN ACTIVATE FIRE EXT. N FALSE WARNING NRNOT REPORTED 1 CA (CAN) FLT CREW REPORTS ON START UP, THEY HAD A FIRE WARNING FOR THE NR 2 ENG, FIRE LIGHTS, BELLS & FIRE HANDLE LIGHT WERE ON. ENG SECURED BY ENG FIRE. QRC- YSB TOWER NOTIFIED & FIRE TRUCKS WERE CALLED. CREW DISCHARGED BOTH FIRE BOTTLES, NO EVIDENCE OF FIRE. A/C PAX DEPLANED & MAINT CALLED. MAINT INVESTIGATION CONFIRMED NO EVIDENCE OF FIRE. RT ENG FIRE DETECTION SYS PLACED ON MEL & FIRE BOTTLES REPLACED. AIRCRAFT RETURNED TO SERVICE. AT NEXT RON, MAINT FOUND NR 2 ENG UPPER FIRE/OVERHEAT DETECTOR LOOP CONNECTORS CONTAMINATED. CONNECTORS CLEANED PER SWPM. NO FAULTS FOUND. ENG FIRE/OVERHEAT SYSTEM TESTED PER MM. NO FAULTS FOUND. MEL CLEARED AND AIRCRAFT RETURNED TO SERVICE. 2L72 4F4 F A16WE E2EA 20030822000432003082200043EA 2003 8 22 CA030729011 220030714G73221041641 SCREW PIPER PA24 PA24180 7102402CE LYC O360 O360A1A 41514EA CARB FLOAT BOWL LOOSE W K NONE O OTHER ININSP/MAINT 1 CA (CAN) SCREWS HOLDING FLOAT BOWL TO CARBURETOR HOUSING. ALL SCREWS LOCKED BUT ALL LOOSE IN HOUSING CAUSING CHAFING BETWEEN BOWL, GASKET HOUSING WITH A 1/16 INCHES GAP AND ALL AROUND. DISCOVERED ON ANNUAL INSPECTION. 1L71 3O3 ONT1A15 E286 20040107000502004010700050NM 2004 1 7 CA030729012 120030702G7603BACC13AA3T556506CONTROL CABLE BOEING727 72722 1384002NM PWA JT8 JT8D7B 52053NE THRUST CONTROL FRAYED W K NONE O OTHER ININSP/MAINT 1 CA 54767 (CAN) DURING INSPECTION OF THE STATION 870 AREA AT C-CHECK IT WAS FOUND THAT THE NR 3 ENGINE THRUST CABLE WAS FRAYED TO THE POINT OF 1 (ONE) STRAND REMAINING. THE CAUSE WAS IMPROPER ROUTING OF THE CABLE. THE CABLE WAS NOT ON THE PULLEY AND WAS CHAFING ON THE PULLEY BRACKET. THE PULLEY/CABLE SECURING PIN WAS IN PLACE. THIS AREA WAS LAST ACCESSED DURING THE PREVIOUS CHECK. 2L73 4F4 F A3WE E2EA 20030822000462003082200046NM 2003 8 22 CA030729013 120030702G5270S586 WARNING SWITCH BOEING727 72725C 138400HNM PWA JT8 JT8D7B 52053NE MLG DOOR OUT OF ADJUST W O OTHER N FALSE WARNING DEDESCENT 1 CA (CAN) JUST PRIOR TO DESCENT THE MAIN CARGO DOOR WARNING LIGHT ILUMINATED. THE CAPTAIN MADE AN EMERGENCY DESCENT AND THE AIRCRAFT LANDED WITHOUT FURTHER INCIDENT. THE MAIN CARGO DOOR WARNING SYSTEM WAS UNDER THE APPROVED MEL AT THE TIME. THE MEL HAD BEEN APPLIED ON A PREVIOUS LEG WHEN MAINTENANCE HAD DETERMINED THAT AS OUT OF RIG WARNING SWITCH HAD CAUSED FALSE WARNINGS. THE MEL HAD BEEN APPLIED IAW THE PUBLISHED INSTRUCTIONS AND THE SYSTEM WAS PLACARDED. 2L73 4F4 F A3WE E2EA 20031020001602003102000160CE 2003 10 20 CA030729014 120030729G251008128111 SPRING CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE HEAD REST MISMANUFACTURED W O OTHER W INADEQUATE Q C NRNOT REPORTED 1 CA (CAN) MAINTENANCE TECHNICIANS WERE REPLACING A BROKEN HEADREST EXTENSION SPRING WITH A NEW PART WHEN THE NEW PART FAILED. THE NEW SPRING SUPPLIED BY CESSNA WAS FOUND TO BE EXTREMELY BRITTLE AND WOULD BREAK IF DEFLECTED. A CALL TO CESSNA CUSTOMER SUPPORT CONFIRMED THAT THE SPRINGS HAD BEEN MANUFACTURED INCORRECTLY. 1L72 4F4 F A22CE E1NE 20030822000472003082200047WP 2003 8 22 CA030729015 220030605G731039423091 SWITCH BEECH 100 100BEECH 1152916CE GARRTTTPE331TPE3316252B 01514WP FUEL SHUTOFF FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) FOLLOWING FLIGHT, THE ENGINE WAS UNABLE TO BE SHUT DOWN BY SELECTING ENGINE STOP BUTTON. 1L72 3T4 T A14CE E2WE 20030822000602003082200060SW 2003 8 22 CA030729016 120030710G6720500N720155 CONTROL CABLE HUGHES500N 500N 3027374SW ALLSN 25OC 250C20R GL T/R PEDAL FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) AT PREFLT, PILOT REPORTED A 'BINDING' AT EXTREME RT PEDAL. MAINT DISCONNECTED SECTIONS OF SYS & COULDN`T REPEAT. DAYS LATER PILOT REPORTED SIMILAR BINDING PLUS A 'BANG' BEFORE MOVING SMOOTHLY AGAIN. DURING INVEST, ENGINEERING FOUND BINDING WHERE 2 CABLES JOIN TOGETHER AT TAILBOOM DISCONNECT. INNER CABLE HAS A MACHINED HEX SECTION THAT MATES WITH A HEX INSIDE CABLE SHEATH. AT EXTREME, PEDAL INNER HEX EXITS SHEATH HEX & IS PRELOADED, & TWISTED (10-20 INCH). WHEN PEDALS WERE MOVED TOWARD NEUTRAL INNER CABLE HEX ATTEMPTED TO ENTER SHEATH HEX, & BECAUSE OF A MISALIGNMENT, BOUND UP, & WHEN ENOUGH PRESSURE EXISTED, IT WOULD SNAP INTO ALIGNMENT (CAUSING BANG & BINDING). BOTH CABLES CHANGED, RETURN TO SERVICE. 1G71 3U3 UNCH3WE E4CE 20031020001612003102000161CE 2003 10 20 CA030729017 120030703G57406147514435 WASHER BEECH 100 100BEECH 1152916CE PWA PT6 PT6A28 EA WING FITTING MISMANUFACTURED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) CAD PLATING MISSING ON 1/2 OF NEW WASHER, BOTH SIDES. 1L72 3T4 T A14CE E4EA 20030908001832003090800183NM 2003 9 8 CA030729018 120030504G7160 ACTUATOR BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA BY-PASS DOOR STUCK W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING PREFLIGHT ENGINE INTAKE BYPASS DOOR CONTROL WAS UNSERVICABLE ON RT ENGINE. STUCK IN OPEN. RELEASED ACCORDING TO MEL. SYSTEMS CHECKED OK. BY-PASS DOOR ACTUATOR WAS REPLACED THE FOLLOWING DAY. 2H72 4T4 TRTA13NM E00062EN 20030822000612003082200061NM 2003 8 22 CA030729019 120030531G275085711423101 BRACKET DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE TORQUE SENSOR CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) CRACKED (X2 PLACES) AT 1-1.5 INCHES LONG TORQUE SENSOR BRACKET PN 85711423-101. BRACKET ATTACHED TO REAR WING SPAR YC37.00 LT BRACKET MADE VERY LIGHT 0.040 INCHES 2024-T3AL 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030822000632003082200063SO 2003 8 22 CA030729020 120030721G52806709010 DOOR PIPER PA34 PA34200T 7103406SO CONT O360 TSIO360E 17025SO MCAULY3AF34C3AF34C502 GL MLG CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) CRACKS ON THE MAIN LANDING GEAR DOOR FLANGE. BOTH LT AND RT DOOR. DOOR IS FIBERGLASS COMPOSITE STRUCTURE. MAIN LANDING GEAR DOOR LT PN 67090-10 MAIN LANDING GEAR DOOR RT PN 67090-11. 1L72 3O3 O A7SO E9CE 5 CP22EA 20030908001852003090800185NM 2003 9 8 CA030729021 120030605G6120 CONTROL UNIT BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA PITCH CONTROL MALFUNCTIONED W C ABORTED TAKEOFF E VIBRATION/BUFFET TOTAKEOFF 1 CA (CAN) AFTER APPLYING TAKEOFF POWER RT PROP FEATHERED TO 200 RPM. UP TRIM ON LT ENGINE, WITH PEC CAUTION ON WARNING/CAUTION PANEL. TAKE OFF ABORTED AND RIGHT ENGINE SHUT DOWN. TAXIED BACK TO GATE WITH NORMAL DEBARKATION. FAULT CODES 260 AND 236 LOGGED IN CDS. FAULT CLEAR PERFORMED. ELECTRICAL CONNECTORS CHECKED ACCORDING FIM TASK 61-20-00-810-898 WITHOUT ANY FINDINGS. PROPELLER CONTROL UNIT REPLACED ACCORDING AMM 61-20-11. 2H72 4T4 TRTA13NM E00062EN 20030908001872003090800187NM 2003 9 8 CA030729022 120030523G2612 FIRE LOOP BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA NR 1 ENGINE DAMAGED W K NONE N FALSE WARNING ININSP/MAINT 1 CA (CAN) 20 MINUTES AFTER ENG SHUTDOWN, FIRE WARNING CAME ON NR 1 ENGINE. AS NO PASSENGERS WERE ONBOARD VISUAL CHECK WAS PERFORMED ON ENGINE & FIRE FIGHTING NOT INITIATED. WARNING WENT OFF AFTER 15 MIN. PEC FIRE LOOP PN 10109601 REPLACED ACCORDING AMM. NOTE STRIP REPORTS OF FIRE LOOPS HAVE SHOWN THAT FIRE DETECTION LOOP ACTIVATION TEMP HAS DECREASED FROM NORMAL 300 DEGREES F SETTING, AS A RESULT OF PROLONGED EXPOSURE TO A HOT ENVIRONMENT. VALUES REMOVED LOOPS RANGE FROM 216 TO 220 DEGREES F. INVESTIGATION FROM MANUFACTURER HAS DETERMINED THAT REDUCTION IN TRIGGER TEMP, IS RESULT OF PREMATURE HYDROGEN OUT GASSING WITHIN INNER TUBE OF FIRE LOOP. GREATER HYDROGEN OUT GASSING, LOWER TRIGGING TEMP. 2H72 4T4 TRTA13NM E00062EN 20030822000672003082200067WP 2003 8 22 CA030729023 220030725G732039423091 SHUTOFF VALVE BEECH 100 100BEECH 1152916CE GARRTTTPE331TPE3316252B 01514WP FUEL SYSTEM DAMAGED W E ENGINE SHUTDOWN O OTHER NRNOT REPORTED 1 CA (CAN) THIS PART HAD PREVIOUSLY FAILED AND WAS SENT FOR REPAIR AND THEN REINSTALLED. THE COMPONENT FAILED FOR THE SAME FAULT AFTER ONLY 13.2 HRS OF OPERATION. THE UNIT WAS AGAIN REMOVED AND SENT FOR REPAIR AT THE SAME FACILITY UNDER WARRANTY. 1L72 3T4 T A14CE E2WE 20031020001672003102000167NM 2003 10 20 CA030729024 120030714G2612 FIRE DETECTOR BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA RT ENGINE FALSE ACTIVATIONW K NONE N FALSE WARNING ININSP/MAINT 1 CA (CAN) 17 MIN AFTER SHUTDOWN, RECEIVED A RT ENG FIRE WARNING. A/C REFUELING, CANCELLED AURAL WARNING & INSPECTED FOR FIRE ON RT ENG. ALL NORMAL, CONTINUED TO FUEL. AFTER 25 MIN. RECEIVED A SUGGESTION FROM TECH. OPEN COVER ON BOTH SIDES OF THE ENG. AFTER A COUPLE OF MINS. LIGHT OUT. FIRE WARNING MOST LIKELY CAUSED BY FAULT OF THE PEC FIRE INDICATION LOOP. STRIP REPORTS OF LOOPS SHOW FIRE LOOP ACTIVATION TEMP DECREASED FROM NORMAL SETTING, AS A RESULT OF PROLONGED EXPOSURE TO A HOT ENVIRONMENT. VALUES OF REMOVED LOOPES RANGE FROM 216 TO 220 DEGREES F. INVEST FROM MANUFACTURER DETERMINED THAT REDUCTION IN TRIGGER TEMP, IS RESULT OF PREMATURE HYDROGEN OUTGASSING WITHIN INNER TUBE OF FIRE LOOP. 2H72 4T4 TRTA13NM E00062EN 20030822000792003082200079CE 2003 8 22 CA030729025 120030724G275099524122 GEAR BEECH 100 100BEECH 1152916CE PWA PT6 PT6A28 EA FLAP GEARBOX STRIPPED W O OTHER O OTHER TXTAXI/GRND HDL 1 CA 2515 (CAN) AFTER LANDING AND FLAPS RETRACTED CREW NOTICED THAT INBOARD FLAPS HAD RETRACTED FULLY BUT THE OUTBOARD FLAP HAD STUCK AT ABOUT THE APPROACH SETTING. FLAP GEARBOX/MOTOR ASSY REPLACED. INSPECTION OF FAILED GEARBOX REVEALED NUMEROUS STRIPPED TEETH ON ONE OF THE GEARS. 1L72 3T4 T A14CE E4EA 20030822000802003082200080SO 2003 8 22 CA030730001 120030725G3210404130405 FORK PIPER PA31 PA31 7103102SO LYC O540 TIO540A2B 41532EA MLG CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA 10920 (CAN) WHILE INSPECTING BRAKE PADS A CRACK WAS NOTICED ON THE RT MAIN LEG CASTING AT THE AXEL RADIUS. FURTHER INSPECTION NOTED A 1.5 INCH CRACK IN THE RT LEG AND A 0.5 CRACK IN THE LT LEG. BOTH MAIN LANDING GEAR LEGS REPLACED WITH SERVICEABLE UNITS. 1L72 3O3 O A20SO E14EA 20030822000812003082200081SO 2003 8 22 CA030730002 120030710G32224027300 TRUNNION PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA NLG CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) NOSE LANDING GEAR HOUSING (TRUNNION) PIPER PN 4027300 NOTED CRACKED DURING WALK AROUND INSPECTION. APPROXIMATELY 6 INCHES CRACK FROM RT SIDE STEERING STOP UP AND BACK ON HOUSING. THE TYPE OF CRACKING RESULTS FROM OVER STEERING OR EXCESSIVE PULL DURING GROUND HANDLING. THE CRACK PROBABLY PROGRESSED TO BE VISIBLE ON THE PROCEEDING LANDING. 1L72 3O3 O A20SO E14EA 20030822000822003082200082GL 2003 8 22 CA030730003 120030721G78102500324 EXHAUST PIPE DIAMONDA20 DA20A1 2990000GL ROTAX 912 ROTAX912S3 EU ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) NOTED SLIGHT DISCOLORATION OF COWL ON ROUTINE DAILY INSPECTION, REMOVED UPPER COWL FOUND LOWER COWLING WITH SLIGHT BURNED AREA AROUND NR 1 CYLINDER REMOVED EXHAUST WRAP TO FIND NR 1 EXHAUST PIPE CRACKED AND BLOWN OUT. THIS IS THE 4TH TIME ON DIFFERENT AIRCRAFT, SAME TYPE OF ENGINE WE HAVE FOUND THIS PROBLEM OVER THE PAST 3 MONTHS. 1L71 3O3 ONTTA4CH E00051EN 20030902000142003090200014GL 2003 9 2 CA030730004 120030707G78102500324 EXHAUST PIPE DIAMONDA20 DA20A1 2990000GL ROTAX 912 ROTAX912S3 EU HOFMANHOV352HOV352F NE ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING ENGINE ROUTINE INSPECTION, WE NOTICED SOME DISCOLORATION ON THE EXHAUST WRAP WHEN COWLS WAS REMOVED (SB 20 78 04A). WHEN EXHAUST WRAP WAS REMOVED, IT REVEALED AN INSIDE BEND OF THE NR 1 CYLINDER AND FOUND THAT THE EXHAUST PIPE HAD BLOWN OUT. THIS WAS NOT OUR FIRST FINDING OVER THE PAST 3 MONTHS. WE HAVE HAD 3 OTHER AIRCRAFT WITH THE SAME IDENTICAL PROBLEM ON THE S3 ENGINES AT THE NR 1 CYLINDER ONLY. WE FEEL THIS PRESENTS A REAL CONCERN TO SAFETY. 1L71 3O3 ONTTA4CH E00051EN5 CTP5BO 20030902000152003090200015EU 2003 9 2 CA030730005 120030729G2731Z4244120000 CABLE ZLIN 242 Z242L 9970204EU LYC O360 AEIO360A1B6 41514EA ELEVATOR TRIM BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) AS A RESULT OF PREVIOUS FRAYED CABLES, SPECIAL ATTENTION IS PAID TO AREAS WHERE THE ELEVATOR TRIM CABLE PASSES THROUGH PULLEYS, CABLE DRUMS. THIS CABLE HAD BROKEN STRANDS WHERE IT PASSED THOUGH THE LT AFT PULLEY. A REPLACEMENT INTERVAL OF THESE CABLES OF 3000 HRS WAS PUT IN PLACE TO PRECLUDE A RAPID DETERIORATION OF THESE CABLES, HOWEVER THIS CABLE HAD ONLY 1199.2 HRS ON IT. 1L71 3O3 O0 A76EU 1E10 20030902000162003090200016EA 2003 9 2 CA030730006 120030709G2761 PCU CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE ACTUATOR ERRATIC W K NONE F FLT CONT AFFECTED ININSP/MAINT 1 CA (CAN) AIRCRAFT OUT OF ROLL TRIM ON T/O, FLAP 8, IMMEDIATELY REQUIRED RIGHT CONTROL INPUT. AUTOPILOT ALSO SHOWED RIGHT CONTROL INPUT. ON APP. HAND FLOWN, FLAP 45, REQD. RWD TRIM TO ALMOST FIRST HASH MARK. REPLACED LT WING OB FLIGHT SPOILER PCU DUE FLOATING/ERRATIC MOVEMENT. 2L72 4F4 FRTA21EA E15NE 20030902000172003090200017EU 2003 9 2 CA030730007 120030708G63204638302024 BEARING RACE BOLKMS105 BO105S 5626006EU ALLSN 250C 250C20B 03013GL M/R GEARBOX SPALLED W K NONE J WARNING INDICATION ININSP/MAINT 1 CA (CAN) LT INPUT ROLLER BEARING OUTER RACE SPALLING/PEELING. METAL CONTAMINATION CAUSED EXSTENSIVE DAMAGE TO OTHER INTERNAL TRANSMISSION BEARINGS. 1G72 3U3 U H3EU E4CE 20030902000182003090200018EA 2003 9 2 CA030730008 120030710G3710 BEARING DHAV DHC3 DHC3 2800202EA WSK ASZ62 ASZ62IRM18 NE HAMSTD23E 23E50 NE VACUUM PUMP FAILED W A UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 CA (CAN) BEARING FAILURE ON ACCESSORY GEARBOX VACUUM PUMP DRIVE (HOLLOW) SHAFT. THE BEARINGS (BUSHINGS) WERE FOUND SEIZED TO THE DRIVESHAFT AND BEARING -EXCESSIVE HEAT THRU FRICTION WAS THEN CREATED AND CAUSEDTHE ALUMINUM PLUG LOCATED INSIDE THE SHAFT TO MELT, WHICH THEN ALLOWED THE ACCESSORY GEARBOX OIL TO BE EXHAUSTED OVERBOARD. ENGINE LOST 8 GALLONS OF OIL IN 20 MINUTES, 3-4 MINUTES LONGER & THE ENGINE WOULD HAVE BEEN TOTALLY STARVED FOR OIL.THIS IS THE THIRD KNOWN FAILURE OF THIS PART IN AREA. 1H71 3R3 R A815 E10NE 6 CP603 20030902000192003090200019EU 2003 9 2 CA030730009 120030623G33206500111 CONTACTOR SAAB SF340 SF340A 7850100EU GE CT7TP CT79B 30030NE ROTOL R390 R3904123F27 NE BULB SOCKET SHORTED W HA DEACTIVATE SYST/CIRCUITSUNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA (CAN) AFTER TAKEOFF FROM YTH A SLIGHT SMOKE HAZE DEVELOPED IN THE CABIN WHEN THE LIGHTS WERE TURNED ON. A SHARP ODOR WAS ALSO NOTICED. THE CABIN LIGHTS WERE TURNED OFF AND THE AIRCRAFT RETURNED TO YTH. INSPECTION REVEALED THAT THE CONTACTS HAD SHORTED AND LAMP HOLDER WAS CHARGED ON THE CABIN LIGHT AT STA 7A. ALL OTHER LIGHTS APPEARED NORMAL. THE LIGHT FITTING AND TUBE AT STA 7A WIRE REPLACED AND THE LIGHTING SYSTEM TESTED NORMAL. NO REPEAT OF THE DEFECT HAS OCCURRED. 2L72 4T4 TRTA52EU E8NE 6 CP31NE 20030902000202003090200020SO 2003 9 2 CA030730010 120030716G32202075209 HOUSING PIPER PA30 PA30 7103002SO LYC O320 IO320B1A 41508EA HARTZLHCE2Y HCE2YL2 GL MLG CRACKED W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) FLUID LEAK FROM HOUSING ASSEMBLY. CRACK DETECTED. 1L72 3O3 O A1EA 1E12 5 CP9EA 20030902000212003090200021SO 2003 9 2 CA030731001 220030522G8500 ENGINE CESSNA180 180C 2072608CE CONT O470 O470K 17026SO MCAULY2A34C 2A34C203 GL OUT OF BALANCE W K NONE E VIBRATION/BUFFET ININSP/MAINT 1 CA (CAN) ENGINE WAS REMOVED DUE TO VIBRATION. ENGINE WAS FOUND TO BE DETUNED. NEW COUNTERWEIGHTS INSTALLED, ENGINE BALANCED AND RE-INSTALLED RECERTIFIED. 1H71 3O3 O 5A6 E273 5 CP3EA 20030902000222003090200022CE 2003 9 2 CA030731002 120030713G7603 CABLE CESSNA206 U206B 2073322CE CONT O520 IO520D 17032SO MCAULY3A32C D3A32C90 GL THROTTLE CONTROLBROKEN W O OTHER E VIBRATION/BUFFET TXTAXI/GRND HDL 1 CA (CAN) DURING TAXI OF AIRCRAFT ADVANCING THROTTLE WOULD NOT INCREASE ENGINE RPM. - INVESTIGATION SHOWED THROTTLE CABLE BROKEN IN ENGINE COMPARTMENT BETWEEN WIRE CABLE AT BASE OF SOLID PUSH ROD ON CONTROL ASSEMBLY (THROTTLE). 1H71 3O3 O A4CE E5CE 5 CP21EA 20030902000232003090200023GL 2003 9 2 CA030731003 220030704G72506886407 BLADE ALLSN BELL 206 206B 1181511SW ALLSN 250C 250C20 03013GL TURBINE WHEEL BROKEN W B EMER. DESCENT DM INFLIGHT SEPARATION OVER TEMP CRCRUISE 1 CA X140758 (CAN) IN-FLIGHT CRUISE CONFIGURATION, HIGH PITCH WHINE STARTED, TOT INCREASED FROM APPROXIMATELY 700 DEGREES C TO 760 DEGREES C. EMERGENCY DESCENT - RUN ON LANDING AT LOCAL AIRPORT. TEARDOWN INSPECTION TO FOLLOW (SUMMARY OF FINDINGS). INITIAL VISUAL (PRE TEARDOWN) INSPECTION REVEALS ONE FRACTURED 1ST STAGE BLADE (APPROXIMATELY 65 PERCENT MISSING) AND PIECES MISSING FROM MANY OTHER BLADE TIPS. LEADING EDGE OF ALL BLADES APPEAR TO BE ABRADED BY FOREIGN OBJECT (FAILED BLADE). NR 8 BEARING HEAT SHIELD AND 1ST STAGE NOZZLE APPEAR TO BE IN GOOD CONDITION (NO OVERTEMP). 1G71 3U3 U H2SW E4CE 20030902000242003090200024CE 2003 9 2 CA030731004 120030717G2730051011110 PUSHROD TUBE CESSNA CESSNA185 A185F 2072821CE CONT O520 IO520D 17032SO MCAULY2A34C D2A34C58 GL ELEVATORS STUCK W D RETURN TO BLOCK CFWF.O.D. FLT CONT AFFECTED INADEQUATE Q C TXTAXI/GRND HDL 1 CA (CAN) ELEVATOR CONTROL JAMMED ON PREFLT FUNCTION TEST. COMPLETE SYSTEM INSPECTED FOR FAULT. FINDINGS: LOOSE NUT (FOD) NR NAS 697A6 FOUND STUCK ON TOP OF ELEVATOR PUSH ROD NR 0510111-10 AT BELLCRANK ASSEMBLY NR 0761202-50 ATTACHMENT. RESTRAINING ELEVATOR MOVEMENT TO THE LOWER STOP. THAT NUT WAS PROBABLY LOST ON TOP OF LOWER ELEVATOR CONTROL STOP - ELEVATOR LOWER NR 0510146-9 AND WAS LEFT THERE UNTAKEN CARE OF AND UNDETECTED FOR YEARS THERE AFTER. THIS NUT I S OFF VERTICAL FIN FORWARD INSTALLATION BOLTS NR AN6-7A. LAST SUSPECTED REMOVAL AND REASSEMBLY OF VERTICAL FIN (WITH NEW NUTS) MAY 1990. AIRCRAFT MAINT TECH SHOULD 'NEVER' LEAVE 'LOST' AND 'UNFOUND' HARDWARE IN AN AIRFRAME. JUST LIVE TOOLS. 1H71 3O3 O 3A24 E5CE 5 CP3EA 20030902000252003090200025EA 2003 9 2 CA030731005 120030715G552060010300563 BUSHING CNDAIRCL601 CL6012A12 1900303EA GE CF34 CF343A 30015NE ELEVATOR FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) AFTER COMPLETION OF TASK, INSPECT ELEVATOR ATTACH BOLTS, VISUAL AND NDT INSPECTION, AND DURING POST INSTALLATION/INDEPENDENT INSPECTION, INSPECTOR NOTICED CLICKING NOISE, FOLLOWING INVESTIGATION FOUND (LT ELEVATOR): LT ELEVATOR ATTACH FITTING CRACKED, DURING LT ELEVATOR REMOVAL FOUND BUSHING MISSING AT PCU TO ELEVATOR ATTACHMENT HARDWARE/OUTBOARD. ALSO FOUND AT INBOARD PCU (LT), BUSHING MISSING WHICH REVEALED 2 CRACKS ON LT ELEVATOR ATTACH FITTING PROPOGAGING FROM HOLE TOP & BOTTOM AREA. RT ELEVATOR NO DEFECT FOUND. PARTS NOT AVAILABLE AT THIS TIME, LOANER ELEVATOR TO BE INSTALLED. 2L72 4F4 FRTA21AE E15NE 20030902000262003090200026SO 2003 9 2 CA030731006 120030629G3220 LANDING GEAR PIPER PA34 PA34200 7103405SO LYC O360 IO360C1E6 41514EA HARTZLHCC2Y HCC2YK2 GL NOSE COLLAPSED W O OTHER O OTHER LDLANDING 1 CA (CAN) ON LANDING NOSE WHEEL COLLAPSED WHILE TOWING AIRCRAFT TO HANGAR. RIGHT MAIN GEAR COLLAPSED. 1L72 3O3 O A7SO 1E10 5 CP920 20030902000272003090200027SO 2003 9 2 CA030731007 220030701G85506521718 DIPSTICK CIRRUSSR SR22 2130001GL CONT O550 IO550N 17042SO HARTZLHCJ3Y PHCJ3YF1 GL OIL BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE DIPSTICK SEPARATED & BROKE OFF FROM THE CAP. 1L71 3O3 ONTA00009CHE3SO 5 CP36EA 20030902000282003090200028NE 2003 9 2 CA030731008 220030708G8530399353 CYLINDER HEAD DHAV DHC2 DHC2MK1 2800102EA PWA R985 R985AN14B 52008NE HAMSTD2D 2D30 NE ENGINE BROKEN W A UNSCHED LANDING E VIBRATION/BUFFET CRCRUISE 1 CA (CAN) CYLINDER HEAD OF NR 7 ASSEMBLY BROKE/SEPARATED IN CRUISE FLT. ENGINE ONLY 36.9 HOURS TTSO. METAL FATIGUE OR OIL LOCK ON PREVIOUS ENGINE START SUSPECTED. OVERHAUL ASSEMBLY INSTALLED, GROUND RUN AND FOUND SATISFACTORY. 1H71 3R3 R A806 5E1 5 CP206 20030902000292003090200029EA 2003 9 2 CA030731009 220030711G8520STD705 BOLT CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA MCAULY1A103 1A103TCM GL IDLER GEAR LOOSE W K NONE O OTHER ININSP/MAINT 1 CA 10730 (CAN) ON OVERHAUL DISASSEMBLY OF THE ENGINE, WE NOTICED THAT THE TWO BOLTS HOLDING THE IDLER GEAR SHAFT UNSCREWED AND THE LOCK PLATES HALF WAY ON THE BOLTS. THIS PROVOKE THE WITHDRAWAL OF THE IDLER GEAR AND CAUSED AN ENGINE SHUTDOWN. THE MANUFACTURER PERFORMED THE LAST OVERHAUL. 1H71 3O3 ONT3A19 E223 5 NP50GL 20030902000302003090200030CE 2003 9 2 CA030731010 120030718G553004310093 BRACKET CESSNA CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA MCAULY1A103 1A103TCM GL VERTICAL STAB CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 10991 (CAN) DURING ROUTINE 200 HOUR INSPECTION THE FORWARD LT VERTICAL FIN ATTACHMENT BRACKET APPEARED TO BE CRACKED ALONG THE BASE EXTERNAL SURFACE WHERE IT MATES WITH THE VERTICAL TABS OF THE PART. DISASSEMBLY REVEALED THE CRACK EXTENDED FORWARD AND AFT ALONG THIS DIMENSION. THE DEFECTIVE BRACKET WAS REPLACED AND AIRCRAFT RETURNED TO SERVICE. 1H71 3O3 ONT3A19 E223 5 NP50GL 20030902000312003090200031CE 2003 9 2 CA030731011 120030609G3240651710917 LINE CESSNA500 560CESSNA 2076750CE PWA 530 PW535A NE BRAKE SYSTEM CHAFED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) LT AND RT BRAKE HYD LINES WERE FOUND TO BE CHAFING ON ELEVATOR CONTROL CABLES AT F.S.178.00. THIS DISCREPANCY IS BELIEVED TO HAVE OCCURRED AT MANUFACTURE. AS THIS WAS THE FIRST TIME THE FLOOR PANEL HAD BEEN REMOVED. THIS AREA IS A PLACE WHERE THE HYDRAULIC BRAKE LINES RUN LATERALLY ACROSS THE FLIGHT CONTROL CABLES. THE PROBLEM WAS RECTIFIED BY REPLACING BOTH LINES ASSEMBLIES AND REPOSITIONING TWO ADJACENT ADEL CLAMPS AS TO PROVIDE MAXIMUM CLEARANCE. THE GENERAL AREA IS 1.0 FT FORWARD OF CABIN DOOR UNDER CENTER FLOORBOARD. LT BRAKE HYD LINE P/N 6517109-17 RT BRAKE HYDRAULIC LINE P/N 6517109-18. 2L72 4F4 FRTA22CE E00053EN 20030902000322003090200032GL 2003 9 2 CA030731012 220030727G73236870035 TUBE BELL 206 206B 1181511SW ALLSN 250C 250C20 03013GL GOVENOR BROKEN W B EMER. DESCENT D INFLIGHT SEPARATION CRCRUISE 1 CA (CAN) A/C WAS ON APROCH 1000 FT ABOVE GROUND ON A RECONNAISSANCE FLIGHT OVER A FOREST FIRE WHEN THE PILOT AND PASSENGER BOTH HEARD A 'POP'. THE ENGINE DECELERATED TO IDLE. AN AUTOROTATION WAS CARRIED OUT TO A MUSKEG AREA WHERE ON TOUCHDOWN THE MAIN ROTOR BLADE SEVERED THE TAILBOOM. IT WAS FOUND THAT THE PC LINE FROME THE GOVENOR TO THE FUEL CONTROL HAD BROKEN. 1G71 3U3 U H2SW E4CE 20030908002112003090800211NE 2003 9 8 CA030731013 220030712G72503020159 RING PWA PT6 PT6A114A 52043NE CT SHROUD MISSING W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ENGINE OVERHAULED IN MAY, 2001 AND RETURNED TO OPERATOR & WHO NOTED THE PERFORMANCE OF ENG HAD DETERIORATED & ENG WAS SENT BACK TO OVERHAULED SHOP. OVERHAUL SHOP DISCOVERED CT SHROUD SEGMENT RETAINING RING WAS NOT INSTALLED IN ITS GROOVE BUT HAD MOVED REARWARDS & JUMPED OVER RETAINING LIP OF THE CT SHROUD HOUSING CAUSING SOME FRETTING WEAR ON THE HOUSING. THIS MOVEMENT OF RETAINING RING ELIMINATED ANY PHYSICAL IMPEDIMENT TO CT SHROUD SEGMENTS, WHICH HAD MIGRATED REARWARDS & LOST LOCATION. THIS CAUSED A HEAVY TIP RUB WITH CT BLADES AND ATLANTIC TURBINES ATTRIBUTES SUBSTANTIAL LOSS OF PERFORMANCE TO THIS RUB. CT SHROUD SEGMENTS WERE REPLACED & CT BLADES WERE WORN BELOW MINIMUM LENGTH ALSO REPLACED. 3 T E4EA 20030904001282003090400128EU 2003 9 4 CA030731015 220030724G7210602070009 GEARBOX BRAERO748 HS7482A 4231001EU RROYCEDART DART5342 EU ROTOL R4304 R2124304 EU RIGHT FAILED W EA ENGINE SHUTDOWN UNSCHED LANDING O OTHER CLCLIMB 1 CA (CAN) ON CLIMBOUT THE STARBOARD GEARBOX FAILED. ENGINE WAS SHUTDOWN AND AIRCRAFT RETURNED TO YNA. AIRCRAFT WAS CHECKED BY AN ENGINEER AND WAS CONFIRMED GEARBOX FAILURE. THE DRIVESHAFT GD2016 S/N DR6306/65 WAS REMOVED, ENGINE CHECKED. AIRCRAFT FERRIED BACK TO YXY BASE ON FERRY FLIGHT, AIRCRAFT RETURNED TO SERVICE. 2L72 3T4 T A24EU A196 6 CP899 20030908002122003090800212EU 2003 9 8 CA030731016 120030724G2910 LINE BRAERO748 HS7482A 4231001EU RROYCEDART DART5342 EU HYD SYSTEM LEAKING W A UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION NRNOT REPORTED 1 CA (CAN) WHILE ENROUTE BOTH THE STARBOAD AND PORT HYDRAULIC PUMP LOW FLOW WARNING LIGHTS ILLUMINATED AND THE SYSTEM PRESSURE DROPPED TO ABOUT 1600-1700 PSI AND SEEMED TO STABILIZE AT THAT RANGE. AIRCRAFT WAS DIVERTED TO YXY. THE LANDING GEAR EXTENDED NORMALLY. A LEAK WAS FOUND IN A HYDRAULIC LINE AND THE HYDRAULIC OIL LEVEL HAD DROPPED. THE HYDRAULIC LINE FROM THE HYDRAULIC FILTER IN LT NACELLE WAS FOUND LOOSE, LINE WAS TIGHTENED, FLUID REPLENISHED, HYDRAULIC SYSTEM BLED AND CHECKED, NO LEAKS. AIRCRAFT RETURNED TO SERVICE. 2L72 3T4 T A24EU A196 20030908002132003090800213NM 2003 9 8 CA030731017 120030729G2730654476114 PCU BOEING737 737204 1384458NM PWA JT8 JT8D15 52051NE ELEVATOR LEAKING W BA EMER. DESCENT UNSCHED LANDING BJ SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CRCRUISE 1 CA (CAN) IN CRUISE, FLT CREW REPORTED AN APU FIRE INDICATION. CREW FOLLOWED CHECKLISTS, DISCHARGED APU FIRE BOTTLE, DECLARED AN EMERGENCY & REQUESTED CLEARANCE DIRECTLY TO YWG. APU FIRE WARNING LIGHT REMAINED ON AND CREW ADVISED OF ABNORMAL LANDING CONFIGURATION. A/C LANDED WITHOUT INCIDENT, CFR CALLED OUT (NO FIRE INDICATION). AIRCRAFT TAXIED TO GATE. MAINTENANCE INSPECTION REVEALED NO FIRE INDICATION. APU & APU FIRE DETECTION SYSTEM MEL'D. AT NEXT RON, A/C INSPECTED & MAINTENANCE FOUND LT ELEVATOR PCU LEAKING HYD FLUID ONTO APU EXHAUST DUCTING. MAINTENANCE REPLACED PCU & GROUND CHECKED SERVICEABLE - NO LEAKS. APU FIRE DETECTION SYSTEM TESTED. NO FAULTS FOUND. A/C RETURNED TO SERVICE. 2L72 4F4 F A16WE E2EA 20030905000012003090500001CE 2003 9 5 CA030731018 120030730G5497 WIRE BEECH 99 99 1154002CE PWA PT6 PT6A20 52043EA LT NACELLE CHAFED W EA ENGINE SHUTDOWN UNSCHED LANDING N FALSE WARNING CLCLIMB 1 CA (CAN) SHORTLY AFTER TAKE OFF FROM FORT SMITH THE OIL PRESSURE INDICATION ON THE LT ENGINE DROPPED TO ZERO AND THE OIL PRESSURE LIGHT CAME ON. A PRECAUTIONARY SHUTDOWN WAS CARRIED OUT AND THE A/C RETURNED TO FORT SMITH. ON INVESTIGATION IT WAS DISCOVERED THAT A WIRE BUNDLE WAS CHAFING ON THE NACELLE UPPER DOOR NEAR THE OIL PRESSURE TRANSMITTER. THE WIRES WERE CHAFED RIGHT THROUGH TO BARE WIRE AND THEY SHORTED TO THE DOOR.THIS CAUSED THE OIL PRESSURE INDICATION TO DROP OFF, AS IF THE ENGINE HAD LOST PRESSURE SUDDENLY. 1L72 3T3 T A14CE E4EA 20030908002142003090800214EA 2003 9 8 CA030731019 220030717G72303031801 BLADE BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA COMPRESSOR FRACTURED W A UNSCHED LANDING YJ ENGINE STOPPAGE WARNING INDICATION CLCLIMB 1 CA (CAN) COMPRESSOR TURBINE BLADE FRACTURED CAUSING COMPLETE ENGINE FAILURE AT APPROX. 40KNOTS FORWARD AIRSPEED, PILOT CARRIED OUT EMERGENCY LANDING.ENGINE REMOVED FOR EXAMINATION BY PWC. 1G71 4U4 U H4SW E22EA 20030905000022003090500002SW 2003 9 5 CA030731020 120030729G632070061L275W210A HOSE BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA GEARBOX OIL RUPTURED W A UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 CA (CAN) TRANSMISSION OIL HOSE SWOLLEN AND BLOWN APPROX.6 INCHES FROM FITTING.PILOT HAD LOW OIL PRESSURE WARNING LIGHTCOME ON AND CARRIED OUT PRECAUTIONARY LANDING TO INVESTIGATE. HOSE IS SUBJECT TO TENSION AND TORSION AS TRANSMISSION IS MOUNTED WITH LORD RUBBER MOUNTS. INVESTIGATING HOSE TSN AND CAUSE. 1G71 4U4 U H4SW E22EA 20030908002152003090800215NM 2003 9 8 CA030801001 120030723G2612 FIRE DETECTOR BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA NR 2 ENGINE MALFUNCTIONED W K NONE N FALSE WARNING ININSP/MAINT 1 CA (CAN) DURING TURN-AROUND A/C UNATTENDED FOR APPROX. 15 MINUTES. WHEN FLIGHT CREW RETURNED TO COCKPIT, NR 2 ENGINE FIRE WARNING WAS ON. PULLED TEE HANDLE.DID NOT DISCHARGE FIRE BOTTLES. CYCLED RT CBS F2, J7, K7, NO HELP. DURING CALL TO MTX CONTROL, WARNING STOPPED. MECHANICS DISPATCHED, NO EVIDENCE OF ACTUAL FIRE AND SYSTEM TEST NORMAL SO AIRCRAFT FERRIED TO BASE FOR PEC APD REPLACEMENT. SB 842603 HAS BEEN ISSUE TO ADDRESS THIS PROBLEM. 2H72 4T4 TRTA13NM E00062EN 20030905000212003090500021NE 2003 9 5 CA030803001 220030802G8500 ENGINE DOUG DC4 C54GDC 3021534WP PWA R2000 R2000* 52023NE MAKING METAL W EO ENGINE SHUTDOWN OTHER JM WARNING INDICATION OVER TEMP CRCRUISE 1 CA (CAN) THIS AIRCRAFT WAS ACTIONING A FOREST FIRE AS AN AIR TANKER AND IT WAS NOTICED THAT THE OIL PRESSURE WAS LOWER THAN NORMAL AND THE OIL TEMPERATURE WAS STARTING TO CLIMB FROM NORMAL. THE ENGINE WAS SHUT DOWN AND THE PROPELLER FEATHERED, THE AIRCRAFT RETURNED TO ITS BASE AND UPON INSPECTION IT WAS FOUND THE ENGINE WAS STIFF WHEN THE PROPELLER WAS MOVED.ALTHOUGH VERY LITTLE METAL WAS FOUND IN THE OIL SCREEN IT WAS CONSIDERED AN INTERNAL FAILURE OF UNKNOWN CAUSES AND THE ENGINE WAS REMOVED AND REPLACED. THE ENGINE WILL BE SENT TO THE OVERHAUL FACILITY TO DETERMINE ITS NATURE. 2L74 4R4 R A762 5E5 20030905000232003090500023CE 2003 9 5 CA030804001 120030804G215011791W5635 HOSE BEECH B300 B300B350C CE PWA PT6 PT6A60A 52043NE RT ENGINE FREON DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING INSPECTION FOUND FREON DISCHARGE HOSE ON RT ENGINE WITH BUBBLES IN EXTERIOR RUBBER SLEEVING. NEW HOSE INSTALLED, AND SYSTEM SERVICED. 2L72 4T4 TRTA24CE E4EA 20030908002162003090800216NM 2003 9 8 CA030805001 120030802G3340 LANDING LIGHT BOEING737 737217 1384464NM PWA JT8 JT8D17 52049NE LT PYLON FIRE W O OTHER B SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 CA (CAN) DURING TROUBLESHOOTING OF AN OUTBOARD (LT HAND) LANDING LIGHT SNAG MAINTENANCENOTICED SMOKE ODOR IN THE COCKPIT AND THEN SEVERAL C/BS POPPED. MAINTENANCE SHUT ALL AIRCRAFT POWER DOWN. SMOKE WAS NOTICED BY MAINTENANCE COMING FROM THE LT PYLON AREA FWD. PYLON PANEL WAS REMOVED AND BURNED WIRING WAS DISCOVERED IN MAIN WIRE BUNDLE. AIRCRAFT IS BEING REPAIRED AND A FULL INVESTIGATION IS UNDERWAY. FURTHER INFORMATION WILL FOLLOW AS IT BECOMES AVAILABLE. 2L72 4F4 F A16WE E2EA 20030905000282003090500028SO 2003 9 5 CA030805002 220030722G7310 LINE CESSNA185 A185F 2072821CE CONT O520 IO520D 17032SO MCAULY2A34C D2A34C58 GL FUEL SYS PLUGGED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) AIRCRAFT IS EQUIPPED WITH AN AFTERMARKET 6 CYLINDER EXHAUST GAS TEMPERATURE ENGINE MONITOR. DURING BREAK-IN PERIOD FOR FACTORY REMANUFACTURED ENGINE, NR 4 CYLINDER EGT RAN 200 DEGREES F HIGHER THAN THE OTHER FIVE CYLINDERS. TROUBLESHOOTING EVENTUALLY FOUND A PLUGGED INJECTOR LINE TO NR 4 CYLINDER. PLUG WAS AN UNKNOWN WHITE POWDERY MATERIAL. PLUG WAS REMOVED, LINE CALIBRATED, ENGINE RETURNED TO SERVICE. NR 4 CYLINDER EGT NORMAL. CESSNA ENGINE GAUGES READ NORMAL BEFORE AND AFTER PROBLEM AND DID NOT INDICATE A PLUGGED FUEL LINE. 1H71 3O3 O 3A24 E5CE 5 CP3EA 20030908002172003090800217NM 2003 9 8 CA030805003 120030722G5320 SUPPORT BOEING727 72722 1384002NM PWA JT8 JT8D7B 52053NE NLG WW CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) DURING 'C' CHECK INSPECTION, NOSE WHEEL WELL SUPPORT FOUND CRACKED BS 294 RBL 12. REPAIR CARRIED OUT AS PER SRM. 2L73 4F4 F A3WE E2EA 20030905000472003090500047NM 2003 9 5 CA030805004 120030702G7603BACC13AA3TSS6506CONTROL CABLE BOEING727 72722 1384002NM PWA JT8 JT8D7B 52053NE THRUST FRAYED W O OTHER O OTHER NRNOT REPORTED 1 CA 54767 (CAN) DURING INSPECTION OF THE STATION 870 AREA AT 'C' CHECK, IT WAS FOUND THAT THE NR 3 ENGINE THRUST CABLE WAS FRAYED TO THE POINT OF ONE (1) STRAND REMAINING. THE CAUSE WAS IMPROPER ROUTING OF THE CABLE. THE CABLE WAS NOT ON THE PULLEY AND WAS CHAFING ON THE PULLEY BRACKET. THE PULLEY/CABLE SECURING PIN WAS IN PLACE. THIS AREA WAS LAST ACCESSED DURING THE PREVIOUS 'C' CHECK. 2L73 4F4 F A3WE E2EA 20030905000502003090500050SO 2003 9 5 CA030805005 120030725G3297 WIRE PIPER PA23 PA23250 7102308SO LYC O540 IO540C4B5 41532EA NLG BROKEN W EL ENGINE SHUTDOWN ABORTED APPROACH O OTHER APAPPROACH 1 CA (CAN) ON APPROACH THE NOSE GEAR INDICATION LIGHT WAS NOT ILLUMINATED. AFTER A FEW RETRACTIONS OF THE LANDING GEAR, THE PILOT PERFORMED A LOW APPROACH TO OVERSHOOT TO CONFIRM VISUALLY THAT THE GEAR WAS DOWN. A PRECAUTIONARY ENGINE OFF LANDING WAS CARRIED OUT. FURTHER INSPECTION REVEALED THAT A WIRE LEADING TO THE NOSE LANDING GEAR SWITCH WAS BROKEN. THE WIRE WAS REPAIRED AND THE AIRCRAFT WAS RETURNED TO SERVICE. 1L72 3O3 O 1A10 1E4 20030908002182003090800218EU 2003 9 8 CA030805006 120030803G3251C20216338203 CONTROL UNIT AIRBUS320 A320231 3930325EU IAE V2500 V2500A1 NE NLG STEERING FAILED W O OTHER ZF SIGNIFICANT FAILURE REPORTFLT CONT AFFECTED LDLANDING 1 CA (CAN) ON APPROACH, AC APPROACH STATUS REVERTED TO CAT III SINGLE WITH WHEEL PAGE SHOWING AMBER STEERING. N/W STEERING SWITCH CYCLED OFF THEN ON WITH INDICATIONS RETURNING TO NORMAL AND CAT III DUAL. UPON LANDING, IDLE REVERSE WAS SELECTED(NOISE ABATEMENT) BUT WHEN LOSS OF BRAKING WAS IDENTIFIED, MAX REVERSE WAS SELECTED AND NLG STEERING SELECTED OFF/ON BUT NORMAL BRAKING WAS NOT RESTORED. NWS SELECTED OFF AND ACCUMULATOR PRESSURE WAS USED TO BRING AC TO A STOP. THREE MLG TIRES BURST AND THE LAST ONE WAS BADLY SCUFFED. FAULT WAS IDENTIFIED AS A DUAL FAILURE OF THE BRAKING/STEERING CONTROL UNIT (BSCU) WHICH IS CURRENTLY BEING SENT FOR EXPERTISE. CVR AND FDR ARE BEING SENT FOR ANALYSIS. 2L72 4F4 FRTA28NM E311NE 20030908002192003090800219WP 2003 9 8 CA030805007 120030726G4990GTC8598DHF APU DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE APU BAY FAILED W O OTHER MJ OVER TEMP WARNING INDICATION CRCRUISE 1 CA (CAN) APU HAD TO BE SHUTDOWN DUE TO HIGH OIL TEMPERATURE. EMERGENCY DECLARED AS ONE CSD WAS PREVIOUSLY DISCONNECTED AND ON MEL, APU WAS GROUND RUN, OIL LEVEL CHECKED, EVERYTHING WAS BACK TO NORMAL. AIRCRAFT RETURNED TO SERVICE. NO PROBLEM FOR THE REST OF THE FLIGHT. 2L72 4F4 FRTA6WE E9NE 20030904000232003090400023CE 2003 9 4 CA030805008 120030513G3397 WIRE BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3I NE ZONE 281 CHAFED W K NONE H ELECT. POWER LOSS-50 PC ININSP/MAINT 1 CA 16604 (CAN) TAIL FLOOD LIGHTS UNSERVICEABLE.TAIL FLOOD LIGHT LAMPS CHECKED. NO FAULT FOUND, VOLTAGE CHECKED & NONE PRESENT. LOCATED CIRCUIT BREAKER & IT WAS FOUND TRIPPED. RESET C/B & TRIPPED RIGHT AWAY. FAULT NOW KNOWN TO BE A DEAD SHORT. SUSPECTING WIRING IN EMPENNAGE SECTION OF A/C. LOCATED PLUG P393 (AFT PRESSURE BULKHEAD CONNECTOR) AND FOUND THAT WIRING HAS BEEN CHAFED BY ACTUAL BACKUP LINER. WIRING REPLACED & WIRING ENCLOSED IN SPIRAL WRAP. TAIL FLOOD LIGHTS CHECKING SERVICEABLE. PLUG P393 ALSO INCLUDES OTHER LIGHTING SYSTEMS & ELECTRIC ELEVATOR TRIM RELAY. NO OTHER WIRING OTHER THAN FLOOD LIGHT WIRING AFFECTED AT THIS TIME. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20030908002202003090800220NM 2003 9 8 CA030805009 120030804G3244H31X97513 TIRE DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE MLG FAILED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) MULTIPLE FAILURES OF THE NR 1 & 3 MAIN WHEEL TIRES, 6 INCH LONG RUPTURES FOUND ON SIDEWALLS OF TIRES DURING A LINE CHECK. TIRES STILL HELD AIR BUT INNER CORDS WERE FULLY EXPOSED. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030908002212003090800221NM 2003 9 8 CA030805010 120030804G3244 TIRE DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE MLG RUPTURED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) LARGE RUPTURE ON SIDEWALL OF TIRE FOUND AFTER LANDING OF AIRCRAFT ON THE NR 1 POSTION RECAPPED TIRE. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030904000342003090400034EU 2003 9 4 CA030805011 120030803G2497350A62252020 WIRE SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE BATTERY DAMAGED W BA EMER. DESCENT UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CLCLIMB 1 CA (CAN) JUST AFTER TAKE OFF THE PILOT & PASSENGERS NOTICED SMOKE COMING IN THE CABIN OF AIRCRAFT. PILOT OPENED DOOR TO VENT SMOKE OUT OF CABIN. PILOT LANDED AS SOON AS PRATICAL. AFTER LANDING INSTRUCTED PASSENGERS TO EXIT A/C, SHUT DOWN THE ENGINE , CLOSED THE FUEL VALVE AND ELECTRICS OFF. THE PILOT GRABBED THE FIRE EXTINGUISHER AND OPENUP THE THE RT BAGGAGE COMPARTMENT WHERE THE FIRE WAS LOCATED. THE PILOT PULLED EVERYTHING THAT WAS ON FIRE OUTOUT OF THE BAGGAGE COMPARTMENT AND EXTINGUISHED THE ON FIRE ITEMS. THE FUSE HOLDER FOR THE EMERGENCY ELECTRICAL POWER CUT OFF SWITCH HAD A SHORT AGAINST THE BATTERY BULKHEAD. THIS CREATED SPARKS WHICH IGNITED PAPER AND GEAR STORED IN THE BAGGAGE COMPARTMENT. 1G71 3U3 U H9EU E19EU 20030904000352003090400035SO 2003 9 4 CA030806001 120030717G57125037707 RIB PIPER PA31T PA31T 7103124SO PWA PT6 PT6A28 EA RT WING CRACKED W O OTHER O OTHER CLCLIMB 1 CA (CAN) UPON GEAR RETRACTION, AFTER TAKE OFF, THE LANDING GEAR WOULD NOT LOCK UP IN THE GEAR WELL. UPON INSPECTION, THE RIGHT MAIN GEAR ACTUATOR ATTACHMENT RIB WAS FOUND TO BE CRACKED BEHIND THE ACTUATOR BRACKET. THIS CRACK CAUSED THE RIGHT MAIN GEAR TO HANG BELOW THE UP LOCK HOOK; PREVENTING IT TO LOCK IN THE UP POSITION. 1L72 3T4 T A8EA E4EA 20030904000392003090400039EA 2003 9 4 CA030806002 120030717G2910 LINE CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE HYS SYSTEM LEAKING W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) ON ARRIVAL FOUND NR 1 HYD SYSTEM QTY AT 0 PERCENT. LARGE HYD LEAK NOTICED IN AFT SERVICE COMPARTMENT. FOUND LINE LEAKING IN AFT COMPARTMENT. NEW LINE FABRICATED AND INSTALLED.SYSTEM FLUSHED. NR 1 EDP REPLACED DUE DISENTIGRATION. ALL FOUR HYD FILTERS REPLACED. SYSTEM SERVICED AND CHECKED SERVICABLE. 2L72 4F4 FRTA21EA E15NE 20030908002222003090800222EU 2003 9 8 CA030806003 120030720G2720 RUDDER AIRBUS320 A320211 3930320EU CFMINTCFM56 CFM565A1 NE TAIL OUT OF ADJUST W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING FLIGHT CONTROL CHECK AT GATE FOUND RUDDER TRAVEL STOPS SHORT OF FULL DEFLECTION TO THE LEFT. ADJUSTED RUDDER MECHANICAL CONTROL IAW AMM. TESTED ARTIFICIAL FEEL AND RTL. IAW AMM AND ALL CHECKED SERVICABLE. 2L72 4F4 FRTA28NM E29NE 20030908002232003090800223NM 2003 9 8 CA030806004 120030725G27512061141 INDICATOR BOEING737 737201 1384454NM PWA JT8 JT8D9A 52048NE TE FLAP FAILED W A UNSCHED LANDING N FALSE WARNING CLCLIMB 1 CA (CAN) FLAPS WILL NOT COME UP, AIRCRAFT RETURNED TO WHITEHORSE. FLAP INDICATOR REPLACED IAW MM 27-58-41 PAGE 401. TEST CARRIED OUT, OPERATION CHECKED FOUND NORMAL. AIRCRAFT ENROUTE ON SCHEDULED FLIGHT. 2L72 4F4 F A16WE E2EA 20030908002242003090800224SW 2003 9 8 CA030806005 120030729G2435150SG1028 STARTER GEN BELL 206 206B 1181511SW ALLSN 250C 250C20 03013GL ENGINE WORN W A UNSCHED LANDING H ELECT. POWER LOSS-50 PC NRNOT REPORTED 1 CA (CAN) STARTER GEN FAILED IN FLT. PILOT OBSERVED A GENERATOR FAIL LIGHT ON, & LANDED SAFELY. UNIT REMOVED & SENT TO AMO FOR INSPECTION. FOUND THE DRIVE END BEARING LINER LOOSE IN ITS CAST ENDBELL. LOOSENESS PERMITTED ARMATURE TO CONTACT STATOR, CAUSING METAL TO HEAT FROM FRICTION & COME APART, SEIZING THE GENERATOR & SHEARING THE QUILL SECTION OF THE DRIVE SHAFT. DRIVE END BEARING LINER IS A STEEL PART CAST INTO THE ENDBELL. IT CAME LOOSE & BEGAN TO TURN WITH THE BEARING & ARMATURE. THE OUTER SURFACE OF THE STEEL LINER, WHICH IS KNURLED BEFORE BEING CAST INTO THE ALUMINUM END BELL, CHEWED THE ENDBELL UNTIL CLEARANCE BETWEEN THE ARMATURE & THE STATOR POLES WAS ZERO. 1G71 3U3 U H2SW E4CE 20030908002252003090800225EA 2003 9 8 CA030806006 120030806G3246C2UF1761 BLOCK BRSTOL DHAV DHC2 DHC2MK1 2800102EA PWA R985 R98539 52008NE HAMSTD2D 2D30 NE RT FLOAT CRACKED W K NONE O OTHER ININSP/MAINT 1 CA BA2329 (CAN) FOUND BEARING BLOCK ASSY. (AFT END OF HYD. CYL.) IN RT FLOAT FOR NOSE WHEEL HAD CRACKED THROUGH CENTER ALLOWING JACK PICK UP BEARING TO MOVE OUT OF BLOCK ASSY AND FORCE CHANNEL ASSY OUT OF POSITION. BLOCK ASSY APPEARED TO HAVE BEEN FRACTURED FOR SOME TIME BEFORE COMPLETE FAILURE. FRACTURE OR CRACKS ARE NOT DETECTABLE WHEN HYD. CYL. AND BEARING BLOCK ARE ASSEMBLED IN FLOAT. 1H71 3R3 R A806 5E1 5 CP206 20030904000482003090400048EA 2003 9 4 CA030806007 220030716G8520AEL18840 LIFTER CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA MCAULY1C160 1C160DTM GL ENGINE WORN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) METAL FOUND IN FILTER DURING INSPECTION AFTER 62.3 HOURS SINCE OVERHAUL. ENGINE DISMANTLED CAMSHAFT AND LIFTERS FAILED. 1H71 3O3 ONT3A12 E274 5 NP910 20030908002262003090800226NM 2003 9 8 CA030806008 120030712G2710550030011 ACTUATOR BOEING767 767233 1385113NM PWA JT9 JT9D7R4D 52054NE RT AILERON MALFUNCTIONED W O OTHER F FLT CONT AFFECTED APAPPROACH 1 CA (CAN) EICAS MSG, AILERON LOCKOUT. OCURRED AT 10,000 FT AT 250 KTS (APPROACH). RT OUTBOARD AILERON LOCKOUT ACTUATOR REPLACED AS PER MM CHECKS SERVICABLE 2L72 4F4 FRTA1NM E3NE 20030908002272003090800227GL 2003 9 8 CA030806009 320030805G6111 BLADE AAR HARTZLHCE3Y HCE3YR2A GL PROPELLER HUB LOOSE W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) PROP (OVERHAULED IN NOV/2000) WAS PURCHASED AND INSTALLED ON PA31 AIRCRAFT. AT 51.6 HOURS SINCE OVERHAUL, 2 OF 3 PROP BLADES WERE NOTICED TO BE VERY LOOSE WHEN MANIPULATED FORE AND AFT AT THE PROP TIP.ONE BLADE IN PARTICULAR MOVED SIGNIFICANTLY. DISCUSSIONS WITH OUR USUAL PROPELLOR OVERHAUL SHOP (NOT WHERE WE BOUGHT THE PROP) CONFIRMED THAT WE SHOULD REMOVE THE PROP AND SEND FOR REPAIR. THEY SURMISED THAT THE PROP NEEDED ADJUSTMENT (TIGHTENING). PROP WAS REMOVED AND SENT FOR REPAIR TO OUR USUAL PROP OVERHAUL FACILITY. (NOT FOR WARRANTY TO COMPANY THAT PROPWAS PURCHASED FROM). TEARDOWN REPORT AND FINDINGS TO BE ENTERED WHEN COMPLETED. 5 CP33EA 20030908002282003090800228EU 2003 9 8 CA030807001 120030719G29132244404523 B-NUT AIRBUS310 A310 EU CASE DRAIN LINE CRACKED W O OTHER K FLUID LOSS CRCRUISE 1 CA (CAN) DURING FLT, THE AIRCRAFT LOST THE B-HYDRAULIC FLUID SYSTEM. DURING INVESTIGATION THE B-NUT WAS FOUND CRACKED ON THE NR 1 ENGINE DRIVEN PUMP CASE DRAIN LINE. THE LINE ASSEMBLY WAS REPLACED, THE HYDRAULIC PUMP WAS REPLACED AS PRECAUTIONARY MEASURE AND THE GREEN HYDRAULIC SYSTEM FLUSHED. 2L72 4F RTA35EU 20030904001092003090400109EA 2003 9 4 CA030807002 120030805G261247259701 CONTROLLER CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE FIRE DETECTION MALFUNCTIONED W O OTHER N FALSE WARNING APAPPROACH 1 CA (CAN) A/C HAD MULTIPLE WARNINGS ON APPROACH. APU FIRE INDICATOR. (APU RUNNING DUE ONE ENG GEN ON MEL) APU AUTO SHUTDOWN. RT & LT JET OVERHEAT MSG, LT & RT FIRE FAIL CAUTION MSG. LT WINDSHIELD HEAT IN FLT. CHGED FIRE DET CONTROLLER ALL CKS SERV. CONTROLLER INSPECTED ON SITE BY MPS TECH AND NO MOISTURE, COFFEE OR CONTAMINATION FOUND. AD CF200035R1 HAD BEEN COMPLIED WITH. PART WILL BE FURTHER TESTED UPON ARRIVAL IN SHOP. 2L72 4F4 FRTA21EA E15NE 20030904001112003090400111EA 2003 9 4 CA030807003 120030730G541022850080801 COWLING CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE LT UPPER DAMAGED W A UNSCHED LANDING D INFLIGHT SEPARATION CLCLIMB 1 CA (CAN) CREW WAS NOTIFIED BY TOWER THAT THE LT UPPER ENGINE COWLING HAD COME OFF THE AIRCRAFT, AND WAS LAYING ON THE RUNWAY. A/C RETURNED AND LANDED THEY FOUND THE FASTENER STILL LOCKED ON THEIR DZEUS RECEPATCLE .THEY REPLACED THE DAMAGED DZEUS RECEPTACLE AND REPLACE UPPER AND LOWER COWL.NO ADDITIONAL DAMAGES ON THE STRUCTURE AND THE NACELLE. 2L72 4F4 FRTA21EA E15NE 20030904001122003090400112EU 2003 9 4 CA030807004 120030806G3233960300110 ACTUATOR PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL MLG MALFUNCTIONED W O OTHER N FALSE WARNING CLCLIMB 1 CA (CAN) AFTER TAKEOFF, WHEN THE LANDING GEAR WAS RETRACTED, THE GREEN DOWN AND LOCKED INDICATION REMAINED ON FOR THE L/H GEAR. THE GEAR WAS CYCLED, BUT THE GEEN INDICATOR REMAINED ON. THE AIRCRAFT RETURNED TO BASE, WHERE IT WAS DETERMINED THAT THE INTERNAL DOWN INDICATOR MICRO SWITCH WAS STAYING ON WHEN THE RAM WAS RETRACTED ON THE MLG ACTUATOR. THE ACTUATOR WAS REPLACED, HYDRAULIC SYSTEM SERVICED, GEAR RETRACTION PREFORMED, AND THE AIRCRAFT RETURNED TO SERVICE. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030908002292003090800229EU 2003 9 8 CA030807005 120030728G2910F50B765252 LINE AMD FALC50FALCON50MYST2730106EU GARRTTTFE731TFE7313 01518WP HYD RETURN SYS LEAKING W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) SMALL LEAK WAS FOUND AFTER GROUND RUNNING AIRCRAFT HYDRAULIC SYSTEM. LEAK WAS SEEN DRIPPING ON RT INBOARD TIRE. LEAKAGE WAS MINIMAL. UPON INVESTIGATION A TINY PIN HOLE WAS DISCOVERED AT A FAIR LEAD JUNCTION 16 INCHES OUTBOARD OF INBOARD FITTING - WS78 (RT WING) ON AILERON RETURN LINE NR 2 SYSTEM, PN F50B765252. PIN HOLE IS VERY SMALL AND MAY POSSIBLY CAUSED BY CORROSION. 2L73 4F4 F A46EU E6WE 20030908002302003090800230EU 2003 9 8 CA030807006 120030801G215020388022 COOLING TURBINE BRAERODH125 BAE125800A 1500285EU GARRTTTFE731TFE7315R 01518WP COOLING FAN FAILED W BG EMER. DESCENT O2 MASK DEPLOYED B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA (CAN) POSSIBLE FAILURE OF BEARING (DEBRIS ON MAGNETIC PLUG) CAUSING SUBSEQUENT HIGH FREQUENCY VIBRATION RESULTING IN FAILURE OF THE FOLLOWING SUB-COMPONENTS: COOLING FAN (VANES BROKEN AND HOUSING PARTIALLY DETACHED. HEAT EXCHANGER 178092-1 (CRACKED AT WELDED COOLING TURBINE ATTACHMENT FLANGE). BLEED AIR DUCT 25-8VF501-1A (SEPERATED ELBOW FITTING AT WELD JOINT). THE DAMAGE TO THE DUCT RESULTED IN A REAR BAY OVERHEAT COCKPIT INDICATION WHEREBY THE FLIGHT CREW ALSO SHUT DOWNTHE APU AND ENGINE BLEED VALVES AS THEY COMMENCED AN EMERGENCY DESCENT ONCE CAB IN PRESSURE WAS LOST WITH THE REFRIGERATION UNIT FAILURE. 2L72 4F4 FRTA3EU E6WE 20030908002322003090800232CE 2003 9 8 CA030807007 120030807G555307120013 FITTING CESSNA180 180J 2072622CE CONT O470 O470S 17026SO MCAULY2A34C 2A34C203 GL VERTICAL STAB CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) UPON REMOVAL OF VERTICAL STABILIZER THE REAR DORSAL FIN ATTACH BRACKET WAS FOUND TO BE CRACKED. THE LT RADIUS HAD FAILED BELOW THE FASTNER ATTACHMENT. 1H71 3O3 O 5A6 E273 5 CP3EA 20030908002332003090800233CE 2003 9 8 CA030808001 120030806G243503601018 BEARING LUCAS BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3I NE STARTER GEN FAILED W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA 97186 (CAN) AIRCRAFT DEPARTED. DURING THE END OF CLIMB OUT THE RT (NR 2) GENERATOR ANNUNCIATOR ILLUMINATED. GENERATOR WOULD NOT RESET, AIRCRAFT RETURNED TO AIRPORT. MAINTENANCE CHECKS CARRIED OUT NR 2 ENGINE WOULD NOT TURN ON START, GENERATOR REMOVED, INSPECTED AND FOUND LARGE AMOUNT OF CIRCULAR MOVEMENT ON DRIVE END DUE TO BEARING FAILURE. GENERATOR REPLACED AND AIRCRAFT RETURNED TO SERVICE. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20030908002342003090800234CE 2003 9 8 CA030808002 120030717G5330 SKIN BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) A CRACK IN THE UPPER FUSELAGE SKIN DUE TO VIBRATION PRODUCED BY A GPS/VHF COMBINATION ANTENNA, CRACKS DEVELOPED VERY RAPIDLY IN SKIN & DOUBLER ALONG EDGES OF ANTENNA BASE, 1L72 4T4 T A24CE E4EA 20030908002362003090800236CE 2003 9 8 CA030808003 120030730G2913PDLM60 CIRCUIT BREAKER BEECH 100 B100 1152919CE GARRTTTPE331TPE331625 WP HYD PUMP FAILED W C ABORTED TAKEOFF J WARNING INDICATION TOTAKEOFF 1 CA (CAN) THE LANDING GEAR FAILED TO RETRACT ON TAKE-OFF. THE 60 AMP HYD DRIVE MOTOR CIRCUIT BREAKER WAS FOUND TRIPPED. THE GEAR WAS LOWERED USING THE EMERGENCY SYSTEM AND THE AIRCRAFT RETURNED AND LANDED WITHOUT FURTHER INCIDENT. THE MOTOR WAS BENCH CHECKED AND FOUND TO BE GOOD. THE CIRCUIT BREAKER FOR THE MOTOR WAS REPLACED AND THE SYSTEM TESTED ALL OK. 1L72 4T4 T A14CE E2WE 20030908002412003090800241EU 2003 9 8 CA030811001 120030808G63204638202007 FREEWHEEL UNIT BOLKMS105 BO105CBS 5626008EU MAIN ROTOR FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THIS TRANSMISSION RECEIVED FROM AN OPERATOR WITH PARTIAL DISASSEMBLY. LT FREEWHEEL CLUTCH SHATTERED. OUTER CAGE BROKEN IN ONE PLACE. INNER CAGE BROKEN IN TWO PLACES.ENERGIZING RIBBON BROKEN IN FOUR PLACES. FOUR SPRAGS DISLODGED FROM CLUTCH ASSY. 1G72 3U NCH3EU 20030908002542003090800254WP 2003 9 8 CA030811003 120030804G3260 PROXIMITY SENSOR DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE NLG OUT OF RIG W L ABORTED APPROACH N FALSE WARNING APAPPROACH 1 CA (CAN) NOSE GEAR UNSAFE LIGHT AND AURAL WARNING ON GEAR UNSAFE AUERAL WARNING PROXIMITYTEST BITE C/OUT IAW MM 32-60-00 COULD NOT DUPLICATE SNAG. RIGGING OF PROXIMITY SENSOR C/O AS PER MAINTENANCE MANUAL - NO DEFECT FOUND. 2L72 4F4 FRTA6WE E9NE 20030908002592003090800259NM 2003 9 8 CA030811004 120030806G324643667 BOLT DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE MLG WHEEL BROKEN W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) WHILE ASSEMBLING THE MAIN WHEEL, THE WHEEL BOLTS WERE TORQUED IN THE PROPER SEQUENCE AND TO PROPER TORQUE AS PER MM, THE BOLTS WERE THENCHECKED TO VERIFY THE TORQUE AND THE NUTWOULD TURN ABOUT 1/8 OF A TURN BEFOREREACHING THE TORQUE. A SECOND VERIFICATION WAS COMPLETED AND THE NUT WOULD AGAINTURN 1/8 OF A TURN AND ONE OF THEM BROKE. THE TORQUE WRENCH WAS RECHECKED FOR PROPER CALIBRATION AND FOUND SERVICEABLE. NEW BOLTS WERE ORDERED AND INSTALLED & PROBLEM RECURRED WITH TWO OF THE NEW BOLTS, ONE STRETCHED AND ONE BROKE. WHEEL MANUFACTURE WAS CONTACTED TO VERIFY THAT THE TORQUE IN THE MAINTENANCE MANUAL WAS CORRECT AND THAT THESE WERE THE CORRECT BOLTS, THEY CONFIRMED THE INFO WAS CORRECT. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030908002602003090800260EU 2003 9 8 CA030811005 120030804G21009738132212 SWITCH PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL ECS OVERHEATED W O OTHER HL ELECT. POWER LOSS-50 PC NO TEST TOTAKEOFF 1 CA (CAN) DURING TAKEOFF THE BREAKER OF THE ENVIRONMENTAL CONTROL SYSTEM POPPED OUT. AFTER VERIFICATION OF THE PROBLEM, AND DISCOVERED THAT THE SWITCH WAS BEING OVERHEATED. BUT FOUND NO TRACES OF BURN MARKS OR OVERHEATED ON THE SWITCH AFTER REMOVAL AND A NEW SWITCH WAS BEING INSTALLED.SWITCH PN 973.81.32.212 (53183-110) 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030908002632003090800263CE 2003 9 8 CA030812001 120030808G273050610000546 HINGE BRACKET BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA ELEVATOR WORN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) LT ELEVATOR BOLT FOUND LOOSE DURING CHECK. HINGE BRACKET & BOLT EXHIBITED ABNORMAL WEAR. BOLT GROOVED .024 TO A DIAMETER OF .225 & BRACKET HOLES ELONGATED TO .284 & .290, RESULTING IN EXCESSIVE MOVEMENT OF HINGE. INSTALATION OF BOLT IAW MM WITH ONE AN960416L & ONE AN960416 WASHERS. IT APPEARS THAT WITH THIS INSTALATION, NUT BOTTOMED ON SHOULDER OF BOLT. C90A MM CONTAINS A CAUTION TO THIS EFFECT (CH 27-30-00 PG 202) INDICATING PREMATURE WEAR MAY OCCUR. ALSO NOTED, BUSHING OVERALL LENGTH .900, BRACKET INTERNAL BORE LENGTH .930. REPLACEMENT OF BOLT, NUT AND WASHERS, BRACKET, BUSHING AND HINGE BEARING, VISUAL INSPECTION OF ATTACHMENT BRACKETS, ELEVATOR BALANCING VERIFIED. NO FURTHER FAULTS FOUND. 1L72 3T4 TRT3A20 E4EA 20030908002662003090800266SW 2003 9 8 CA030812002 120030811G3211206031302269S SUPPORT BELL 206 206B 1181511SW ALLSN 250C 250C20 03013GL CROSSTUBE CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA 12957 (CAN) DURING SERVICABILITY CHECK CRACKS WERE FOUND ON THE LT AFT CROSS TUBE SUPPORT P/N 206031301123 , THE RT AFT CROSS TUBE SUPPORT PN 206031301124 AND ON BULKHEAD PN 206031302193. ALL PARTS WILL BE CHANGED OUT. 1G71 3U3 U H2SW E4CE 20031020001702003102000170SO 2003 10 20 CA030812003 220030812G8530 ROCKER CESSNA150 150L 2071826CE CONT O200 O200A 17020SO CYLINDER HEAD WORN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ON VISUAL INSPECTION OF VALVE TRAIN ASSY ON ALL FOUR CYLINDERS. NOTED EXCESSIVE WEAR TO ROCKER ARM BOSSES, ROCKER ARM BUSHINGS & ROCKER SHAFTS. SHAFTS ARE ANCHORED BY SET SCREWS. FIRST INDICATION IS THAT THE LINE UP MARKS ON THE ENDS OF THE PINS DO NOT MATCH THE DIRECTION OF THE SET SCREW. SET SCREWS FOUND LOOSE.AT THIS POINT WE DISSMANTLED THE ASSY & THEN NOTED THE WEAR ON ALL OF THE OTHER PARTS.THIS IS THE THIRD OCCASION THAT THIS HAS BEEN FOUND ON OUR FLEET. TELEDYNE CONTINENTAL IS STILL INVESTIGATING CAUSE OF PROBLEM. 1H71 3O3 O 3A19 E252 20030909000022003090900002CE 2003 9 9 CA030812004 120030731G8012S19911 SOLENOID CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA MCAULY1C160 1C160DTM GL STARTER FAILED W O OTHER H ELECT. POWER LOSS-50 PC CRCRUISE 1 CA (CAN) DURING CRUISE THE PILOT EXPERIENCED AN ELECTRICAL FAILURE. UPON LANDING BACK AT BASE IT WAS DETERMINED THE STARTER SOLENOID WAS STUCK AND SUBSEQUENTLY THE BATTERY NEGATIVE POST MELTED. THE STARTER & MASTER RELAYS, STARTER AND BATTERY WERE REPLACED. THE ENTIRE ELECTRICAL SYSTEM WAS INSPECTED AND FOUND TO BE SERVICEABLE. THE ENGINE WAS GROUND RUN AND THE CHARGING SYSTEM FOUND TO BE OPERATING NORMALLY. 1H71 3O3 ONT3A12 E274 5 NP910 20030909000032003090900003CE 2003 9 9 CA030812005 120030807G3242215286 STATOR CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE BRAKE ASSY FAILED W D RETURN TO BLOCK J WARNING INDICATION TXTAXI/GRND HDL 1 CA 0511 (CAN) STATOR BROKEN ON LT BRAKE ASSY. ACCORDING TO THE WEAR INDICATORS, THERE WAS APPROX. 150-200 CYCLES OF BRAKE LIFE REMAINING.PROBLEM DESCRIPTION WOULD PROBABLY BE PREMATURE BRAKE FAILURE. THE LT WHEEL ASSY WAS ALSO REPLACED. INSPECTION OF THE RT BRAKE ASSY. ALSO SHOWED SIGNS OF STATOR CRACKING.THE RT BRAKE ASSY WAS ALSO REPLACED. SN REMOVED 0733. 1L72 4F4 F A22CE E1NE 20030909000042003090900004EA 2003 9 9 CA030813002 220030808G853075089 PISTON CESSNA172 172P 2072436CE LYC O320 O320D2J 41508EA ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DEFECTIVE PART FOUND DURING A TOP OVERHAUL AT 1785.8 HOURS (ENGINE TIME). THIS ENGINE CYLINDERS HAD NEVER BEEN REMOVED SINCE LYCOMING OVERHAUL. PERTINENT INFORMATION: CRACK IN PROGRESS, 3/4 INCH LONG. WE CAN OBSERVE POROSITY IN THE MATERIAL AT THE CRACK LOCATION. PART KEPT FOR INVESTIGATION. 1H71 3O3 ONT3A12 E274 20030909000052003090900005NM 2003 9 9 CA030813003 120030810G2750652661433 TRANSMISSION BOEING727 727233 138408ANM PWA JT8 JT8D15A 52051NE TE FLAP DAMAGED W O OTHER F FLT CONT AFFECTED APAPPROACH 1 CA (CAN) ON APPROACH TO I/B T/E FLAPS WOULD NOT EXTEND IN NORMAL OR MANUAL MODE. POST LANDING INSPECTION DETERMINED NR 4 FLAP TRANSMISSION (I/B, I/B) WAS UNSERVICEABLE. THE UNIT WAS REPLACED THE FLAP SYSTEM RIG CHECKED AND FUNCTION TESTED. AIRCRAFT RETURNED TO SERVICE. 2L73 4F4 FRTA3WE E2EA 20030909000062003090900006NM 2003 9 9 CA030813004 120030810G2750652661433 TRANSMISSION BOEING727 727233 138408ANM PWA JT8 JT8D15A 52051NE TE FLAP DAMAGED W O OTHER F FLT CONT AFFECTED APAPPROACH 1 CA (CAN) ON APPROACH TO I/B T/E FLAPS WOULD NOT EXTEND IN NORMAL OR MANUAL MODE. POST LANDING INSPECTION DETERMINED NR 4 FLAP TRANSMISSION (I/B, I/B) WAS UNSERVICEABLE. THE UNIT WAS REPLACED THE FLAP SYSTEM RIG CHECKED AND FUNCTION TESTED. AIRCRAFT RETURNED TO SERVICE. 2L73 4F4 FRTA3WE E2EA 20030909000072003090900007CE 2003 9 9 CA030813005 120030808G2910MS28893C6 RELIEF VALVE BEECH 100 B100 1152919CE GARRTTTPE331TPE3316252B 01514WP HYD SYSTEM LEAKING W D RETURN TO BLOCK J WARNING INDICATION TXTAXI/GRND HDL 1 CA (CAN) THE LANDING GEAR HAD A SERIES OF 2 FAILURES WHERE THE 60 AMP BREAKER TRIPPED AS THE MLG WAS RETRACTING & WOULD NOT RESET THEREBY FORCING THE CREW TO LOWER THE GEAR WITH THE EMERGENCY SYS & RETURN TO BASE. THE FAILURE COULD NOT BE DUPLICATED WHEN THE GEAR WAS SWUNG BY MAINT. THE HYD DRIVE MOTOR WAS BENCH CHECKED OK & BREAKER REPLACED. A THIRD INCIDENT WHERE BREAKER TRIPPED WHILE THE A/C WAS STILL ON THE RAMP PROMPTED MAINT TO CARRY OUT A FULL 1000 HR SYS INSPECTION DURING WHICH THE THERMAL RELIEF VALVE WAS DISCOVERED TO OPEN AT RANDOM CAUSING THE HYD PUMP TO CYCLE RAPIDLY UNTIL CIRCUIT HEATED UP & THE BREAKER TRIPPED. IT WAS REPALCED WITH AN OVERHAULED VALVE AND THE A/C RETURNED TO SERVICE. 1L72 4T4 T A14CE E2WE 20031126000592003112600059NE 2003 11 26 CA03081300A 220030813G852015373 PISTON NAMER T6 HARVARDMK4 1922828GL PWA R1340 S3H1 52016NE ENGINE DAMAGED W K NONE P NO WARNING INDICATION ININSP/MAINT 1 CA (CAN) AT INSPECTION, A VERY SMALL AMOUNT OF FERROUS MATERIAL FOUND IN PRESSURE FILTER. ADDITIONAL INSPECTION FOUND A PISTON WITH BROKEN TOP COMPRESSION RING. INSPECTION OF OTHER PISTONS FOUND THEM TO HAVE BEEN WORN BEYOND LIMITS IN THE TOP RING GROOVE WIDTH. WORN PISTONS WERE REPLACED WITH NEW. 1L71 3R3 R EXPA1L71E143 20031106000012003110600001NE 2003 11 6 CA030813AAA 220030813G853015373 PISTON NAMER T6 HARVARDMK4 1922828GL PWA R1340 S3H1 52016NE ENGINE DAMAGED W K NONE P NO WARNING INDICATION ININSP/MAINT 1 CA (CAN) AT INSPECTION, A VERY SMALL AMOUNT OF FERROUS MATERIAL FOUND IN PRESSURE FILTER.ADDITIONAL INSPECTION FOUND A PISTON WITH BROKEN TOP COMPRESSION RING.INSPECTION OF OTHER PISTONS FOUND THEM TO HAVE BEEN WORN BEYOND LIMITS IN THE TOP RINGGROOVE WIDTH. WORN PISTONS WERE REPLACED WITH NEW. 1L71 3R3 R EXPA1L71E143 20030909000082003090900008 2003 9 9 CA030814001 420030813G3418 HEATER PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL AOA SENSOR INTERMITTENT W K NONE L NO TEST ININSP/MAINT 1 CA 0068 (CAN) PILOT REPORTED THAT AMBER 'AOA DEICE' LAMP ILLUMINATED INTERMITTENTLLY ON ANNUNCIATOR PANEL. CLOSE INSPECTION OF AOA DEICE SYSTEM WITH CONTINUITY TESTER INDICATED FLUCTUATION IN METER READINGS WHEN NOSE CONE OF SUSPECTED AOA WAS HEATED AND COOLED. AOA TRANSMITTER REPLACED WITH SERVICEABLE SPARE . DEFECT ELIMINATED. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20030909000092003090900009SW 2003 9 9 CA030814002 120030814G275019023 CONTROL CABLE BBAVIA8 8GCBC 1220803SW LYC O360 O360C2E 41514EA TE FLAPS FRAYED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) STAINLESS STEEL CABLE, RT FLAP CABLE FRAYED AT PULLEY WHEN FLAPS SELECTED DOWN. 1H71 3O3 O A21CE E286 20030909000102003090900010SW 2003 9 9 CA030814003 120030814G272012364 CONTROL CABLE BBAVIA8 8GCBC 1220803SW LYC O360 O360C2E 41514EA RUDDER FRAYED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) CABLES ARE STAINLESS STEEL. LT AND RT CABLES FRAYED AT CABIN PULLEY IN NEUTRAL POSTION. 1H71 3O3 O A21CE E286 20030909000112003090900011SW 2003 9 9 CA030815001 120030809G7120 MOUNT BBAVIA8 8GCBC 1220803SW LYC O360 O360C2E 41514EA ENGINE CORRODED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING THE 100 HR INSPECTION, A SMALL RUST LINE WAS DETECTED ON THE UPPER LT MOUNT LOCATION AT THE WELD. FURTHER INSPECTION WITH 10 POWER MAGNIFYING GLASS DETERMINED THAT THE AREA WAS CRACKED 1/2 INCH. 1H71 3O3 O A21CE E286 20030909000122003090900012EU 2003 9 9 CA030817001 120030808G2710RZ1241 SPRING GROB G115 G115C 1660303EU LYC O320 O320D1A 41508EA AILERONS BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) WHILE TOWING THE AIRCRAFT TO ITS PARKING SPOT, A BANG WAS HEARD. THE AILERONS DEFLECTED FULL SCALE LT. THE AILERON AND RUDDER WERE NO LONGER INTERCONNECTED. ONE OF THE SPRINGS WAS FOUND TO HAVE BROKEN OFF AT THE ATTACHMENT POINT. WHILE REPLACING THE SPRING THE OTHER SPRING WAS FOUND TO BE SUBSTANTIALLY WEAKER THAN THE NEW SPRING. BOTH SPRINGS WERE REPLACED IN ACCORDANCE WITH THE MANUFACTURER'S DIRECTIVES. 1L71 3O3 ONTA57EU E274 20030909000132003090900013SO 2003 9 9 CA030818001 220030815G8530AEC648029 PISTON BEECH 95 95B55 1152729CE CONT O470 IO470L 17026SO ENGINE BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) UPON DOING A CYLINDER INSPECTION IT WAS NOTICED THAT THE COMPRESSION ON THE NR 4 CYLINDER WAS LOW. REMOVAL OF THE CYLINDER REVEALED A PISTON SKIRT LAYING IN OIL SUMP WHICH HAD COME FROM THE NR 5 CYLINDER. THESE PISTON SKIRTS BREAKING OFF HAVE CREATED 2 INFLT ENGINE FAILURES WITHIN THE LAST YEAR AND A HALF FOR PERIMETER. THE PROBLEM WAS IDENTIFIED AS POOR HEAT TREATMENT BY THE MANUFACTURER 'ECI'. NO AIRWORTHINESS DIRECTIVE HAS BEEN ISSUED FOR THIS PROBLEM AS OF YET. ALL THE PISTONS INVOLVED HAD A CASTING NUMBER OF '04' STAMPED ON THE INSIDE OF THE PISTON. 3 ECI CYLINDER ASSEMBLIES WERE REPLACED ON THIS ENGINE TO AVOID ANY FUTURE FAILURES. 1L72 3O3 ORT3A16 3E1 20030909000142003090900014SW 2003 9 9 CA030818002 120030818G2497GS550 STUD FRCHLDSA227 SA227DC 3377521SW GARRTTTPE331TPE33112UHR WP MCAULY4HFR344HFR34C652 NE GROUND BURNED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING AN AREA INSPECT, MECHANIC NOTICED THAT GROUND STUD & WIRE FOR GROUND POWER RECEPTICLE APPEARED BURNED. ON INVEST FOUND CONNECTION LOOSE & FUSELAGE LUG, GROUND STUD & WIRE TERMINAL BURNED & OVERHEATED. ACCORDING TO PARTS LIST IN WIRING MANUAL GROUND STUD INCORRECTLY ASSEMBLED. STUD WAS LAST ASSEMBLED WHEN A/C WAS BUILT. STUD BOLT SHOULD BE AN AN6-10 BUT WAS A-5 & WAS MISSING SOME WASHERS THAT ARE CALLED OUT IN PARTS LIST & WIRING MANUAL. 2L72 4T4 TRTA18SW E4WE 6 C3PNE 20030909000152003090900015NE 2003 9 9 CA030818003 220030814G7532 BLEED VALVE CESSNA500 550 2076604CE PWA 530 PW530A NE COMPRESSOR MALFUNCTIONED W O OTHER WRJINADEQUATE Q C PARTIAL RPM/PWR LOSS WARNING INDICATION APAPPROACH 1 CA (CAN) RT ENGINE SURGES UPON DECELERATING THRU 70 PERCENT, SECONDARY ORIFICE ON BLEED OFF VALVE TORQUE MOTOR INSPECTED AND CLEANED. P3 AIR SEPERATOR INSPECTED AND CLEANED ASPER PRATT AND WHITNEY. BLEED OFF VALVES SWAPPED (RT TO LT). ENGINE GROUND RAN , NO FAULT COULD BE DUPLICATED. 1L72 4F4 F A22CE E00053EN 20030909000162003090900016GL 2003 9 9 CA030818004 320030816G611057A24041 PITCH STOP BEECH 95 95B55 1152729CE CONT O470 IO470L 17026SO HARTZLHCC2Y BHCC2YF2 GL PROP CYLINDER STRIPPED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING INSPECTION OF THE PROP, MAINTENANCE ATTEMPTED TO REMOVE THE SPINNER BUT COULDN'T BECAUSE THE LOW PITCH STOP THREADS WERE STRIPPED, WHERE THE SPINNER ATTACHES TO THE LOW PITCH STOP. THE LOW PITCH STOP HAD TO BE REMOVED FROM THE P ROPELLER SO THE SPINNER COULD BE REMOVED. IT WAS ALSO NOTED THAT THE HOLE IN THEFRONT OF THE SPINNER FOR THE LOW PITCH STOP WAS ENLARGED ALLOWING THE SPINNER T O WOBBLE SLIGHTLY DURING OPERATION CAUSING THE SPINNER AND SPINNER BULKHEAD TO CRACK. THE PROPELLER, LOW PITCH STOP AND SPINNER AND BULKHEAD ASSEMBLY WERE REPLACED. 1L72 3O3 ORT3A16 3E1 5 CP920 20030909000172003090900017NE 2003 9 9 CA030818005 220030818G8530 EXHAUST VALVE DOUG B26 B26C 3200524WP PWA R2800 R280079 52026NE NR 3 CYLINDER FAILED W E ENGINE SHUTDOWN B SMOKE/FUMES/ODORS/SPARKS APAPPROACH 1 CA (CAN) ON APPROACH TO WHITE SMOKE WAS OBSERVED EXITING THE LT INBOARD EXHAUST STACK. THE ENGINE WAS SHUT DOWN AND SECURED, THE A/C LANDED WITHOUT INCIDENT. UPON INVESTIGATION THE NR 3 CYL. EXHAUST VALVE STEM HAD SEVERED AND WAS INGESTED INTO THE CYL. OIL SCREENS WERE CHECKED AND CYL. CHANGED A/C RETURNED TO SERVICE. 2M72 4R4 R L34 5E8 20030909000182003090900018 2003 9 9 CA030819001 420030813G221030513126 SERVO AIRBUS310 A310300 3930305EU GE CF6 CF680C2A5 NE YAW MALFUNCTIONED W O OTHER O OTHER TOTAKEOFF 1 CA (CAN) DURING TAKE-OFF ROLL, OUT OF EXETER AND A COUPLE OF TIMES IN FLT, CREW REPORTED RUDDER KICKED, FOLLOWED BY A BANK OF 10 DEGREES. THE YAW AUTOPILOT ACTUATOR WAS REPLACED AND THE SYSTEM WAS CONFIRMED SERVICEABLE AFTER A VERIFICATION FLT. 2L72 4F4 FRTA35EU E13NE 20030909000192003090900019EA 2003 9 9 CA030819002 220030814G7230T102401 BLADE PWA PT6 PT6A27 52043EA GAS GENERATOR FRACTURED W EA ENGINE SHUTDOWN UNSCHED LANDING O OTHER CRCRUISE 1 CA (CAN) ENGINE WAS SHUTDOWN IN CRUISE DUE TO TORQUE INDICATION DROPPING OFF AND ITT CLIMBING TO 6900C. DISMANTLE INVESTIGATION HAS REVEALED THAT CT DISK ASSEMBLY EXHIBITED ONE FRACTURED CT BLADE AT THE ROOT OF THE AIRFOIL OR BLADE PLATFORM. THE FRACTURED AIRFOIL WAS LODGED BETWEEN THE CT SHROUD SEGMENTS AND CT BLADE TIPS. SEVERE RUBBING OF CT BLADE TIPS WAS EVIDENT. COMPRESSOR ALSO SUFFERED HEAVY RUBBING DAMAGE. ROOT CAUSE IS STILL BEING ANALYSED. 4 T E4EA 20030909000202003090900020NM 2003 9 9 CA030819003 120030810G2913 PUMP BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA HYD SYSTEM MALFUNCTIONED W O OTHER J WARNING INDICATION CRCRUISE 1 CA (CAN) DURING FLIGHT NR 2 ENG HYD PUMP CAUTION ON. FLIGHT CONTINUED TO DESTINATION AND LANDING WAS UNEVENTFUL. METAL FOUND IN CASE DRAIN FILTER. EDP REPLACED AND LINES FLUSHED. ALL NR 2 HYD FILTER ELEMENTS REPLACED. 2H72 4T4 TRTA13NM E00062EN 20030909000302003090900030EU 2003 9 9 CA030820001 120030816G3246 WHEEL AIRBUSA340 A340313 EU CFMINTCFM56 CFM565C4 13802NE MLG SYSTEM FAILED W O OTHER J WARNING INDICATION NRNOT REPORTED 1 CA (CAN) AFTER TAKE OFF UNABLE TO CLOSE GEAR DOOR TO CLOSE AIRCRAFT RETURN TO GATE, FOUND BOTH CENTER GEAR WHEEL AT RIM, CENTER GEAR DOORS DAMAGED 2L74 4F4 FRTA197 E37NE 20030909000312003090900031NM 2003 9 9 CA030820002 120030818G2121 FAN BOEING747 747433 NM PWA 4056 PW4056 NE CABIN SMOKE W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 CA (CAN) SMOKE IN CABIN, AIRCRAFT DIVERTED INTO ICELAND SUSPECT RE-CIRCULATING FAN INVESTIGATION UNDER WAY 2L74 4F4 FRTA20WE E24NE 20030909000322003090900032NM 2003 9 9 CA030820003 120030817G276165449617 ACTUATOR BOEING BOEING737 737201 1384454NM PWA JT8 JT8D9A 52048NE DRAG CONTROL CRACKED W K NONE K FLUID LOSS ININSP/MAINT 1 CA 1531 (CAN) UPON ROUTINE PRE-FLIGHT WALK AROUND INSPECTION, ENGINEER DISCOVERED TRACES OF FLUID UNDER THE RT WING O/B FLAP TRACK FAIRINGS. FLAPS WERE BROUGHT DOWN AND SPEED PANELS RAISED. ENGINEER DISCOVERED NR 8 GRD SPOILER ACTUATOR COVERED IN HYD FLUID. AFTER PRESSURIZING THE HYD SYS, THE SPOILER PANELS WERE CYCLED A FEW TIMES. A SMALL LEAK WAS LOCATED IN THE MIDDLE OF THE ACTUATOR CYL, BUT ONLY LEAKED ON THE WAY FROM EXTEND TO RETRACT POSITION. THE SPOILERS WERE KEPT CYCLING TO TRY TO LOCATE THE EXACT POSITION OF THE LEAK, AFTER ABOUT 6 CYCLES, THE CYL SUDDENLY CRACKED WITH A LOUD BANG FROM THE TOP TO THE BOTTOM OF THE CYL RELEASING APPROX 1 GAL OF FLUID IN ABOUT 15 SECONDS. A NEW ACTUATOR WAS ORDERED. 2L72 4F4 F A16WE E2EA 20030909000412003090900041NM 2003 9 9 CA030825001 120030720G261210109601 FIRE LOOP BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA NR 1 ENGINE MALFUNCTIONED W EA ENGINE SHUTDOWN UNSCHED LANDING N FALSE WARNING NRNOT REPORTED 1 CA (CAN) AIRCRAFT OPERATING DEMO FLIGHTS FOR CUSTOMER UNDER CANADIAN REGISTRATION WITH BOMBARDIER CREW. AFTER LAST DEMO FLIGHT DURING PASSENGER DEPLANING THE NR 1 FIRE WARNING ACTIVATED. CREW FIRED ONE BOTTLE (AFT) AND THE FIRE WARNING STOPPED NO EVACUATION NECESSARY. ENGINE WAS ALREADY SHUTDOWN. WARNING WAS DETERMINED TO BE A NUISANCE AS PER Q400 ISAR 2003-05 ITEM 3 'NUISANCE PEC FIRE LOOP INDICATION' 40 HRS TSN ON LOOP. 2H72 4T4 TRTA13NM E00062EN 20030909000442003090900044SW 2003 9 9 CA030825002 120030815G2720 PEDAL BLANCA BBAVIA8 8GCBC 1220803SW LYC O360 O360C2E 41514EA MCAULY1A200 1A200* GL TOE BRAKE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) AME WAS DOING A QUICK VISUAL OF THE COCKPIT AREA BEFORE THE AIRCRAFT WAS TO LEAVE FOR THE DAYS FLIGHT, WHEN HE NOTICED A CRACKED ON THE FACE OF THE PEDAL. ON FURTHER INPECTION OF THE PEDAL IT WAS DISCOVERED THAT THE CRACK CONTINUED AROUND THE BACK ON INTO ONE OF THE MAIN ATTACH POINTS. 1H71 3O3 O A21CE E286 5 NP874 20030909000472003090900047NM 2003 9 9 CA030825003 120030821G322089607 BOSS DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE NLG CENTER MOUNTCRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING REINSTALLATION OF THE NOSE LANDING GEAR CENTERING MECHANISM A CRACK WAS NOTICED IN THE MAIN BODY BEHIND THE MOUNTING BOSS OF THE CENTRING MECHANISM, THE CRACK AS 3/4 INCH IN LENGTH. THE LOCATION OF THE CRACK DOES NOT ALLOW IT TO BE VISIBLE WITH OUT REMOVING THE CENTERING MECHANISM. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20030909000492003090900049EA 2003 9 9 CA030825005 220030719G7322233615 FLOAT VALVE PRECISION PIPER PA28 PA28140 7102802SO LYC O320 O320E3D 41508EA SNSNCH74D 74DM EA CARBURETOR FAILED W O OTHER YJ ENGINE STOPPAGE WARNING INDICATION LDLANDING 1 CA (CAN) FLOAT VALVE AND SEAT ASSEMBLY FOUND TO BE STICKING IN THE OPEN POSITION CAUSING A HIGH FUEL LEVEL IN THE FLOAT CHAMBER. THEREFORE GIVING A RICH MIXTURE IN THE IDLE RANGE CAUSING ENGINE TO STALL IN IDLE RANGE AND ROLL-OUT ON RUNWAY. TO CORRECT THIS CONDITION, FLOAT VALVE POLISHED ND REASSEMBLED AND HAS BEEN RUNNING GOOD EVER SINCE. 1L71 3O3 O 2A13 E274 5 NP88614 20030909000512003090900051SW 2003 9 9 CA030825006 120030721G2551 SPRAY BOOM BELL 206 206B 1181511SW ALLSN 250C 250C20 03013GL EXTERIOR FAILED W O OTHER D INFLIGHT SEPARATION DEDESCENT 1 CA (CAN) THE RT SPRAY BOOM FAILED AND FLEW UP INTO THE MAIN ROTOR BLADES. THE PILOT KEPT CONTROL OF THE AIRCRAFT AND LANDED SAFELY AT THE AIRPORT. UPON INVESTIGATION WE DETERMINED THAT THE TWO MAJOR FACTORS CAUSING THE INCIDENT WERE: THE BOOM HAD A WELDED JOINT HALF WAY OUT ON THE RT SIDE (BROKE AT THE WELD). THE BOOM HAD AN AIRFOIL SHAPE CAUSING IT TO FLY UP INTO MAIN ROTOR BLADES. WE CONFIRMED THAT NONE OF OUR AIRCRAFT HAVE THE AIRFOIL SHAPE BOOMS (THIS AC WAS THE ONLY ONE). WE REPLACED XX'S BOOMS WITH SIMPLEX ROUND SHAPED BOOMS. WE ALSO CONFIRMED THAT OUR AIRCRAFT DO NOT HAVE ANY WELDED JOINTS ON THE BOOMS. 1G71 3U3 U H2SW E4CE 20030909000532003090900053CE 2003 9 9 CA030825007 120030818G2797 WIRE CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE CONTROL WHEEL CHAFED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING REASSEMBLY CONTROL WHEEL, A TECHNICIAN DISCOVERED TWO BARE WIRES HIDDEN INSIDE THE CONTROL WHEEL ASSY. THE BARE WIRES COULD BE PARTIALLY SEEN FROM A SMALL OPENING IN THE FRONT SIDE OF THE CONTROL WHEEL PAD. AFTER DISMOUNTING THE CONTROL WHEEL ASSEMBLY AND REMOVING ITS ASSOCIATED PARTS (WHEEL FRONT AND AFT COVER, BEARING AND SHAFT), IT BECAME POSSIBLE TO PERFORM A CLOSER INSPECTION OF THE WIRES. THE WIRES ARE BUNDLED UP AND ROUTED INSIDE A SMALL SHAFT USED FOR HOLDING THE CONTROL WHEEL TOGETHER. TWO SCREWS ATTACHED THE SHAFT TO THE CONTROL WHEEL. FURTHER INVESTIGATION OF THE ASSEMBLY REVEALED THAT THE WIRES WERE FORCIBLY DAMAGED BY THE TWO SCREWS DURING PERIODIC MAINTENANCE. 1L72 4F4 F A22CE E1NE 20031126000712003112600071SW 2003 11 26 CA030825008 120030726G5302212030161001 ATTACH FITTING BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA TAILBOOM BROKEN W O OTHER D INFLIGHT SEPARATION NRNOT REPORTED 1 CA 13319 (CAN) DURING CRUISE FLIGHT THE CREW FELT A (POP) ON THE AIRCRAFT WITH NO OTHER INDICATIONS. NO WARNING LIGHTS, NO CONTROL OR HANDLING PROBLEMS. AFTER LANDING, THE ENGINEER CARRIED OUT HIS ROUTINE (BEFORE FLIGHT) INSPECTION. LOOKING AT THE TAILBOOM TO FUSELAGE ATTACH FITTINGS, HE FOUND THE FITTING P/N 212-030-161-001 BROKEN IN HALF. DETAILED INSPECTION AFTER REMOVING THE TAILBOOM FOUND THE UPPER LT CAP ANGLE P/N 212-030-191-001 UNDER THE UPPER ATTACHMENT FITTING CRACKED. 1G71 4U4 U H4SW E22EA 20030909000562003090900056WP 2003 9 9 CA030825009 120030809G1430528075 BOLT MENASCO 528400 CVAC 580 580 2422806WP ALLSN 501D 501D13 03004GL MLG STRUT BROKEN W O OTHER D INFLIGHT SEPARATION LDLANDING 1 CA (CAN) UPON LANDING AT YCG THE FLT CREW EXPERIENCED A SEVERE SHIMMY FROM THE LANDING GEAR. THE AIRCRAFT WAS BROUGHT TO A STOP ON THE RUNWAY WITHOUT THE USE OF BRAKES. THE CREW WAS INFORMED BY RADIO THAT THE RT MLG WAS NOT TRACKING STRAIGHT. AFTER ENSURING THERE WAS NO FIRE THE AIRCRAFT WAS TAXIED TO THE TANKER BASE. IT WAS DETERMINED THAT THE RT MLG TORQUE LINK BOLT HAD BROKEN CAUSING THE WHEEL ASSY TO ROTATE THROUGH 180 DEGREES SEVERING THE BRAKE LINES. SEVERAL BRAKE CALIPER RETAINING BOLTS WERE ALSO FOUND SEVERED. THERE WAS SOME MINOR DAMAGE TO THE TORQUE LINK. NO PARTS WERE FOUND ON WHEN THE RUNWAY WAS CHECKED. THE AIRCRAFT WAS INSPECTED, REPAIRED AND RETURNED TO SERVICE. 2L72 4T4 TRT E282 20030909000572003090900057CE 2003 9 9 CA030825010 120030818G282415507A SEAL ITT CESSNA441 441 2076020CE GARRTTTPE331TPE331* 01514WP FUEL VALVE LEAKING W K NONE K FLUID LOSS ININSP/MAINT 1 CA L04635 (CAN) LT CROSSFEED VALVE WAS FOUND TO BE LEAKING (WEEPING FUEL PAST SEALS THAT FAILED. PN 15507A HAD TURNED TO A SOFT PUTTY LIKE SUBSTANCE, MS29513011 0-RINGS HAD GONE HARD. NOTE: THIS VALVE DID NOT APPEAR TO HAVE BEEN REPLACED, HENCE APPROXIMATELY 20 YEARS SERVICE, 5300 HRS. 1L72 3T3 TRTA28CE E2WE 20030909000592003090900059CE 2003 9 9 CA030825011 120030715G2460 DIODE BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCD4N3HCD4N3A GL DC POWER FAILED W O OTHER H ELECT. POWER LOSS-50 PC APAPPROACH 1 CA (CAN) A/C ON APPROACH, TURNED RECOG LIGHT ON, LOST INTERCOM, NR 2 RADIO, COULD NOT EXTEND LAND GEAR. EMER EXTENSION CARRIED OUT. AC LANDED WITHOUT FURTHER INCIDENT. MAINT FOUND NR 2 DUAL FED BUS RT DIODE FAILED AND A LOOSE BUS WIRE NR 2 DUAL FED BUS. DIODE REPLACED AND WIRE TIGHTENED. PERFORMED GEAR FUNCTION CHECKS AFTER EMER EXT. GROUND CHECKS CARRIED OUT. INTERCOM, NR 2 RADIO AND LANDING GEAR FUNCTION NORMALLY. AC RETURNED TO SERVICE. THERE WAS A FEEDER DIODE INSPECTION CARRIED OUT AT LAST PHASE 3 INSPECTION DATED 13 JUNE 2003. 1L72 4T4 T A24CE E4EA 5 CSTC 20030909000612003090900061CE 2003 9 9 CA030825012 120030810G3230AE3660120G0230 HOSE BEECH 99 99 1154002CE PWA PT6 PT6A28 EA HARTZLHCB3T HCB3TN3 GL NLG RUPTURED W O OTHER KJ FLUID LOSS WARNING INDICATION CLCLIMB 1 CA (CAN) TIME ON HOSE UNKNOWN ALTHOUGH DATA PLATE ON IT INDICATES 13 YEARS OLD. LANDING GEAR WAS SELECTED UP AND ONLY 2 MAIN GREEN LIGHTS CAME ON. THERE WAS ALSO A STRONG ODRO OF HYD FLUID. PILOT SELECTED DOWN AND THE NOSE GEAR LIGHT DID NOT COME ON. PILOT THEN HAND PUMPED THE GEAR DOWN AND GOT 3 GREEN LIGHTS. AIRCRAFT RETURNED TO BASE AND MAINTENANCE REPLACED THE NOSE GEAR RETRACT LINE. GEAR SWINGS CHECKED SERVICEABLE. 1L72 3T4 T A14CE E4EA 6 CP15EA 20030909000632003090900063SW 2003 9 9 CA030825013 120030811G32512719087009 ACTUATOR AIRTIGHT SWRNGNSA227 SA227AC 8780603SW GARRTTTPE331TPE331* 01514WP MCAULY4HFR344HFR34C652 NE NLG STEERING LOOSE W D RETURN TO BLOCK D INFLIGHT SEPARATION TXTAXI/GRND HDL 1 CA (CAN) TOTAL TIME UNKNOWN, NOT TRACKED, PILOT STARTED TO TAXI AND REPORTED BAD VIBRATION WITH THE NOSE STEERING ON OR OFF. THE INTERNAL PART OF THE STEERING ACTUATOR COULD BE MOVED BY HAND. STEERING ACTUATOR WAS REMOVED, SYSTEM FLUSHED OUT AND SERVICEABLE STEERING ACTUATOR INSTALLED. SYSTEM WAS RETURNED TO SERVICE. 2L72 4T3 TRTA8SW E2WE 6 C3PNE 20030909000642003090900064CE 2003 9 9 CA030825014 120030821G27801013800006 SHAFT BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3A NE LE SLAT CONTROL BROKEN W O OTHER F FLT CONT AFFECTED CLCLIMB 1 CA (CAN) DURING CLIMB, CREW SELECTED FLAPS '0' BUT NOTED THAT PANEL NR 4 DID NOT APPEAR TO RETRACT ALL THE WAY UP. FLIGHT CONTINUED TO DESTINATION AND FLAPS WERE CONFIRMED TO BE ALL UP EXCEPT NR 4 WHICH WAS HANGING DOWN BY APPROX 4 DEGREES. THE .5000 & .7500 PANEL PAIRS ARE PROTECTED BY A 3 TO 6 DEGREE SPLIT IN PAIR WHICH LOCKS SYSTEM, ONLY RESETTABLE ON GROUND. MAINT FOUND THAT FLEXIBLE DRIVE CABLE FOR NR 4 WAS BROKEN INSIDE OF EXTERNAL COVERING. A FACTORY INSTALLED CLAMP APPEARS TO HAVE BEEN OVERTIGHENED WHICH CAUSED A LOSS OF COVERING INTEGRITY ALLOWING MOISTURE TO ENTER CABLE SHEATH. LOW PORTION COLLECTED MOISTURE AND EVENTUALLY CORRODED ENOUGH TO ALLOW TORQUE TO BREAK STRANDS. MFG HAS BEEN NOTIFIED. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20030909000652003090900065CE 2003 9 9 CA030825015 120030824G24251143800331 INDICATOR BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3I NE AC VOLT METER SHORTED W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA 12568 (CAN) DURING CURISE FLIGHT, CREW NOTED ELECTRICAL ODOR AND SMOKE IN COCKPIT AREA. THE AIRCRAFT RETURNED TO ORIGINAL DEPARTURE LOCATION. THE DURATION OF THE SMOKE/SMELL WAS VERY BRIEF. MAINTENANCE REPLACED THE AC VOLTMETER INDICATOR WHICH APPEARS TO HAVE SHORTED INTERNALLY. THE UNIT HAS BEEN SENT FOR INVESTIGATION AND A STRIP HAS BEEN REQUESTED FOR FURTHER FOLLOWUP. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20030909000672003090900067 2003 9 9 CA030825016 420030716G83006014T81G28 GEARBOX CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE ACCESSORY FAILED W O OTHER XJ ENGINE FLAMEOUT WARNING INDICATION APAPPROACH 1 CA 807537 (CAN) LT FUEL PUMP AND LT SCAV EJECTOR CAUTION MESSAGES WERE POSTED AND LT ENGINE FUEL PRESSURE WENT TO ZERO CAUSING THE LT ENGINE TO SHUT DOWN. NO N2 ROTATION WHEN STARTER MOTORED. REPLACED ENGINE QEC ASSEMBLY. 2L72 4F4 FRTA21EA E15NE 20030909000692003090900069EA 2003 9 9 CA030825017 120030815G5610NP1393221 WINDOW CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE COCKPIT DELAMINATED W K NONE O OTHER ININSP/MAINT 1 CA 24190 (CAN) LT SIDE WINDOW WAS FOUND DELAMINATED. THERE IS NO POST OR PRE SB CONFIGURE FOR THE WINDOW. 2L72 4F4 FRTA21EA E15NE 20030909000712003090900071CE 2003 9 9 CA030826001 120030728G523085355041 DOOR BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCD4N3HCD4N3A GL WING LOCKER FAILED W O OTHER D INFLIGHT SEPARATION DEDESCENT 1 CA (CAN) DURING DESCENT OUT OF FL270 AND DESCENDING THRU FL240 THE LT WING LOCKER OPENED IN FLIGHT. AIRCRAFT LANDED WITHOUT INCIDENT. WING LOCKER INSPECTED FOR DAMAGE, NO DAMAGED NOTED. TWO LOCKING LATCHES WERE STILL IN THE CLOSED POSITION. AIRCRAFT RETURNED TO BASE. MAINT FURTHER INSPECTED LATCHING SYSTEM, NO FAULTS NOTED. KEY LOCK WAS NOT USED AT TIME OF FLIGHT. COMPANY PROCEDURE WILL CHANGE TO USEKEY LOCK ON WING LOCKERS. 1L72 4T4 T A24CE E4EA 5 CSTC 20030909000722003090900072SO 2003 9 9 CA030826002 120030812G2821100871002 STRAINER PIPER PIPER PA28 PA28160 7102806SO LYC O320 O320B2B 41508EA SNSNCH74DM M74DM EA GASCOLATOR STRIPPED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) DURING INSPECTION OF THE FUEL GASCOLATOR AT THE ANNUAL, THE STUD FOR THE SAFETY NUT WAS FOUND TO BE STRIPPED. THE GASCOLATOR BALE WAS REPLACED WITH A NEW PART AS A RECTIFICATION TO THE PROBLEM. 1L71 3O3 O 2A13 E274 5 NP88614 20030909000742003090900074CE 2003 9 9 CA030826003 120030808G281056181065 PLATE CESSNA401 401B 207590ECE CONT O520 TSIO520EB 17040SO FUEL CELL CRACKED W K NONE K FLUID LOSS ININSP/MAINT 1 CA 11516 (CAN) DURING A NR 3 INSPECTION, A FUEL STAIN WAS NOTICED AROUND THE RT NAVIGATION LIGHTCOVER. THE COVER WAS REMOVED AND A CRACK WAS FOUND ON THE FORWARD FUEL TANK PLATE. THE CRACK WAS UNDER THE LOWER STROBE LIGHT BRACKET, CAUSING FUEL TO LEAK INTO THE STROBE LIGHT/NAV LIGHT AREA. 1L72 3O3 O A7CE E8CE 20030909000752003090900075SW 2003 9 9 CA030826004 120030817G634032005023 PLATE BELL 206 206L 1181522SW ALLSN 25OC 250C20R GL MOUNTING LOOSE W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) LOOSE CONNECTOR MOUNTING PLATE. INSTALLED SERVICEABLE UNIT TSO 0:0. 1G71 3U3 U H2SW E4CE 20030909000772003090900077NE 2003 9 9 CA030826006 220030825G7200 ENGINE AIRBUSA340 A340313 EU CFMINTCFM56 CFM565C4 13802NE NR 4 OVERHEATED W FE ACTIVATE FIRE EXT. ENGINE SHUTDOWN MEJOVER TEMP VIBRATION/BUFFET WARNING INDICATION CLCLIMB 1 CA 26815 741670 (CAN) CLIMBING THROUGH FL130, NR 4 ENGINE STALLED AND HIGH TEMPS. A/C RETURNED HNL WITH ENG SHUT DOWN AND FIRE BOTTLES BLOWN. ENG HAD 17,536 HRS SINCE SHOP VISIT AND 2,068 CYCLES SINCE SHOP VISIT 2L74 4F4 FRTA197 E37NE 20030909000792003090900079 2003 9 9 CA030826007 420030824G3140066040211113 SYMBOL GENERATOR PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL COCKPIT FAILED W A UNSCHED LANDING H ELECT. POWER LOSS-50 PC CLCLIMB 1 CA (CAN) NR 1 SYMBOL GENERATOR FOR THE CAPTAIN'S ELECTRONIC FLIGHT INSTRUMENTS CAUSED BOTH UPPER AND LOWER CATHODE RAY DISPLAY TUBES TO FAIL ON THE CAPTAIN'S SIDE. UPPER AND LOWER CRT'S ON THE CAPTAIN'S SIDE WOULD INTERMITTENTLY GO INTO SELF TEST, AND WOULD ONLY SHOW 'SELF TEST' ON THE SCREENS OR BE COMPLETELY BLANK, NO FLIGHTDATA WAS AVAILABLE. NR 1 AND 2 SYMBOL GENERATORS WERE SWAPPED AND THE FAILURE FOLLOWED TO THE NR 2 (CO-PILOT) SIDE SYMBOL GENERATORS WERE RETURNED TO THEIR ORIGINAL LOCATION. NR 1 SYMBOL GENERATOR WAS REPLACED AND RECONFIGURED IN ACCORDANCE WITH THE MAINTENANCE MANUAL. SYSTEM OPERATED NORMAL. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20031106001232003110600123 2003 11 6 CA030826008 420030826G2562 BATTERY ACK ELT CORRODED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) TWO ELTS, THE AK-450 AND THE E-01, ARE APPROVED TO USE ALKALINE BATTERIES. AT PRESENT, WE ARE ABLE TO PURCHASE COMMERCIALLY BATTERIES WITH THE EXPIRATION DATE YEAR 2010. OTHER ELT MANUFACTURERS THAT USE SIMILAR BATTERIES HAVE A MANDATORY REPLACEMENT CYCLE OF 2 YEARS. WE HAVE ENCOUNTERED CORROSION DAMAGE ON ELTS THAT HAD BATTERIES INSTALLED LONGER THAN 2 YEARS. IT MAY BE ADVISABLE TO INFORM THE INDUSTRY TO REPLACE THE BATTERIES WITHIN A 2 YEAR PERIOD, REGARDLESS OF THE MANUFACTURER'S PROPOSED EXPIRATION DATE. 20030909000802003090900080GL 2003 9 9 CA030826009 320030818G6111 BLADE MCAULY1A100 1A100MCM GL PROPELLER CORRODED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) EXTRA WORK TO REMOVE CORROSION FROM PROPELLER CAMBER FACE. 5 NP918 20030909000822003090900082SW 2003 9 9 CA030826010 120030808G2497RCR326820JM RESISTOR BELL 206 206L1 1182107SW ALLSN 250C 250C28B 03013GL POTENTIOMETER BURNED W A UNSCHED LANDING BH SMOKE/FUMES/ODORS/SPARKS ELECT. POWER LOSS-50 PC CRCRUISE 1 CA (CAN) DURING NORMAL LEVEL CRUISE SMOKE & FUMES SEEN ESCAPING OVERHEAD ELECTRICAL PANEL. AIRCRAFT LANDED AND SHUTDOWN. SMOKE DISAPPEARED AND ALL SYSTEMS FOUND FUNCTIONAL EXCEPT INSTRUMENT LIGHTS. INSTRUMENT LIGHTS BREAKER PULLED AND DEACTIVATED. UPON INSPECTION OF OVERHEAD PANEL, RESISTOR FOR INSTRUMENT LIGHTS FOUND CHAFED THROUGH TO ANOTHER WIRE CAUSING RESISTOR TO SHORT OUT AND BURN. BETTER CARE IN INSTALLATION OF PARTS, PROPER SHEATHING AND BUNDLE LOCATING. 1G71 3U3 U H2SW E1GL 20030909000832003090900083NE 2003 9 9 CA030826011 220030806G8530356995 CYLINDER DOUG DC6 DC6B 3021712WP PWA R2800 CB3 52026NE HAMSTD43E 43E60 NE ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE AIRCRAFT WAS ORBITING THE FIRE WHEN THE FLIGHT CREW HEARD A BACKFIRE FROM THE NR 4 ENGINE. THE ENGINE WAS SHUT DOWN AND THE PROPELLER WAS FEATHERED. THE AIRCRAFT RETURNED TO BASE. MAINTENANCE CREWS FOUND THE NR 2 CYLINDER WAS CRACKED AT THE EXHAUST EAR. THE CYLINDER WAS REPLACED WITH A SERVICEABLE ASSEMBLY. THE ENGINE WAS GROUND RUN AND LEAK CHECKED SERVICEABLE. THE AIRCRAFT WAS RETURNED TO SERVICE. 2L74 4R4 R 6A4 E264 6 CP871 20030909000842003090900084NE 2003 9 9 CA030826012 220030729G8530356996 CYLINDER DOUG DC6 DC6B 3021712WP PWA R2800 CB3 52026NE HAMSTD43E 43E60 NE ENGINE LOOSE W E ENGINE SHUTDOWN D INFLIGHT SEPARATION CRCRUISE 1 CA (CAN) DURING CRUISE THE FLIGHT CREW NOTICED NR 1 ENGINE WAS BACKFIRING. THE ENGINE WAS SHUT DOWN AND THE PROPELLER WAS FEATHERED. THE AIRCRAFT RETURNED TO BASE. MAINTENANCE CREWS FOUND THE INTAKE INSERT ON NR 11 CYLINDER WAS LOOSE. THE CYLINDER WAS REPLACED WITH A SERVICEABLE ASSEMBLY. THE ENGINE WAS GROUND RUN AND LEAK CHECKED SERVICEABLE. THE AIRRAFT WAS RETURNED TO SERVICE. 2L74 4R4 R 6A4 E264 6 CP871 20030909000852003090900085WP 2003 9 9 CA030826013 120030731G2612351005 CONNECTOR CVAC 580 580 2422806WP ALLSN 501D 501D13 03004GL FIRE DETECTOR BROKEN W E ENGINE SHUTDOWN N FALSE WARNING CRCRUISE 1 CA (CAN) DURING CRUISE THE FLIGHT CREW RECEIVED A FIRE WARNING INDICATION FOR THE ZONE 1 AREA OF THE RT ENGINE. THE LOAD WAS JETTISONED, THE 'E' HANDLE WAS PULLED ON THE RT ENGINE AND THE AIRCRAFT RETURNED TO LOON RIVER. UPON INVESTIGATION THE CONNECTOR WAS FOUND BROKEN CAUSING THE FALSE INDICATION. THE CONNECTOR WAS REPLACED, THE SYSTEM WAS FUNCTION CHECKED SERVICEABLE AND THE AIRCRAFT WAS RETURNED TO SERVICE. 2L72 4T4 TRT E282 20030909000872003090900087EA 2003 9 9 CA030826014 220030825G8500 ENGINE GRUMANTS2 TS2ACALFORST3951102WP WRIGHTR1820 982C9HE2 67020EA HAMSTD43D 43D51 NE NR 2 FAILED W EA ENGINE SHUTDOWN UNSCHED LANDING BJ SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CLCLIMB 1 CA (CAN) DURING CLIMB THE PILOT NOTED NR 2 ENGINE WAS BACK FIRING AND SMOKE WAS VISIBLE. THE ENGINE WAS SHUT DOWN AND THE PROPELLER WAS FEATHERED. THE AIRCRAFT RETURNED TO YWL. UPON INVESTIGATION THE MAINTENANCE CREW NOTED THAT THE MAIN OIL SCREEN WAS CONTAMINATED WITH ALUMINUM AND STEEL. THE ENGINE IS BEING REPLACED WITH A SERVICEABLE UNIT. THE PROPELLER AND DOME WILL BE DRAINED AND FLUSHED PRIOR TO BEING REINSTALLED. THE ENGINE WILL BE GROUND RUN AND LEAK CHECKED PRIOR TO THE AIRCRAFT BEING RELEASED TO SERVICE. 2H72 4R4 R A25WE E259 6 CP8879 20030909000892003090900089WP 2003 9 9 CA030826015 120030818G2421696233B CSD DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE AC SYSTEM FAILED W H DEACTIVATE SYST/CIRCUITS M OVER TEMP CRCRUISE 1 CA 5061 (CAN) THE AIRCRAFT TOOK OFF FROM CANCUN AND THE CSD TEMPERATURE ON THE RT ENGINE WAS APPROACHING CAUTION SO THE PILOT DECIDED TO DISCONNECT THE CSD AND, DUE TO THE AIRCRAFT APU ON MEL, DECLARE AN EMERGENCY AND LANDED IN FLL. MAINTENANCE IN FLL CHECKED THE CSD OIL LEVEL AND FILTER DIFFERENTIAL PRESSURE INDICATOR. NO DEFECT FOUND, AIRCRAFT RETURNED TO SERVICE. FLIGHT TO YUL NO PROBLEM EXCEPT CSD TEMPERATURE IN YELLOW BAND. CSD WAS REPLACED AS A PRECAUTION IN YYZ. 2L72 4F4 FRTA6WE E9NE 20030909000902003090900090NM 2003 9 9 CA030826016 120030820G528059423782 HINGE BRACKET BOEING737 737201 1384454NM PWA JT8 JT8D9A 52048NE MLG DOOR CRACKED W O OTHER O OTHER TXTAXI/GRND HDL 1 CA (CAN) CRACK FOUND ON MAIN LANDING GEAR INNER DOOR ATTACH BRACKET FOR PUSH ROD. DOOR REMOVED AND OPERATED ON CDL 32-10-4. DOOR RECEIVED AND WILL BE INSTALLED. 2L72 4F4 F A16WE E2EA 20031020001742003102000174EA 2003 10 20 CA030826017 220030813G7250 ENGINE PWA PT6 PT6A28 EA NACELLE FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ENGINE CONTINUED TO BE OPERATED FOR APPROXIMATELY ONE HOUR BEFORE SEIZING TO A STOP, AFTER A 'LOW OIL LEVEL' INDICATOR ILLUMINATED IN THE COCKPIT. ENGINE WAS REMOVED AND SHIPPED TO REPAIR STATION TO REVIEW ENGINE AND DETERMINE REQUIRED WORKSCOPE. ATLANTIC TURBINES BELIEVES THAT THE EXCESSIVE HEAT GENERATED FROM THE LACK OF OIL BEING SUPPLIED TO THE LUBRICATED COMPONENTS CAUSED THE 1ST STAGE CARRIER ASSEMBLY TO SEIZE. NO DAMAGE WAS FOUND IN THE ENGINE THAT WOULD CAUSE A MAJOR OIL LOSS. 4 T E4EA 20030909000942003090900094NE 2003 9 9 CA030826018 220030813G7250 TURBINE BLADES AIRBUS320 A320211 3930320EU CFMINTCFM56 CFM565A1 NE NR 2 ENGINE SHINGLED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ON ROUTINE SERVICE CHECK FOUND NR 2 ENGINE NOZZLE ASSY CRACKED APPROX 3/4 OF THE WAY AROUND. NO NOTICABLE VIBRATIONS. UPON REMOVAL OF NOZZLE ASSY NOTICED SOME TURBINE BLADES SHINGLED. ENGINE HAD BEEN INSTALLED NOV 2002. ENGINE REMOVED FOR SHOP INVESTIGATION. ENG SER 731399 TOTAL HRS 28,672 TOTAL CYCLES 10,342 TIME SINCE INSTALLED 1,847 AND CYCLES 833 2L72 4F4 FRTA28NM E29NE 20030909000952003090900095NE 2003 9 9 CA030826019 220030813G74219550175400 IGNITER SNIAS 350 AS350BA 8680817EU TMECA ARRIELARRIEL1B 6OO30NE ENGINE FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ON ROUTINE INSPECTION BOTH ENGINE IGNITERS WERE FOUND TO HAVE LOOSE CENTER ELECTRODES. IN LIGHT OF RECENT TURBOMECA SERVICE LETTERS REGARDING IGNITERS (N/A TO THIS PN THOUGH) IT WAS DEEMED NECESSARY TO REPLACE THEM TO PREVENT POSSIBLE ENGINE DAMAGE CAUSED BY AN ELECTRODE DETACHING AND FODDING THE ENGINE. 1G71 3U3 UNCH9EU E19EU 20031020001772003102000177CE 2003 10 20 CA030827001 120030821G532026111441 SUPPORT CESSNA208 208B 2073701CE PWA PT6 PT6A114A 52043NE MCAULY3AF34C3GFR34C703 GL FLAP ACTUATOR CRACKED W O OTHER F FLT CONT AFFECTED APAPPROACH 1 CA 1841618416 (CAN) ON APPROACH, FLAPS WERE SELECTED TO 30 DEGREES. FLAP INDICATION WAS SHOWING 20 DEGREES & AIRSPEED CONFIRMED FLAPS WERE INOPERATIVE. FLAP MOTOR CIRCUIT BREAKER WAS POPPED & STANDBY FLAP MOTOR WAS TRIED WITH NO RESULTS. A SUCCESSFUL LANDING WAS MADE & FLAPS WERE FOUND STUCK IN THE 20 DEGREE POSITION. INSPECTION REVEALED FLAP ACTUATOR SUPPORT ASSY TORN & CRACKED. TRANSMISSION HAD TWISTED SUPPORT ASSY & JAMMED. ATTEMPTED USE OF ALTERNATE FLAP MOTOR BY CREW HAD SHEARED DRIVE COUPLING. MM CALLS UP AN INSPECTION OF FLAP SUPPORT ASSY EACH 400 HRS. SUPPORT ASSY APPEARED TO HAVE NUMEROUS CRACKS PRESENT PRIOR TO BREAKING POINT, LEADING TO INCREASED STRESS & UNSUPPORTABLE LOAD. 1H71 3T3 T A37CE E4EA 5 CP60GL 20030909000962003090900096SO 2003 9 9 CA030827002 220030825G8530654004 EXHAUST VALVE CESSNA150 150M 2071830CE CONT O200 O200A 17020SO ENGINE ERODED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) DURING THE BOROSCOPE INSPECTION OF THE ON-CONDITION PROGRAM, SPECIAL EFFORT WAS MADE TO INSPECT THE EXHAUST VALVE AS WE HAD FOUND A PREVIOUS VALVE OF THE SAME PART NUMBER IN POOR CONDITION. THE NR 2 CYLINDER EXHAUST VALVE WAS FOUND SEVERELY ERODED 1/3 TO 1/2 OF THE WAY ACROSS THE DIAMETER OF THE VALVE STEM WHERE THE STEMOF THE VALVE MEETS THE HEAD OF THE VALVE. THE PROBLEM APPEARS TO BE A METALLURGICAL PROBLEM OR A DEFECT IN THE MANUFACTURE OF THE VALVE. THE VALVE WILL BE REPLACED NEW. ALL OTHER ASPECTS OF THE ENGINE WERE INSPECTED FOR A CAUSE OF THIS PROBLEM AND NONE WERE EVIDENT. 1H71 3O3 O 3A19 E252 20030909000992003090900099NM 2003 9 9 CA030827003 120030825G3244 TIRE BOEING767 767233 1385113NM PWA JT9 JT9D7R4D 52054NE MLG FAILED W C ABORTED TAKEOFF O OTHER TOTAKEOFF 1 CA (CAN) ON ROTATION NR 2 TIRE BLEW RECAP OFF. FLASH OF LIGHT SEEN FROM FLT DECK, LOUD BANG AND RUBBER ODOR IN C/P. RETURNED TO YYZ. ON ARRIVAL FOUND RECAP MISSING AND TIRE STILL INFLATED. CREW REPORTED NR 1 ENG VIBS UP TO 1.7 UPON INSPECTION FOUND DAMAGE TO SOME FAN BLADES ON NR 1 ENG. A/C HANGERED FOR INSPECTION AND OVERWIEGHT LANDING CHECK. TIRE HAD BEEN INSTALLED MAY 02 2003. ASSY HAD HAD TWO RECAPS 2L72 4F4 FRTA1NM E3NE 20030909001012003090900101CE 2003 9 9 CA030827004 120030818G3245600X6 TUBE CESSNA207 207 2073602CE CONT O520 IO520D 17032SO NLG TIRE PINCHED W E ENGINE SHUTDOWN E VIBRATION/BUFFET TXTAXI/GRND HDL 1 CA (CAN) AFTER LANDING, THE PILOT EXPERIENCED A SHIMMY IN THE AIRFRAME WHILE TAKING OFF THE RUNWAY. THE PILOT STOPPED AND SHUTDOWN THE AIRCRAFT. THE NOSE WHEEL WAS FOUND TO BE FLAT. MAINTENANCE PERSONNEL REPLACED NOSE WHEEL ASSEMBLY WITH SERVICEABLE UNIT. THE FLAT NOSE WHEEL ASSEMBLY WAS DISASSEMBLED AND THE TUBE WAS FOUND PINCHED ALONG ITS CENTRE LINE ADJACENT TO THE TIRE CENTRE LINE. IT APPEARS THAT THE BALANCE WEIGHT ATTACHED INSIDE THE TIRE WAS WHAT CAUSED THE TUBE FAILURE. 1H71 3O3 O A16CE E5CE 20030909001022003090900102NE 2003 9 9 CA030827006 220030819G7200 ENGINE SKRSKYS61 S61N 8142104NE GE CT58 CT581401 30011NE FAILED W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) AC WAS INVOLVED IN FIREFIGHTING OPERATIONS. AFTER PICKING UP LOAD OF WATER WITH A 95 PERCENT TORQUE SETTING AC BEGAN A CLIMB. 5 SECONDS INTO CLIMB AT 95 PERCENT TORQUE PILOTS HEARD WHAT WAS DESCRIBED AS A COMPRESSOR STALL AND FELT A SLIGHT KICK IN AIRFRAME. THE NR 1 TORQUE DROPPED TO 20 PERCENT AND FLUCTUATED MOMENTARILY. PILOT THEN REDUCED POWER AND LOWERED BUCKET BACK INTO WATER. ALL INDICATIONS WERE NORMAL. AC THEN RETURNED TO SERVICE LANDING. NR 1 ENGINE HAS BEEN REMOVED AND REPLACED. BOTH FREEWHEEL UNITS HAVE BEEN REMOVED AND REPLACED. CAUSE OF THE MOMENTARY POWER LOSS, UNKNOWN. FREEWHEEL UNITS WILL BE BROUGHT TO OUR OVERHAUL FACILITY FOR A DOCUMENTED TEARDOWN AND INSPECTION. 2G72 4U4 U 1H15 1E3 20030909001032003090900103CE 2003 9 9 CA030827007 120030819G7810NH100089740 CLAMP CESSNA401 401 207590CCE CONT O520 TSIO520E 17040SO MCAULY3AF32C3AF32C* GL EXHAUST PIPE BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING A NR 4 INSPECTION, THE V-BAND CLAMP ATTACHING THE EXHAUST TAIL PIPE TO THE TURBOCHARGER, WAS FOUND BROKEN. THE CLAMP WAS BROKEN IN HALF. THE ONLY THING HOLDING THE TAIL PIPE ON WAS A SUPPORTING HOSE TYPE CLAMP MOUNTED HALF WAY DOWN THE PIPE. THE BROKEN CLAMP WAS REPLACED. 1L72 3O3 O A7CE E8CE 5 CP22EA 20030909001042003090900104 2003 9 9 CA030827008 420030813G256569492111 NUT PLATE BOEING727 727251 138408HNM PWA JT8 JT8D15A 52051NE GIRT BAR MISSING W K NONE O OTHER ININSP/MAINT 1 CA (CAN) L-2 DOOR ESCAPE SLIDE GIRT BAR FORWARD FLOOR FITTING NUT PLATE ASSY MISSING, UNDER FLOOR PANEL. THIS NUT PLATE REENFORCED THE GIRT BAR FITTING ATTACHMENT TO THE FLOOR. IN CASE OF CHUTE DEPLOYEMENT, THE LOAD IN THE SLIDE WOULD PULL ON THE ATTACH FITTING AND COULD PULL ON THE FLOOR PANEL, LEAVING THE CHUTE ATTACHED BY ONLY ONE FITTING. 2L73 4F4 F A3WE E2EA 20030909001062003090900106EA 2003 9 9 CA030827009 220030630G8530SL11795 VALVE SPRING PIPER PA28 PA28181 7102807SO LYC O360 O360A4M 41514EA SNSNCH76E 76EM8S5 EA ENGINE BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) BOTH EXHAUST VALVE SPRING BROKEN, NR 1 CYLINDER. NEW SPRINGS INSTALLED ALL CYLINDER. RAN OK, SLIGHT INCREASE IN EXHAUST GAS TEMPERATURE NR 1 RPBE. 1L71 3O3 O 2A13 E286 5 NP4EA 20030909001072003090900107SO 2003 9 9 CA030827010 120030821G55207C103053 HORN GULSTMGA7 GA7 3960401SO LYC O320 O320D1D 41508EA HARTZLHCF2Y HCF2Y* GL ELEVATOR CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA 14673 (CAN) LT ELEVATOR HORN ASSEMBLY WAS FOUND TO BE CRACKED. 1L72 3O3 O A17SO E274 5 CP27EA 20030909001082003090900108NM 2003 9 9 CA030827011 120030813G2740MS202204 PULLEY BOEING727 727251 138408HNM PWA JT8 JT8D15A 52051NE STAB TRIM WORN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) WHILE INSPECTING THE TAIL AREA (C-CHECK), IT WAS NOTICED THAT THE RT STABILIZER TRIM CABLE WAS TRAVELLING VERY CLOSE TO THE PULLEY HOLDING BRACKET. FURTHER INVESTIGATION REVEALED ONE MORE RT CABLE PULLEY WORN AND TWO OTHERS WORN OUT ON THE LT CABLE. CABLES TENSION TEST WAS CARRIED OUT AND BOTH CABLES TENSION VALUE WERE FIVE LBS BELOW THE MINIMUM SPECIFIED MANUFACTURER TENSION LIMIT. ALL FOUR PULLEYS WERE REPLACED, SYSTEM RIGGED AND NORMAL FUNCTION RESUMED IAW MM. 2L73 4F4 F A3WE E2EA 20030909001102003090900110NM 2003 9 9 CA030827012 120030813G575366147195 BOLT BOEING727 727251 138408HNM PWA JT8 JT8D15A 52051NE TE FLAP ROLLER MISSING W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING INSPECTION FOUND RT INBOARD FLAP 2ND INBOARD TRACK, FORWARD ROLLER BOLTS (2) ASSY MISSING. 2L73 4F4 F A3WE E2EA 20031020001792003102000179CE 2003 10 20 CA030827013 120030827G30801013800159 HOSE BEECH 200 B200 1152922CE PWA PT6 PT6A42 52043NE BRAKE DEICE SYS DETERIORATED W KK NONE NONE O OTHER ININSP/MAINT 1 CA (CAN) BRAKE DE-ICE HOSE WAS FOUND TO BE BLOCKED DUE TO DETERIORATION OF THE INSIDE OF HOSE. THE UPPER FLEXIBLE HOSE WAS FOUND TO PASS SHOP AIR THROUGH AN AIR NOZZLE BUT WAS NOT FOUND TO PASS THE VOLUME SUPPLIED BY THE ENGINE BLEED AIR. THE LARGE VOLUME OF AIR BLOCKED THE INSIDE OF THE HOSE COMPLETELY AND WOULD NOT ALLOW THE LT BRAKE TO BE DE-ICED. 1L72 4T4 T A24CE E4EA 20031020001802003102000180SW 2003 10 20 CA030828001 120030820G291070012F000X204 HOSE BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA HYD SYSTEM RUPTURED W A UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 CA (CAN) DURING FLIGHT THE PILOT NOTICED A LOSS OF HYD PRESSURE ON NR 1 HYDRAULIC SYSTEM. THE SYSTEM WAS DEACTIVATED AND THE PILOT RETURNED TO BASE. AFTER LANDING, SYSTEM NR 1 WAS INSPECTED AND A HYD PRESSURE HOSE WAS FOUND RUPTURED. THE HOSE ASSEMBLY WAS REPLACED AND THE SYSTEM SERVICEABILITY CHECKS WERE COMPLETED. 1G71 4U4 U H4SW E22EA 20030909001112003090900111SO 2003 9 9 CA030828002 220030820G8530 EXHAUST VALVE PIPER PA46 PA46310P 7104605SO CONT O550 TSIO550C SO CYLINDER HEAD BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) CRUISING AT 25,000 FT, MANIFOLD PRESS DROPPED BY 5 INCHES, DID NOT RECOVER UNTIL BELOW 10,000 FT. MAINT CHECKS ON GROUND DETERMINED NO (ZERO) COMPRESS ON NR 6 CYL UPON REMOVAL OF CYL EXHAUST VALVE WAS DISCOVERED TO HAVE .2500 OF VALVE FACE MISSING. PIECE OF VALVE WAS FOUND LODGED IN LT TURBOCHARGER CAUSING WHEEL DAMAGE. EXAM OF ENG CASE REVEALED A 4 INCH CRACK ON MAIN JOURNAL BETWEEN CYL 4 AND 6. NOTE: 137 HRS PRIOR TO THIS INCIDENT, MAINT FACILITY HAD NOTED SMALL CRACK IN ENG CASE BETWEEN CYL 4 AND 6, LOG BOOK. NOTATION READS 'SEALED SMALL CRACK IN LT CRANKCASE BETWEEN CYLINDER NR 4 AND NR 6 BELOW 7TH. STUD CRACK TO BE MONITERED AT SCHEDULED INSP'. 1L71 3O3 ORTA25SO E5SO 20030909001132003090900113EA 2003 9 9 CA030828003 220030813G7414 IMPULSE COUPLINGBENDIX PIPER PA28 PA28140 7102802SO LYC O320 O320E2A 41508EA MAGNETO SEIZED W K NONE O OTHER ININSP/MAINT 1 CA 877086 (CAN) ENGINE FAILED TO START. THE LT MAGNETO IMPULSE COUPLING SEIZED. MAGNETO REMOVED FOR REPAIR. 1L71 3O3 O 2A13 E274 20030909001152003090900115CE 2003 9 9 CA030828004 120030821G7330811015 INDICATOR BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA FUEL QTY ARCED W O OTHER O OTHER TXTAXI/GRND HDL 1 CA (CAN) PILOT REPORTS (SNAG VERIFIED LATER) LT FUEL QUANTITY INDICATOR FLUCTUATES BETWEEN 1000 & 1400 LBS. (FREQUENCY OF NEEDLE FLUCTUATION RENDERS NEEDLE A BLUR). INSPECTION OF INDICATOR REVEALED WATER MARKS ON LOWER FORWARD FACE OF INDICATOR AND ON REAR OF INDICATOR EVIDENCE OF WATER DRIPPING WAS APPARENT. SUSPECT WATER DRIPPING IN ON FUEL PANEL WHEN WINDOW OPENED AFTER A RAIN. 1L72 3T4 TRT3A20 E4EA 20030909001172003090900117NE 2003 9 9 CA030828005 220030822G72503028601 BLADE CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE TURBINE SECTION FRACTURED W O OTHER E VIBRATION/BUFFET CLCLIMB 1 CA (CAN) PILOTS NOTICED SLIGHTLY HIGHER ITT TEMP ON RT ENG A SLIGHT RISE IN N2 SPEEDS. TEMP AND N2 INDICATIONS, AS WELL AS ALL OTHER INDICATIONS WHERE NOTED TO BE WELL WITHIN NORMAL OPERATING PARAMETERS.ON FINAL INTO CALGARY AIRPORT WHILE POWERING BACK A SLIGHT VIBRATION WAS NOTED BY PIC.PILOT LANDED WITH BOTH ENGINES RUNNING.ONCE SHUTDOWN, PILOT INVESTIGATED BOTH ENGINES BY VISUALLY LOOKING IN INTAKES AND EXHAUSTS. PILOT NOTICED SEVERAL SMALL PARTICLES OF METAL INSIDE EXHAUST DUCT ON RT ENG. HOT SECTION OF RT ENG REMOVED FOR INVESTIGATION. HIGH PRESSURE TURBINE BLADES FOUND SEVERELY DAMAGED (3 OR MORE BLADE TIPS MISSING AND/OR TIPS CURLED OVER). ENGINE REMOVED FROM AIRFRAME FOR INVEST. 1L72 4F4 F A22CE E1NE 20030909001182003090900118EA 2003 9 9 CA030828006 220030820G8520LW10346 CRANKSHAFT PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA ENGINE SHEARED W EA ENGINE SHUTDOWN UNSCHED LANDING EY VIBRATION/BUFFET ENGINE STOPPAGE CRCRUISE 1 CA (CAN) PILOT DEPARTED NORWAY HOUSE FOR WINNIPEG. AFTER REACHING CRUSE ALTITUDE THE L/H ENGINE RAN ROUGH FOR A SHORT PERIOD OF TIME THEN FEATHERED ON ITS OWN AND SHUT DOWN. THE PILOT RETURNED TO NORWAY HOUSE AND LANDED UNEVENTFULLY. ON THE GROUND IT WAS DETERMINED THAT WHEN THE PROPELLER WAS TURNED THROUGH BY HAND THAT PISTONS IN CYLINDERS 6,5,4, & 3 WERE NOT MOVING. THE LT ENGINE WAS REPLACED AND THE AIRCRAFT RETURNED WITH OUT FURTHER INCIDENT. INVESTIGATION OF THE FAILED ENGINE IS ON-GOING. PRELIMINARY INVESTIGATION SHOWS THAT THE CRANKSHAFT SHEARED IN 2 PLACES CAUSING EXTENSIVE DAMAGE. 1L72 3O3 O A20SO E14EA 20031017000022003101700002EA 2003 10 17 CA030829001 120030821G3212C2UF1085 STRUT DHAV DHC3 DHC3 2800202EA PWA R1340 R134059 52016NE HAMSTD23D 23D40 NE LT FLOAT CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) LT FLOAT MAIN FORWARD STRUT FOUND CRACKED AT TOP ATTACHMENT LUG DURING AIRCRAFT REFUELING, GROUNDED, AWAITING NEW STRUT. 1H71 3R3 R A815 5E2 6 CP719 20030909001192003090900119GL 2003 9 9 CA030829002 220030822G725023031937 NOZZLE BELL 206 206B 1181511SW ALLSN 250C 250C20B 03013GL TURBINE CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) WHILE TROUBLESHOOTING AN ENGINE THAT WAS RUNNING HOTTER THAN NORMAL, WE PRFORMED A HOT SECTION INSPECTION AND FOUND THE 1ST STAGE NOZZLE CRACKED 90 DEGREES AROUND THE INNER RIM. IF THE CRACK HAD NOT BEEN FOUND, A TURBINE FAILURE MAY HAVE OCCURRED. 1G71 3U3 U H2SW E4CE 20031020000052003102000005NM 2003 10 20 CA030902002 120030825G2421 CIRCUIT BOARD BOEING737 737281 138448PNM PWA JT8 JT8D17 52049NE 3 PHASE FAILED W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) AIRCRAFT REPORTS SHORTLY AFTER TAKE OFF ROTATION, NUMEROUS THREE PHASE CIRCUIT BREAKERS (2 AND 3 THRUST REVERSER, GASPER FAN AND PANEL INSTRUMENT INDICATOR NR 1 DC) POPPED CAUSING LOSS OF SEVERAL SYSTEMS AND ANNUNCIATIONS. NR 2 2L72 4F4 F A16WE E2EA 20031020000062003102000006 2003 10 20 CA030902003 420030808G34178220372436 ADC CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE COCKPIT DEFECTIVE W C ABORTED TAKEOFF H ELECT. POWER LOSS-50 PC TOTAKEOFF 1 CA (CAN) AN ABORTED TAKE OFF ROLL OCCURED AT 100 KTS IAS FOR A 20 KTS SPLIT BETWEEN PILOT AND CO-PILOT INDICATED AIRSPEED. LT 60 KTS - RT 60 KTS, LT 70 KTS = RT 80 KTS, LT 100 KTS = RT 120 KTS. AIR DATA COMPUTER NR 1 REPLACED WITH A SERVICEABLE UNIT IAW AMM. SYSTEM CHECKED AND FOUND SERVICEABLE. DEFECTIVE UNIT RETURNED TO VENDOR. 2L72 4F4 FRTA21EA EOOO63EN 20031020000072003102000007EA 2003 10 20 CA030903001 220030817G8520 CASE PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL ENGINE CRACKED W O OTHER K FLUID LOSS NRNOT REPORTED 1 CA (CAN) PILOT REPORTED ENGINE OIL ON NR 1 COWL WHEN COWL WAS REMOVED IT WAS NOTICED THAT THERE WAS OIL ON TOP OF THE NR 6 CYL. HOLD DOWN STUDS. AFTER THE ENGINE WAS CLEANED IT WAS GROUND RUN AND THE OIL APEARED TO BE COMING FROM AROUND THE STUD BUT AFT ER FURTHER INSPECTION AND PAINT REMOVAL THERE WAS A HAIRLINE CRACK APPROX. 1.5 INCHES IN LENGTH.THE ENGINE WAS REMOVED AND A NEW CASE WAS INSTALLED. 1L72 3O3 O A20SO E14EA 5 CP33EA 20031020000082003102000008EU 2003 10 20 CA030903002 120030901G291010546649 MANIFOLD BOLKMS 10545028 BOLKMS105 BO105C 5626005EU ALLSN 250C 250C20B 03013GL VALVE BODY FAILED W O OTHER F FLT CONT AFFECTED NRNOT REPORTED 1 CA 052235 (CAN) THE INDICATOR LIGHT FOR THE NR 1 HYD SYS WILL NOT EXTINGUISH WHEN POWERED BY THE HYDRAULIC CART NOR WILL THE RESERVOIR DRAIN INTO THE HYDRAULIC CART. (SUSPECT THE TEST SCREW ORIFICE IN THE VALVE BODY IS PLUGGED). THE HYDRAULIC POWER PACK ASSEMBLY WAS REPLACED AND GROUND CHECKED SERVICEABLE. THE SUSPECT ASSEMBLY WAS SENT FOR REPAIR. 1G72 3U3 U H3EU E4CE 20031020001822003102000182EA 2003 10 20 CA030903003 220030717G72303023401 BLADE DHAV DHC6 DHC6300 2802606EA PWA PT6 PT6A27 52043EA HARTZLHCB3T HCB3TN3 GL COMPRESSOR FAILED W AE UNSCHED LANDING ENGINE SHUTDOWN YJ ENGINE STOPPAGE WARNING INDICATION CRCRUISE 1 CA (CAN) RT ENGINE SHUTDOWN DUE TO LOW TORQUE 10 PSI AND RISING T5 SHUTDOWN AT 690 DEGREES C. PILOT WAS IN CRUISE ABOUT 9 MINS AFTER TAKEOFF FROM GJOA HAVEN. AIRCRAFT RETURNED TO GJOA HAVEN AND PERFORMED AN UNEVENTFUL LANDING. MAINTENANCE DISCOVERED A FUEL LINE BETWEEN START CONTROL AND FCU WAS BROKEN. INTAKE SCREEN WAS REMOVED TO GAIN ACCESS TO COMPRESSOR INLET. COMPRESSOR WAS DETERMINED TO BE SEIZED. ENGINE WAS SUBSEQUENTLY REMOVED AND SENT TO STANDARD AERO FOR EXAMINATION. IT WAS DETERMINED THAT THE CT DISC HAD A BLADE FAILURE CAUSING AN INTERNAL ENGINE VIBRATION WHICH CAUSED THE FUEL LINE TO CRACK AND CAUSED FAILURE OF THE ENGINE MAIN BEARINGS. 1H72 3T4 TRTA9EA E4EA 6 CP15EA 20031020001832003102000183CE 2003 10 20 CA030903004 120030820G2810 LINE BEECH 100 A100 1152915CE PWA PT6 PT6A28 EA HARTZLHCB3T HCB3TN3 GL FUEL CELL BLOCKED W O OTHER XJ ENGINE FLAMEOUT WARNING INDICATION CRCRUISE 1 CA (CAN) AIRCRAFT HAD LT ENGINE SHUTDOWN IN FLIGHT. AFTER EXTENSIVE TROUBLESHOOTING FOUND THAT AN INTERNAL PATCH ON FUEL BLADDER HAD COME OFF AND BLOCKED THE LINE TO NACELLE TANK. ALL TANKS WERE INSPECTED AND 2 OTHER TANKS HAD INTERNAL PATCHES. FUEL CELL REPAIRER TOLD US THAT INTERNAL PATCHES ARE COMMON PRACTICE. WE HAVE INSTITUTED AN INSPECTION OF ALL BLADDER MACHINES TO DOCUMENT PATCHED TANKS AND PUT THEM ON A 12 MONTH INSPECTION. 1L72 3T4 T A14CE E4EA 6 CP15EA 20031020001852003102000185WP 2003 10 20 CA030903005 120030818G6520369D25146 BEARING HUGHES369 369E 4470707WP ALLSN 250C 250C20R2 GL M/R TRANSMISSIONFAILED W A UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 CA (CAN) AS DESCRIBED ABOVE ROLLER BEARING PN 369D25146 INNER RACE FAILURE. IN THIS CASE THIS FAILURE WAS DETECTED BY THE AIRCRAFTS WARNING SYSTEM. THE AIRCRAFT WAS FOR CED TO MAKE AN UNSCHEDULED LANDING. THE FAILURE OF THIS P/N BEARING HAS BEEN SEEN ON MORE THAN ONE OCCASION. THIS PROBLEM NEEDS TO BE REVIEWED BY THE MANUFACTURER AND A CHECK OF THE BEARINGS TOLERANCE ETC. BEFORE A MORE SERIOUS INCIDENT OCCURS. 1G71 3U3 U H3WE E4CE 20031020001862003102000186EA 2003 10 20 CA030903006 120030827G27316009230165 ACTUATOR CNDAIRCL601 CL6012A12 1900303EA GE CF34 CF341A NE PITCH TRIM FAILED W A UNSCHED LANDING FJ FLT CONT AFFECTED WARNING INDICATION APAPPROACH 1 CA (CAN) ATTEMPT TO TRIM AIRCRAFT NOSE UP OR NOSE DOWN CAUSED BOTH PITCH TRIM CHANNELS TO INDICATE (OFF). THUS HORIZONTAL PITCH TRIM SYSTEM DE-ACTIVATED. 2L72 4F4 FRTA21AE E15NE 20031020001932003102000193SO 2003 10 20 CA030903007 220030812G73106524323A1M VALVE BEECH 58 58P 1152744CE CONT O520 TSIO520WB 17040SO HARTZLHCC3Y PHCC3YF2 GL RT ENGINE LEAKING W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) PN 6524323A1M (FLOW DIVIDED) LEAKING FUEL AFTER ENGINE SHUT DOWN/NEW PART INSTALLED. 1L72 3O3 O A23CE E8CE 5 CP25EA 20031020001952003102000195EA 2003 10 20 CA030903008 120030705G281021564075 FUEL CELL CNDAIRCL215 CL2156B11415 EA PWA PW120 PW123 NE HAMSTD14SF 14SF* NE RT WING LEAKING W O OTHER K FLUID LOSS NRNOT REPORTED 1 CA (CAN) FUEL LEAKING FROM RT WING FROM FRONT SPAR IN FRONT OF FUEL CELL NR 6 FUEL CELLS NR 6,7,8 REMOVED FROM A/C TO INSPECT FOR LEAKS. NR 6, NR 7 FUEL CELL PRESSURE TESTED AND FOUND SERVICEABLE. NR 8 FUEL CELL PRESURE TESTED AND A HOLE WAS FOUND AT THE BOTTOM OF THE CELL. NR 8 FUEL CELL PN 21564075 SN 72846 REMOVED AND CELL REPLACED. A/C REFUELED AND NO LEAKS DETECTED OVERNIGHT. A/C RETURNED TO SERVICE. 2H72 4T4 TRTA14EA E20NE 6 CP7NE 20031020001962003102000196SW 2003 10 20 CA030903009 120030813G5302206031329103 ATTACH FITTING BELL 206 206L1 1182107SW ALLSN 250C 250C28B 03013GL TAILBOOM CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ON SCHEDULED 100 HR INSPECTION, VISUAL INSPECTION OF TAILBOOM ATTACH FITTINGS. UPPER LT AIRFRAME FITTING FOUND CRACKED. UPON FURTHER INVESTIGATION AFT AIRFRAME BULKHEAD FOUND CRACKED AT UPPER LT LOCATON. SUSPECTED CAUSE LONG IDLE TIMES AT 60 PERCENT N1 AND HEAVY SLING LOADS. MANUFACTURING DEFECTS POSSIBLY A FACTOR ALSO. SHORTEN IDLE TIMES TO ONLY NECESSARY COOL DOWN AND WARM UP TIMES. WHEN IDLING FOR PERIODS OF TIME, USE 70 PERCENT N1. 1G71 3U3 U H2SW E1GL 20031021000022003102100002EA 2003 10 21 CA030903010 120030812G2810215640024 FUEL CELL CNDAIRCL215 CL2156B11415 EA PWA PW120 PW123 NE HAMSTD14SF 14SF* NE RT WING LEAKING W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) UPON INSPECTION OF RT WING FUEL LEAKING FROM SPAR AREA IN FRON OF CELL NR 6 ON OUTBOARD SIDE OF ENGINE NACELLE. NR 7 FUEL BLADDER SN 72863 PN 215-64002-4 FROM HOLE IN THE BOTTOM OF THE BLADDER CELL REPLACED, A/C REFUELED, LEAK CHECKED OK. A/C RETURNED TO SERVICE. 2H72 4T4 TRTA14EA E20NE 6 CP7NE 20031020001972003102000197EA 2003 10 20 CA030903011 120030826G281021564002 FUEL CELL CNDAIRCL215 CL2156B11415 EA PWA PW120 PW123 NE HAMSTD14SF 14SF* NE RT WING LEAKING W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) FUEL LEAK DETECTED RT WING. CELL NR S POSITION 1,2,3,4,5, REMOVED FOR TESTING.CELLS NR 1,2 TESTED OK AND REINSTALLED CELL NR 3 PN 21564002-4 S NR 72862 TESTED DEFECTIVE AND REPLACED. CELL NR 4 PN 21564002 S NR 72826 TESTED DEFECTIVE AND REPLACED. CELL NR 5 PN 21564002-6 S NR 72856 TESTED DEFECTIVE AND REPLACED. CELL NR 6 PN 21564002 SN 72848 TESTED DEFECTIVE AND REPLACED. A/C GROUND RUN AND LEAKED CHECK SERVICABLE. 2H72 4T4 TRTA14EA E20NE 6 CP7NE 20031020001982003102000198EA 2003 10 20 CA030903012 120030804G2810215640024 FUEL CELL CNDAIRCL215 CL2156B11415 EA RIGHT LEAKING W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) RT FUEL CELL POSITION NR 7 REPLACED PN 215640024, SN 72562 REMOVED AND FOUND LEAKING. CELL REPLACED A/C REFUELED AND LEAK TESTED OK. A/C RETURNED TO SERVICE. 2H72 4T RTA14EA 20031020001992003102000199EA 2003 10 20 CA030903013 120030828G2810215640024 FUEL CELL CNDAIRCL215 CL2156B11415 EA LEFT LEAKING W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) UPON INSPECTION LT WING WAS FOUND LEAKING. FUEL CELLS POSITION NR 4, PN 215-640024, SN 82119 TESTED DEFECTIVE AND REPLACED.POSITION NR 7, PN 21564002 SN 72478 TESTED DEFECTIVE AND REPLACED.POSITION NR 8 PN 21564075 SN 75337 TESTED DEFECTIVE AND REPLACED. REFUELED GROUND CHECKED SERVICEABLE. 2H72 4T RTA14EA 20031020002002003102000200WP 2003 10 20 CA030903014 120030823G2131 CONTROLLER DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE CABIN PRESSURE FAILED W A UNSCHED LANDING O OTHER CLCLIMB 1 CA (CAN) ON DEPARTURE YYZ, HAD A PRESSURE (PRESSURIZATION) BUMP, GAGES CHECKED NORMAL THROUGH 1000 FEET, HAD A CABIN ALT OF 1000 FT. DIFFERENTIAL, PRESSURE OF 2.0 PSI. QRH FOLLOWED AND LANDED BACK TO YYZ. A/C PRESSURIZED TO 8 PSI ON GROUND IN MANUAL MODE, NO FAULT FOUND. MEL RAISED AND CLEARED BY THE ACCOMPLISHMENT OF BITE TEST ON BOTH CABIN PRESSURE CONTROLLERS, NIL FAULT FOUND. 2L72 4F4 FRTA6WE E9NE 20031020002012003102000201WP 2003 10 20 CA030903015 120030825G5241 SEAL DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE AFT GALLEY DOOR FAILED W BI EMER. DESCENT CABIN DEPRESSURIZATION J WARNING INDICATION CLCLIMB 1 CA (CAN) DURING CLIMB FROM YQX, CABIN ALT. WAS ANNUNCIATED WITH MASTER WARNING. FLOW LITEWAS ON PRESSURE CONTROLLER. EMERGENCY DESXENT INITIATED AND LANDED BACK TO YQX. AFT GALLEY DOOR ANNUNCIATED BRIEFLY DURING DESCENT. AFT SERVICE DOOR SEAL AND LATCHES CHECKED, DOOR CYCLED, AIRCRAFT PRESSURIZED ON GROUND AND NO LEAK NOTED, ANNUNCIATOR LIGHT OUT. AIRCRAFT RELEASED FOR FLIGHT. 2L72 4F4 FRTA6WE E9NE 20031020002022003102000202EA 2003 10 20 CA030903016 120030414G281021564002 FUEL CELL CNDAIRCL215 CL2156B11415 EA LT WING LEAKING W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) DURING WINTER MAINTENANCE IT WAS DISCOVERED THAT A/C HAD SOME AMOUNTS OF FUEL LEAKING FROM WINGS. 6 CELLS IN ALL WERE FOUND LEAKING ON THE LT WING. 2H72 4T RTA14EA 20031020002032003102000203SW 2003 10 20 CA030903017 120030824G2897PT02E82P CONNECTOR SWRNGNSA226 SA226TC 8780404SW RT BOOST PUMP BURNED W O OTHER O OTHER DEDESCENT 1 CA (CAN) PILOT'S SELECTED RT MAIN BOOST PUMP ON AND CIRCUIT BREAKER POPPED. CIRCUIT BREAKER POPPED AGAIN AND WAS LEFT ALONE FOR REMAINDER OF FLIGHT. THE BOOST PUMP WAS REMOVED AND FOUND THAT THE CONNECTOR ON THE PUMP AND THE AIRFRAME WIRING HAD SHORTED INTERNALLY. CONNECTOR AND BOOST PUMP WAS REPLACED. 2L72 4T RTA8SW 20031020002042003102000204NM 2003 10 20 CA030904001 120030831G243411521062 STARTER GEN BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA NR 1 FAILED W O OTHER BO SMOKE/FUMES/ODORS/SPARKS OTHER APAPPROACH 1 CA (CAN) NR 1 DC STARTER- GENERATOR SHAFT SHEARED ON APPROACH. PASSENGERS NOTICED SPARKS COMING FROM THE NACELLE. THE INTENSE HEAT DISCOLOURED AND BLISTERED THE PAINT AND WARPED THE COMPOSITE AROUND THE GENERATOR EXHAUST OUTLET. STARTER-GENERATOR REPLACED, COWL REPLACED. A/C RETURNED TO SERVICE. 2H72 4T4 TRTA13NM E00062EN 20031020002052003102000205NM 2003 10 20 CA030904002 120030824G528083231027001 CONNECTING ROD DHAV DHC8 DHC8101 2809002NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE FWD MLG DOOR BROKEN W O OTHER JO WARNING INDICATION OTHER CRCRUISE 1 CA 27532 (CAN) LT MLG DOOR LIGHT ILLUMINATED IN FLIGHT. CREW WITNESSED FWD MLG DOOR WAS OPEN. LANDING COMPLETED WITHOUT INCIDENT. UPON INSPECTION BY ENGINEERING IT WAS FOUND THAT THE FWD MLG DOOR CONNECTING ROD ASSY HAD SHEARED. THE CONNECTING ROD WAS REPLACED AND AN OPERATION CHECK PERFOR MED ON THE MLG SYSTEM. AIRCRAFT WAS RELEASED BACK INTO SERVICE. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20031020002112003102000211NE 2003 10 20 CA030904003 220030728G852010992 LINK DHAV DHC3 DHC3 2800202EA PWA R1340 S3H1G 52016NE ENGINE BROKEN W A UNSCHED LANDING PY NO WARNING INDICATION ENGINE STOPPAGE CRCRUISE 1 CA (CAN) THE AIRCRAFT WAS IN CRUISE FLT WHEN THE ENGINE ABRUPTLY FAILED. THE AIRCRAFT CARRIED OUT AN UNSCHEDULED LANDING. MAINTENANCE DISCOVERED A BROKEN LINK ROD AND THE ENGINE WAS REPLACED. 1H71 3R3 R A815 E142 20031020002122003102000212EA 2003 10 20 CA030904004 120030814G3211TBC6U11373 BLOCK DHAV DHC6 DHC6 2802606EA MLG FAILED W O OTHER W INADEQUATE Q C NRNOT REPORTED 1 CA (CAN) REBOUND BLOCKS FOUND TO HAVE WRONG THREAD. BLOCKS CAN BE REPAIRED. REPAIR FOUND TO BE MINOR. PAPER TRAIL FOLLOWED TO EXACT POINT DEFECT OCCURRED. ALL BLOCKS, BY S/N LOCATED. A FIELD REPAIR AND SB CURRENTLY BEING DEVELOPED. WILL BE ISSUED TO CUSTOMERS WITH THE SN'S LISTED. PROCESS SHEETS AND INSPECTION CRITERIA CHANGED TO PREVENT REOCCURRENCE. 1H72 3T RTA9EA 20031020002142003102000214EA 2003 10 20 CA030904005 120030814G3211TBC6U11373 BLOCK DHAV DHC6 DHC6 2802606EA MLG FAILED W O OTHER W INADEQUATE Q C NRNOT REPORTED 1 CA (CAN) REBOUND BLOCKS FOUND TO HAVE WRONG THREAD. BLOCKS CAN BE REPAIRED. REPAIR FOUND TO BE MINOR. PAPER TRAIL FOLLOWED TO EXACT POINT DEFECT OCCURRED. ALL BLOCKS, BY S/N LOCATED. A FIELD REPAIR AND SB CURRENTLY BEING DEVELOPED. WILL BE ISSUED TO CUSTOMERS WITH THE SN'S LISTED. PROCESS SHEETS AND INSPECTION CRITERIA CHANGED TO PREVENT REOCCURRENCE. 1H72 3T RTA9EA 20031020002572003102000257NM 2003 10 20 CA030905001 120030902G27406355B000103 ACTUATOR BOEING737 737* NM CFMINTCFM567CFM567B22 13802NE STAB TRIM FAILED W H DEACTIVATE SYST/CIRCUITS F FLT CONT AFFECTED CRCRUISE 1 CA (CAN) CREW REPORTED AT CRUISE, STAB OUT OF TRIM WARNING LIGHT ILLUMINATED. CREW FOLLOWED NON NORMAL CHECKLIST. THEY WERE UNABLE TO RE-CONNECT AUTO PILOT IN EITHER 'A' OR 'B' COMMAND. A/C WOULD NOT RESPOND TO MAIN ELECTRIC TRIM. CREW RESORTED TO MANUAL TRIM. CREW CONTACTED MCC AND WERE INSTRUCTED TO PULL ASSOCIATED CIRCUIT BREAKERS FOR MAIN ELECTRIC TRIM (NO CHANGE). A/C LANDED UNEVENTFULLY, NO EMERGENCY WAS DECLARED. MAINT INSP DISCOVERED MAIN ELECTRIC MOTOR HAD FAILED. POWER WAS AVAILABLE TO MOTOR. WHEN MOTOR WAS REMOVED FROM THE GEARBOX, TRIM WHEELS WERE FREE TO TURN. MAINTENANCE REPLACED STAB TRIM MOTOR, SYSTEM GROUND CHECKED SERVICEABLE. AIRCRAFT RETURNED TO SERVICE WITH NO FURTHER INCIDENTS TO REPORT. 2L72 4F4 FRTA16WE E00055EN 20031020002272003102000227EA 2003 10 20 CA030905002 120030903G2120601R9500115305 ODOR CNDAIRCL600 CL6002B19 1900309EA ECS SYSTEM DETECTED W B EMER. DESCENT B SMOKE/FUMES/ODORS/SPARKS CLCLIMB 1 CA (CAN) WHILE CLIMBING TO FLIGHT LEVEL 360 THE CREW NOTICED A VERY STRONG ODOR INDICATIVE OF EITHER AN ECS SYSTEM OVERHEATING OR ELECTRICAL FIRE. THE ECS & ELECTRICAL SYNOPTIC PAGES SHOWED NO ANOMALIES. THE ODOR INCREASED IN INTENSITY AND THE CREW DECLARED AN EMERGENCY, THEN PROCEEDED WITH A HIGH SPEED DESCENT. THE ODOR SIGNIFICANTLY DECREASED AT LOWER ALTITUDES AND THE AIRCRAFT LANDED WITHOUT FURTHER OCCURENCES. UPON SHUT DOWN, THE CAPTAIN & FIRE CHIEF OPENED THE AFT EQUIPMENT BAY AND EXPERIENCED THE SAME ODOR THAT WAS PRESENT DURING THE FLIGHT, BUT ONLY STRONGER. AFTER THE ECS SYSTEM WAS TESTED PER FTP 601R2103 WITH NO FAULT FOUND. THE WATER SEPARATOR BAGS WERE VERIFIED FOR CONTAMINATION AND NONE FOUND. 2L72 4F RTA21EA 20031020002282003102000228NE 2003 10 20 CA030905003 220030803G8520 ENGINE DHAV DHC2 DHC2MK1 2800102EA PWA R985 R985AN14B 52008NE NACELLE FAILED W A UNSCHED LANDING EJ VIBRATION/BUFFET WARNING INDICATION CRCRUISE 1 CA (CAN) THE AIRCRAFT WAS IN CRUISE FLIGHT A LOUD BANG WAS HEARD. THE PILOT CARRIED OUT AN UNSCHEDULED LANDING. THE AIRCRAFT WAS CHECKED BY MAINTENANCE AND THE OIL SCREEN WAS FOUND TO HAVE METAL PARTICLES. THE AIRCRAFT WAS FLOWN TO A MAINTENANCE FACILITY WHERE THE ENGINE WAS REPLACED. 1H71 3R3 R A806 5E1 20031020002302003102000230CE 2003 10 20 CA030905004 120030830G32341013841377 SELECTOR BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3I NE MLG FAILED W O OTHER O OTHER DEDESCENT 1 CA (CAN) AIRCRAFT WENT ON LOCAL FLIGHT, WHEN GEAR SELECTED DOWN ON PREPARATION FOR LANDING GEAR DID NOT GO DOWN, CREW MANUALLY PUMPED GEAR DOWN AND RECEIVED 3 GREEN INDICATION. AFTER LANDING, AIRCRAFT WAS PLACED ON JACKS AND GEAR SWINGS CARRIED OUT. GEAR FUNCTIONED CORRECTLY ON FIRST 7 RETRACTION/EXTENSION CYCLES. ON EIGHTH EXTENSION GEAR DID NOT START TO EXTEND. GEAR HANDLE 'JIGGLED' IN DOWN POSITION AND GEAR OPERATED AT THIS POINT.NEW SELECTOR ASSEMBLY INSTALLED GEAR RE-SWING NUMEROUS TIMES AND FOUND TO OPERATE NORMALLY. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20031020002312003102000231 2003 10 20 CA030905005 420030905G3416 ALTIMETER PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL COCKPIT STUCK W K NONE H ELECT. POWER LOSS-50 PC ININSP/MAINT 1 CA (CAN) DURING A PITOT/STATIC CHECK,, IT WAS FOUND THAT THE BAROMETRIC SCALE, ON THE CAPTAIN'S ENCODING ALTIMETER, WOULD NOT MOVE WITH THE ADJUSTMENT KNOB. ALTIMETER POINTERS WOULD MOVE WHEN BAROMETRIC ADJUSTER WAS TURNED, HOWEVER THE SCALE INDICATING THE PRESSURE ADJUSTED TO, WOULD NOT MOVE. ALTIMETER REPLACED, PITOT/STATIC SYSTEM TESTED SERVICEABLE. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20031020002322003102000232 2003 10 20 CA030905006 420030905G3425066031252500 DISPLAY PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL EFIS BROKEN W O OTHER H ELECT. POWER LOSS-50 PC CRCRUISE 1 CA (CAN) CAPTAIN'S LOWER ELECTRONIC FLIGHT INSTRUMENT DISPLAY UNIT, (CATHODE RAY TUBE), WOULD FADE TO UNREADABLE LEVEL, DURING LONG OPERATIONS. LOWER DISPLAY UNIT GIVE HSI AND COMPASS/GPS NAVIGATION INFORMATION WHICH WOULD BE LOST AFTER A FADE OUT. UNIT WOULD FUNCTION AGAIN AFTER A POWER SHUT DOWN AND UNIT WAS ALLOWED TO COOL. EFIS DISPLAY UNIT REPLACED AND SYSTEM OPERATED NORMALLY. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20031020002332003102000233WP 2003 10 20 CA030905007 120030827G5241 DOOR DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE GALLEY NOT CLOSED W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) DURING CLIMB FROM YYZ, 'CABIN ALT' WARNING LIGHT ON DUE TO 'AFT GALLEY DOOR OPEN'. QRH PROCEDURES CARRIED OUT AND AIRCRAFT LANDED BACK TO YYZ. GALLEY DOOR FOUND IMPROPERLY CLOSED BY MAINTENANCE. SEAL CLEANED AND AIRCRAFT PRESSURIZED ON GROUND, NO LEAK FOUND AND NO DOOR WARNING INDICATION. TEST C/OUT IAW MM REF. 21-50-00. 2L72 4F4 FRTA6WE E9NE 20040126000902004012600090EU 2004 1 26 CA030905008 120030902G3246AH42883 WHEEL STBROSSC7 SC7SERIES3 8100512EU GARRTTTPE331TPE3312201A WP HARTZLHCB3T HCB3TN5 GL MLG DAMAGED W C ABORTED TAKEOFF E VIBRATION/BUFFET TOTAKEOFF 1 CA (CAN) ON TAKEOFF THE CREW HEARD A LOUD NOISE UPON SETTING MAX POWER. AN IMMEDIATE REJECTED TAKEOFF WAS CARRIED OUT, DIRECTIONAL CONTROL WAS MAINTAINED, AND THE AIRCRAFT WAS STOPPED ON THE RUNWAY. IB WHEEL HALF PN/AH 42883, S/N 994 AND CALIPER SUSTAINED DAMAGE. ALTHOUGH THE WHEEL HALF IS NOT SUSPECTED THE CAUSE OF THIS REPORT, THE MFG SUGGESTS 12 MONTH OVERHAUL PERIODS ON WHEEL ASSEMBLY. THIS WHEEL HALF WAS NDT INSPECTED SEPT 17, 2002. 1H72 3T4 TNTA15EU E3WE 6 CP15EA 20031020002342003102000234EU 2003 10 20 CA030908001 120030829G32609740926112 RELAY PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL MLG FAILED W O OTHER N FALSE WARNING APAPPROACH 1 CA (CAN) THE AIRCRAFT WAS ON APPROACH AND THE NOSE GEAR GREEN LIGHT DID NOT COME ON, BOTH MAINS INDICATED GREEN.THE GEAR WAS EXTENDED MANUALLY WITH THE HAND PUMP AND A N UNEVENTFUL LANDING CARRIED OUT. MAINTENANCE FOUND THE HYDRAULIC POWERPACK WAS NOT RUNNING DUE TO AN UNSERVICEABLE MOTOR RELAY R601. THE RELAY WAS REPLACED AND THE SYSTEM FUNCTIONED PROPERLY. THE 974.09.26.112 RELAY IN QUESTION HAS BEEN FAILING IN THE PAST. THIS IS THE 3RD INSTANCE THE SAME PART NUMBER RELAY HAS FAILED, EITHER OPEN OR CLOSE. ONE PRIOR TO THIS FAILED OPEN AND WOULD NOT ALLOW THE PUMP TO RUN, AND THE ONE PRIOR TO THAT FAILED CLOSED AND THE PUMP RAN CONTINUOUSLY. PILATUS HAS BEEN NOTIFIED VIA A DEFECT REPORT. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20031020002372003102000237SO 2003 10 20 CA030908002 120030902G29101771703 LINE PIPER PA23 PA23250 7102308SO LYC O540 IO540C4B5 41532EA HYD SYSTEM CHAFED W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) AFTER TAXIIING THE AIRCRAFT FOR MAINTENANCE WE NOTICED HYDRAULIC FLUID ON THE FLOOR UNDER THE RT WING ROOT. AFTER REMOVING THE BELLY PANEL FOR INSPECTION THE LEAK WAS FOUND TO BE LOCATED ABOUT 20 INCHES AFT OF THE LEADING EDGE OF THE RT WING WHERE THE LANDING GEAR HYDRAULIC EXTENSION LINE PN 1771703 IS CROSSED BY THE AILERON CABLE. INSUFFICIENT CLEARANCE BETWEEN THE HYDRAULIC LINE AND CABLE APPEAR TO HAVE ALLOWED FOR THE CABLE TO CHAFE THROUGH THE HYDRAULIC LINE. CLOSE CONSIDERATION WHILE INSPECTING THIS AREA SHOULD BE CARRIED OUT. 1L72 3O3 O 1A10 1E4 20031020002382003102000238NE 2003 10 20 CA030908003 220030828G8520 ENGINE DHAV DHC2 DHC2MK1 2800102EA PWA R985 R985AN14B 52008NE SEIZED W A UNSCHED LANDING YJ ENGINE STOPPAGE WARNING INDICATION CRCRUISE 1 CA (CAN) ENGINE SEIZED. INFLIGHT EMERGENCY UDE AT 1200 FT ASL. AIRCRAFT LANDED UNDAMAGED ON FLOATS. OIL TANK LEVEL CONFIRMED AT 5 QAL. CAUSE UNKNOWN AT THIS TIME. 1H71 3R3 R A806 5E1 20031020002402003102000240CE 2003 10 20 CA030908004 120030810G24201100718 ALTERNATOR BEECH 95 D95A 1153408CE LYC O360 IO360B1B 41514EA HARTZLHC92W HC92WK2 GL ENGINE FAILED W O OTHER HH ELECT. POWER LOSS-50 PC ELECT. POWER LOSS-50 PC CRCRUISE 1 CA (CAN) NOTICED NO CHARGE, MINIMIZED ELECTRICAL LOAD TURNED OFF ALTERNATORS RESET ON CHANGED RELAY LT TO RT. NO CHARGE TURNED MASTER OFF, 25 MILES FROM AIRPORT, TURNED MASTER ON AND 1 RADIO GOT ATIS AND CALLED TOWER LOST ALL POWER, CALLED TOWER ON CELL DID A MANUAL GEAR EXTENSION AND FLY BY TOWER TO CONFIRM GEAR DOWN THEN JOINED CIRCUT AND LANDED. 1L72 3O3 O 3A16 1E10 5 CP16EA 20031020002422003102000242CE 2003 10 20 CA030908005 120030826G2434E54118 BRUSHES CESSNA CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA MCAULY1C160 1C160DTM GL ALTERNATOR WORN W K NONE O OTHER ININSP/MAINT 1 CA 8010181 (CAN) PREMATURELY WORN FIELD BRUSHES, SHORTED FIELD CIRCUIT FAILING ALTERNATOR, VOLTAGE REGULATOR AND OVERVOLTAGE SENSOR. 1H71 3O3 ONT3A12 E274 5 NP910 20031020002452003102000245EA 2003 10 20 CA030908007 120030903G2435BC09100 BEARING LUCAS DHAV DHC7 DHC7102 2802708EA PWA PT6 PT6A50 52043EA HAMSTD24PF 24PF305 GL STARTER-GEN FAILED W H DEACTIVATE SYST/CIRCUITS J WARNING INDICATION CLCLIMB 1 CA 1510 (CAN) TWO MIN AFTER TAKEOFF THE NR 3 DC STARTER-GEN FAILED, THE GENERATING SYSTEM WAS SHUTDOWN. MAINTENANCE FOUND THAT THE STARTER MODE FUNCTIONING OK. AFTER TROUBLESHOOTING THE STARTER-GENERATOR WAS REPLACED DUE TO HEAVY BRUSH WEAR AND THE BEARING WAS FAILING. THIS UNIT HAD 1385.9 HRS SINCE BEARING CHECK / BRUSH REPLACEMENT. 2H74 4T4 T A20EA E4EA 6 CP1NE 20031020002472003102000247EA 2003 10 20 CA030908008 120030903G2435BC09101 SHAFT LUCAS DHAV DHC7 DHC7102 2802708EA PWA PT6 PT6A50 52043EA HAMSTD24PF 24PF305 GL STARTER-GEN SHEARED W H DEACTIVATE SYST/CIRCUITS J WARNING INDICATION CRCRUISE 1 CA 1372 (CAN) SHORTLY AFTER TAKEOFF THE NR 3 DC GEN LIGHT CAME ON, THE SYSTEM WAS DEACTIVATED. AFTER ABOUT FIVE MINUTES THE NR 3 DC GEN HOT LIGHT CAME ON FOR ABOUT 20 SECONDS. FOR TROUBLESHOOTING WE ATTEMPTED TO START THE NR 3 ENG, WHICH KNOCKED THE GROUND POWER UNIT OFF LINE AND BURNED OUT THE GROUND POWER LIMITER. DURING THE REMOVAL OF THE STARTER-GEN WE FOUND THE STARTER DISCOLOURED FROM THE HEAT AND WHEN THE STARTER WAS PULLED AWAY FROM THE ENG, THE SHAFT PULLED OUT OF IT. THE STATOR HAD SHEARED OFF OF THE SHAFT. 2H74 4T4 T A20EA E4EA 6 CP1NE 20040108000012004010800001EA 2004 1 8 CA030908009 120030827G7500C6VW10263 DUCT DHAV DHC6 DHC6300 2802606EA PWA PT6 PT6A27 52043EA HARTZLHCB3T HCB3TN3 GL BLEED AIR DAMAGED W HA DEACTIVATE SYST/CIRCUITSUNSCHED LANDING J WARNING INDICATION DEDESCENT 1 CA (CAN) RT BLEED AIRS LINE RUPTURED IN THE BRADED FLEX AREA. THE BLEED AIR THEN MELTED THE WIRE BUNDLE RUNNING FROM THE ENGINE INTO THE WING. THE ONLY INDICATION WAS THAT THE BETA BACKUP SYSTEM MALFUNCTIONED. ALL THE WIRES EXCEPT FOUR HAD DAMAGE WHEN REMOVED. 1H72 3T4 TRTA9EA E4EA 6 CP15EA 20031020002482003102000248CE 2003 10 20 CA030908010 120030827G7922723747 RELIEF VALVE STWARNER BEECH B300 B300B350C CE PWA PT6 PT6A60A 52043NE OIL COOLER FAILED W EA ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA 2769 (CAN) LT ENGINE OIL TEMP WENT INTO THE YELLOW ON CLIMB OUT. PILOT DID A PRECAUTIONARY SHUTDOWN OF THE ENGINE AND RETURNED TO THE AIRPORT. 2L72 4T4 TRTA24CE E4EA 20031020002502003102000250EA 2003 10 20 CA030909001 220030831G8530CON008046305 CYLINDER HEAD GRUMAVS2 TS2A 3951110SO WRIGHTR1820 982C9HE2 67020EA HAMSTD43D 43D51 NE ENGINE SEPARATED W K NONE E VIBRATION/BUFFET ININSP/MAINT 1 CA (CAN) PILOT REPORTED THAT THE LT ENGINE WAS RUNNING ROUGH. DURING INVESTIGATION BY MAINTENANCE CREW IT WAS DISCOVERED THAT BOTH NR 2 AND NR 8 CYLINDER HEADS WERE SEPERATING FROM THE BARREL. ONE CYLINDER HAD A SLIGHT OIL LEAK EVIDENT AND THE OTHER AN AIR COULD BE FELT IN THE AREA OF SEPERATION. THE CYLINDERS WERE REPLACED WITH SERVICEABLE ASSEMBLIES AND THE AIRCRAFT WAS RETURNED TO SERVICE. 2H72 4O4 RRTEXPA2H72E259 6 CP8879 20031020002512003102000251SW 2003 10 20 CA030909002 120030907G2913MS28775314 O-RING AIRTRCAT802 AT802A 0390308SW PWA PT6 PT6A65AG 52043NE MLG TORN W O OTHER J WARNING INDICATION CRCRUISE 1 CA (CAN) DURING FLIGHT 1 HYDRAULIC PUMP LIGHT ILLUMINATED INDICATING LOW HYDRAULIC FLUID LEVEL. THE LANDING GEAR WAS EXTENDED NORMALLY AND THE AIRCRAFT RETURNED TO THE AIRPORT FOR A NORMAL LANDING. DURING INVESTIGATION THE MAINTENANCE CREW FOUND A HYDRAULIC LEAK IN THE RT FLOAT MLG. THE O-RING WAS REPLACED AND A GEAR RETRACTIONTEST WAS COMPLETED. THE AIRCRAFT WAS RETURNED TO SERVICE. 1L71 3T4 TNCA19SW E4EA 20031020002532003102000253CE 2003 10 20 CA030909003 120030808G3242215286 STATOR CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE RT BRAKE ASSY FAILED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) STATOR BROKEN ON RT BRAKE ASSY. IN REFERENCE TO A PREVIOUS SDR CA20030812005 SUBMITTED FOR ALT BRAKE FAILURE ON SAME A/C, THE RT BRAKE WAS REMOVED FOR CLOSER INSPECTION DURING AN UNRELATED PHASE INSPECTION.THE R/H BRAKE WAS ALSO FOUNDTO HAVE A BROKEN / CRACKED STATOR WHICH MAY HAVE LED TO ANOTHER PREMATURE BRAKE FAILURE.THE BRAKE ASSY WAS REMOVED AND TAGGED UNSERVICEABLE.BRAKE PN 215286, S/N0753R. THIS BRAKE WAS APPROX. INTO ITS LIFE. ACCORDING TO THE WEAR INDICATORS ON THE BRAKE ASSY, THERE WAS 150-200 CYCLES REMAINING ON THE BRAKE. 1L72 4F4 F A22CE E1NE 20031020002592003102000259CE 2003 10 20 CA030910001 120030903G261299120363 FIRE LOOP CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE LT ENGINE CHAFED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) THE FIRE DETECTION SENSOR LOOP ON THE LT ENGINE WAS FOUND CHAFING ON THE REAR TOP BRACKET (SUPPORT AFT OF ENGINE COVER) DURING PHASE 1,2,3, & 4 INSPECTION. THE LOOP RESISTANCE MEASURED BEYOND LIMITS AND WAS REPLACED. WEAR DAMAGE ON THE BRACKET WAS REPAIRED AS PER AC43131B. 1L72 4F4 F A22CE E1NE 20031020002612003102000261EA 2003 10 20 CA030910002 120030905G5230HSP115P0941400 PIN CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE CARGO DOOR FAILED W O OTHER J WARNING INDICATION CLCLIMB 1 CA (CAN) DURING CLIMB THROUGH 15,000 FT CARGO DOOR CAUTION MESSAGE CAME ON. PRESSURIZATION NORMAL. PIN FOUND SHEARED ON LATCH TO STOW DOOR HANDLE. PIN REPLACED CHECKS SERVICABLE. 2L72 4F4 FRTA21EA E15NE 20031020002622003102000262NE 2003 10 20 CA030910003 220030904G7200 ENGINE BOEING737 737204 1384458NM PWA JT8 JT8D15 52051NE FAILED W O OTHER E VIBRATION/BUFFET DEDESCENT 1 CA (CAN) THE ENGINE HAS BEEN REMOVED FOR TEARDOWN TO DETERMINE THE CAUSE OF THE PROBLEM. 2L72 4F4 F A16WE E2EA 20031020002632003102000263SW 2003 10 20 CA030910004 120030717G5320205030163095 SPAR CAP BELL 205 205A1 1181414SW LYC T53 T5317A 41549NE ENGINE BAY CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) WHILE DOING A ROUTINE INSPECTION, A 15 INCH CRACK WAS FOUND IN THE ENGINE DECK AT ITS FORWARD END UNDER THE TRANSMISSION TAIL ROTOR OUTPUT AREA. FURTHER INVESTIGATION WAS CARRIED OUT AND FOUND THAT THE SPAR CAP WAS CRACKED. UPON DISSAMBLY FOR THE CAP REPLACEMENT A 13' CRACK WAS FOUND IN THE WALL PN 205030169411. TH E SPAR CAP AND ENGINE DECK ASSY'S WERE REPLACED WITH NEW PARTS AND THE WALL ASSY WAS REPAIRED AS PER A BELL HELICOPTER APPROVED REPAIR SCHEME. THE REPAIR WAS CARRIED OUT BY A APPROPRIATLY RATED AMO. 1G71 4U4 U H1SW E17EA 20031020002642003102000264NM 2003 10 20 CA030910005 120030902G261287858201 CONNECTOR KIDDE BOEING737 7372H4 138448CNM PWA JT8 JT8D9A 52048NE UPPER FIRE LOOP WEAK W FE ACTIVATE FIRE EXT. ENGINE SHUTDOWN N FALSE WARNING TXTAXI/GRND HDL 1 CA 3236 (CAN) BOTH THE UPPER FIRE LOOP AND CONNECTOR RESISTANCE VALUES WERE BEYOND LIMITS. BOTH WERE REPLACED. 2L72 4F4 F A16WE E2EA 20031020002812003102000281NM 2003 10 20 CA030910006 120030902G261287858201 CONNECTOR KIDDE BOEING737 7372H4 138448CNM PWA JT8 JT8D9A 52048NE UPPER FIRE LOOP WEAK W FE ACTIVATE FIRE EXT. ENGINE SHUTDOWN N FALSE WARNING TXTAXI/GRND HDL 1 CA 3236 (CAN) BOTH THE UPPER FIRE LOOP AND CONNECTOR RESISTANCE VALUES WERE BEYOND LIMITS. BOTH WERE REPLACED. 2L72 4F4 F A16WE E2EA 20031020002862003102000286EU 2003 10 20 CA030910007 120030815G2910SC5083 SERVO SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE HYD SYSTEM UNSERVICEABLE W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) DURING GRD CHECKS AT IDLE & FLIGHT IDLE, CYCLIC CONTROL MOVING UNCOMMANDED LT & FORWARD. CYCLIC CONTROL WOULD CONTACT STOP, AFTER 1-2 SECONDS IT COULD BE BROUGHT BACK TO CENTER POSITION & APPEARED NORMAL. MOVEMENT COULD BE DUPLICATED ON SUBSEQUENT RUNS, FORWARD & LT UNCOMMANDED & WITH SUBSTANTIAL FORCE REQUIRED TO HOLD CYCLIC IN NEUTRAL POSITION. AFTER TROUBLESHOOTING & WITH STAFF PRESENT, IT WAS DETERMINED ONE LATERAL HYD SERVO WAS CAUSING LT FWD MOVEMENT ON CYCLIC CONTROL. BOTH LATERAL SERVO'S REPLACED WITH REPAIRED UNITS. THIS CAUSED AN AFT & RT MOVEMENT ON CYCLIC. FINAL FIX WAS TO REPLACE RT SERVO ONLY & REINSTALL ORIGINAL LT SERVO. SUBSEQUENT RUNS ACHIEVED NO UNCOMMANDED MOVEMENTS LT OR RT. 1G71 3U3 U H9EU E19EU 20031020002872003102000287NE 2003 10 20 CA030910008 220030814G725070BM055420 MODULE SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE ENGINE MAKING METAL W A UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 CA (CAN) ENGINE MAKING METAL INVESTICATION LED US TO BELIEVE METAL COMING FROM MO5 MODULE. REPLACED MODULE AND NO LONGER MAKING METAL. 1G71 3U3 U H9EU E19EU 20031020002892003102000289CE 2003 10 20 CA030910009 120030908G3233508202085 ACTUATOR BEECH 100 A100 1152915CE PWA PT6 PT6A34 52043EA NLG NOISY W K NONE E VIBRATION/BUFFET ININSP/MAINT 1 CA (CAN) DURING LANDING GEAR EXTENSION THE NOSE GEAR ACTUATOR MADE A LOAD SCREECH NOISE. THE ACTUATOR WAS REPLACED AND THE GEAR SWINGS PERFORMED NORMALLY. 1L72 3T4 T A14CE E4EA 20031020002912003102000291EU 2003 10 20 CA030910010 120030812G6510350A35105901 FLEX COUPLING SNIAS 350 AS350B1 8680811EU TMECA ARRIELARRIEL1D NE T/R DRIVE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING ROUTINE INSPECTION, A SMALL MARK, SLITE DENT WAS FOUND ON THE OUTER DISC OF THE FLEX COUPLING FURTHER INVESTIGATION FOUND THAT THIS DENT HAD SET UP A STRESS RISER IN WHICH HAD CAUSED THE DISC TO CRACK THE COUPLING WAS REPLACED WITH NEW PARTS AND RETURNED TO SERVICE. 1G71 3U3 U H9EU E19EU 20031020002962003102000296EU 2003 10 20 CA030911001 120030910G271031055150 SERVO AIRBUS310 A310300 3930305EU GE CF6 CF680C2* GL AILERON JAMMED W D RETURN TO BLOCK F FLT CONT AFFECTED TXTAXI/GRND HDL 1 CA (CAN) DURING TAXI ,THE ECAM MESSAGE AILERON BLUE SYSTEM JAM CAME ON UPON THE FLIGHT CONTROL CHECK BY THE FLIGHT CREW. PROCEDURE PERFORMED AS PER CHECK LIST AND THE AIRCRAFT RETURNED TO THE GATE DUE TO HARD DEFLECTION OF CONTROL WHEEL AND UNABLE TO DETERMINE MOVEMENT OF RT AILERON. TROUBLE SHOOTING CONFIRMED THE RT AILERON SERVO AT FAULT. SERVO ASSY WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE WITH NO FURTHER INCIDENT. UNIT ROUTED TO THE VENDOR FOR STRIP REPORT. 2L72 4F4 FRTA35EU E23EA 20031020002992003102000299EU 2003 10 20 CA030911002 120030911G2910AC67244 SERVO SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE HYDRAULIC DAMAGED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) PILOT CONDUCTED PREFLIGHT CHECK AND ON AIRCRAFT RUN UP COMPLIED WITH THE INTENT OF AD CF 200315R1. DURING THE TEST UPON DEPLETION OF THE HYDRAULIC SYSTEM ACCUMULATORS, CYCLIC MOVED TO THE LT FWD QUADRANT UNCOMMANDED. THE TEST WAS REPEATED 12 TIMES AT BOTH GROUND AND FLIGHT IDLE AND EVERY CHECK CONCLUDED IN THE SAME UNCOMMANDED CYCLIC MOVEMENT. RT LATERAL SERVO WAS ISOLATED AS BEING THE CAUSE OF THE UNCOMMANDED CYCLIC MOVEMENT AND REPLACED. THE AD WAS AGAIN PERFORMED AND THE A/C CONTROLS AND HYDRAULIC SYSTEM FUNCTIONED NORMALLY. 1G71 3U3 U H9EU E19EU 20031020003002003102000300NE 2003 10 20 CA030911003 220030730G8530 PUSHROD TUBE DOUG A26 A26CSHIELDS 3020506WP PWA R2800 R280079 52026NE RT ENGINE CHAFED W E ENGINE SHUTDOWN K FLUID LOSS CLCLIMB 1 CA (CAN) ON CLIMB OUT AFTER BOMB RUN OIL NOTICED ON NACELL OF RT ENGINE. PRECAUTIONARY ENGINE SHUT DOWN COMPLETED, A/C LANDED WITHOUT INCIDENT.BREASEWAY FOUND TO HAVE CHAFED SMALL HOLE IN CYLINDER NUMBER 15 EX. PUSH ROD TUBE. PUSH ROD TUBE REPLACED BREASEWAY SECURED AND A/C RETURNED TO SERVICE. 2M72 4R4 R L34 5E8 20031021000032003102100003SO 2003 10 21 CA030911004 120030819G574489W121CSM100121 HINGE GRUMAVS2 S2F 3951006SO WRIGHTR1820 982C9HE2 67020EA HAMSTD43D 43D51 NE LT AILERON BROKEN W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) AIRCRAFT PERFORMED FIREBOMBING MISSION. UPON RETURN, THE PILOT COMPLAINED OF FLUTTER IN THE CONTROLS. INITIAL INSPECTION REVEALED NO DAMAGE. FURTHER IN-DEPTH DETAILED INSPECTION REVEALED A BROKEN LT WING INBOARD AILERON HINGE. DUE TO THE CONDITION OF THE HINGE, IT WAS DETERMINED TO HAVE HAPPENED SOME TIME BEFORE. BECAUSE IT COULD NOT BE DETERMINED WHEN THE FAILURE OCCURRED, BOTH HINGES WERE REPLACED DUE TO POTENTIAL STRESS THE BREAKAGE APPLIED ON THE UNDAMAGED HINGE. THE AILERON HINGES WERE NDT'ED 315.9 HOURS PREVIOUS DURING THE AIRCRAFT'S AIRFRAME EXTENSION PROGRAM. 2H72 4O4 RRTEXPA2H72E259 6 CP8879 20031021000042003102100004CE 2003 10 21 CA030912001 120030908G7120121343317 MOUNT CESSNA206 U206G 2073356CE CONT O520 IO520F 17032SO MCAULYD3A34 D3A34C404 GL ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) CRACKS IN RADIUS OF ENGINE MOUNT SUPPORT 1H71 3O3 O A4CE E5CE 5 CP47GL 20031021000052003102100005WP 2003 10 21 CA030912002 120030813G6210 PIN DOUG HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL M/R BLADE FAILED W K NONE O OTHER ININSP/MAINT 1 CA 0098848032 (CAN) PIN FAILURE, SHEARED AT TOP THREAD OF THREADED SHANK FOR ADJUSTER NUT. CHIEF ENGINEERS COMMENTS: THIS IS THE SECOND PIN TO SHEAR ON THIS AIRCRAFT, SEEMS BOTH PINS WERE MANUFACTURED ATABOUT THE SAME TIME. 1G71 3U3 U H3WE E4CE 20031021000062003102100006 2003 10 21 CA030912003 420030728G8300107010101 GEAR BELL 205 205A1 1181414SW LYC T53 T5313B 41549NE ACCESSORY G/B FAILED W O OTHER XJ ENGINE FLAMEOUT WARNING INDICATION APAPPROACH 1 CA (CAN) A/C PERFORMING NORMAL APPROACH. DURING FINAL, A LIGHT WHINING SOUND HEARD AS POWER APPLIED. AS POWER INCREASED, SOUND INCREASED. AT APPROX 8 FT FROM TOUCHDOWN, ENG STOPPED, & CHIP CAUTION LIGHT ILLUMINATED. CONTROL MAINTAINED HELICOPTER LANDED WITHOUT INCIDENT. INVESTIGATION REVEALED ENG OIL LOW. MAG CHIP DETECTOR REMOVED & FOUND SILVER METAL PARTICLES. OIL FROM GEARBOX COLLECTED & FOUND TO CONTAINED SILVER & BLACK METAL PARTICLES UP TO 1/16 IN DIAMETER. ENGINE REMOVED FROM SERVICE & RENTAL ENGINE INSTALLED. A/C RETURNED TO SERVICE. FAILED ENG SENT IN FOR EVAL & REPAIR. PRELIMINARY INVEST REVEALED ACCESSORY DRIVEN GEAR FAILED & BROKE IN TWO. PRIMARY REASON FOR GEAR FAILURE UNDER INVESTIGATION BY NTSB. 1G71 4U4 U H1SW E17EA 20031021000072003102100007SO 2003 10 21 CA030912004 120030907G323289H10528 ACTUATOR GRUMAVS2 S2F 3951006SO WRIGHTR1820 982C9HE2 67020EA HAMSTD43D 43D51 NE MLG DOOR LEAKING W O OTHER J WARNING INDICATION CRCRUISE 1 CA (CAN) AIRCRAFT DEPARTED ENROUTE TO A FIRE. PILOT OF ANOTHER AIRCRAFT IN THE GROUP NOTICED RT MLG DID NOT FULLY RETRACT AND GEAR DOORS DID NOT CLOSE. THE GEAR WAS CYCLED BUT NO CHANGE SO AIRCRAFT FLEW AND LANDED WITHOUT INCIDENT. MAINTENANCE CREW REPLACED THE MLG DOOR ACTUATOR, A GEAR SWING WAS COMPLETED AND THE AIRCRAFT WAS RETURNED TO SERVICE. 2H72 4O4 RRTEXPA2H72E259 6 CP8879 20031021000082003102100008SO 2003 10 21 CA030912005 120030909G29131213HBG310A PUMP PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HYD SYSTEM FAILED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) DURING OPERATIONAL CHECK OF HYDRAULIC SYSTEM FOUND RT HYDRAULIC PUMP LANDING GEAR SELECTION HANDLE WON'T RETURN TO NEUTRAL POSITION WITHIN POINTED IN MM PERIOD OF TIME ( THREE TO NINE ) SECONDS. THE PUMP WAS IN SERVICE FOR 177.3 HRS SINCE NEW. 1L72 3O3 O A20SO E14EA 20031021000092003102100009SW 2003 10 21 CA030915001 120030908G6310CL422501 CAGE BELL BELL 206 206B 1181511SW ALLSN 250C 250C20 03013GL SPRAG CASE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA BLA2684 (CAN) SPRAG CAGE CRACKED. 1G71 3U3 U H2SW E4CE 20031021000102003102100010CE 2003 10 21 CA030915002 120030912G275026620185 TUBE CESSNA208 208B 2073701CE PWA PT6 PT6A114A 52043NE MCAULY3AF34C3GFR34C703 GL TE FLAP CONTROL WORN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE ROD CONNECTING THE LT AND RT FLAP BELLCRANKS WAS FOUND WORN WHERE IT PASSES OVER THE PASSENGER READING LIGHT MOUNTING BRACKET ON THE LT SIDE OF THE CABIN. TWO WEAR MARKS WERE NOTED. THE WEAR CORRESPONDING TO THE FLAP UP POSITION WAS THE DEEPEST WITH THE SECOND ONE AT BEING AT THE FULL DOWN FLAP SETTING. THE FLAP SYSTEM WAS DETERMINED TO BE INSTALLED AND RIGGED CORRECTLY BUT POSITIONING OF THE READING LIGHT BRACKET CAUSED INSUFFICIENT CLEARANCE 1H71 3T3 T A37CE E4EA 5 CP60GL 20031021000112003102100011EA 2003 10 21 CA030915003 120030714G5521C2TE37ND SPAR DHAV DHC2 DHC2MK1 2800102EA PWA R985 R985AN14B 52008NE LT & RT ELEVATORCRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) LT AND RT ELEVATOR FRONT SPAR UPPER ATTACH HOLES FOR CENTER HINGE POSITION HAS A SMALL CRACKS AROUND THE UPPER AN3 BOLT HOLE. 1H71 3R3 R A806 5E1 20031021000122003102100012EA 2003 10 21 CA030915004 120030807G5521C2TE37ND SPAR DHAV DHC2 DHC2MK1 2800102EA PWA R985 R985AN14B 52008NE LT CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) LT AND RT ELEVATOR FRONT SPAR UPPER ATTACH HOLE FOR CENTRE HINGE POSITION HAS A SMALL CRACK(S) AROUND THE UPPER AN3 BOLT HOLE. 1H71 3R3 R A806 5E1 20031021000132003102100013EA 2003 10 21 CA030915005 120030807G5521C2TE37ND SPAR DHAV DHC2 DHC2MK1 2800102EA PWA R985 R985AN14B 52008NE LT ELEVATOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) LT ELEVATOR FRONT SPAR UPPER ATTACH HOLE FOR CENTRE HINGE HAS A SMALL RADIAL CRACK AROUNG THE UPPER AN3 BOLT HOLE. 1H71 3R3 R A806 5E1 20031021000142003102100014CE 2003 10 21 CA030915006 120030905G571105233151 SPAR CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA MCAULY1C160 1C160DTM GL RT WING CORRODED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) RT WING FORWARD UPPER SPAR PLATE HAS SEVERAL AREAS OF EXHALATION. PART REPLACED. 1H71 3O3 ONT3A12 E274 5 NP910 20031021000152003102100015EA 2003 10 21 CA030915007 120030913G5280CC67010520 DOOR CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE MLG MISSING W O OTHER D INFLIGHT SEPARATION NRNOT REPORTED 1 CA (CAN) THE RT MLG DOOR WAS FOUND MISSING ON POST FLIGHT INSPECTION. DAMAGE WAS FOUND ON THE FUSELAGE, RT INBOARD FLAP AND WING LOWER SKIN. REPAIR SCHEM WILL BE GIVEN F OR THE FUSELAGE AND THE FLAP. 2L72 4F4 FRTA21EA EOOO63EN 20031021000162003102100016SW 2003 10 21 CA030915008 120030907G6310205040176101 BOOT BELL BELL 205 205A1 1181414SW LYC T53 T5313B 41549NE M/R DRIVE TORN W O OTHER K FLUID LOSS NRNOT REPORTED 1 CA A202038 (CAN) DURING THE INSPECTION AFTER THE LAST FLIGHT OF THE DAY, THE ENGINEER INSPECTED THE MAIN DRIVESHAFT BOOTS FOR LEAKAGE. THERE WAS NO VISUAL SIGN OF A GREASE LEAKAGE. AS THE ENGINEER PUT HIS HAND UNDER THE, ENGINE SIDE, DRIVESHAFT COUPLING, HE FELT A BUILT UP OF GREASE IN THE PARTICLE SEPARATOR BOOT TUNNEL. THE DRIVESHAFT WAS REMOVED AND THE INSPECTION OF THE BOOT REVEALED THAT THE RUBBER OF THE BOOT HAD SEPARATED APPROXIMATELY 80 PERCENT CIRCUMFERENTIAL FROM ITS METAL RING. THE DRIVESHAFT WAS REPLACED. 1G71 4U4 U H1SW E17EA 20031021000172003102100017EA 2003 10 21 CA030915009 220030904G7314025323101 PUMP BEECH 100 A100 1152915CE PWA PT6 PT6A28 EA FUEL SYSTEM FAILED W EA ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) WHILE CLIMBING AFTER TAKEOFF, NOTICED LOSS OF TORQUE AND OIL PRESSURE. SECURED THE LT ENGINE. FAILURE TROUBLE SHOT TO LOSS OF FUEL FLOW. HIGH PRESSURE FUEL PUMP AND FUEL CONTROL UNIT REMOVED AND EXAMINED. FOUND THE INPUT GEAR OF THE PUMP HAD STRIPPED SPLINES AND REPLACED HIGH PRESSURE FUEL PUMP WITH OVERHAULED UNIT AND REASSEMBLED ENGINE. ENGINE GROUND RUN SERVICEABLE AND AIRCRAFT RETURNED TO SERVICE. TEAR DOWN REPORT ON FAILED UNIT WILL BE REQUESTED FROM OVERHAUL SHOP. 1L72 3T4 T A14CE E4EA 20031021000182003102100018CE 2003 10 21 CA030915010 120030908G7120121343317 MOUNT CESSNA206 U206A 2073316CE CONT O520 IO520F 17032SO ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) CRACKS IN RADIUS OF ENGINE MOUNT SUPPORT. 1H71 3O3 O A4CE E5CE 20031021000192003102100019EU 2003 10 21 CA030915011 120030909G531207125033 BULKHEAD REIMS 182 F182Q 7530302EU CONT O470 O470U 17026SO MCAULY2A34C C2A34C204 GL FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING ANNUAL INSPECTION, TAIL INSPECTED, STA 124.0 FOUND BULKHEAD CRACKED IN CORNER. REPLACED WITH NEW. DURING REPLACEMENT FOUND ALSO BULKHEAD P/N 0712511 ON STA 140.0 CRACKED ON LT CORNER. REPLACED WITH NEW. POSSIBLE HARD LANDING DAMAGE. 1H71 3O3 O A42EU E273 5 CP3EA 20031021000202003102100020SW 2003 10 21 CA030915012 120030910G7600410MV COMPARATOR BELL 206 206B 1181511SW ALLSN 250C 250C20 03013GL DROOP DAMAGED W O OTHER RJ PARTIAL RPM/PWR LOSS WARNING INDICATION NRNOT REPORTED 1 CA (CAN) PILOT REPORTED DROOP IN RPM AT TAKEOFF. FLEW TO BASE WITH NO PROBLEM. CHANGED OUT GOVERNOR. COULD NOT RIG CONTROLS AS PER MAINTENANCE MANUAL. INVESTIGATION RESULTED IN FINDING INOPERATIVE DROOP COMPENSATOR DUE TO SHEARED RIVET. RIVET REPLACED, CONTROLS RIGGED. OPS NORMAL. 1G71 3U3 U H2SW E4CE 20031021000212003102100021SW 2003 10 21 CA030915013 120030912G5302H20503281177 PANEL BELL BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA TAILBOOM DELAMINATED W K NONE O OTHER ININSP/MAINT 1 CA 00298 (CAN) THIS WAS FOUND ON A DAILY INSPECTION. THE TAILBOOM HELICOMB PANEL WAS DELAMINATED JUST AFT OF THE BAGGAGE COMPARTMENT. THIS AIRCRAFT WAS ON FIRES, DOING LOTS OF HOVERING WHICH MAY HAVE CONTRIBUTED TO THE DELAMINATION DUE TO HOT EXHAUST HITTING IT. 1G71 4U4 U H4SW E22EA 20031106000032003110600003SO 2003 11 6 CA030916002 220030915G74146320 POINTS SLICK CESSNA210 T210M 2073451CE CONT O520 TSIO520R 17040SO MCAULYD3A34 D3A34C402 GL CONTACT BROKEN W K NONE O OTHER ININSP/MAINT 1 CA 99101361 (CAN) POINT ASSEMBLY CONTACT ARM FAILED. 1H71 3O3 O 3A21 E8CE 5 CP47GL 20031021000222003102100022NE 2003 10 21 CA030916003 220030829G7300 ENGINE CNDAIRCL600 CL600* EA LYC ALF502ALF502L 41580NE LEFT SHUTDOWN W O OTHER YJ ENGINE STOPPAGE WARNING INDICATION CRCRUISE 1 CA (CAN) DURING CRUISE AT FL390, THE LT ENGINE ROLLED BACK AND SHUTDOWN. AN EMERGENCY WAS DECLARED. AT 10,000 FT. AN IN-FLIGHT WINDMILL START WAS SUCCESSFULLY ACCOMPLISHED. ALL ENGINE PARAMETERS WERE NORMAL PRIOR TO THE EVENT, AND ALSO FOR THE REMAINDER OF THE FLIGHT AFTER IT WAS RESTARTED. SUBSEQUENT MAINTENANCE PERFORMED AFTER LANDING REVEALED NO ANOMOLIES. ALL FILTERS, SUMPS, AND CHIP DETECTORS WERE INSPECTED AND WERE ALL FOUND TO BE NORMAL. THE FCU WAS REPLACED AS A PRECAUTION. 2L72 4F4 FRTA21EA E6NE 20031021000232003102100023GL 2003 10 21 CA030918001 220030908G7250MS9732019 WASHER ALLSN BOLKMS105 BO105C 5626005EU ALLSN 250C 250C20B 03013GL TURBINE ASSYTURBMISSING W E ENGINE SHUTDOWN K FLUID LOSS NRNOT REPORTED 1 CA 24175 (CAN) AFTER INSTALLATION OF TURBINE ASSEMBLY ON ENGINE, GROUND RUNS WERE BEING DONE. OIL WAS NOTICED LEAKING EXCESSIVELY FROM THE NR 6 & 7 OIL PRESSURE TEE FITTING. UPON DISASSEMBLY OF FITTING, IT WAS NOTICED THAT THE CRUSH WASHER PN MS9372019 WAS MISSING BETWEEN OIL STRUT AND TURBINE CASE. TURBINE TSO WAS 0.0 HOURS. 1G72 3U3 U H3EU E4CE 20031021000242003102100024CE 2003 10 21 CA030918002 120030828G2710 BEARING CESSNA177 177 2073704CE LYC O360 O360A3A 41514EA AILERON CONTROL BRINELLED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) SNAPPING NOISE HEARD WHEN AILERON MOVED. BEARING AREAS ON CONTROL TUBES FRONT OF FIREWALL FOUND SEVERELY BRINELLED. 1H71 3O3 ONTA13CE E286 20031021000252003102100025EU 2003 10 21 CA030918003 120030908G2915 CONTROLLER SAMM SNIAS 350 AS350BA 8680817EU TMECA ARRIELARRIEL1B 6OO30NE REGULATOR STUCK W E ENGINE SHUTDOWN F FLT CONT AFFECTED NRNOT REPORTED 1 CA 311 (CAN) HYDRAULIC SELECTED OFF. HYDRAULICS TOOK 35 SECONDS TO TURN OFF. SUSPECT SLIDER STICKING OPEN. REPLACED HYDRAULIC CONTROLLER (REGULATOR) WITH SERVICEABLE UNIT. TEST NORMAL. 1G71 3U3 UNCH9EU E19EU 20031021000262003102100026SO 2003 10 21 CA030918004 120030916G322167054003 TRUNNION PIPER PIPER PA44 PA44180 7104402SO DRAG LINK CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) DURING SCHEDULED MAINTENANCE, CREW DETECTED A LATERAL CRACK IN THE NOSE GEAR TRUNNION ASSEMBLY WHERE THE DRAG LINK ASSEMBLY ATTACHES TO THE NOSE GEAR TRUNNION. PART REMOVED AND REPLACED WITH NEW ASSEMBLY. 1L72 3O A19S0 20050427003112005042700311CE 2005 4 27 CA030918005 120030917G242199105922 ALTERNATOR CESSNA208 208B 2073701CE PWA PT6 PT6A114A 52043NE MCAULY3AF34C3GFR34C703 GL ENGINE MISMANUFACTURED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) WHILE ATTEMPTING TO REPLACE THE STAND-BY ALTERNATOR IT WAS DISCOVERED THAT THE ELECTRICAL CONNECTION WOULD NOT ENGAGE INTO THE SOCKET PROVIDED IN THE ALTERNATOR BECAUSE THE SOCKET WAS OVERFILLED WITH EPOXY RESIN. ATTEMPTS WERE MADE TO CLEAR THE EXCESS RESIN BUT IT WAS FEARED THAT DAMAGE TO THE ALTERNATOR WOULD RESULT. THE MFG HAS BEEN RECENTLY TAKEN OVER BY A NEW OWNER AND SINCE THIS TAKEOVER THIS IS THE SECOND TIME WE HAVE COME ACROSS THIS PROBLEM. THE UNIT WAS RETURNED TO THE VENDOR FOR REPLACEMENT. 1H71 3T3 T A37CE E4EA 5 CP60GL 20031021000362003102100036NE 2003 10 21 CA030918006 120030731G32127625102701101 ROD END SKRSKY SKRSKYS76 S76A 8143006NE ALLSN 250C 250C30S 03013GL EXPLOSIVE LINK SHEARED W O OTHER O OTHER NRNOT REPORTED 1 CA 5125 (CAN) UPON RETURN FROM A ROUTINE FLIGHT, IT WAS NOTED THAT THE RT EXPLOSIVE LINK ROD END WAS SHEARED. EXPLOSIVE LINK REPLACED WITH SERVICEABLE PART, A/C RETURNED TO SERVICE. 1G72 3U3 U H1NE E1GL 20031021000382003102100038NM 2003 10 21 CA030918007 120030916G5330 SKIN BOEING737 7372Q9 138448MNM PWA JT8 JT8D9A 52048NE FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING ROUTINE DAILY CHECKS A CRACK WAS FOUND ON THE EXTERIOR FUSELAGE AT STN 935-937 STRINGER 24L. CRACK WAS REPAIRED IAW SRM 53-30-3 FIG 48 SHEET 29 DETAIL VI. ACFT TIMES 58839.13 ACFT CYCLES 55678. 2L72 4F4 F A16WE E2EA 20050427003102005042700310NM 2005 4 27 CA030918008 120030911G3220BACB30GE BOLT BOEING737 737* NM PWA JT8 JT8D17 52049NE NLG IMPROPER PART W L ABORTED APPROACH WDJINADEQUATE Q C INFLIGHT SEPARATION WARNING INDICATION DEDESCENT 1 CA (CAN) NOSE LANDING GEAR LOCK ACTUATOR LOWER ATTACH BOLT SHEARED, ALLOWING ACTUATOR TO FAIL. BOLT IDENTIFIED AS AN UNAPPROVED PART. THIS BOLT WAS NOT INSTALLED BY THIS OPERATOR. 2L72 4F4 FRTA16WE E2EA 20031021000482003102100048EA 2003 10 21 CA030918009 120030916G2822 DIAPHRAGM DHAV DHC2 DHC2MK1 2800102EA PWA R985 R985AN14B 52008NE WOBBLE PUMP FAILED W O OTHER K FLUID LOSS ININSP/MAINT 1 CA 10300 (CAN) ON INSPECTION THE WOBBLE PUMP WAS FOUND TO BE LEAKING FUEL FROM THE DIAPHRAGM SEAL AREA DURING A SYSTEM PRESSURE TEST. THE OVERHAUL FACILITY CONFIRMED THAT THE SEAL AND O-RINGS WERE OLD AND IN NEED OFREPLACEMENT. 1H71 3R3 R A806 5E1 20031021000502003102100050WP 2003 10 21 CA030918010 120030918G6320369D25416 BEARING DOUG HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL M/R TRANSMISSIONCRACKED W O OTHER J WARNING INDICATION NRNOT REPORTED 1 CA 0022220405 (CAN) TAIL ROTOR O/P PINION ROLLER BEARING CRACKED AND SPALLED. SPUN ON T/R O/P PINION ROLLER BEARING JOURNAL. JOURNAL NOW UNDERSIZE 1G71 3U3 U H3WE E4CE 20031021000512003102100051EU 2003 10 21 CA030918011 120030918G6220350A31190703 STARFLEX SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE MAIN ROTOR WORN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING THE BEFORE THE FRIST FLIGHT (BFF) INSPECTION, THE PILOT FOUND THE STARFLEX ARM END BUSHING DEBONDED AND DISPLACED OUTBOARD BY APPROXIMATELY 3/8 OF AN INCH. UPON DISASSEMBLY OF THE M/R HEAD THE FREQUENCY ADAPTER PN EIT-3023-01 INNERBORE WAS FOUND TO BE DAMAGED BY BUSHING AND RETAINING BOLT MIGRATION OUTBOARD.DURING THE PREVIOUS DAYS FLYING, THE PILOT NOTICED A SLIGHT DIFFERENCE IN THE HELICOPTERS VIBRATORY LEVEL. 1G71 3U3 U H9EU E19EU 20031021000572003102100057NE 2003 10 21 CA030918012 120030916G2430 GENERATOR SKRSKYS76 S76A 8143006NE TMECA ARRIELARRIEL1S1 60030NE ENGINE OUT OF ADJUST W A UNSCHED LANDING YJ ENGINE STOPPAGE WARNING INDICATION NRNOT REPORTED 1 CA (CAN) DURING TRAINING, INFLIGHT ENGINE SHUTDOWN AND RESTART PROCEDURES WERE BEING DEMONSTRATED. WHEN START WAS ATTEMPTED THE THE OVERSPEED SYSTEM TRIPPED AND PREVENTED THE RESTART. TROUBLESHOOTING INDICATES THAT A OUTPUT VOLTAGE OF 28.55 VDC FROM THE OPERATING ENGINE GENERATOR WILL TRIP THE OVERSPEED SYSTEM AND PREVENT STARTING. ADJUSTMENT OF THE OUTPUT VOLTAGE TO 28.5 VDC HAS CORRECTED THIS PROBLEM. 1G72 3U3 U H1NE E19EU 20031021000592003102100059WP 2003 10 21 CA030919002 120030915G6210369A10045 PIN HUGHES HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL M/R BLADE SHEARED W O OTHER O OTHER NRNOT REPORTED 1 CA 0098846211 (CAN) WHEN PIN WAS OPENED TO REMOVE MAIN ROTOR BLADE PIN FELL APART. IT WAS NOTED PIN WAS SHEARED OFF WHERE LAST THREAD WAS CUT. 1G71 3U3 U H3WE E4CE 20031021000672003102100067 2003 10 21 CA030919003 420030907G3450 CONTROL PANEL BOEING767 767375 1385217NM GE CF6 CF680C2B6F 30025NE TCAS MALFUNCTIONED W A UNSCHED LANDING O OTHER NRNOT REPORTED 1 CA (CAN) A/C HAD A DUAL ATC FAILURE AFTER DEPARTURE LHR. UK ATC WOULD NOT LET THE A/C PROCEED SO RETURNED TO LHR. OVERWEIGHT LANDING CHECK CARRIED OUT. ATC CONTROL PANEL CHANGED AND NO FURTHER FAULT 2L72 4F4 FRTA1NM E13NE 20031021000682003102100068EA 2003 10 21 CA030921001 120030912G5610NP13932110 WINDSHIELD CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE COCKPIT CRACKED W O OTHER O OTHER CRCRUISE 1 CA (CAN) AIRCRAFT HAS RECEIVED A REPORT WHICH WE FEEL IS A REPORTABLE EVENT. RT WINDSHIELD INNER PLY CRACKED WHILE EN-ROUTE FROM ORD TO AUS. THE AIRCRAFT WAS FERRIED TO ORD FOR THE WINDSHIELD REPLACEMENT. 2L72 4F4 FRTA21EA E15NE 20031021000742003102100074EA 2003 10 21 CA030922002 120030803G2710 PCU CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE COCKPIT JAMMED W O OTHER F FLT CONT AFFECTED DEDESCENT 1 CA (CAN) DURING DESCENT, THE CREW RECEIVED A 'OB SPOILERON' CAUTION AND 'OB FLIGHT SPOILER' CAUTION MESSAGES.THE MDC REPORTED THE LT OUTBOARD MFS PCU JAM. CREW DECLARED AN EMERGENCY AND LANDED SAFELY WITH NO OTHER INCIDENTS REPORTED. FOLLOWING REPLACEMENT OF THE LT OUTBOARD MFS POWER CONTROLLER, THE AIRCRAFT RETURNED TO SERVICE. 2L72 4F4 FRTA21EA EOOO63EN 20031021000762003102100076 2003 10 21 CA030922003 420030918G22108220044001 CONTROL PANEL CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE AUTOPILOT MALFUNCTIONED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) UPON AUTOPILOT DISCONNECT ON APPROACH ELEVATORS WERE STUCK AND HAD TO OVERPOWER TO REGAIN CONTROL.FLT DID NOT ENTER ANY VISIBLE MOISTURE DURING FLT. A/C LANDED NORMALLY. PANEL REPLACED (FCP)AS PER AMM 22-11-07-400-801 AND ALL OPERATES NORMALLY. 2L72 4F4 FRTA21EA E15NE 20031021000792003102100079EA 2003 10 21 CA030922004 220030922G8530 STUD PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA NR 2 NACELLE BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING 100 HR. INSPECTION THE NR 2 ENGINE COWL WAS REMOVED. WHEN THE COWL WAS LOWERED TWO NUTS WITH HALF THE STUDS FELL OUT ONE 3/8 INCH AND ONE 1/2 INCH. AFTER FURTHER INSPECTION IT WAS NOTICED THAT THE NR 2 CYL HOLD DOWN STUDS ON THE LOWER HALF OF THE CYL WAS MISSING. WHEN THE CYL. WAS REMOVED IT WAS NOTED THAT THE CYL HAD A LARGE CRACK BETWEEN THE TOP SPARK PLUG HOLE TO THE EXHAUST VALVE. THE PARTS HAVE BEEN SENT OFF TO TSB TO DETERMINE THE REASON FOR BREAKAGE. 1L72 3O3 O A20SO E14EA 20031021000812003102100081NM 2003 10 21 CA030922005 120030905G561007802 WINDSHIELD DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE COCKPIT CRACKED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA 2275722757 (CAN) DURING CRUISE FLIGHT AT 25,000 FT THE LT WINDSHIELD STARTED ARCING WITH SUBSEQUENT SHATTERING OF THE WINDSHIELD OUTER PLY. AIRCRAFT REQUESTED ALOWER ALTITUDE TO DESEND BELOW ICING CONDITIONS , AND CONTINUED TO DESTINATION. MAINTENANCE REPLACED WINDSHIELD ASSEMBLY AND AIRCRAFT RETURNED TO SERVICE. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20031021000822003102100082NM 2003 10 21 CA030923001 120030905G7931ST1042 TRANSMITTER BOEING737 737210C 1384459NM PWA JT8 JT8D9A 52048NE OIL PRESSURE FAILED W O OTHER N FALSE WARNING TXTAXI/GRND HDL 1 CA (CAN) ON START UP NR 2 ENGINE OIL PRESSURE WOULD NOT COME UP. START ABORTED AND ENGINES SHUT DOWN.FOUND NR 2 ENGINE OIL PRESSURE TRANSMITTER PN ST1042 TO BE UNRELIABLE AT TIMES. TRANSMITTER REPLACED AND ALL INDICATIONS NORMAL. AIRCRAFT RELEASED RETURN TO SERVICE. 2L72 4F4 F A16WE E2EA 20031021000832003102100083GL 2003 10 21 CA030923002 320030918G6114D7015 HUB CESSNA414 414 2075908CE CONT O520 TSIO520N 17040SO MCAULY3AF32C3AF32C93 GL PROPELLER MISOVERHAULED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) HUB UNIT BLADE SOCKET NR 2, EXPANSION PLUG HOLES DRILLED TOO DEEP BY THE PREVIOUS OVERHAUL. HUB UNIT REPLACED. 1L72 3O3 ORTA7CE E8CE 5 CP22EA 20031021000852003102100085GL 2003 10 21 CA030923003 320030918G6111S82NC55 BLADE CESSNA414 414 2075908CE CONT O520 TSIO520N 17040SO MCAULY3AF32C3AF32C93 GL PROPELLER DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) PROPELLER BLADES MEASURED WHEN RECEIVED IN SHOP. BLADES FOUND TO BE BELOW MIN. WIDTH AND THICKNESS. BLADES REPLACED. 1L72 3O3 ORTA7CE E8CE 5 CP22EA 20031021000862003102100086GL 2003 10 21 CA030923004 320030918G6111S82NC55 BLADE CESSNA414 414 2075908CE CONT O520 TSIO520N 17040SO MCAULY3AF32C3AF32C93 GL PROPELLER DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) BLADES MEASURED WHEN RECEIVED IN SHOP, FOUND BLADE WIDTH TO BE BELOW MIN. ALLOWABLE. BLADES REPLACED. 1L72 3O3 ORTA7CE E8CE 5 CP22EA 20031021000872003102100087GL 2003 10 21 CA030923005 220030914G7230 BEARING BELL 206 206L1 1182107SW ALLSN 250C 250C28B 03013GL COMPRESSOR FAILED W O OTHER J WARNING INDICATION CRCRUISE 1 CA (CAN) NR 1 ENGINE BEARING FAILED, CHIP LIGHT NOTIFIED PILOT. AIRCRAFT WAS IN CRUISE FLIGHT. UPON INVESTIGATION THE BEARING CAGE AND BALLS WERE NO LONGER CONTAINED BETWEEN THE INNER AND OUTER RACES. THE IMPELLER WAS ALLOWED TO TILT AND AS A RESULT RUBBED A GROOVE INTO THE COMPRESSOR HOUSING. COMPRESSOR ASSEMBLY WAS REPLACED WITH SERVICEABLE UNIT. AIRCRAFT WAS GROUND RUN AND RETURNED TO SERVICE. 1G71 3U3 U H2SW E1GL 20031021000972003102100097EA 2003 10 21 CA030923006 220030917G7210 ENGINE PWA PT6 PT6A50 52043EA FAILED W O OTHER J WARNING INDICATION CRCRUISE 1 CA 15537 (CAN) ENG SHUTDOWN IN FLT WHEN OIL PRESSURE DROPPED BELOW 75 PSI. REMOVED FOR INVEST. ENG FOUND TO HAVE 3 SOURCES OF OIL LOSS, PRINCIPAL ONE IS THOUGHT TO HAVE RESULTED IN RAPID OIL LOSS & MAIN PRESSURE PUMP OIL STARVATION, AN OIL GALLERY PORT ON RGB ACCESSORY G/B WHICH HAD A STRIPPED THREAD & BLANKING PLUG MISSING. THERE WAS NO EVIDENCE IN ENG OF ANY DAMAGE CAUSED BY LACK OF LUBE & PROMPT ENG SHUTDOWN PREVENTED SIGNIFICANT DAMAGE. ENG FOUND TO HAVE BALL BEARING ON ALTERNATOR DRIVE SHAFT FAILED, CAUSING SHAFT TO LOSE LOCATION & ALLOW OIL LEAKAGE AT SEAL. PROPSHAFT OIL SEAL RUNNER & NR 7 BEARING INNER RACE HAD BOTH SPUN ON PROP SHAFT CAUSING SIGNIFICANT MATERIAL LOSS TO ALL 3 PARTS & AN OIL LEAKAGE PATH. 4 T E4EA 20031021000982003102100098NM 2003 10 21 CA030923007 120030919G5753654642821 FLAP TRACK BOEING737 737242C 1384478NM PWA JT8 JT8D9A 52048NE RT WING CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) WHILE PERFORMING AD 2002-05-07 (BOEING SB737-57A1249), THE RT SIDE FLAP TRACK POSITION NR 7 WAS FOUND CRACKED. TRACK WAS REPLACED. 2L72 4F4 F A16WE E2EA 20031021001002003102100100NM 2003 10 21 CA030923008 120030919G5312 BEAM BOEING737 737242C 1384478NM PWA JT8 JT8D9A 52048NE BULKHEAD CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 65308 (CAN) WHILE PERFORMING SB 737-53A1173 (INSPECTION OF THE VERTICAL BEAMS AT STATION 178 PRESSURE BULKHEAD) THE FOLLOWING DEFECTS WERE FOUND, VERTICAL BEAM WEB CRACKED AT BS178 RBL 5.7 WL 1832-VERTICAL BEAM WEB CRACKED AT BS 178 RBL 17.1 WL 230 BOTH CRACKS WERE REPAIRED AS PER BOEING 737 SRM. 2L72 4F4 F A16WE E2EA 20031021001012003102100101NM 2003 10 21 CA030923009 120030919G5330 SKIN BOEING737 737242C 1384478NM PWA JT8 JT8D9A 52048NE FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 65308 (CAN) WHILE LOOKING AT FUSELAGE ON THE LT SIDE,THE TECHNICIAN WAS QUESTIONNING WHAT SEEM TO BE A SCRATCH MARK. AFTER FURTHER INVESTIGATION AND INTERIOR LINING REMOVAL,IT WAS DISCOVERED THAT THE SCRATCH WASINDEED A CRACK IN THE FUSELAGE LOCATED AT FUSELAGE STA 771, BETWEN STRINGER 16L AND 17L.THE CRACK WAS 2 INCHES LONG,BETWEEN STA 771 AND STA 773 ABOVE FLOOR LEVEL. CRACK WAS REPAIRED USING 737 SRM. 2L72 4F4 F A16WE E2EA 20031021001022003102100102SW 2003 10 21 CA030923010 120030912G6420204011722005 YOKE BELL 204 204B 1181404SW LYC T53 T5311B 41549NE TAIL ROTOR HEAD CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) TAIL ROTOR HUB ASSY WAS SENT FOR OVERHAUL. YOKE WAS SENT FOR NDT AS PART OF O/H AND WAS FOUND TO BE CRACKED. 1G71 4U4 U H1SW E1EA 20031021001062003102100106NE 2003 10 21 CA030923011 220030812G853012081 STUD DHAV DHC2 DHC2MK1 2800102EA PWA R985 R985AN14B 52008NE CYLINDER BASE BROKEN W A UNSCHED LANDING O OTHER CRCRUISE 1 CA (CAN) ALL NR 6 HOLD DOWN STUDS FOUND BROKEN. 1H71 3R3 R A806 5E1 20031021001072003102100107CE 2003 10 21 CA030924001 120030922G52101144000301 SEAL BEECH 1900 1900C 1154161CE PWA PT6 PT6A65B 52043EA PAX DOOR DETACHED W BG EMER. DESCENT O2 MASK DEPLOYED W INADEQUATE Q C CRCRUISE 1 CA (CAN) SEAL BECAME DETACHED FROM RETAINER AT UPPER AFT CORNER OF AIRSTAIR DOOR CAUSING RAPID DEPRESSURIZATION OF AIRCRAFT IN FLIGHT. 2L72 4T4 TRTA24CE E4EA 20031021001082003102100108EU 2003 10 21 CA030924002 120030924G32609733033111 PROXIMITY SWITCH PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL MLG FAILED W A UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 CA (CAN) AFTER TAKE OFF THE SYSTEMS RELATED TO THE RT PROXIMITY SWITCH STARTED TO FLASH. THE AIRCRAFT RETURNED TO BASE. THE AIRCRAFT WAS PUT ON JACKS AND THE WIRING WAS INSPECTED. THERE WERE NO DEFECTS FOUND AND THE SNAG COULD NOT BE DUPLICATED. AS THE AIRCRAFT HAD FLOWN THROUGH HEAVY RAIN THE DAY BEFORE ALL THE CONNECTORS WERE CLEANED AND RESEALED. THE PROXIMITY SWITCHES WERE SWAPPED FROM LT TO RT TO SEE IF THE SNAG WOULD FOLLOW. THE AIRCRAFT WAS TEST FLOWN AND THE SNAG DID NOT RETURN. THE AIRCRAFT WAS RETURNED TO SERVICE. SDR TO BE CLOSED IN 1 WEEKIF THE ARE NO MOVE OCCURANCES. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20031021001092003102100109NM 2003 10 21 CA030924003 120030906G2761A44700009 ACTUATOR DHAV DHC8 DHC8* NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE SPOILER FAILED W A UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 CA 35059 (CAN) THE AIRCRAFT EXPERIENCED A FLIGHT TURNBACK DUE TO TOTAL LOSS OF HYDRAULIC FLUID FROM THE NR 2 HYDRAULIC SYSTEM. BECAUSE OF THE FLUID LOSS AN EMERGENCY EXTENSION OF THE LANDING GEAR HAD TO BE CARRIED OUT PRIOR TO LANDING. THE CAUSE OF THE FLUID LOSS WAS DUE TO A CATASTROPHIC FRACTURE FAILURE OF LT HAND OUTBOARD SPOILER ACTUATOR METAL BODY, ALLOWING THE WHOLE CONTENT OF THE NR 2 HYD SYSTEM TO BE RELIEVED THROUGH THE ACTUATOR BODY. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20031021001112003102100111EA 2003 10 21 CA030924004 220030910G753254009494 BLEED VALVE BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ENGINE FAILED W E ENGINE SHUTDOWN J WARNING INDICATION CRCRUISE 1 CA (CAN) IN FLIGHT SHUTDOWN DUE FADEC CAUTION LIGHT CREW SHUT THE ENGINE DOWN, FADEC FAULT CODE WAS 912. A FAULTY P2.2 BLEED VALVE WAS IDENTIFIED VALVE. 2.2 BLEED VALVE REPLACED AND AIRCRAFT WAS DECLARED SERVICEABLE. 2H72 4T4 TRTA13NM E00062EN 20031021001122003102100112EA 2003 10 21 CA030924005 220030919G8530381369679 STUD PIPER PA31 PA31 7103102SO LYC O540 TIO540A2B 41532EA NR 5 CYLINDER BROKEN W E ENGINE SHUTDOWN D INFLIGHT SEPARATION CRCRUISE 1 CA (CAN) LT ENGINE CYLINDER NR 5 CYLINDER BASE STUDS SHEARED OFF IN CASE. STUDS APPEAR TO HAVE BEEN CRACKED INSIDE CASE AREA. POSSIBLY FROM OVER TORQUEING. 1L72 3O3 O A20SO E14EA 20031021001142003102100114CE 2003 10 21 CA030924006 120030905G2823662820010003 SHUTOFF VALVE LEAR 45 45LEAR 5170805CE GARRTTTFE731TFE7312 01518WP FUEL SYSTEM FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) WHEN LT ENGINE FUEL SHUTOFF VALVE WAS SELECTED CLOSED AND AIRFRAME POWER WAS SELECTED OFF, NOISE WAS HEARD COMING FROM THE VALVE. IT WAS DISCOVERED THAT THECURRENT WAS NOT CUT OFF WHEN THE VALVE WASCLOSED.REPLACED SHUTOFF VALVE. 2L72 4F4 FRTT00008WIE6WE 20031021001172003102100117WP 2003 10 21 CA030925001 220030408G72503060690 BLADE RAYTHNDH125 HAWKER800XP 7150012CE GARRTTTFE731TFE7315BR WP LPT3 FAILED W E ENGINE SHUTDOWN O OTHER CRCRUISE 1 CA (CAN) FAILURE OF LPT3 BLADE. THESE BLADES WERE INSTALLED AT TIME OF MANUFACTURE. BASED ON EXPERIENCE FROM OTHER EVENTS, SEPARATIONS OF THE LPT 3 BLADE HAVE BEEN TRACED TO EXCESSIVE MECHANICAL ADJUSTMENT DONE DURING TIME OF MANUFACTURE. WHILE THIS IS A COMMON PRACTICE IN THE AEROSPACE CASTING INDUSTRY, THE GEOMETRY OF THIS BLADE MAKES IT SENSITIVE TO THIS PROCESS. THE FRACTURE APPEARS AS A STRESS RUPTURE FRACTURE MODE. IN AN EFFORT TO REDUCE ADDITIONAL FAILURES, HONEYWELL ISSUED SERVICE BULLETIN TFE731-3686 TO REQUIRE EDDY CURRENT AND FLUORESCENT PENETRANT INSPECTION OF AT MPI OR TIME OF TURBINE ACCESS. 2L72 4F4 FRTA3EU E6WE 20031017000032003101700003NM 2003 10 17 CA030925002 120030905G291082920010307 LINE DHAV DHC8 DHC8101 2809002NM PWA PW121 PW121 52124NE HAMSTD14SF 14SF7 NE HYD SYSTEM RUPTURED W D RETURN TO BLOCK K FLUID LOSS TXTAXI/GRND HDL 1 CA (CAN) DURING TAXI-OUT, FUSELAGE HYD LINE RUPTURED AT A POINT OVERHEAD ROW 4 - 5 (CA. FS X 407.7 + 2) JUST FORWARD OF THE PRESSURE FITTING AND BELOW THE 90 DEGREE BEND ROUTING THE LINE DOWNWARD. 7 PASSENGERS WERE ON BOARD (1 PASSENGER AND 1 FA WERE TAKEN TO HOSPITAL FOR TREATMENT). THE HYDRAULIC LINE WAS REPLACED. DURING THE SUBSEQUENT PRESSURE CHECK, THE ADJACENT LINE (P/N 82920010263 / NLG RETRACT) WAS FOUND TO BE SEEPING AT THE BULKHEAD PRESSURE FITTING SWAGE. THE OPERATOR HAS EXPRESSED THEIR INTENT TO VISUALLY INSPECT THEIR FLEET FOR LEAKAGE IN THIS AREA. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20031021001212003102100121CE 2003 10 21 CA030925003 120030921G275026600111 CONTROL ROD CESSNA208 208B 2073701CE PWA PT6 PT6A114A 52043NE MCAULY3AF34C3GFR34C703 GL TE FLAPS CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 1857418574 (CAN) WHILE CARRYING OUT A PHASE INSPECTION, THE CONTROL COLUMN CONNECTING TUBE WAS FOUND CRACKED. THE CRACK WAS LOCATED AT ONE OF THE ATTACHMENT BOLT HOLES TO THE KNUCKLE FITTING. THE CRACK EMANATED FROM THE BOLT HOLE CLOSEST TO THE END OF THE TUBE, TO THE END OF THE TUBE. A NEW TUBE WAS INSTALLED IN THE AIRCRAFT AND RETURNED TO SERVICE. 2 OTHER AIRCRAFT IN OUR FLEET WERE INSPECTED WITH NO DEFECTS FOUND. 1H71 3T3 T A37CE E4EA 5 CP60GL 20031021001242003102100124CE 2003 10 21 CA030925004 120030923G21612297009 SOLENOID VALVE BEECH 100 B100 1152919CE GARRTTTPE331TPE3316252B 01514WP HARTZLHCB4T HCB4TN5 GL RT ENGINE SHORTED W O OTHER RJ PARTIAL RPM/PWR LOSS WARNING INDICATION CRCRUISE 1 CA (CAN) WHILE IN CRUISE, THE 5 AMPS CIRCUIT BREAKER (CABIN TEMP) TRIPPED. CREW RESET ONE TIME AND TRIPPED AGAIN. UPON INVESTIGATION FOUND RT AMBIENT SOLENOID SHUTOFF VALVE SHORTED CAUSING CIRCIUT BREAKER TO TRIPPED. SOLENOID VALVE REPLACED WITH NEW AND SYSTEM GROUND TESTED OK IAW M/M. 1L72 4T4 T A14CE E2WE 6 CP40EA 20031021001252003102100125CE 2003 10 21 CA030925005 120030916G324030162 PAD BEECH 200 B200C 1152924CE PWA PT6 PT6A42 52043NE HARTZLHCD4N3HCD4N3A GL BRAKE ASSY LOOSE W O OTHER D INFLIGHT SEPARATION LDLANDING 1 CA (CAN) DURING LANDING THE AIRCRAFT WAS PULLING TO THE LEFT SIDE OF THE RUNWAY. UPON APPLICATION OF THE BRAKE ON THE LEFT SIDE AIRCRAFT STARED TO VIBRATE. THE BRAKE WAS ALSO NOTED TO BE SOFT AND INEFFECTIVE. MAINTENANCE INSPECTED IT AND FOUND THE LT OUTBOARD BRAKE WEAR PADS BECAME DISLODGED AND DAMAGED THE BRAKE ASSEMBLY AND THE WHEEL HALF. THE WEAR PADS ARE RIVETED ON AND IT APPEARS THAT A RIVET LET GO AND STARTED A CHAIN REACTION BREAKING ALL THE OTHER RIVETS LETTING THE WEAR PAD MOVE AND DAMAGE THE OTHER PARTS. 1L72 4T4 T A24CE E4EA 5 CSTC 20031021001272003102100127GL 2003 10 21 CA030925006 320030901G6197KX5116 SWITCH DHAV DHC6 DHC6100 2802610EA PWA PT6 PT6A20 52043EA HARTZLHCB3T HCB3TN3 GL PROP RESET SHORTED W O OTHER E VIBRATION/BUFFET TXTAXI/GRND HDL 1 CA (CAN) WHILE TAXIING FROM DOCK, NR 1 ENGINE DID NOT RESPOND TO (REVERSE) COMMAND BUT POWERED UP TO FORWARD MODE. FOUND WIRING WRAP INTERFERED WITH PROP RESET SWITCH IN OVERHEAD POWER LEVER QUADRANT. MODIFICATION WAS COMPLETED IAW DHC-6-100, MOD6/1912 (INSTALLATION OF SPARK IGNITION). 1H72 3T3 TRTA9EA E4EA 6 CP15EA 20031021001302003102100130NM 2003 10 21 CA030926001 120030911G291082970010477 LINE DHAV DHC8 DHC8* NM PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE HYD SYSTEM CRACKED W O OTHER KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 CA (CAN) DURING THIS FLIGHT WE EXPERIENCED A HYDRAULIC FAILURE OF THE NR 2 HYDRAULIC SYSTEM NUMBER . AFTER THE LANDING, THE INSPECTION REVEALED A CRACKED ENGINE DRIVEN PUMP FEED PRESSURE TUBE.MOD 8Q100820 WAS INTRODUCED TO IMPROVE THE RELIABILITY OF THE TUBES BY CHANGING THE MATERIAL FROM ALUMINIUM TO STAINLESS STEEL, AND TO INTRODUCE MACHINED FLARED END FITTINGS IN LIEU OF THE FORMED FLARED. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20031021001322003102100132SO 2003 10 21 CA030926002 120030922G325070933003 SHAFT PIPER PA42 PA42 7104202SO PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL NLG STEERING CRACKED W O OTHER O OTHER TXTAXI/GRND HDL 1 CA (CAN) PILOT REPORTED LACK OF NOSE WHEEL STEERING CONTROL. UPON INSPECTION, THE NOSE WHEEL STEERING SHAFT WAS FOUND CRACKED LONGITUDINALLY BETWEEN BOLT HOLES. 1L72 4T4 T A23SO E4EA 6 CP15EA 20031021001352003102100135EA 2003 10 21 CA030926003 220030917G741467542 BEARING PIPER PA23 PA23250 7102308SO LYC O540 IO540C4B5 41532EA HARTZLHCE2Y HCE2YR2 GL LT MAGNETO WORN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) RT ENGINE, LT MAGNETO-ENGINE HOURS: 1230.5 SN. L-8588-48. DAMAGE WAS DISCOVERED DURING 100 HOUR INSPECTION. REMOVAL OF ONE LT MAGNETO WAS REQUIRED TO COMPLETE A MAGNETO INSPECTION. WHEN MAGNETO WAS REMOVED MAGNETO GEAR RETAINER ASSY AND BEARING PULLED OUT OF THE ENG TOGETHER WITH DRIVE COUPLING YET AGAIN . UPON FURTHER INSP NO DAMAGE TO GEAR RETAINER ASSY AND BEARING WAS FOUND AND ASSY WAS REPLACED WITH NEW AND REINSTALLED. ALSO BEARING RECESS WAS INSP AND MEASURED TO BE WITH-IN LIMITS AND CHECKED OK. 1L72 3O3 O 1A10 1E4 5 CP9EA 20031021001372003102100137SO 2003 10 21 CA030926004 120030813G28233085600 CONTROL CABLE PIPER PIPER PA23 PA23250 7102308SO LYC O540 IO540C4B5 41532EA HARTZLHCE2Y HCE2YR2 GL FUEL SELECTOR BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) WHILE TESTING OPERATION OF LT FUEL SELECTOR CONTROL NOTICED THAT THE LT SIDE WAS MOVING VERY EASY. FURTHER INSPECTION FOUND THAT THE INNER CABLE HAD BROKEN LEAVING THE FUEL VALVE IN AN UNKNOWN POSITION. CABLE WAS REPLACED WITH NEW. 1L72 3O3 O 1A10 1E4 5 CP9EA 20031021001392003102100139SO 2003 10 21 CA030926005 120030819G32301742003 DRAG LINK PIPER PA23 PA23250 7102308SO LYC O540 IO540C4B5 41532EA HARTZLHCE2Y HCE2YR2 GL LT MLG CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE LT GEAR LEG SUPPORT BRACE AT THE REAR ATTACHEMENT FITTING WAS CRACKED COMPLETELY TO THE BOLT HOLE. PART WAS REMOVED AND WAS WELD REPAIRED. IT WAS SENT FOR NDT TOGETHER WITH RIGHT DRAG LINK AND DRAG LINK CASTING AND PASSED. PARTS WERE RE-INSTALLED CHECKS OK NO OTHER LOCAL DAMAGE WAS DETECTED. 1L72 3O3 O 1A10 1E4 5 CP9EA 20031021001412003102100141NE 2003 10 21 CA030926006 220030520G7321 CAP WOODWARD BELL 412 412 1182202SW PWA PT6T PT6T3B 52045NE FUEL CONTROL FRACTURED W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA A34702 (CAN) FUEL DRIPPED FROM THE AFCU AND ENTERED THE CABIN OF THE AIRCRAFT. POST FLIGHT TROUBLESHOOTING IDENTIFIED A MAJOR LEAK FROM THE ALUMINUM CAP PLUG ON THE SIDE OF THE AFCU. EXAMINATION HAS IDENTIFED THAT THE FRACTURE IS DUE TO LCF. THE EXACT TOTAL TIME OF THE CAP IS NOT KNOWN, BUT IS ESTIMATED AT +2,000 HOURS. 1G72 4U4 U H4SW E22EA 20031021001422003102100142CE 2003 10 21 CA030928001 120030927G35101145600585 LINE BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3I NE OXYGEN SYSTEM CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 1372613726 (CAN) WHEN TRYING TO SERVICE OXYGEN SYSTEM ONLY THE LT BOTTLE WOULD FILL AND A LOUD LEAK COULD BE HEARD. AFTER INVESTIGATION BY MAINTENANCE THE FILLER INTERCONNECT LINE WAS FOUND TO BE CRACKED WHERE IT ATTACHES TO THE RT BOTTLE. THE LINE WAS REPLACED AND LEAK TESTED SERVICABLE. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20031021001432003102100143CE 2003 10 21 CA030928002 120030914G27500512128 PULLEY BRACKET CESSNA185 A185F 2072821CE CONT O550 IO550D 17042SO MCAULYD3A34 D3A34C401 GL TE FLAPS DETACHED W O OTHER OI OTHER FLT. ATTITUDE INST. APAPPROACH 1 CA (CAN) ON FINAL APPROACH TO LAND THE AIRCRAFT WAS BUFFETED BY A GUST OF WIND AT WHICH TIME THE LT FLAP PARTIALLY RETRACTED. THE AIRCRAFT MADE AN UNEVENTFULL LANDING AND DURING INVESTIGATION BY MAINTENANCE THE LT FLAP PULLEY BRACKET WAS FOUND DETACHED FROM THE AIRFRAME. IT WAS REPLACED AND THE SYSTEM WAS TESTED AND FOUND OPERATING NORMALLY. 1H71 3O3 O 3A24 E3SO 5 CP47GL 20031021001442003102100144NE 2003 10 21 CA030929001 220030914G7200 ENGINE BOEING717 717200 1383700NM RROYCEBR700 BR700715A130 NE NR 1 BURNED W F ACTIVATE FIRE EXT. AJ FLAME/FIRE WARNING INDICATION TXTAXI/GRND HDL 1 CA (CAN) ENG FIRE ON A/C 796 NR 1 POS. A/C WAS FULLY LOADED WITH PASS. DURING ENG START RECEIVED A FIRE IND ON NR 1 ENG, FIRST BTL WAS RELEASED, FIRE IND RE-APPEARED, SECOND BTL RELEASED. NO FURTHER FIRE IND WERE RECEIVED. PAX EXITED A/C AND NO EMER EVACUATION WAS DECLARED. ENG AT RRC FOR INVEST, INSP REVEALED SIGNIFICANT DAMAGE TO ACOUSTIC LINING, MANY MELTED WIRES. FUEL SYS ON ENG 13245 WAS PRESSURIZED ON TEST CELL W/ENG STATIC TO VERIFY FOR LEAKS, NO LEAKS OBSERVED. DRY AND WET MTR CYCLES WERE CARRIED OUT, NO LEAKS OBSERVED. FUEL DRAIN TANK WAS EMPTIED PRIOR TO WET CRANK, THERE WAS EVIDENCE OF FUEL DRAIN I.E. MANIFOLD DRAINING PROPERLY. EEC WILL BE SENT TO VENDOR FOR NON VOLATILE MEMORY DOWNLOAD/CHECK. 2L72 4F4 FTRA6WE E00061EN 20031021001452003102100145NE 2003 10 21 CA030929002 220030918G73141143880425 PUMP BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE FUEL SYSTEM LEAKING W A UNSCHED LANDING BKJSMOKE/FUMES/ODORS/SPARKS FLUID LOSS WARNING INDICATION CRCRUISE 1 CA (CAN) CREW NOTICED A FUEL ODOR IN AIRCRAFT AT ALTITUDE AND A PASSENGER NOTIFIED THAT FLUID APPEARED TO BE COMING FROM COWL AREA THAT NORMALLY PROVIDES EXHAUST AIR FROM THE STARTER GENERATOR. THE AIRCRAFT DIVERTED TO THE CLOSEST AIRPORT. MAINTENANCE FOUND THE RT ENGINE LOW PRESSURE FUEL PUMP WAS LEAKING FUEL. THE PUMP WAS REPLACED AND THE AIRCRAFT CONTINUED. THE PUMP STRIP FOUND THAT A GASKET BETWEEN THE REGULATOR AND THE MAIN BODY WAS BLOWN OUT OF POSITION ALLOWING FUEL LEAKAGE. 2L72 4T4 TRTA24CE E26NE 20031021001462003102100146NE 2003 10 21 CA030929003 220030919G73141143880425 PUMP BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE FUEL SYSTEM LEAKING W O OTHER BKJSMOKE/FUMES/ODORS/SPARKS FLUID LOSS WARNING INDICATION CRCRUISE 1 CA (CAN) SIMILIAR TO A PREVIOUS SDR ON THE RT SIDE ON SEPT 18, 2003, THE LT HAND LOW PRESSURE FUEL PUMP BEGAN LEAKING IN FLIGHT ALLOWING ODOR AND FUEL ESCAPE FROMTHE AIRCRAFT. MAINTENANCE AGAIN REPLACED THE PUMP AND THE STRIP SHOWED THE SAME GASKET BLOW OUT ALLOWING FOR FUEL TO ESCAPE. 2L72 4T4 TRTA24CE E26NE 20031021001472003102100147EU 2003 10 21 CA030929004 120030926G3250 STEERING SYS ISRAEL1125 ASTRASPX 4500205EU GARRTTTFE731TFE73140 29001NE NLG MALFUNCTIONED W O OTHER O OTHER LDLANDING 1 CA (CAN) AFTER TOUCH DOWN APROX 80 KNOTS THE NOSE GEAR STEERING WHEEL AUTOMATILLY WHEN TO A FULL LEFT TURN COMMAND. THE AIRCRAFT DEPARTED THE RUNWAY TO THE LT AND CAME TO A REST AT APROX 90 DEGREES TO THE RUNWAY IN THE SOIL AREA NEXT TO RUNWAY. THE RT WING TIP STRUCK THE GROUND AT APROX 20 KNOTS IN THE SOIL AREA DAMAGE WAS OBSERVED IN THE NOSE GEAR AREA AND ALSO THE RIGHT TIP AREA. 2L72 4F4 FRTA16NM E1NM 20031021001542003102100154NM 2003 10 21 CA030929006 120030928G2761654456110 ACTUATOR BOEING737 737217 1384464NM PWA JT8 JT8D17 52049NE SPOILER MALFUNCTIONED W A UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CLCLIMB 1 CA (CAN) ON CLIMB OUT THE AIRCRAFT EXPERIENCED A TOTAL LOSS OF HYDRAULIC SYSTEM A FLUID. AIRCRAFT TURNED BACK TO YUL AND LANDED WITHOUT INCIDENT. THE NR 3 SPOILER ACTUATOR WAS FOUND TO BE THE CAUSE OF THE FLUID LEAK.ACTUATOR REPLACED AND AIRCRAFT RETURNED TO SERVICE. A SHOP REPORT HAS BEEN REQUESTED FOR THE ACTUATOR UNIT. WILL ADD MORE INFO WHEN AVAILABLE. 2L72 4F4 F A16WE E2EA 20031021001552003102100155NE 2003 10 21 CA030930001 220030925G722080337035003 BREATHER TUBE PIAGIOP180 P180 6960204EU PWA PT6 PT6A66 52043NE HARTZLHCE5N HCE5N3 GL RT ENGINE KINKED W O OTHER B SMOKE/FUMES/ODORS/SPARKS TOTAKEOFF 1 CA (CAN) THE AIRCRAFT WAS WORKED ON FOR HOT ENVIRONMENTAL ODOR. THE ENVIRONMENTAL SYSTEM WAS CHECKED OVER AND THE DUCT WORK WAS CHECKED WITH A BORESCOPE. PILOTS REPORTED THE ODOR WAS BACK WITH SMOKE WHEN THE POWERED UPTHE ENGINES.THE ENGINE COWLS WERE REMOVED AND OIL WAS FOUND IN THE BLEED AIRVALVE OF THE RIGHT ENGINE.THE ENGINE BREATHER LINE WAS FOUND KINKED AND BADLY RESTRICTED CAUSING NR 1 BEARING CAVITY TO FLOOD. THE LINE WAS REPLACED COMPRESSOR WASH CARRIED OUT, ENGINE GROUND RUNS AND TEST FLIGHT WAS SATISFACTORY. 1H72 3O4 TRTA59EU E26NE 5 CPZONE 20031107000092003110700009EU 2003 11 7 CA030930002 120030929G21501879009 ODOR AIRESRCH AIRBUS310 A310300 3930305EU HEAT EXCHANGER DETECTED W O OTHER B SMOKE/FUMES/ODORS/SPARKS DEDESCENT 1 CA (CAN) FLIGHT CREW REPORTED AN ELECTRICAL BURNING ODOR IN THE CABIN ON APPROACH WITH GEAR SELECTED DOWN.DURING GROUND TEST , THE PROBLEM WAS TRACED TO THE RT AIR CONDITIONING PACK .THE HEAT EXCHANGER HAD BEEN REPLACED ON THE PREVIOUS FLIGHT AND WAS FRESHLY O/H AND PAINTED. THE COELESER BAG WAS REPLACED AND THE AIR CONDITIONING PACK WAS OPERATED AND CHECKED SERVICEABLE. 2L72 4F RTA35EU 20031021001572003102100157NM 2003 10 21 CA030930003 120030827G2710 ACTUATOR DHAV DHC8 DHC8* NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE ROLL SPOILER FAILED W O OTHER F FLT CONT AFFECTED NRNOT REPORTED 1 CA 24621 (CAN) DURING SCHEDULED MAINTENANCE AN OPERATIONAL CHECK OF THE ROLL SYSTEM DISCONNECT WAS PERFORMED IAW MFG MRB TASK 2760/02. IT WAS DISCOVERED THAT AILERON TRAVEL WAS RESTRICTED AT THE FULL LT WING DOWN SELECTION CAUSING THE ROLL SYSTEM DISCONNECT CLUTCH TO DISENGAGE AT FULL TRAVEL AND SUBSEQUENTLY ILLUMINATING THE ASSOCIATED CAUTION LIGHT. FURTHER INVESTIGATION DETERMINED THAT THE LT OUTBOARD ROLL SPOILER ACTUATOR HAD AN INTERNAL FAILURE CAUSING RESTRICTED TRAVEL DURING EXTENSION OF ROLL SPOILER. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20031021001582003102100158NM 2003 10 21 CA030930004 120030518G2761A44700009 ACTUATOR DHAV DHC8 DHC8* NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE ROLL SPOILER CRACKED W O OTHER KJ FLUID LOSS WARNING INDICATION NRNOT REPORTED 1 CA 30561 (CAN) ROLL SPOILER ACTUATOR SERIAL NUMBER 0963 FOUND TO BE LEAKING AFTER ENGINEERS PERFORMED TROUBLESHOOTING FOR A HYDRAULIC LEAK ON LT WING. THE ACTUATOR WAS SUBSEQUENTLY REMOVED FROM THE AIRCRAFT AND SENT FOR REPAIR. THE REPAIR AGENCY REPORT FINDING A CRACK IN THE ACTUATOR HOUSING, AND THE ASSY WAS RETURNED TO THE OPERATOR FOR SCRAP. THIS ACTUATOR HAS NOW BEEN FORWARDED TO THE AT SB FOR INSPECTION AND REPORT. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20031021001592003102100159SW 2003 10 21 CA030930005 120030824G6330BSH16ATC32 BEARING BELL BELL 206 206B 1181511SW ALLSN 250C 250C20B 03013GL PIN ASSY UNSTAKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) BEARING IN PIN ASSEMBLY BECAME UNSTAKED. 1G71 3U3 U H2SW E4CE 20031021001602003102100160GL 2003 10 21 CA030930006 220030827G72306895803 SCROLL ALLSN BELL 206 206L1 1182107SW ALLSN 250C 250C28B 03013GL COMPRESSOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA CAC70614 (CAN) DURING INSPECTION A CRACK WAS FOUND IN THE COMPRESSOR SCROLL. 1G71 3U3 U H2SW E1GL 20031021001612003102100161CE 2003 10 21 CA030930007 120030821G273005341221 BELLCRANK CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA MCAULY1A170 1A170E GL ELEVATOR CONTROLWORN W K NONE F FLT CONT AFFECTED ININSP/MAINT 1 CA (CAN) THE ELEVATOR BELLCRANK MAIN BEARING WAS FOUND SPINING LOOSE INSIDE THE BELLCRANK ASSEMBLY. THE BELLCRANK WAS WORN OUT BY THE OUTER PORTION OF THE BEARING. THE BEARING IS A PRESSED FIT, AND CANNOT BE REPLACED. THE ENTIRE ELEVATOR BELLCRANK ASSEMBLY HAD TO BE REPLACED WITH NEW. CABLE TENSIONS WERE INSPECTED AND FOUND TO BE NORMAL. 1H71 3O3 ONT3A12 1E10 5 NP857 20031021001622003102100162CE 2003 10 21 CA030930008 120030924G7820175400114 MUFFLER CESSNA172 172L 2072432CE LYC O320 O320E2D 41508EA MCAULY1C160 1C160DTM GL ENGINE LEAKING W A UNSCHED LANDING BJ SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CRCRUISE 1 CA (CAN) PILOT NOTICED CO DETECTOR INDICATING MONOXIDE IN CABIN AND COULD DETECT EXHAUST ODOR. CABIN HEAT SHUT OFF AND VENTS OPENED AND UNSCHEDULED LANDING CARRIED OUT AT ERICKSON, MB. MUFFLER WAS REPLACED BY AME WITH OVERHAUL ACORN WELDING UNIT AND FURTHER FLIGHT WAS UNEVENTFUL. PRESSURE TESTING OR REMOVED MUFFLER DETECTED TINY LEAK AT EXHAUST EXIT BAFFLE, NOT LEAKING INTO HEAT MUFFLER. NO LEAKAGE DETECTED INTO MUFFLER AREA, BUT SOOT WAS PRESENT IN MUFFLER. SUSPECT LEAKAGE OCCURS AT ELEVATED TEMPERATURES. AIRCRAFT WAS CURRENT WITH CF-90-03R2 HEAT MUFFLER INSPECTION. 1H71 3O3 ONT3A12 E274 5 NP910 20031021001632003102100163CE 2003 10 21 CA030930009 120030919G3340C6220010201 WIRE CESSNA172 172S 2072439CE LYC IO360 IO360L2A EA MCAULY1A170 1A170E GL WING TIP BURNED W O OTHER L NO TEST NRNOT REPORTED 1 CA (CAN) THE NAV. LIGHT CIRCUIT BREAKER/SWITCH WOULD TRIP INSTANTLY WHEN SELECTED ON. ALSO THE AMMETTER WOULD SPIKE TO 20+ AMPS FOR A MICRO-SECOND. I DEAD SHORT WAS DETECTED IN THE NAV LIGHT CIRCUIT. FURTHER INSPECTION REVEALED THAT, WITHIN THE LT WINGTIP THE LT NAV LIGHT WIRE HAD WORN INTO THE BONDING STRAP OF THE LT STROBE LIGHT AND FUSED TOGETHER. THE WIRE CONNECTED TO THE BASE OF THE NAV LIGHT SOCKET HAD ALSO SUFFERED HEAT DAMAGE FROM THE DEAD SHORT. BOTH WIRE SEGMENTS WERE REPLACED WITH NEW. AND RE-ROUTED. SYSTEM TESTED CHECKS OK. 1H71 3O3 ONT3A12 1E10 5 NP857 20031021001642003102100164SW 2003 10 21 CA030930010 120030915G6510AN1747A BOLT BELL BELL 206 206L3 1182108SW ALLSN 250C 250C30P 03013GL THOMAS COUPLING STRIPPED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) ON THOMAS COUPLING TORQUE CHECK TWO BOLTS FOUND LOOSE. ON INVESTIGATION OF BOLTS, THREADS FOUND TO BE STRIPPED OFF ON LOWER END. ALL OTHER BOLTS ON FORWARD DRIVESHAFT INSPECTED FOR SERVICEABILITY. BOLT REPLACED NEW AND TORQUED. CAUSE OF DIFFICULT MIGHT HAVE BEEN BOLTS UNDER TORQUED/OVER TORQUED. BETTER INSPECTION OF BOLTS WHEN REMOVING AND INSTALLING HARDWARE. COMPLY WITH 10-25 HOURS TORQUE CHECK INSPECTION IAW MANUFACTURER. 1G71 3U3 U H2SW E1GL 20031021001652003102100165 2003 10 21 CA030930011 420030819G2562 ANTENNA AMERIKING PIPER PA28 PA28161 7102803SO LYC O320 O320D3G 41508EA SNSNCH74D 74DM EA ELT SEPARATED W K NONE O OTHER ININSP/MAINT 1 CA 465776 (CAN) ANTENNA SEPARATED AT ANTENNA WIRE TO BASE CONNECTION. 1L71 3O3 O 2A13 E274 5 NP88614 20031021001662003102100166 2003 10 21 CA030930012 420030818G2562 ANTENNA AMERIKING PIPER PA28 PA28161 7102803SO LYC O320 O320D3G 41508EA SNSNCH74D 74DM EA ELT SEPARATED W K NONE O OTHER ININSP/MAINT 1 CA 465777 (CAN) GLUE JOINT FAILED AND ALLOWING ANTENNA TO SEPARATE FROM BASE NUT. 1L71 3O3 O 2A13 E274 5 NP88614 20031021001672003102100167EA 2003 10 21 CA030930013 120030930G2820601R6227221 TUBE CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE FUEL INJECTOR BURNED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING AMJOR INSPECTION (C-CHECK AND 96 MTH INSP.) A FUEL TUBE ASSEMBLY IN CENTER TANK WAS DISCOVERED WITH EVIDENCE OF ARCING. FURTHER INSPECTION REVEALED ADJACENT PART (STIFFENER PN 60010011193) HAD ALSO SIMILAR EVIDENCE OF ARCING. TUBE ASSEMBLY WAS REINSTALLED TEMPORARILY TO TAKE MEASUREMENTS. THE ACTUAL DISTANCE BETWEEN STIFFENER AND FUEL TUBE IS APPROXIMATELY .250 INCH IAW OEM SPECIFICATIONS. DAMAGE ON TUBE IS 0.300 X 0.370 WITH A DEPTH OF 0.010 DAMAGE ON STIFFENER IS 0.300 X 0.350 WITH A DEPTH 0.030 ALL COMPONENTS: TUBE, CLAMPS, SLEEVES, ETC HAVE BEEN QUARANTINED. OEM HAS BEEN ADVISED OF SITUATION. 2L72 4F4 FRTA21EA E15NE 20031021001682003102100168WP 2003 10 21 CA030930014 120030930G2822 HOUSING DOUG DC9 DC932 3022066WP PWA JT8 JT8D7 52053NE PUMP CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA 7470 (CAN) THIS FUEL PUMP WAS INSTALLED TO REPLACED A TIME (X) FUEL PUMP, AFTER MANY ATTEMPS TO REPAIRED A FUEL LEAK,THE TECH DISCOVERED A CRACK IN THE PUMP HOUSING.THE CRACK FOUND LOCATED AT THE BOLTS FLANGE ATTACHMENT. THE PUMP WAS O/H IN NOV/02 THIS PUMP WAS REPLACED AGAIN AND THE AIRCRAFT RETURN TO SERVICE. 2L72 4F4 F A6WE E2EA 20031021001692003102100169EA 2003 10 21 CA030930015 120030929G5610NP1393225 WINDOW CNDAIRCL600 CL6002C10 1390015EA COCKPIT CRACKED W O OTHER O OTHER DEDESCENT 1 CA (CAN) LT SIDE WINDOW CRACKED DURING DESCENT INTO NAS. AIRCRAFT WAS FERRIED FOR SIDE WINDOW REPLACEMENT. 2L72 4F RTA21EA 20031021001702003102100170EA 2003 10 21 CA030930016 120030813G24201K4XD TRU CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE NR 1 FAILED W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA (CAN) AT CRUISE ALT ADG DEPLOYED, AC1 AUTO TRANSFER MSG DISPLAYED. SMOKE IN COCKPIT. NR 1 TRU FAILED. FOLLOWED QRH. DIVERTED. 2L72 4F4 FRTA21EA E15NE 20031021001712003102100171EA 2003 10 21 CA031001000 120030904G5610NP1393219 WINDSHIELD CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE COCKPIT CRACKED W O OTHER O OTHER CRCRUISE 1 CA (CAN) DURING FLIGHT, LT WINDSHIELD CRACKED. OLD STYLE WINDSHIELD 2L72 4F4 FRTA21EA E15NE 20031021001722003102100172EA 2003 10 21 CA031001001 120030813G5610NP1393226 WINDSHIELD CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE COCKPIT CRACKED W O OTHER O OTHER CRCRUISE 1 CA 10906 (CAN) RT WINDSHIELD INNER LAYER CRACKED DURING FLIGHT. AIRPLANE FERRIED. RT WINDSHIELD REPLACED. 2L72 4F4 FRTA21EA E15NE 20031021001732003102100173EA 2003 10 21 CA031001002 120030518G5610NP1393226 WINDSHIELD CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE COCKPIT CRACKED W O OTHER O OTHER DEDESCENT 1 CA (CAN) RT COCKPIT WINDOW CRACKED DURING DESCENT AT 18000 FT. AIRPLANE FERRIED FOR WINDOW REPLACEMENT. 2L72 4F4 FRTA21EA EOOO63EN 20031021001742003102100174EA 2003 10 21 CA031001003 120030508G5710NP13932110 WINDSHIELD CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE COCKPIT CRACKED W O OTHER O OTHER CRCRUISE 1 CA (CAN) IN CRUISE, AT FL 300 THE INNER PLY OF THE RT WINDOW CRACKED. THE QRH WAS APPLIED AND THE FLT CONTINUED WITHOUT FURTHER INCIDENT. THE AIRCRAFT WAS FERRIED WHERE THE WINDOW WAS REPLACED. 2L72 4F4 FRTA21EA E15NE 20040107000602004010700060CE 2004 1 7 CA031001004 120030924G2810 FUEL TANK BEECH 100 A100 1152915CE PWA PT6 PT6A28 EA AFT MIDDLE CONTAMINATED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) WHILE INSPECTING THE INSIDE OF THE BLADDER TANKS FOR LOOSE PATCHES BECAUSE OF LOOSE PATCHES FOUND ON ANOTHER AIRCRAFT. MAINTENANCE FOUND A BABY SLEEPER INSIDE AFT MIDDLE FUEL TANK. THIS AIRCRAFT CAME INTO THE FLEET 3 YEARS AGO AND AS THIS COMPANY DOES NOT USE OLD CLOTHS AS RAGS IT HAS BEEN IN THE AIRCRAFT FOR SOME TIME. OBVIOUSLY THERE WAS NO CLOSEUP INSPECTION DONE BEFORE. THE PANEL WENT ON AFTER MAINTENANCE LAST TIME. 1L72 3T4 T A14CE E4EA 20031021001752003102100175SO 2003 10 21 CA031001005 220030926G8530AEC631397SNA CYLINDER HEAD CESSNA185 A185F 2072821CE CONT O520 IO520D 17032SO MCAULY2A34C D2A34C58 GL ENGINE SEPARATED W B EMER. DESCENT DE INFLIGHT SEPARATION VIBRATION/BUFFET CRCRUISE 1 CA (CAN) IN FLIGHT SEPARATION OF CYLINDER HEAD (POSITION NR 2), VIBRATION AND LOST OF POWER. CYLINDER PREVIOUSLY INSTALLED MAY 23/03, AIRCRAFT TIME 3792.1 HOURS AND ACCUMULATED 119.4 HOURS OF FLIGHT AT TIME OF SEPARATION. CYLINDER REPLACED WITH SA ME MODEL AND MFG. 1H71 3O3 O 3A24 E5CE 5 CP3EA 20031021001762003102100176SW 2003 10 21 CA031001006 120030825G5340212030154001 FITTING BELL 205 205A1 1181414SW LYC T53 T5313B 41549NE FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 11367 (CAN) PART REMOVED FROM SERVICE.NEW PART INSTALLED. 1G71 4U4 U H1SW E17EA 20031021001772003102100177SW 2003 10 21 CA031001007 120030824G63402060763731 TACHOMETER BELL 206 206L 1181522SW ALLSN 25OC 250C20R GL MAIN ROTOR WORN W C ABORTED TAKEOFF F FLT CONT AFFECTED TOTAKEOFF 1 CA (CAN) DURING GROUND RUN PILOT EXPERIENCED LOSS OF HYDRAULIC POWER TO THE FLIGHT CONTROLS. THE MAIN ROTOR TACHOMETER WAS REMOVED. THE INTERNAL SPLINES OF THE TACH WERE WORN ALLOWING THE HYD PUMP SPLINES NOT TO ENGAGE. 1G71 3U3 U H2SW E4CE 20031021001782003102100178GL 2003 10 21 CA031001008 220030910G725023038160 BEARING BELL 206 206L 1181522SW ALLSN 25OC 250C20R GL NR 5 FAILED W O OTHER J WARNING INDICATION CRCRUISE 1 CA (CAN) DURING FLIGHT PILOT REPORTED AN ENGINE CHIP WARNING LIGHT. DURING SERVICEABILITY CHECK 2ND CHIP LIGHT REPORTED. THE ENGINE WAS DISASSEMBLED. THE TURBINE SECTION OF THE ENGINE, IN THE NR 5 BEARING AREA THE SNAP RING AND SPACER WERE UNSEATED AND RESTING ON THE POWER TURBINE SHAFTING. FURTHER INSPECTION REVEALED THAT A BALL OF THE NR 5 BEARING WAS MISSING. THE TURBINE FORWARDED TO AN OVERHAUL FACILITY. 1G71 3U3 U H2SW E4CE 20031021001792003102100179CE 2003 10 21 CA031001009 120030923G275014601007 CONTROL CABLE CESSNA337 337G 2075730CE CONT O360 IO360G 17025SO MCAULY2AF34CD2AF34C306 GL TE FLAPS DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) A SPECIAL INSPECTION WAS INITIATED TO COMPLY WITH REMOVAL AND INSPECTION OF FLAP CONTROL CABLES THAT ARE CONNECTED TO THE INBOARD FLAP BELLCRANK. CABLE P/N 1460 100-7 AND 1460100-8 WERE BOTH FOUND TO HAVE SEVERAL BROKEN STRANDS AND REQUIRED REPLACEMENT. SERVICE DIFFICULTY ALERT AL2003-05 REFERS TO THIS PROBLEM. 1H72 3O3 O A6CE E1CE 5 CP5EA 20031021001802003102100180CE 2003 10 21 CA031001010 120030923G275014601007 CONTROL CABLE CESSNA337 337G 2075730CE CONT O360 IO360C 17025SO MCAULY2AF34CD2AF34C310 GL TE FLAPS DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) A SPECIAL INSPECTION WAS INITIATED TO COMPLY WITH REMOVAL AND INSPECTION OF FLAP CONTROL CABLES THAT ARE CONNECTED TO THE INBOARD FLAP BELLCRANK. CABLE PN 14601007 AND 14601008 WERE BOTH FOUND TO HAVE SEVERAL BROKEN STRANDS AND REQUIRED REPLACEMENT SERVICE DIFFICULTY ALERT AL 2003-05 REFERS TO THIS PROBLEM. 1H72 3O3 O A6CE E1CE 5 CP5EA 20031021001812003102100181NM 2003 10 21 CA031002001 120030821G243523088002B STARTER GEN DHAV DHC8 DHC8* NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE ENGINE FAILED W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) DURING TAKE OFF ROLL, NR 1 DC GEN CAUTION LIGHT ILLUMIN CAUSING LOSS OF ASSOC SYS AND CIRCUITS TO THAT PWR BUS. CREW CYCLED NR 1 DC GEN SWITCH OFF THEN ON TO RESET SYS BUT CAUTION LIGHT CONTINUED TO FLASH CAUSING VARIOUS SYS TO DROP OFF LINE. DC STARTER GENERATOR HAD BEEN INSTALLED PREVIOUS NIGHT DURING LINE CHECK AND ENGINE GROUND RUN FUNCTIONAL CHECK WAS CARRIED OUT WITH NIL DEFECTS EVIDENT. UNSERVICEABLE DC START GENERATOR WAS REPLACED AND A/C WAS GROUND RUN AND CHECKED SERVICEABLE. STRIP REPORT CONFIRMED THAT STATOR WIRE (COLOR YELLOW) PIN E WITHIN ENCLOSURE WAS FRAYED RESULTING IN SHORT TO SPEED SENSOR WIRE (COLOR WHITE) PIN H. START GENERATOR WAS REPAIRED AND TESTED SERVICEABLE IAW CMM 24-30-20. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20031021001822003102100182NM 2003 10 21 CA031002002 120030930G29136617302 SHAFT BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA E/D PUMP SHEARED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) FLIGHT CREW REPORT LANDING, TAXI IN AND ENGINE SHUT ALL NORMAL. AFTER NR 2 ENGINE START, NR 2 ENG HYD PUMP CAUTION LIGHT REMAINED ON AND SYSTEM PRESSURE DIDN'T INCREASE. METAL FILINGS WERE FOUND IN THE HYDRAULIC FILTER. NR 2 EDP SHAFT FOUND SHEARED. TECHNICIANS CARRY OUT THE APPLICABLE AMM SYSTEM FLUSHINGS PRIOR TO RETURNING A/ C TO SERVICE . ALSO PLEASE REFER TO TR 29054 TASK 29-1000617807 CARRIED OUT FLUSHING OF THE NR 1 AND NR 2 HYDRAULIC SYSTEM SUCTION LINES AFTER THE EDP FAILURE AND TR 29-056, TASK 291000617809 AND FLUSHING OF THE HEAT EXCHANGER'S TUBES OF THE NR 2 HYDRAULIC SYSTEM AFTER AN EDP OR PTU FAILURE. 2H72 4T4 TRTA13NM E00062EN 20040126000912004012600091CE 2004 1 26 CA031002003 120031001G27102300003231 CABLE LEAR 35 35LEAR 5170600CE CONTROL COLUMN MISROUTED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) DURING A DUAL FLIGHT CONTROL INSPECTION,( ON A SCHEDULED AILERON CONTROL CABLE REPLACEMENT). FOUND CABLE MIS-ROUTED INSIDE THE CONTROL COLUMN ASSY BOROSCOPE INSPECTION CONFIRMED THE CABLE WAS NOT ROUTED THROUGH THE CABLE GUIDE. CABLE WAS RE-ROUTED. 2L72 4F A10CE 20031021001832003102100183NM 2003 10 21 CA031002004 120030930G7931 PUMP BOEING767 767333 1385301NM PWA 4060 PW4060 52119NE ENGINE OIL FAILED W EA ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 CA (CAN) A/C WAS ENROUTE FROM YYZ TO FCO AND WHILE OVER YQB HAD A NR 1 ENG LOW OIL PRESSURE WARNING. CREW SHUTDOWN NR 1 ENG AND DIVERTED TO YUL. APPEARS TO BE MAIN OIL PUMP FAILURE. METAL HAS BEEN FOUND IN GEARBOX. ENGINE CHANGE UNDERWAY. 2L72 4F4 FRTA1NM E24NE 20031021001842003102100184EA 2003 10 21 CA031002005 220030930G852013B27121B CRANKSHAFT CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA MCAULY1C235 1C235LFA GL ENGINE CORRODED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) CRANKSHAFT FAILED SB 505. AFTER REMOVAL OF PROTECTIVE COATING, CRANKSHAFT FOUND CORRODED. ALSO AREA FOUND TO HAVE BEEN MACHINED TO LARGEST DIAMETER PERMITTED BY SB 505. THIS IS ONE OF MANY FOUND DURING OVERHAUL, SB 530 DOES NOT SEEM TO BE WORKING. 1H71 3O3 ONT3A12 1E10 5 NP12EA 20031021001852003102100185SO 2003 10 21 CA031002006 120030924G214094E423 SWITCH PIPER PA31 PA31 7103102SO LYC O540 TIO540A2C 41532EA HARTZLHCE3Y HCE3YR2A GL HEATER FAILED W K NONE L NO TEST ININSP/MAINT 1 CA (CAN) WHEN ACCOMPLISHING A O/H ON THE HEATER WE FOUND THE DIFFERENTIAL PRESS SW STUCK IN THE CLOSED POSITION. THIS IS THE FOURTH SWITCH FOUND DEFECTIVE IN OUR O/H SHOP. THE SUPPOSEDLY NEW IMPROVED SWITCH MFG HAS PRODUCED IS NO BETTER THAN THE OLD SWITCH THAT IT REPLACES. 1L72 3O3 O A20SO E14EA 5 CP33EA 20031021001862003102100186EU 2003 10 21 CA031003001 120031003G291010546641 MANIFOLD BOLKMS117 BK117A1 5626010EU HYD SYSTEM CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING A SCHEDULED INSPECTION OF THE HYDRAULIC UNIT A CRACK WAS FOUND IN THE SYSTEM 1 VALVE BODY MANIFOLD. THE CRACK ORIGINATES FROM A BLANKING PLUG AND PROGRESSES OUTWARDS APPROXIMATELY 11 MM. NO LEAK OF HYDRAULIC FLUID APPARENT. THIS UNIT WAS RECEIVED FOR INSPECTION FROM A US CUSTOMER. UNIT TOTAL TIME IS 8935.5 HOURS. MANIFOLD TIME NOT KNOWN. 1G72 3U H13EU 20031021001872003102100187NM 2003 10 21 CA031003002 120030929G2710 BUSHING BOEING767 767333 1385301NM PWA 4060 PW4060 52119NE AILERON CONTROL LOOSE W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ROLLING AILERON BEYOND 3 UNITS ON CONTROL COLUMN BINDING FELT. WHEEL VERY SLOW TO RETURN TO NORMAL. NOT AS STIFF WITH INPUT TO THE LEFT. WHEEL WOULD NOT RETURN TO NEUTRAL ON ITS OWN. FOUND INBOARD DROOP QUADRANT SIEZED. (CROSS SHAFT) ON INSPECTION OF REMOVED UNIT , FOUND BEARING SIEZED AND BUSHING MIGRATED. UNIT P/N 251T1602-6 UNIT REPLACED AND AILERON SYSTEM NORMAL. 2L72 4F4 FRTA1NM E24NE 20031021001882003102100188NM 2003 10 21 CA031003003 120030427G5250 LOCK DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE COCKPIT DOOR FAILED W O OTHER O OTHER CRCRUISE 1 CA (CAN) DURING CRUISE, DISCOVERED HANDLE FOR FLT DECK DOOR DEADBOLT MISSING & PILOTS WERE LOCKED IN THE COCKPIT. CREW LATER BELIEVED AIRCRAFT VIBRATION UNSCREWED HANDLE & IT FELL TO FLOOR. AN EFFORT TO UNHINGE DOOR MADE BY CAPTAIN & FLT ATTENDANT. CREW UNABLE TO RELEASE LOWER HINGES OR TO RESET ANY OF HINGES AS DOOR HAD POPPED OUT & JAMMED. UPON ARRIVAL, CAPTAIN CLIMBED OUT THROUGH EMERGENCY HATCH, MAINT CALLED OUT, DOOR REINSTALLED, ELECTRICAL PORTION OF DEADBOLT SYS DISABLED & SYS DEFERRED. UPON INVEST DISCOVERED 5 REPORTED CASES OF BENT/BROKEN DEADBOLT HANDLES. DUE TO FLT CREWS FORCING HANDLE. CREATED AN IN-HOUSE TASK 5250/01X FOR THE INSPECT CHECK OF THE EMERGENCY DOOR HINGE DISENGAGEMENT SYS. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20031021001892003102100189EA 2003 10 21 CA031004001 220031003G7314RG9080J7AM PUMP PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL ENGINE FAILED W O OTHER O OTHER TXTAXI/GRND HDL 1 CA (CAN) ENGINE DRIVEN FUEL PUMP IN SERVICE 100.1 HRS SINCE NEW. ON ENGINE RUN UP WOULD NOT SUPPLY RATED FUEL PRESSURE. ON IDLE PRESSURE 29 PSI. THERE IS ANOTHER PROBLEM WITH THOSE PUMPS RG9080J7A-OUTLET AND INLET FITTING OFTHE PUMP ARE HIGH PROFILE AND DIMENSION IN BETWEEN THE FITTINGS IS ABOUT 6 INCHES. BUT TO INSTALL PUMP THIS DIMENSION SHOULD BE NO MORE THAN 5 INCHES OTHERWISE ENGINE MOUNT WOULD NOT ALLOW TO INSTALL PUMP TO ITS PLACE. YOU HAVE TO CHANGE ONE OF FITTINGS EVERY TIME INCREASING POSSIBILITY TO GET INTERNAL STRUCTURE DAMAGED. IT LOOKS LIKE THE PUMP WAS NOT DESIGNED FOR THIS ENGINE. 1L72 3O3 O A20SO E14EA 5 CP33EA 20031021001902003102100190SW 2003 10 21 CA031005001 120031001G2460023470000 BATTERY BELL 206 206L1 1182107SW ALLSN 250C 250C28B 03013GL ELT FAILED W D RETURN TO BLOCK HW ELECT. POWER LOSS-50 PC INADEQUATE Q C TXTAXI/GRND HDL 1 CA (CAN) RECURRING DEFECT ON BATTERY (2BT1 - DESIGNATORS IAW ELECTRICAL DRAWING) ON LINE FAULT. BATTERY REMOVED AND INSPECTED. VOLTAGE AND CURRENT DRAW SATISFACTORY ON BENCH. VISUAL INSPECTION REVEALED LOOSE RETAINING NUT ON ONE TERMINAL CAUSING INTERNAL ARCING AT HIGH AMPERAGE DRAW. FURTHER INVESTIGATION OF COMPLETE BATTERY CIRCUIT ALSO REVEALED DAMAGED (OVERHEAT) WIRES (P17A22 AND P18A22N) AT BATTERY SWITCH(2S1) PROBABLE CAUSE EFFECT OF DIODE (2CR1) PREVIOUSLY FOUND DEFECTIVE. ALL BATTERY TERMINALS TORQUED, NEW WIRES FABRICATED, MARKED AND INSTALLED. 1G71 3U3 U H2SW E1GL 20031021001912003102100191SO 2003 10 21 CA031006001 120030929G32331959500004 ACTUATOR EMB 120 EMB120ER 3260203SO PWA 118 PW118A NE HAMSTD14RF 14RF9 NE MLG UNSERVICEABLE W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA 1794317943 (CAN) AFTER TAKE OFF, PILOT SELECTED GEAR UP, HAD A RED LIGHT INDICATION ON RT MAIN LANDING GEAR. PILOT DECIDED TO RETURN TO BASE, GEAR WAS SELECTED DOWN WITH 3 GREEN LIGHTS.AIRCRAFT WAS PUT ON JACKS, 3 RETRACTIONS TEST CARRIED OUT, UNABLE TO DUPLICATE THE RETRACTION PROBLEM. GEAR VISUALLY INSPECTED FOUND PLAY ON RT RETRACTION ACTUATOR. ACTUATOR REMOVED AND FOUND ROD END WORN OUT WITH EXCESSIVE PLAY. (.125 INCH OF PLAY FWD AND AFT) NEW ROD END INSTALLED AND SYSTEM CHECK SERVICEABLE. THE ACTUATOR TBO IS 18000 CYCLES. NO OTHER INSPECTIONS OR TASK CARDS ARE CALLED FOR THIS SPECIFIC ACTUATOR. 2L72 4T4 TRTA31SO E20NE 6 CP11NE 20031021001922003102100192SW 2003 10 21 CA031006002 120031006G275019023 CONTROL CABLE BBAVIA8 8GCBC 1220803SW LYC O360 O360C2E 41514EA MCAULY1A200 1A200* GL TE FLAPS FRAYED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) RT FLAP CABLE FRAYED AT WING ROOT PULLEY AT FLAP FULL DOWN POSITION. 1H71 3O3 O A21CE E286 5 NP874 20031021001932003102100193 2003 10 21 CA031006003 420030909G3457AIS20035 SWITCHING UNIT COLLINS BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA HARTZLHCB3T HCB3TN3 GL GPS FAILED W O OTHER P NO WARNING INDICATION CRCRUISE 1 CA (CAN) REPORTED FAULTY NR2 RMI COMPASS BEARING, ADF INDICATION ON RMI NR1, NR2 BOTH NEEDLES WITH NO FLAGS. WHEN BOTH RMI S HAVE NEEDLES NR1, NR2 SELECTED TO NAV COMPASS INDICATION ON NR 2 RMI FREEZES NON IT S CURRENT HEADING. NR 2 RMI COMPASS CANNOT BE SLAVED WITH NR 1 HEADING SWITCH IN MANUAL OR FREE MODES, NO HEADING FLAG IS DISPLAYED ON NR 2 RMI. STORM SCOPE ALSO DISPLAYS FAULTY HDG INFO AND IS NOT FLAGGED. RMI NEEDLES SELECTED TO ADF, NR 1 & 2 NEEDLES INDICATE 180 DEGREES OFF TRUE ADF BEARING. THE RMI, ADF NEEDLES DO NOT DEFLECT IN TEST MODE. EHSI, ADF NEEDLE INDICATES NORMALLY AND DEFLECTSIN TEST. THE ADF AUDIO IS RECEIVED NORMALLY. REPLACING THE GPS SWITCHING UNIT PN AIS200-35 CLEARS ALL FAULTS. 1L72 3T4 TRT3A20 E4EA 6 CP15EA 20031021001942003102100194CE 2003 10 21 CA031006004 120030929G552150610000415 RIB BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA HARTZLHCB3T HCB3TN3 GL LT ELEVATOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) UPON REMOVAL OF LOOSE SKIN RIVETS (AFT OF BALANCE WEIGHT, OUTBOARD OF HINGE), AN ENLARGED HOLE WAS OBSERVED WITH APPARENT CRACKING OF THE UNDERLYING RIB. UPON FURTHER INVESTIGATION, RIB P/N 50-610000-415 WAS FOUND CRACKED ALONG THE BEND RADIUS IN 3 OUT OF 4 CORNERS. C/A REQUIRED REPLACEMENT OF THE LOWER SKIN, RIB ASSEMBLY, LOOSE RIVETS, AND PAINTING AND BALANCING OF THE ELEVATOR ASSEMBLY. 1L72 3T4 TRT3A20 E4EA 6 CP15EA 20031021001972003102100197EA 2003 10 21 CA031006005 120030925G2751601R930301 TRANSMITTER CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE TE FLAP POSITIONFAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) FLAPS FAILED AT 42 DEGREES ON LEFT FLAP (HAD 45 DEG ON RT FLAP) FOUND TO BE THE FLAP POSITION TRANSMITTER AT FAULT. 2L72 4F4 FRTA21EA E15NE 20031021001982003102100198EA 2003 10 21 CA031006006 220030925G75109091010017 ANTI-ICE SYSTEM BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA HARTZLHCB3T HCB3TN3 GL INTAKE CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) THE ENGINE ANTI-ICE INTAKE TUBE HAS BEEN REPLACED TWICE SINCE SERVICE BULLETIN 71-3142 WAS INCORPORATED. OTHER SIMILAR FAILURES HAVE BEEN DOCUMENTED ON THIS AIRCRAFT. 1L72 3T4 TRT3A20 E4EA 6 CP15EA 20031110000222003111000022 2003 11 10 CA031006007 420031006G2561WARL8A LIGHT LIFE JACKET FAILED W K NONE L NO TEST ININSP/MAINT 1 CA (CAN) EASTERN AERO MARINE LIFE JACKET P/N P0723E105P WERE SENT FOR OVERHAUL AND RECERTIFICATION. 100 PERCENT OF THE JACKETS RETURNED WITH FAILED WATER ACTIVATED LIFE JACKET LIGHT ASSEMBLIES. THESE UNITS WERE ONLY 2 YEARS OLD, MANUFACTURED IN AUGUST/2001. THE LIFE JACKET LIGHT ASSEMBLIES WERE MANUFACTURED BY PROSAR TECHNOLOGIES INC. OF DEERFIELD BEACH, FLA. THE PART NUMBER OF THE DEFECTIVE UNIT IS WARL-8A. ALL WATER ACTIVATED LIGHT ASSEMBLIES WERE REPLACED AT OVERHAUL AND THE LIFE JACKETS WERE RE-INSTALLED BACK INTO THE AIRCRAFT. IN SPEAKING WITH THE OVERHAUL FACILITY, THEY CONFIRMED THAT IT IS VERY COMMON FOR THESE UNITS TO FAIL AT OVERHAUL INSPECTION. 20031021002052003102100205SW 2003 10 21 CA031006008 120031002G3250 WIRE SWRNGNSA226 SA226AT 8780405SW GARRTTTPE331TPE33110UA 01514WP HARTZLHCB3T HCB3TN2 GL NLG STEERING DAMAGED W O OTHER O OTHER LDLANDING 1 CA (CAN) FLT LANDING, ONCE DECELERATED TO 60 KNOTS NOSE WHEEL STEERING WAS ARMED, RESULTING IN AN UN-COMANDED FULL AUTHORITY LT TURN CAUSING A/C TO LEAVE RUNWAY. A/C WAS TAXIED OUT ON IT OWN POWER, AFTER INSP FERRIED ON FLIGHT PERMIT FOR MORE STRUCTURAL INSP AND REPAIR OF NOSE WHEEL STEERING SYS. NO STRUCTURAL DAMAGE WAS FOUND. TEST AND INSP OF NOSE WHEEL STEERING SYS REVEALED TINY SINGLE STRAND OF WIRE INSIDE THE HARNESS SIDE OF CONNECTOR FOR THE SERVO VALVE. STRAND OF WIRE WAS REMOVED, SYS TESTED AND A/C RETURNED TO SERVICE.COMPANY POLICY OF THE USE OF NOSE WHEEL STEERING HAS BEEN CHANGED TO: UNLESS EXTENUATION CIRCUMSTANCES THE USE OF NOSE WHEEL STEERING IS LIMITED TO SPEEDS UNDER10 KNOTS. 2L72 4T4 TRTA5SW E4WE 6 CP15EA 20031110000232003111000023NE 2003 11 10 CA031006009 220031003G7320ETPU10002C CONTROL UNIT BOEING757 757256 1384925NM RROYCERB211 RB211535E43754555NE TPU WILL NOT TEST W D RETURN TO BLOCK XJ ENGINE FLAMEOUT WARNING INDICATION TXTAXI/GRND HDL 1 CA 30880 (CAN) LT ENGINE FLAMED OUT ON WHILE TAXIING IN. EICAS MSG 'LT ENG LP PUMP'. TROUBLESHOOT PER FIM 75-32-00 BITE CODE 90 ON THE TRANSIENT PRESSURE UNIT LED TO ITS REPLACEMENT. DURING ENGINE RUN N3 WAS NOTED TO BE ON LOWER END OF LIMIT PER MM71-00-00 FIG.517A. FUEL FLOW GOVERNOR REPLACED. 2L72 4F4 FRTA2NM E12EU 20031021002062003102100206GL 2003 10 21 CA031007001 120030923G7120MS213061C WASHER DIAMONDA20 DA20C1 2990001GL CONT O240 IO240B 17063SO SNSNCHW69EK W69EK63 EA ENGINE MOUNT WORN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) INVEST OF CLUNKING SOUND COMING FROM NOSE AREA OF DA20-C1 , FOUND THAT LT LWR ENG MNT TO FIREWALL ATTACH BOLT WAS UNDER TORQUE (5 FT LBS VS. 15 FT LBS). MNT HAD APPROX. 60 THOU END PLAY,WAS SOURCE OF CLUNKING SOUND. RT MNT WAS ALSO UNDER TORQUE AT ABOUT 5 FT LBS. ALL OF THE MS21306-1C WASHERS UNDER THE HEAD OF THESE BOLTS HAD BEEN DISHED IN. UPPER ENG MNT TO FIRE WALL BOLTS ON A/C WERE REMOVED AND FOUND MS21306-1C WASHERS UNDER BOLT HEAD WERE ALSO DISHED IN. MS21306-1C WASHERS HAVE ID OF AN-7 WASHER ON AN ENG MNT BOLT THAT IS AN AN-6. A/C WAS CHECKED AND FOUND ALL WASHERS TO BE DAMAGE UPPER AND LOWER WITH THE LOWER SHOWING MORE WEAR. 1L71 3O3 ONTTA4CH E7SO 5 NTA4CH 20031021002102003102100210EU 2003 10 21 CA031007002 220031003G7322 SEAL BRAERO748 HS7482A 4231001EU RROYCEDART DART5342 EU FUEL CONTROL FAILED W A UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 CA (CAN) APPROXIMATELY ONE HOUR AFTER DEPARTING THE CREW OBSERVED A FINE SPRAY COMING FROM NR 2 OUTBOARD NACELLE DRAIN. THE AIRCRAFT RETURNED TO YFB. TROUBLE SHOOTING DETERMINED THAT THE FCU SEAL HAD FAILED. THE UNIT WAS REPLACED , THE AIRCRAFT GROUND RUN RETURNED TO SERVICE. 2L72 3T4 T A24EU A196 20031021002122003102100212CE 2003 10 21 CA031007004 120031003G32301145802283 CLEVIS BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA EMER GEAR EXT OUT OF RIG W O OTHER L NO TEST NRNOT REPORTED 1 CA (CAN) WHILE ON A TRAINING FLIGHT AND DEMONTRATING AN EMERGENCY GEAR EXTENSION, THE GEAR WAS UNABLE TO BE RETRACTED AFTER EMERGENCY EXTENSION. THE A/C LANDED SAFELY AND WAS PULLED INTO THE HANGAR AND PLACED ON JACKS. MAINTENANCE FOUND THAT THE THICK CARPET PREVENTED THE HANDLE FROM RESETING THE BYPASS VALVE. THIS PREVENTED THE GEAR FROM RETRACTING. THE SYSTYEM WOULD WORK CORRECTLY ONLY AFTER FOECEFULLY PRESSING THE HANDLE INTO THE CARPET BEFORE ENGAGING THE STOW CLIP. THE CLEVIS WASADJUSTED SO THAT THE BYPASS VALVE RESETS BEFORE THE HANDLE REACHES THE CARPET AND STOW CLIP. 1L72 3T4 TRT3A20 E4EA 20031110000342003111000034CE 2003 11 10 CA031008001 120031007G26201199111992 SWITCH BEECH 100 A100 1152915CE PWA PT6 PT6A28 EA EXTINGUISHER SEPARATED W K NONE L NO TEST ININSP/MAINT 1 CA 16822 (CAN) RECENTLY BEECH ADDED FIRE EXTINGUISHER ACTIVATION CHECK TO PHASE 2 INSPECTION, UPON COMPLETION THIS INSPECTION, FOUND BOTH LT AND RT FAILED TEST. WITH FURTHER INVESTIGATION WE FOUND THE BACK PART OF THE SWITCHES HAD FALLEN OFF. SWITCH IS A 2 PART SWITCH. PART YOU SEE IN THE COCKPIT IS A LIGHT TO INDICATE AN ENGINE FIRE WHICH YOU PUSH TO EXTINGUISH A FIRE. THIS PART OF THE SWITCH SENDS A SIGNAL TO SQUIB. PUSHED INDICATING PART OF SWITCH, PUSHES ON ACTIVATION PART OF SWITCH WITCH WILL FIRE SQUIB. THE ACTIVATION PART OF SWITCH IS ATTACHED TO THE BACK OF INDICATION PART WITH CLASPS. CLASPS HAD FAILED ALLOWING ACTIVATION PART OF SWITCH TO FALL OFF OF THE INDICATION PART LEAVING THE SYSTEM FULLY DISABLED. 1L72 3T4 T A14CE E4EA 20031021002142003102100214NE 2003 10 21 CA031008002 320031008G611170242 RETAINER CNDAIRCL215 CL2151A10 1900320EA HAMSTD43E 43E60 NE PROPELLER BLADE FAILED W K NONE P NO WARNING INDICATION ININSP/MAINT 1 CA (CAN) THE PROPELLER WAS REMOVED AND DISASSEMBLED FROM THE RT SIDE OF A CL 215 FOR SHIPMENT TO AN OVERHAUL FACILITY WHEN IT WAS DISCOVERED THAT NR 1 BLADE RETAINER ASSY WAS CRACKED AND SEVERAL ROLLERS WERE DESTROYED. UPON A CLOSER INSPECTION THE OTHER TWO BLADES HAD SIMILAR DAMAGE BUT NOT TO THE SEVERE DEGREE THAT NR 1 HAD. THE PROP FORWARD BARREL HALF P/N 521463-1 ALSO HAD SOME MINOR DAMAGE. THE PROP ASSY WAS FORWARD TO THE OVERHAUL FACILITY FOR ACCESSMENT. 2H72 4R RTA14EA 6 CP871 20031021002172003102100217EU 2003 10 21 CA031008003 220031006G7322861115 DIAPHRAGM ROTAX DIAMONDA20 DA20A1 2990000GL ROTAX 912 ROTAX912F3 EU CARBURETOR SWOLLEN W O OTHER E VIBRATION/BUFFET NRNOT REPORTED 1 CA 980074 (CAN) WHEN THE CARB WAS DISASSEMBLED THE DIAPHRAGM WAS FOUND TO HAVE SWOLLEN AND WAS BUBBLED UP WHEN INSTALLED IN THE CARBURETOR. THE AIRCRAFT OPERATES PRIMARILY ON UNLEADED MOGAS WITH OCCASIONAL USE OF 100LL AVGAS. 1L71 3O3 ONTTA4CH E00051EN 20031021002192003102100219EU 2003 10 21 CA031008004 220031006G7322861115 DIAPHRAGM ROTAX DIAMONDA20 DA20A1 2990000GL ROTAX 912 ROTAX912F3 EU CARBURETOR SWOLLEN W O OTHER E VIBRATION/BUFFET NRNOT REPORTED 1 CA 980137 (CAN) WHEN THE CARBURETOR WAS DISASSEMBLED THE DIAPHRAGM WAS FOUND TO BE SWOLLEN AND WHEN INSTALLED IN THE CARBURETOR IT DID NOT SEAT PROPERLY. THE AIRCRAFT IS OPERATED PRIMARILY ON UNLEADED MOGAS WITH OCCASIONAL USE OF 100LL AVGAS. 1L71 3O3 ONTTA4CH E00051EN 20031021002202003102100220EA 2003 10 21 CA031008005 220030827G7597C6VW10263 LINE DHAV DHC6 DHC6300 2802606EA PWA PT6 PT6A27 52043EA BLEED AIR BURST W A UNSCHED LANDING S AFFECT SYSTEMS CRCRUISE 1 CA 30215 (CAN) THE PILOTS HAD THE BETA BACKUP SYSTEM ON THE RT ENGINE FAIL IN FLIGHT. IT WAS DISCOVERED BY THE ENGINEER THAT THE BLEED AIR LINE HAD RUPTURED IN THE BRADED AREA WHERE IT LEAVES THE ENGINE COMPARTMENT AND GOES INTO THE WING. THE WIRE BUNDLE SUSTAINED DAMAGED BY THE BLEED AIR, WHICH RESULTED IN THE HARNESS SHORTING OUT CAUSING THE BETA LIGHT FAILURE. THE LINE WAS ORIGINAL AND WAS CORRODED FROM THE IN SIDE OUT. 1H72 3T4 TRTA9EA E4EA 20031110001242003111000124EA 2003 11 10 CA031009001 220031006G7414M3100 IMPULSE COUPLINGSLICK 4372 ZLIN 242 Z242L 9970204EU LYC O360 AEIO360A1B6 41514EA MAGNETO LOOSE W K NONE O OTHER ININSP/MAINT 1 CA 98040711 (CAN) DUE TO PREVIOUS IMPULSE COUPLING FAILURES, THE MAGNETO IMPULSE COUPLING IS INSPECTED EVERY 100 HOURS OF OPERATION.THIS MAGNETO WAS REMOVED FOR A 500 HOUR INSPECTION AND THE HUB WAS FOUND TO BE VERY LOOSE.THIS COUPLING HAD ONLY 93.1 HOURS TSN. 1L71 3O3 O0 A76EU 1E10 20031110001252003111000125CE 2003 11 10 CA031009002 120031004G561010138402522 WINDSHIELD BEECH B300 B300B350C CE PWA PT6 PT6A60A 52043NE COCKPIT CRACKED W B EMER. DESCENT O OTHER CRCRUISE 1 CA (CAN) AT CRUISE ALTITUDE RIGHT HAND WINDSHIELD INNER PLY SHATTERED IN FLIGHT. PART WASREPLACED PRIOR TO NEXT FLIGHT. 2L72 4T4 TRTA24CE E4EA 20031021002212003102100221CE 2003 10 21 CA031009003 120031007G79221584653 CONTROL VALVE LEAR 35 35LEAR 5170600CE GARRTTTFE731TFE73122B 01518WP ENGINE OIL TEMP ERRATIC W O OTHER J WARNING INDICATION CRCRUISE 1 CA (CAN) ENGINE OIL TEMPERATURE WITH FLUCTUATION ON LT ENGINE IN FLIGHT, IN RESPECT WITH THROTTLE LEVER. TEMPERATURE CONTROL VALVE REPLACED WITH NEW UNIT, GROUND POWER CHECK CARRIED OUT SATISFACTORY 2L72 4F4 F A10CE E6WE 20031110001262003111000126CE 2003 11 10 CA031010001 120031002G57111181200291 SPAR CAP RAYTHN BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3I NE RT WING CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 1696116961 (CAN) A CRACK WAS FOUND IN THE RT LOWER SPAR CAP HORIZONTAL FLANGE AT STATION 117.0 BL.THE CRACK EXTENDED FROM THE RIVET HOLE AFT TO THE EDGE OF THE FLANGE, AND FORWARD JUST SHY OF THE FLANGE RADIUS (OF THE VERTICAL LEG).THE CRACK WAS NOTICED ON A PREFLIGHT INSPECTION BY MAINTENANCE PERSONNEL. THE MANUFACTURER WAS CONTACTED AND AN APPROVED REPAIR INITIATED TO SPLICE IN A NEW PIECE OF THE LOWER CAP. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20031021002222003102100222GL 2003 10 21 CA031010002 220030924G72506893647 LABYRINTH SEAL SKRSKYS76 S76A 8143006NE ALLSN 250C 250C30S 03013GL ENGINE FAILED W A UNSCHED LANDING J WARNING INDICATION NRNOT REPORTED 1 CA (CAN) SEVERAL CHIP LIGHTS WERE EXPERIENCED DURING OPERATION WHICH PROMPTED THE REMOVALOF ENGINE. MAGNETIC PARTICLES WERE NOTED ON THE UPPER GEARBOX CHIP DETECTOR. UPON FLUSHING THE TURBINE NR 8 BEARING AREA FERROUS PARTICLES AND SILVER FLAKES WERE FOUND. UPON DISASSEMBLY, THE TURBINE AFT LABYRINTH STATIONARY SEAL WAS FOUND TO HAVE ITS SILVER PLATED ID SEPARATED AS A RING. THE ROTATING SEAL WAS NOTED TO HAVE THE OIL SLINGER MACHINED OFF FROM CONTACT WEAR. THE FAILURE AND ASSOCIATED REPAIR PROCESSES FOR THIS PART ARE UNDER REVIEW. 1G72 3U3 U H1NE E1GL 20031110001282003111000128CE 2003 11 10 CA031013001 120031013G5751122008515 BALANCE WEIGHT CESSNA206 U206G 2073356CE CONT O520 IO520F 17032SO AILERONS CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) UPON INSPECTION IT WAS DISCOVERED THAT THERE WERE SMALL HAIRLINE CRACKS (HORIZONTAL) AT THE THREE MOST OUTBOARD MASS BALLANCE WEIGHT ATTACH SCREW LOCATIONS. ONE INCH IN LENGTH. 1H71 3O3 O A4CE E5CE 20031110001292003111000129SO 2003 11 10 CA031014001 120030425G2520 FRAME PIPER PA28 PA28140 7102802SO LYC O320 O320E3D 41508EA CABIN SEAT CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) THIS FORWARD CABIN SEAT AND SOME SEATS IN OTHER SAME MODEL. DUE TO THEIR AGE, HAVE WEAKENED AND CRACKED AT WELDED JOINTS. THE MOST COMMON LOCATON HAS BEEN THE WELDED JOINT BETWEEN THE SEAT CUSHION FRAME AND THE 'S' BEND SUPPORT TUBE. THE OPPOSITE END OF THIS SUPPORT TUBE IS ALSO WELDED TO THE SEATLOWER TUBULAR FRAMEWORK WHICH IS STRONG ENOUGH NOT TO CRACK. ALTHOUGH THE SEATISSTILL STYRONG ENOUGH TO BEAR THE WEIGHT OF THE PILOT/PASSENGER EVEN WITH BOTHTHE LEFT AND RIGHT SUPPORT TUBE FAILURE, THE DANGER IS AS FOLLOWS:WITH BOTH SUPPORT TUBES FAILED, IF THE PILOT WOULD LEANBACK WITH ENOUGH REARWARD FORCE ON THE SEAT BACK, THE SEAT WILL DISENGAGE FROM THE SEAT TRACKS INADVERTENTLY AND SLIDE BACK. 1L71 3O3 O 2A13 E274 20031110001312003111000131SO 2003 11 10 CA031014002 120030612G2750400673 BOLT PIPER PIPER PA28 PA28140 7102802SO LYC O320 O320E3D 41508EA FLAP HANDLE WORN W K NONE O OTHER ININSP/MAINT 1 CA AB2311 (CAN) IN SPITE OF REPLACEMENT OF CLEVIS BOLT (AN23-11) AND BUSHING (63900-174) IN COMPLIANCE WITH AD 96-10-03, PIPER SERVICE BULLETIN 965, EXCESSIVE WEAR AND ELONGATION OF BUSHING HOLE WAS DISCOVERED. ALTHOUGH AD 96-10-03 DOES NOT REQUIRE A RECURRENT INSPECTION OF THE BUSHING INSTALLATION. THIS DISCREPANCY WAS FOUND AT THE TIME OF ROUTINE MAINTENANCE EVENT, ALTHOUGH A RECURRENT INSPECTION IS NOT REQUIRED BY AD 96-10-03, IT WOULD BE PRUDENT TO INSPECT THIS AREA PERIODICALLY. 1L71 3O3 O 2A13 E274 20031110001322003111000132EA 2003 11 10 CA031014003 220030925G8520LW11775 PLUG FOUND FBA FBA2C 3640102EA LYC O540 O540A1C5 41532EA PISTON PIN WORN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) END PLUG IN QUESTION WAS WORN AWAY TO NO MORE THAN .030 OF AN INCH. AT WHICH POINT THE STEEL WRIST PIN WOULD HAVE BEEN WEARING HARDON THE CYLINDER WALL, IF THE ALUMINUM PIN WORE ANYMORE. ALSO NOTED, THE WRIST PIN MOVED ALL THE WAY OVER TOTHE WORN SIDE. THIS CREATED A SITUATION WHERE THE PISTON, ON ONE SIDE HAS A COM PLETE STEEL WRIST PIN INSIDE. THE OTHER SIDE HAD ONLY ABOUT 3/4 OF WRIST PIN INTHE PISTON HOLE. THIS HAS APPEARED TO CREATE A 'HOT' SPOT ON THE SIDE WITH NO W RIST PIN IN IT. THE PISTON IS BURNED. THIS ALSO HAPPENED TO BE THE EXHAUST SIDE OF THE CYLINDER. THE CYLINDER HEAD ITSELF LOOKS LIKE IT WAS OVER HEATED AND THE HEAD LOOKS CRACKED. THESE PINS WERE INSTALLED IN 1993. 1H71 3O3 O A7EA E295 20031110001332003111000133EA 2003 11 10 CA031014004 220030925G8530 EXHAUST VALVE FOUND FBA FBA2C 3640102EA LYC O540 O540A1C5 41532EA ENGINE CRACKED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) EXHAUST VALVE IS BURNED, CRACKED IN TWO PLACES, RADIAL FROM CENTRE. SIDES OF VALVE ARE CHIPPED AND MISSING PIECES. FACE OF ROCKER ARM THAT CONTACTS TOP OF EXHAUST VALVE IS BADLY WORN AWAY. THE HARDENEDFACE IS COMPLETELY GONE AND ARM OF ROCKER ASSEMBLY WAS RIDING ON VALVE SPRING RETAINER WASHER. VALVE RETAINER WASHER ISCRACKED THROUGH IN THREE PLACES. ROCKER ARMS ARE OF SAME CONFIGURATION. SHOULDBE ONE OF EACH TWO DIFFERENT STYLES. CYLINDER NR 4 HAS TWO ROCKER ARMS OF SAME CONFIGURATION, BUT OPPOSITE TO NR 2. ROCKER ARMS WERE NOT INSTALLED CORRECTLY. 1H71 3O3 O A7EA E295 20031110001342003111000134EA 2003 11 10 CA031014005 120031003G2750C3CF1709 CONTROL ROD DHAV DHC3 DHC3 2800202EA PWA PT6 PT6A34 52043EA TE FLAPS CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 16887 (CAN) DURING ROUTINE INSPECTION THE FLAP CONTROL ROD (TUNING FORK) WAS FOUND TO HAVE A .70 INCH CRACK RUNNING LENGTHWISE FROM THE THREADED END OF THE ROD. 1H71 3R4 T A815 E4EA 20031110001352003111000135NE 2003 11 10 CA031014006 220031012G7230ALF502R5 FAN BLADE BAC 146 146200A 1500266EU LYC ALF502ALF502R5 41580NE ENGINE DAMAGED W A UNSCHED LANDING EJ VIBRATION/BUFFET WARNING INDICATION CLCLIMB 1 CA 3067830678 (CAN) WHEN CLIMBING THROUGH 1200 FT AFTER TAKEOFF, BIRDSTRIKE WAS NOTED AND NR 2 ENGINE VIBRATION CLIMBED TO 1.0. AIRCRAFT RETURNED FOR NORMAL LANDING. MAINTENANCE INSPECTION FOUND BENT AND TORN BLADES ON THE NR 2 ENGINE MAIN FAN. BIRD FEATHERS AND OTHER RESIDUE NOTED INSIDE ENGINE AND OVER WINGS FLAPS ETC. AIRFRAME CLEANED AND INSPECTED WITH NO DAMAGE FOUND, NR 2 ENGINE REMOVED FROM SERVICE & REPLACED WITH SERVICEABLE SPARE. AIRCRAFT RETURNED TO SERVICE. 2H74 4F4 F A49EU E6NE 20031110001362003111000136EA 2003 11 10 CA031014007 120031014G541022850081141 DOOR CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE LT NACELLE MISSING W O OTHER O OTHER TXTAXI/GRND HDL 1 CA (CAN) A/C TAXIED TO GATE AFTER LANDING. THE LOWER LEFT FIXED COWL DOOR WAS MISSING FROM AIRCRAFT. SEVERAL MOMENTS LATER THE COWL WAS FOUND OUT ON TAXI WAY AND RECOVERED BY AIRPORT AUTHORITIES.A NUMBER OF CAMLOC FASTENERS WERE FOUND IN COWL.THE REMAINDER OF FASTENERS WERE STILL ATTACHED TO COWL SUPPORT ON ENGINE. ADDITIONAL DAMAGE TO COVER ASSY P/N 228-59154-801 AND PANEL ASSY P/N 228-50082-811 WAS ALSO SUSTAINED. 2L72 4F4 FRTA21EA E15NE 20031110001372003111000137EA 2003 11 10 CA031014008 120030904G3220 LANDING GEAR CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE NOSE MALFUNCTIONED W O OTHER P NO WARNING INDICATION APAPPROACH 1 CA (CAN) PILOT REPORTED NOSE GEAR NOT DOWN AND LOCKED. TOWER COULD NOT VERIFY NOSE GEAR DOWN. COMPANY AIRCRAFT DID A FLY BY AND VERIFIED NOSE GEAR DOORS OPEN BUT NOSE GEAR NOT DOWN AND LOCKED. AIRCRAFT WAS RUNNING LOW ON FUEL.CREW DECLARED EMERGENCY AND LANDED WITH THE NOSE GEAR NOT FULLY EXTENDED. CREW REPORTED THEY FOLLOWED QRH PROCEDURES FOR GEAR DOWN DISAGREE.AIRCRAFT TEMPORARILY REPAIRED AND FERRIED FOR PERMANENT REPAIRS. 2L72 4F4 FRTA21EA E15NE 20031110001382003111000138SW 2003 11 10 CA031015001 120031013G2497AN44AWGN405 TERMINAL BELL BELL 430 430 1182150SW ALLSN 250C 250C40B 03032NE POWER CABLE DETACHED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA NS (CAN) THE P56A4 POWER CABLE WAS DETACHED FROM THE CRIMPED AN-4 4AWG N-40-50 ELECTRICAL LUG. 1G72 3U3 URTH9SW E1GL 20031110001392003111000139EA 2003 11 10 CA031015002 120031013G2913848847 PUMP CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE HYD SYSTEM FAILED W A UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 CA (CAN) HYD NR 2 QUANTITY DROPPED STEADILY DURING FLT. AT LANDING HAD NR 2 QTY AT 25 PERCENT DECLARED EMERGENCY AND LANDED NORMALLY IN ALBANY. PUMP CHANGED, SYSTEM FLUSHED AND FILTERS CHANGED ALL NOW NORMAL 2L72 4F4 FRTA21EA E15NE 20031106000022003110600002NM 2003 11 6 CA031015003 120031007G32316546059 LINK BOEING737 737217 1384464NM PWA JT8 JT8D17 52049NE MLG DOOR BROKEN W A UNSCHED LANDING D INFLIGHT SEPARATION NRNOT REPORTED 1 CA (CAN) A LOUD BANG WAS HEARD UPON GEAR RETRACTION. ONCE GEAR WAS RETRACTED A STRONG VIBRATION WAS FELT. WHEN GEAR EXTENTED, VIBRATION WENT AWAY. RETURNED TO YYC FOR A NORMAL LANDING. RT NOSE LANDING GEAR DOOR DOG LINK FOUND BROKEN. LINK REPLACED, SWING CARRIED OUT AND ALL RETURNED TO NORMAL. 2L72 4F4 F A16WE E2EA 20031106000042003110600004NM 2003 11 6 CA031015004 120031011G3320325070 BALLAST AIRBUSA319 A319114 3930350NM CFMINTCFM56 CFM565A1 NE CABIN LIGHTS BURNED W O OTHER B SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 CA (CAN) A STRONG ELECTRICAL ODOR WAS PRESENT OVER MID WING AREA. PRODUCED A BURNING WIRE ODOR. A LIGHT BALLAST WAS FOUND TO BE AT FAULT. BALLAST, FLUORESCENT LIGHT ASSY AND BULB REPLACED AND ALL CHECKS NORMAL. 2L72 4F4 FRTA28NM E29NE 20031106000062003110600006 2003 11 6 CA031015005 420031010G2330J5500 CONTROL BOX AIRBUS320 A320211 3930320EU CFMINTCFM56 CFM565A1 NE VIDEO SYSTEM CONSMOKE W K NONE B SMOKE/FUMES/ODORS/SPARKS ININSP/MAINT 1 CA (CAN) VIDEO TRANSCOM POWER BOX WAS SMOKING ON GROUND. NO OTHER DAMAGE FOUND. UNIT REPLACED AND ALL CHECKS NORMAL 2L72 4F4 FRTA28NM E29NE 20031106000072003110600007SW 2003 11 6 CA031015006 120030929G28221C2710FR CARTRIDGE BELL BELL 206 206B 1181511SW ALLSN 250C 250C20B 03013GL BOOST PUMP FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) FUEL BOOST PUMP STOPPED PUMPING. PUMP CHANGED. 1G71 3U3 U H2SW E4CE 20031106000092003110600009GL 2003 11 6 CA031015007 320031010G61105262163312 O-RING MCAULY MCAULY2A34C 2A34C66 GL PROP CYLINDER WORN W O OTHER O OTHER NRNOT REPORTED 1 CA 733167 (CAN) CUSTOMER COMPLAINED OF RED OIL IN HIS ENGINE OIL. THE PROPELLER WAS SENT IN OFR REPAIR, AND IT WAS DETERMINED THAT THE CYLINDER WAS BADLY WORN INTERNALLY AND THAT THE SEAL WAS ALSO BADLY WORN. THIS ALLOWED RED OIL FROM INSIDE THE HUB TO ENTER THE OIL SYSTEM. A NEW SEAL AND CYLINDER WERE INSTALLED, THE PROPELLER WAS ASSEMBLED, AND LOCKED. 5 CP3EA 20031106000102003110600010GL 2003 11 6 CA031015008 320031002G61141A105SCM7154 HUB MCAULY1A105 1A105* GL PROPELLER DAMAGED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) UPON O/H OF THIS FIXED PITCH PROP, FOUND AN INCLUSION IN HUB AREA THAT MEASURED ABOUT 1 INCH IN TOTAL LENGTH. GROUND ABOUT 0.030 OUT OF IT AND IT SEEMED TO GET LARGER IN SIZE. SENT MFG AN EMAIL ABOUT IT, REPLIED THAT IT APPEARED TO BE A FORGING LAP IN MATERIAL, PROP WAS THEREFORE SCRAP. THEY INFORMED US THAT WARRANTY WOULD NOT BE CONSIDERED BECAUSE SB 137W HAD NOT BEEN FOLLOWED. THIS SB SAYS THAT PROP REQUIRES OVERHAUL 72 MONTHS OR 2000 HRS. THIS PROP WAS INSTALLED IN THE 70S, AND HAS NEVER SEEN AN OVERHAUL. IF THIS PROP HAD BEEN INSPECTED AS REQUIRED BY THE FACTORY, CUSTOMER WOULD HAVE BEEN COVERED UNDER WARRANTY, NOT TO MENTION PROBLEMS THAT COULD HAVE A RISEN IF THIS PROGRESSED INTO A CRACK. 5 NP918 20031106000152003110600015CE 2003 11 6 CA031015009 120031006G272004115262 BAR CESSNA CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA RUDDER PEDAL CRACKED W O OTHER F FLT CONT AFFECTED CRCRUISE 1 CA (CAN) LOSS OF LT RUDDER CONTROL IN FLIGHT. LT RUDDER TORQUE TUBE BAR FOUND CRACKED AND DEFORMED WHERE THE 'TEE' IS WELDED TO THE BAR. LT RUDDER PEDAL ON THE RT. (AIRCRAFT BEING FLOWN FROM RT SEAT) CRACK 2 INCHES LONG, FROM END OF PIPE, AROUND HEAT AFFECTED ZONE OF THE WELD, CONTINUING FOR .7500 INCH ALONG PIPE (INBOARD). AIRCRAFT LANDED SAFELY AT DESTINATION AIRPORT (CYBW). 1H71 3O3 ONT3A19 E223 20031106000162003110600016CE 2003 11 6 CA031015010 120030929G551007126153 BULKHEAD CESSNA182 182L 2072726CE CONT O470 O470R 17026SO MCAULY2A34C 2A34C66 GL FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) RIVETS LOOSE AT TOP OF ANCHOR DOUBLERS ON BOTH SIDES AND CRACK STARTING ON RIVET ON LEFT SIDE DOUBLER FOR ANCHOR NUT TO RECEIVE HORIZONTAL STAB FRONT ATTACH BOLTS. 1H71 3O3 ONT3A13 E273 5 CP3EA 20031106000172003110600017EA 2003 11 6 CA031015011 220030926G7414ES10384585 POINTS BENDIX 04RN3000 CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA MCAULY1C160 1C160CTM GL MAGNETO WORN W O OTHER O OTHER NRNOT REPORTED 1 CA G01JA047 (CAN) AT ROUTINE INSPECTION, THE MAGNETO TO ENGINE TIMING WAS FOUND TO BE CONSIDERABLY OFF (ABOUT 5 DEG OFF). THE MAGNETO WAS REMOVED AND FOUND THAT THE E-GAP AND POINT OPENING WERE WAY OFF. THE POINTS ONLY HAD 100 HOURS ON THEM AND THE PLASTIC/NYLON FOOT WAS WEARING SO THAT THE POINT GAP WAS GETTING SMALLER AND SMALLER. ( HAD A C172 DO A PRECAUTIONARY LANDING IN MAY 03 DUE TO ENGINE PROBLEM WHICH TURNED OUT TO BE MAGNETO POINTS NOT OPENING AT ALL.) 1H71 3O3 ONT3A12 E274 5 NP910 20031106000182003110600018CE 2003 11 6 CA031015012 120030925G5711042640032 SPAR CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA MCAULY1A103 1A103TCM GL RT WING CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) RT WING AFT SPAR FOUND CRACKED AT AFT WING ATTACH POINT. 1 INCH CRACK LOCATED FROM INBOARD END OF AFT SPAR P/N 0426400-32 JUST BELOW SPAR REINFORCEMENT CRACK EXTENDS ALONG THE LENGTH OF THE SPAR 1 INCH. WING REMOVED FOR REPAIR. 1H71 3O3 ONT3A19 E223 5 NP50GL 20031106000192003110600019EU 2003 11 6 CA031015013 120030925G6520350A33020005 GEARBOX SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE TAIL ROTOR MAKING METAL W A UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 CA (CAN) PILOT HAD AN TGB CHIP LIGHT INFLIGHT. LANDED AT HIS BASE FOR THE ENGINEER TO CHECK IT OUT. THEY FOUND A LOT OF A DARK GRAY SLUDGY SUBSTANCE WHICH PUT THE CHIP LIGHT ON. THEY DRAINED THE GEARBOX ANDDID A GROUND RUN FOR ABOUT .5 HOUR AND FOUND NOTHING (NO METAL). WE REPLACED THE GEARBOX WITH A NEW OVERHAULED ONE AND SENT THIS GEARBOX FOR REPAIR OR OVERHAUL. 1G71 3U3 U H9EU E19EU 20031106000202003110600020CE 2003 11 6 CA031015014 120031002G551212120031 DOUBLER CESSNA206 U206B 2073322CE CONT O520 IO520F 17032SO MCAULYD3A34 D3A34C401 GL BULKHEAD CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) HORIZONTAL ATTACHMENT POINT DOUBLER FORWARD RT CRACKED AT TOP NUTPLATE RIVET. DOUBLER REPLACED WITH NEW. AREA INSPECTED. NO OTHER FAULTS FOUND. CAUSE IMPROPER GROUND HANDLING (SPECULATION). 1H71 3O3 O A4CE E5CE 5 CP47GL 20040106000282004010600028EA 2004 1 6 CA031015015 120031009G3242213293 BRAKE ASSY DHAV DHC7 DHC7102 2802708EA PWA PT6 PT6A50 52043EA HAMSTD24PF 24PF305 GL MLG LEAKING W O OTHER W INADEQUATE Q C NRNOT REPORTED 1 CA (CAN) BRAKE WAS SENT TO SHOP FOR WARRANTY REPAIR. SNAGGED AS LEAKING FROM PIN ON OCT 02, 2002. THE UNIT WAS REPAIRED AND RETURNED. BRAKE WAS INSTALLED ON 13 AUG 03, IT WORKED FOR 132.1 HOURS AND THEN STARTED TO LEAK FROM ONE OF THE PISTONS. THIS IS NOT THE FIRST BRAKE THAT WE HAVE SENT IN FOR WARRANTY REPAIR, AND IS ONLY THE LATEST EXAMPLE. IT IS STARTING TO CAUSE SOME CONCERN WITH REGARDS TO THE REPAIR FACILITY. 2H74 4T4 T A20EA E4EA 6 CP1NE 20031106000212003110600021EA 2003 11 6 CA031015016 220030924G852061151 SHAFT CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA MCAULY1A103 1A103TCM GL CRANKCASE LOOSE W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) CRANKSHAFT IDLER GEAR SHAFT P/N 61151 FOUND LOOSE AT ENGINE DISASSEMBLY. 2 BOLTS STD-705 UNLOOKED, BACK OFF 2C3 THREADS. LOCKPLATE 73817 NOT BENT FAR ENOUGH ONBOLT HEAD. THIS ENGINE WAS REBUILT. 1H71 3O3 ONT3A19 E223 5 NP50GL 20031106000222003110600022NE 2003 11 6 CA031015017 220031011G8530399353 CYLINDER HEAD DHAV DHC2 DHC2* 2800108EA PWA R985 R985AN14B 52008NE ENGINE CRACKED W O OTHER RJ PARTIAL RPM/PWR LOSS WARNING INDICATION CRCRUISE 1 CA (CAN) CYLINDER HEAD CRACKED 360DEG FROM CYLINDER (BARREL PN 47517) 1H71 3R3 R A806 5E1 20040106000292004010600029NM 2004 1 6 CA031015018 120031002G30204100S0283 HEATER BOMBDRDHC8 DHC8402 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU INTAKE SHORTED W O OTHER MBHOVER TEMP SMOKE/FUMES/ODORS/SPARKS ELECT. POWER LOSS-50 PC DEDESCENT 1 CA (CAN) 1ST -NR 1 ENG HEATER ELEMENT UNSERVICEABLE, NO LIGHT INTO BY-PASS DOOR SWITCH, AND ENG ADAPTER HTR NR 1 CAUTION LIGHT, C/B INTAKE LIP ENG NR 1 POP-OUT. FOUND BOTH ELEMENT OF NR 1 INTAKE HTR (SHORTED). NO FAULT FOUND INTO AC (CDS). HTR ELEMENT REPLACED. 2ND - DURING APPROACH, CREW NOTICE A STRONG ELEC BURN SMELL INTO CABIN. NR 1 ENG INTAKE LIP HTR C/B POP-OUT, CAUTION LIGHT ENG ADAPTER HTR SMELL ORIGIN IDENTIFIED BY PILOTS, FIREMEN ASST REQUESTED BEFORE LANDING. AC LAND SAFELY. FOUND ENG AIR INTAKE ADAPTER HTR SHORTED, BURNED. THIS TIME CDS FAULT CODE FOUND 'TMU 3 FAIL', TMU P/N 4100S018-06 REPLACED, S/N 0214 (AERAZUR). COMPLETE SYSTEM TESTED 'S'. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20031106000232003110600023GL 2003 11 6 CA031015019 220030911G725023038160 TURBINE BELL 206 206L 1181522SW ALLSN 25OC 250C20R GL N1 FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) AFTER ENGINE WAS SHUTDOWN A RUBBING NOISE WAS HARD COMING FROM THE N1 TURBINE WHEELS. IT WAS CONFIRMED BY MOTORING THE ENGINE AFTER SHUTDOWN. TURBINE WAS REPLACED AND SENT TO AN APPROVED REPAIR FACILITY. 1G71 3U3 U H2SW E4CE 20031106000242003110600024EU 2003 11 6 CA031015020 120031013G28107583552 SPACER SNIAS 350 AS350D 8680803EU LYC LTS101LTS101600A3 41560NE FUEL TANK BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) SENDER REMOVED FOR CLEANING TANK, AND NOTICED SEVERAL BRIDGE SPACERS HAD EITHER BROKEN OR LOOSE RIVETS. 1G71 3U3 U H9EU E5NE 20031106000262003110600026SW 2003 11 6 CA031015021 120031015G52302720063907 RECEPTACLE SWRNGNSA226 SA226TC 8780404SW GARRTTTPE331TPE33110UA 01514WP HARTZLHCB3T HCB3TN5 GL CARGO DOOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 19836 (CAN) DISCOVERED CARGO DOOR (KLICK-KLACK) RECEPTACLE CRACKED WHILE COMPLYING WITH SERVICE LETTER 226-SL-027, WHICH DEALS WITH THIS PROBLEM. DISCOVERED BY REMOVING ECCENTRIC BUSHING, AND IT WAS IMMEDIATELY VISIBLE. PART WAS CRACKED THROUGH FROM THE CENTER OF THE HOLE TO THE EDGE OF THE BRACKET. THE REST OF THE AIRCRAFT WAS INSPECTED, FOUND NO DEFECTS. AS THIS WAS THE FIRST OF THE COMPANY FLEET TO BE INSPECTED, AND THE LOWEST TIME, MAINTENANCE WILL COMPLETE THE REST OF THE FLEET AS SOON AS POSSIBLE. 2L72 4T4 TRTA8SW E4WE 6 CP15EA 20031106000592003110600059EA 2003 11 6 CA031016001 220031015G73103011857 LINE EMB 110 EMB110P1 3260122SO PWA PT6 PT6A34 52043EA HARTZLHCB3T HCB3TN3 GL FUEL SYS RUPTURED W O OTHER K FLUID LOSS NRNOT REPORTED 1 CA (CAN) WHILE CARRYING OUT MAINTENANCE IN THE ACCESSORY SECTION AREA OF THE LT ENGINE (PT6A-34) A STRONG FUEL SMELL WAS NOTICED BY MAINTENANCE. A FURTHER INVESTIGATION REVEALED THAT WITH THE AIRFRAME FUEL BOOST PUMPS SELECTED ON THAT THERE WAS FUEL SPRAYING FROM A RIGID LINE (FUEL PRESSURE) CONNECTING THE START CONTROL UNIT AND THE FUEL CONTROL UNIT. THE RUPTURE WAS FOUND TO BE AT THE END OF THE LINE ADJACENT TO THE FITTING. THE LINE CAN BE FOUND IN MFG PT6A-34 IPC73-10-03 FIGURE 1 ITEM 20 (LINE P/N 3011857). THE LINE WAS REPLACED, LEAK CHECK ED, AND THE AIRCRAFT WAS RETURNED TO SERVICE. INCLUDED IS AN ILLUSTRATION FROM THE IPC WITH THE AFFECTED LINE IDENTIFIED. 1L72 4T4 T A21SO E4EA 6 CP15EA 20031106000622003110600062CE 2003 11 6 CA031016002 120031016G3230ADNE5323 ROD END BEECH 58 58 1152740CE CONT O520 IO520C 17032SO HARTZLHCJ3Y PHCJ3YF2 GL MLG BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ON GEAR RETRACTION ON OUR BEECH 58, A BANG WAS HEARD AND FLIGHT CREW NOTICED THE NOSE GEAR PARTIALLY RETRACTED. AIRCRAFT LANDED AND NOSE GEAR COLLAPSED. DAM AGE TO AIRCRAFT WAS THE FOLLOWING: LT AND RT PROPELLERS BENT, NOSE GEAR DOORS DAMAGED, HEATER EXHAUST STACK DAMAGED, PITOT TUBE DAMAGED. AFTER JACKING AIRCRAFT WE FOUND THE FORWARD ROD END ON THE RETRACT ARM TO HAVE BROKEN AROUND THE BEARING HOUSING ROD END PART NUMBER ADNE5-323. AIRCRAFT TOTAL TIME:7064.0 BEARING DOES NOT APPEAR TO HAVE SEIZED AS IT IS STILL FREE ON THE ATTACHING BOLT. 1L72 3O3 O 3A16 E5CE 5 CP36EA 20031106000872003110600087 2003 11 6 CA031016003 420031005G61223032125 LINE BEECH 1900 1900C 1154161CE PWA PT6 PT6A65B 52043EA HARTZLHCB4M HCB4MP3 GL ENGINE CRACKED W E ENGINE SHUTDOWN O OTHER APAPPROACH 1 CA 32507 (CAN) ON APPROACH INTO SEATTLE THE RT ENGINE POWER DECREASED SLOWLY ON ITS OWN. THE CREW SHUTDOWN AND SECURED THE ENGINE. THE AIRCRAFT LANDED UNEVENTFULLY AND WAS TOWED FROM THE RAMP. DURING INVESTIGATION BY MAINTENANCE IT WAS FOUND THAT THE ENGINE WOULD ACTUALLY IDLE BUT AT MIN FLOW. THE PY AND P3 LINES WHERE REMOVED AND BY PRESSURE TESTING REVEALED A CRACK JUST FORWARD OF THE AFT B NUT. CRACK WAS RUNNING HALFWAY AROUND THE CIRCUMFERENCE OF THE TUBE. 2L72 4T4 TRTA24CE E4EA 6 CP56GL 20031106000882003110600088NM 2003 11 6 CA031017001 120030929G2420 GENERATOR DHAV DHC8 DHC8* NM PWA PW120 PW123 NE HAMSTD14SF 14SF15 NE AC SYS FAILED W O OTHER H ELECT. POWER LOSS-50 PC CRCRUISE 1 CA (CAN) AN OPERATOR HAS REPORTED THAT DURING THE TROUBLESHOOTING OF AN AIRCRAFT THAT HAD EXPERIENCED A DUAL AC GENERATOR FAILURE, FINDING THAT THE CAUSE TO BE TWO AC FEEDER CABLES (2421-10003G12C-1, 2421-20003F12C-1) SHORTED TO ONE OF THE BRACKETS ALONG THE LOWER TRAILING EDGE OF THE WING. THE BRACKET WAS FOUND TO BE MISSING IT S BONDED CATERPILLAR GROMMET. THESE GROMMETS PROVIDE PROTECTION TO THE WIRING FROM THE BRACKETS SHARP EDGES. SERVICE LETTER DH8-SL-24-010 TO BE ISSUED TO PROVIDE INSPECTION CRITERIA AND REPAIR PRACTICES TO PREVENT WIRE CHAFING IN THE TRAILING EDGE AREA INBOARD OF THE NACELLE, WING STATION NUMBER YW 47.5 TO YW132.70. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20031106000892003110600089EA 2003 11 6 CA031017002 120031013G5610NP1393225 WINDOW CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE COCKPIT FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) LT SIDE WINDOW SHATTERED IN FLIGHT. (EXTERNAL) NO CHANGE TO PRESSURIZATION. LT WINDOW CHANGED AND NO FURTHER FAULTS. 2L72 4F4 FRTA21EA E15NE 20031106000902003110600090EA 2003 11 6 CA031017003 120031015G5270 SWITCH CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE DOOR WARNING SYSDIRTY W A UNSCHED LANDING N FALSE WARNING NRNOT REPORTED 1 CA (CAN) PAX DOOR WARNING AT FL200. DOOR RIGGING CARRIED OUT IAW AMM 52-11-02. NOTE: A/C HAD TWO PREVIOUS SNAGS. BIT CHECK FAULTED S47 AT WHICH TIME SWITCH WAS CLEANED AND LUBED. 2L72 4F4 FRTA21EA E15NE 20031106000932003110600093GL 2003 11 6 CA031017004 220031004G732123070108 FUEL CONTROL HUGHES500N 500N 3027374SW ALLSN 250C 250C20R2 GL ENGINE FAILED W K NONE O OTHER ININSP/MAINT 1 CA CAE295410 (CAN) AFTER LANDING, THROTTLE WAS SNAP ROLLED TO IDLE. N2 WAS NR IMMEDIATELY INCREASED TO 105 PERCENT AND STABILIZED. ENGINE WAS SHUT DOWN BY ROLLING THROTTLE TO CUT OFF. NOTE: ENGINE WAS DUE FOR HOT SECTION, SO RENTAL WAS INSTALLE4D. SUSPECT ENGINE, FCU AND GOVERNOR SENT TO REPAIR STATION FOR TEST CELL AND RECERTIFICATION, AND TO SEE IF THEY COULD REPRODUCE THE PROBLEM. 1G71 3U3 UNCH3WE E4CE 20031106000942003110600094NM 2003 11 6 CA031017005 120031017G33506050251 BATTERY PACK BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA EMERGENCY LIGHT SHORTED W O OTHER B SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 CA (CAN) DURING TROUBLE SHOOTING OF A CONTINUOUS POPPING OF CIRCUIT BREAKER G3 (EMERG LTS) HAS BEEN REPORTED. INVESTIGATION SHOWED BURNED WIRING AT EMERGENCY LIGHT POWER SUPPLY BOX EPS4, FROM CONNECTOR 3351-P6. THERE WAS SIGNS OF AN INTERNAL SHORT INSIDE BATTERY PACK. 2H72 4T4 TRTA13NM E00062EN 20031106000972003110600097SW 2003 11 6 CA031017006 120031010G2120 SMOKE SWRNGNSA227 SA227AC 8780603SW GARRTTTPE331TFE33112UHR WP MCAULY4HFR344HFR34C652 NE CABIN DETECTED W K NONE B SMOKE/FUMES/ODORS/SPARKS ININSP/MAINT 1 CA 2356223562 (CAN) PILOT REPORTED SMOKE IN CABIN WHEN BATTERY MASTER WAS TURNED ON. ODOR WAS CONFIRMED BY MAINTENANCE. ALL ELECTRICAL INSTRUMENTS, INDICATORS & AVIONICS WERE INSPECTED ON THE CAPTAINS SIDE. GLARESHIELD AND CAPTAINS SEAT WERE REMOVED AND WIRING INSPECTED. NO DEFECTS WERE FOUND. AIRCRAFT WAS REASSEMBLED AND GROUND CHECKS CARRIED OUT WITH NO FAULTS PRESENT. AIRCRAFT RETURNED TO SERVICE AND NO ADDITIONAL DEFECTS HAVE BEEN REPORTED TO DATE IN REGARDS TO THIS INCIDENT. 2L72 4T4 TRTA8SW E4WE 6 C3PNE 20031106000982003110600098CE 2003 11 6 CA031017007 120031006G56101013840251 WINDSHIELD BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL COCKPIT FAILED W I CABIN DEPRESSURIZATION D INFLIGHT SEPARATION CRCRUISE 1 CA (CAN) CO-PILOTS WINDSHIELD INNER PANE COMPLETELY SHATTERED IN FLIGHT. 1L72 4T4 T A24CE E4EA 6 CP15EA 20031106000992003110600099CE 2003 11 6 CA031017008 120031017G5753 SKIN CESSNA500 550 2076604CE TE FLAP DAMAGED W A UNSCHED LANDING F FLT CONT AFFECTED NRNOT REPORTED 1 CA (CAN)FLAP HAS BEEN REPAIRED ON TWO AREAS ALONG LE. RETURNED AFTER SEVERAL FLIGHTS WITH MAJOR DISBOND BETWEEN CARBON SKIN PLIES AND FOAM CORE ON LOWER SKIN AT TE EXTENDING FROM IB CLOSE OUT RIB 60' SPAN WISE AND 13' FWD IN CHORD WISE DIRECTION. SOLID LAMINATE TE SKIN HAS ALSO DELAMINATED AT TE 13-3/4' SPAN WISE FROM CLOSE OUT RIB. UPON EXAMINATION OF FLAP, CRACKING HAS ALSO BEEN OBSERVED AT LE IN LOCATION OF FILLET WHERE LE PROFILE MEETS FWD IB ROLLER LUG. CRACKING OF PAINT ON LE OF IB ACTUATOR LUG AT BOND LINE IS ALSO VISIBLE. HOLES IN ACTUATOR MOUNT FOR RETAINING PIN HAVE BEEN OVERSIZED AND ELONGATED. CONTINUING TO EVALUATE THE FULL EXTENT OF DAMAGE. LIKELY CAUSE OF DAMAGE HAS NOT YET BEEN DETERMINED. 1L72 4F A22CE 20031106001002003110600100CE 2003 11 6 CA031017009 120031017G2820 CHECK VALVE BEECH 100 A100 1152915CE PWA PT6 PT6A28 EA FUEL SYS FAILED W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) AFTER PILOTS HAD DEPLANED PASSENGERS AND BAGGAGE AT A SCHEDULED STOP THEY NOTICED FUEL COMING OUT OF THE FUEL VENT. MAINTENANCE TOWED THE A/C TO THE HANGER AND DEFUELED THE A/C. THEY FOUND THAT THE ONEWAY VALVE GOING TO THE AUX TANK, SOMETHING HOLDING THE FLAPPER OFF THE SEAT LETING FUEL GO TO THE AUX TANK OVER FILLINGIT MAKING IT DRAIN ON THE GROUND. VALVE CLEANED AND CHECKED AND INSTALLED LINES WERE CHECKED FOR CONTAMINATION AND NONE FOUND. A/C WAS RETURNED TO SERVICE. 1L72 3T4 T A14CE E4EA 20031106001022003110600102 2003 11 6 CA031017010 420031017G2562400010 ELT CABIN FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING ANNUAL RECERTIFICATION OF THE ELT IT WAS DISCOVERED THAT THE UNIT HAD NO MEASURABLE TRANSMIT POWER. UNIT WAS RETURNED TO THE MANUFACTURER FOR REPAIR. 20031106001032003110600103EA 2003 11 6 CA031020001 120030919G3230 SELECTOR VALVE CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE MLG LEAKING W O OTHER O OTHER APAPPROACH 1 CA (CAN) THE PILOT REPORTED UPON APPROACH, THE MLG DID NOT EXTEND AND THE DISAGREE MSG APPEARED. A SECOND ATTEMPT PRODUCED THE SAME RESULTS. THE LANDING GEAR WAS SUCCESSFULLY EXTENDED MANUALLY IAW EMERGENCY PROCEDURE. THE AIRCRAFT RETURNED TO SERVICE FOLLOWING REPLACEMENT OF THE FOLLOWING PARTS. MLG SELECTOR VALVE, P/N 750005000, S/N 0828 MLG PRIORITY VALVE, P/N 4619-3, S/N 1157 NLG PRIORIY VALVE, P/N 4622,S/N 1172 NOTE: DURING INSPECTION/TROUBLESHOOTING OF THE AIRCRAFT BY THE MECANIC, EVIDENCE OF HEAVY HYD LEAKAGE WAS FOUND AT THE MLG SELECTOR VALVE. 2L72 4F4 FRTA21EA E15NE 20031106001042003110600104EA 2003 11 6 CA031020002 120030928G4900WE38007703 APU CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE APU BAY SMOKE W C ABORTED TAKEOFF N FALSE WARNING TOTAKEOFF 1 CA (CAN) DURING THE TAKE OFF ROLL, THE SMOKE AFT LAV WARNING MESSAGE BECAME EVIDENT. THE LAVATORY SMOKE ALARM WAS GOING OFF AND THERE WAS A PRESENCE OF SOME SMOKE ACCORDING TO THE FLIGHT ATTENDANT. MAINTENANCE PERFORMED SOME TROUBLESHOOTING AND IN COMBINATION WITH THE HISTORICAL ASSOCIATION OF THIS ANOMALY WITH A MALFUNCTION IN THE APU ELECTED TO PLACE THE APU ON MEL. THE AIRCRAFT RETURNED TO SERVICE. LATER THE APU WAS REPLACED AND THE MEL WAS REMOVED. 2L72 4F4 FRTA21EA EOOO63EN 20031106001092003110600109EA 2003 11 6 CA031020003 120031019G5270 SENSOR CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE PAX DOOR MALFUNCTIONED W A UNSCHED LANDING N FALSE WARNING NRNOT REPORTED 1 CA (CAN) AFTER T/O UNABLE TO PRESSURIZE ABOVE 1.5 PSI. PASSENGER LATCH WARNING ON DOOR SYNOPTIC PAGE WITH ASSOCIATED (OB COOL) CAUTION EICAS MESSAGE AND (IB COOL) EICAS STATUS MESSAGE WITH PASS DOOR OPEN. REPLACED OUTER DOOR HANDLE LOCKED SENSOR. ALL CHECKS NORMAL. 2L72 4F4 FRTA21EA E15NE 20031106001102003110600110NM 2003 11 6 CA031020004 120031018G3231709121 PRIORITY VALVE 709121 BOEING767 7673Y0 NM PWA 4060 PW4060 52119NE MLG DOOR MALFUNCTIONED W K NONE O OTHER ININSP/MAINT 1 CA 00100 (CAN) BEFORE LANDING (GEAR DISAGREE) MSG CAME ON AND NOSE GEAR WOULD NOT EXTEND. ALTEXTENSION USED AND GEAR DOWN AND LOCKED. REPLACED NOSE GEAR PRIORITY VALVE AND GEAR SWING CARRIED OUT AND ALL NORMAL. 2L72 4F4 FRTA1NM E24NE 20031106001112003110600111NM 2003 11 6 CA031020005 120031016G2120 ODOR BOEING747 747475 NM GE CF6 CF680C2B2 30025NE CABIN DETECTED W K NONE B SMOKE/FUMES/ODORS/SPARKS ININSP/MAINT 1 CA (CAN) AFTER T/O THRU 8,000 FT HAD A STRONG ODOR OF SMOKE IN C/P CABIN. THE ODOR WAS SULPHERUS AND NOT ELECTRICAL. TURNED OFF RECERC AND GASPER FANS AND ODOR DISSAPPEARED. FLT CONTINUED TO DESTINATION AND NO FURTHER FAULT. 2L74 4F4 FRTA20WE E13NE 20031106001122003110600112NE 2003 11 6 CA031020006 220031020G73141143890425 PUMP BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3I NE LP FUEL LEAKING W K NONE KB FLUID LOSS SMOKE/FUMES/ODORS/SPARKS ININSP/MAINT 1 CA (CAN) CREW ARRIVED AT TERMINAL AND UPON SHUTDOWN WERE ALERTED TO FUEL COMING FROM RIGHT COWL. MAINTENANCE FOUND LOW PRESSURE FUEL PUMP HAD BLOWN OUT GASKET BETWEEN MAIN BODY AND THE REGULATOR ASSEMBLY. PUMP WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20031106001192003110600119CE 2003 11 6 CA031020007 120031010G2424DGR3 CONTROL UNIT CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA MCAULY1C160 1C160DTM GL ALTERNATOR SHORTED W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA (CAN) ACU SHORTED INTERNALLY CAUSING ALTERNATOR TO RUN UNCONTROLLED WHILE IN FLIGHT. PROBLEM RESULTED IN SMOKE IN COCKPIT WITH ALL RADIOS AND INSTRUMENTS THAT ARE ELECTRICAL TO TAKE TO MUCH POWER AND DESTROYED THEM ALL INTERNALLY. 1H71 3O3 ONT3A12 E274 5 NP910 20031106001202003110600120EU 2003 11 6 CA031020008 120031016G52465711012353 STRUT PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL OIL COOLER DOOR WORN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING INSPECTION, IT WAS NOTED THAT THE ATTACHMENT HOLE FOR THE OIL COOLER DOOR STRUT WAS SEVERLY WORN. THE STRUT WAS REPLACED WITH NEW. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20031106001212003110600121CE 2003 11 6 CA031020009 120031001G8011 BRUSHES LUCAS CESSNA500 S550 2076607CE PWA JT15 JT15D4 52112NE STARTER GEN WORN W K NONE L NO TEST TXTAXI/GRND HDL 1 CA 96291 (CAN) LT ENGINE WOULD NOT ROTATE ON START. INSPECTION OF THE STARTER GENERATOR DETERMINED THAT THE BRUSHES WERE EXCESSIVELY WORN. THE ASSEMBLY ONLY HAD 139.5 HOURS SINCE OVERHAUL. 1L72 4F4 FRTA22CE E1NE 20031106001222003110600122CE 2003 11 6 CA031020010 120031006G2435 BEARING LUCAS CESSNA500 S550 2076607CE PWA JT15 JT15D4 52112NE STARTER GEN WORN W K NONE J WARNING INDICATION TXTAXI/GRND HDL 1 CA 969 (CAN) NR 2 GENERATOR WENT OFF LINE DURING TAXI TO THE RAMP. WOULD NOT RESET. MAINTENANCE DETERMINED THAT THE GENERATOR WAS DEFECTIVE. THERE WAS PLAY IN THE SHAFT BEARING GS CAUSING REJECTION OF THE UNIT. REPORT FROM THE OVERHAUL SHOP CONFIRMED A BEARING FAILURE INSIDE THE ASSEMBLY. UNIT HAD ONLY 164 HOURS SINCE OVERHAUL. 1L72 4F4 FRTA22CE E1NE 20031106001262003110600126WP 2003 11 6 CA031020011 220031016G7250310166811 CASE BAG JETSTMJETSTM3101 1500215EU GARRTTTPE331TPE33110UG 01514WP ROTOL R333 R333482F12 GL COMBUST SECTION CRACKED W L ABORTED APPROACH J WARNING INDICATION APAPPROACH 1 CA 11374 (CAN) A/C WAS APPROACHING AIRPORT WITH INTENTIONS TO LAND. RT ENG BETA LIGHT ON WITH OTHER ABNORMAL ENG INDICATIONS. A MISSED APPROACH INITIATED. RT ENGINE WOULD ONLY GENERATE 70 PERCENT TORQUE AND TEMPS AND FUEL FLOW WERE HIGH. PILOT IN COMMAND RETURNED TO YELLOWKNIFE AFTER CONSULTATION WITH MAINT. A/C LANDED NORMALLY. ON INVESTIGATION THE RT ENGINE WAS FOUND TO HAVE A CRACKED COMBUSTION CASE. CRACK APPEARS TO ORIGINATE AT WELD SURROUNDING FWD PLENUM DRAIN FITTING. CRACK TRAVELED A THIRD OF WAY AROUND FITTING, THEN PROGRESSED AFT FOR THREE INCHES. CRACK BRANCHED AND PORTION OF CASE FELL AWAY, CAUSING AIR LOSS THAT WAS RESPONSIBLE FOR SYMPTOMS OBSERVED ON FLIGHT DECK. ENGINE WAS REMOVED FOR REPAIR. 2L72 4T4 TRTA21EU E4WE 6 CP61GL 20031106001292003110600129NM 2003 11 6 CA031021001 120031015G38203051110137 HEAT TAPE BOEING767 767233 1385113NM PWA JT9 JT9D7R4D 52054NE WATER SYS BURNED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) WATER LINE P/N 10-61998-310 OUTER WOVEN COVERING BURNED THROUGH AND PLASTIC INNER CORE PARTIALLY BURNED. ALL FOUR WIRE STRANDS WERE BURNED THROUGH ON THE HEATER TAPE. IN SECTION 45H20 LINE AND HEATER TAPE REPLACED. 2L72 4F4 FRTA1NM E3NE 20031106001312003110600131EU 2003 11 6 CA031021002 120030926G2897E0437DL20 WIRE AIRBUS320 A320211 3930320EU CFMINTCFM56 CFM565A1 NE FUEL SYSTEM DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING A MTCE PREP VISIT FOR RETURNING THE A/C BACK TO LESSOR , MTCE IDENTIFIED A PROBLEM WITH NR 2 ENGINE LP VALVE DURING THE OPERATIONAL TEST OF THE VALVE IAW TASK 28-24-00-790-003. FURTHER TROUBLESHOOTING IDENTIFIED WIRE DL-20-AE-FR-F, SPEC MIL-W-25038/3, 18' BACK FROM FACTORY SPLICE 4010VS, CONTAMINATED AND BRITTLE WITH EVIDENCE OF DECOLORIZATION. ON FURTHER EVALUATION, THE WIRE WAS FOUND TO BE CORRODED. WIRE NR 2824-4543 WAS REPLACED AND INSTALLED FROM 4010VS TO 4008VS IAW MFG ELECTRICAL STANDARDS PRACTICE MANUAL. OPERATIONAL TEST OF NR 2 ENGINE LP VALVE WAS COMPLETED SATISFACTORY. AIRCRAFT TOTAL TIME:39,434, LDG 14,870 2L72 4F4 FRTA28NM E29NE 20031106001322003110600132NE 2003 11 6 CA031021003 220031015G7321V319 SWITCH DHAV DHC8 DHC8* NM PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE ENGINE STUCK W E ENGINE SHUTDOWN W INADEQUATE Q C CLCLIMB 1 CA (CAN) ENGINE EXPERIENCED TORQUE SURGE DURING CLIMBOUT. ENGINE WAS SHUT DOWN IN FLIGHT. PRELIMINARY INFO STATES THAT TQ DID NOT EXCEED 120 PERCENT. PLA BETA LOCKOUT SWITCH 6141-S4 FOUND STUCK. SWITCH HAS BEEN REPLACED. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20031106001332003110600133EA 2003 11 6 CA031021004 220031010G8500 ENGINE PIPER PA31 PA31 7103102SO LYC O540 TIO540A2C 41532EA HARTZLHCE3Y HCE3YR2A GL LEFT FAILED W A UNSCHED LANDING J WARNING INDICATION CRCRUISE 1 CA (CAN) IN CRUISE THE LT ENGINE LOST POWER FOR APPROXIMATELY 5 MINUTES, THEN RESTARTED. THE ONLY INDICATION WAS A LOSS OF M.P. TO 20' AND A YAW TO THE LEFT. THE LT PROP WAS FEATHERED BUT CONTINUED TO ROTATE SO THE PILOT FELT THE ENGINE WAS STILL RUNNING AND UNFEATHERED THE PROP AT WHICH TIME SHORTLY AFTER THE ENGINE REGAINED POWER. IN THE PROCESS OF TROUBLESHOOTING, THE FUEL WAS SELECTED TO INBOARDS FROM OUTBOARDS. A COMPLETE INSPECTION OF THE TURBO CHARGER, INDUCTION SYSTEM AND FUEL DELIVERY SYSTEM WAS CARRIED OUT ALONG WITH SAMPLES OF FUEL FROM THE TANKS AND NO PROBLEM COULD BE FOUND. THE AIRCRAFT WAS TEST FLOWN FOR 30 MIN WITH NO FURTHER PROBLEMS. 1L72 3O3 O A20SO E14EA 5 CP33EA 20031106001352003110600135CE 2003 11 6 CA031021005 120030516G5511 SPAR CESSNA175 175 2072502CE LYC O360 O360A1A 41514EA HARTZLHCC2Y HCC2YR1 GL HORIZONTAL STAB BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DISCOVERED A BREAK IN THE STABILIZER SPAR DURING AN ANNUAL INSPECTION. 1H71 3O3 ONT3A17 E286 5 CP920 20031106001432003110600143EU 2003 11 6 CA031021006 120031014G2597224695 TRANSFORMER AIRBUS310 A310300 3930305EU GE CF6 CF680C2A5 NE PSM BURNED W H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA (CAN) DURING FLIGHT, THE CABIN CREW REPORTED AN ELECTRICAL BURNING ODOR IN CABIN AT ROW 13. THE LIGHTS WERE EXTINGUISHED AND THE ODOR DISAPPEARED AFTER 15 MINUTES. MAINTENANCE FOUND THE TRANSFORMER AT ROW 14 ABC SMELLED BURNED. THE PASSENGER SERVICE MODULE AT ROW 14 ABC WAS REPLACED AND THE SYSTEM WAS TESTED SERVICEABLE. 2L72 4F4 FRTA35EU E13NE 20040126001082004012600108WP 2004 1 26 CA031021007 120031002G2820S4913808AS12722 LEVER DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE LT ENGINE FUEL BROKEN W O OTHER E VIBRATION/BUFFET TXTAXI/GRND HDL 1 CA 14725 (CAN) LT ENGINE DID NOT START. NO FUEL FLOW. MAINTENANCE FOUND FUEL VALVE CONTROL CABLE BROKEN AT LT AFT FUSELAGE SECTION. A FLEET CAMPAIGN WILL BE PERFORMED. AWAITING RESULT. 2L72 4F4 FRTA6WE E9NE 20031106001442003110600144SO 2003 11 6 CA031021008 220031015G8530628488 CAM FOLLOWER BEECH 95 95B55 1152729CE CONT O470 IO470L 17026SO HARTZLHCA3V PHCA3VF2 GL LT ENG NR 5 CYL SPALLED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) WHILE INVESTIGATING PROBLEM OF LEAKING EXHAUST VALVE CYLINDER NR 6. A CHECK OF THE VISABLE CAMSHAFT INDICATED SEVERE SPALLING ON CAM FOLLOWER FOR NR 5 CYLINDER. CHECK OF OIL SCREEN SHOWED NO METAL. CHECK OF OIL SCREEN WELL REVEALED METAL. AIRCRAFT HAS BEEN INACTIVE DURING THE PREVIOUS 9 MONTHS. STORED IN A HEATED HANGAR. 1L72 3O3 ORT3A16 3E1 5 CP6EA 20031106001472003110600147EU 2003 11 6 CA031021010 120031020G8011 STARTER GEN PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL ENGINE FAILED W O OTHER O OTHER TXTAXI/GRND HDL 1 CA (CAN) STARTER WOULD NOT COME ON LINE WHEN START BUTTON PUSHED. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20031106001482003110600148NM 2003 11 6 CA031021011 120030720G3260 PROXIMITY SENSOR BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA NLG FAILED W C ABORTED TAKEOFF O OTHER TOTAKEOFF 1 CA (CAN) LANDING GEAR FAILURE, AFTER TAKE-OFF GEAR UP SELECTED. NOSE DOOR ADVISORY LIGHT CAME ON FOR ABOUT 30 SEC AND OFF. ON AGAIN FOR 1 MIN AND SO ON. RETURNED BACK TO BASE. LIGHT OFF BEFORE LANDING. INVESTIGATION/ACTION NOSE LANDING GEAR DOOR CLOSED PROXIMITY SENSOR REPLACED IAW AMM 32-61-06. 2H72 4T4 TRTA13NM E00062EN 20031106001502003110600150SW 2003 11 6 CA031021012 120031010G65102060403459 HANGER ASSY BELL 206 206B 1181511SW ALLSN 250C 250C20 03013GL TAIL ROTOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING 1200 HR INSPECTION AFT OIL COOLER BEARING HANGER WAS FOUND TO BE CRACKED AT THE 1200 O'CLOCK POSITION. 1G71 3U3 U H2SW E4CE 20031106001512003110600151EA 2003 11 6 CA031022001 120031002G2760M633741 BALL JOINT CNDAIRCL601 CL6013A 8070802EA GE CF34 CF343A 30015NE SPOILER SEPARATED W O OTHER F FLT CONT AFFECTED APAPPROACH 1 CA (CAN) PRIOR TO TOUCHDOWN THE AIRCRAFT ROLLED TO THE RT. FLIGHT SPOILERS WERE SELECTED, BOTH EXTENDED AT FIRST THEN THE LT SPOILER SUDDENLY RETRACTED TO THE '0' POSITION AS A RESULT OF THIS THE AIRCRAFT IMMEDIATELY ROLLED TO THE RT. THE PILOT CORRECTED THE CONDITION BY TURNING THE CONTROL WHEEL TO THE LEFT. ON GROUND, MAINTENANCE INSPECTED THE SPOILER SYSTEM AND IT WAS NOTICED THAT THE BALL JOINT ON THE SPOILER CABLE HAD SEPARATED. 2L72 4F4 FRTA21EA E15NE 20031107000012003110700001NM 2003 11 7 CA031022002 120030723G32416007047 TRANSDUCER BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA WHEEL SPEED INOPERATIVE W O OTHER O OTHER LDLANDING 1 CA (CAN) WHEN LANDING THE BRAKES HAD ALMOST NO EFFECT, ONLY AT VERY SLOW SPEEDS DID THE BRAKES SEEM TO WORK A LITTLE AND ONLY WITH VERY HARD APPLICATION ON THE BRAKE PEDALS. RESULT WAS A VERY LONG LANDING, BUT WITH PLENTY TO SPARE. INVESTIGATION/ACTION, HYD SYSTEM NR 1 BLED IAW AMM 29-10-00. BRAKE TEST PERFORMED. THESE ACTIONS DID NOT SOLVE THE PROBLEM. THE PROBLEM HAVE RE-OCCURRED. THIS TIME BOTH HYD SYSTEM 1 AND 2 WERE BLED. ALL BRAKES BLED AND THEN TAXI AND BRAKE TEST PERFORMED W/O SUCCESS. DURING A MORE THOROUGH INSPECTION OF WHEEL SPEED TRANSDUCERS, A MECHANICAL RESISTANCE WAS NOTED ON WHEEL SPEED TRANSDUCERS POS 2,3 AND 4. WHEEL SPEED TRANSDUCERS REPLACED ACC AMM 32-46-11. 2H72 4T4 TRTA13NM E00062EN 20040107000742004010700074NM 2004 1 7 CA031022003 120031020G5313 STRINGER BOEING737 737201 1384454NM PWA JT8 JT8D9A 52048NE FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING TIE CLIP INSPECTION IAW SB 737-53-1085, FOUR CRACKS WERE FOUND ON STRINGER 10R AT STN 807, 827, 847, AND 867. ALL CRACKS WILL BE REPAIRED IAW SRM 53-10-3PG 15, FIG 2, ( SHEET 7). ACFT TIMES 56965.51. ACFT CYCLES 53441. 2L72 4F4 F A16WE E2EA 20031106001532003110600153EA 2003 11 6 CA031022004 120031011G32469543077 WHEEL 9543077 DHAV DHC6 DHC6300 2802606EA PWA PT6 PT6A27 52043EA RIM FAILED W O OTHER D INFLIGHT SEPARATION LDLANDING 1 CA 74196 (CAN) ON THE LANDING ROLL, A BANG WAS HEARD AND THEN THE AIRCRAFT LEANED AND TURNED TOTHE RIGHT A BIT. THE CO-PILOT OBSERVED THE RIGHT MAIN TIRE WAS FLAT. THE A/C WAS SHUT DOWN AND PASSENGERS AND CARGO WERE OFF-LOADED. A PIECE OF THE WHEEL RIM WAS FOUND 100 METERS BEHIND THE AIRCRAFT. MAINTENANCE WAS DISPATCHED AND THE AIRCRAFT REPAIRED AND RETURNED TO SERVICE. 1H72 3T4 TRTA9EA E4EA 20031106001562003110600156EU 2003 11 6 CA031022005 120030817G243523085024 BEARING PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL STARTER GEN FAILED W A UNSCHED LANDING O OTHER CRCRUISE 1 CA (CAN) FRONT BEARING FAILED IN FLIGHT AND PILOTS REPORTED VIBRATION/RUMBLE FROM ENGINE. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20031106001732003110600173CE 2003 11 6 CA031022006 120031021G552210061004217 COUNTERWEIGHT BEECH 1156100102 BEECH 100 100BEECH 1152916CE PWA PT6 PT6A28 EA LT ELEVATOR LOOSE W K NONE O OTHER ININSP/MAINT 1 CA 14478 (CAN) ON PRE-FLIGHT INSPECTION, THE LT ELEVATOR WAS MOVED AND A RATTLING NOISE WAS HEARD.FURTHER INSPECTION REVEALED THE INBOARD BALANCE WEIGHT, OUTBOARD BALANCE WEIGHT SUPPORT WAS LOOSE. THE THREE ATTACHING BOLTS PN AN174-6 WERE FOUND BACKEDOUT APPROX. 1/8 INCH. THE ELEVATOR SKIN HAD TO BE DE-RIVETED TO ACCESS THESE BOLTS. 1L72 3T4 T A14CE E4EA 20040126001112004012600111NM 2004 1 26 CA031022007 120031017G3233NAS759011 BUSHING DHAV DHC8 DHC8* NM PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE NLG MISSING W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) RELEASED IN-SERVICE ACTIVITY REPORT2003-09. AN ARTICLE IN THIS REPORT REFERENCED A SITUATION DURING MANUFACTURE OF SOME AC, BUSHING PN: NAS75-9-011 WAS OMITTED FROM ASSEMBLE PROCESS OF THE NOSE LANDING GEAR RETRACTION ACTUATOR INTO AIRCRAFT. ALL OF OUR FLEET AIRCRAFT WERE SUBJECTED TO INSPECTION IAW THE INFORMATION PROVIDED IN THE IN-SERVICE ACTIVITY REPORT AND AS A RESULT OF THE INSPECTIONS ONE OF OUR A/C WAS FOUND TO HAVE THE BUSHING, AS DESCRIBED, OMITTED DURING ASSEMBLE. DUE TO THE MISSING BUSHING SUPPORT BRACKET PN: 85310340-015 WAS FOUND TO BE DAMAGED. NO OTHER DAMAGE WAS IDENTIFIED IN THE WHEEL WELL. THE DAMAGED SUPPORT BRACKET WAS CHANGED ALONG WITH A NEW BUSHING AND ATTACH BOLT. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20031106001762003110600176CE 2003 11 6 CA031022008 120030925G554011564000035 HINGE BEECH 100 100BEECH 1152916CE PWA PT6 PT6A28 EA RUDDER LOOSE W K NONE O OTHER ININSP/MAINT 1 CA 14388 (CAN) DURING VERTICLE STAB. DE-ICE BOOT REPLACEMENT, IT WAS NOTED THAT THREE OF THE SIX JO-BOLT FASTENERS THAT ATTACH THE UPPER RUDDER HINGE BRACKET TO THE SPAR WERE LOOSE.THESE FASTENERS WERE REPLACED WITH NEW. 1L72 3T4 T A14CE E4EA 20031106001782003110600178EU 2003 11 6 CA031022009 120031021G27529787320003 DRIVE UNIT PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL TE FLAPS FAILED W O OTHER F FLT CONT AFFECTED LDLANDING 1 CA (CAN) FLAPS FAILED TO FULLY RETRACT AND FLAP WARNING LIGHTS CAME ON.FOUND THE FLAP POWER DRIVE UNIT HAD FAILED INTERNALLY AND WOULD NOT DRIVE THE FLAPS. PDU REPLACED AND FLAPS RIGGED AS PER THE MAINTENANCE MANUAL. FLAP SYSTEM OPERATED SERVICEABLE. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20031106001792003110600179SO 2003 11 6 CA031022010 120031003G5711 SPAR PIPER PA23 PA23250 7102308SO LYC O540 IO540C4B5 41532EA DRAG LINK CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) CRACKED AT BOLT HOLES AT SPAR ATTACHMENT. 1L72 3O3 O 1A10 1E4 20031107000082003110700008CE 2003 11 7 CA031022011 120031012G3233S24266 BEARING CESSNA177 177RG 2073709CE MLG BROKEN W O OTHER O OTHER APAPPROACH 1 CA (CAN) PILOT WAS COMING INTO LAND SELECTED GEAR DOWN. HEARD LOUD BANG FROM REAR OF A/C AND GOT NO GREEN DOWN LIGHT INDICATION. ABORTED APPROACH & TRIED SEVERAL TIMES TO GET GEAR DOWN, NO SUCCESS. PUT GEAR HANDLE DOWN & DID FLY-BY. TOWER REPORTED HE HAD NOSE GEAR DOWN BUT MAIN GEAR WAS PARTIALLY DOWN. PILOT ELECTED TO DO LANDING ON GRASS BESIDE RUNWAY. LANDED SUCESSFULLY LITTLE DAMAGE TO AIRCRAFT. NLG WAS DOWN & LOCKED. A/C LIFTED UP AND GEAR WAS LOCKED DOWN. AIRCRAFT WAS PUT ON JACKS AT HANGER. FLOOR WAS LIFTED & FOUND ROD END ATTACHING MLG ACTUATOR TO MLG LINKAGE BROKEN, PART HAD BROKEN OFF GOT UNDERNEATH LINKAGE &STOPPED GEAR FROM LOCKING DOWN. ROD END REPLACED & GEAR SWING COMPLETED WITH NO PROBLEMS. 1H71 3O A20CE 20031107000102003110700010 2003 11 7 CA031023001 420031022G22116229815704 CIRCUIT CARD CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE ACTUATOR MALFUNCTIONED W O OTHER F FLT CONT AFFECTED CRCRUISE 1 CA 111 (CAN) IN CRUISE THE RUDDER MOVED WITH NO INPUT CAUSING YAW. THE MOVEMENT WAS INTERMITTENT ALWAYS RETURNING TO NEUTRAL. REPLACED FCC CARD AND YAW DAMPER ACTUATOR, CHECKS SERVICABLE. 2L72 4F4 FRTA21EA E15NE 20040126000922004012600092NM 2004 1 26 CA031023002 120031022G27512061121 INDICATOR BOEING727 727223 1384074NM PWA JT8 JT8D15A 52051NE TE FLAPS STICKING W A UNSCHED LANDING F FLT CONT AFFECTED CLCLIMB 1 CA (CAN) ON CLIMB, RT OB FLAP STOPPED AT 3 DEGREES. A FLAP ASYMMETRY CONDITION OBSERVED. AIRCRAFT RETURNED TO BASE WITHOUT INCIDENT. OB FLAP INDICATOR REPLACED IAW MM 27-52-21 AND FUNCTIONALLY TESTED SERVICEABLE. NO FURTHER INCIDENT ON SUBSEQUENT FLIGHT. 2L73 4F4 F A3WE E2EA 20031107000112003110700011CE 2003 11 7 CA031023003 120031012G3233S24266 BEARING CESSNA177 177RG 2073709CE MLG ACTUATOR BROKEN W O OTHER O OTHER APAPPROACH 1 CA (CAN) ON APPROACH FOR LANDING PILOT SELECTED GEAR DOWN ANDHEARD A LOUD BANG FROM BEHIND HIM RECIEVING NO GREEN DOWN LIGHT THE PILOT ABORTED HIS LANDING. HE CIRCLED THE AIRPORT AND TRIED NUMEROUS TIMES TO GET HIS GEAR DOWN. FINALLY HE SELECTED GEAR DOWN AND DID A FLY BY OF THE TOWER. TOWER PERSONNEL SAW TOLD HIM THAT HIS NOSE GEAR WAS DOWN BUT HIS MAIN GEAR WAS JUST HANGING THERE. PILOT LANDED ON GRASS BESIDE RUNWAY AND LANDED SAFELY. THE NOSE GEAR WAS LOCKED DOWN BUT THE MAIN GEAR WAS NOT.THE FLOOR WAS LIFTED AND DISCOVERED THAT THE MAIN GEAR ACTUATOR ROD EN D THAT IS ATTACHED TO THE GEAR HAD BROKEN AND THE BROKEN PIECE HAD FALLEN INTO THE GEAR BELLCRANK AND JAMMED STOPPING THE GEAR FROM LOCKING DOWN CORRECTLY.1H71 3O A20CE 20040105001122004010500112NM 2004 1 5 CA031023005 120031020G3260464505 DOWNLOCK SENSOR BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA RT MLG FAILED W O OTHER N FALSE WARNING APAPPROACH 1 CA (CAN) WHEN SELECTING GEAR DOWN DURING APPROACH RIGHT MAIN LANDING INDICATED UNSAFE. GO-AROUND PERFORMED AND MALFUNCTION CHECKLIST CONSULTED AND PERFORMED FOR ALTERNATE GEAR EXTENSION. ALTERNATE GEAR INDICATION SHOWED 3 GREEN LIGHTS, BUT NORMAL LANDING GEAR INDICATION STILL SHOWED RIGHT MAIN GEAR UNSAFE. PASSENGERS SEATED AROUND PROPELLERS RESEATED FOR PAX COMFORT REASONS. NORMAL LANDING PERFORMED WITH FIRE AND RESCUE ON STANDBY.SAFETY PIN INSTALLED AFTER SHUTDOWN. PASSENGERS DEBRIEFED IN AIRCRAFT AND PAX OFFERED ADDITIONAL DEBRIEFING.R/H MLG DOWNLOCK SENSOR REPLACED. AIRCRAFT RETURNED TO SERVICE. 2H72 4T4 TRTA13NM E00062EN 20031107000122003110700012EU 2003 11 7 CA031023006 120031022G27529787320308 ACTUATOR PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL TE FLAP BINDING W K NONE O OTHER ININSP/MAINT 1 CA (CAN) WHILE EXTENDING THE FLAPS FOR LUBRICATING, A CHATTERING NOISE WAS HEARD, FOLLOWED BY A FLAP FAILURE. INVESTIGATION REVEALED THE L/H INBOARD AND RT OUTBOARD FLAP ACTUATORS TO BE EXTREMLY HOT AND BINDING. THE ACTUATORS WERE REPLACED AND RIGGED, AND THE AIRCRAFT RETURNED TO SERVICE. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20031107000132003110700013SW 2003 11 7 CA031023007 120031019G6510407040339101 DRIVE SHAFT BELL 407 407 1182206SW ALLSN 250C 250C47B GL TAIL ROTOR FAILED W A UNSCHED LANDING O OTHER CRCRUISE 1 CA (CAN) PILOT HAD TAKEN OFF. SHORTLY THEREAFTER HEARD A THUMP FROM THE REAR FOLLOWED BY VIBRATION. ON REACHING FINAL DESTINATION INSPECTION REVEALED NR 5 TR DRIVE SHAFT BEARING 407-040-339-101 FAILED.OVERHEAT EVIDENCE ON THE HANGAR AND DAMAGE SUSTAINED TO THE RELATED DRIVE SHAFT SEGEMENT AS A RESULT OF WOBBLING WITHIN THE HANGAR. 3 BALLS STILL IN THE BEARING RACE AND 6 LODGED IN THE TAIL ROTOR GEARBOX FAIRING. 1G71 3U3 UO H2SW E1GL 20031107000142003110700014NM 2003 11 7 CA031023008 120031010G29136617302 PUMP BOMBDRDHC8 DHC8402 NM PWC 150 PW150A EA HYD SYS LEAKING W H DEACTIVATE SYST/CIRCUITS KJ FLUID LOSS WARNING INDICATION DEDESCENT 1 CA (CAN) DURING DESCENT FLIGHT CREW REPORT LT HYRAULIC SYSTEM PRESSURE GOING DOWN AND CONFIRM HYD. LEAK COMMING FROM LT NACELLE. FLAP EXTENSION CUTOUT BUT VERY SLOW. A/C LANDED OK. LT ENGINE DRIVE HYDRAULIC PUMP FOUND LEAKING AT PUMP INTERFACE (SPLIT LINE). NEW PUMP INSTALLED, HYD SYSTEM FLUSHED AND RESERVOIR SERVICED, CASE DRAIN, PRESSURE AND RETURN FILTER INSPECTED AND REPLACED . A/C RETURN TO SERVICE. 2H72 4T4 TRTA13NM E00062EN 20031107000152003110700015EU 2003 11 7 CA031024001 120031022G5320 ATTACH FITTING AIRBUS330 A330243 3930330EU RROYCERB211 RB211TRENT77 NE MAINT LADDER CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) THE LT UPPER ATTACH PLATE OF THE MAINTENANCE LADDER, LOCATED IN THE AFT SECTIONOF THE AIRCRAFT, HAS FAILED (FATIGUE CRACK ) BRINGING THE RELEASED POST TO 0.87 5 INCH FROM THE RUDDER INPUT ROD. EVENTUAL FAILURE OF THE RT UPPER ATTACH PLATE COULD POSSIBLY BRING THE LADDER IN CONTACT WITH THE RUDDER INPUT ROD.AIBUS INDUSTRIE WAS ADVISED AND WILL PROVIDE A REPAIR SCHEME. 2L72 4F4 FRTA46NM E39NE 20031107000162003110700016NE 2003 11 7 CA031024002 220031023G7200 ENGINE AIRBUSA319 A319114 3930350NM CFMINTCFM56 CFM565A3 NE LEFT OVERSPEED W EA ENGINE SHUTDOWN UNSCHED LANDING WMJINADEQUATE Q C OVER TEMP WARNING INDICATION CLCLIMB 1 CA 19143 (CAN) WHILE CLIMBING OUT BETWEEN 10,000 AND 11,000 FT THERE WAS AN OVERSPEED ON THE LEFT ENGINE FOLLOWED BY EGT GOING OFF THE CLOCK. ENGINE SHUT DOWN AND RETURNED TO LAX. ENGINE CHANGE UNDERWAY. WILL AWAIT ENGINE REPORT WHEN RETURNED TO SHOP. 2L72 4F4 FRTA28NM E29NE 20031107000192003110700019 2003 11 7 CA031024003 420031022G34178220372154 ADC CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE COCKPIT MALFUNCTIONED W O OTHER N FALSE WARNING NRNOT REPORTED 1 CA (CAN) ON DEPARTURE AT 2000 FT THE SPEED BUG WENT FROM 200 KTS TO 40 KTS UN COMMANDED AT THE SAME TIME THE 'STALL FAIL MSG' ON FOR 30 SEC. PURGED NR 1 AND 2 PITOT LINES AND CHANGED ADC NR 1. 2L72 4F4 FRTA21EA E15NE 20031107000622003110700062SW 2003 11 7 CA031024004 120031023G7920GT331 OIL FILTER SWRNGNSA226 SA226TC 8780404SW GARRTTTPE331TPE33110UA 01514WP RT ENGINE DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING A SCHEDULED OIL SAMPLE ON THE RT ENGINE THE OIL FILTER REMOVED WAS NOTEDTO BE DAMAGED AT THE RADIUS OF THE MOUNTING FLANGE. THIS IS THE OIL FILTER THAT IS INCLUDED IN THE WEAR CHECK CANADA INC. P/N GT-331 OIL SAMPLE KITS. 2L72 4T4 TRTA8SW E4WE 20031107000632003110700063SW 2003 11 7 CA031024005 120031023G7920GT331 OIL FILTER SWRNGNSA226 SA226TC 8780404SW GARRTTTPE331TPE33110UA 01514WP RT ENGINE DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ON PILOT PREFLIGHT INSPECTION IT WAS DISCOVERED THE RT ENGINE OIL FILTER BYPASS WAS POPPED, THE OIL FILTER WAS REPLACED, AND OIL SAMPLE TAKEN. IT WAS NOTED THE THE REMOVED OIL FILTER WAS DAMAGED WITH MATERIAL MISSING FROM THE FLANGE. WE BELIEVE THE FILTER WAS PLUGGED FROM THE MISSING MATERIAL OF THE FLANGE AFTER ENTERING THE OIL PUMP. 2L72 4T4 TRTA8SW E4WE 20031107000642003110700064SW 2003 11 7 CA031024006 120031023G7920GT331 OIL FILTER SWRNGNSA226 SA226TC 8780404SW GARRTTTPE331TPE33110UA 01514WP LT ENGINE DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE OIL FILTER BYPASS PIN WAS FOUND POPPED ON THE LT ENGINE.THE OIL FILTER WAS REPLACED AND OIL SAMPLE TAKEN. DAMAGE TO THE REMOVED OIL SAMPLE WAS NOTED. THE MOUNTING FLANGE OF THE FILTER WAS MISSING FROM THE RADIUS INWARD. THE OIL FILTER IS INCLUDED IN THE WEAR CHECK CANADA INC. P/N GT-331 OIL SAMPLE KITS.THE FILTER WAS BELIEVED TO BE PLUGGED FROM THE MISSING MATERIAL OF THE OIL FILTER AFTER ENTERING THE OIL PUMP. 2L72 4T4 TRTA8SW E4WE 20031107000662003110700066NE 2003 11 7 CA031024007 220031021G731030607591 PUMP ISRAEL1125 ASTRASPX 4500205EU GARRTTTFE731TFE73140 29001NE FUEL SYSTEM LEAKING W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) ASTRA SPX SN 079 EXPERIENCED A STRIPPED FUEL LINE FITTING ON THE RT ENGINE MOTIVE FLOW PUMP INLET PORT. FOUND DURING THE ENGINEER'S MORNING POST-FLIGHT INSPECTION, 21 OCT 2003. THE AIRCRAFT EXPERIENCED HEAVY TURBULENCE THE PREVIOUS NIGHT,THOUGH THIS IS NOT CONSIDERED THE CAUSE OF THE FAILURE, IT MAY HAVE CONTRIBUTED TO THE FINALITY OF IT. FUEL PUMP REPLACED AND AIRCRAFT RETURNED TO SERVICE. 2L72 4F4 FRTA16NM E1NM 20031107000672003110700067NE 2003 11 7 CA031027001 220031024G7310EM4843 SHUTOFF VALVE PIAGIOP180 P180 6960204EU PWA PT6 PT6A66 52043NE FUEL SYSTEM LEAKING W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE ENGINE COWLS WERE REMOVED FOR 150 HOUR INSPECTION AND A SMALL AMOUNT OF FUEL WAS FOUND IN THE BOTTOM RIGHT COWL. WHEN THE RT FUEL BOOST PUMP WAS TURNED ON TO LOCATE THE SOURCE FUEL WAS OBSERVED DRIPPING AT ABOUT 1 DROP PER 2 SECONDSFROM THE RT ENGINE FIREWALL SHUTOFF VALVE. THE LEAK WAS FROM THE ACTUATOR END NOT THE MAIN BODY. FAA AD 2003-17-03 HAD BEEN COMLIED WITH THE VALVE HAD BEEN MODIFIED AS PER ELECTROMECH SB 484-3AB. 1H72 3O4 TRTA59EU E26NE 20031107000702003110700070NM 2003 11 7 CA031027002 120031022G5512 PANEL BOEING767 767333 1385301NM GE CF6 CF680C2B6F 30025NE HORIZONTAL STAB MISSING W K NONE O OTHER ININSP/MAINT 1 CA (CAN) RT HORIZONTAL STABILIZER LOWER TRAILING EDGE ACCESS PANELS AFT SUPPORT BEAMS MISSING 7 HORIZONTAL ATTACH BOLTS BASED ON THE CONDITION OF THE AREA IN WHICH THE DISCREPANCIES WERE FOUND AND THEFACT THAT THE ACFT WAS ON A M01 CHECK INDICATES THAT THE ACFT WAS RECEIVED FROM THE FACTORY IN THIS CONDITION. 2L72 4F4 FRTA1NM E13NE 20040126001142004012600114NM 2004 1 26 CA031027003 120031024G5330 SKIN BOEING737 737201 1384454NM PWA JT8 JT8D9A 52048NE FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) SMALL CRACK (APPROX..5000 INCH). FOUND IN OUTER SKIN AT STR.14L,BETWEEN BS 824 ANDBS828. CRACK REPAIRED IAW REV87,SRM 53-30-3 FIG48 DETAIL XIV SHEET12. 2L72 4F4 F A16WE E2EA 20031107000722003110700072CE 2003 11 7 CA031027004 120031009G6120 CONTROLLER BEECH 99 99 1154002CE PWA PT6 PT6A28 EA HARTZLHCB3T HCB3TN3 GL PROPELLER MALFUNCTIONED W C ABORTED TAKEOFF O OTHER TOTAKEOFF 1 CA (CAN) TAKE-OFF WAS REJECTED IN YXY DUE TO AUTO FEATHER FAILING TO ARM ON THE RIGHT SIDE A/C GROUND RUN TESTED-NORMAL-NO FAULT FOUND A/C RELEASED FOR RETURN TO SERVICE 1L72 3T4 T A14CE E4EA 6 CP15EA 20031126000722003112600072NM 2003 11 26 CA031027005 120031025G2910 MODULE BOEING737 737217 1384464NM PWA JT8 JT8D17 52049NE A-HYD SYS FAILED W O OTHER J WARNING INDICATION DEDESCENT 1 CA (CAN) ON DECENT NR1 A SYS LOW PRESSURE LIGHT ILLUMINATED. SHORTLY, NR 2 A SYS LOW PRESSURE LIGHT ILLUM. CREW ACCOMPLISHED QRH FOR LOSS OF SYS A. EMERGENCY DECLARED & LANDED. MAINT CHECKED SERVICEABLE HYD SYS RES STANDPIPE & PRESSURE. ENG RAN AND HYD PRESSURE SERVICEABLE AT 3000 PSI. MAINT SUSPECTED PRESSURE RELIEF VALVE IN A SYS PRESSURE MODULE TO BE AT FAULT. A SYS PRESSURE MODULE REPLACED AND GROUND RUNS SATISFACTORY. AC RELEASED FOR SERVICE. TO PERFORM A FULL INSP AND FUNCTION OF RESERVOIR AIR PRESSURE SYS TO ENSURE FAULT WAS NOT CAUSED BY CAVITATING PUMPS DUE TO HEAD PRESSURE LOSS. 2L72 4F4 F A16WE E2EA 20031107000732003110700073CE 2003 11 7 CA031027006 120031017G322151420025 DRAG BRACE CESSNA441 441 2076020CE NLG CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) WHEN COMPLYING WITH CESSNA SERVICE BULLETIN CQB91-9 FOUND CRACK AT RAM ATTACH LUG. REPLACED DRAG BRACE. 1L72 3T RTA28CE 20031107000852003110700085CE 2003 11 7 CA031027007 120031001G551104320016 RIB CESSNA150 150K 2071822CE CONT O200 O200A 17020SO HORIZONTAL STAB CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) WHEN REPLACING THE LT LEADING EDGE HORIZONTAL STABILIZER SKIN PN 0432001-16 DUE TO IT BEING DENTED. IT WAS FOUND THAT BOTH INBOARD NOSE RIB ASSEMBLIES WERE CRACKED. THEY WERE REPLACED WITH NEW FACTORY PART PN 0432001-6 RT AND PN 0432001-46 LT. 1H71 3O3 O 3A19 E252 20031107000862003110700086CE 2003 11 7 CA031027008 120031011G2731335240253 SHAFT BEECH 1900 1900C 1154161CE PWA PT6 PT6A65B 52043EA ELEVATOR DRIVE SHEARED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ELECTRIC TRIM (ELEVATOR) DRIVE SHAFT SHEARED. THIS CAUSED ONE CAPSTAND TO OPERATE AND THE OTHER TO MOVE FREELY ON ITS OWN. THIS MOVEMENT CAUSED THE BRIDAL CABLES TO UNWIND AND CREATE RESTRICTION. THE TRIM WAS RESTRICTED FROM GOING NOSE DOWN. MANUAL MOVEMENT OF THE TRIM WAS ALSO RESTRICTED. 2L72 4T4 TRTA24CE E4EA 20031107000872003110700087NM 2003 11 7 CA031028001 120031028G2720 ROD END BOEING767 767333 1385301NM GE CF6 CF680C2B6F 30025NE RUDDER CONTROL UNSAFETIED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) RT ELEVATOR LOST MOTION DEVICE TO ELEVATOR CONTROL ROD END AT LOST MOTION DEVICE NOT IN SAFETY. ROUTINE INSPECTION DURING A M01 CHECK FOUND THE ROD END WAS NOT IN SAFETY. LOCKWIRE COULD BE INSERTED THROUGH THE INSPECTION HOLE. THE WITNESS SEAL FROM THE FACTORY WAS ALSO INTACT. REF IPC 27-31-53-02 SHT 1 ITEM 40 & 45 AND AMM 27-31-00 SHT 3 FIG 3. AIRCRAT TOTAL TIME: 9,414HRS/1,352CYC 2L72 4F4 FRTA1NM E13NE 20031229001912003122900191 2003 12 29 CA031028002 420031011G3497S10711 TUBE CESSNA172 172RG 2072438CE LYC O360 O360F1A6 41514EA MCAULY2D34C B2D34C220 GL PITOT MELTED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING A ROUTINE INSPECTION OF THE AIRFRAME IT WAS FOUND THAT THE SECTION OF PITOT TUBE IN THE WING NEAR THE PITOT TUBE ASSEMBLY WAS FOUND MELTED. THE REASON FOR THIS CONDITION WAS DETERMINED TO BE INTERFERENCE ON THE TUBE BY THE WIRING FROM THE PITOT HEATER ELEMENT. THERE WAS NO PREVIOUS REPORT BY THE CREW INDICATING ANY RELATED SYSTEMS FAILURE HOWEVER AT THE TIME OF INSPECTION IT WAS DEFINITELY FOUND TO BE DEFECTIVE. THE LINE WAS REPLACED AND ROUTING VERIFIED AS NOT TO INTERFERE WITH WIRING AGAIN. AIRCRAFT TOTAL TIME WAS 11770. 1H71 3O3 O 3A17 E286 5 CP7EA 20031107000882003110700088CE 2003 11 7 CA031028003 120031028G32301158100283 PINION GEAR BEECH 100 100BEECH 1152916CE PWA PT6 PT6A28 EA MLG CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) DURING GEAR SWING LT HAND MAIN LANDING GEAR WAS SHUTTERING ON RETRACTION. REMOVED ACTUATOR AND REPLACED WITH OVERHAULED PART.TOOK ACTUATOR TO OVER HAUL FACILITY AND DISASSEMBLED AND DISCOVERED DEFECT. 1L72 3T4 T A14CE E4EA 20031107000892003110700089SO 2003 11 7 CA031028004 120031016G2424756055 VOLT REGULATOR PIPER PA28 PA28160 7102806SO LYC O320 O320D2A 41508EA FAILED W O OTHER H ELECT. POWER LOSS-50 PC CRCRUISE 1 CA (CAN) VOLTAGE REGULATOR FAILED AND ALSO CAUSED DAMAGE TO THE ALTERNATOR DIODES. THE ALTERNATOR DIODES WERE REPLACED, AND THE VOLTAGE REGULATOR REPLACED WITH A NEW VR200A UNIT. CHARGING SYSTEM TESTED OK. 1L71 3O3 O 2A13 E274 20031126001052003112600105EU 2003 11 26 CA031028005 120031026G5280 DOOR ISRAEL1125 ASTRASPX 4500205EU GARRTTTFE731TFE73140 29001NE LT MLG DETACHED W O OTHER D INFLIGHT SEPARATION DEDESCENT 1 CA (CAN) AT 30,000 FT. ON DESCENT AT 300KIAS A SHUDDER WAS FELT ON AIRCRAFT. ALL GEAR INDICATION WAS NORMAL. LANDING GEAR LOWERED FOR LANDING ALL GREEN LIGHTS NO RED LIGHT IN HANDLE. LANDED NORMALLY, AT CHALKSIT WAS OBSERVED LT OUTBOARD GEAR DOOR WAS SEPERATED FROM HINGE. 2L72 4F4 FRTA16NM E1NM 20031126001062003112600106CE 2003 11 26 CA031028006 120031027G3244178K431 TIRE LEAR 60 60LEAR 5170707CE PWA 305 PW305A 52128NE MLG SEPARATED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING PRE-FLIGHT INSPECTION BY CREW, THE CAPTAIN NOTICED NR 2 TIRE HAS THE THREAD SEPARATED FROM THE ASSY. THE WHEEL ASSY WAS REPLACED WITH A REPAIRED UNIT, AIRCRAFT RETURN TO SERVICE. 2L72 4F4 FRTA10CE E35NE 20031230001002003123000100NM 2003 12 30 CA031028007 120031021G5330 SKIN BOEING737 737201 1384454NM PWA JT8 JT8D9A 52048NE FUSELAGE DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) IAW MM-7200-03-00640 DATED OCT.21 03. FILLET SEAL WAS REMOVED AT THE LOWER EDGE OF THE LAP JOINTS AT STRINGERS S4,S10 AND S14, BOTH LT AND RT SIDE. CLOSE VISUAL INSPECTION CARRIED OUT AND SCRIBE MARKS FOUND ON S4,S10 ANDS14, BOTH LT AND RT SIDES. 2L72 4F4 F A16WE E2EA 20040126000802004012600080SO 2004 1 26 CA031028008 120031027G2822421136 PUMP PIPER PA31 PA31350 7103110SO FUEL BOOST LEAKING W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) DURING THE WALK AROUND THE PILOT NOTICED FUEL LEAKING FROM ONE OF THE PANELS UNDER THE AIRCRAFT. MAINTENANCE WAS NOTIFIED AND INVESTIGATION REVEALED THAT THE ELECTRIC FUEL BOOST PUMP WAS LEAKING FROM THE PRESSURE REGULATOR ADJUSTMENT. PUMP WAS REPLACE WITH A SERVICEABLE UNIT AND THE AIRCRAFT RETURNED TO SERVICE. THE PUMP IN QUESTION HAD RECENTLY BEEN OVERHAULED AND HAD ONLY BEEN IN OPERATION FOR 28.1 HOURS. 1L72 3O A20SO 20031107000902003110700090EA 2003 11 7 CA031028009 220030702G7200 COMPRESSOR BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA ENGINE FAILED W EFA ENGINE SHUTDOWN ACTIVATE FIRE EXT. UNSCHED LANDING XAJENGINE FLAMEOUT FLAME/FIRE WARNING INDICATION CRCRUISE 1 CA (CAN) ENGINE FAILURE, ENGINE FIRE, FIRE EXTINGUISHED. - AIRCRAFT LANDED SINGLE ENGINE. 1G71 4U4 U H4SW E22EA 20031107000912003110700091EA 2003 11 7 CA031028010 220031015G8530 PISTON ROBSINR44 R44 7640120WP LYC O540 O540F1B5 41532EA ENGINE FAILED W A UNSCHED LANDING E VIBRATION/BUFFET CRCRUISE 1 CA (CAN) PILOT FELT A VIBRATION IN THE A/C. CARRIED OUT A PRECAUTIONARY LANDING, DURING WHICH HE NOTICED A LACK OF POWER. ON INSPECTION IT WAS DISCOVERD THAT NR 5 PISTON HAD FAILED. 1G71 3O3 O H11NM E295 20040106000302004010600030EA 2004 1 6 CA031029001 120031026G2910601R7514771 LINE CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE HYD SYSTEM LEAKING W O OTHER KJ FLUID LOSS WARNING INDICATION APAPPROACH 1 CA (CAN) DURING APPROACH TO EWR UNABLE TO LOWER LANDING GEAR. HAD HYD 3 LOW PRESSURE WARNING. HYD LEVEL 'O' MANUAL GEAR EXTENSION PERFORMED '3 GREEN' FOUND LEAK COMING FROM 3A PUMP PRESSURE HOSE. PUMP AND HOSE REPLACED, LEAK AND OPERATION NORMAL. 2L72 4F4 FRTA21EA E15NE 20031107001182003110700118EA 2003 11 7 CA031029002 120031028G79203033315 OIL FILTER DHAV DHC6 DHC6300 2802606EA PWA PT6 PT6A27 52043EA EXTERNAL DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING A ROUTINE OIL FILTER CHANGE, THE NEW FILTER WAS VISUALLY INSPECTED AND FOUND TO HAVE 2 WIRE THREADS PROTRUDING FROM THE FILTER. THE ORIGINAL FILTERS WERE VISUALLY INSPECTED AND WERE FOUND TO BEIN THE SAME CONDITION. REFERENCING OUR STORES, WE ESTABLISHED THAT THE SUSPECT FILTERS WERE PURCHASED FROM PACE ENTERPRISES IN MARCH 2003 AND WERE FROM BATCH NR 0552. ALL FILTERS PURCHASED FROM THAT P ERIOD, REGARDLESS OF BATCH NR WERE VISUALLY INSPECTED, EITHER FROM STOCK ORFROM AIRCRAFT AND IT WAS FOUND THAT THE ABNORMALITY WAS LIMITED TO THOSE FROM BATCH NR 0552. THE DISTRIBUTOR WAS INFORMED AND THE SUSPECT PARTS RETURNED. 1H72 3T4 TRTA9EA E4EA 20040106000312004010600031 2004 1 6 CA031029003 420031027G3420 BULB PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL ANNUNCIATOR BURNED OUT W O OTHER O OTHER CRCRUISE 1 CA (CAN) (HDG) ANNUNCIATOR LIGHT INOP. BULBS ARE NOT FIELD REPLACEABLE, THEREFORE A SERVICEABLE CONTROLLER WAS INSTALLED. THERE IS 2 OTHER SOURCES OF THE HDG ANNUNCIATOR IN THE EFIS SYSTEM. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20031110000022003111000002NM 2003 11 10 CA031029004 120031023G2761 CASE DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE ACTUATOR CRACKED W O OTHER FKJFLT CONT AFFECTED FLUID LOSS WARNING INDICATION LDLANDING 1 CA 3151531515 0965 (CAN) LT NR 1 OUTBOARD SPOILER WOULD NOT DEPLOY ON TOUCH DOWN. NR 1 OUTBOARD ACTUATOR CASING FOUND CRACKED. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20031110000032003111000003WP 2003 11 10 CA031029005 120031029G5311C0201 FRAME ROBSINR44 R44 7640120WP LYC O540 O540F1B5 41532EA FUSELAGE WORN W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) CLAMP FROM MR GEARBOX COOLING HOSE FOUND WEARING INTO FRAME. WORN ALMOST COMPLETELY THROUGH FRAME. 1G71 3O3 O H11NM E295 20040106000712004010600071CE 2004 1 6 CA031029006 120031022G2820050042355 LINE CESSNA172 172P 2072436CE LYC O320 O320D2J 41508EA MCAULY1C160 1C160DTM GL FUEL SYSTEM WORN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING ROUTINE INSP, TECH WAS FOCUSED ON STEERING ARM INSTALLATION AND NOTICED THAT RT STEERING ARM WAS CHAFING ON FUEL LINE. SECTION OF FUEL LINE AFFECTED RUNS FROM UNION FITTING NEAR FUEL SELECTOR TO FUEL STRAINER BOWL LOCATED AT FIREWALL. REASON FOR THE CHAFING CONDITION WAS APPARENTLY DUE TO THE FUEL LINE INSTALLATION HAVING BEEN DISTORTED. THE CONTOUR OF THE LINE WAS ORIGINALLY DESIGNED TO AVOID ANY CONTACT WITH OTHER MOVING PARTS. SOMEHOW THAT CONTOUR HAD BEEN COMPROMISED ALLOWING CONTACT FROM THE MOVING STEERING ARM. THE EXTENT OF WEAR HAD PROGRESSED TO THE POINT OF ABOUT 90 PERCENT THROUGH THE WALL THICKNESS OF THE LINE. THE LINE WAS REMOVED FROM SERVICE AND REPLACED WITH A NEW PART. 1H71 3O3 ONT3A12 E274 5 NP910 20040126000712004012600071SW 2004 1 26 CA031029007 120031029G712010048512 PIN BELL BELL 206 206L 1181522SW ALLSN 250C 250C20B 03013GL ENGINE MOUNT CORRODED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING SPECIAL INSPECTION OF ENGINE MOUNT LEGS, INTRODUCED ON OPERATOR'S A/C, LOWER PINS P/N 100-048-5-12 WERE FOUND TO BE SEVERELY CORRODED. ONE OF THE PINS, SEE ATTACHED PHOTO WAS SEVERED. VARYING DEGREE OF CORROSION WAS ALSO OBSERVED ON ID OF THE MOUNT LEGS. SOME LEGS WERE REJECTED UPON PRELIMINARY INSPECTION. OPERATOR HAS INTRODUCED MANDATORY 3-YEAR CORROSION INSPECTION OF ENGINE MOUNT LEGS, REQUIRING REMOVAL OF PINS AND DISASSEMBLY OF LEGS. 1G71 3U3 U H2SW E4CE 20040126000722004012600072CE 2004 1 26 CA031029008 120031029G243051538001A GCU BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3I NE DC SYSTEM FAILED W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA 1118211182 (CAN) A/C DEPARTED AND SHORTLY AFTER TAKEOFF THE LT GENERATOR FELL OFFLINE. IT COULD NOT BE RESET SO THE CREW ELECTED TO RETURN TO THE AIRPORT. THRU TROUBLESHOOTING BY MAINTENANCE THE LT GENERATOR CONTROL UNIT WAS FOUND AT FAULT. IT WAS REPLACED AND TESTED SERVICABLE. ON A SIDE NOTE BOTH LT AND RT FUEL FLOW INDICATORS WHERE DAMAGED WHEN THE GCU FAILED. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20031110000042003111000004NM 2003 11 10 CA031030001 120031028G213310604954 OUTFLOW VALVE BOEING727 727225 1384077NM PWA JT8 JT8D15 52051NE CABIN PRESSURE FAILED W GA O2 MASK DEPLOYED UNSCHED LANDING W INADEQUATE Q C CLCLIMB 1 CA (CAN) A/C EXPERIENCED LOSS OF PRESSURIZATION ON CLIMB OUT. CREW DISCOVERED RT PACK INOPERATIVE. A/C LANDED AT COMPANY MAINTENANCE FACILITY WHERE THE RT FWD PACK VALVE WAS REPLACED AND A/C RETURNED TO SERVICE. 2L73 4F4 F A3WE E2EA 20040106000992004010600099SO 2004 1 6 CA031030002 220031029G741410400615B CONDENSER CIRRUSSR SR22 2130001GL CONT O550 IO550N 17042SO HARTZLHCJ3Y PHCJ3YF1 GL MAGNETO FAILED W K NONE L NO TEST ININSP/MAINT 1 CA (CAN) FOUND MAGNETO IS ALIVE WITH MAGNETO SWITCHED OFF. CONDENSOR IS OPEN CIRCUIT INTERNALLY. 1L71 3O3 ONTA00009CHE3SO 5 CP36EA 20040106001012004010600101GL 2004 1 6 CA031030003 120031029G7120AN817A BOLT CIRRUSSR SR20 05628AJGL CONT O360 IO360ES SO HARTZLHCJ2Y BHCJ2YF1 GL ENGINE MOUNT LOOSE W K NONE O OTHER ININSP/MAINT 1 CA (CAN) BOTTOM TWO ENGINE MOUNT TO FIREWALL ATTACHMENT BOLTS FOUND WITH TORQUE MARKING MISALIGNED. BOLTS REQUIRED ONE TURN IN ORDER TO BRING TORQUE BACK TO SPEC. 1L71 3O3 ONTA00009CHE1CE 5 CP37EA 20031110000052003111000005NM 2003 11 10 CA031030004 120031023G2750734382D TORQUE TUBE DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE TE FLAP GROOVED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING MAINTENANCE IT WAS DISCOVERED THAT THE R/H WING FLAP PRIMARY TORQUE TUBE AT APPROX. WING STN YW 325.00 WAS DEEPLY GROOVED. GROOVE WAS AT ABOUT THE MIDLENGTH OF THE TUBE AROUND ITS CIRCUMFERENCE. TUBE HAD BEEN WEARING ON A NEARBY ELECTRICAL BUNDLE 'P' CLAMP.TORQUE TUBE REPLACED AND CLAMP ADJUSTED TO GIVE ADEQUATE CLEARANCE. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040120000232004012000023EA 2004 1 20 CA031030005 120030913G2910DSC252B4012 LINE DHAV DHC8 DHC8311 1386006EA PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE DRAG STRUT FAILED W L ABORTED APPROACH KJ FLUID LOSS WARNING INDICATION APAPPROACH 1 CA (CAN) DURING ILS APPROACH, CAPT CALLED FOR LANDING GEAR TO BE LOWERED 'NR 2 HYD PRESSCAUTION LIGHT CAME ON FOLLOWED BY LANDING GEAR UNSAFE LIGHTS. APPROACH DISCONTI NUED, A/C ORBITED UNDER RADAR CONTROL TO EAST OF AIRFIELD. EMERGENCY CHECK LISTCONSULTED. NR 2 HYD. FAILURE DRILL CARRIED OUT AND LANDING GEAR LOWERED USINGSTANDBY SYSTEM. PAN PAN DECLARED. NR 2 HYD QUANTITY FELL TO ZERO (EXPECTED). PASS ENGERS KEPT INFORMED THROUGH OUT EVENT. A/C LANDED WITHOUT FURTHER INCIDENT. INVESTIGATION FOUND THAT THE CAUSE WAS THE NLG DRAG STRUT ACTUATOR FLEXI PIPE FRACTURING P/NO DSC252B4-0124 AND THE PTU PRESSURE PIPE P/N 829400010-159 AND SUBSEQUENTLY FAILING, POSSIBLY DUE TO LOAD AND THE INFREQUENT USE OF THE PX PIPE. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040126000892004012600089EA 2004 1 26 CA031030006 120031024G5610601R330334 WINDOW CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE COCKPIT CRACKED W A UNSCHED LANDING O OTHER CRCRUISE 1 CA (CAN) FOS SIDE WINDOW CRACKED WHILE IN CRUISE. EMERGENCY DECLARED, AIRCRAFT RETURNED AND LANDED WITHOUT FURTHER INCIDENT. AIRCRAFT RETURNED TO SERVICE FOLLOWING THE WINDOW REPLACEMENT. (SEE ALSO: US NR 2003121000202) 2L72 4F4 FRTA21EA E15NE 20040106001032004010600103NE 2004 1 6 CA031030007 220031025G7200 ENGINE CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE LEFT FAILED W E ENGINE SHUTDOWN YJ ENGINE STOPPAGE WARNING INDICATION CRCRUISE 1 CA (CAN) LOUD BANG AT 3000 FT AND LT ENGINE SHUT DOWN. AIRCRAFT LANDED IN TLH WITHOUT FURTHER INCIDENT. LT ENGINE REPLACED, AIRCRAFT RETURNED TO SERVICE. 2L72 4F4 FRTA21EA E15NE 20040106001732004010600173EU 2004 1 6 CA031031001 120031030G5610 SEAL PPG PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL WINDSCREEN DELAMINATED W K NONE L NO TEST ININSP/MAINT 1 CA 98355H5908 (CAN) DURING THE PRESSURIZATION SYSTEM TEST AIR LEAKAGE WAS NOTED COMING FROM AROUND THE MAIN WINDSCREENS. UPON REMOVAL OF THE WINDSCREEN THE SEAL THAT IS ATTACHED TO THE WINDSCREEN WAS FOUND TO BE DELAMINATING. NO FIELD REPAIR IS AVAILABLE SO THE WINDSCREEN WAS REPLACED WITH A NEW UNIT. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040107000162004010700016EU 2004 1 7 CA031031002 120031030G5610 SEAL PPG PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL WINDSCREEN DELAMINATED W K NONE L NO TEST ININSP/MAINT 1 CA 98329H3985 (CAN) DURING THE PRESSURIZATION SYSTEM TEST IT WAS NOTED THERE WAS AIR LEAKAGE AROUND THE MAIN WINDSCREENS. UPON REMOVAL OF THE WINDSCREEN THE SEAL ATTACHED TO THE WINDSCREEN WAS FOUND TO BE DELAMINATING. THERE IS NO FIELD REPAIR AVAILABLE SO THEWINDSCREEN WAS REPLACED WITH A NEW UNIT. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040121000012004012100001GL 2004 1 21 CA031031003 120031024G3240AE2463509E02 LINE DHAV DH82 DH82 2801000GL PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE BRAKE RUPTURED W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) AFTER ENGINE SHUT DOWN AND CHECKS COMPLETED, ATC CALLED TO SAY THAT SMOKE WAS COMING FROM LT BRAKES AND THAT THE FIRE SERVICE WAS ON ITS WAY. F.D. AND PILOT VERIFIED HYDRAULIC FLUID ON THE GROUND IN THE WHEELS AREA. THE SMOKE DECLARED BY ATC WAS MORE LIKE A FINE STREAM OR VAPOR, CLEARLY CAUSED BY HYDRAULIC FLUID SPRAYING FROM A RUPTURED PIPE OVER THE WARM BRAKES. INVESTIGATION BY ENGINEERS FOUND FLEXIBLE HYDRAULIC PIPE PN AE2463509E0230 SN 71867 TO NR 1 BRAKE UNIT WAS LEAKING, IPC REFERENCE 32-10-20 FIG 32 ITEM 20. 1Q71 3I4 T EXPA1Q71E20NE 6 CP7NE 20040126000672004012600067NM 2004 1 26 CA031031004 120031028G2497AA4N103 CONTACTOR DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE STARTER GEN STUCK W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ON SHUTDOWN OF THE RT ENGINE, THE CREW NOTICED THE RT PROPELLER CONTINUED TO ROTATE. THE CREW TURNED OFF ALL POWER ON THE AIRCRAFT AND THE PROPELLER STOPED ROTATING. INVESTIGATION SHOWED CONTACTOR 2431-K2(P/N A-A4N103) WAS STUCK IN THE CLOSED POSITION. CONTACTOR WAS REPLACED AND AIRCRAFT RETURNED TO SERVICE. (STARTER/GENERATOR ALSO REPLACED AS PRECAUTION) 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040126000682004012600068CE 2004 1 26 CA031031005 120031029G5524043200171 HINGE CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA RT ELEVATOR WORN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) RT ELEVATOR OB HINGE ASSY BOLT HOLE IS WORN AND OBLONGED IN SHAPE AS WELL AS THE HINGES INNER FACES ARE GROOVED FROM BUSHING. NOTE THAT BUSHING IS NOT SE IZED IN THE BEARING ASSY ON THE ADJOINING HORIZONTAL STAB HINGE. 1H71 3O3 ONT3A19 E223 20040126000692004012600069GL 2004 1 26 CA031031006 220030612G732323065123 GOVERNOR BELL 206 206L 1181522SW ALLSN 250C 250C20R2 GL DROOP COMP FAILED W O OTHER W INADEQUATE Q C CRCRUISE 1 CA (CAN) NR DROOPING TO 97 WITHOUT RECOVERY UNDER POWER AND OVER SPEEDING TO 107 WHEN POWER REDUCED. 1G71 3U3 U H2SW E4CE 20040107000342004010700034WP 2004 1 7 CA031031007 120030606G6210 PIN DOUG HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL M/R BLADE FAILED W K NONE O OTHER ININSP/MAINT 1 CA 0098849059 (CAN) ON DI FOUND PIN .1250 OF AN INCH ABOVE LEAD/LAG LINK WHILE PREPARING TO INSTALL PIN INTO LEAD/LAG LINK. UPON UNLATCHING OF CLIP OFF BOTTOM PORTION OF PIN, LOWER PORTION OF PIN WAS FOUND SHEARED OFF ABOUT .7500 INCH FROM BOTTOM. REMOVAL OF PIN REVEALED POSSIBLE CRACK STARTING OFF THREADED PORTION OF PIN. 1G71 3U3 U H3WE E4CE 20040107000352004010700035EU 2004 1 7 CA031031008 120030605G6730 BEARING SNIAS 350 AS350B 8680801EU TMECA ARRIELARRIEL1B 6OO30NE ROTOR SERVO LOOSE W K NONE O OTHER ININSP/MAINT 1 CA DN124 (CAN) ON THE DAILY INSPECTION, THE BEARING WAS FOUND LOOSE IN THE HOUSING( MOVEMENT AXIALLY ) BECAUSE OF STAKING FAILURE. FURTHERMORE, WITH THE FREEDOM OF THE BEARING TO MOVE AXIALLY PLUS THE RADIAL STRESSES IMPOSED, THE SLEEVE BETWEEN THE BEARING OUTER RACE AND ITS HOUSING STARTED TO BREAK UP. 1G71 3U3 U H9EU E19EU 20040107000362004010700036EU 2004 1 7 CA031031009 120030613G7170 DRAIN VALVE SNIAS 350 AS350B 8680801EU TMECA ARRIELARRIEL1B 6OO30NE ENGINE FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ON ENGINE SHUTDOWN, A SINGLE POP SOUND IS HEARD AT THE EXHAUST AREA. FURTHER INVESTIGATION DETERMINE THE DRAIN / OVERSPEED VALVE TO BE THE CAUSE. A SMALL JET BENEATH THE T-FITTING WAS FOUND TO BE MISSING. THE DRAIN/ OVERSPEED VALVE HAD JUST BEEN REPLACED DUE TO 10 YEAR CALENDAR LIFE 1G71 3U3 U H9EU E19EU 20040107000442004010700044CE 2004 1 7 CA031031010 120031030G541010191004911 DUCT BEECH 200 B200 1152922CE PWA PT6 PT6A42 52043NE HARTZLHCB3T HCB3TN3 GL NACELLE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DISCOVERED COWL DUCT CRACKING DURING ROUTINE MAINTENANCE INSPECTION. MFG HAS PREVIOUSLY IDENTIFIED THIS PROBLEM AND DESIGNED A FIELD REPAIR TO RECTIFY IT. INCORPORATED FIELD REPAIR FR-KA-00038 TO BOTH ENGINE COWLS. DUCT PN 101-910049-12 ALSO AFFECTED IN SAME MANNER. SIMILAR REPAIRS CONDUCTED TO ALL OTHER COMPANY B200 COWLINGS. 1L72 4T4 T A24CE E4EA 6 CP15EA 20040107000452004010700045EA 2004 1 7 CA031103001 120031030G5297601R5800511 WIRE HARNESS CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE CARGO DOOR PINCHED W A UNSCHED LANDING N FALSE WARNING CLCLIMB 1 CA (CAN) CLIMBING THRU 10,000 FT CREW RECEIVED PASS AND SERVICE DOOR FLASHING RED. DURING APPROACH CARGO INDICATION AS WELL. AT GATE FOUND CB DOOR INDICATOR POPPED. ON INVESTIGATION FOUND SERVICE DOOR HARNESS PINCHED IN DOOR. F.M.R. ISSUED TO CHECK OTHER A/C IN FLEET FOR CORRECT INSTALATION. 2L72 4F4 FRTA21EA E15NE 20040121000022004012100002NM 2004 1 21 CA031103002 120031030G212032167441 ISOLATION VALVE BOEING727 727260 NM PWA JT8 JT8D17 52049NE AIR DISTRIBUTIONFAILED W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) DURING CLIMB, IT WAS OBSERVED THAT CABIN PRESSURE WAS NOT CONSISTENT WITH FLIGHT LEVEL. AIRCRAFT RETURNED TO BASE WITHOUT INCIDENT. AIRCRAFT WAS DISPATCHED UND ER MEL 21-01-01 WITH RT PACK INOP FLYING AT AN ALTITUDE OF FL 25,000 FT. THE ISOLATION VALVE WAS HARD FAULTED. NO FURTHER INCIDENT DURING SUBSEQUENT FLIGHT. 2L73 4F4 FRTA3WE E2EA 20040126000732004012600073NM 2004 1 26 CA031103003 120031101G2120AP500219101 DUCT BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU CABIN AIR DAMAGED W B EMER. DESCENT W INADEQUATE Q C CRCRUISE 1 CA (CAN) AN OPERATOR EXPERIENCED A RAPID DECOMPRESSION AT 22000FT, CAUSING AN EMERGENCY DESCENT WITH AT LEAST ONE PASSENGER THAT LOST CONSCIOUSNESS. MAINTENANCE FOUND A BLOWN DUCT IN THE ECS COMPARTMENT P/N AP500219-101 THE DUCT IS DAMAGED AND WILL REQUIRE REPLACEMENT. OPERATOR STATED THAT THE DUCT BLEW AT THE SEAM (GLUED EDGES). REF. IPC 21-22-16-01-065. ALSO THE FIRST TWO OVERHEAD BINS ON THE RT SIDE ALSO RECEIVED COSMETIC DAMAGE, THE LAMINATE DEBONDED FROM THE BIN. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20040126000742004012600074SO 2004 1 26 CA031103004 220031031G8530654286 EXHAUST VALVE CESSNA206 U206G 2073356CE CONT O550 IO550F 17042SO MCAULYD3A34 D3A34C402 GL ENGINE BROKEN W A UNSCHED LANDING ER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CRCRUISE 1 CA (CAN) THE FLIGHT CREW REPORTED A MINOR ENGINE VIBRATION AND HIGH NR 2 CYLINDER EGT AS WELL AS ERRATIC CHT INDICATIONS. EXAMINATION FOUND THAT DUE TO FAULTY INFORMATION FROM THE MULTI PROBE SYSTEM THE OBSERVED INFORMATION ACTUALLY REFLECTED NR 6 CYLINDER OPERATION. NR 6 CYLINDER WAS REMOVED AND THE EXHAUST VALVE WAS FOUND BROKEN IN THE SEAT AREA. THE ASSEMBLY WAS REPLACED AND THE AIRCRAFT WAS RETURNED TO SERVICE. 1H71 3O3 O A4CE E3SO 5 CP47GL 20040126000932004012600093EA 2004 1 26 CA031103005 220031007G7200 ENGINE PWA PT6 PT6A50 52043EA LIGHTNING STRIKEW O OTHER O OTHER NRNOT REPORTED 1 CA 27101 (CAN) AC WAS HIT BY LIGHTNING STRIKE. REVIEWED ENG ON GROUND AND RESIDUAL MAGNETISM WAS FOUND ON PROP SHAFT. IT WAS CONFIRMED THAT ENG DID SUFFER FROM LIGHTNING STRIKE, PARTS FOUND WITH HIGH MAGNETISM ON THEM. PRESENCE OF ARCING ON FRONT RED GB MAIN BEARINGS ARE TYPICAL RESULTS FROM LIGHTNING STIKES. ONE 1ST STG PLANET GEARS WAS FOUND WITH SPALLING ON ONE GEAR TOOTH. DETERMINED THAT THIS DAMAGE DID NOT COME FROM LIGHTNING STRIKE. NO OTHER MATING GEAR WAS FOUND WITH MATCHING DAM. THAT WOULD BE PRESENT IF SPALLING FROM AN ELEC DISCHARGE ARC. DAMAGE INDICATES IMPACT ON TIP OF TOOTH CAUSING MATERIAL DISPLACEMENT TOWARDS SPALLED SIDE. DISPLACEMENT INCREASED SURFACE STRESS CAUSING SURFACE TO FRACTURE AND SPALL. 4 T E4EA 20040126001062004012600106SW 2004 1 26 CA031103006 120031028G6410206016201131 BLADE BELL 206 206B3 1181506SW ALLSN 250C 250C20B 03013GL TAIL ROTOR OVERSIZED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) CHAMFERS 44 DEG 30 INCHES - 45 DEG 30 INCHES (2 PLACES) X .395 - .415 DIMENSION ARE ACTUALLY OVERSIZE TO .450. BLADES CAN BE REWORKED BY RE-MACHINING THE CHAMFERS TO THE REQUIRED DIMENSION. THE CHAMFERS ARE LOCATED AT THE ROOT END OF THE BLADE WHERE IT MATES WITH THE PITCH HORN 206-011-809. 1G71 3U3 U H2SW E4CE 20040107000622004010700062EU 2004 1 7 CA031104001 120031025G2720NAS62038 BOLT SAAB 7255700511 SAAB SF340 SF340A 7850100EU GE CT7TP CT79B 30030NE RUDDER STOP BROKEN W O OTHER F FLT CONT AFFECTED CRCRUISE 1 CA (CAN) THE PILOT REPORTED A RUDDER TRAVEL PROBLEM AND TEMPORARY STIFFNESS AT END OF TRAVEL. AFTER INVESTIGATION FROM MAINTENANCE, FOUND LEFT RUDDER STOP PAD ATTACHING BOLT CAME LOOSE AND BROKE. AREA INSPECTED AND BOLT REPLACED. REFERENCE IPC 55-50-00-02 ITEM 535 2L72 4T4 TRTA52EU E8NE 20040315000252004031500025CE 2004 3 15 CA031104002 120031027G2842S33311 TRANSMITTER CESSNA172 172R 2072401CE LYC IO360 IO360L2A EA MCAULY1C235 1C235LFA GL FUEL QTY INCORRECT W K NONE O OTHER ININSP/MAINT 1 CA (CAN) UPON COMPLIANCE OF THE FUEL QTY INDICATORS PERFORMANCE TEST (ANNUAL ITEM), IT WAS NOTED THAT THE LT WING TRANSMITTER DID NOT GO QUITE TO ZERO. (INDICATED SLIGHTLY ABOVE THE '0' READING ON THE GAUGE) FURTHER INSPECTION REVEALED THAT THE TRANSMITTER ARM WAS RESTING ON A STRINGER INSIDE THE TANK. IT WAS DETERMINED THAT THE TRANSMITTER INSTALLED IN THE LT WING WAS THE CORRECT PART NUMBER FOR THE RT WING. INSTALLED THE CORRECT SENDING UNIT, SYSTEM FUNCTIONS NORMALLY. THIS AIRCRAFT WAS DELIVERED FROM THE FACTORY WITH THIS INSTALLATION. 1H71 3O3 ONT3A12 1E10 5 NP12EA 20040126000782004012600078SW 2004 1 26 CA031104003 120031104G5350407030609101 CASTING BELL 407 407 1182206SW FUSELAGE MISINSTALLED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ON DISASSEMBLY OF THE AIRCRAFT FOR REPAIR, THE PART WAS FOUND NOT TO BE ATTACHED TO IT'S MATING FAIRING AS REQUIRED. THE RIVETS WERE PULLED BETWEEN THE ATTACHING PARTS AND NOT THROUGH THE CASTING. 1G71 3U O H2SW 20040126000942004012600094NE 2004 1 26 CA031104004 220031101G7261208313801 GEARBOX BAC 146 146200A 1500266EU LYC ALF502ALF502R5 41580NE NR 4 ENGINE WORN W EA ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA LFO5567A (CAN) DURING CLIMB , RED MASTER WARNING , RED NR 4 OIL PX WARNING, NR 4 OIL PX GUAGE IN RED. CREW ELECTED TO SHUTDOWN NR 4 ENGINE. AIRCRAFT RETURNED TO DEPARTING AIRPORT FOR NORMAL LANDING. INSPECTION FOUND OIL PUMP DRIVE GEAR IN GEARBOX SPLINES WORN, ALONG WITH WEAR ON OIL PUMP SHAFT RESULTING IN OIL PUMP NOT BEING DRIVEN. NR 4 ENGINE REMOVED AND REPLACED WITH SERVICEABLE SPARE. 2H74 4F4 F A49EU E6NE 20040126001052004012600105EA 2004 1 26 CA031105001 120031028G5250CDSP10154 LOCK CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE COCKPIT DOOR BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ON GROUND CREW UNABLE TO OPEN FLIGHT DECK DOOR. DOOR UNHINGED TO ALLOW EXIT FROM C/P. A/C FERRIED BACK FOR REPAIRS. AFTER DISASSEMBLY AN INTERNAL PART WAS FOUND BROKEN. 2L72 4F4 FRTA21EA E15NE 20040107001132004010700113 2004 1 7 CA031105002 420031103G34257003974722 COMPUTER DHAV DHC8 DHC8301 1386003NM PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE COCKPIT SHORTED W A UNSCHED LANDING BJ SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CLCLIMB 1 CA (CAN) DURING CLIMB SMOKE APPEARED IN COCKPIT. SIMULTANEOUSLY, AUTOPILOT AURAL WARNING WAS HEARD. AUTOPILOT STAYED ENGAGED. FLIGHT CREW PUT SMOKE HOOD ON AND ABORTED FLIGHT. AIRCRAFT RETURNED TO BASE. EXHAUSTIVE INSPECTION OF ALL EQUIPMENT IN COCKPIT DID NOT REVEAL ANY VISUAL SIGNS OF FIRE. IT WAS NOTICED THAT THERE FLIGHT GUIDANCE COMPUTER HAD STRONG BURNT ODOR BUT HAD NO EXTERNAL OVERHEAT /FIRE DAMAGE. THE RT FLIGHT GUIDANCE COMPUTER WAS REPLACED. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040107001152004010700115WP 2004 1 7 CA031105003 220031103G7200 ENGINE SWRNGNSA226 SA226TC 8780404SW GARRTTTPE331TPE33110UA 01514WP LEFT SURGES W EA ENGINE SHUTDOWN UNSCHED LANDING WJ INADEQUATE Q C WARNING INDICATION CLCLIMB 1 CA (CAN) UPON DEPARTURE/CLIMB PHASE OF FLIGHT, LT ENGINE CHIP DETECTOR LIGHT CAME ON STEADY. FLIGHT CREW MONITORED GAUGES AND NOTICED LT OIL PRESSURE GAUGE HAD EXCEEDED RED LINE LIMIT. SHORTLYAFTER ENGINE POWER BEGAN TO SURGE. LT POWER LEVER WAS REDUCED IN SMALL INCREMENTS AND INTIALLY EASED SURGING. AFTER SHORT BREIFING TO PASSENGERS, ENGINE SURGING RETURNED AND WAS WORSENING, DECISION WAS THEN MADE TO SHUT-DOWN ENGINE. FLIGHT CREW DECIDED THAT THE MOST ADEQUATE PLACE TO LAND THE AIRCRAFT WAS ISLAND LAKE, MANITOBA. THE APPROACH AND LANDING WERE UNEVENTFU L. THE ENGINE WAS REPLACED BY MAINTENANCE AND BROUGHT BACK TO WINNIPEG FOR TEAR DOWN AND ANALYSIS. MORE INFORMATION TO FOLLOW ONCE TEAR DOWN IS COMPLETE. 2L72 4T4 TRTA8SW E4WE 20040126001152004012600115CE 2004 1 26 CA031105004 120031105G76033011543 LEVER BEECH 100 100BEECH 1152916CE PWA PT6 PT6A28 EA HARTZLHCB3T HCB3TN3 GL ENGINE CONROL CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) UPON INSPECTION OF THE REVERSING LEVER GUIDE PIN BRACKET FOR WEAR DURING AN ENGINE BUILD UP IT WAS NOTICED THAT THE BRACKET PLATE THAT THE GUIDE PIN IS WELDED TO WAS CRACKED. THE CRACK WAS ADJACENT TO THE PIN WELD AND ON THE FORWARD SIDE OF THE PLATE. TOTAL FAILURE OF THE PLATE WOULD CAUSE THE PIN TO DISLODGE ALLOWING THE BETA ARM TO ROTATE OUT OF THE PROPELLER REVERSING ARM SLIP RING. SEE PT6A-27/2 8 ILLUSTRATED PARTS MANUAL CHAPTER 76-10-00 FIGURE 2 ITEM 390 1L72 3T4 T A14CE E4EA 6 CP15EA 20031126000732003112600073SW 2003 11 26 CA031105005 120030922G6520427034851101 SUPPORT BELL 427 427 1182207SW PWC PW207 PW207D NE T/R GEARBOX CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) FOREIGN OPERATOR NOTICED, DURING WALK AROUND, A ROUTINE MAINTENANCE CRACK ON THE TAIL ROTOR GEAR BOX/VERTICAL FIN SUPPORT ASSEMBLY. PART HAD 310 HOURS SINCE NEW. PART HAS BEEN REMOVED AND SENT FOR INVESTIGATION. 1G71 3U3 U R00001RCE42NE 20031126000842003112600084NM 2003 11 26 CA031105006 120030728G6120697070212 BUSS BAR 697071234 BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU NR 6 BLADE SHORTED W O OTHER H ELECT. POWER LOSS-50 PC CRCRUISE 1 CA NA (CAN) DURING CRUISE THE AC GEN NR 2 CAUTION LIGHT CAME ON TOGETHER WITH (PROP DEICE) CAUTION LIGHT. GEN AND PROP DEICE RESET ACC. TO QRH. AFTER APPROX. 5-10 SEC. BOTH (AC GEN NR 1) AND (AC GEN NR 2) CAUTION LIGHTS CAME ON WITH ASSOCIATED BUS FAULT CAUTION LIGHTS. 2ND ATTEMPT TO RESET GEN NOT TRIED. DESCENT STARTED TO LEAVE ICING COND. AFTER QRH CHECKLIST COMPLETED. NORMAL LANDING WITHOUT AC PWR. INVESTIGATION/ACTION TROUBLESHOOTING IDENTIFIED THE FAULT TO BE BUSS BARS P/N 697070212 AND 697070213 ON BLADE NO 6. THE BUS BARS HAD APPARENTLY BEEN LOOSE AND IN CONTACT WITH EACH OTHER, THERE BY CAUSING A SHORT BETWEEN THE PHASES OF AC POWER. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20031126000852003112600085EU 2003 11 26 CA031106001 120031105G2752697511007 ACTUATOR AIRBUS330 A330342 EU RROYCERB211 RB211TRENT77 NE TE FLAP MALFUNCTIONED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ON APPROACH ECAM FLAP FAULT, FLAPS WOULD NOT EXTEND. CARRIED OUT FLAPLESS LANDING. WITH SLATS AT 2 FOUND WATER IN NR 2 RT FLAP INPUT GEARBOX ROTARY ACTUATOR. DRAINED ACTUATOR AND REPLACED FLUID, ALL CKS NORMAL. MPD TASK TO CHANGE FLUID IS CALLED FOR AT C4. A/C PRESENTLY 190 DAYS BEFORE C3 IS DUE. 1L72 4F4 FRTA46NM E39NE 20031126000872003112600087NM 2003 11 26 CA031106003 120031015G574020001201 ATTACH FITTING PIPER PA60 PA60600 7106001NM LYC O540 IO540K1J5 41532EA HARTZLHCC3Y HCC3YR2 NE WING CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING ANNUAL ISPECTION OF WING TO FUSELAGE ATTACH FITTINGS IAW MFG SB 600-136, THE LT AFT FITTING WAS FOUND TO BE CRACKED. ALL OTHER AIRCRAFT IN THE FLEET WERE INSPECTED WITH NO FURTHER DEFECTS NOTED. THE AIRCRAFT WILL BE REPAIRED PRIOR TO BEING RELEASED FOR SERVICE. 1M72 3O3 ORTA17WE 1E4 5 CP25EA 20031126000882003112600088NM 2003 11 26 CA031106004 120031106G273182700550001 CONTROL CABLE DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE HORIZONTAL STAB FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING THE HEAVY CHECK AT THE YHZ BASE THE FOLLOWING HAS BEEN DISCOVERED. THE ELEVATOR TRIM CHAINS IN THE HORIZONTAL STAB HAVE BEEN FOUND TO HAVE SEVERAL CRACKS IN THE LINKS. ONE OF THE CHAINS FELL APART DURING MAINTENANCE IN THE AREA. IPCREFERENCE 27-38-00 FIG 20 ITEM 170. THE CHAIN/CABLE ASSEMBLY HAS BEEN REPLACED. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20031230001012003123000101EA 2003 12 30 CA031106005 120031015G5711 SPAR CAP CNDAIRCL215 CL2151A10 1900320EA PWA R1340 CWASP 52016NE HAMSTD43E 43E60 NE LT WING CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING ACCOMPLISHMENT OF AD CF-92-26R1, THE ULTRASONIC INSPECTION WAS BEING COMPLETED IAW SB 215-A454. CRACKS WERE DETECTED ON THE LOWER RT AND LOWER LT SPAR CAPS. THE AIRCRAFT WILL BE REPAIRED IAW MFG REO PRIOR TO BEING TO RETURNED TO SERVICE. 2H72 4R3 RRTA14EA ATC14 6 CP871 20031230001022003123000102EA 2003 12 30 CA031106006 120031024G523085230448001 LINK DHAV DHC8 DHC8311 1386006EA PWA PW120 PW123 NE HAMSTD14SF 14SF15 NE CARGO DOOR BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING GROUND HANDLING WHILE CLOSING THE CARGO DOOR THE LINK ASSEMBLY BROKE CAUSING THE HANDLE FREE TO TURN. RAMP CREW WAS NOT ABLE TO LOCK THE DOOR USING THE HANDLE. THE LINK WAS FOUND BROKEN AT THE LOWER SECTION EYE END. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040105001032004010500103WP 2004 1 5 CA031106007 120031029G4920 CASE GARRTT DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE APU GEARBOX SHEARED W F ACTIVATE FIRE EXT. J WARNING INDICATION TXTAXI/GRND HDL 1 CA P3009 (CAN) APU FIRE WARNING DURING APU START (AUTO SHUTDOWN). MAINTENANCE FOUND THE APU GEARBOX CASE SHEARED, THE TURBINE PLENUM TWISTED AND TURBINE WHEEL DISK DISINTEGRATED. AWAITING REPORT FROM MFG. APU ASSEMBLY REPLACED. 2L72 4F4 FRTA6WE E9NE 20040105001142004010500114EA 2004 1 5 CA031106008 120031015G534021531033800 FITTING CNDAIRCL215 CL2151A10 1900320EA HAMSTD43E 43E60 NE FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING ACCOMPLISHMENT OF AD CF97-07R2,THE WING TO FUSELAGE FITTINGS WERE BEING INSPECTED IAW SB 215-A476. DURING THE INSPECTION THE RT FORWARD OUTBOARD ANGLE OF THE WING TO FUSELAGE FITTING WAS FOUND CRACKED. THE AIRCRAFT WILL BE REPAIRED IAW MFG REPAIR ENGINEERING ORDER PRIOR TO BEING RETURNED TO SERVICE. 2H72 4R RTA14EA 6 CP871 20040105001152004010500115NM 2004 1 5 CA031106009 120030803G243511521062 STARTER GEN BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ENGINE INOPERATIVE W O OTHER J WARNING INDICATION CLCLIMB 1 CA (CAN) STARTER GENERATOR FAILURE DURING CRUISE DC GEN NR 2 CAUTION LIGHT CAME ON. RESET ACCORDING TO QRH WITHOUT SUCCESS. AFTER 30 MINUTES, FLIGHT WHEN DESCEND WAS INITIATED AT A LOWER POWER SETTING RESET WAS PERFORMED WITH SUCCESS. OK FOR REST OF FLIGHT. INVESTIGATION/ACTION TROUBLESHOOTING SHOWED A FAULTY STARTER-GENERATOR WHICH WAS REPLACED. THE FAULT WAS CONFIRMED AT THE SHOP. 2H72 4T4 TRTA13NM E00062EN 20040105001182004010500118SW 2004 1 5 CA031106010 120031103G553041000885 CHANNEL GULSTM690TP 690A 0141722SW GARRTTTPE331TPE3315251K NM HARTZLHCB3T HCB3TN5 GL VERTICAL STAB CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING X-RAY INSPECTION OF THE VERTICAL STABILIZER A CRACK APPROXIMATELY .7500 INCH LONG WAS NOTED ON P/N 410008-85 CHANNEL LOCATED IN THE LOWER SECTION OF THE VERTICAL STABILIZER. THIS PART IS LOCATED IN THE AREA SUBJECT TO AD 95-13-02. THE CRACK IS RUNNING ALONG THE RT VERTICAL FLANGE OF THE CHANNEL AND STARTS AT THE CORNER RELIEF. THE AIRCRAFT HAD BEEN MODIFIED IAW SB 218 PT 2. THE AIRCRAFT WILL BE REPAIRED PRIOR TO RETURNING TO SERVICE. 1H72 3T4 T 2A4 E2WE 6 CP15EA 20040105001192004010500119 2004 1 5 CA031106011 420030818G2210C18112AA ACTUATOR BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA YAW DAMPER FAILED W C ABORTED TAKEOFF F FLT CONT AFFECTED TOTAKEOFF 1 CA (CAN) DURING TAKE OFF ROLL YAW DAMPER-DISENGAGED. TAKEOFF ABORTED AND TCC CONTACTED. THE PROBLEM WAS LOCALIZED TO THE YAW DAMPER ACTUATOR WHICH WAS REPLACED. THE FAULT WAS LATER CONFIRMED TO BETHE LINEAR POTENTIOMETER AT THE SHOP. 2H72 4T4 TRTA13NM E00062EN 20040105001202004010500120SW 2004 1 5 CA031106012 120031103G553041000885 CHANNEL GULSTM690TP 690A 0141722SW GARRTTTPE331TPE3315 01514WP HARTZLHCB3T HCB3TN5 GL VERTICAL STAB CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) WHILE COMPLETING A X-RAY INSPECTION ON THE VERTICAL STABILIZER, A CRACK WAS NOTED ON THE RT VERTICAL FLANGE OF THE CHANNEL. THE CRACK IS APPROXIMATELY .6250 INCH IN LENGTH. IT IS LOCATED IN THE AREA COVERED BY AD95-13-02. THE AIRCRAFT HAD BEEN MODIFIED IAW SB218 PT2.THE AIRCRAFT WILL BE REPAIRED PRIOR TO BEING RETURNED TO SERVICE. 1H72 3T4 T 2A4 E4WE 6 CP15EA 20040121000032004012100003SW 2004 1 21 CA031106013 120031103G553141000823 SPAR AEROCD GULSTM690TP 690A 0141722SW GARRTTTPE331TPE3315251K NM VERTICAL STAB CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING X-RAY INSPECTION OF THE VERTICAL STABILIZER, A CRACK WAS NOTED ON THE CENTER SPAR FLANGE LOCATED 2 FASTENERS UP FROM THE EXTERNAL DOUBLER APEX. THE CRACKIS APPROXIMATELY 5/8 - 3/4 INCH IN LENGTH AND RUNS 90 DEGREES TO THE FLANGE. A CRA CK APPROXIMATELY 1INCH IN LENGTH WAS DETECTED ON CHANNEL P/N 410008-85. THIS CRACK RUNS VERTICALLY UP THE RIGHT HAND FLANGE. THIS AREA IS COVERED BY AD 95-13-02. THE AIRCRAFT HAD BEEN MODIFIED IAW SB 208 PT2. 1H72 3T4 T 2A4 E2WE 20040121000042004012100004NM 2004 1 21 CA031107003 120030821G31504100S01806 TMU BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA COCKPIT FAILED W O OTHER S AFFECT SYSTEMS CRCRUISE 1 CA (CAN) MULTIPLE CAUTIONS, DURING CRUISE AT FL240 THE FOLLOWING CAUTIONS APPEARED AND STAYED ON DURING THE REST OF THE FLIGHT: PUSHER SYS FAIL, PITOT HEAT NR 2, ENG ADPT HEAT NR 2, DEICE TIMER. QRH CONSULTED AND MANUAL FLYING PERFORMED ACCORDINGLY. NORMAL LANDING COMPLETED. CONTACTOR K2 IN RT AC CONTACTOR BOX WAS REPLACED, BUT THE FAULT WAS STILL PRESENT ON NEXT FLT. THE PROBLEM WAS IDENTIFIED AS THE TIMER AND MONITOR UNIT (TMU) IN THE DE-ICING SYSTEM. 2H72 4T4 TRTA13NM E00062EN 20040106000722004010600072WP 2004 1 6 CA031107004 120031103G6210369A10045 ATTACH FITTING HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL M/R BLADE SHEARED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) BROKEN PIN WAS FOUND ON 100 HOUR INSPECTION. LOCATION WAS AT THE JUNCTION OF SHANK AND THREADS. 1G71 3U3 U H3WE E4CE 20040106000732004010600073SO 2004 1 6 CA031107005 220030911G8530 GUIDE CONT CESSNA305 305A 2074002CE CONT O470 O47011 17026SO MCAULY1A200 1A200FM GL INTAKE LOOSE W K NONE O OTHER ININSP/MAINT 1 CA 6931701 (CAN) OTHER CYLINDERS INSTALLED ON THIS ENGINE DID NOT HAVE THE INTAKE GUIDE SEALS INSTALLED. (SHORTER GUIDES REQUIRES SEALS, WHILE LONGER GUIDES DO NOT REQUIRE SEALS.) THE INTAKE SPRINGS WERE REMOVED TO MEASURE THE GUIDE TO SEE IF THE SEALS WERE REQUIRED FOR INSTALLATION. ONCE THE SPRINGS WERE REMOVED, IT WAS NOTED THAT THE GUIDE COULD ROCK FROM SIDE TO SIDE. THE CYLINDER IS BEING RETURNED TO FOR WARRANTY. THE CYLINDER WAS REPAIRED UNDER THEIR WO NR 69317-01. 1H71 3O3 O 5A5 E269 5 NP874 20040121000052004012100005SO 2004 1 21 CA031107006 220030911G8530UK GUIDE CONT CESSNA305 305A 2074002CE CONT O470 O47011 17026SO CYLINDER INTAKE LOOSE W K NONE O OTHER ININSP/MAINT 1 CA 6931701 (CAN) DURING INSPECTION, IT WAS NOTED THAT THE INTAKE GUIDES WERE LEAKING OIL.THE SPRINGS WERE REMOVED TO MEASURE THE GUIDE HEIGHTS.THERE ARE NOW SHORTER GUIDES THAT REQUIRE THE INSTALLATION OF A SEAL. SOME OF THESE SEALS WERE NOT INSTALLED ON A BATCH OF CYLINDERS.WE WERE GOING TO MEASURE THE GUIDE HEIGHTS TO SEE IF THE SEALS WERE MISSING.IT WAS AT THIS TIME IT WAS NOTED THAT THE GUIDE ON NR 6 CYLINDER WAS LOOSE. 1H71 3O3 O 5A5 E269 20040106000742004010600074 2004 1 6 CA031107007 420030823G3160C12432AA05 PROCESSOR BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU ELEVATOR FEEL FAILED W O OTHER O OTHER CRCRUISE 1 CA (CAN) MULTIPLE CAUTIONS, DURING CRUISE FL180 (ELEVATOR FEEL) CAUTION LIGHT ON. THEREAFTER (AVIONICS) AND (PROP DEICE) CAUTION LIGHT ON. ON ED IOP2 CAUTION LIGHT. QRH CONSULTED AND PRIORITY LANDING (STBY 1). PERFORMED. AFTER THIS OCCURRENCE THE NR 2 INPUT, OUTPUT PROCESSOR WAS REPLACED. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20040106000752004010600075SO 2004 1 6 CA031107008 220030911G8530 GUIDE CONT CESSNA305 305A 2074002CE CONT O470 O47011 17026SO MCAULY1A200 1A200FM GL INTAKE LOOSE W K NONE O OTHER ININSP/MAINT 1 CA 6931701 (CAN) DURING INSPECTION, IT WAS NOTED THAT THE INTAKE GUIDES WERE LEAKING OIL. THE SPRINGS WERE REMOVED TO MEASURE THE GUIDE HEIGHTS. THERE ARE NOW SHORTER GUIDES THAT REQUIRE THE INSTALLATION OF A SEAL. SOME OF THESE SEALS WERE NOT INSTALLED ON A BATCH OF CYLINDERS. WE WERE GOING TO MEASURE THE GUIDE HEIGHTS TO SEE IF THE SEALS WERE MISSING. IT WAS AT THIS TIME IT WAS NOTED THAT THE GUIDE ON NR 6 CYLINDER WAS LOOSE. THE CYLINDER WAS REMOVED AND SENT FOR WARRANTY CONSIDERATION. 1H71 3O3 O 5A5 E269 5 NP874 20040106000762004010600076NM 2004 1 6 CA031107009 120030920G242111522184 GENERATOR BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU NR 2 AC FAILED W C ABORTED TAKEOFF O OTHER TOTAKEOFF 1 CA (CAN) AC GENERATOR FAILURE, AC NR 2 GEN CAUTION LIGHT CAME ON FEW SECONDS AFTER TAKE OFF POWER SET FOR TAKE OFF. TAKE OFF ABORTED AND AIRCRAFT WAS TAXIED BACK. INVESTIGATION/ACTION TROUBLESHOOTING SHOWED THAT THE AC GENERATOR WAS FAILING. THE GENERATOR WAS REPLACED. NO FURTHER FAULT REPORTED. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20040106000812004010600081EA 2004 1 6 CA031107010 120031029G2910601R7528657 LINE CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE NR 2 HYD SYSTEM CRACKED W K NONE K FLUID LOSS NRNOT REPORTED 1 CA (CAN) NR 2 HYDRAULIC SYSTEM LEAKING. QUANITY READS ZERO. MAINTENANCE FOUND RESERVOIR FILL TUBE ASSEMBLY FOR NR 2 SYSTEM IN REAR EQUIPMENT BAY CRACKED ABOUT ONE INCH FROM FILL ADAPTER PORT. 2L72 4F4 FRTA21EA E15NE 20040106001072004010600107EA 2004 1 6 CA031107011 120031102G2913N6521123 PUMP CNDAIRCL600 CL6002D24 1390016EA GE CF34 CF343B1 NE HYD SYSTEM FAILED W EA ENGINE SHUTDOWN UNSCHED LANDING KMJFLUID LOSS OVER TEMP WARNING INDICATION CRCRUISE 1 CA (CAN) AFTER T/O, CREW NOTICED ENG NOISES WERE ROUGH. AUDIO CK AT AFT BLKHD IND RT ENG. NO ABNORMAL IND, AT 15,000 FT DURING PRESS CHECKS, HYD 2LO PRESS AMBER MSG POSTED ON AND OFF. ENG FLOW LINE WAS GREEN/AMBER ON AND OFF, 2800 PSI. QTY WAS NML, TEMP OF 47 DEG C, HYD NR 1 TEMP WAS AT 11 DEGREES C. THRUST WAS REDUCED TO IDLE ON RT ENG, HYD PRESS DROPPING TO 2600 PSI, TEMP INCREASING. CREW PERFORMED ENG SHUT DOWN, QTY DROPPED TO ZERO, ROUGH ENG NOISE DISAPPEARED. A/C LANDED W/O INCIDENT. HYD FLUID WAS LEAKING FROM BELLY NEAR AFT EQUIP BAY. FOUND PRES LINE FROM ENG DRIVEN PUMP WITH CRACK INSIDE ELBOW WHICH CAUSED IND AND DEPLETED SYS OF FLUID. INDICATES PUMP IS AT FAULT AND CAUSED VIB CRACKING LINE. 2L72 4F4 FRTA21EA E15NE 20040121000062004012100006 2004 1 21 CA031107012 420031103G2562ELT910 ELT PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL TAIL FAILED W K NONE L NO TEST ININSP/MAINT 1 CA (CAN) ELT TEST WAS PERFORMED. THE REMOTE SWITCH IN THE COCKPIT WAS USED TO TEST THE ELT FUNCTION. WHEN THE ELT WAS ACIVATED THEN TURNED OFF, THE ELT CONTINUED TO TRANSMIT. FLIGHT SERVICES WAS NOTIFIED AS TO THE PROBLEM. THE SWITCH ON THE ELT WAS TURNED OFF AND THE ELT CONTINUED TO TRANSMIT. THE ANT ENNA WAS DISCONNECTED TO LIMIT THE TRANSMISSION SIGNAL. THE ELT WAS REMOVED FROM THE AIRCRAFT AND TAKEN TO A LOCAL AVIONICS SHOP. THEY CONFIRMED THAT THE ELT WA S STILL TRANSMITTING. THE ELT WAS OPENED UP AND THE BATTERY WAS DISCONNECTED. ELT RECERTIFIED SEP. 05, 2003 BATTERY DUE AUG. 11, 2005 INSTALLED IN C-XX SEP.11, 2003 A/F HRS. AT INSTALL 2958.6 A/F HRS. AT FAILURE 3100.2 TOTAL TIME IN AIRCRAFT 141.6 HRS. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040217000972004021700097NM 2004 2 17 CA031107013 120031106G243523088002B STARTER GEN DHAV DHC8 DHC8301 1386003NM PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE NR 2 FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS TXTAXI/GRND HDL 1 CA 18380 (CAN) DUAL DC GENERATOR FAILURE, NR1 GENERATOR FOUND BURNED. NORMAL ENG START, BEFORE TAXI, COMPLETE ELECTRICAL FAILURE, QRH PROCEDURES UNSUCCESSFUL. ENGINES SHUT DOWN, DURING DISEMBARKATION OBSERVED WHITE SMOKE FROM NR1 ENGINE, FIRE BRIGADE ARRIVED, NO DANGER TO CREW OR PASSENGERS. FOUND NR1 DC STARTER GEN BURNED. NR1 STARTER GEN AND CONTACTOR 2431K1 REPLACED. GROUND RUN PERFORMED, NR2 DC GEN CAUTION LIGHT ON, NOT RESETABLE. NR2 STARTER GEN AND CONTACTOR 2431K2 REPLACED. NORMAL OPERATION, AIRCRAFT BACK IN SERVICE. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040106001102004010600110CE 2004 1 6 CA031107014 120031106G56105042006935 WINDSHIELD BEECH 90 C90 1152913CE PWA PT6 PT6A28 EA HARTZLHCB3T HCB3TN3 GL COCKPIT BROKEN W BA EMER. DESCENT UNSCHED LANDING O OTHER CRCRUISE 1 CA (CAN) PILOTS REPORTED THAT WHILE CRUISING AT 23 000 FT THEY A HEARD CRACKLING SOUND. SOON AFTER THEY DETECTED THIS SOUND, THE INTERIOR PANE OF THE LEFT WINDSHIELD SHATTERED. HEAT WAS NOT IN USE, AND THE AMBIENT TEMPERATURE WAS -30 C. THE PILOTS IMMEDIATELY REDUCED PRESSURE AND DECENDED TO 10 000 FT, THEN RETURNED TO AMO FOR MAINTENANCE. 1L72 3T4 T 3A20 E4EA 6 CP15EA 20040106001112004010600111SW 2004 1 6 CA031107015 120031107G5510AN4730A EYEBOLT AIRTRCAT802 AT802 0390305SW PWA PT6 PT6A67A 52043NE HARTZLHCB5M HCB5MA3 GL HORIZONTAL STAB CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING ANNUAL INSPECTION THE HORIZONTAL STAB STRUT ATTACH EYEBOLTS WERE REMOVED FOR INSPECTION. DURING MPI THERE WAS A CRACK OF APPROXIMATELY .3125 INCH IN LENGTH NOTED AT THE RADIUS. ALL OTHER AIRCRAFT IN OUR FLEET WILL BE INSPECTED. THE EYEBOLTS WILL BE REPLACED WITH NEW PRIOR TO THE AIRCRAFT BEING RETURNED TO SERVICE. I WOULD LIKE TO SUGGEST THAT ALL OPERATORS OF THIS AIRCRAFT TYPE INSPECT THE EYEBOLTS FOR CRACK INDICATIONS. 1L71 3T4 TNCA19SW E26NE 6 CP44GL 20040106001122004010600112SW 2004 1 6 CA031107016 120031107G5510AN4730A EYEBOLT AIRTRCAT802 AT802 0390305SW PWA PT6 PT6* 52043EA HARTZLHCB5M HCB5MA3 GL HORIZONTAL STAB CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING MPI INSPECTION OF THE HORIZONTAL STABILIZER STRUT ATTACH EYEBOLTS, A CRACK APPROXIMATELY .1875 INCH IN LENGTH WAS NOTED. ALL EYEBOLTS WILL BE REPLACED PRIOR TO THE AIRCRAFT BEING RETURNED TO SERVICE. 1L71 3T3 TNCA19SW E2NE 6 CP44GL 20040126000602004012600060EA 2004 1 26 CA031107017 120031107G5340215260533 LEVER CNDAIRCL215 CL2151A10 1900320EA PWA R2800 CA3 52026NE HAMSTD43E 43E60 NE UPLOCK ACTUATOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING 'C' CHECK OF THE WATER SYSTEM A MPI INSPECTION WAS COMPLETED ON THE WATERDOOR UPLOCK ACTUATING LEVER MOUNTING LUG. A CRACK WAS NOTED ON THE MOUNTING FLANGE. THE CRACK IS APPROXIMATELY .5000 INCH IN LENGTH. THE PART WILL BE REPLACED WITH A SERVICEABLE UNIT. 2H72 4R4 RRTA14EA E231 6 CP871 20040126000612004012600061NM 2004 1 26 CA031109001 120031106G323069600892 SPRING BOEING737 737275C NM PWA JT8 JT8D17A 52049NE MLG FAILED W A UNSCHED LANDING D INFLIGHT SEPARATION CLCLIMB 1 CA (CAN) UPON DEPARTURE FROM THE NOSE LANDING GEAR FAILED TO LOCK UP. AFTER SELECTING GEAR HANDLE TO NEUTRAL POSITION THE NOSE GEAR FELL OUT OF THE NOSE WHEEL WELL. SEVERAL SUBSEQUENT GEAR UP SELECTIONS WERE UNSUCCESSFUL. THE AIRCRAFT RETURNED AND MADE AN UNEVENTFUL LANDING. RECERTIFICATION THE AC WAS DISPATCHED IAW FERRY FLIGHT PERMIT. MAINTENANCE DISCOVERED THAT ONE OF THE NOSE GEAR SKI SPRINGS HAD FAILED THEREBY INTERFERING WITH THE RETRACTION OF THE SKI AND IN TURN PREVENTING THE NOSE GEAR FROM LOCKING UP. THE SKI SPRING WAS REPLACED AND GEAR SWUNG WITH NO FURTHER FAULT. 2L72 4F4 F A16WE E2EA 20040106001742004010600174NM 2004 1 6 CA031110001 120031109G323365B0150422 ACTUATOR BOEING747 747433 NM PWA 4056 PW4056 NE MLG INOPERATIVE W O OTHER J WARNING INDICATION NRNOT REPORTED 1 CA 0569 (CAN) AFTER T/O, UNABLE TO RETRACT GEAR. GEAR TILT MSG ON EICAS AND RT BODY GEAR TILT INDICATION. FLT RETURNED TO FRA AT 38,000 KG OVERWEIGHT. ACTUATOR AND FLEX LINE BORROWED AND INSTALLED, ALL CKS NORMAL. O/W LANDING CHECK CARRIED OUT. 2L74 4F4 FRTA20WE E24NE 20040315000772004031500077SW 2004 3 15 CA031110002 120031107G6420 BUSHING BELL BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA TAIL ROTOR HEAD INCORRECT W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA AHW50066 (CAN) TWO PITCH HORNS WERE IN FOR REPAIR, ONE HAD BUSHINGS IN HOLES AND BOTH HAD ODD SERIAL NUMBERS. WE CONTACTED OEM AND THEY SAID THAT THE BUSHED HOLES WOULD NOT BE APPROVED BY THEM. AS FOR THE SERIAL NUMBERS, ONE COULD NOT BE CONFIRNED AS BEING MADE BY MFG AND THE OTHER SERIAL NUMBER WAS SOLD TO THE VENEZUELA MILITARY AND IT IS POSSIBLE FOR IT TO MAKE ITS WAY BACK TO THE COMMERCIAL MARKET. WE ARE HOLDING THE PARTS PENDING FURTHER INVESTIGATION. 1G71 4U4 U H4SW E22EA 20040107000132004010700013NE 2004 1 7 CA031110003 220031107G7261 ENGINE BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3I NE RIGHT LEAKING W O OTHER KBJFLUID LOSS SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION APAPPROACH 1 CA PS0163 (CAN) DURING APPROACH AND LANDING, CREW NOTED BURNING ODOR AND LIGHT SMOKE IN CABIN. LAVATORY SMOKE DETECTOR TRIPPED AND RIGHT ENGINE OIL PRESSURE BEGAN TO DROP. LANDING AND ROLL WAS COMPLETED SO THE EGNINE WAS SECURED AT THE GATE. SEVERAL QUARTS OF OIL WERE EXHAUSTED OUT THRU THE COMPRESSOR INLET ONTO THE RAMP. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20040107000142004010700014SW 2004 1 7 CA031110004 120031029G32301114174S0135 HOSE SWRNGNSA226 SA226TC 8780404SW GARRTTTPE331TPE33110UA 01514WP HARTZLHCB3T HCB3TN5 GL MLG LEAKING W L ABORTED APPROACH KJ FLUID LOSS WARNING INDICATION DEDESCENT 1 CA (CAN) UPON DESCENT, CREW SELECTED GEAR DOWN. RT GEAR INDICATED ONLY (IN TRANSIT). CREW DID A FLY BY AND TOWER CONFIRMED THAT THE GEAR WAS NOT DOWN. THE CREW CLIMBED OUT, SELECTED THE EMERGENCY GEAR SYSTEM, AND THE GEAR EXTENDED NORMALLY. THEY DID ANOTHER FLY BY, AND TOWER CONFIRMED ALL 3 GEAR WERE DOWN, AND THEY HAD 3 GREEN LIGHTS INDICATED. MAINTENANCE INSPECTED THE AIRCRAFT, DETERMINED THAT MAIN GEAR DOWN HOSE HAD FAILED (SEVERE LEAK) CAUSING A LOSS OF PRESSURE TO THE NORMAL GEAR DOWN ACTUATOR. MAINTENANCE REPLACED THE HOSE, CONDUCTED GEAR SWINGS, AND INSPECTED THE GEAR SYSTEM FOR ANY FURTHER ANOMALIES. HYDRAULIC FLUID WAS REPLENISHED, AND THE AIRCRAFT RETURNED TO SERVICE WITH NO FURTHER DIFFICULTIES. 2L72 4T4 TRTA8SW E4WE 6 CP15EA 20040126000622004012600062NE 2004 1 26 CA031110006 120030803G6220S161026005 PISTON ROD SKRSKY S161026000 SKRSKYS58T S58ET 8141803NE PWA PT6T PT6T3 52045EA DAMPER ASSY SEVERED W O OTHER D INFLIGHT SEPARATION LDLANDING 1 CA 41585 (CAN) ON AIRCRAFT APPROACH FOR LANDING, AIRFRAME VIBRATION WAS FELT. UPON LANDING AIRCRAFT WAS GROUND ROCKING. REDUCTION OF ENGINE THROTTLES INCREASED GROUND ROCK AND AIRFRAME VIBRATION. THROTTLES SHUT-OFF AND ROTOR BRAKE APPLIED, UPON BRAKING M/R BLADE SWEPT FORWARD. INVESTIGATION FOUND M/R DAMPER PISTON ROD SEVERED AT THREADED PORTION. DAMPER PISTON ROD SENT OUT FOR METALLURGY TESTING. 2G72 4U4 U 1H11 E22EA 20040126000632004012600063EA 2004 1 26 CA031110007 220030901G7250 BLADE SKRSKYS58T S58ET 8141803NE PWA PT6T PT6T3 52045EA TURBINE SECTION BROKEN W O OTHER E VIBRATION/BUFFET CRCRUISE 1 CA (CAN) THE AIRCRAFT WAS ENGAGED IN FIRE FIGHTING DUTIES WHEN ENGINE VIBRATION WAS FELT. ALL AIRCRAFT SYSTEMS WERE IN NORMAL, OPERATIONAL AND PERFORMANCE LIMITS. SUBSEQUENT TROUBLESHOOTING OF THE POWER SECTION WAS COMPLETED AND THE POWER SECTION WAS REMOVED FROM THE AIRCRAFT FOR FURTHER INVESTIGATION. PRELIMINARY TEARDOWN FOUND THAT COMPRESSOR TURBINE WHEEL HAD THREE PARTIAL BLADES MISSING. ONE BLADE WAS MISSING HALF OF ITS LENGTH AND TWO OTHERS MISSING APPROXIMATELY .1250 INCH FROM THE TIP OF THE BLADES. THE POWER SECTION IS CURRENTLY AT AN ENGINE OVERHAUL SHOP FOR FURTHER INVESTIGATION. INVESTIGATION REPORTS ARE CURRENTLY PENDING. 2G72 4U4 U 1H11 E22EA 20040107000402004010700040EA 2004 1 7 CA031110008 120031101G35106044441011 CONTROLLER CNDAIRCL604 CL604 1900301EA GE CF34 CF343B1 NE PAX OXYGEN BURNED W BA EMER. DESCENT UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS TOTAKEOFF 1 CA (CAN)AFTER T/O, CREW NOTICED OVERHEATING ELECTRONIC SMELL, SMALL AMOUNT OF SMOKE FROM PASSENGER'S OXY CNTL PANEL. CREW DIVERTED AC, HEADED BACK TO AIRPORT OF ORIGIN. LIGHT DIMMER ASSY (PS1LN) WIRE LN15C22 FEEDING 5 VAC TO OXYGEN CTRL PANEL (P/N 6044441011, WIRED DURING COMPLETION PHASE) FOR INTEGRAL LIGHT WAS CONNECTED TO HIGH VOLTAGE (HV) POST, THUS FEEDING 115 VAC FROM CBP2-C12 (BUSS 2) DIRECTLY TO INTEGRAL LIGHTING. THIS RESULTED IN SHORT CIRCUIT INTERNALLY TO INTEGRAL LIGHTING FACEPLATE BURNING FUSE (OVER CURRENT) IN LIGHTING CIRCUIT DIM. SYS WAS SERVICEABLE UPON CONNECTING WIRE LN15C22 TO LV2 POST OF PS1L, IAW WIRING DIAGRAM, REPLACING PASS OXYGEN CTRL PANEL AND THE PS1L'S FUSE. 2L72 4F4 FRTA21EA E15NE 20040107000412004010700041NE 2004 1 7 CA031113001 220031014G7200 ENGINE CNDAIRCL601 CL6012A12 1900303EA GE CF34 CF341A NE RIGHT SHUTDOWN W A UNSCHED LANDING YJ ENGINE STOPPAGE WARNING INDICATION CRCRUISE 1 CA 35102 (CAN) DURING CRUISE AT FL 390, THE RT ENGINE SHUTDOWN. THE CREW REPORTED ALL ENGINE PARAMETERS WERE NORMAL AT THE TIME AND NO MESSAGES OR CAUTIONS WERE POSTED. THE CREW DECENDED AND PERFORMED A SUCCESSFUL WINDMILL RELIGHT AT 10,000 FT. FOLLOWED BY AN UNEVENTFUL LANDING. THE FOLLOWING MAINTENANCE ACTIONS WERE PERFORMED ON THE RT ENGINE: PERFORMED FLAME-OUT INSPECTION, INSPECTED FUEL FILTER AND A/C TANKS FOR WATER. BOROSCOPED ENGINE. INSPECTED RIGGING OF VSVS AND FEEDBACK CABLE. INSPECTED OIL FILTER, INSTALLED AND INSPECTED MAGNETIC CHIP DETECTORS. PERFORMED EXTENSIVE ENGINE RUNS AND POWER ASSURANCE CHECK. NO ABNORMALITIES NOTED. AIRCRAFT FLOWN FOR FURTHER TROUBLESHOOTING. 2L72 4F4 FRTA21AE E15NE 20040107000422004010700042EA 2004 1 7 CA031113002 220030812G8550S19515 DRAIN VALVE CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA MCAULY1A103 1A103TCM GL OIL SUMP FAILED W O OTHER W INADEQUATE Q C NRNOT REPORTED 1 CA (CAN) AFTER DRAINING ENGINE OIL DURING A 100 HOUR INSPECTION, THE VALVE WAS CLOSED. UPON CLOSING THE VALVE, IT CAME APART. NO ABNORMAL AMOUNT OF FORCE WAS APPLIED. THE VALVE IS SPRING LOADED CLOSED. IF THIS WERE TO HAPPEN IN FLIGHT ALL OIL COULDBE LOST AT A RAPID RATE. THE VALVE WAS REPLACED WITH A DIFFERENT STYLE OF UNIT. ALL THESE VALVES SHOULD BE REMOVED FROM SERVICE. 1H71 3O3 ONT3A19 E223 5 NP50GL 20040107000432004010700043NM 2004 1 7 CA031113003 120031109G5330 SKIN BOEING737 737201 1384454NM PWA JT8 JT8D9A 52048NE FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 60021 (CAN) 2 INCH CRACK AT S 17R BETWEEN BS 727B AND BS 747 ON RT AFT SIDE OF FUSELAGE. CRACK REPAIRED IAW MFG SRM 53-30-3 FIG 48 PROCEDURE IV AND VII. 2L72 4F4 F A16WE E2EA 20040126000642004012600064SW 2004 1 26 CA031113004 120031113G5751250000283 SPAR GULSTM690TP 690 0141720SW GARRTTTPE331TPE3315251K NM HARTZLHCB3T HCB3TN5 GL AILERON CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING ANNUAL INSPECTION A CRACK WAS NOTED ON THE AILERON SPAR AT IB HINGE FITTING ATTACH POINT. THE CRACK IS APPROXIMATELY .5000 INCH IN LENGTH, AND STARTS AT THE IB END OF THE SPAR AND IS RUNNING SPAN WISE APPROXIMATELY .1250 INCH BELOW THE IB LOWER FITTING ATTACH HOLE. WE WILL BE INSPECTING THE REST OF OUR FLEET. THE AILERON WILL BE REPAIRED PRIOR TO THE AIRCRAFT BEING RETURNED TO SERVICE. 1H72 3T4 T 2A4 E2WE 6 CP15EA 20040126000752004012600075CE 2004 1 26 CA031113005 120031110G555112320131 FITTING CESSNA207 207A 2073604CE CONT O520 IO520F 17032SO MCAULYD3A34 D3A34C404 GL HORIZONTAL STAB CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING GROUND HANDLING, HOR. STAB. FOUND TO HAVE FREEPLAY ON RT SIDE. UPON FURTHER INSP, THE RT FWD ATTACH FITTING WAS FOUND TO BE CRACKED. ALL OTHER EMPANAGE FITTINGS AND ATTACH POINTS WERE INSPECTED FOR LOOSENESS AND CONDITION. ALL AREAS FOUND SERVICEABLE. THE FITTING WAS REPLACED AND STABILIZERS WERE RE-INSTALLED. PRIOR TO DETECTION OF CRACKED FITTING, PILOT'S HAD NO REPORTS OF VIBRATION OR UNUSUAL FLIGHT CHARACTERISTICS. AFTER MAINTENANCE WAS C/O, AIRCRAFT WAS RETURNED TO SERVICE. 1H71 3O3 O A16CE E5CE 5 CP47GL 20040126000762004012600076NE 2004 1 26 CA031113006 220031110G73100301007710 LINE SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE FUEL SYSTEM BROKEN W E ENGINE SHUTDOWN O OTHER TXTAXI/GRND HDL 1 CA 9547 (CAN) THE PILOT EXPERIENCED A SLOW SLUGGISH START. ON INVESTIGATION HE FOUND FUEL ON THE DECK AND DOWN THE LT SIDE OF THE ENGINE. HE FOUND THE LT START INJECTOR FUEL SUPPLY LINE CRACKED NEAR THE FLARE AT THE POINT WHERE IT IS ATTACHED TO THE INJECTOR. THE LINE WAS REPLACED. 1G71 3U3 U H9EU E19EU 20040126000772004012600077CE 2004 1 26 CA031113007 120031112G273062342051 TORQUE TUBE CESSNA650 650 2076802CE GARRTTTPE731TFE7313C WP ELEVATOR CHAFED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING A PHASE 5 INSPECTION A TASK INVOLVE THE REMOVAL OF THE AFT VERTICAL FIN TOP FAIRING, TO INSPECTED INSIDE THIS AREA. MAINTENANCE PERSONNEL FOUND THE TWO ELEVATOR TORQUE TUBES WERE CHAFED. MAINTENANCE PERSONNEL MAINTENANCE DEPARTMENT SENT THE PART TO MFG FOR REPAIR. THE DAMAGE WAS BEYOND LIMITS. 2L72 4F4 F A9NM E6WE 20040126000952004012600095CE 2004 1 26 CA031113008 120031113G27106260102439 CONTROL CABLE CESSNA650 650 2076802CE GARRTTTPE731TFE7313C WP SPOILER FRAYED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING A SCHEDULE INSPECTION ON RT WING OB FLIGHT SPOILER. THE OB RT SPOILER ACTUATING CABLE (FOR THE FLT SPOILER ACTUATOR) WAS FOUND FRAYED UNDER A PULLEY ASSY. 2L72 4F4 F A9NM E6WE 20040107000462004010700046NE 2004 1 7 CA031113009 220031110G7200 ENGINE AIRBUSA340 A340313 EU CFMINTCFM56 CFM565C4 13802NE NR 4 MALFUNCTIONED W E ENGINE SHUTDOWN J WARNING INDICATION NRNOT REPORTED 1 CA (CAN) ON FLT FROM YYZ TO DELLI, 3HRS INTO FLT, NR 4 ENG ROLLED BACK TO 75 PERCENT N1 THEN RECOVERED APROX 1,500 NM FROM DESTINATION. LATER ENG OIL FILTER CLOGGED LT CAME ON THEN ENG REDUCED TO 67 PERCENT FOR REST OF FLT. DURING DESCENT NR 4 ENG SHUTDOWN. ENGINE, MANPOWER AND EQUIPMENT ENROUTE FOR ENG CHANGE. 2L74 4F4 FRTA197 E37NE 20040126001122004012600112EU 2004 1 26 CA031113010 120031016G6410355A12004008 BLADE SNIAS 350 AS350BA 8680817EU TMECA ARRIELARRIEL1B 6OO30NE TAIL ROTOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING A 500 HR INSPECTION, PERFORMED A TAIL ROTOR SPAR INSP WITH DISASSEMBLY AS REQUIRED BY AD.1D(3). FOUND A LARGE PIECE OF SPAR SEPARATED ON EDGE IN LONGITUDINAL DIRECTION APPROX. 8 MM IN WIDTH AND 2 MM THICK. SEPARATION EXTENDS FROM REINFORCED ATTACHMENT SECTION DOWN TO THE BLADE ROOT. THE TAIL ROTOR WAS REPLACED. 1G71 3U3 UNCH9EU E19EU 20040107000472004010700047WP 2004 1 7 CA031113012 220031109G7261GT331 OIL FILTER SWRNGNSA226 SA226TC 8780404SW GARRTTTPE331TPE33110UA 01514WP LT ENGINE DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE OIL FILTER BYPASS PIN WAS FOUND POPPED ON THE LT ENGINE. THE OIL FILTER WAS REPLACED AND OIL SAMPLE TAKEN. DAMAGE TO THE REMOVED OIL SAMPLE WAS NOTED. THE MOUNTING FLANGE OF THE FILTER WAS MISSING FROM THE RADIUS INWARD. THE OIL FILTER IS INCLUDED IN THE WEAR CHECK P/N GT-331 OIL SAMPLE KITS. 2L72 4T4 TRTA8SW E4WE 20050427003122005042700312EU 2005 4 27 CA031113013 120031106G32461388920629 BEARING RACE SAAB SF340 SF340A 7850100EU GE CT7TP CT75A2 30030NE ROTOL R389 R3894123F25 NE NLG WHEEL BROKEN W K NONE O OTHER ININSP/MAINT 1 CA JAN911074 (CAN) AIRCRAFT ON LANDING FELT A VERY STRONG SHIMMY AT THE NOSE, THE PILOTS DID THEIR INVESTIGATION AND ONE OF THE NOSE WHEEL BEARINGS WAS COMPLETELY BROKEN AND THE WHEEL WAS LOOSE ON THE AXLE. TECHNICIAN WAS SENT TO REPLACE BOTH NWA'S. AFTER INVESTIGATION, LOOSE HUB BOLTS WERE FOUND AND AT BUILD UP PROCEDURE THE OPTIONAL SB340-32-34 IS NOW IMPLEMENTED MANDATORY. THE BEARING CLEANING PROCEDURE WAS REVIEWED AND A NOTICE OF NO PRESSURE WASHING OF WHEEL AREAS WAS ALSO GIVEN AND THE SB 50 06227-32-01 (IB SEAL IMPROVEMENT WILL BE PROGRESSIVELY IMPLEMENTED. 2L72 4T4 TRTA52EU E8NE6 6 CP30NE 20040126001042004012600104CE 2004 1 26 CA031113014 120031111G2710666000164 CONTROL CABLE CESSNA560 560XL 2076702CE PWA 545 PW545A NE AILERON CONTROL BROKEN W O OTHER F FLT CONT AFFECTED LDLANDING 1 CA (CAN) PILOT REPORTED CONTROL FELT DIFFERENT DURING LANDING. MAINT FOUND RT WING AILERON CABLE ASSY WING UP, BROKEN. CABLE AND PULLEYS ARE ORIGINAL HAVE NOT BEEN REPLACED. CABLE BROKE AT AFT PULLEY AT WS53.07, BRAKE WAS NOT POLISHED. PRELIMINARY INSPECTION REVEALED FOLLOWING: PULLEY ATTACH BOLT PN AN4H15A WAS ROCKING IN AFT BRACKET PN 66603194. BOLT HAS EVIDENCE OF PLATING WORN OFF, SUSPECT BOTTOM AREA. AFT PULLEY BRACKET BOLTHOLE ELONGATED TO .3 INCH. PULLEY PN S3784 HAD ONLY ONE SMALL SPOT THAT WAS RUFF. SIDES OF PULLEY HAD POLISHED AFT PULLEY BRACKET. PULLEY BEARING ROTATES OK. NO EVIDENCE OF CABLE CHAFING ANYTHING, CABLE MISS ROUTING OR PULLEY BINDING. 2L72 4F4 FRTA22CE E00059EN 20040126000652004012600065EA 2004 1 26 CA031114001 120031106G2820T99A378603 EJECTOR CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) FUEL WAS TRANSFERRING FROM THE RT TANK TO THE CENTER TANK. THE TRANSFER WAS NOTICED WHILE THE A/C WAS ON GROUND. INVESTIGATION REVEALED THAT THE RT PRIMARY EJECTOR WAS CRACKED AND THE FUEL WAS LEAKING FROM THE EJECTOR TO THE CENTER TANK. THE EJECTOR WAS REPLACED AND A/C RETURNED TO SERVICE. 2L72 4F4 FRTA21EA EOOO63EN 20040126000662004012600066EA 2004 1 26 CA031114002 120031104G5610NP13932110 WINDSHIELD CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE COCKPIT CRACKED W A UNSCHED LANDING O OTHER CLCLIMB 1 CA 20077 CA031114004(CAN) THE RT WINDSHIELD CRACKED AFTER TAKE OFF. THE WINDSHIELD WAS A PRE SERVICE BULLETIN. THE WINDSHIELD WAS REPLACED AND A/C IS BACK IN SERVICE. 2L72 4F4 FRTA21EA E15NE 20040126000962004012600096 2004 1 26 CA031114004 420031104G2397 WIRE HARNESS BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCD4N3HCD4N3A GL AUDIO SELECOTR CHAFED W C ABORTED TAKEOFF H ELECT. POWER LOSS-50 PC TOTAKEOFF 1 CA (CAN) A/C DEPARTED, AFTER TAKEOFF, CREW EXPERIENCED A COMMUNICATIONS FAILURE. CREW SQUAKED 7600 & RETURNED FOR LANDING. MAINT TROUBLESHOT COMMUNICATIONS SYS. NR 1 COMM FAILED, REPLACED COMM WITH SERVICEABLE VHF UNIT, COMM NR 1 OPERATING NORMAL. AWAITING STRIP REPORT. NR 2 VHF COMM - WIRE CHAFED (NR 2 COMM 'MIC KEY' WIRE) BETWEEN NR 2 VHF COMM & NR 1 AUDIO SELECTOR. CHAFED WIRE GOING TO GROUND. REPAIRED WIRE & CHECKED NR 2 COMM SYS. OPERATING NORMAL. HF - FOUND LOOSE HF PIN IN NR 1 AUDIO SELECTOR, ADJUSTED PIN LOCKING MECHANISM AND RE-INSTALLED. HF STILL HAD TUNING PROBLEM. INSTALLED SERVICEABLE HF REC/EXC AND HF AMP. GROUND TUNING ACCOMPLISHED. D) GROUND CHECKS OF RADIOS CARRIED OUT. 1L72 4T4 T A24CE E4EA 5 CSTC 20040107000482004010700048EA 2004 1 7 CA031114005 220031104G8520 THRU BOLT CESSNA172 172N 2072434CE LYC O320 O320H2AD 41508EA MCAULY1C160 1C160DTM GL ENGINE LEAKING W O OTHER KBJFLUID LOSS SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CRCRUISE 1 CA (CAN) SMOKE IN CABIN. OIL LEAK ON FRONT OF ENGINE, LEADKED OIL DOWN BAFFLE TO HEAT MUFF INLET. OIL DRIPPED INSIDE HOT MUFFLER CREATING SMOKE. 2 FORWARD CRANK CASE THROUGH BOLTS FOUND LEAKING. REPAIRS ARE NOT COMPLETED YET, 4 NOV. 03. 1H71 3O3 ONT3A12 E274 5 NP910 20040126000702004012600070WP 2004 1 26 CA031114006 120031103G3610321417611 REGULATOR DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE DOOR SEAL FAILED W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) DURING CLIMB, FLOW LIGHT (PRESS) COME ON, UNABLE TO STABILIZE, ACFT LANDED BACK. FOUND AFT GALLEY DOOR SEAL NOT PROPERLY SEATED. DURING SECOND CLIMB, SAME FLOW LIGHT CAME ON WITH BOTH AIRCRAFT PACKS BETWEEN 0-2 PSI ACFT LANDED BACK AND ACFT FERRIED TO BASE. LT PNEUMATIC PILOT PRESSURE REGULATOR REPLACED ALSO RT PRESSURE REGULATOR VALVE REPLACED AND RT AIR CONDITIONING PILOT PRESSURE REGULATOR REPLACED. 2L72 4F4 FRTA6WE E9NE 20040126000792004012600079EU 2004 1 26 CA031114007 120031016G2897 CONNECTOR AEROSPAS355 AS355F1 8680810EU ALLSN 250C 250C20F 03013GL FUEL PUMP BURNED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA (CAN) WHILE THE AIRCRAFT WAS IN CRUISE FLIGHT, A BURNING ODOR WAS NOTICED IN THE CABIN. THE PILOT LANDED THE AIRCRAFT UNEVENTFULLY. THE BURNING ODOR WAS TRACED TO THE OVERHEAD LT FUEL PUMP SWITCH. WHEN THE OVERHEAD PANELS WERE REMOVED A BURNED PUMP SWITCH CONNECTOR WAS SEEN. CONNECTOR WAS REPLACED. THE RT SIDE WAS ALSO CHECKED AND IT WAS NOTED THAT THE CONNECTOR IS SHOWING SIGNS OF OVER HEAT. TWO SEPARATE D.C. BUSES, PUMP SWITCHES AND PUMPS AFFECTED. 1G72 3U3 U H11EU E4CE 20040126000972004012600097EA 2004 1 26 CA031114008 120031114G2721 THRUST BEARING CNDAIRCL215 CL2151A10 1900320EA PWA R2800 CA3 52026NE HAMSTD43E 43E60 NE RUDDER WORN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) SPRING TAB WAS STIFF, IT WAS LUBED AND WORKED NORMAL. ON SCHEDULED WINTER MAINTENANCE INSPECTION BEARING WAS FOUND TO BE WORN PAST LIMITS. 2H72 4R4 RRTA14EA E231 6 CP871 20040126000872004012600087SW 2004 1 26 CA031114009 120031114G5751250000283 SPAR GULSTM690TP 690A 0141722SW GARRTTTPE331TPE3315251K NM HARTZLHCB3T HCB3TN5 GL AILERON CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) AS A FOLLOW UP INSPECTION ON THE REST OF OUR FLEET FOLLOWING THE DISCOVERY OF THE CRACKED AILERON SPAR ON OUR AIRCRAFT, THE LT AILERON SPAR WAS FOUND CRACKED ON THIS AIRCRAFT. THE CRACKS ARE ALL LOCATED IN THE SAME AREA AS PREVIOUSLY REPORTED AND ARE APPROXIMATELY .5000 INCH IN LENGTH. THE IB AILERON RIBS ON THE LT AILERONS WERE ALSO FOUND CRACKED. THE CRACKS ON THE RIBS WERE APPROXIMATELY .5000 INCH IN LENGTH. I WOULD LIKE TO SUGGEST THAT ALL OPERATORS OF THIS AIRCRAFT TYPE DO AN INSPECTION OF THEIR AIRCRAFT. WE INSPECTED THE RT AILERONS BUT FOUND NO DAMAGE. THE AIRCRAFT WILL BE REPAIRED PRIOR TO BEING RETURNED TO SERVICE. 1H72 3T4 T 2A4 E2WE 6 CP15EA 20040126000812004012600081NE 2004 1 26 CA031117001 220031109G7200 ENGINE CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE RIGHT FAILED W A UNSCHED LANDING RJ PARTIAL RPM/PWR LOSS WARNING INDICATION CLCLIMB 1 CA (CAN) MFG HAS RECEIVED A REPORT WHICH WE FEEL IS A REPORTABLE EVENT. AFTER TAKE OFF HEARD LOUD BANG AND VIBRATION FROM RT ENGINE. ENGINE SHUTDOWN. RETURNED TO AIRPORT. ENGINE SUFFERED INTERNAL FAILURE. ENGINE REPLACED, AIRCRAFT RETURNED TO SERVICE. NOTE: TIME SINCE LAST BOROSCOPE 666.5 HRS, 552 CYCLES. 2L72 4F4 FRTA21EA E15NE 20040107000492004010700049NM 2004 1 7 CA031117002 120031111G5330 SKIN BOEING737 737296 1384486NM PWA JT8 JT8D9A 52048NE FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) 3 INCH CRACK IN FUSELAGE SKIN AFT OF REAR WING TO BODY FAIRING TOP OF 18L BETWEEN BS 747 - BS 767. REPAIRED SRM IAW 53-30-3 FIG 48 (SHEET 33) DETAIL XI, REF PROCEDURE IV AND VII. AIRCRAFT TIME 56,88:17CYCLES52,484 C 2L72 4F4 FRTA16WE E2EA 20040126000882004012600088NM 2004 1 26 CA031117003 120031111G5330 SKIN BOEING737 737296 1384486NM PWA JT8 JT8D9A 52048NE FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) 2.34 CRACK IN FUSELAGE TOP OF S18L BETWEEN BS 727A AND BS 727B. REPAIRED IAW SRM 53-30-3,FIG 48, SHEET 33, DETAIL XI REFERENCE PROCEDURE IV AND VII. AIRCRAFT TIME 56,880:17 CYCLES52,484 C 2L72 4F4 FRTA16WE E2EA 20040107000512004010700051NM 2004 1 7 CA031117004 120031113G5330 SKIN BOEING727 727243 138408DNM PWA JT8 JT8D15 52051NE FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 48876 (CAN) THE AIRCRAFT WAS ON A (C CHECK. UPON INSPECTION OF THE FUSELAGE, A QUESTIONABLE SCRATCH WAS FOUND AT STATION BS 700 STRINGER NR 1. PAINT WAS STRIPPED AND NDT INSPECTION CARRIED OUT. A CRACK OF HALF INCH LONG WAS DISCOVERED. THE FUSELAGE WAS REPAIRED IAW SRM. 2L73 4F4 FRTA3WE E2EA 20040126001092004012600109SW 2004 1 26 CA031117005 120031031G7120206062101013 LEG ASSY BELL 206 206B 1181511SW ALLSN 250C 250C20B 03013GL ENGINE DENTED W K NONE O OTHER ININSP/MAINT 1 CA 11003 (CAN) DURING ENGINE COMPRESSOR CHANGE (SCHEDULED), 6 ENGINE LEGS WERE SENT OUT TO BE STRIPPED, NDT ED, AND REPAINTED. DURING STRIPPING STAGE IT WAS NOTED THAT P/N 206-062-101-014 HAD A SMALL DENT ON IT (ABOUT 4 =FROM TOP). IT WAS FOUND TO BE BEYOND MFG LIMITATION FOR REPAIR. DENT HAS APPEARANCE OF BEING CAUSED BY MECHANICAL DAMAGE AT SOME POINT IN TIME. DURING NDT INSPECTION OF WAS FOUND TO HAVE A SMALL PIN HOLE ABOUT 2 FROM THE TOP. IT WAS NOTED THAT THERE WERE 2 SMALL MARKS ON EITHER SIDE OF PIN HOLE THAT LOOK LIKE A LOCKWIRE TWIST. IT APPEARS THAT A LOCKWIRE TWIST FROM ENGINE MOUNT HAS CONTACTED THE ENGINE LEG AT SOME POINT IN TIME. THERE IS NO REQUIREMENT FROM MFG TO NDT ENGINE LEGS. 1G71 3U3 U H2SW E4CE 20040126001102004012600110SW 2004 1 26 CA031117006 120031031G7120206062111101 MOUNT BELL 206 206B 1181511SW ALLSN 250C 250C20B 03013GL ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 11003 (CAN) DURING AN ENGINE COMPRESSOR CHANGE (SCHEDULED), THE 3 ENGINE MOUNTS P/N 206-062-111-101 WERE SENT OUT TO BE STRIPPED, NDT , AND REPAINTED. DURING THE NDT STAGE THERE WERE CRACK INDICATIONS FOUND ON 2 OF THE MOUNTS ALONG THE TREADED PORTION. THE SUBJECT MOUNTS WERE REPLACED WITH NEW ASSY S. THERE IS NO REQUIREMENT FROM THE MANUFACTURER TO NDT THE ENGINE MOUNTS. 1G71 3U3 U H2SW E4CE 20040315001152004031500115EU 2004 3 15 CA031117007 120031110G33108623 LAMP STBROSSD3 SD360 8100606EU PWA PT6 PT6A65AR 52043NE HARTZLHCB5M HCB5MP3 GL COCKPIT SHORTED W O OTHER B SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 CA (CAN) TRANSFORMER IS DESIGNED TO STEP DOWN 115 VAC SUPPLY VOLTAGE TO A MAX OF 5 VAC REQUIRED BY REST OF CIRCUITRY. OUTPUT WIRES FROM ABOVE MENTIONED TRANSFORMER ARE INCREASED IN GAUGE SIZE TO 16 AWG, SO THAT IN EVENT OF A GROUND FAULT TRANSFORMER OUTPUT WIRING WOULD HAVE SUFFICIENT ELECTRICAL CURRENT CAPACITY TO TRIP CB AND PROTECT OVER ALL CIRCUIT INTEGRITY. DUE TO A DESIGN OVERSIGHT, ONE OF TWO TRANSFORMER OUTPUT WIRES SELECTED WAS OF INSUFFICIENT SIZE, 24 AWG. THEREFORE, ANY GROUND FAULTED COMPONENT PRESENT ON ITS ASSOCIATED LIGHTING BUSS IE: LAMP MODULE, CAUSED THIS WIRE TO ACT LIKE AN ELECTRICAL HEATING ELEMENT. THIS CAUSED A SERIOUS FIRE HAZARD SITUATION, DUE TO EXCESSIVE CURRENT FLOW WITHIN CIRCUIT.2H72 4T4 T A41EU E4EA 6 CP44GL 20040126001032004012600103EU 2004 1 26 CA031117008 120031110G31508623 LAMP STBROSSD3 SD360 8100606EU PWA PT6 PT6A65AR 52043NE HARTZLHCB5M HCB5MP3 GL FUEL TOTALIZER SHORTED W O OTHER B SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 CA (CAN) PILOT NOTED ELEC BURNING ODOR. CREW DISENGAGED AC ELEC MASTER. FOUND TRANS & WIRING WARM TO TOUCH. WIRES MELTING A PLASTIC ABRASION SHIELD. DAMAGE DETECTED IN WIRING WITH TRANS & WIRES WITHIN SAME BUNDLE. TRANS DISCONNECTED FROM CIRCUIT & CHECKED. DAMAGED WIRING & ABRASION SHIELD WERE REPAIRED & TRANS REINSTALLED. MAINT PERFORMED A LIGHTING CHECK & REPLACED A LINE LAMP MODULE INSTALLED IN FUEL TOTALIZER DISPLAY. LAMP ASSY HAD A MFG DEFECT. DEFECT SHORT CIRCUITED LIGHTING BUSS. RESULTED IN EXCESS CURRENT PRESENT WITHIN SYS, CAUSING TRANS & ASSOC WIRES TO OVERHEAT. CONCLUDED THAT THE FAULTY BULB INITIATED PROBLEM A POSSIBLE FLAW IN CIRCUITS WIRING CAUSED WIRING FAILURE. DEFECTIVE CIRCUIT. 2H72 4T4 T A41EU E4EA 6 CP44GL 20040126000992004012600099CE 2004 1 26 CA031117010 120031112G5280 DOOR CESSNA441 441 2076020CE GARRTTTPE331TPE33110 01514WP MLG MISMANUFACTURED W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) WHEN LANDING GEAR WAS SELECTED UP THE RED INTRANSITE LIGHT WOULD NOT GO OUT. THE A/C WAS PLACED ON JACKS AND FOUND THE RT GEAR DOOR WAS TOO TIGHT NOT ALLOWING THE GEAR TO LOCK UP AND TURN THE INTRANSITE LIGHT OUT. 1L72 3T4 TRTA28CE E4WE 20040126001012004012600101SO 2004 1 26 CA031117012 120031116G3297 WIRE PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL MLG BROKEN W A UNSCHED LANDING J WARNING INDICATION NRNOT REPORTED 1 CA (CAN) ON THE LANDING APPROACH GEAR WAS SELECTED DOWN. THE LT GEAR LIGHT WOULD NOT COME ON. A FLY PAST WAS DONE AND MTCE CONFIRMED THE GEAR WAS DOWN. THE C/B WAS PULLED AND GEAR WAS SELECTED DOWN TO HYD LOCK THE GEAR DOWN. LANDING WAS MADE AND FOUND A BROKEN WIRE ON THE GEAR SWITCH. REPAIRED WIRE AND RETURNED TO SERVICE. 1L72 3O3 O A20SO E14EA 5 CP33EA 20040126001022004012600102WP 2004 1 26 CA031117013 120031114G6220369A1228901 STOP DOUG HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL DROOP UNSERVICEABLE W O OTHER FD FLT CONT AFFECTED INFLIGHT SEPARATION NRNOT REPORTED 1 CA 2472 (CAN) PILOT REPORTED M/R HUB ASSY STIFF TO FLAP DURING DAILY INSPECTION. UPON INVESTIGATING THE DROOP STOP ASSY WAS FOUND THAT THE ROLL PINS (P/N NAS561C5-14) THAT HOLD THE T-HEAD (P/N 369A1229-3) TO THE PLUNGER (P/N 369A1240-3) HAD WORKED THERE WAY OUT ON 3 ASSY'S. THE ROLL PINS DAMAGED THE PLUNGERS AS WELL AS THE BEARINGS (P/N 369A1237) IN WHICH THE PLUNGERS RIDE IN ON THE 3 LOCATIONS WHEN THEY CAME OUT. ALL THREE PLUNGERS AND BEARINGS REQUIRED REPLACEMENT AND ALL ROLL PINS REPLACED WITH NEW. M/R HUB ASSY HAS TO BE REMOVED FOR THE REPLACEMENT AND RE-INSTALLED. 1G71 3U3 U H3WE E4CE 20040126000822004012600082CE 2004 1 26 CA031117014 120031113G52601015141439 CABLE BEECH 200 B200C 1152924CE PWA PT6 PT6A42 52043NE HARTZLHCD4N3HCD4N3A GL AIRSTAIR LATCH FRAYED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING INSPECTION OF CABIN DOOR CAM LOCK LATCHES, THE DOOR LATCHING CABLE WAS FOUND TO HAVE HALF TO THREE QUARTERS OF THE CABLE STRANDS BROKEN. IF THIS CABLE WOULD HAVE BROKEN COMPLETELY IT COULD HAVE CAUSED ONE COMPLETE SIDE OF DOOR TO BECOME UNLATCHED DURING FLIGHT. THESE CABLES HAVE AN 8000-CYCLE LIFE AND ONLY LASTED 2814 CYCLES. THE CABLES WERE REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 1L72 4T4 T A24CE E4EA 5 CSTC 20040126000832004012600083NM 2004 1 26 CA031117015 120031113G3000AS323710 FASTENER BOEING737 73776N 13844CHNM CFMINTCFM567CFM567B22 13802NE MANIFOLD LOOSE W K NONE O OTHER ININSP/MAINT 1 CA NA (CAN) REGULAR SCHEDULE MAINTENANCE INSPECTION. MAINTENANCE ENGINEER FOUND NR 1 AND NR 2 ENGINE THERMAL ANTI ICE MANIFOLD FOR NOSE COWL BOLTS BACKING OUT WHILE CONDUCTING MFG TASK CARD NR 36-020-01-00 (FUNCTION CHECK PRECOOLER CONTROL VALVE, WING TAI SOLENOID). COMPANY ISSUED FLEET INSPECTION FOR LOOSE FASTENERS. SEVERAL AIRCRAFT FOUND WITH LOOSE BOLTS. INSPECTED AND CORRECTED THROUGH COMPANY SPECIAL MAINTENANCE ITEM INSPECTION. REFERENCE: POWERPLANT BUILD UP MANUAL, FIGURE 13-1, 12 O'CLOCK STRUT INSTALLATION, 71-00-02, PAGES 1-4. 2L72 4F4 FRTA16WE E00055EN 20040126000842004012600084EU 2004 1 26 CA031118001 120031117G26129751210099 CLAMP PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL FIRE DETECTOR WORN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) FIRE DETECTION SYSTEM ON ENGINE, QUICK RELEASE CLAMPS WHICH HOLD ISOLATORS AND FIRE LOOP IN PLACE FOUND WORN. CAUSED FIRE LOOP TO BECOME UNSECURE. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040126000852004012600085EU 2004 1 26 CA031118002 120031116G2530 MODULE AIRBUS320 A320212 3930322EU CFMINTCFM56 CFM565A3 NE COFFEEMAKER BURNED W A UNSCHED LANDING MB OVER TEMP SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 CA (CAN) AIRCRAFT DIVERTED DUE TO SMOKE/BURNING ODOR IN FWD GALLEY. FAULT WAS DETERMINED TO BE THE NR 2 COFFEEMAKER AND WAS REMOVED. FURTHER INVESTIGATION OF COFFEEMAKER REVEALED A LOOSE TERMINAL NUT ON POWER MODULE ASSEMBLY. THIS CAUSED THE TERMINAL TO HEAT UP AND IN TURN MELTED/BURNED INSULATION ON TERMINAL LUG. 2L72 4F4 FRTA28NM E29NE 20040126000862004012600086EU 2004 1 26 CA031118003 120031117G3251 CASTING SAAB SF340 SF340A 7850100EU GE CT7TP CT75A2 30030NE ROTOL R389 R3894123F25 NE YOKE BROKEN W O OTHER DE INFLIGHT SEPARATION VIBRATION/BUFFET LDLANDING 1 CA (CAN) AFTER LANDING, THE AIRCRAFT FELT A SHIMMY VIBRATION. AT THE GATE THE PILOT NOTICED A BROKEN PIECE MISSING OFF THE NOSE STEERING COLLAR YOKE ASSY. AFTER INVESTIGATION THE PART INSTALLED IS PRE SB32-099 WHICH CALLS FOR REGULAR INSPECTION DUE TO THAT SAME REASON AS NAMED ABOVE. AT THIS MOMENT THIS IS NOT A MANDATORY SB OR AD. WE WILL BE IMPLEMENTING THE SB WITH THE NEW PN 3931074101 AS PART OF OUR FLEET RELIABILITY PROGRAM. 2L72 4T4 TRTA52EU E8NE6 6 CP30NE 20040127000162004012700016NE 2004 1 27 CA031118004 220031102G7200 ENGINE CNDAIRCL600 CL600* EA LYC ALF502ALF502L 41580NE RIGHT FAILED W EA ENGINE SHUTDOWN UNSCHED LANDING E VIBRATION/BUFFET CLCLIMB 1 CA (CAN) APPROX 20 MIN AFTER TAKE-OFF, THE CREW NOTICED A HIGH VIBE INDICATION ON THE RT ENGINE. THEY THROTTLED BACK TO IDLE WITH NO CHANGE IN VIBES. THE CREW ELECTED TO SHUTDOWN THE ENGINE AND RETURN TO THEIR POINT OF DEPARTURE, WHERE THEY MADE AN UNEVENTFUL LANDING. SUBSEQUENT CHECKS REVEALED CHIPS IN THE CHIP DETECTORS AND SOME RESISTANCE WHEN ROTATING THE FAN BY HAND. THE ENGINE WAS REMOVED AND A LOANER INSTALLED. 2L72 4F4 FRTA21EA E6NE 20040127000172004012700017EA 2004 1 27 CA031118005 220031103G72201099100299 DUCT BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA HARTZLHCB3T HCB3TN3 GL ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) CRACK DETECTED IN UPPER FORWARD AREA OF THE INLET DUCT EXTENDING FORWARD AND 1 AFT OF THE OUTBOARD RIVET ROW OF THE INLET LIP. THIS EXCEEDED THE SR-KA-00011 LIMITS, REQUIRING DUCT REPLACEMENT. WHEN DISASSEMBLING THE COWL FOR DUCT REPLACEMENT IT WAS NOTED THAT THE INLET ANTI-ICE TUBES WERE CRACKED WHERE THEY ATTACH TO THE INLET LIP (PN 109-910049-1) AND REQUIRED REPAIR BY WELDING BEFORE REASSEMBLY, SEE SRM 54-00-04, PG 201. 1L72 3T4 TRT3A20 E4EA 6 CP15EA 20040127000182004012700018CE 2004 1 27 CA031118006 120031112G27305052441029 BELLCRANK BEECH 90 C90 1152913CE PWA PT6 PT6A21 52043EA HARTZLHCB3T HCB3TN3 GL ELEVATOR INTERFERENCE W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE FORWARD ELEVATOR BELLCRANK, CABLE LOCK TAB, WAS FOUND TO BE INTERFERING WITH THE LANDING GEAR MOTOR RELAY OUTBOARD MOUNTING BOLT, PREVENTING THE BELLCRANK FROM CONTACTING ITS MAX NOSE UP STOP (ELEVATOR SECONDARY STOPS). THE RELAY MOUNTING BOLT WAS EXCESSIVELY LONG, AND MOUNTED HEAD REARWARD SUCH THAT ITS ASSOCIATED NUT/WASHER WAS CATCHING ON THE CABLE LOCK TAB INSTALLED ON THE ELEVATOR BELLCRANK. THIS IS THE SAME CONDITION THAT WAS DISCOVERED ON ASSOCIATED SDR 20030416002. 1L72 3T4 T 3A20 E4EA 6 CP15EA 20040107000632004010700063EU 2004 1 7 CA031118007 120031114G2422MGH182100 INVERTER BRAERO748 HS7482A 4231001EU RROYCEDART DART5342 EU ROTOL R4304 R2124304 EU NR 2 FAILED W O OTHER J WARNING INDICATION CRCRUISE 1 CA (CAN) NR 2 INVERTER FAILED ON ROUTE TO VANCOUVER. A/C LANDED WITHOUT INCIDENT. NR 2 INVERTER WAS REPLACED, TESTED SERVICEABLE, A/C RETURNED TO SERVICE. 2L72 3T4 T A24EU A196 6 CP899 20040107000642004010700064NM 2004 1 7 CA031118008 120031110G3246315731 WHEEL BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA NR 4 CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE NR 4 MAINWHEEL WAS IN FOR A TIRE CHANGE. AFTER THE WHEEL WAS STRIPPED DOWN AND CLEANED, A LARGE CRACK WAS FOUND IN THE INNER BEARING HOUSING, RUNNING APPROX. 4 INCHES VERTICALLY DOWN THE TUBEWELL SIDE OF THE WHEEL FROM THE BEARING HOUSING. SECOND CRACK SUBSEQUENTLY FOUND. 2H72 4T4 TRTA13NM E00062EN 20040217001952004021700195GL 2004 2 17 CA031118009 120031025G2741VF465F11 RELAY DIAMONDA20 DA20C1 2990001GL CONT O240 IO240B 17063SO SNSNCHW69EK W69EK63 EA ELEVATOR TRIM STUCK W O OTHER F FLT CONT AFFECTED CLCLIMB 1 CA (CAN) TRIM WAS STUCK IN NOSE UP. TRIM INDICATOR WAS NOT SHOWING FULL UP (ONE LIGHT FROM FULL UP IND), WHEN TRIM WAS SELECTED BY EITHER TRIM SWITCHES THERE WAS NO RESPONSE. FOLLOWING MFG EMER PROCEDURES CHECK CB, (IN) AS THE TRIM MOVED TO FULL UP INDICATION AND WOULD NO LONGER MOVE. EMER PROCEDURES INDICATE THAT HIGHER FORCES CAN BE EXPECTED AND TO LAND AT NEAREST SUITABLE AIRPORT. STUCK TRIM DID NOT PREVENT FULL DEFLECTION OF ELEVATOR CONTROL OTHER THAN HIGHER FORCES REQUIRED. AFTER SEVERAL HOURS IT WAS PINNED DOWN THAT TRIM SWITCHES WERE WIRED THROUGH TWO RELAYS. FOUND THAT DOWN RELAY WOULD STICK WHEN TRIM WAS SELECTED IN FULL UP POSITION. REPLACED BOTH RELAYS AND THEN UNABLE TO FAIL SYS. 1L71 3O3 ONTTA4CH E7SO 5 NTA4CH 20040127000192004012700019WP 2004 1 27 CA031118010 120030808G2435150SG1028 LINER HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL STARTER GEN LOOSE W A UNSCHED LANDING EJ VIBRATION/BUFFET WARNING INDICATION CRCRUISE 1 CA 4947 (CAN) VIBRATION SNAG. STARTER GENERATOR REPLACED. OVERHAUL SHOP FOUND THE STEEL BEARING LINER IN THE DRIVE END ENDBELL HAD BROKEN LOOSE FROM ITS CASTING AND WORE DOWN THE ALUMINUM ENDBELL. THE LINER IS CURLED ON THE OUTSIDE, AND THE ROUGH SURFACE CHEWED THE ENDBELL SUFFICIENTLY TO ALLOW THE ARMATURE TO RUB ON THE STATOR POLES, CAUSING LOSS OF DIAMETER OF BOTH PARTS, RENDERING THE ARMATURE AND STATOR SCRAP. THE DRIVE SHAFT DID NOT SHEAR, AND WAS NOT DAMAGED (MPI DONE). SERVICE BULLETIN SB150SG106 WAS FOUND COMPLIED WITH, THAT SB INSTALLS A DOWEL PIN TO LOCK THE LINER TO THE ENDBELL IN CASE IT SHOULD COME LOOSE. 1G71 3U3 U H3WE E4CE 20040127000202004012700020NM 2004 1 27 CA031118011 120031020G555265174305 RIB BOEING727 72722C 138400FNM PWA JT8 JT8D7B 52053NE ELEVATOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING ACCOMPLISHMENT OF AD 2002-12-13 AND ENGINEERING ORDER 7-5510-7-5001PT1 INSPECTION OF THE ELEVATOR HINGE SUPPORT RIBS FOR CRACKS IN THE FLANGES ON AIRCRAFT WITH KNOWN 7079-T6 MATERIALS. A CRACK WAS FOUND IN A NON-TYPICAL AREA NOT COVERED BY THE AD OR THE EO. 2L73 4F4 F A3WE E2EA 20040127000212004012700021EA 2004 1 27 CA031118012 120031115G323016600103 UPLOCK CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE NLG FAILED W O OTHER J WARNING INDICATION APAPPROACH 1 CA (CAN) CREW HAD TO CYCLE THE GEAR HANDLE TWICE TO GET THE NOSE GEAR TO COME DOWN. REMOVED AND REPLACED THE UPLOCK ASSY. AIRCRAFT RETURNED TO SERVICE. 2L72 4F4 FRTA21EA E15NE 20040127000222004012700022EA 2004 1 27 CA031118013 120031116G5610NP1393229 WINDOW CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE COCKPIT FAILED W O OTHER O OTHER DEDESCENT 1 CA (CAN) THE FIRST OFFICER'S SIDE WINDOW SHATTERED AS THE AIRCRAFT DESCENDED OF 41,000 FT. THERE WERE NO REPORTED PROBLEMS AFTER THIS OCCURRENCE. MAINTENANCE REPLACED THE DAMAGED SIDE WINDOW AND THE AIRCRAFT RETURNED TO SERVICE. (SEE ALSO: US NR 2003121700181) 2L72 4F4 FRTA21EA EOOO63EN 20040127000232004012700023NM 2004 1 27 CA031119001 120031107G6220A1581 BEARING ROBSINR22 R22BETA 7640110NM LYC O320 O320B2C 41508EA M/R HEAD ROUGH W O OTHER E VIBRATION/BUFFET CRCRUISE 1 CA (CAN) PILOT REPORTED MAIN ROTOR SYSTEM ROUGH INTERMITTENT. INSPECTED BY AME, SPINDLE BEARINGS FOUND ROUGH. SENT FOR REPAIR. 1G71 3O3 O H10WE E274 20040127000242004012700024EA 2004 1 27 CA031119002 220031113G732325241673 GOVERNOR DHAV DHC6 DHC6100 2802610EA PWA PT6 PT6A20 52043EA HARTZLHCB3T HCB3TN3 GL NR 1 ENGINE FAILED W O OTHER X ENGINE FLAMEOUT NRNOT REPORTED 1 CA (CAN) NR 1 ENGINE POWER SURGING PRIOR TO LANDING, AFTER LANDING ENGINE FLAME OUT OCCURED. 1H72 3T3 TRTA9EA E4EA 6 CP15EA 20040107000652004010700065SO 2004 1 7 CA031119003 220031113G7322 CARBURETOR CESSNA150 150M 2071830CE CONT O200 O200A 17020SO MCAULY1A102 1A102OCM GL ENGINE ICED W B EMER. DESCENT R PARTIAL RPM/PWR LOSS DEDESCENT 1 CA (CAN) DEPARTING, CLIMBED UP TO CRUISING ALTITUDE OF 4,500 FT, STARTED DESCENT BY REDUCING POWER FROM 2,500 RPM TO APPROX 2,350 RPM. TEMP WAS -2 AND DEWPOINT -9 FOR 6,000 FT. GOT DOWN TO 3,500, LEVELED OFF, WENT TO ADD POWER FOR CRUISE, ENG SPUTTERED, WENT TO IDLE, THEN BACK TO FULL RPMS AND CONTINUED, FORCING SHALLOW DESCENT. PULLED ON CARB HEAT MIX FULL RICH, CKD FUEL VALVE, PRIMER, MAGS, OIL TEMP, OIL PRESS, CKD OK. REACHING 500 FT AGL, POWER DID NOT REGAIN SO COMMITTED TO FORCED APPROACH BY SHUTTING DOWN ENG. AC TOUCH DOWN IN FIELD AND CAME TO A ROLLING STOP, NO DAMAGE. RCMP WERE DISPATCHED. GROUND PERSONNEL PULLED COWL OFF, INSP ENG, FUEL SYS, DID RUN-UP, DETERMINED CARB ICE WAS PROBLEM. 1H71 3O3 O 3A19 E252 5 NP918 20040127000252004012700025CE 2004 1 27 CA031119004 120031030G812012509291 COUPLING GARRETTLTD CESSNA337 T337G 2075726CE CONT O360 TSIO360CB 17025SO MCAULY2AF34CD2AF34C303 GL TURBOCHARGER SEPARATED W A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CRCRUISE 1 CA BAO06000 (CAN) COUPLING SEPARATED FROM TURBOCHARGER COMPRESSOR HOUSING CAUSING INDUCTION LEAK AND RESULTING POWER LOSS. 1H72 3O3 O A6CE E9CE 5 CP5EA 20040127000262004012700026SW 2004 1 27 CA031119005 120031023G6310206040222005 SHAFT BELL BELL 206 206B 1181511SW ALLSN 250C 250C20 03013GL FREEWHEEL UNIT DAMAGED W K NONE K FLUID LOSS ININSP/MAINT 1 CA B12165 (CAN) FREEWHEEL SENT FOR OVERHAUL. NEW INNER SHAFT REQUIRED. INNER SHAFT PURCHASED NEW AND INSTALLED WITH NEW SEALS. FREEWHEEL INSTALLED ONTO AIRCRAFT FOR 24.3 HOURS THEN REMOVED FORWARD SEAL LEAKING. FREEWHEEL ASSEMBLY RETURNED TO OVERHAUL SHOP FOR SEAL WARRANTY, SEAL REPLACED. FREEWHEEL RE-INSTALLED AND REMOVED ONCE AGAIN FORWARD SEAL LEAKING. ASSEMBLY DISASSEMBLED AND INSPECTED. INNER SHAFT FOUND TO BE OUT OF ROUND OR BENT CAUSING SEAL TO LEAK. SHAFT TAGGED UNSERVICEABLE AND RETURNED TO MANUFACTURER FOR INSPECTION. NEW SHAFT INSTALLED INTO FREEWHEEL ASSEMBLY AND CONFIRMED STRAIGHT. QUALITY CONTROL OF NEW PARTS BETTER CONTROLLED AT MANUFACTURER. 1G71 3U3 U H2SW E4CE 20040127000272004012700027NM 2004 1 27 CA031119006 120031116G5330 SKIN BOEING737 737201 1384454NM PWA JT8 JT8D9A 52048NE FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 61732 (CAN) 2 INCH CRACK FOUND BELOW S17L BETWEEN BS 749 - 751. CRACK REPARED IAW SRM CHAPTER53-30-3, FIG 48, DETAIL XI. 2L72 4F4 F A16WE E2EA 20040107000662004010700066EU 2004 1 7 CA031119007 120031119G3242AN52765 BRAKE BRAERO748 HS7482A 4231001EU RROYCEDART DART5342 EU ROTOL R4304 R2124304 EU RT MLG DRAGGING W C ABORTED TAKEOFF B SMOKE/FUMES/ODORS/SPARKS TOTAKEOFF 1 CA (CAN) RIGHT BRAKE DRAGGED ON TAKEOFF OUT OF YXY A/C RETURNED TO GATE WITH NO INCIDENTS. NR 3 BRAKE REPLACED. 2L72 3T4 T A24EU A196 6 CP899 20040127000282004012700028SO 2004 1 27 CA031119008 120031117G3610442CW6 PUMP PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL PNEUMATIC SYS INOPERATIVE W K NONE J WARNING INDICATION ININSP/MAINT 1 CA (CAN) AT RT ENGINE RUN UP FOUND LIGHT PNEUMATIC SOURCE MALFUNCTION STAYING ON TILL 2000 RPM. AFTER TROUBLESHOOTING FOUND THE PUMP PN 442CW-6 WOULD NOT DELIVER RATED PNEUMATIC PRESSURE. 1L72 3O3 O A20SO E14EA 5 CP33EA 20040127000292004012700029 2004 1 27 CA031119009 420031119G25621104 ELT SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE CABIN MISINSTALLED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) ARTEX ELT MODEL ELT 110-4 P/N 453-0150 WAS WIRED INCORRECTLY- THE ELT WOULD ONLY ACTIVATE BY PANEL SWITCH OR THE SWITCH ON THE ELT. FOR THE ELT TO BE OPERATED IN AUTOMATIC MODE A JUMPER WIRE BETWEEN PINS 5 AND 8 OF MOLEX TRAY CONNECTOR NEEDS TO BE INSTALLED. ON THIS A/C THE JUMPER WIRE WAS MISSING. THERE IS A CAUTION DECAL BESIDE THE PANEL SWITCH ABSENCE OF LIGHT DURING FIRST 3 SECONDS OF TEST INDICATES POSSIBLE G-SWITCH FAILURE. IN INSTRUCTIONS STEP 4, IT IS VERY IMPORTANT THAT LIGHT COME ON DURING THE FIRST FEW SECONDS OF TEST. IF THE LIGHT FAILS TO COME ON IMMEDIATELY CHECK PINS 5 AND 8 OF THE ELT UNIT MOLEX CONNECTOR TO MAKE SURE THAT THEY ARE JUMPERED PROPERLY. 1G71 3U3 U H9EU E19EU 20040127000302004012700030SW 2004 1 27 CA031120001 120030505G6730C4264269 ACTUATOR RONSON BELL 206 206L4 1182110SW HYD SERVO BENT W K NONE O OTHER ININSP/MAINT 1 CA RH4578A (CAN) WHILE SERVICING THE HYDRAULIC ACTUATORS BY HELICOPTER ACCESSORY SERVICE IT WAS NOTICED THAT BOTH CYCLIC AND THE COLLECTIVE ACTUATOR EXTENSIONS WERE BENT LATERALLY ON THE LONGITUDINAL AXIS. NO ACCIDENT OR INCIDENT REPORTED ON THE SUBJECT HELICOPTER. 1G71 3U NCH2SW 20040127000312004012700031EU 2004 1 27 CA031120002 120031118G24353022376 SEAL PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL STARTER GEN LEAKING W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) UPON RETURNING TO BASE, IT WAS NOTICED THAT OIL WAS COMING OUT OF THE STARTER GEN COOLING VENT. THE STARTER GEN SEAL (P/N 3022376) WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040127000322004012700032EU 2004 1 27 CA031120003 120031118G24309882115103 GCU PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL NR 2 GENERATOR FAILED W O OTHER J WARNING INDICATION TXTAXI/GRND HDL 1 CA (CAN) JUST BEFORE SHUTDOWN, IT WAS NOTED THAT THE GEN 2 CAWS LIGHT WOULD COME ON INDICATING GEN 2 FAILURE. THE GENERATOR CONTROL UNIT P/N 988.21.15.103 WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040127000332004012700033EU 2004 1 27 CA031120004 120031030G27429787314202 ACTUATOR PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL HORIZONTAL TRIM INOPERATIVE W O OTHER F FLT CONT AFFECTED DEDESCENT 1 CA (CAN) DURING LEVEL FLIGHT, THE CREW ATTEMPTED TO INITIATE A SLOW DESCENT USING HORIZONTAL STAB PITCH TRIM AND NOTICED IT WAS INOPERATIVE. THEY TRIED TO USE THE SECONDARY (ALTERNATE) TRIM FUNCTION AND NOTICED IT WAS ALSO INOPERATIVE. THEY PERFORMED APPROPRIATE CHECK LIST FUNCTIONS AND FINISHED FLIGHT WITHOUT USE OF PITCH TRIM WITHOUT INCIDENT. WHEN TROUBLESHOOTING THE SYSTEM WE COULD HEAR THE MOTORS ON BOTH PRIMARY AND ALTERNATE SYSTEMS WHEN ACTIVATED BUT NO MOVEMENT WAS NOTICED. THE REST OF THE SYS WAS OK SO WE CONCLUDED THAT PITCH TRIM ACTUATOR WAS FAULTY AND HAD FAILED INTERNALLY. THE ACTUATOR WAS REPLACED AND THE SYSTEM RESUMED BEING AIRWORTHY. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040127000342004012700034WP 2004 1 27 CA031120005 120031107G2730S4913801CS38808 CONTROL CABLE DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE ELEVATOR FAILED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) DURING 'C' CHECK, MAINTENANCE FOUND THE LT ELEVATOR UP AND DOWN CABLE TWISTED ONE FULL TURN TOGETHER BETWEEN VERTICAL STABILIZER CABLE RETAINER (IPC 27-30-00 FIG 4A ITEM C) AND HORIZONTAL STABILIZER PULLEYS (IPC 27-30-00 FIG 5B ITEM M). CABLE STRANDS FOUND WORN TO APPROXIMATELY 50 PERCENT. BOTH CABLES REPLACED. IT WAS FOUND THAT THE VERTICAL STABILIZER ASSEMBLY WAS REMOVED AND REINSTALLED BY THE PREVIOUS OPERATOR. 2L72 4F4 FRTA6WE E9NE 20040127000352004012700035CE 2004 1 27 CA031120006 120031120G5230 LATCH BEECH 99 99 1154002CE PWA PT6 PT6A28 EA HARTZLHCB3T HCB3TN3 GL CARGO DOOR UNSECURE W A UNSCHED LANDING WJ INADEQUATE Q C WARNING INDICATION CLCLIMB 1 CA (CAN) NOTICED BAGGAGE DOOR LITE ON AFTER TAKEOFF, RETURNED TO BASE FOUND LATCH UNDONE. LATCH CLOSED. AIRCRAFT RETURNED TO SERVICE. 1L72 3T4 T A14CE E4EA 6 CP15EA 20040127000362004012700036EU 2004 1 27 CA031120007 120031120G6220704A3363320851 SPHERICAL STOP SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE MAIN ROTOR WORN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) A WORN SPHERICAL STOP WAS CHANGED DUE TO DEBOND. WITH THE ONE STOP CHANGED AND THE ROTORS TURNING AT FULL RPM ON THE GROUND AND HYDRAULIC SYSTEM TURNED 'OFF' THE CYCLIC STICK MOVED VIA ROTOR HEAD FEED BACK. TO DETERMINE THE CAUSE OF THE FEED BACK , THE TWO OTHER STOPS WERE CHANGED SO THAT WE WOULD HAVE STOPS WITH THE SAME ELASTOMERIC QUALITIES. THE PROBLEM OF THE FEED BACK WITH HYDRAULICS OFF WENT AWAY. MFG ALLOWS ONE STOP OF THE SAME PART NUMBER TO BE CHANGED OUT, BUT IN THIS CASE WE HAD A PROBLEM. 1G71 3U3 U H9EU E19EU 20040127000372004012700037NE 2004 1 27 CA031120008 120031025G79210401272820 DUCT SKRSKYS76 S76A 8143006NE TMECA ARRIELARRIEL1S1 60030NE ENG OIL COOLER SEPARATED W O OTHER J WARNING INDICATION CRCRUISE 1 CA (CAN) DURING NORMAL DAILY TREND CHECK, PILOT NOTICED GRADUAL INCREASE IN ENG OIL TEMP ON NR 2 AND REPORTED TO THE ENGINEER. INSPECTION CARRIED OUT ON THE NR 2 OIL COOLER DUCT INSTALLATION IN WHICH THE FLEXIBLE DUCT LOCATED BELOW THE BLOWER ON THE INSIDE OF THE AIRFRAME WAS FOUND TO HAVE SEPERATED INTERNALLY AND PARTIALLY COLLAPSED. THE DUCT WAS CHANGED OUT AND OIL TEMP WENT BACK TO NORMAL. DUCT HAD BEEN INSTALLED ON 11MAY 2003.THIS IS THE SECOND OCCURRENCE OF FAILURE OF THIS PART.(REFER ALSO I2002-192) 1G72 3U3 U H1NE E19EU 20040127000382004012700038WP 2004 1 27 CA031120009 120031113G56105887275505 WINDSHIELD DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE COCKPIT FAILED W A UNSCHED LANDING D INFLIGHT SEPARATION CLCLIMB 1 CA (CAN) DURING CLIMB, EXCESSIVE NOISE CAME FROM CENTER WINDSHIELD. AIRCRAFT LANDED BACK TO DEPARTURE. THE CENTER WINDSHIELD WAS PREVIOUSLY REPLACED. MAINTENANCE FOUND SCREW TORQUE NOT PROPERLY SETTED. WINDSHIELD RETORQUED AND RESEALED IAW AMM AND AIRCRAFT RETURNED TO SERVICE. 2L72 4F4 FRTA6WE E9NE 20040107000672004010700067GL 2004 1 7 CA031120010 220031104G732123070609 FUEL CONTROL BELL 206 206L 1181522SW ALLSN 25OC 250C20R GL ENGINE FAILED W A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CRCRUISE 1 CA 51490 (CAN) PILOT RETURNING TO BASE NOTICED RAPID TORQUE GAUGE FLUCTUATION BETWEEN 5 PERCENT TO 10 PERCENT, OCCURRING MOSTLY AT AROUND 85 PERCENT TORQUE. LATER PILOT AND AME CONDUCTING TEST FLIGHT TO CONFIRM PROBLEM NOTICED SLIGHT ENGINE SURGING NOTICEABLE ONLY BY ENGINE SOUND, NO OTHER GAUGES INDICATED ANY PROBLEM. AFTER EXTENSIVE TROUBLESHOOTING, IT WAS FOUND THAT THE FUEL CONTROL UNIT WAS CAUSING THE TORQUE FLUCTUATION. 1G71 3U3 U H2SW E4CE 20040217001962004021700196EA 2004 2 17 CA031120011 220031113G7230 BLADE PWA PT6 PT6* 52043EA ENGINE FAILED W K NONE O OTHER ININSP/MAINT 1 CA 15958 (CAN) DAMAGE TO PT COMPONENTS IS SUBSTANTIAL AND MOST ARE CONSIDERED SCRAP. DAMAGE INCLUDES LG NR OF PT2 BLADES (3115863-01) FRACTURED AT BLADE ROOT AND AT PT SHAFT HSG ASSY WHICH HAS MNT FLANGE SEPARATED FROM MAIN BODY OF HSG. ALL COMPONENTS EXCEPT GB ARE SCRAP. AN INTERSTAGE AIR SEAL FAILURE WHERE PART OF ROTATING SEAL FATIGUES AND BREAKS AWAY AND JAMS UP PT2 AIRSEAL CAUSING INNER SEAL TO BE TORN FROM PT2 STATOR AND PIECES INGESTED INTO PT1, PT2 ROTORS CAUSING BLADES TO FRACTURE, WITH OUT OF BALANCE CAUSING PT SHAFT HSG TO FRACTURE WITH MASSIVE DAMAGE RESULTING, PT SHAFT HSG FAILURE, CONSIDERED THAT A PRIMARY FAILURE. FRACTURE AROUND HSG JUST AT FLANGE CORNER RADIUS WAS VERY UNIFORM ALL AROUND. 3 T E2NE 20040127000392004012700039EA 2004 1 27 CA031120012 120031119G324295503774 BRAKE ASSY DHAV DHC6 DHC6300 2802606EA PWA PT6 PT6A27 52043EA HARTZLHCB3T HCB3TN3 GL MLG FROZEN W O OTHER O OTHER LDLANDING 1 CA (CAN) THE AIRCRAFT WAS OPERATING OUT OF A REMOTE STRIP. UPON BACK-TRACK AND TURN-AROUND FOR TAKE-OFF, THE A/C ENCOUNTERED DEEP SNOW AT THE END OF THE STRIP. NORMAL TAKE-OFF PROCEDURES WERE C/O. UPON LANDING AT YVQ, PILOTS EXPERIENCED ABRUPT DECELLERATION. THE A/C CAME TO A STOP ON THE RUNWAY SHORTLY AFTER TOUCHDOWN. MAINTENANCE WAS DISPATCHED TO MEET THE A/C ON THE RUNWAY TO LOOK INTO THE PROBLEM. ICE BUILD UP WAS FOUND IN BOTH MAIN GEAR BRAKE ASSY. AFTER MELTING THE ICE WITH METHYL HYDRATE, THE A/C WAS ABLE TO TAXI OFF RUNWAY. INSPECTION WAS C/O ON MAIN GEAR AND BRAKE ASSEMBLIES FOR ANY ABNORMALITIES. NO DEFECTS FOUND. BRAKES WERE CHECKED SERVICEABLE AND A/C RETURNED TO SERVICE. 1H72 3T4 TRTA9EA E4EA 6 CP15EA 20040127000402004012700040EU 2004 1 27 CA031121001 120031118G5713 STRINGER BRAERO748 HS7482A 4231001EU RROYCEDART DART5342 EU ROTOL R4304 R2124304 EU RT WING CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 33599 (CAN) DURING A ROUTINE SCHEDULED MAINTENANCE, A SMALL CRACK ON STRINGER 8 JUST IB OF WS251.3 RT WING WAS FOUND. A TEMPORARY/PERMANENT REPAIR SCHEME WAS OBTAINED. A PERMANENT REPAIR WAS CARRIED OUT IAW BARA/748/6591/03-MJC WASH S/N 000397. 2L72 3T4 T A24EU A196 6 CP899 20040127000412004012700041CE 2004 1 27 CA031121002 120031119G783020200081 IDLER LINK ROHR CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE THRUST REVERSER BROKEN W O OTHER EJ VIBRATION/BUFFET WARNING INDICATION LDLANDING 1 CA 466 (CAN) LT ENGINE THRUST REVERSER, LOWER DOOR, INBOARD AFT, IDLER LINK ASSY BROKEN AROUND THE BEARING SUPPORT BOSS. IDLER LINK FOUND JAMMED IN THRUST REVERSER STRUCTURE CAUSING THRUST REVERSER TO REMAIN CLOSED AND LOCKED WHEN SELECTED TO DEPLOY ON LANDING. IT IS LIKELY THIS HAPPENED ON THE PREVIOUS LANDING AND UPON STOWING THE T/R JAMMED IN A CLOSED AND LOCKED POSITION. 1L72 4F4 F A22CE E1NE 20040127000422004012700042SW 2004 1 27 CA031121003 120031113G325021525 SPRING BBAVIA7 7ECA 21101NNSW LYC O235 O235K2C 41505EA SNSNCH72C 72CK EA TAIL STEERING BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) BROKEN TAILWHEEL SPRING DISCOVERED DURING GROUND HANDLING. HOOK HAD BROKEN OFF ONE END. BREAK APPEARED TO HAVE STARTED AT BEND WHERE HOOK IS FORMED FROM SPRING COIL. 1H71 3O3 O A759 E223 5 NP9045 20040127000432004012700043SO 2004 1 27 CA031121004 120031120G3232 SHAFT PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL ACTUATOR SHEARED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING POST FLIGHT WALK AROUND THE PILOT NOTICED THE IB GEAR DOOR WAS IN THE DOWN POSITION, AFTER FURTHER INSPECTION IT WAS NOTICED THAT THE GEAR DOOR ACUATOR PISTON SHAFT WHERE IT IS THREADED HAD SNAPPED OFF. THERE WAS NO OTHER DAMAGE TO THE A/C. AFTER FURTHER INSPECTION THERE APPEARED TO BE A OLD CRACK APPROX HALFWAY THROUGH THE SHAFT WHICH WOULD NOT BE NOTICABLE DURING ROUTINE INSPECTIONS. 1L72 3O3 O A20SO E14EA 5 CP33EA 20040127000442004012700044NM 2004 1 27 CA031124001 120030911G3320404830 SOCKET BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU CABIN LIGHT BURNED W K NONE B SMOKE/FUMES/ODORS/SPARKS ININSP/MAINT 1 CA (CAN) CEILING LIGHT, SHORT CIRCUIT. UPON ENTERING AIRCRAFT, THE CABIN ATTENDANT SMELLED SMOKE AROUND ROW 20 AND AFT. PILOT CONFIRMED THE SMELL OF SMOKE AND SAW VISIBLE SMOKE FROM AROUND ROW 20 SEAT AC AND TURNED OFF ALL ELECTRICITY AND THE SMOKE STOPPED. MAINTENANCE WAS CALLED FOR ASSISTANCE. INVESTIGATION/ACTION TROUBLESHOOTING SHOWED AN OVERHEATED LAMP HOLDER PN 404830 AT POSITION 20. THE LAMP HOLDER WAS REPLACED. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20040127000452004012700045WP 2004 1 27 CA031124002 120031121G6710369A7304 SUPPORT BRACKET HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL COLLECTIVE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ON A SCHEDULED 100 HR INSP, A CRACKED WAS FOUND ON THE UPPER BEARING CAP THAT SUPPORTS THE IB END OF THE COLLECTIVE JACKSHAFT. AFTER REMOVAL, IT WAS NOTED THAT THE CRACK HAD NOT YET GONE FULLY THRU THE MATERIAL. THE ASSY WAS REPLACED WITH A SERVICEABLE UNIT AND AIRCRAFT RETURNED TO SERVICE. 1G71 3U3 U H3WE E4CE 20040127000462004012700046SW 2004 1 27 CA031124003 120030401G3246 SKID BELL 206 206B 1181511SW ALLSN 250C 250C20 03013GL MLG BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING FLIGHT OPERATION THE SKID GEAR (SUPPLEMENTAL TYPE CERTIFICATE HIGH SKID WITH FLIGHT STEP CONFIGURATION) WAS FOUND WITH 14 INCHES BROKEN. 1G71 3U3 U H2SW E4CE 20040127000472004012700047SW 2004 1 27 CA031124004 120031121G7920 PIN SWRNGNSA226 SA226TC 8780404SW GARRTTTPE331TPE33110UA 01514WP HARTZLHCE4N HCE4N3 NE OIL FILTER POPPED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE OIL FILTER BYPASS PIN WAS FOUND POPPED ON THE LT ENGINE. THE OIL FILTER WAS REPLACED. DAMAGE TO THE REMOVED OIL SAMPLE WAS NOTED. THE MOUNTING FLANGE OF THE FILTER WAS MISSING FROM THE RADIUS INWARD. THE OIL FILTER P/N 3001436-1 IS INCLUDED IN THE WEAR CHECK. P/N GT331 OIL SAMPLE KITS. 2L72 4T4 TRTA8SW E4WE 5 CP10NE 20040127000482004012700048CE 2004 1 27 CA031125001 120031117G3297 WIRE LEAR 35 35A 5170602CE GARRTTTFE731TFE7312 01518WP MLG BROKEN W O OTHER F FLT CONT AFFECTED LDLANDING 1 CA (CAN) IN APPROACH FLIGHT CREW CANNOT EXTEND THE GEAR NORMALLY. EMERGENCY BLOW DOWN SYSTEM ACTIVATED(EMERGENCY EXTENSION). MAINTENANCE FOUND WIRE TO DIODE CR105(LOCATED ON RT INSTRUMENT PANEL NEAR EMERGENCY BATTERY SWITCH) BROKEN OFF. WIRE RECONNECTED TO DIODE CR105. GEAR SWING FUNCTIONAL CHECK COMPLETED. AIRCRAFT RETURN TO SERVICE. 2L72 4F4 F A10CE E6WE 20040127000492004012700049 2004 1 27 CA031125002 420030911G342042000332501 COMPUTER BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU AHRS MALFUNCTIONED W O OTHER P NO WARNING INDICATION CLCLIMB 1 CA (CAN) AHRS NR 1 AND AP FAILURE: DURING CLIMB TROUGH FL 190 (FOR FL 230), SPEED 221, CLEAN CONFIG AND PITCH 5 DEGREE NOSE UP. ELEVATOR FEEL CAUTION LIGHT CAME ON AND PFD/MFD ON LT SIDE LOST ALL INDICATIONS. WE LEVELED OFF AT FL 200 AND SPEED CAME BACK TO MAX 200, CHANGE AP OVER TO RT PILOT AND CONDUCTED MANUAL FLYING FOR THE REST OF THE FLIGHT. ADC NR 1 WAS CHANGED FROM NORMAL TO NR 2. RETURNED TO BASE (REST OF THE FLIGHT UNEVENTFUL). INVESTIGATION/ACTION: AFTER ARRIVAL TO BASE, THE AHRS WAS REPLACED. THE FAULT WAS LATER CONFIRMED AT SHOP. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20050427003132005042700313EU 2005 4 27 CA031125003 120031124G532025W26110200 BRACKET ISRAEL1125 ASTRASPX 4500205EU GARRTTTFE731TFE73140 29001NE LT WHEEL WELL MISINSTALLED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) PROBLEM WAS FOUND ON LT SIDE GEAR DOOR STOP. BRACKET WAS INSTALLED BY AIRCRAFT MFG IN THE WRONG POSITION AND WRONG PN IAW MFG IPC BRACKET WAS CHANGED AND DOOR RIGGED IAW MM AND WORKED OK. 2L72 4F4 FRTA16NM E1NM 20040127000502004012700050WP 2004 1 27 CA031125004 220031124G7200 ENGINE BRAERODH125 BAE125800A 1500285EU GARRTTTFE731TFE7315R 01518WP RIGHT MALFUNCTIONED W O OTHER RJ PARTIAL RPM/PWR LOSS WARNING INDICATION CLCLIMB 1 CA (CAN) A/C CLIMBING THROUGH 10K, RT ENGINE SPOOLED DOWN. STILL TROUBLESHOOTING. 2L72 4F4 FRTA3EU E6WE 20040127000512004012700051EU 2004 1 27 CA031126001 120031114G28203510541 LINE BOLKMS105 BO105S 5626006EU ALLSN 250C 250C20B 03013GL FUEL SYSTEM LEAKING W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) REFERENCE AIRCRAFT SB 351 054 AIRFRAME FUEL FILTER SUBSTITUTION. FUEL LINE PN 351-054-1 LEAKS THROUGH THE STAINLESS STEEL BRAIDED CASING OF THE LINE. MAINTENANCE SUSPECTS THE LINE HAS DETERIORATED WITH AGE. THE LINE WAS MANUFACTURED IN 1994 AND HAS ACCUMULATED NINE YEARS IN SERVICE. 1G72 3U3 U H3EU E4CE 20040127000522004012700052NE 2004 1 27 CA031126002 220031101G7250 TURBINE WHEEL BOEING717 717200 1383700NM RROYCEBR700 BR700715A130 NE NR 2 ENGINE OVERHEATED W EA ENGINE SHUTDOWN UNSCHED LANDING MJ OVER TEMP WARNING INDICATION CLCLIMB 1 CA 13247 (CAN) AIRCRAFT 478 NR 2 ENGINE, FLIGHT 376 LIH-HNL. DURING CLIMB AT 10,000 FT, NR 2 ENGINE EXPERIENCED A LOUD BOOM AND OVERHEATED TO 1093 DEGREES. ENGINE WAS SHUTDOWN. AIRCRAFT MADE NORMAL SINGLE ENGINE LANDING. MCD WAS CHECKED AND FOUND CLEAN. FAN ROTOR WAS SPUN AND BUMPS IN THE ROTATION COULD BE FELT. INSPECTION OF THE TAILPIPE REVEALED METAL PARTICLES. ENGINE JUST ARRIVED NOV 25 ATRRC FOR INVESTIGATION OF FAILURE. 2L72 4F4 FTRA6WE E00061EN 20040127000532004012700053SW 2004 1 27 CA031126003 120031126G6310406040509101 CAP BELL 407 407 1182206SW FREEWHEEL ASSY MISMANUFACTURED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) FREEWHEEL ASSEMBLIES WERE DISOVERED TO HAVE A MISSING MACHINING FEATURE ON THEIR CAPS 509-101, .188. 1G71 3U O H2SW 20040127000542004012700054CE 2004 1 27 CA031126004 120031122G321311581000654 STRUT BEECH 100 A100 1152915CE PWA PT6 PT6A28 EA MCAULY4HFR344HFR34C652 NE MLG CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) AFTER A PILOT REPORTING THE RT MAIN GEAR OLEO WAS LOW, MAINTENANCE ATTEMPTED TO INFLATE THE OLEO WITH NITROGEN. THE NITROGEN IMMEDIATELY STARTED TO LEAK FROM A LARGE CRACK AROUND THE UPPER TORQUE KNEEBOSS ON THE BRACE ASSEMBLY. THE CRACK WAS APPROXIMATELY 6 INCHES IN LENGTH STARTING AT THE BOTTOM OF THE BRACE ASSEMBLY, GOING UP THE RADIUS ON THE LT SIDE OF THE BOSS AND TURNING AND CROSSING OVER THE TOP OF THE BOSS. THIS GEAR HAD 277 CYCLES SINCE INSPECTION. 1L72 3T4 T A14CE E4EA 6 C3PNE 20040127000552004012700055SW 2004 1 27 CA031126005 120031126G6310406040509101 CAP BELL 206 206L4 1182110SW FREEWHEEL ASSY MISMANUFACTURED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) FREEWHEEL ASSEMBLIES WERE DISCOVERED TO HAVE A MISSING MACHINING FEATURE ON THEIR CAPS 509-101, .188 1G71 3U NCH2SW 20040127000562004012700056CE 2004 1 27 CA031126006 120031029G534307900066 ATTACH FITTING CESSNA180 180G 2072616CE CONT O470 O470R 17026SO MCAULY2A34C 2A34C66 GL MLG CORRODED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING SCHEDULED MAINTENANCE, IT WAS DISCOVERED THAT P/N 0790006-6 WAS BROKEN DUE TO INTERGRANULAR CORROSION. FLOOR AND ADJACENT STRUCTURES DRILLED APART TO FACILITATE CHANGING THE BRACKET. REASSEMBLED USING EXISTING RIVET SIZE AND PATTERN AS ORIGINAL. 1H71 3O3 O 5A6 E273 5 CP3EA 20040127000572004012700057SW 2004 1 27 CA031126007 120031124G5302206031329001 ATTACH FITTING BELL 206 206B 1181511SW ALLSN 250C 250C20B 03013GL TAILBOOM CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 15731 (CAN) CRACK LOCATED AT UPPER LT TAILBOOM ATTACHMENT FITTING (AIRFRAME SIDE), P/N 206031329001. CRACK EXTENDS BETWEEN FIRST SET OF RIVETS FORWARD OF ATTACHMENT BOLT HOLE, AS WELL AS ABOVE UPPER RIVET TO THE TOP EDGE OF THE FITTING. CRACK FOUND DURING A 100/300 HR INSPECTION. SUBJECT PART TO BE REPLACED. 1G71 3U3 U H2SW E4CE 20040127000582004012700058CE 2004 1 27 CA031126008 120031125G321311581000654 STRUT BEECH 100 A100 1152915CE PWA PT6 PT6A28 EA MCAULY4HFR344HFR34C652 NE MLG CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) AFTER FINDING THE RT MAIN GEAR BRACE CRACKED WE INSPECTED THE LT GEAR AND FOUND A SMALL CRACK AT THE UPPER END OF THE RADIUS OF THE UPPER TORQUE KNEEBOSS. LIQUID PENETRANT WAS REQUIRED TO CONFIRM THE CRACK. IT STARTED AT THE TOP OF RADIUS AND TRAVELED DOWNWARDS ABOUT 1.5 INCHES. 1L72 3T4 T A14CE E4EA 6 C3PNE 20040127000592004012700059WP 2004 1 27 CA031126009 120031124G6410369A10045 PIN HUGHES369 369D 4470706WP ALLSN 250C 250C20R2 GL M/R BLADE BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) BLADE PIN FOUND TO BE BROKEN WHERE THREAD MEETS THE PIN. 1G71 3U3 U H3WE E4CE 20040127000602004012700060CE 2004 1 27 CA031126010 120031107G2131 CONTROLLER LEAR 45 45LEAR 5170805CE GARRTTTFE731TFE7312 01518WP CABIN PRESSURE MALFUNCTIONED W BG EMER. DESCENT O2 MASK DEPLOYED J WARNING INDICATION CRCRUISE 1 CA (CAN) IN CRUISE AT AN ALTITUDE IN EXCESS OF FL 40 AFTER ALTITUDE CHANGES DOWN AND UP IN EXCESS OF 1000 FEET THE PRESSURIZATION CONTROLLER FAILED TO MAINTAIN CABIN PRESSURIZATION. AN EMERGENCY DESCENT WAS INITIATED AND PASSENGER OXYGEN MASKS DEPLOYED. THE PRESSURIZATION CONTROL WAS ABLE TO BE RESET PRIOR TO LANDING. INVESTIGATION FOUND THAT THIS WAS A KNOWN PROBLEM WITH THIS AIRCRAFT AND WAS ADDRESSED BY AD WIRE 21-004. MFG HAS JUST LATELY RELEASED S/B 45-21-13 WHICH HAS BEEN INSTALLED IN THIS AIRCRAFT AND CONFIRMED TO HAVE CORRECTED THIS PROBLEM. 2L72 4F4 FRTT00008WIE6WE 20040127000612004012700061NM 2004 1 27 CA031126011 120031120G5753 SKIN BOEING727 727243 138408DNM PWA JT8 JT8D15 52051NE TE FLAP CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 48876 (CAN) WHILE PERFORMING A (C CHECK), CORROSION WAS FOUND ON THE LT IB FLAP AT WBL 124. AFTER PAINT REMOVING IT WAS DISCOVERED THAT A CRACK OF .5000 INCH LONG WAS BENEATH THE PAINT. CRACK REPAIR IAW SRM. 2L73 4F4 FRTA3WE E2EA 20040127000622004012700062NM 2004 1 27 CA031126012 120031112G5330 SKIN BOEING727 727243 138408DNM PWA JT8 JT8D15 52051NE FUSELAGE LIGHTNING STRIKEW K NONE O OTHER ININSP/MAINT 1 CA 48876 (CAN) WHILE PERFORMING A (C CHECK) IT WAS FOUND THAT THE AIRPLANE HAD BEEN HIT BY LIGHTING. POINT OF ENTRY WAS AT NOSE DOOR AND EXIT POINT AT RT ELEVATOR TAB. REPAIR HAD TO BE CARRIED OUT BETWEEN BS 196 TO 203, BS 219 TO 235 , FORWARD OF NOSE LDG FS 188, NOSE DOOR AND RT ELEVATOR TAB. NO DAMAGE TO RADIO. CARRY OUT MFG LIGHTING STRIKE PROCEDURE IAW MM. 2L73 4F4 FRTA3WE E2EA 20040127000632004012700063CE 2004 1 27 CA031127001 120031125G3210508103327 BRACE BEECH BEECH 100 A100 1152915CE PWA PT6 PT6A28 EA MCAULY4HFR344HFR34C652 NE MLG STRUT CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) AFTER FINDING TWO OTHER GEAR BRACES CRACKED (SDR 20031126008, 20031126004) WE INSPECTED THE LT GEAR AND FOUND A POSSIBLE CRACK AT THE UPPER END OF THE RADIUS OF THE UPPER TORQUE KNEEBOSS. LIQUID PENETRANT WAS REQUIRED TO CONFIRM THE CRACK. IT STARTED AT THE TOP OF RADIUS AND TRAVELED DOWNWARD TO THE END OF THE GEAR BRACE. THE GEAR WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 1L72 3T4 T A14CE E4EA 6 C3PNE 20040127000642004012700064CE 2004 1 27 CA031127002 120031127G32429550634 KEY GOODYEAR LEAR 35 35A 5170602CE GARRTTTFE731TFE73122B 01518WP TORQUE TUBE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA JAN8175 (CAN) DURING A BRAKE ASSY OVERHAUL IAW MM, FOUND TORQUE TUBE KEY CRACKED. WE EXPERIENCE THIS TWICE SINCE LAST MONTH. THE TORQUE TUBE HOLD THE STATIONARY DISK IN PLACE. TORQUE TUBE REPLACED. 2L72 4F4 F A10CE E6WE 20040127000652004012700065CE 2004 1 27 CA031127003 120031125G57110001102501 ATTACH FITTING BEECH BEECH 100 A100 1152915CE PWA PT6 PT6A28 EA MCAULY4HFR344HFR34C652 NE WING SPAR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 19436 (CAN) DURING AN UNSCHEDULED INSPECTION A SMALL CRACK WAS FOUND IN THE UPPER FORWARD WING ATTACH FITTING, THE CRACK WAS APPROXIMATELY .0625 OF AN INCH LONG STARTING AT THE TOOLING HOLE HEADING TOWARD THE TUB. THE AIRCRAFT IS GROUNDED WAITING FOR WING SPAR REPLACEMENT. THE CRACK IS VERY HARD TO SEE, IF YOU LOOK AT THE 3RD PICTURE, TAKEN THOUGHT A MAGNIFYING GLASS YOU WILL SEE A FINE BLACK LINE LEAVING THE HOLE AT 7 O CLOCK THIS IS THE CRACK. 1L72 3T4 T A14CE E4EA 6 C3PNE 20040127000662004012700066NE 2004 1 27 CA031127004 220031117G74219550175400 IGNITER SNIAS 350 AS350BA 8680817EU TMECA ARRIELARRIEL1B 6OO30NE ENGINE FAILED W K NONE O OTHER ININSP/MAINT 1 CA 4251 (CAN) DURING 100 HOUR INSPECTION IT WAS FOUND THAT THE CERAMIC INSIDE THE IGNITORS X 2 WERE LOOSE AND RATTLING AROUND INSIDE THE IGNITERS. IGNITERS WERE MANUFACTURED BY CHAMPION PN CH34745. IGNITERS REPLACED. UNSERVICEABLE IGNITERS SENT TO MFG FOR REPLACEMENT. 1G71 3U3 UNCH9EU E19EU 20040127000672004012700067CE 2004 1 27 CA031127005 120031118G532007136713 ANGLE CESSNA182 182K 2072724CE CONT O470 O470R 17026SO MCAULY2A34C 2A34C66 GL CABIN FLOOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) CABIN FLOOR ON RT SIDE. DISCOVERED FLOOR HAD MOVED DOWN. ON INVESTIGATION FOUND THE LT AND RT TUNNEL ANGLES BROKEN AND CRACKED. REMOVED BOTH ANGLES PN 07136713 AND -4, PARTS WERE NOT MADE BY MFG. NO RECORD OF A REPAIR FOUND IN TECHNICAL LOGS. 1H71 3O3 ONT3A13 E273 5 CP3EA 20040127000682004012700068EU 2004 1 27 CA031127006 220031120G7532EU13933 PLATE RROYCETAY TAY6118 EU BLEED VALVE MISMANUFACTURED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) A REQUEST CAME FROM MFG TO VERIFY A POSSIBLE MANUFACTURING PROBLEM ON PLATE EU13933. MFG FOUND THEIR STOCK OF EU13933 WRONGLY MANUFACTURED. RADIUS OF PLATE WAS MACHINED ON WRONG SIDE OF PLATE BY MANUFACTURER IN SPAIN. HAVING NO RADIUS IN CORRECT AREA COULD CAUSE A POTENTIAL STRESS TO THE TAY HP COMPRESSOR BLEED VALVE STRAP WHICH COULD CAUSE A POTENTIAL FAILURE OF BLEED VALVE. DEFECTIVE PLATES HAVE BEEN REMOVED FROM USAGE AN PLACED IN QUARANTINE AND PROBLEM REPORTED TO MFG IAW THEIR REQUEST. MFG ARE PRESENTLY INVESTIGATING PROBLEM AND POTENTIAL SAFETY HAZARD. MEANWHILE MFG INSTALLING USED SERVICEABLE PLATE UNDER TECHNICAL VARIANCES FROM MFG. CONTAINMENT ACTIONS ARE PRESENTLY UNDERGOING BY MFGS. 4 F E25NE 20040127000692004012700069EA 2004 1 27 CA031127007 120031125G2823TC173007 SELECTOR DHAV DHC2 DHC2MK1 2800102EA PWA R985 R985AN14B 52008NE HARTZLHCB3R HCB3R304 GL FUEL SYSTEM CORRODED W D RETURN TO BLOCK L NO TEST TXTAXI/GRND HDL 1 CA (CAN) THE PILOT REPORTED THAT THE FUEL SELECTOR WAS HARD TO MOVE. ON INSPECTION THE STEEL DETENT PLATE LOCATED ON THE SELECTOR, BEHIND THE CABLE DRUM WAS FOUND TO BE CORRODED. THE VALVE WAS REMOVED FOR OVERHAUL. 1H71 3R3 R A806 5E1 5 CP28EA 20040127000702004012700070EA 2004 1 27 CA031127009 120031125G2820C2P1107 LINE DHAV DHC2 DHC2MK1 2800102EA PWA R985 R985AN14B 52008NE HARTZLHCB3R HCB3R304 GL FUEL SELECTOR CORRODED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING A FUEL SELECTOR CHANGE INTERGRANULAR CORROSION WAS NOTED ON THE FUEL LINE ELBOW. CORRODED PART REPLACED WITH NEW UNIT. 1H71 3R3 R A806 5E1 5 CP28EA 20040127000712004012700071EU 2004 1 27 CA031127010 120031118G2910704A336900004 DRIVE BELT SNIAS 350 AS350BA 8680817EU TMECA ARRIELARRIEL1B 6OO30NE HYS SYSTEM DELAMINATED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) UPON RECEIPT OF INFORMATION REGARDING BELT CONDITION, BELT WAS REMOVED FROM THE AIRCRAFT AND INSPECTED. DELAMINATION OF TOP FABRIC 100 PERCENT OF WIDTH TO A DEPTH OF 2-3 MILLIMETERS. EDGES SHOWED CRACKS IN RUBBER, VISIBLE WITH 10X GLASS. LIFE OF PART 600 HOURS. 1G71 3U3 UNCH9EU E19EU 20040127000722004012700072CE 2004 1 27 CA031127011 120031125G531208130225 BULKHEAD CESSNA310 310L 2074230CE CONT O470 IO470VO 17026SO HARTZLHCJ3Y PHCJ3YF2 GL FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING THE 100 HOUR INSPECTION PLAY WAS NOTICED IN THE NOSE GEAR AREA. UPON INSPECTION THE LT NOSE SECTION BULKHEAD WAS FOUND TO BE CRACKED VERTICALLY THROUGH THE CENTER OF THE LIGHTENING HOLE. DOUBLER PATCHES WERE INSTALLED AND RIVETED INTO PLACE AND THE NOSE GEAR WAS AGAIN INSPECTED FOR PLAY. 1L72 3O3 O 3A10 3E1 5 CP36EA 20050427003142005042700314EA 2005 4 27 CA031127012 120031119G27505912577 TORQUE SHAFT CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE TE FLAPS DISCONNECTED W O OTHER F FLT CONT AFFECTED APAPPROACH 1 CA (CAN) THIS AIRCRAFT WAS ON ITS FIRST FLIGHT AFTER A C-CHECK HAD BEEN CARRIED OUT. THE FLAP SYSTEM HAD EXPERIENCED SEVERAL PROBLEMS AFTER THE CHECK AND PRIOR TO THIS FLIGHT. TORQUE SHAFTS AND BPSUS HAD BEEN REPLACED DURING THE C-CHECK AND THERE HAD BEEN MECHANICAL MIS-RIG PROBLEMS WHEN RETURNING TO SERVICEABILITY. SUBSEQUENT TO THE FAILURE INBOUND AIRPORT, IT WAS DISCOVERED THAT THE LT WING TORQUE SHAFT HAD BECOME DISCONNECTED FROM THE ADJACENT SPLINE DRIVE. WHEN THE SHAFT HAD BEEN INSTALLED, THE BOLT HAD NOT BEEN SECURED THROUGH THE SPLINE DRIVE. THE SHAFT WAS SECURED PROPERLY, SYSTEM CHECKED AND THE AIRCRAFT RETURNED TO SERVICE. 2L72 4F4 FRTA21EA EOOO63EN 20040127000732004012700073EA 2004 1 27 CA031127013 120031126G5610NP1393225 WINDOW CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE COCKPIT CRACKED W A UNSCHED LANDING D INFLIGHT SEPARATION CRCRUISE 1 CA (CAN) CAPT'S SIDE WINDOW SHATTERED AT FL240. AIRCRAFT FERRIED. WINDOW REPLACED, AIRCRAFT RETURNED TO SERVICE. 2L72 4F4 FRTA21EA EOOO63EN 20040127000742004012700074NE 2004 1 27 CA031127014 220031101G7200 ENGINE CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE RIGHT LIGHTNING STRIKEW O OTHER XJ ENGINE FLAMEOUT WARNING INDICATION APAPPROACH 1 CA (CAN) DURING DESCENT, AROUND 7000 FT, AIRCRAFT HIT BY LIGHTNING STRIKE ON THE RT SIDE OF THE COCKPIT. AT THE SAME TIME, MESSAGER ENG FLAMEOUT (C) POSTED ON EICAS. THE RT ENGINE PARAMETERS ROLLED BACK, AFTER A FEW SECONDS THE PARAMETERS CAME BACK TO NORMAL AND THE ENGINE OPERATED NORMALLY. AIRCRAFT LANDED WITHOUT FURTHER INCIDENT. ON THE GROUND, THE INSPECTION REVEALED THAT THE ENTRY POINT OF THE LIGHTNING STRIKE WAS ON THE RIGHT FORWARD NLG DOOR. THE EXIT POINT WAS ON THE HORIZONTAL STAB TRAILING EDGE. NO DEFECTS WERE FOUND ON THE ENGINE. THE QAR DISK WAS REMOVED FOR ANALYSIS WHICH CONFIRMED THE ENGINE FLAMEOUT WITH N2 PARAMETER GOING BELOW IDLE FOR A FEW SECONDS. 2L72 4F4 FRTA21EA EOOO63EN 20040127000752004012700075EA 2004 1 27 CA031127015 120031124G3234555405 SELECTOR VALVE CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE NLG LEAKING W O OTHER J WARNING INDICATION APAPPROACH 1 CA (CAN) ON APPROACH WHEN SELECTING GEAR DOWN RECEIVED NOSE DOOR AURAL AND GEAR DOWN DISAGREE. MISSED APPROACH AND RAN CHECKLIST. SELECTED GEAR UP TO MODERATE FLIGHT CONDITIONS. NEXT APPROACH SAME THING HAPPENED. THIS TIME USED MANUAL GEAR RELEASE. GEAR INDICATED DOWN AND LOCKED. NLG SELECTOR VALVE FOUND LEAKING AND ELECTRICAL CONNECTOR COMPLETED SATURATED INTERNALLY WITH HYD FLUID. REPLACED NLG SELECTOR VALVE AND OPS OK. AIRCRAFT RETURNED TO SERVICE. 2L72 4F4 FRTA21EA E15NE 20040127000762004012700076EU 2004 1 27 CA031128001 120031118G7120601741 BEARING BOLKMS105 BO105S 5626006EU ALLSN 250C 250C20B 03013GL ISOLATION MOUNT WORN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING PERIODIC 100-HOUR INSPECTION A VIBRATION ISOLATOR BEARING WAS FOUND ROUGH. UPON DISASSEMBLY, DAMAGE WAS FOUND ON THE INNER AND OUTER RACES OF THE BEARING DUE TO LACK OF LUBRICATION. METAL PARTICLE PASTE WAS EVIDENT IN THE BEARING AREA. 1G72 3U3 U H3EU E4CE 20040217001972004021700197EA 2004 2 17 CA031128002 220031117G7261 CHIP DETECTOR PWA PT6 PT6A41 52043EA ENGINE BROKEN W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) ENG WAS REMOVED AFTER COMPRESSOR SEIZURE AND OIL LOSS DUE TO A BROKEN CHIP DETECTOR. CONFIRMED COMPRESSOR SEIZED. FOUND THAT NR 1 BRG HAD COLLAPSED DUE TO OIL STARVATION. NR 1 BRG FAILURE RESULTED IN HIGH LEVEL OF HEAT GENERATION, LOSS OF COMPRESSOR LOCATION, AS RESULT OF BRG DETERIORATION, CAUSING EXTENSIVE ROTATING TO STATIC PARTS RUBBING. COMPRESSOR DAMAGE WILL REQUIRE REPLACEMENT OF DAMAGED PARTS. MELTING METAL FROM COMPRESSOR SPACERS, FLOWING MELTED METAL PARTICLES THRU DIFFUSER TUBES DEPOSITING ON INSIDE OF GG CASE AND FACE OF EXHAUST DUCT. NR 1 BRG DETERIORATION ALSO CAUSED CT AXIAL MOVEMENT RESULT IN BLADE PLATFORMS RUBBING CT VANE. SPALLING DAMAGE CAN BE RESULT OF INADEQUATE LUBRICATION. 4 T E4EA 20040127000772004012700077SW 2004 1 27 CA031128003 120031127G3397186187192 WIRE BBAVIA8 8GCBC 1220803SW LYC O360 O360C2E 41514EA MCAULY1A200 1A200* GL STROBE LIGHTS MISROUTED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) DURING COMPANY STRUCTURAL INSPECTION AND REPAIR PROGRAM (SIRP), FABRIC WAS REMOVED FROM THE WINGS. ON INSPECTION OF THE WIRES, IT WAS DISCOVERED THAT THE POWER WIRES FOR THE NAV AND STROBE LIGHTS WERE INCORRECTLY ROUTED ALLOWING THE WIRES TO RUB ON A RIB. FURTHER INSPECTION FOUND THAT THESE WIRES WERE NOT SUPPORTED OVER A COMPRESSION STRUT ALLOWING THE WIRE TO RUB IN THIS AREA. ON INSPECTION OF THE WIRE ROUTING DOWN THE LEADING EDGE NOW INCLUDING THE STALL WARNING WIRES, 2 GROMMETS ON THE NOSE RIBS WERE FOUND DETERIORATED AND SPLIT ALLOWING WIRES TO RUB ON THE NOSE RIBS. 2 OTHER GROMMETS WERE FOUND PARTIALLY SPLIT AND DETERIORATING. 1H71 3O3 O A21CE E286 5 NP874 20040127000782004012700078SW 2004 1 27 CA031128005 120031128G575321583 MOUNT BBAVIA8 8GCBC 1220803SW LYC O360 O360C2E 41514EA MCAULY1A200 1A200* GL TE FLAP CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ON THE COMPANY STRUCTURAL INSPECTION AND REPAIR PROGRAM (SIRP), FLAP MOUNT (LEFT WING ROOT POSITION) WAS INSPECTED AND CRACKS WERE FOUND ON THE MOUNTING FACE BOTTOM BOLT HOLE. 1H71 3O3 O A21CE E286 5 NP874 20040127000792004012700079SW 2004 1 27 CA031128006 120031128G2120212073111001 PLENUM BELL 412 412EP 1182205SW PWA PT6T PT6T3 52045EA CABIN AIR CONTAMINATED W O OTHER O OTHER CRCRUISE 1 CA (CAN) WATER ENTERED IN PLENUM CHAMBER OF CABIN AIR INTAKE OVERFLOWED ONTO CEILING INSULATION CAUSING ELECTRICAL ARCING. 1G72 4U4 U H4SW E22EA 20040127000802004012700080NM 2004 1 27 CA031128007 120031127G3211104451 SPRING DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE MLG BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) UPON INSPECTION, FOUND RT SPRING ASSY ON THE LT GEAR WHICH THE PROX. SWITCH IS CONNECTED TO, BROKEN. THE BRAKE WAS NOT ON A LUG, IT WAS RIGHT IN THE COILS. THIS SPRING WAS INSTALLED ON A PRE MOD STAB STAY ASSY. PRE S/B 8-32-148, OR DHC8-32-86.THIS CAUSED THE PROX SENSOR TO SEE A NEAR/FAR CONDITION INTERMITTENTLY. THIS CAUSED THE GEAR LIGHT TO CYCLE BETWEEN GREEN AND RED. RECTIFICATION: MLG SIDE STAY REMOVED AND SPRING ASSY REPLACED. OPERATION CHECKED SERVICEABLE. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040127000812004012700081EA 2004 1 27 CA031201001 120031115G2420 RELAY CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE GENERATOR FAILED W H DEACTIVATE SYST/CIRCUITS F FLT CONT AFFECTED CRCRUISE 1 CA (CAN) FLAPS FAIL, CAUTION MESSAGE POSTED AND SLATS FAIL, CAUTION MSG POSTED ON ADG (AIR DRIVEN GENERATOR) POWER, UNABLE TO MOVE FLAPS. AFTER POWER WAS RESTORED, SLATS HALFSPEED AND FLAPS HALFSPEED STATUS MSG WERE POSTED AND DISAPPEARED AFTER LANDING. RELAY HAS BEEN CYCLED AND RETESTED IAW OUR FLIGHT TEST PROCEDURE NR S670-242301 PARA. 8.1.6 AND 8.1.7. SLATS AND FLAPS FOUND SERVICEABLE IAW FTP S670-275001. SUBSEQUENT FLIGHT TESTING BEING SUCCESSFUL. CURRENTLY, ENGINEERING IS UNDER INVESTIGATION FOR A SIMILAR ISSUE WITH ANOTHER AC 10118 WHERE NO ACCESS BUS POWER WAS AVAILABLE ON ADG POWER DURING A FLIGHT TEST AND AFTER POWER RESTORATION, EVERYTHING CAME BACK NORMAL. THE SECOND ATTEMPT ON ADG WAS SUCCESSFUL. 2L72 4F4 FRTA21EA EOOO63EN 20040127000822004012700082SW 2004 1 27 CA031201002 120031201G339733 WIRE BBAVIA8 8GCBC 1220803SW LYC O360 O360C2E 41514EA MCAULY1A200 1A200* GL NAV LIGHTS CHAFED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) NAV WIRE IN LT WING FOUND ATTACHED WITH MASKING TAPE TO COMPRESSION TUBE. WIRE WAS CHAFING ON TUBE AND EXPOSED WIRE CAUSING SHORT AGAINST COMPRESSION TUBE, BLOWING FUSE. 1H71 3O3 O A21CE E286 5 NP874 20040127000832004012700083SW 2004 1 27 CA031201003 120031201G339733 WIRE BBAVIA8 8GCBC 1220803SW LYC O360 O360C2A 41514EA MCAULY1A200 1A200* GL NAV LIGHTS CHAFED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) NAV WIRE IN LT WING FOUND ATTACHED WITH MASKING TAPE TO COMPRESSION TUBE. WIRE WAS CHAFING ON TUBE AND EXPOSED WIRE CAUSING SHORT AGAINST COMPRESSION TUBE, BLOWING FUSE. 1H71 3O3 O A21CE E286 5 NP874 20040127000842004012700084SW 2004 1 27 CA031201004 120031201G33973359 WIRE BBAVIA8 8GCBC 1220803SW LYC O360 O360C2E 41514EA MCAULY1A200 1A200* GL NAV LIGHTS CHAFED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) NAV WIRE IN LT WING FOUND ATTACHED WITH MASKING TAPE TO 2ND AND 3RD COMPRESSION TUBES FROM OB, AND RT WING FOUND ATTACHED WITH MASKING TAPE TO 3RD (FROM OB) COMPRESSION TUBE. WIRES CHAFFING ON TUBE AND EXPOSED WIRE CAUSING SHORT AGAINST COMPRESSION TUBE, BLOWING FUSE. 1H71 3O3 O A21CE E286 5 NP874 20040127000852004012700085SO 2004 1 27 CA031201005 120031127G8120 BEARING GARRETTLTD LW1268985 PIPER PA31 PA31325 7103105SO LYC O540 TIO540F2BD 41532EA HARTZLHCE3Y HCE3YR2A GL TURBOCHARGER FAILED W A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CLCLIMB 1 CA ZIO14456 (CAN) AFTER TAKEOFF ENGINE MANIFOLD PRESS DROPPED TO 23 INCHES, THE PILOT TURNED AND LANDED BACK AT AIRPORT. MANTENANCE FOUND THE TURBO BEARINGS FAILED. ENGINE WAS FLUSHED AND NEW FILTER AND OIL INSTALLED WITH THE TURBO BEING REPLACED. A/C WAS GROUND RUN AND TEST FLOWN FILTER WAS CHECKED FOR METAL AND INSIGNIFICANT AMOUNTS WERE FOUND. ANOTHER FILTER WAS INSTALLED AND A/C RETURNED TO SERVICE. 1L72 3O3 O A20SO E14EA 5 CP33EA 20040127000862004012700086WP 2004 1 27 CA031201006 120031123G215039613011 CONTROL VALVE DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE LT PACK FLOW INOPERATIVE W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) FLOW LITE ILLUMINATED ON CLIMB, CABIN CONTINUED TO DEPRESSOR AND AFT GALLEY DOOR LIGHT ILLUMINATED PRIOR TO DESCENT. AIRCRAFT LANDED BACK TO YYZ. MAINTENANCE FOUND LT PACK FLOW CONTROL VALVE INOPERATIVE. FLOW CONTROL VALVE REPLACED AND SYSTEM CHECKED SERVICEABLE. 2L72 4F4 FRTA6WE E9NE 20040127000872004012700087SO 2004 1 27 CA031201007 120031127G32606720300 SPRING PIPER PA44 PA44180 7104402SO LYC O360 O360* 41514EA HARTZLHCC2Y HCC2YR2 GL MLG DOWNLOCK BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING A WALK AROUND BEFORE FLIGHT, AN INSTRUCTOR AND STUDENT PILOT NOTICED THAT THE RT MAIN LANDING GEAR DOWNLOCK SPRING WAS BROKEN. THIS SPRING IS TO KEEP THE DOWNLOCK MECHANISM IN PLACE. UPON FURTHER INVESTIGATION BY MAINTENANCE THE STUDENT WHO FLEW THE AIRCRAFT LAST NOTED THAT THE LANDING GEAR HYDRAULIC PUMP WOULD COME ON AND OFF WHILE TAXIING THE AIRCRAFT, INDICATING THAT THE BRACKET WAS LIFTING OFF OF THE DOWNLOCK SWITCH ENOUGH TO TURN THE PUMP ON. IF THE AIRCRAFT WAS MOVED BY TOW BAR WITH THE POWER OFF THE PUMP WOULD NOT KICK ON TO KEEP THE GEAR DOWN AND LOCKED AND THERE WOULD BE A POSSIBILITY OF THE MAIN GEAR COLLAPSING. 1L72 3O3 O A19S0 E286 5 CP920 20040127000882004012700088SO 2004 1 27 CA031201008 120031127G32116720300 SPRING PIPER PA44 PA44180 7104402SO LYC O360 O360A1H 41514EA HARTZLHCC2Y HCC2YR2 GL MLG DOWNLOCK WORN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) UPON DISCOVERY OF A BROKEN DOWNLOCK SPRING THE LT DOWNLOCK SPRING WAS INSPECTED AND IT WAS FOUND TO BE WORN ON THE LOWER END ON THE CURVED PART OF THE SPRING WHERE IT HOOKS ONTO THE TRUNION. THIS SPRING KEEPS THE DOWNLOCK HOOKS IN PLACE. IF IT BREAKS THE ONLY THING KEEPING THE MAIN GEAR LOCKED IS THE HYDRAULIC PUMP. IF POWER TO THE AIRCRAFT IS REMOVED ANY GROUND HANDLING OF THE AIRCRAFT COULD POSSIBLY CAUSE THE GEAR TO COLLAPSE. 1L72 3O3 O A19S0 E286 5 CP920 20040127000892004012700089EU 2004 1 27 CA031201009 120031126G2750Z4243300014 SPRING ZLIN 242 Z242L 9970204EU LYC O360 AEIO360A1B6 41514EA LT TE FLAP BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING A ROUTINE INSPECTION THE LT FLAP CONTROL LEVER UPLOCK SPRING WAS FOUND TO BE BROKEN. THIS SPRING KEEPS PRESSURE ON THE UPLOCK HOOK THAT HOLDS THE FLAP I N THE UP POSITION. THERE ARE ALSO SPRINGS THAT ASSIST IN KEEPING THE FLAP IN THE UP POSITION, BUT THEY DO NOT LOCK IT, ONLY THE HOOK LOCKS THE FLAP. WITH THIS SPRING BEING BROKEN THERE IS NO POSITIVE PRESSURE ON THE HOOK. IF THE PILOT DOES HIS WALK AROUND WITH THE FLAPS EXTENDED THIS DEFECT WOULD GO UNNOTICED. 1L71 3O3 O0 A76EU 1E10 20040127000902004012700090WP 2004 1 27 CA031202001 120031125G71206252220928 WASHER DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE ENGINE MOUNT FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING ENGINE INSTALLATION, COULD NOT TORQUE ENGINE MOUNT YOKE BOLT P/N 3935739-1 IAW MM SECTION 20-10-14 PAGE 201. UNABLE TO COMPRESS, THE INNER PLI WASHER RING OF PLI WASHER SET P/N PL120-117-8. THESE PLI WASHERS WERE PROVIDED FROM FOLLOWING SUPPLIERS: THE ALTERNATE PLY WASHER P/N 62522-20-92-8 SHOWN IN THE IPC 71-20-00 PURCHASED FROM MFG WAS USED AND INSTALLED IAW AMM 20-10-14 PAGE 201. 2L72 4F4 FRTA6WE E9NE 20040217001982004021700198NE 2004 2 17 CA031202002 320031129G6111802253180225 COLLAR HAMSTD DHAV DHC8 DHC8301 1386003NM PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE PROP BLADE SEPARATED W A UNSCHED LANDING D INFLIGHT SEPARATION CLCLIMB 1 CA 10648 (CAN) DURING TAKEOFF ROLL NR1 PROP, NR 4 BLADE COLLAR P/N 802253-1, -2 SEPARATED FROM PROP BLADE AND STRUCK NR2 BLADE CAUSING IMPACT DAMAGE TO ITS LE NICKEL SHEATH. DEBRIS IMPACTED ONTO LT ROW 5 CABIN WINDOW CAUSING A HOLE IN OUTER PANE AND DAMAGE TO WINDOW FRAME. INNER PANE OF WINDOW WAS NOT IMPACTED AND REMAINED INTACT. AC PERFORMED AN UNSCHEDULED LANDING. SMALL SECTION OF COLLAR WAS ABLE TO BE RECOVERED FROM RUNWAY. FAILURE MAY BE DUE TO COLLAR CRACKING AND/OR FAILURE OF ADHESIVE USED TO SECURE COLLAR TO PROPELLER BLADE. MFG HAS BEEN INVOLVED WITH THE INVESTIGATION AND FOLLOWING WAS OBTAINED FROM LOCAL HS FIELD SUPPORT REPRESENTATIVE. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040127000912004012700091 2004 1 27 CA031202003 420031129G25624530150 TRANSPONDER BOEING727 727260 NM PWA JT8 JT8D17 52049NE ELT FAULTY W K NONE N FALSE WARNING ININSP/MAINT 1 CA (CA) WAS NOTIFIED THAT SEARCH AND RESCUE WAS RECEIVING AN ELT RESPONSE FROM A COMPANY AIRCRAFT. INSPECTED AND IT WAS DETERMINED THIS AIRCRAFT WAS AT FAULT. THE UNIT WAS DISCONNECTED AND A FURTHER INSPECTION FOUND WATER LOCATED AROUND THE RECEPTACLE AND CONNECTOR. THE ELT WAS CONFIRMED. NO FURTHER ACTION WAS TAKEN BY RESPONDING AUTHORITIES. 2L73 4F4 FRTA3WE E2EA 20040127000922004012700092 2004 1 27 CA031202004 420031201G3414 GYRO CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE ADG SYSTEM FAILED W H DEACTIVATE SYST/CIRCUITS H ELECT. POWER LOSS-50 PC CRCRUISE 1 CA (CAN) NAV NR 1 LOST ALL DATA FOLLOWING ADG DROP ON PILOT PFD. WHEN ADG AUTO DEPLOYED, PILOT PFD BLANKED COMPLETELY FOR A MOMENT, THEN SPEED TAPE CAME BACK, NUMEROUS REDFLAGS ANNUNCIATED UNTIL POWER WAS TRANSFERRED AND IRS NR 1 RE-ALIGNED IN ATT. MODE . ALSO STAB FAULT- STATUS MESSAGE POSTED AFTER ADG DROP AND UNABLE TO RESET. THE SYSTEM HAS BEEN VERIFIED AND RETESTED ON GROUND WITHOUT ANY DEFECT DISCOVERED. ANOTHER TEST FLIGHT WITH ADG DROP WAS ATTEMPTED WITHOUT ANY OCCURRENCE. MFG ENGINEERING IS INVESTIGATING THE SOURCE OF PROBLEM. 2L72 4F4 FRTA21EA EOOO63EN 20040217001992004021700199EU 2004 2 17 CA031202005 120031201G2597 WIRE AIRBUSA321 A321211 3930370EU IAE V2530 V2530A5 NE BUFFET/GALLEYS DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) WIRE DAMAGE IN COMPARTMENT 2411, DAMAGED OVEN WIRES IN GALLEY 5, COMPARTMENT 2408. WIRES FOR ALL OVENS IN GALLEY 5 ARE COLLECTED TOGETHER AND ROUTED THROUGH THIS COMPARTMENT 2408. O/NIGHT CREWS PERFORM AN OVEN FIT CHECK IN COMPARTMENT 2411 WITH SIMULATED 0.5 INCH THICK X 3 INCH LONG X 1 INCH WIDE RUBSTRIP MOUNTED TO SIDE WALL OF THIS COMPT JUST IN FRONT OF WIRE BUNDLE IN THIS COMPT. BECAUSE IN LATEST PROPOSED REVISION OF MFG SB THEY ARE PROPOSING TO INSTALL RUB STRIPS IN BOTH COMPARTMENTS 2408 AND 2411. ONLY VALIDATED THE RUBSTIP FIT CHECK IN COMPARTMENT 2408, WHERE PROBLEMS ARE OCCURRING. 2L72 4F4 FRTA28NM E40NE 20040127000932004012700093NM 2004 1 27 CA031202006 120031127G562085323917001 WINDOW DHAV DHC8 DHC8201 2809001NM PWA 120 PW123D 52152NE HAMSTD14SF 14SF23 NE CABIN CRACKED W O OTHER O OTHER CRCRUISE 1 CA (CAN) DURING FLIGHT, MODERATE RIME ICE WAS REPORTED AT FL 180 (-18C), WE STARTED ACCUMULATING ICE, REQUESTED A DESCENT TO FL 160. IN DESCENT, STARTED GETTING SOME PROP VIBRATION, 1050 RPM WAS SET TO AID SHEDDING. ACCUMULATION WAS MODERATE BOOTS EASILY KEEPING UP, SET ON SLOW, PROPS SET ON BELOW -10C. AFTER 5 TO 10 MINUTES FA CALLED, ADVISED WINDOW, SEAT 2E EITHER HAD CRACK IN IT OR A STREAK OF ICE ACROSS IT. PILOT CHECKED PRESSURIZATION, IT SHOWED NO INDICATIONS OF A LEAK. THERE WAS A PLEXIGLASS COVER ON OUTSIDE OF WINDOW THAT HAD A CRACK IN IT NOT ACTUAL WINDOW, SINCE ICE STRIKES ARE COMMON THERE AND FUSELAGE IS BEEFED UP. AFTER CHECKING ON THE GROUND IT WAS OBVIOUS IT WAS THE WINDOW. MAINTENANCE NOTIFIED. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040127000942004012700094SW 2004 1 27 CA031203001 120031202G322171470209L TUBE BBAVIA8 8GCBC 1220803SW LYC O360 O360C2E 41514EA MCAULY1A200 1A200* GL LT MLG BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) VERTICAL FRAME TUBE JUST ABOVE AND ATTACHING TO MLG TRUSS FITTING BROKEN JUST ABOVE WELD AT MLG FITTING.CRACK TRAVELS COMPLETELY AROUND AND SECOND CRACK GOES VERTICAL 2 INCHES FROM FIRST LOWER CRACK, THEN AROUND THE TUBE AGAIN APPROX 75 PERCENT. 1H71 3O3 O A21CE E286 5 NP874 20040127000952004012700095SW 2004 1 27 CA031203002 120031202G57104149641497 SUPPORT BBAVIA8 8GCBC 1220803SW LYC O360 O360C2E 41514EA FUEL TANK CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) FUEL TANK SUPPORT BRACKETS CRACKED AT ENDS DIRECTLY OFF OF WELDS. 5 OUT OF 6 BRACKETS CRACKED IN LT WING AND ONLY 1 FOUND CRACKED IN RT WING. 1H71 3O3 O A21CE E286 20040127000962004012700096SW 2004 1 27 CA031203003 120031202G57104149641497 SUPPORT BBAVIA8 8GCBC 1220803SW LYC O360 O360C2E 41514EA MCAULY1A200 1A200* GL FUEL TANK CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) FUEL TANK SUPPORT BRACKETS FOUND CRACKED AT ENDS DIRECTLY OFF OF WELDS. 3 IB BRACKETS CRACKED IN RT WING NONE IN LT WING. NUMBER OF CRACKS VARY FROM 2 TO ALL 4 POINTS OF EACH BRACKET. 1H71 3O3 O A21CE E286 5 NP874 20040127000972004012700097NE 2004 1 27 CA031203004 220031130G7200 ENGINE BOEING737 737204 1384458NM PWA JT8 JT8D15 52051NE NR 1 FAILED W EA ENGINE SHUTDOWN UNSCHED LANDING BEJSMOKE/FUMES/ODORS/SPARKS VIBRATION/BUFFET WARNING INDICATION CLCLIMB 1 CA 57181 702874 (CAN) FLIGHT ENROUTE, FLIGHT CREW REPORTED INCREASED VIBRATIONS COMING FROM NR 1 ENGINE AND SPARKS REPORTED ON VISUAL INSPECTION. CREW SHUTDOWN ENGINE AND DECLARED AN EMERGENCY. AIRCRAFT RETURNED AND LANDED WITHOUT FURTHER INCIDENT. ENGINE CHANGE BEING CONDUCTED AND ENGINE TO BE SENT TO OVERHAUL FACILITY FOR INVESTIGATION. WILL FOLLOW UP WITH RESULTS OF OVERHAUL. 2L72 4F4 F A16WE E2EA 20040127000982004012700098EA 2004 1 27 CA031203005 220031119G8550O320A2B LINE BBAVIA7 7GCBC 1220601SW LYC O320 O320A2B 41508EA MCAULY1C172 1C172AGM GL OIL PRESS LOOSE W A UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 CA (CAN) PILOT REPORTED LOW OIL PRESSURE AND SMOKE. LANDED OFF AIRPORT TO MINIMIZE POSSIBLE DAMAGE TO ENGINE. NO LOSS OF POWER. INSPECTION REVEALED A LOOSE OIL PRESSURE LINE AT ENGINE. THE TECHNICAL RECORDS SHOWED NO INDICATION OF WORK BEING CARRIED OUT IN THAT AREA. THE LINE WAS REMOVED AND INSPECTED NO DAMAGE WAS FOUND. RE-INSTALLATION AND CLEANING OF THE ENGINE COMPARTMENT WAS CARRIED OUT. BOTH OIL FILTER AND SUCTION SCREEN REMOVED AND INSPECTED NO PROBLEM FOUND. ENGINE FILLED WITH AEROSHELL 15W50 AND GROUND RUN CARRIED OUT NO LEAKS AIRCRAFT RETURNED TO SERVICE. SUBSEQUENT OIL FILTER AND SUCTION SCREEN INSPECTION CARRIED OUT TWICE IN 10 HRS WITH NO PROBLEM FOUND. 1H71 3O3 ONCA759 E274 5 NP910 20040127000992004012700099GL 2004 1 27 CA031203006 120031114G2730AN3165 NUT DIAMONDA20 DA20C1 2990001GL CONT O240 IO240B 17063SO SNSNCHW69EK W69EK63 EA PUSH PULL ROD LOOSE W K NONE O OTHER ININSP/MAINT 1 CA C0234 (CAN) DURING 100 HR INSPECTION THE ROD END JAM NUT OF THE ELEVATOR PUSH PULL ROD P/N 22-2730-02-00 WAS FOUND LOOSE. THE OPPOSITE ATTACHMENT OF THE PUSH PULL ROD IS SUCH THAT THERE IS NO POSSIBILITY OF THE ROD END TURNING IN THE TUBE THEREFORE THERE WAS NO LOSS OF RIGGING. JAM NUT WAS TIGHTENED AND AIRCRAFT RETURN TO SERVICE. 1L71 3O3 ONTTA4CH E7SO 5 NTA4CH 20040127001002004012700100CE 2004 1 27 CA031203007 120031130G1430817851223 BOLT BEECH 100 A100 1152915CE PWA PT6 PT6A28 EA HARTZLHCB3T HCB3TN3 GL RT WING FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ON A SIRM INSP OF THE WING BOLTS THE RT FWD UPPER WING BOLT SHOWED REJECTIONABLE INDICATIONS. THE BOLT WAS REPLACED AND A/C RETURNED TO SERVICE. 1L72 3T4 T A14CE E4EA 6 CP15EA 20040127001012004012700101CE 2004 1 27 CA031203008 120031130G1430817851223 BOLT BEECH 100 A100 1152915CE PWA PT6 PT6A28 EA HARTZLHCB3T HCB3TN3 GL RT WING FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ON INSP OF A/C AT SIRM INSP FOUND REJECTIONABLE INDICATIONS ON THE FORWARD UPPER RT WING BOLT. REPLACED AND A/C RETURNED TO SERVICE. PART WAS 9 YEARS OLD. 1L72 3T4 T A14CE E4EA 6 CP15EA 20040127001022004012700102CE 2004 1 27 CA031203009 120031130G1430 BOLT BEECH 100 A100 1152915CE PWA PT6 PT6A28 EA HARTZLHCB3T HCB3TN3 GL RT WING FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ON DOING A SIRM WING BOLT INSP THE FWD UPPER RT WING BOLT SHOWED REJECTIONABLE INDICATIONS. BOLT WAS CHANGED AND RETURNED TO SERVICE. BOLT LIFE WAS 9YEARS. 1L72 3T4 T A14CE E4EA 6 CP15EA 20040127001032004012700103CE 2004 1 27 CA031203010 120031203G33102K40F3 RESISTOR BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL COCKPIT LIGHT BURNED W O OTHER B SMOKE/FUMES/ODORS/SPARKS APAPPROACH 1 CA 12387 (CAN) ON APPROACH CREW NOTICED SMOKE COMING FROM UNDER THE CAPTAINS INSTRUMENT PANEL. AFTER A UNEVENTFUL LANDING AND INSPECTION OF THE WIRING UNDER THE CAPTAINS INSTRUMENT PANEL WAS CARRIED OUT. FOUND THAT CABIN FLUORESCENT LIGHTING RESISTOR BURNED UP CAUSING THE SMOKE IN THE FLIGHT DECK. SYSTEM INOPERATIVE AND REPLACEMENT PART ORDERED. GROUND RUNS CARRIED OUT. NO FURTHER FAULTS FOUND. 1L72 4T4 T A24CE E4EA 6 CP15EA 20040127001042004012700104 2004 1 27 CA031204001 420031121G3425 SYMBOL GENERATOR DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE FLT COMPUTER FAILED W O OTHER O OTHER DEDESCENT 1 CA (CAN) CAPTAIN EADI AND EHSI WENT BLANK TWICE DURING DESCENT AND APPROACH. EACH TIME THEY STAYED OFF FOR ABOUT 5-10 SECONDS, THEN CAME BACK ON. SYMBOL GENERATOR NR 1 SWAPPED WITH NR 2 AND COULD NOT DUPLICATE SNAG ON GROUND. AIRCRAFT DISPATCHED SERVICEABLE. SUSPECT PROBLEM RELATED WITH BAD VENTILATION. FOUND HSI AND ADI SCREEN PACKED WITH DUST. 2L72 4F4 FRTA6WE E9NE 20040127001052004012700105NM 2004 1 27 CA031204002 120030820G575285740011101 MOUNT DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE SPRING TAB CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 3303933039 (CAN) WHILE THE AILERON WAS IN THE SHOP FOR REPAIR OF DAMAGE UNRELATED TO THIS INCIDENT, CRACKS WERE DISCOVERED ON THE RT AILERONS SPAR WEB AND DOUBLER BEHIND THE THE SPRING TAB MOUNTING BRACKET P/N 85740011-101. THE FINDINGS WERE REPORTED TO MFG AND RD8-57-1433 ISSUE 5 WAS ISSUED FOR THE REPAIR, IT CALLS FOR THE AILERON FRONT SPAR WEB TO BE REPLACED/SPLICED AS WELL AS A DOUBLER ADDED TO THE SPAR BETWEEN STATION YW 430.7 AND YW 437.9. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040217002002004021700200 2004 2 17 CA031204003 420031029G312073910193001 CLOCK DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE COCKPIT MALFUNCTIONED W O OTHER N FALSE WARNING CRCRUISE 1 CA (CAN) AC HAD INTERMITTENT WOW CAUTION LIGHT COMING ON IN DIFFERENT STAGES OF FLIGHT. TROUBLESHOOTING INDICATED THAT FAULT WAS A WIRING DEFECT. AFTER HOURS OF INSTALLING NEW WIRING TO SENSOR THAT PSEU INDICATED FAULT ON AC WAS RETURNED TO SERVICE ONLY TO RETURN. EXPLAINED THAT WHEN CLOCK WAS COLD IT WOULD EMIT A ROGUE EMI SIGNAL INTO AC ELECTRICAL SYS THUS CAUSING PSEU TO INDICATE A FAULT WITH A WOW SENSOR ON AC. OFFENDING PART WAS IDENTIFIED AND REPLACED WITH NO REOCCURRENCE OF PROBLEM ON AC. OFFENDING PART WAS 8 VDC INPUT VOLTAGE REGULATOR P/N 340T 8. IT WAS REPLACED AND THE CLOCKED CHECKED TO ALL FACTORY SPECS AND RECERTIFIED. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040127001062004012700106CE 2004 1 27 CA031205001 120031204G561010138402524 WINDSHIELD BEECH 200 B200 1152922CE PWA PT6 PT6A42 52043NE HARTZLHCE4N HCE4N3 NE COCKPIT CRACKED W A UNSCHED LANDING D INFLIGHT SEPARATION CRCRUISE 1 CA (CAN) WHILE IN CRUISE FLIGHT THE PILOT HEARD A 'CLAP' AND THEN NOTICED A CRACK IN THE RT WINDSHIELD. THE AIRCRAFT RETURNED TO BASE. INSPECTION DETERMINED CRACK TO BE IN THE EXTERIOR PANE, LIKELY ORIGINATING FROM A SMALL STONE BRUISE. WINDSHIELD TO BE REPLACED. 1L72 4T4 T A24CE E4EA 5 CP10NE 20040127001072004012700107EA 2004 1 27 CA031205002 220031204G7297 CONNECTOR PIPER PA31T PA31T 7103124SO PWA PT6 PT6A28 EA HARTZLHCB3T HCB3TN3 GL WIRE HARNESS BROKEN W O OTHER N FALSE WARNING DEDESCENT 1 CA (CAN) WHEN REDUCING POWER FOR DESCENT THE PILOT NOTICED A NORMAL REDUCTION IN TORQUE INDICATION, THEN AS POWER FURTHER REDUCED THE TORQUE INDICATION WOULD CLIMB TO REDLINE VALUES. NO OTHER ENGINE PARAMETERS OR AIRCRAFT BEHAVIOR AGREED WITH THIS INDICATION AND THROUGH CONSULTATION WITH MAINTENANCE PERSONNEL ON THE GROUND, THE DESCENT AND LANDING CONTINUED UNEVENTFULLY. INSPECTION DISCOVERED TWO BROKEN WIRES (PINS D AND B) WHERE THEY ENTER CONNECTOR CONNECTION E232. THIS WIRING HARNESS MAKES A 180 DEGREE BEND JUST PRIOR TO ENTERING THE PLUG. AIRCRAFT TTSN 1763 1L72 3T4 T A8EA E4EA 6 CP15EA 20040127001082004012700108EA 2004 1 27 CA031205003 120031201G5730 SKIN CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF341A NE LT WING DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING FTP STALLS, BUFFET WAS EXPERIENCED JUST PRIOR TO PUSHER ACTIVATION FOR BOTH THE CLEAN AND F20 STALLS. ADDITIONALLY A MILD LT WING DROP WAS EXPERIENCED ON THE F20 STALL. AFTER LANDING, SEALANT WAS OBSERVED TO HAVE SPREAD OUT OF THE LT WING LEADING EDGE JOINTS (CHORDWISE) AND HAD FLOWED BACK ONTO THE WING SURFACE. MEASURES HAVE BEEN TAKEN TO INCLUDE AN INSPECTION TO BE CARRIED OUT WALK AROUND OF PILOT AND TECHNICIAN TO VERIFY INSTALLATION OF SEALANT AT CRITICAL AREAS. 2L72 4F4 FRTA21EA E15NE 20040127001092004012700109NE 2004 1 27 CA031205004 220031128G7421SC2036 IGNITER SNIAS 350 AS350B 8680801EU TMECA ARRIELARRIEL1B 6OO30NE ENGINE BROKEN W K NONE O OTHER ININSP/MAINT 1 CA 4299 (CAN) ON REMOVAL OF IGNITORS ON ENGINE S/N 4299, IT WAS OBSERVED THAT THE LT IGNITOR HAD LOST IT'S CORE (IGNITOR P/N SC2036). A BORESCOPE INSPECTION REVEALED THERE WAS SUBSTANTIAL DAMAGE TO THE 1ST STAGE TURBINE BLADES (7 BLADES DAMAGED). THE ENGINE WAS REMOVED FROM SERVICE AND MODULE 2/3 SENT TO ACRO IN VANCOUVER FORASSESSMENT. 1G71 3U3 U H9EU E19EU 20040127001102004012700110CE 2004 1 27 CA031205005 120031201G2497 WIRE HARNESS CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA MCAULY1C160 1C160DTM GL ALTERNATOR BURNED W D RETURN TO BLOCK H ELECT. POWER LOSS-50 PC TXTAXI/GRND HDL 1 CA (CAN) PILOT NOTICED HIGH VOLTAGE LIGHT- ELECTRICS TURNED OFF - RETURNED TO BASE. CONTACT WITH TOWER BY CELL PHONE.- ON INSPECTION AT AMO FACILITY IT WAS LEARNED THAT THE WIRING HARNESS TO THE ALTERNATOR FAILED/SHORTED OUT.- REPAIRS TO THE HARNESS WAS MADE AND THE AIRCRAFT RETURNED TO SERVICE. 1H71 3O3 ONT3A12 E274 5 NP910 20040127001112004012700111EA 2004 1 27 CA031205007 120031201G5710C3W255 STRUT DHAV DHC3 DHC3 2800202EA PWA PT6 PT6A34 52043EA WING CORRODED W K NONE O OTHER ININSP/MAINT 1 CA 17743 (CAN) WING STRUT WAS REMOVED TO INSPECT/REPAIR SLOPPY STRUT ATACHMENT CONDITION. UPON REMOVING STRUT ASSEMBLY, LUG FACES (FORWARD/AFT) FOUND CORRODED. REF. PSM 1-3-3 FIG 2-1 (DHC-3 REPAIR MANUAL). 1H71 3R4 T A815 E4EA 20040127001122004012700112EA 2004 1 27 CA031205008 120031201G5740C3W10433 ATTACH FITTING DHAV DHAV DHC3 DHC3 2800202EA PWA R1340 S3H1G 52016NE HAMSTD23D 23D40 NE WING STRUT CORRODED W K NONE O OTHER ININSP/MAINT 1 CA 233 (CAN) FRETTING EXFOLIATION CORROSION ON LINK ATTACH LUG (1 ONLY). 1H71 3R3 R A815 E142 6 CP719 20040127001132004012700113WP 2004 1 27 CA031205009 120031205G5302 MOUNT ROBSIN ROBSINR44 R44 7640120WP LYC O540 O540F1B5 41532EA AFT ANTENNA CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 0379 (CAN) DURING INSPECTION AFT GPS ANTENNA SEALENT WAS NOTICED TO BE CRACKED AND THE ANTENNA WAS LOOSE. UPON REMOVING THE ANTENNA, 3.5 INCH CRACKED WAS FOUND ON THE TAILCONE SKIN. THE CRACK DID NOT ORIGINATE FROM ANY OF THE MANUFACTURED RIVET OR SCREW HOLES. IT COULD NOT BE DETERMINED IF THE ANTENNA HAD BEEN PULLED ON AS THERE WAS NO DAMAGE TO THE ANTENNA OR BENDING OF THE TAILCONE SKIN. PICTURES HAVE BEEN FORWARDED TO TRANSPORT MAINTENANCE AND MANUFACTURER. THE TAILCONE HAS BEEN SENT TO THE MANUFACTURER FOR INSPECTION AND REPAIR. 1G71 3O3 O H11NM E295 20040127001142004012700114NE 2004 1 27 CA031205010 220031201G72503020159 SHROUD PWA PT6 PT6A114A 52043NE TURBINE SECTION COLLAPSED W K NONE O OTHER ININSP/MAINT 1 CA A00086EW (CAN) AFTER LIGHTNING STRIKE THE ENGINE WAS REMOVED FOR MAJOR REPAIR. WHEN THE ENGINE WAS SPLIT THE TECHNICIAN NOTICED A DISLODGED COMPRESSOR TURBINE SHROUD SEGMENT, RETAINING RING. THE SEGMENTS DROPPED AND CAUSED COMPRESSOR TURBINE BLADE TIP RUBS. THIS PROBLEM HAS BEEN DOCUMENTED ON AT LEAST 5 OTHER ENGINES THAT THE AUTHOR IS AWARE OF. 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 SUCH AS THE 114A ENGINE MODEL TO ALLOW THE MORE ROBUST RETAINING RING TO BE USED. 3 T E4EA 20040127001152004012700115NE 2004 1 27 CA031205011 220031201G72503020159 RETAINER PWA PT6 PT6A114A 52043NE TURBINE SECTION COLLAPSED W K NONE O OTHER ININSP/MAINT 1 CA A00021X9 (CAN) DEGRADED ENGINE PERFORMANCE (HIGH ITT/LOW NG) LEAD TO HOT SECTION MAINTENANCE BY CUSTOMER. THE COMPRESSOR TURBINE SHROUD SEGMENT RETAINING RING HAD BECOME LOOSE. THE SEGMENTS WERE LOOSE AND CAUSED COMPRESSOR TURBINE BLADE TIP RUBS. THIS PROBLEM HAS BEEN DOCUMENTED ON AT LEAST 5 OTHER ENGINES THAT THE AUTHOR IS AWARE OF. 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 SUCH AS THE 114A ENGINE MODEL TO ALLOW THE MORE ROBUST RETAINING RING TO BE USED. 3 T E4EA 20040127001162004012700116NE 2004 1 27 CA031205012 220031201G72503020159 RETAINER PWA PT6 PT6A114A 52043NE TURBINE SECTION COLLAPSED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DEGRADED ENGINE PERFORMANCE (ITT LIMITED) LEAD TO HOT SECTION MAINTENANCE. A DISLODGED COMPRESSOR TURBINE SHROUD SEGMENT-RETAINING RING WAS FOUND. THE SEGMENTS WERE LOOSE, SHIFTED AND CAUSED COMPRESSOR TURBINE BLADE TIP RUBS. THIS PROBLEM HAS BEEN DOCUMENTED ON AT LEAST 5 OTHER ENGINES THAT THE AUTHOR IS AWARE OF. 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 SUCH AS THE 114A ENGINE MODEL TO ALLOW THE MORE ROBUST RETAINING RING TO BE USED. 3 T E4EA 20040127001172004012700117NE 2004 1 27 CA031205013 220031201G72503020159 RETAINER PWA PT6 PT6A114A 52043NE TURBINE SECTION COLLAPSED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) AFTER HOT SECTION INSPECTION THE ENGINE WAS RUNNING HOT. WHEN THE ENGINE WAS SPLIT THE TECHNICIAN NOTICED THE COMPRESSOR TURBINE SHROUD SEGMENT RETAINING RING HAD FALLEN BEHIND THE VANE. THE SEGMENTS MOVED AND CAUSED COMPRESSOR TURBINE BLADE TIP RUBS. THIS PROBLEM HAS BEEN DOCUMENTED ON AT LEAST 5 OTHER ENGINES THAT THE AUTHOR IS AWARE OF. 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 SUCH AS THE 114A ENGINE MODEL TO ALLOW THE MORE ROBUST RETAINING RING TO BE USED. 3 T E4EA 20040127001182004012700118NE 2004 1 27 CA031205014 220031202G73141143890425 PUMP BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3I NE FUEL PRESS LEAKING W O OTHER BK SMOKE/FUMES/ODORS/SPARKS FLUID LOSS NRNOT REPORTED 1 CA (CAN) CREW NOTED THAT FUEL WAS LEAKING FROM THE RT ENGINE COWL. MAINTENANCE FOUND THAT THE LOW PRESSURE FUEL PUMP HAD BLOWN OUT THE GASKET BETWEEN THE MAIN BODY AND THE REGULATOR ASSEMBLY ALLOWING FUEL UNDER PRESSURE TO ESCAPE. THE PUMP WAS REPLACED AND THE AIRCRAFT RELEASED. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20040127001192004012700119SO 2004 1 27 CA031205015 120031202G3230 UPLOCK PIPER PA31 PA31 7103102SO LYC O540 TIO540A1B 41532EA HARTZLHCE2Y HCE2YR2 GL MLG FROZEN W O OTHER P NO WARNING INDICATION APAPPROACH 1 CA (CAN) LANDING GEAR UPLOCK FROZEN. WOULD NOT RELEASE TO LOWER GEAR. A MANUAL GEAR EXTENSION WAS COMPLETED. AIRCRAFT GEAR INSPECTED AND RE-LUBRICATED. FLIGHTS SINCE THEN HAVE BEEN SATISFACTORY. 1L72 3O3 O A20SO E14EA 5 CP9EA 20040127001202004012700120SO 2004 1 27 CA031205016 120031130G3260 BULB PIPER PA31 PA31 7103102SO LYC O540 TIO540A1B 41532EA HARTZLHCE2Y HCE2YR2 GL MLG INDICATOR LOOSE W L ABORTED APPROACH P NO WARNING INDICATION APAPPROACH 1 CA (CAN) NO RT LANDING GEAR DOWN AND LOCKED INDICATION. SOURCE CONFIRMED TO BE A LOOSE LIGHT BULB SOCKET. NO OTHER ACTION TAKEN. 1L72 3O3 O A20SO E14EA 5 CP9EA 20040127001212004012700121 2004 1 27 CA031208001 420031204G34137040 INDICATOR PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL LEFT VSI INOPERATIVE W O OTHER N FALSE WARNING DEDESCENT 1 CA (CAN) LT VSI WAS NOTED TO READ UP TO 250 FPM HIGH AS COMPARED TO THE RT AND PRESELECT SETTING. IT WAS NOTED TO READ ZERO IN LEVEL FLIGHT. VSI REPLACED WITH SERVICEABLE UNIT. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040127001222004012700122EU 2004 1 27 CA031208002 120031204G52305523512071 CABLE PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL CARGO DOOR FRAYED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE CABLE USED TO LOWER THE CARGO DOOR WAS FOUND TO HAVE A BROKEN STRAND. CABLE WAS REPLACED WITH NEW. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040127001232004012700123EU 2004 1 27 CA031208003 120031203G32979740926112 RELAY PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL MLG FAILED W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) AFTER TAKE-OFF, LANDING GEAR WOULD NOT FULLY RETRACT. NOSE GEAR CAME PARTWAY UP ONLY. GEAR WAS SELCTED DOWN AND LOCKED AND AC RETURNED TO BASE. HYD RELAY 947.09.26.112 WAS REPLACED, GEAR SWINGS CARRIED OUT AND AC RETURNED TO SERVICE. EVENING BEFORE, CREWS HAD COMPLAINED OF GEAR BEING SLOW. MAINT WAS INVESTIGATING AND IN PROCESS GEAR WOULD NOT RETRACT WHILE ON JACKS, A DIRTY CONNECTOR WAS TO HYD CONTROL RELAY 947.09.26 .112. CONNECTOR WAS CLEANED AND SYS OPERATED NORMALLY THROUGHOUT GEAR SWINGS. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040127001242004012700124NM 2004 1 27 CA031208004 120031201G213032194211 CONTROL VALVE BOEING737 737281 138448PNM PWA JT8 JT8D17 52049NE CABIN PRESSURE MALFUNCTIONED W G O2 MASK DEPLOYED J WARNING INDICATION CLCLIMB 1 CA (CAN) ON CLIMB OUT THROUGH 25,000 FT. FLIGHT CREW REPORTED, DUCT OVERHEAT ON RT PACK. COULD NOT CONTROL TEMPERATURE WITH RT PACK ON. AIRCRAFT LOST ALL PRESSURIZATION AT ABOUT 25,000 FT. AND COULD NOT CONTROL CABIN PRESSURE IN MANUAL. CREW CONTACTED ATC AND CONDUCTED RAPID DESCENT DOWN TO 9,000 FT. CREW COULD NOT RESTORE PRESSURIZATION, SO THEY RETURNED. WHEN AIRCRAFT LEVELLED OFF AT 9,000 FT. CAPTAIN WAS INFORMED OXYGEN MASKS HAD DROPPED DOWN IN THE CABIN. 2L72 4F4 F A16WE E2EA 20040127001252004012700125NE 2004 1 27 CA031208005 220031201G72503020159 RETAINER PWA PT6 PT6A114A 52043NE TURBINE SECTION COLLAPSED W O OTHER O OTHER CRCRUISE 1 CA (CAN) THE CUSTOMER EXPERIENCED A NEGATIVE SHIFT IN PERFORMANCE AND INCREASED ITT. THE HOT SECTION WAS INSPECTED. THE CT SHROUD SEGMENTS HAD SHIFTED AND THE CT BLADES WERE RUBBED. THIS PROBLEM HAS BEEN DOCUMENTED ON AT LEAST 5 OTHER ENGINES THAT THE AUTHOR IS AWARE OF. PWA 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 SUCH AS THE114A ENGINE MODEL TO ALLOW THE MORE ROBUST RETAINING RING TO BE USED. 3 T E4EA 20040127001262004012700126EU 2004 1 27 CA031208006 120031206G27505275212133 LINK PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL TE FLAP CONTROL BENT W K NONE O OTHER ININSP/MAINT 1 CA (CAN) RT AFT LINK PART NUMBER 527.52.12.133 AT CENTER FLAP POSITION FOUND BENT. FLAP FAIRINGS WERE REMOVED AND ALL LINKAGES INSPECTED. NO OTHER FAULTS FOUND. RT FLAP INSPECTED, NO FAULTS FOUND. BOTH RT FLAP FLEX DRIVE CABLES INSPECTED, NO FAULTS FOUND. SUSPECT FOD ICE/SLUSH FROM RUNWAY FILLED FAIRING AND FROZE. WHEN FLAPS WERE SELECTED IT INTERFERED WITH AFT LINKAGE CAUSING IT TO BEND. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040127001272004012700127WP 2004 1 27 CA031208007 120031128G308039271012 AUGMENT VALVE DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE RIGHT FAILED W A UNSCHED LANDING JM WARNING INDICATION OVER TEMP CLCLIMB 1 CA 3798 (CAN) RT ICE PROTECTION TEMPERATURE HIGH ILLUMINATED IN CLIMB. AIRCRAFT LANDED. MAINTENANCE REPLACED THE RT AUGMENTATION VALVE P/N 392710-2, S/N 3798 AND THE RT ICE ANTICIPATORS P/N 129110-2-1, S/N P118 AND P/N 129112-1-1, S/N N4216. SYSTEM WAS SERVICEABLE FOLLOWING THESE ACTIONS. 2L72 4F4 FRTA6WE E9NE 20040127001282004012700128NE 2004 1 27 CA031208008 120031208G63206135345133 BEARING SKRSKY 613520600 SKRSKYS61 S61NM 8142710NE M/R GEARBOX MISMANUFACTURED W K NONE O OTHER ININSP/MAINT 1 CA 65659 (CAN) BRG IS ONE OF FOUR BABBITT BRS LOCATED IN INPUT HOUSING AND COVER OF MGB. BRG IN QUESTION IS LOCATED IN THE INPUT COVER IN THE NR 1 POSITION. THIS GB WAS BEING TEST RUN BY MFG AC, TEN MINUTES IN TO RUN TEST STAND SHUT DOWN BECAUSE OF AN OVERTEMP ON SUBJECT BRG. INVESTIGATION REVEALED THAT IT WAS DUE TO OIL STARVATION THAT WAS DUE TO THE OIL GALLERY IN BRG BEING LOCATED INCORRECTLY. OIL HOLE WAS LOCATED APPROX. 45 DEG OUT. THIS RESULTED IN NO OIL FLOW TO JOURNAL ON HIGH SPEED INPUT THAT RUNS IN IT. ORIENTATION OF BEARING WAS LOCATED CORRECTLY, THERE IS A PIN CUT OUT ON THE FLANGE OF BEARING TO PRECLUDE THIS POSSIBILITY. 2G72 4U 1H15 20040127001292004012700129NE 2004 1 27 CA031209001 220030810G7320CASC501 REGULATOR FOKKERF27 F27MK100 4990617EU RROYCETAY TAY62015 04564NE FUEL FLOW MISINSTALLED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) NR 2 ENGINE FAILED TO ACCELERATE AT ALTITUDE DURING ALPHA FLOOR PROTECTION TEST. (AIRCRAFT SLOWS TO MINIMUM SPEED. AUTO THROTTLE SHOULD KICK IN AND ACCELERATE AIRCRAFT.) INVESTIGATION OF THE CASC501 FUEL FLOW REGULATOR FROM THIS ENGINE SHOWED THAT IT HAD BEEN SET TO DELIVER LOWER THAN REQUIRED FUEL FLOW BECAUSE IT WAS TESTED WITH A GD501 FUEL PUMP INSTEAD OF A GD500 FUEL PUMP AS SPECIFIED. A REVIEW OF R AND O RECORDS HAS SHOWN THAT 7 OTHER REGULATORS ARE AT RISK BECAUSE OF THE SAME ERROR. 2H72 4T4 F A817 E25NE 20040127001302004012700130NE 2004 1 27 CA031209002 120031209G63106135020459102 BUSHING SKRSKY SKRSKYS61 S61NM 8142710NE FREEWHEEL UNIT MISMANUFACTURED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) THE SUBJECT BUSHING INSIDE DIAMETER WAS NOT WITHIN DRAWING LIMITS. DRAWING LIMITS ARE 2.533 - 2.536. ACTUAL WAS 2.532. THIS BUSHING WOULD NOT FIT ON TO THE SHAFT. IT WAS SUPPLIED AS NEW. 2G72 4U 1H15 20040127001312004012700131SW 2004 1 27 CA031209003 120031202G2810 BLADDER BELL BELL 206 206B 1181511SW ALLSN 250C 250C20B 03013GL FUEL CELL LEAKING W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) WHEN FUEL TANK FILLED TO MAXIMUM CAPACITY A DRIP WOULD SHOW ON THE BELLY OF THE AIRCRAFT NEAR THE FUEL CAVITY DRAIN HOLE. 1G71 3U3 U H2SW E4CE 20040127001322004012700132SW 2004 1 27 CA031209004 120031208G4940980871103P261 PRESSURE SWITCH SWRNGNSA226 SA226AT 8780405SW GARRTTTPE331TPE33110UA 01514WP HARTZLHCB3T HCB3TN5 GL APU CRACKED W E ENGINE SHUTDOWN KJ FLUID LOSS WARNING INDICATION TXTAXI/GRND HDL 1 CA (CAN) ON TAXI IN FROM THE LAST FLIGHT OF THE DAY, THE CREW NOTICED THE OIL PRESSURE LIGHT ILLUMINATED. THE GAUGE CONFIRMED THE INDICATION. THE CREW SHUT THE ENGINE DOWN. ON ARRIVAL AT THE RAMP, A SUBSTANTIAL AMOUNT OF OIL WAS FOUND LEAKING FROM THE COWL. MAINTENANCE WAS NOTIFIED, AND TRACED THE PROBLEM TO A THE AUTO IGNITION PRESSURE SWITCH INSTALLED ON THE TORQUE PRESSURE MANIFOLD. THE SWITCH WAS INSTALLED AS PART OF AD 2002-01-16. PART TOTAL TIME WAS 580 HOURS SINCE NEW. A SERVICEABLE SWITCH WAS INSTALLED AND GROUND RUN CARRIED OUT SERVICEABLE. 2L72 4T4 TRTA5SW E4WE 6 CP15EA 20040127001332004012700133CE 2004 1 27 CA031209005 120031208G3297 DOWNLOCK SWITCH BEECH 99 99A 1154003CE PWA PT6 PT6A28 EA HARTZLHCB3T HCB3TN3 GL MLG BROKEN W L ABORTED APPROACH N FALSE WARNING APAPPROACH 1 CA (CAN) LT MAIN LANDING GEAR NOT INDICATING DOWN AND LOCKED ON APPROACH. AIRCRAFT RETURNED TO BASE. BROKEN WIRE ON DOWN SWITCH FOUND AND REPAIRED. GEAR SWING CARRIED OUT NORMAL FOR TYPE. AIRCRAFT RELEASED FOR RETURN TO SERVICE 1L72 3T4 T A14CE E4EA 6 CP15EA 20040127001342004012700134EU 2004 1 27 CA031210001 120031208G21339631411001 SOLENOID HONEYWELL PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL OUTFLOW VALVE STUCK W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA 118B0244 (CAN) AIRCRAFT WOULD NOT PRESSURIZE AFTER TAKE OFF. RETURNED TO BASE AND IT WAS FOUND SAFTEY VALVE WAS OPEN. THE REASON WAS THE SOLENIOD VALVE WAS STUCK IT WAS REMOVED AND CLEANED INSTALLED AND TESTED. GROUND RUNS WERE CONDUCTED AND PRESSURIZATION WAS FUNCTIONAL TESTED AND FOUND SERVICABLE. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040127001352004012700135SO 2004 1 27 CA031210002 220031208G8530646657A2 CYLINDER CESSNA310 310R 2074245CE CONT O520 IO520M 17032SO MCAULY3AF32C3AF32C* GL ENGINE CRACKED W O OTHER D INFLIGHT SEPARATION DEDESCENT 1 CA 270746R (CAN) ON APPROACH TO LANDING RT ENGINE STARTED TO RUN ROUGH. PILOT LANDED WITHOUT INCIDENT. AIRCRAFT WAS BROUGHT INTO THE HANGER AND A DP TEST WAS CONDUCTED ON THE ENGINE AND NR 6 CYLINDER WAS FOUND TO BE CRACKED FROM THE TOP SPARK PLUG HOLE ALL THE WAY AROUND TO THE LOWER SPARK PLUG HOLE. CYLINDER WAS REMOVED AND NO OTHER DAMAGE WAS NOTED. 1L72 3O3 O 3A10 E5CE 5 CP22EA 20040127001362004012700136EA 2004 1 27 CA031210003 220031206G72503022797 OIL RUNNER DHAV DHC7 DHC7102 2802708EA PWA PT6 PT6A50 52043EA HAMSTD24PF 24PF305 GL TURBINE SECTION LOOSE W K NONE K FLUID LOSS ININSP/MAINT 1 CA 23583 86031 (CAN) DURING THE UNSCHEDULED REMOVAL OF NR 2 PROP DUE TO OIL LEAKING FROM THE PROP SHAFT, IT WAS NOTICED THAT THE PROP SHAFT OIL RUNNER (PART OF THE POWER SECTION) WOULD ROTATE WITHOUT THE PROP SHAFT MOVING. INFORMED US THAT THIS IS AN INDICATION THAT BEARING RETAINING NUT ASSY (NUT P/N 3022710) MAY HAVE LOOSENED UP. THE POWER SECTION WAS REMOVED AND SENT FOR REPAIR. 2H74 4T4 T A20EA E4EA 6 CP1NE 20040127001372004012700137NE 2004 1 27 CA031210004 220031201G72503020159 RETAINER PWA PT6 PT6A114A 52043NE TURBINE SECTION COLLAPSED W K NONE O OTHER ININSP/MAINT 1 CA A00086EW (CAN) DURING A SCHEDULED HOT SECTION INSPECTION THE TECHNICIAN FOUND SHIFTED CT SHROUD SEGMENTS. THE RETAINING RING HAD RELAXED IN SERVICE AND MOVED OUT OF THE RING GROOVE. THIS PROBLEM HAS BEEN DOCUMENTED ON AT LEAST 5 OTHER ENGINES THAT THE AUTHOR IS AWARE OF. 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 SUCH AS THE 114A ENGINE MODEL TO ALLOW THE MORE ROBUST RETAINING RING TO BE USED. 3 T E4EA 20040127001382004012700138SW 2004 1 27 CA031210005 120031208G5510 ATTACH FITTING AIRTRCAT802 AT802 0390305SW PWA PT6 PT6A67A 52043NE HARTZLHCB5M HCB5MA3 GL HORIZIONTAL STABCRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING ANNUAL INSPECTION THE RT HORIZONTAL STABILIZER AUX FIN WAS FOUND TO BE LOOSE. UPON INVESTIGATION BY MAINTENANCE PERSONNEL THE FORWARD STABILZER BRACE AND AUX FIN ATTACH PLATE P/N 30653-2 WAS FOUND CRACKED COMPLETELY THROUGH AND AFT STABILIZER BRACE AND THE AUX FIN ATTACH PLATE WAS CRACKED APPROXIMATELY 1 INCH. THE CRACKS STARTED AT THE RADIUS OF EACH PLATE. THE ATTACH PLATES WERE REPLACED WITH NEW PARTS. 1L71 3T4 TNCA19SW E26NE 6 CP44GL 20040127001392004012700139EA 2004 1 27 CA031210006 120031209G551121523107821 RIB CNDAIRCL215 CL2151A10 1900320EA PWA R1340 AWASP 52016NE HAMSTD43E 43E60 NE HORIZONTAL STAB CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING ANNUAL INSPECTION IT WAS NOTED THAT THE INBOARD RIB P/N 215-23107-821 WAS CRACKED ON THE UPPER FLANGE. THE REMAINING AIRCRAFT IN THE FLEET WERE INSPECTED AND ALL 3 HAD CRACKS ON THE SAME RIB. THE CRACKS VARIED IN LENGTH FROM 1 INCH TO APPROXIMATELY 4 INCH. THE TAT'S WERE 3545.3, 3274.8 AND 2919.5. 2H72 4R3 RRTA14EA ATC14 6 CP871 20040315000262004031500026WP 2004 3 15 CA031210007 120030129G6520369A53525 BEARING RACE HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL CLUTCH INCORRECT W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA HT8920 (CAN) AT 300 HR. INSPECTION IT WAS NOTED THE OUTER RACE DID NOT HAVE A P/N, S/N OR A HEAT TREATMENT NR ETCHED ON IT. THIS WAS NOTED ON THE AD COMPLIANCE RECORD ALSO (BUT USED ANYWAY). MD HELICOPTERS SERVICE ENGINEERING WAS CONTACTED AND WE WERE INFORMED THAT IAW NOTES NR 19 AND 20 OF DRAWING THE PART MUST BE SERIALIZED AND IT WAS RECOMMENDED TO REMOVE FROM SERVICE (FAX LETTER ON FILE). 1G71 3U3 U H3WE E4CE 20040127001402004012700140EA 2004 1 27 CA031210008 220031210G7397 CONNECTOR BELL BELL 412 412EP 1182205SW PWA PT6T PT6T3 52045EA PRESSURE SWITCH CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DIAPHRAGM BROKEN AND LEAKING AROUND PINS ON ELECTRICAL HARNESS. 1G72 4U4 U H4SW E22EA 20040315000272004031500027WP 2004 3 15 CA031210009 120030129G6500369D25102 HOUSING HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL T/R COVER CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 1094 (CAN) AT REMOVAL OF TRANSMISSION FROM AIRFRAME A SUSPECTED CRACK IN THE T/R O/P COVER AT THE OIL PRESSURE SENDING UNIT WAS NOTED. THIS AREA WAS PAINT STRIPPED AND THE AREA WAS NOT ONLY CRACKED IT HAD ALSO BEEN STOP DRILLED, FILLED WITH EPOXY AND PAINTED. THIS IS NOT A REPAIRABLE ITEM. IT WAS ALSO NOTED THE TOP COVER HAD A BOLT MISSING. THE CUSTOMER WAS NOTIFIED AND THEN NOTIFIED THE REPAIR FACILITY THAT OVERHAUL THIS UNIT NOV.19/01 AND REPAIRED JULY 8/02. THEY REPLACED THE HOUSING FEB.26/03. 1G71 3U3 U H3WE E4CE 20040126001162004012600116CE 2004 1 26 CA031211001 120031209G2820040031158 LINE CESSNA150 152 2071835CE LYC O235 O235N2C 41505EA MCAULY1A103 1A103TCM GL FUEL SYSTEM CORRODED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) FUEL LINE HAD A ROUGH LOOK TO THE SURFACE. THE FUEL LINE WAS ACCESSED BY REMOVING CENTER CONSOLE COVER AND PEELING BACK CARPET. CLOSER EXAMINATION OF LINE REVEALED CORROSION PITS AND RESIDUE THAT WAS DETERMINED TO BE CAUSED BY THE FUEL LINE CONTACT WITH MOISTURE SOAKED CARPET. LINE IS ROUTED UP FROM FLOOR THROUGH A CUT-OUT AND CLAMPED FURTHER UP WHERE IT CONNECTS TO A UNION FITTING. THIS IS ON RT SIDE OF CONSOLE AND ADJACENT TO WHERE INSTRUCTORS LT FOOT WOULD BE RESTING. MOISTURE FROM HIS/ HERFOOTWEAR IS ABSORBED INTO CARPET AND RESTS ALONG FUEL LINE WHERE IT EXITS FLOOR. LINE WAS REMOVED AND REP LACED WITH A NEW PART. CONSOLE WILL BE REINSTALLED WITH EDGE OF CARPET RESTING OVER BASE OF CONSOLE. 1H71 3O3 ONT3A19 E223 5 NP50GL 20040126001172004012600117NM 2004 1 26 CA031211002 120031207G2910659603 SOLENOID VALVE DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE HYD SYSTEM SEPARATED W A UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CLCLIMB 1 CA 3095919335 (CAN) DURING CLIMB CREW REPORTED LOSS OF NR 2 HYD FLUID. NR 2 HYD ISO VALVE CAUTION LIGHT ILLUMINATED. NR 2 HYD QUANTITY GAUGE SHOWING DECLINE. AIRCRAFT RETURNED TO ORIGINATING AIRPORT, ALTERNATE GEAR EXTENSION USED, NORMAL LANDING. MAINTENANCE FOUND NR 2 HYD FLIGHT SPOILER VALVE CAP HAD SEPARATED, ALLOWING LOSS OF HYD FLUID. VARIOUS PARTS LOCATED IN THE NACELLE. CAP SHOULD BE SECURED TO VALVE BODY WITH 4 SCREW/STUDS, 3 STUDS REMAINED IN BODY, ONE MISSING. 2 HEADS STILL LOCKWIRED TOGETHER LOCATED IN NACELLE, REMAINING ATTACHMENT PARTS NOT LOCATED. VALVE REPLACED WITH SERVICEABLE UNIT, FUNCTION, LEAK CHECKED. AIRCRAFT RETURNED TO SERVICE. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040126001182004012600118NE 2004 1 26 CA031211003 320031201G61118022532 COLLAR HAMSTD DHAV DHC8 DHC8101 2809002NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE PROP BLADE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 8660457 (CAN) DURING A FLEET INSPECTION OF PROPELLER BLADES TO CHECK INTEGRITY AND CONDITION OF THE BLADE CUFFS. AS A RESULT OF THE INSPECTIONS, ONE COLLAR ASSY WAS FOUND TO BE CRACKED, HOWEVER, STILL SECURELY ATTACHED. THE BLADE ASSY WAS REMOVED FROM SERVICE AND HAS BEEN SENT FOR REPAIR. MFG HAS BEEN INFORMED OF FINDINGS. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040126001192004012600119EA 2004 1 26 CA031211004 120031204G79205085T10G01 TUBE CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE HEAT EXCHANGER CHAFED W O OTHER K FLUID LOSS NRNOT REPORTED 1 CA (CAN) DURING TROUBLESHOOTING OF POSSIBLE OIL LEAK ON NR 1 ENGINE, MAINTENANCE FOUND OIL LINE FROM HEAT EXCHANGER TO LUBE SCAVENGE PUMP DEEPLY CHAFED ON FLANGE OF A AND B SUMP SUPPLY LINE. LINE REPLACED. A AND B SUMP SUPPLY LINE REPOSITIONED AND ADDITIONAL CLAMPING INSTALLED. 2L72 4F4 FRTA21EA E15NE 20040126001202004012600120NE 2004 1 26 CA031211005 220031207G7532311269001 PIPE DHAV DHC8 DHC8311 1386006EA PWA PW120 PW123 NE HAMSTD14SF 14SF15 NE BLEED VALVE CRACKED W C ABORTED TAKEOFF J WARNING INDICATION TOTAKEOFF 1 CA (CAN) ON TAKEOFF NR 1 ENGINE FUEL FLOW INDICATING 150 LBS HIGHER THAN NR 2 ENGINE. ON NR 1 ENGINE MAINTENANCE FOUND P3 VENTURI TUBE WITH CRACKS JUST ABOVE FLANGE THAT HAD JOINED TOGETHER TO PUSH OUT PART OF THE WALL OF THE TUBE TO CREATE A HOLE. TUBE WAS REPLACED. ENGINE TSN: 24434 TSO: 4853 CSN: 34845 CSO: 6528 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040126001212004012600121NE 2004 1 26 CA031212001 120031202G6220S611520107 RECEPTACLE SKRSKYS61 S61N 8142104NE GE CT58 CT581401 30011NE M/R HEAD CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) POCKETS 20,21,22 FOUND CRACKED SPAN WISE ON UNDER SIDE OF POCKET. AFTER REMOVAL OF POCKET FROM THE BLADE, IT WAS FOUND THAT THE POCKETS WERE NOT BONDED TO THE BACK FACE OF THE SPAR. THIS ALLOWED THE POCKETS TO WORK UP AND DOWN CAUSING THE SURFACE CRACKS. 2G72 4U4 U 1H15 1E3 20040126001222004012600122NM 2004 1 26 CA031212002 120031127G271082700563S001 CONTROL CABLE DHAV DHC8 DHC8301 1386003NM PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE AILERON SYSTEM MISRIGGED W O OTHER W INADEQUATE Q C NRNOT REPORTED 1 CA (CAN) AILERON CTRL CABLES FOUND TO BE INCORRECTLY ROUTED AT OB CNTL QUADRANTS ON BOTH WINGS, UNDER ACCESS PANELS 532AT AND 632AT. IT WAS ONLY DUE TO OTHER AILERON MAINT THAT PANELS 532AT, 632AT WERE LIFTED TO FACILITATE RIGGING CHECKS. INCORRECT ROUTING ISSUE, CABLES IN QUESTION HAD NOT BEEN LOCATED IN QUADRANT GROOVE AS REQUIRED HENCE WERE OPERATING ON TOP OF QUADRANT RESULTING IN RUBBING ON QUADRANT. ALTHOUGH CABLES HAD BEEN RUBBING ON QUADRANT THEY HAD NOT GENERATED WEAR OUTSIDE OF MM LIMITS, ONCE RIGGED THEY HAVE REMAINED IN SERVICE. IN ADDITION, HAD AILERONS NOT BEEN CHANGED, PANELS WOULD NOT HAVE BEEN LIFTED AT THIS VISIT. DEFECT DISCOVERED IS BELIEVED TO HAVE BEEN IN A/C SINCE MANUFACTURE. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040126001232004012600123SW 2004 1 26 CA031212003 120031203G5302206032409001P FITTING BELL 206 206L4 1182110SW ALLSN 250C 250C30P 03013GL TAILBOOM CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING ROUTINE 100 HR INSPECTION TO AIRCRAFT, THE LT UPPER TAILBOOM ATTACHMENT FITTING WAS FOUND CRACKED. CRACK APPEARED TO BE BETWEEN AND EXTENDED BELOW THE TWO FORWARD MOST ATTACHING RIVETS. NO INDICATION OF CRACK WAS NOTED ON PREVIOUS INSPECTION. TAILBOOM WAS REMOVED FROM AIRCRAFT, SENT TO APPROVED REPAIR FACILITY, FITTING REPLACED AND TAILBOOM PLACED BACK IN SERVICE. 1G71 3U3 UNCH2SW E1GL 20040126001242004012600124NM 2004 1 26 CA031212004 120031209G2710 CONTROL CABLE BOEING727 727243 138408DNM PWA JT8 JT8D15 52051NE AILERON SYSTEM OUT OF ADJUST W K NONE O OTHER ININSP/MAINT 1 CA 48876 (CAN) CONTROL WHEEL VERY STIFF WHEN DEFLECTED LT AND SLOW TO RETURN ON RT DEFLECTION. LOST MOTION CABLES ADJUSTED IAW MM 27-10-0 AILERON INPUT PUSHROD ADJUSTED IAW MM 27-10-0CENTERING PUSHROD ADJUSTED A PER MM 27-10-0 SPOILER MIXER CONTROL ROD ADJUSTED MM 27-61-0 SPRING CARTRIDGE ROD ADJUSTED IAW MM 27-10-0 AILERON SPOILER FUNCTIONAL CHECK CARRIED OUT AND FOUND OK IAW MM 27-10-0 AND 27-60-0. 2L73 4F4 FRTA3WE E2EA 20040302000012004030200001CE 2004 3 2 CA031212005 120031212G551004320049 BRACKET CESSNA CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA HORIZONTAL STAB CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 22758 (CAN) AN INSPECTION WAS PERFORMED TO THE BRACKET AT THE REAR OF THE HORIZONTAL STABILIZER IN PREPARATION FOR COMPLIANCE WITH CESSNA SERVICE BULLETIN 03-6.ONCE THE STABILIZER AND BRACKET WERE REMOVED FROM THE AIRCRAFT, A CLOSE VISUAL EXAMINATION REVEALED A CRACK MEASURING ABOUT 1/2 INCH IN LENGTH RUNNING ALONG THE WELD ADJACENT TO ONE OF THE INSTALLED NUTPLATES. THE BRACKET WAS REMOVED FROM SERVICE AND A REPLACEMENT BRACKET WAS PLACED ON ORDER FROM THE MANUFACTURER. 1H71 3O3 ONT3A19 E223 20040127000012004012700001EA 2004 1 27 CA031212006 120031210G6240269A46193 DRIVE ASSY SCWZER269 269D 8059501EA LYC O360 HIO360D1A 41514EA ROTOR TACH CORRODED W A UNSCHED LANDING N FALSE WARNING CRCRUISE 1 CA (CAN) PILOT REPORTED LOST ROTOR TACH INDICATION. ROTOR DRIVE CABLE WAS REMOVED FROM ITS OUTER SHEATH FOR INSPECTION AND WAS FOUND SNAPPED IN TWO JUST BEFORE IT ENTERS INTO THE TRANSMISSION. IT WAS REMOVED PREVIOUSLY DUE TO REPORT THAT ROTOR NEEDLE WAS BOUNCING. IT WAS INSPECTED AND RELUBED AND NO INDICATION OF DEFECTS WERE REPORTED. IT WAS THEN REINSTALLED. WHEN IT WAS INSPECTED THE SECOND TIME AFTER FAILURE, IT WAS NOTED THAT IT HAD BEEN CORRODING FROM THE INSIDE OUT. 1G71 3U3 O0 4H12 1E10 20040127000022004012700002EA 2004 1 27 CA031214001 120031202G5610NP13932210 WINDOW CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE COCKPIT CRACKED W O OTHER O OTHER DEDESCENT 1 CA (CAN) RT SIDE WINDOW CRACKED DURING DESCENT. WINDOW REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 2L72 4F4 FRTA21EA EOOO63EN 20040127000032004012700003NE 2004 1 27 CA031214002 220031123G73204120T01P02 FMU CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE FUEL CONTROL DEFECTIVE W O OTHER W INADEQUATE Q C CLCLIMB 1 CA (CAN) DURING CLIMB THERE WAS A L FADEC FAULT 1 STATUS MESSAGE. LT FUEL FLOW DROPPED FROM 890 KG/HR TO 670 KG/HR LT N1 INCREASED TO 98 PERCENT, LT ENG FLAMEOUT CAUTION AND CONTIGNITION STATUS MESSAGES APPEARED. MESSAGES THEN DISAPPEARED AND ENGINE RETURNED TO NORMAL. FDR ANALYSIS REVEALED THAT THE ENGINE DID NOT FLAME OUT. IAW MFG RECOMMENDATION THE FMU (FUEL METERING UNIT) HAS BEEN REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 2L72 4F4 FRTA21EA EOOO63EN 20040127000042004012700004EA 2004 1 27 CA031215001 220031029G853073772 COOLING JET AAR PIPER PA31 PA31 7103102SO LYC O540 TIO540A2B 41532EA HARTZLHCE3Y HCE3YR2A GL CYLINDER SEPARATED W K NONE D INFLIGHT SEPARATION ININSP/MAINT 1 CA L58061 (CAN) PISTON COOLING JET BACKED OUT OF HOLE. BOUNCED AROUND INSIDE OF ENGINE BEFORE THE CRANKSHAFT PUSHED IT THROUGH THE TOP OF THE CASE 1L72 3O3 O A20SO E14EA 5 CP33EA 20040127000052004012700005CE 2004 1 27 CA031215002 120031210G27000510105325 CONTROL CABLE CESSNA185 A185E 2072818CE CONT O520 IO520D 17032SO MCAULYD3A34 D3A34C403 GL FRAYED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) CABLE INSPECTION REVILED WEAR & FRAYING AT THE POINT WERE THE CABLE CHANGES DIRECTION ENTERING THE FUSELAGE. 1H71 3O3 O 3A24 E5CE 5 CP47GL 20040127000062004012700006NE 2004 1 27 CA031216001 220031212G73204120T01P02 FMU CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE FUEL CONTROL DEFECTIVE W E ENGINE SHUTDOWN M OVER TEMP CRCRUISE 1 CA (CAN) DURING CRUISE THE CREW SAW THE RT ENGINE EGT CLIMBING, THE CREW SHUT DOWN THE ENGINE. EGT HAD REACHED 936DEG FOR 10.9 SECS. THE AIRCRAFT LANDED WITHOUT FURTHER PROBLEM. THE FUEL METERING UNIT (FMU) WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 2L72 4F4 FRTA21EA EOOO63EN 20040127000072004012700007CE 2004 1 27 CA031216003 120031117G712005131329 BRACKET CESSNA172 R172K 2072431CE CONT O360 IO360KB 17025SO MCAULY2A34C 2A34C203 GL ENG MNT ATTACH CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ENGINE MOUNT TO FIREWALL 1/B LT LOWER CHANNEL BRACKET FOUND CRACKED. REPLACED WITH NEW. 1H71 3O3 O 3A17 E1CE 5 CP3EA 20040127000082004012700008 2004 1 27 CA031216004 420031212G2200 CONTROL UNIT CVAC 580 580 2422806WP ALLSN 501D 501D13D 03004GL AILERON JAMMED W O OTHER F FLT CONT AFFECTED CRCRUISE 1 CA (CAN) ON FLT, AUTO-PILOT WAS UNABLE TO CHANGE AC DIRECTION, AUTO-PILOT WAS DISCONNECTED AND CREW DISCOVER THAT THEY WERE UNABLE TO MOVE AILERON CONTROL WHEEL. THEY MOVED TRIM AND SUDDENLY AILERON CONTROL WHEEL TURNED, CONTROL WHEEL DID NOT JAM AGAIN. AFTER ARRIVAL, INVESTIGATION REVEALED THAT LT AILERON CONTROL (FUSELAGE) PRESSURE SEAL WAS COATED WITH A .7500 INCH COAT OF ICE. ICE WAS MELTED AND WATER DRYED. WE DISCOVERED THAT ONE CARGO CONTAINER WAS LOADED WITH SMALL AMOUNT OF SNOW, WHICH MELTED AND DRIPPED UNDER FLOOR ON CONTROL CABLES ON THE LT SIDE. WE SEALED FLOOR PANEL 5 FEET FORWARD AND AFT OF CONTROL CABLES. AN INSP WAS CARRIED OUT FOR TWO FOLLOWING FLIGHTS AND NO ICE OR WATER WHERE FOUND IN AREA. 2L72 4T4 TRT E282 20040217002012004021700201NE 2004 2 17 CA031216005 220031211G731082820127101 TUBE DHAV DHC8 DHC8102 2809003NM PWA 120 PW120A NE HAMSTD14SF 14SF7 NE ENGINE CHAFED W K NONE O OTHER ININSP/MAINT 1 CA 37521 PCE120367 (CAN) TEARDOWN OF ENGINE FOR A HOT SECTION INSP. FROM A/C NR 2 POS, ENGINEER DISCOVERED STAINLESS STEEL TUBE ASSY, ENGINE WASTE FUEL RETURN LINE P/N 82820127-101, CHAFFED. THE IPC, PSM 1-8-4, REF IS 71-70-00 FIG 10 ITEM NR 245 MM, PSM 1-8-10, REF IS 71-00-02 FOR COMPONENT IN QUESTION. FOUND THAT IT WAS RUBBING AGAINST AFT FIREWALL INSTALLATION LOWER SECTION AT STN XN.107.18,P/N 85411444-101 IPC REF IS 54-10-00 FIG 5 ITEM NR70. FIX FOR THIS IS FUEL RETURN LINE NEEDS TO BE POSITIONED IN A MANNER THAT BOTH SECTIONS OF LINE ARE IN SAME HORIZONTAL PLANE, SHOULD BE AS CLOSE TO CASE DRAIN FITTING AS POSSIBLE. IF THERE ARE ANY LINES FOUND WITH CHAFFING DAMAGE,WILL BE CHANGED OUT DEPENDING ON THE SEVERITY. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040127000092004012700009GL 2004 1 27 CA031216006 120031116G3240GW41571253 CONTROL UNIT BOMBDRBD700 BD7001A10 1390006GL RROYCEBR700 BR700710A22009500NE MLG BRAKES FAILED W O OTHER H ELECT. POWER LOSS-50 PC LDLANDING 1 CA (CAN) AFTER TAKE OFF, (BRAKE FAULT) AND (GND LIFT DUMP) ADVISORY CAS MESSAGE WERE POSTED UPON GEAR RETRACTION AND REMAIN POSTED THROUGHOUT THE FLIGHT. ON TOUCHED DOWN, THE PILOT NOTICED THAT THERE WAS NO DECELERATION FELT WHEN APPLYING THE PEDALS. THE THRUST REVERSERS AND EMERGENCY BRAKE WERE USED TO STOP THE AIRCRAFT. TROUBLESHOOTING REVEALED THAT THE BRAKE CONTROL UNIT (BCU) WAS SHOWING AN (INTERNAL FAILURE). THE BCU WAS REPLACED, THE SYSTEM TESTED FULLY OPERATIONAL AND THE AIRCRAFT WAS RETURNED TO SERVICE. 2L72 4F4 FRTT00003NYE00061EN 20040127000102004012700010NE 2004 1 27 CA031216007 220031216G73100301007720 LINE SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE ENGINE FUEL BROKEN W O OTHER O OTHER TXTAXI/GRND HDL 1 CA 9631 (CAN) PILOT ATTEMPTED A START AND THE ENGINE FAILED TO ACCELERATE. INITIAL T4 INDICATION WAS VERY LOW AND THE T4 DID NOT INCREASE AS THE THROTTLE WAS MOVED FORWARD DURING THE STARTING SEQUENCE. THE PILOT ABORTED THE START. UPON INSPECTION THE PILOT NOTICED FUEL LEAKING FROM THE ENGINE OVERBOARD DRAIN. THE PILOT LIFTED THE ENGINE COWLING AND TRACED THE FUEL LEAKAGE TO THE RT FUEL INJECTOR PIPE. THE PIPE FAILED BEHIND THE FLARE AT THE INJECTOR JUNCTION. 1G71 3U3 U H9EU E19EU 20040127000112004012700011SW 2004 1 27 CA031217001 120031215G275021903 CONTROL CABLE BBAVIA8 8GCBC 1220803SW LYC O360 O360C2E 41514EA MCAULY1A200 1A200* GL FLAP HANDLE FRAYED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING THE COMPANIES STRUCTURAL INSPECTION AND REPAIR PROGRAM (SIRP), THE FLAP CABLE ATTACHED TO THE FLAP HANDLE WAS FOUND FRAYED AS IT STARTS TO ENTER AND TURN AROUND THE SECTOR (P/N 3-1128). THERE WAS NO INDICATION OF FRAYING UNTIL THE CABLE WAS REMOVED AND INSPECTED. IT WAS ESTIMATED THAT THE CABLE WAS FRAYED 70 PERCENT. 1H71 3O3 O A21CE E286 5 NP874 20040127000122004012700012EA 2004 1 27 CA031217002 220031216G8520ST203 RING CESSNA172 172N 2072434CE LYC O320 O320D2J 41508EA MCAULY1C160 1C160DTM GL PISTONS FAILED W K NONE L NO TEST ININSP/MAINT 1 CA RL1657939 (CAN) REPORTED ENGINE BACKFIRING AT LOW RPM. CARRIED OUT COMPRESSION TEST ON ALL FOUR CYLINDERS. COMPRESSIONS WERE AS FOLLOWS, NR 1 70/80, NR 2, 72/80, NR 3, 60/80, NR 4, 74/80. REMOVED NR 3 CYLINDER AND FOUND MARKS IN CYLINDER AND RINGS WERE EXCESSIVELY SHARPENED FOR ONLY 51. 2HRS TT. THROUGH CONVERSATION WITH THE ENGINE SHOP THEY HAVE FIGURED THE RINGS FAILED. ALL FOUR CYLINDERS ARE BEING REMOVED AND REPLACED WITH DIFFERENT RINGS AND COMPLETE CYLINDER ASSY. THIS SDR IS ALSO BEING FORWARDED TO THE ENGINE SHOP AND WOULD SUSPECT IT BEING PASSED ON TO THE FAA ALONG WITH THERE OWN PARTS FAILURE NOTIFICATION SYSTEM. 1H71 3O3 ONT3A12 E274 5 NP910 20040127000132004012700013NE 2004 1 27 CA031217003 220031213G7200 ENGINE CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE RIGHT MALFUNCTIONED W E ENGINE SHUTDOWN R PARTIAL RPM/PWR LOSS CLCLIMB 1 CA (CAN) THRUST LOSS RT ENGINE ON CLIMB ACCOMPANIED BY VIB ICON. QRH CARRIED OUT, ENGINE SECURED, WAITING FOR REPORT. 2L72 4F4 FRTA21EA E15NE 20040127000142004012700014NE 2004 1 27 CA031217004 220031216G7200 ENGINE CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE MALFUNCTIONED W E ENGINE SHUTDOWN EJ VIBRATION/BUFFET WARNING INDICATION CRCRUISE 1 CA (CAN) LOUD BANG, N1 VIB, N2 VIB AND ITT MAX TEMP NEEDLE PEGGED. ENGINE SHUT DOWN. AWAITING REPORT. 2L72 4F4 FRTA21EA E15NE 20040127000152004012700015EA 2004 1 27 CA031217005 120031206G4920 ENGINE CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE APU FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) APU ENGINE FAILED FOUND MOST OF THE EXHAUST TURBINE ON RAMP, AWAITING REPORT. 2L72 4F4 FRTA21EA E15NE 20040127001412004012700141NM 2004 1 27 CA031217006 120030829G3297461651 WIRE HARNESS BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU MLG SHORTED W O OTHER O OTHER LDLANDING 1 CA (CAN) UPON LANDING PILOT GOT IB ANTI SKID CAUTION LIGHT ON FOR APPROX. 5 SEC. AFTER LANDING. CAUTION LIGHT THEN DISAPPEARED. WHEN PARKED PILOT FOUND RT MAIN INNER TIRE TO BE TOTALLY BLOWN. PAX TOLD US THAT THEY SAW A TIRE THAT NEVER HAD ANY ROTATION AND EXPLODED SHORTLY AFTER LANDING ROLL WAS STARTED. WHEELS NR 3 AND NR 4 REPLACED IAW AMM 32-41-01. AIRCRAFT WAS THEN RELEASED FOR FLIGHT IAW MEL 32-40-2. DURING FURTHER TROUBLESHOOTING WIRES TO RT IB/OB WHEEL SPEED TRANSDUCERS FOUND SHORTED TO GROUND. WIRES REPLACED AND SYSTEM TESTED IAW AMM 32-46-00. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20040127001422004012700142 2004 1 27 CA031217007 420031210G2297 WIRE BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU AUTOPILOT SYSTEMCHAFED W O OTHER N FALSE WARNING CRCRUISE 1 CA (CAN) MULTIPLE FAIL MESSAGES, YD NOT CENTER, AIR DATA FAIL AND ATT DATA FAIL. FOUND CHAFED DATA BUSS WIRES BEHIND MFD2 CAUSED BY 3428-P1-A3 CONNECTOR BACKSHELL. SPLICE REPAIRED. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20040217002022004021700202CE 2004 2 17 CA031217008 120031209G25205045164038088 RESTRAINT CESSNA182 T182T 2072738CE LYC O540 TIO540AK1A EA MCAULY3D36C B3D36C424 GL PAX CABIN INOPERATIVE W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING INSPECTION IT WAS NOTICED THAT BOTH REAR SEAT RESTRAINT SYSTEM INERTIA REELS WOULD INTERMITTENTLY LOCK AND NOT ALLOW BELT TO EXTEND. IT WAS DECIDED THAT IF RESTRAINTS WERE RELEASED IN FLIGHT IT MAY NOT BE POSSIBLE TO REFASTEN THEM SO BOTH UNITS WERE REPLACED. PARTS WILL BE RETURNED TO THE MANUFACTURER AS THE AIRCRAFT IS STILL ON WARRANTY. OUR MFG TECH. SUPPORT PERSON WAS ADVISED OF THIS PART DEFECT. 1H71 3O3 ONT3A13 5 CP58GL 20040217002032004021700203NM 2004 2 17 CA031218001 120031217G323110605801 SEQUENCE VALVE BOEING727 727227 1384078NM PWA JT8 JT8D9A 52048NE MLG DOOR DAMAGED W K NONE K FLUID LOSS TXTAXI/GRND HDL 1 CA (CAN) JUST AS AC STARTED TO TAXI CREW NOTED LOSS OF ALL HYD FLUID IN SYSTEM A. A/C SHUT DOWN AND PUSHED BACK INTO PARKING SPOT. LEAK DETERMINED TO BE COMING FROM THE RT MLG DOOR SEQUENCE VALVE. BODY OF VALVE FOUND SPLIT. A/C UNLOADED, VALVE CHANGED, GEAR SWINGS CARRIED OUT AND A/C RETURNED TO SERVICE. 2L73 4F4 F A3WE E2EA 20040217002042004021700204NM 2004 2 17 CA031218002 120031216G6120697073001A PITCH CONTROL BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU PROPELLER INOPERATIVE W E ENGINE SHUTDOWN EW VIBRATION/BUFFET INADEQUATE Q C CRCRUISE 1 CA (CAN) EVERY 20 SECONDS IN FLIGHT, PROP SPEED DROPS BY 10 RPM AND ALL OTHER ENGINE PARAMETERS ALSO DROP. CREW COULD FEEL THE DROP IN POWER, NOT AN INDICATION PROBLEM. FADEC WAS REPLACED, ON GROUND HIGH POWER RUNS NO DEFECT NOTICED. TAKE-OFF WAS FINE, BUT ON CLIMB, PARAMETER FLUCTUATIONS RESURFACED EVERY 20 SECS. NR 1 ENGINE SHUTDOWN AND AIRCRAFT RETURNED TO BACK BASE. PCU CHANGED AND CHECK FLIGHT WAS SUCCESSFUL, AIRCRAFT RETURNED TO SERVICE. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20040217002052004021700205CE 2004 2 17 CA031218003 120031129G5210 LATCH BEECH 1900 1900C 1154161CE PWA PT6 PT6A65B 52043EA HARTZLHCB4M HCB4MP3 GL PAX DOOR FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) AFTER COMPLETING FLIGHT AND TAXIING THE PILOT WAS UNABLE TO OPEN THE AIRSTAIR DOOR TO DISEMBARK PASSENGERS. THEY WERE REQUIRED TO EXIT THE AIRPLANE USING THE OVER WING EMERGENCY EXIT. BEFORE MAINTENANCE PERSONNEL WERE ABLE TO ARRIVE ON THE SCENE THE PILOT HAD MANAGED TO OPEN THE AIRSTAIR DOOR BY USING A SCREWDRIVER TO RELEASE THE DOOR CAM MECHANISMS. MAINTENANCE INVESTIGATED AND FOUND THAT THE INTERNAL DOOR CABLE HAD BROKEN AND THEREFORE THE DOOR COULD NOT BE OPENED NORMALLY. 2L72 4T4 TRTA24CE E4EA 6 CP56GL 20040315000752004031500075EA 2004 3 15 CA031218004 120031217G2731C3CF4187 ROD DHAV DHC3 DHC3 2800202EA PWA R1340 S3H1G 52016NE HAMSTD23D 23D40 NE ELEVATOR TAB WORN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ROD HAS BEEN DISCOVERED TO BE WORN. 1H71 3R3 R A815 E142 6 CP719 20040217002062004021700206NM 2004 2 17 CA031218005 120031204G3070 RIBBON HEATER BOEING767 767233 1385113NM PWA JT9 JT9D7R4D 52054NE WATER LINE BURNED W K NONE B SMOKE/FUMES/ODORS/SPARKS ININSP/MAINT 1 CA (CAN) DURING THE CURRENT MAINT VISIT ON VA704 A BURNED HEATER TAPE HAS BEEN DISCOVERED. THE 7.1 FOOT LONG DRAIN LINE ELEMENT IS THE HEATER B193 (COX P/N 3051-01 MODEL 110-7.1-71) LOCATED AT BSTA 1560, WL 174, RBL 62. IN THIS CASE, HEATER AND PROTECTIVE TAPE EXHIBITS HEAT DAMAGE ALONG ITS ENTIRE LENGTH. NOTE THAT ADJACENT INSULATION BLANKET MATERIAL ON BULKHEAD ALSO EXHIBITS HEAT DAMAGE. REF /L/INDICATES THAT THE REF /F/ RELEASE WITH NON-ESSENTIAL HEATER DEACTIVATION INSTRUCTIONS IS STILL SEVERAL MONTHS AWAY. QUITE ANXIOUS TO DETERMINE WHICH LINES MAY BE DEACTIVATED. 2L72 4F4 FRTA1NM E3NE 20040217002072004021700207EA 2004 2 17 CA031218006 120031217G2731C3CF4187 ROD DHAV DHC3 DHC3 2800202EA PWA R1340 S3H1G 52016NE HAMSTD23D 23D40 NE STABILATOR CHAFED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE ROD HAS FOUND TO BE A PROBLEM IN THIS TYPE OF A/C SHOULD BE INSPECTED IN CONJUNCTION WITH THE STABILATOR TRIM JACK AT 400 HRS. 1H71 3R3 R A815 E142 6 CP719 20040217002082004021700208EU 2004 2 17 CA031218007 120031217G7997K11A24NK10A24 WIRE DEUTSCH PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL CHIP DETECTOR FRAYED W O OTHER N FALSE WARNING CRCRUISE 1 CA (CAN) INTERMITTENT CHIP LIGHT IN FLIGHT. THE INSULATION CRACKED RADIALLY IN RUBBER AT STRAIN RELIEF, THE FRAYING OF THE WIRES CAUSED THEM TO TOUCH INTERMITTENTLY CAUSING THE CHIP LIGHT TO FLICKER. WIRE INSULATION REPAIRED. A/C RETURNED TO SERVICE. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040217002092004021700209NM 2004 2 17 CA031218008 120031212G575369378535 FITTING BOEING737 737217 1384464NM PWA JT8 JT8D17 52049NE FLAP TRACK BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ON WALK AROUND, MAINTENANCE FOUND THE RT OB FOREFLAP OB LINK BROKEN. MAINTENANCE REPLACED THE FOREFLAP AND AIRCRAFT RETURNED TO SERVICE. CAUSE UNKNOWN. WILL UPDATE IF ADDITIONAL INFORMATION AVAILABLE. 2L72 4F4 F A16WE E2EA 20040315000792004031500079CE 2004 3 15 CA031219001 120031217G55110432001646 RIB CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA MCAULY1A103 1A103TCM GL HORIZONTAL STAB CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE STABILIZER WAS REMOVED FROM THE AIRCRAFT TO PERFORM OTHER UNRELATED REPAIRS WHEN IT WAS DISCOVERED THAT BOTH OF THE IB LEADING EDGE NOSE RIBS WERE CRACKED. THE CRACKS APPEAR ON THE FLANGE ADJACENT TO THE MOST AFT ATTACHING TABS. CRACKS WERE FOUND TO BE .1250 TO .2500 INCH IN LENGTH AND FOUND AT THE TOP AND BOTTOM POSITIONS. WITH THE STABILIZER OFF WE REPLACED BOTH RIBS WITH NEW PARTS. THIS DEFECT SEEMS TO BE A COMMON FINDING FOR OPERATORS OF 152 SERIES AIRCRAFT. 1H71 3O3 ONT3A19 E223 5 NP50GL 20040315000802004031500080GL 2004 3 15 CA031222001 120031217G32463006202 WHEEL DHAV DH82 DH82 2801000GL PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE MLG FRACTURED W D RETURN TO BLOCK D INFLIGHT SEPARATION TXTAXI/GRND HDL 1 CA 24258 (CAN) TAXIING FOR TAKE-OFF WHEN THE OB WHEEL OF THE LT MLG SUFFERED A STRUCTURAL FRACTURE. DURING THE TAXI, THE FLIGHT CREW HEARD A LOUD BANG FROM THE AIRCRAFT, AND DIRECTLY FOLLOWING, THE AIR TRAFFIC CONTROL RADIOED THE CREW TO ADVISE THAT THERE WERE SIGNS OF SMOKE EMANATING FROM THE LT OF THE AIRCRAFT. 1Q71 3I4 T EXPA1Q71E20NE 6 CP7NE 20040217002102004021700210NM 2004 2 17 CA031222002 120031219G2751 SKIN BOEING727 727225 1384077NM PWA JT8 JT8D15A 52051NE AILERON DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING LOADING OF CARGO, THE DOLLY AND CONTAINER UNLATCHED AND ROLLED UNDER THE LT WING SCORING THE PAINT AND CREASING THE LT OB AILERON LOWER SURFACE. THE RESULTING DAMAGE FOUND 2 CREASES ON THE AILERON WITH 1 AT 14 INCHES LONG AND THE OTHER AT 7 INCHES LONG. ANOTHER CREASE WAS NOTED ON THE ACCESS PANEL AT 14 INCHES LONG. THE DAMAGES WERE ASSESSED AND WERE FOUND WITHIN LIMITS IAW SRM 57-50-5. NO PROBLEMS DURING SUBSEQUENT FLIGHT. 2L73 4F4 F A3WE E2EA 20040218000012004021800001WP 2004 2 18 CA031222003 120031021G6520369D25430 GEAR HUGHES HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL GEARBOX BROKEN W K NONE O OTHER ININSP/MAINT 1 CA 0065 (CAN) UNIT RECEIVED TO INSPECT FOR REPORTED METAL GEN. (9 PREVIOUS REPORTS) REPAIRED BY FACILITY FAA REPAIR STATION 6 TIME (10 BEARINGS REPLACED) THEN OH. LAST REPORT WAS 104.6 HRS. AFTER OH, WHEN IT WAS OPENED THE INTERIOR HAD A THICK SLUDGE THROUGHOUT. I/P AND O/P SPACERS FOUND SPINNING AND /OR DAMAGED. O/P GEAR WAS BROKEN AT ALIGNMENT BEARING JOURNAL (ALIGNMENT BEARING STILL ON BROKEN PIECE) 1G71 3U3 U H3WE E4CE 20040218000022004021800002WP 2004 2 18 CA031222004 120031112G6320369A535051 CLUTCH HUGHES369 369E 4470707WP ALLSN 250C 250C20B 03013GL MAIN ROTOR UNSERVICEABLE W K NONE O OTHER ININSP/MAINT 1 CA (CAN) UNIT RECEIVED TO REINSPECT AFTER CUSTOMER REPORTED OIL LEAK FROM CLUTCH, (NEAR TO DRY) TO FACILITY FAA REPAIR STATION (THEY O/H THIS UNIT 88 HRS AGO). THIS FACILITY REPORTED TO THE CUSTOMER THAT THEY CHANGED THE SEAL, AND THAT WAS ALL THAT WAS NEEDED. CUSTOMER RECEIVED UNIT AND NOTICED THE OIL IN THE CLUTCH WAS STILL BLACK THEY SHIPPED IT TO OUR FACILITY. UPON RECEIPT, REMAINING OIL WAS DRAINED (THICK BLACK AND FULL OF METAL PARTICLES), UNIT DISASSEMBLED. BOTH LARGE AND SMALL OIL BEARINGS WERE FOUND PITTED AND SPALLED, REQUIRED REPLACEMENT. ALSO THE OUTER RACE SPLINES WERE NOTIBLY WORN (MEASURED AT 1.3050 INCH. MDHI COMPONENT O/H MANUEL LIMIT IS 1.3054 INCH), IT ALSO REQUIRED REPLACEMENT. 1G71 3U3 U H3WE E4CE 20040218000032004021800003WP 2004 2 18 CA031222005 120031118G6520369D25400 GEARBOX HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL TAIL ROTOR CORRODED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) UNIT RECEIVED TO INSPECT FOR REPORTED METAL GENERATION. THE FOLLOWING WAS FOUND AT DISASSEMBLY. I/P GEAR 369D25434 U/S DUE TO SEVERE CORROSION PITS, O/P GEAR 369D 25430 ALSO PITTED BUT POLISHABLE. THE DUPLEX BEARINGS 369D25420 HAD NO CLAMP UP(.001-.003 INCH REQUIRED), THEY SPUN IN THE RETAINER 369D25409. ALSO THE O/P ALIGN . BEARING 369D25419 WAS LOOSE IN ITS' RETAINER (SPINNING). THIS UNIT WAS O/H THEN REPAIRED FOR METAL GEN. 3 TIMES BY REPAIR FACILITY FAA STATION. 1G71 3U3 U H3WE E4CE 20040315000812004031500081 2004 3 15 CA031222006 420031215G8300 GEARBOX CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE ACCESSORY INOPERATIVE W E ENGINE SHUTDOWN EY VIBRATION/BUFFET ENGINE STOPPAGE DEDESCENT 1 CA 10813 (CAN) ON DESCENT FROM 310 TO 290, NR 1 ENGINE ABRUPTLY SHUT DOWN WITH A LOUD VIBRATION NOISE. 20 MINUTES OUT, NR 1 ENGINE SHUT DOWN OWN IT'S OWN WITH A LOUD VIBRATION. ENGINE WAS SECURED AND THE AC LANDED WITHOUT INCIDENT. MAINTENANCE INSPECTED THE AIRCRAFT AND FOUND NO OBVIOUS PROBLEMS. ATTEMPTED TO START. DID NOT SEE A RISE IN NR 2, ENGINE WOULD NOT START. MUCH METAL FOUND IN FILTERS. ACCESSORY GEAR BOX WAS NOT SPINNING. ENGINE REMOVED AND REPLACED. GEAR BOX INPUT'S ROTATE, BUT NO ACCESSORY GEARS TURN. 2L72 4F4 FRTA21EA E15NE 20040218000042004021800004 2004 2 18 CA031223001 420031210G34606225798022 CONTROL PANEL COLLINS BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3A NE FMC ODOR W O OTHER B SMOKE/FUMES/ODORS/SPARKS APAPPROACH 1 CA 10833 4236 (CAN) ON FINAL APPROACH THE CREW SMELLED A STRANGE ODOR IN COCKPIT. INVESTIGATION BY MAINTENANCE REVEALED THAT THE ODOR CAME FROM NR 1 FLIGHT CONTROL PANEL. IT WAS REPLACED ALONG WITH THE NR 1 FLIGHT COMPUTER WITH NO FURTHER REOCCURRENCES. BOTH UNITS WHERE FORWARDED TO REPAIR SHOP AND THEN FURTHER TO ORIGINAL MANUFACTURER. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20040218000052004021800005EA 2004 2 18 CA031223003 120031222G2421AE2132MK6 SHAFT LUCAS DHAV DHC7 DHC7102 2802708EA PWA PT6 PT6A50 52043EA HAMSTD24PF 24PF305 GL AC GENERATOR SHEARED W K NONE O OTHER ININSP/MAINT 1 CA 33338 2028 (CAN) AFTER FLIGHT MAINTENANCE NOTICED AN OIL LEAK FROM THE NR 2 NACELLE, FURTHER INVESTIGATION FOUND THE NR 2 AC GENERATOR SHAFT SHEARED. THE FLIGHT CREW HAD NOT NOTICED ANY FAILURES SINCE IN THE NORMAL OPERATION MODE THIS AC GEN IS IN STANDBY AND ONLY WORKS IF AN OTHER GEN FAILS. THE GEN WAS REMOVED AND THE AIRCRAFT RETURNED TO SERVICE. 2H74 4T4 T A20EA E4EA 6 CP1NE 20040315000962004031500096WP 2004 3 15 CA031223004 120031021G6520369D25400 GEARBOX HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL TAIL ROTOR DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) UNIT RECEIVED AFTER REPORT OF METAL GENERATION (UNIT INSPECTED AND REPORTED NO DEFECTS AND RETURNED). CUSTOMER WAS NOT PLEASED AS THEY HAVE REPORTED METAL GEN. IN THIS UNIT 5 TIMES PREVIOUS GEARBOX WAS NOT INSTALLED ON A/C IT WAS SHIPPED TO OUR FACILITY FOR A 2ND OPINION. PICTURES WERE TAKEN AT DISASSEMBLY AND THE FOLLOWING WAS FOUND: BOTH I/P AND O/P SPACER WERE DAMAGED FROM SPINNING, PREVIOUS REMOVALS, THE LARGE I/P BEARING WAS PITTED. PARTS REPLACED WERE SHOWN TO AIRWORTHINESS INSPECTOR. 1G71 3U3 U H3WE E4CE 20040315000972004031500097WP 2004 3 15 CA031223005 120031212G6520369D25434 GEAR HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL T/R GEARBOX UNSERVICEABLE W K NONE O OTHER ININSP/MAINT 1 CA HD1007 (CAN) CUSTOMER REPORTED METAL GEN. 51.2 HRS AFTER LAST REPAIR. REQUESTED THE RETURN OF THIS UNIT, AFTER DISASSEMBLY IT WAS NOTED THE I/P SPACER WAS WORN AGAIN, AN O/H DIMENSION CHECK (NOT REQUIRED AT THIS TIME) WAS CARRIED OUT AND THE I/P BEARING JOURNAL IS BELOW DIMENSION. AS THIS UNIT HAS BEEN REPAIRED 6 TIMES SINCE O/H WAS CARRIED OUT. THE I/P GEAR IS SUSPECTED FOR BEING UNDER DIM FOR SOME TIME. THE GEAR HAS BEEN SENT TO AN APPROVED FACILITY TO CARRY OUT THE NICKEL PLATING REQUIRED. 1G71 3U3 U H3WE E4CE 20040223000022004022300002EU 2004 2 23 CA031223006 220031219G8530922230 SOCKET BOMBDR DIAMONDA20 DA20A1 2990000GL ROTAX 912 ROTAX912F3 EU HOFMANHOV352HOV352F NE CYLINDER HEAD CRACKED W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) A CRACKED DEVELOPED AROUND APPROX. .5000 THE CIRCUMFERENCE OF THE SOCKET ABOUT .2500 INCH BEYOND THE TREADS. THE LOCATION OF THE CRACK IS APPROX. COINCIDENTAL WITH THE START OF THE BEND IN THE SOCKET. COOLANT WAS NOTED LEAKING FROM THE CRACK. 1L71 3O3 ONTTA4CH E00051EN5 CTP5BO 20060612004252006061200425EU 2006 6 12 CA031224001 120031216G2697 WIRE HARNESS AIRBUS320 A320211 3930320EU CFMINTCFM56 CFM565A1 NE SMOKE DETECTOR CHAFED W O OTHER N FALSE WARNING NRNOT REPORTED 1 CA F/A NOTICED SPARK FROM OXYGEN PNL. A/C REMAINED IN SERV SEVERAL DAYS. UPON INSPECT, WIRE BUNDLE DIRECTLY ABOVE LAV "E" SMOKE DETECT FOUND CHAFFED ON SMOKE DETECT. INSPECT FOUND ROUTING OF WIRE BUNDLE WITH LITTLE CLEARANCE BETWEEN BUNDLE AND DETECTOR AND REPEAT OF INCIDENT WITH MORE SERIOUS CONSEQUENCES COULD BE LIKELY. WIRED BUNDLE RECEIVES IT'S POWER FROM 2000 C/B PANEL AND SUPPLIES PWR TO AFT CARGO LOADING SYS, AFT DRAIN MAST AND VARIOUS RIBBON HEATERS, ETC. FEW A/C WERE INSPECTED 401, 408, 410, 219, 224 HERE. NO A/C HAD WIRE BUNDLE TOUCHING SMOKE DETECTOR. HOWEVER, DISTANCE BETWEEN BUNDLE AND SMOKE DETECTOR IS NEVER SAME. NOTICED FLEXIBLE EXTRACT DUCT IS NEVER INSTALLED SAME WAY. 2L72 4F4 FRTA28NM E29NE 20050112000012005011200001WP 2005 1 12 CA031224002 220031223G72108679225 CASE SWRNGNSA226 SA226TC 8780404SW GARRTTTPE331TPE33110UA 01514WP PLANETARY GEAR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 17040 (CAN) ACRFT RETURNED WITH A LOW OIL PRESS. ON RESEARCHING ENG TRENDS, OIL PRESS HAD BEEN STEADILY DECLINING FOR APPROX A MONTH AT 1-2 PSI A DAY. PROBLEM WASN`T NOTICED BY FLT CREW UNTIL A SUBSTANTIAL DROP ON DAY OF INCIDENT. OIL PRESSURE WOULD ONLY DROP ON A HIGHER POWER SETTING. MX REPLACED SEVERAL ENG OIL REGULATING COMPONENTS IN AN ATTEMPT TO REPAIR PROBLEM. DURING RUN-UP AT HIGH POWER OIL PRESS LOW & TORQUE BEGAN TO FLUCTUATE. A FEW OPS TESTS ACCOMPLISHED TO ISOLATE PROBLEM. ENG PROBLEM DIFFICULT TO DIAGNOSE. AS PRECAUTION REDUCTION GEAR CASE DISASSEMBLED FOR INSPECT OF OIL SYS. DURING DISASSEMBLY, FOUND PLANETARY GEAR SYS CARRIER CRACKED AROUND ENTIRE CIRCUMFERENCE. SUSPECT THAT DAMAGE WAS CAUSED BY AN OVE2L72 4T4 TRTA8SW E4WE 20040315001112004031500111EA 2004 3 15 CA031224003 220031124G72003028004 ENGINE BEECH 99 99 1154002CE PWA PT6 PT6A28 EA MAKING METAL W K NONE O OTHER ININSP/MAINT 1 CA PCE40252 (CAN) ENGINE S/N PCE40252 WAS SENT FOR METAL IN OIL. ENGINE WAS DISSASSEMBLED AND IT WAS FOUND THAT THE NR 2 BEARING ROLLER CAGE SILVER PLATE HAD FLAKED OFF. MFG HAS A SIL NR PT6A-106 ON THIS CONDITION. THIS ENGINE WAS REPAIRED IAW MFG LATEST SPECIFICATIONS AND RETURNED TO SERVICE. 1L72 3T4 T A14CE E4EA 20040315001122004031500112 2004 3 15 CA031229001 420031228G3197HJ2A20 WIRE BOLKMS117 BK117B2 5626013EU LYC LTS101LTS101750B1 41560NE INSTRU PANEL BURNED W H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS CLCLIMB 1 CA (CAN) WIRE NR HJ2A20 CHAFED AGAINST MOUNT FOR KMD850 MFD DISPLAY. ECU SELECTED TO ON AND BURNING ODOR NOTICED, ECU SELECTED TO OFF AND CB WAS NOTED POPPED. SIX WIRES DAMAGED AS A RESULT OF EXCESSIVE HEAT. DAMAGED SECTION OF WIRE REMOVED AND REPAIRED. THREE OTHER WIRES REPAIRED FOR CHAFING IN AN UNRELATED POSITION. 1G72 3U3 UNCH13EU E5NE10 20040315001212004031500121EA 2004 3 15 CA040102003 120031112G5610NP1393215 WINDSHIELD CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE COCKPIT CRACKED W A UNSCHED LANDING O OTHER CRCRUISE 1 CA (CAN) LT WINDSHIELD ARCING IN LT CORNER AND PROPAGATING OUTWARDS. UPON LANDING, FOUND LT WINDSHIELD WAS ALSO CRACKED. REPLACED LT WINDSHIELD. WINDSHIELD REPLACED. AIRCRAFT RETURNED TO SERVICE. 2L72 4F4 FRTA21EA E15NE 20040315001232004031500123CE 2004 3 15 CA040103002 120031205G2435M230881320 BRUSHES LEARSIEGLER BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3A NE STARTER GEN WORN W O OTHER O OTHER TXTAXI/GRND HDL 1 CA 96189 (CAN) COULD NOT GET LT GENERATOR ON LINE. MAINTENANCE REPLACED STARTER GENERATOR BRUSH INSPECTION ON REMOVED UNIT SHOWED EXCESSIVE WEAR. ONLY 755.9 HRS SINCE NEW. STARTER GEN OH 1500 HRS. BRUSH INSP EVERY 400 HRS. NORMAL BRUSH LIFE 2200 HRS BUT ALWAYS REPLACED AT O/H. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20040315001242004031500124CE 2004 3 15 CA040103003 120031114G2435M230881320 BRUSHES LEARSIEGLER BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3I NE STARTER GEN WORN W K NONE O OTHER ININSP/MAINT 1 CA 96188 (CAN) DURING ROUTINE BRUSH CHECK, BRUSHES FOUND BELOW MINIMUM LIMIT. STARTER GEN REPLACED. STARTER GEN O/H 1500 HRS NORMAL BRUSH LIFE 2200 HRS ALWAYS REPLACED AT OH. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20040315001252004031500125CE 2004 3 15 CA040103004 120031205G2435M230881320 BRUSHES LEARSIEGLER BEECH 1900 1900D 1154162CE PWA PT6 PT6A67D NE HARTZLHCE4A HCE4A3I NE STARTER GEN WORN W K NONE O OTHER ININSP/MAINT 1 CA 96199 (CAN) DURING ROUTINE BRUSH INSPECTION, MAINTENANCE FOUND STARTER GEN BRUSHES BELOW MINIMUM LIMITS. STARTER GEN REPLACED. NORMAL BRUSH LIFE 2200 HRS STARTER GEN OH 1500 HRS. BRUSHES ALWAYS REPLACED AT OH. 2L72 4T4 TRTA24CE E26NE 5 CP10NE 20040315001422004031500142SO 2004 3 15 CA040105002 120030817G2913 SHAFT AIRBORNE PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL HYD PUMP BROKEN W O OTHER O OTHER LDLANDING 1 CA 3437 (CAN) AFTER LANDING THE PILOT SHUTDOWN THE RT ENGINE SO HE COULD CHECK THE LT HYDRAULIC PUMP WHICH HE DID BY PUTTING THE GEAR HANDLE DOWN, GEAR HANDLE DID NOT COME BACK TO NEUTRAL. MAINTENANCE REMOVED THE HYDRAULIC PUMP AND FOUND THE SHAFT SHEARED, ORDERED AN OVERHAUL AND INSTALLED BEFORE NEXT FLT. 1L72 3O3 O A20SO E14EA 5 CP33EA 20040315001432004031500143EU 2004 3 15 CA040105003 120031116G5310137978C5 DOOR FRAME BAG BAG JETSTMJETSTM3212 1500217EU GARRTTTPE331TPE33110UG 01514WP ROTOL R333 R333482F12 GL PAX DOOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 23564 712 (CAN) DURING ROUTINE INSPECTION, A .1250 INCH CRACK WAS FOUND IN THE CABIN DOOR FRAME AT THE UPPER FORWARD DRAW BOLT. THROUGH CONTACT WITH MFG AND OTHER LOCAL VENDORS, IT WAS DETERMINED TO BE MORE COST EFFECTIVE TO REPLACE THE ENTIRE DOOR ASSEMBLY RATHER THAN JUST THE FRAME. AS THIS CRACK WAS DISCOVERED BY MAINTENANCE CREW DURING A GROUND INSPECTION. THE DOOR WAS REPLACED AND DEFECT RECTIFIED WITHOUT ANY INCIDENT. 2L72 4T4 TRTBA15CAA E4WE 6 CP61GL 20040315001442004031500144CE 2004 3 15 CA040105004 120031216G3213519400113 STRUT CESSNA421 421A 2076012CE CONT O520 GTSIO520D 17032SO MCAULY3AF34C3AF34C92 GL MLG CRACKED W O OTHER O OTHER LDLANDING 1 CA (CAN) LT MAIN LANDING GEAR COLLAPSED UPON TOUCH-DOWN WITH ALL 3 GREEN LIGHTS ON. FOUND DOWN LOCK ARM BROKEN AWAY FROM LUG ON TOP END OF STRUT. LOCK ARM NORMALLY HOLDS SIDE BRACE IN PLACE AND ACTUATES DOWN SWITCH. REPLACED COMPLETE MAIN LANDING GEAR ASSEMBLY AND RETRACT MECHANISM WITH SERVICEABLE COMPONENTS. 1L72 3O3 O A7CE E7CE 5 CP22EA 20040315001452004031500145EU 2004 3 15 CA040105005 120031205G7170MY20515108003 DRAIN LINE AMD FALCONFALCON20 2730103EU GE CF700 CF7002D2 30010NE ENGINE CHAFED W O OTHER J WARNING INDICATION CLCLIMB 1 CA 2454427 (CAN) NR 2 ENGINE FIRE WARNING MOMENTARILY SOUNDED ON TAKEOFF. UPON INVESTIGATION THE EP CAN DRAIN LINE WAS FOUND WITH A HOLE IN IT, DUE TO THE STAINLESS STEEL OIL TORCH VENT LINE CHAFING AGAINST THE ALUMINUM DRAIN LINE. ENGINE INSPECTED FOR DAMAGE, DAMAGED DRAIN LINE REPLACED. FIRE SYSTEM FUNCTION TESTED AND ENGINE GROUND RUN COMPLETED, AIRCRAFT RETURNED TO SERVICE. QUALITY BULLETIN ISSUED TO MAINTENANCE BASES FOR INSPECTION OF ALL E.P. CAN DRAIN LINES AND REPLACEMENT OF ANY DAMAGED LINES OR PORTS FOUND. 2L72 4F4 FRTA7EU E7EA 20040315001462004031500146NM 2004 3 15 CA040105006 120031218G3230 CABLE DHAV DHC8 DHC8301 1386003NM PWA PW120 PW123 NE HAMSTD14SF 14SF23 NE NLG RELEASE BROKEN W K NONE O OTHER ININSP/MAINT 1 CA 17222 (CAN) AN OPERATOR REPORTED FINDING A BROKEN NLG ALTERNATE RELEASE CABLE AT THE TEE HANDLE DURING OVERNIGHT SERVICING. CABLE REPLACED AND A/C RETURNED TO SERVICE. SB 8-32-146 HAS NOT BEEN COMPLETED ON THIS A/C, WHICH ADDRESSES THIS ISSUE. RELATED ISAR 96-07. AD PENDING. 2H72 4T4 TRTA13NM E20NE 6 CP7NE 20040315001472004031500147CE 2004 3 15 CA040105007 120031203G27000510105325 CONTROL CABLE CESSNA185 A185E 2072818CE CONT O520 IO520D 17032SO MCAULYD3A34 D3A34C403 GL FRAYED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) CABLE INSPECTION REVEALED WEAR AT THE POINT WHERE THE CABLE CHANGES DIRECTION ENTERING THE FUSELAGE. 1H71 3O3 O 3A24 E5CE 5 CP47GL 20040315001662004031500166SO 2004 3 15 CA040106003 120031219G3700 SHAFT AIRBORNE PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL DRY AIR PUMP BROKEN W O OTHER J WARNING INDICATION CRCRUISE 1 CA 22633 (CAN) DURING THE LAST FLIGHT OF THE DAY THE LT INDICATOR LIGHT ON THE INSTRUMENT PANEL CAME ON, INDICATING THAT THE VACUUM PUMP HAD FAILED. AFTER LANDING, MAINTENANCE FOUND THAT THE SHAFT HAD BROKEN. RECEIVED OH PUMP NEXT MORNING INSTALLED, GROUND RUN NO FAULTS FOUND. 1L72 3O3 O A20SO E14EA 5 CP33EA 20040315001672004031500167CE 2004 3 15 CA040106004 120031219G561071286 WINDOW BBAVIA8 8KCAB 2110612CE LYC O320 IO320E1A 41508EA HARTZLHCC2Y HCC2YL1 GL COCKPIT BROKEN W O OTHER O OTHER CRCRUISE 1 CA (CAN) TOP WINDOW (SKY LIGHT) SHATTERED AND BROKE AWAY AFTER LEVELLING OFF FROM DOING A CUBAN EIGHT. 1H71 3O3 O A21CE 1E12 5 CP920 20040315001682004031500168SO 2004 3 15 CA040106005 120031209G32604195200 DOWNLOCK PIPER PA31 PA31 7103102SO LYC O540 TIO540A2B 41532EA HARTZLHCE2Y HCE2YR2 GL MLG INOPERATIVE W L ABORTED APPROACH N FALSE WARNING LDLANDING 1 CA (CAN) AIRCRAFT WAS PREPARING TO LAND, PILOT SELECTED GEAR DOWN, ONLY THE NOSE AND RT GEAR HAD A LOCK INDICATION, UNSAFE GEAR INDICATION. 1L72 3O3 O A20SO E14EA 5 CP9EA 20040315001812004031500181SO 2004 3 15 CA040106006 120031231G6123 LATCH PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL PROPELLER INOPERATIVE W K NONE O OTHER ININSP/MAINT 1 CA DJ8460A (CAN) ON ENGINE SHUT DOWN RT PROP WENT TO FEATHER. ENGINE WAS GROUND RUN AND MAX RPM WAS ONLY 1900. MAINTENANCE REPLACED PROPELLER AND RETURNED AC TO SERVICE. PROP BLADE LATCHES ARE PRESUMED TO BE THE PROBLEM. PROP IS BEING SENT TO REPAIR SHOP. 1L72 3O3 O A20SO E14EA 5 CP33EA 20040315001822004031500182SO 2004 3 15 CA040106007 220031121G741410790206 MAGNETO CESSNA337 337C 2075712CE CONT O360 IO360C 17025SO MCAULY2AF34CD2AF34C61 GL ENGINE DAMAGED W D RETURN TO BLOCK RJ PARTIAL RPM/PWR LOSS WARNING INDICATION TXTAXI/GRND HDL 1 CA (CAN) FRONT ENGINE WOULD NOT RUN WHEN LT SETTING WAS SELECTED DURING GROUND RUN UP. IT WAS LATER DISCOVERED THAT THE LT MAGNETO NOISE SUPRESSOR WAS ALSO DEFECTIVE, P/N A293. 1H72 3O3 O A6CE E1CE 5 CP5EA 20040315001842004031500184GL 2004 3 15 CA040106009 320031229G6114C130195 CLAMP DHAV DHC6 DHC6300 2802606EA PWA PT6 PT6A27 52043EA HARTZLHCB3T HCB3TN3 GL PROPELLER HUB CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) CRACKED CLAMP NOT DISCOVERED UNTIL THE OVERHAUL. PART MPI INSPECTED IAW ASTM-E-1444 WHEN FOUND. 1H72 3T4 TRTA9EA E4EA 6 CP15EA 20040315001852004031500185GL 2004 3 15 CA040106010 320031229G6114A1851T BEARING RACE DHAV DHC6 DHC6300 2802606EA PWA PT6 PT6A27 52043EA HARTZLHCB3T HCB3TN3 GL PROPELLER HUB CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) BEARING RACE CRACKED, DISCOVERED AT OVERHAUL, DURING THE NDT PROCESS. 1H72 3T4 TRTA9EA E4EA 6 CP15EA 20040315001872004031500187WP 2004 3 15 CA040107001 120031126G7830M6335421 BALL JOINT DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE THRUST REVERSER WORN W K NONE L NO TEST ININSP/MAINT 1 CA (CAN) THRUST REVERSER FOLLOW-UP CABLE FOUND DETACHED. BALL JOINT CONNECTED TO ROD FOUND DISMANTLED FROM ITS JOINT SHELL. 2L72 4F4 FRTA6WE E9NE 20040325000302004032500030EA 2004 3 25 CA040107003 220031216G741410400405 DISTRIBUTOR GEARBENDIX PIPER PA34 PA34200 7103405SO LYC O360 LIO360C1E6 41515EA HARTZLHCC2Y HCC2YK2 GL MAGNETO BROKEN W D RETURN TO BLOCK E VIBRATION/BUFFET TXTAXI/GRND HDL 1 CA A32562 (CAN) 20 TEETH BROKEN OFF DISTRIBUTOR GEAR ASSEMBLY AND THE DISTRIBUTOR GEAR ELECTRODE BROKEN OFF. FOLLOWING INSTRUCTIONS OF MFG SB 658 FOR CORRECT PRACTICES FOR MAGNETO INSTALLATION ON ENGINE WILL ELEMINATE THE PROBLEM. 1L72 3O3 O A7SO 1E10 5 CP920 20040325000312004032500031EA 2004 3 25 CA040107004 220031222G741410400405 DISTRIBUTOR GEARBENDIX PIPER PA34 PA34200 7103405SO LYC O360 LIO360C1E6 41515EA HARTZLHCC2Y HCC2YK2 GL MAGNETO BROKEN W D RETURN TO BLOCK E VIBRATION/BUFFET CRCRUISE 1 CA A32562 (CAN) 8 TEETH BROKEN OFF DISTRIBUTOR GEAR ASSEMBLY. A GEAR HOLDING TOOL WAS USE FOR THE MAGNETO INSTALLATION ON ENGINE NOT RECOMMENDED IAW MFG MSB NR 528 AND MFG SB 658. 1L72 3O3 O A7SO 1E10 5 CP920 20040325000322004032500032CE 2004 3 25 CA040107005 120031219G731210585 HEATER BEECH 1900 1900C 1154161CE PWA PT6 PT6A65B 52043EA HARTZLHCB4M HCB4MP3 GL OIL/FUEL CRACKED W EA ENGINE SHUTDOWN UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 CA (CAN) OIL PRESSURE ANNUNCIATOR ILLUMINATED FOLLOWED BY OIL PRESSURE FLUCTUATIONS. CREW THEN SHUT ENGINE DOWN AND LANDED WITH NO FURTHER PROBLEMS. UPON INSPECTION BY MAINTENANCE IT WAS CLEAR THAT THERE WAS AN EXCESSIVE OIL LEAK AND LOW OIL LEVEL. THIS WAS THE CAUSE OF THE FLUCTUATIONS IN THE OIL PRESSURE. FURTHER INSPECTION REVEALED THAT A CRACK IN THE OIL TO FUEL HEATER CAUSED THE EXCESSIVE OIL LEAK. THE CRACK WAS LOCATED AT A WELD IN THE SEAM AREA. THE ENGINE WAS INSPECTED IAW MFG MM 72-00-00 PAGE643. OIL TO FUEL HEATER WAS REPLACED AND SEVERAL GROUND RUNS WERE CARRIED OUT. ENGINE WAS FOUND TO BE OPERATING WITHIN DESIRED SERVICEABLE LIMITS AND AIRCRAFT WAS RETURNED TO SERVICE. 2L72 4T4 TRTA24CE E4EA 6 CP56GL 20040325000332004032500033NE 2004 3 25 CA040107006 220031201G72503020159 RETAINER PWA PWA PT6 PT6A114A 52043NE TURBINE SECTION COLLAPSED W K NONE O OTHER ININSP/MAINT 1 CA 9Y415 (CAN) THE HOT SECTION WAS GIVEN A SCHEDULED BORESCOPE INSPECTION. A COMPRESSOR TURBINE SHROUD SEGMENT HAD SHIFTED SLIGHTLY. THE RETAINING RING HAD COME OUT OF THE 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. 3 T E4EA 20040325000342004032500034NE 2004 3 25 CA040107007 220031230G72503020159 RETAINER CESSNA208 208B 2073701CE PWA PT6 PT6A114A 52043NE MCAULY3AF34C3GFR34C703 GL TURBINE SECTION COLLAPSED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE HOT SECTION WAS REPAIRED TO CORRECT DEGRADED PERFORMANCE. THE RETAINING RING HAD POPPED OUT OF THE RING GROOVE AND A CT SHROUD SEGMENT HAD SHIFTED. 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 SUCH AS THE114A ENGINE MODEL TO ALLOW THE MORE ROBUST RETAINING RING TO BE USED. 1H71 3T3 T A37CE E4EA 5 CP60GL 20040325000412004032500041EU 2004 3 25 CA040108001 120031118G2435 BRUSHES LUCAS BAG JETSTMJETSTM3212 1500217EU GARRTTTPE331TPE33110UG 01514WP ROTOL R333 R333482F12 GL STARTER GEN DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA 257 TA5344 (CAN) BRUSH PIGTAILS WERE FOUND TO BE BADLY FRAYED, BRUSHES WERE DAMAGED. RETURNED UNIT FOR EVALUATION. ARMATURE FAILED, COMMUTATOR BARS LIFTED CAUSING DESTRUCTION OF BRUSHES AND DAMAGE TO 4 BRUSH SPRINGS. ARMATURE WAS SERVICEABLE AT TIME OF PREVIOUS O/H. CAUSE OF FAILURE UNDETERMINED. O/H REQUIRED AND INSTALLATION OF STANDARD OEM BRUSHES RECOMMENDED. MIRAJ MILLENNIUM BRUSHES THAT WERE INSTALLED ON THE UNIT WERE SUSPECTED OF CAUSING EXCESSIVE HEAT BUILD UP, SUGGESTED THAT IMPROPER SEATING OF ANY TYPE OF BRUSH WILL CAUSE OVERHEATING. ASSURED THAT THEIR BRUSHES WOULD NOT GENERATE EXCESSIVE HEAT IF INSTALLED CORRECTLY. UNIT INSTALLED TO REPLACE THIS ONE FAILED AFTER 42.6 HRS. 2L72 4T4 TRTBA15CAA E4WE 6 CP61GL 20040325000442004032500044NE 2004 3 25 CA040108004 220031215G72300292152880 TAB TMECA ARRIELARRIEL1D1 NE COMPRESSOR CRACKED W K NONE C F.O.D. ININSP/MAINT 1 CA 9646 (CAN) ON AN OCCURRENCE TEARDOWN OF ENGINE, BETWEEN MODULE 2 AND MODULE 3, THE TECHNICIANS DISCOVERED A TAB BRIDGE CRACKED AND WAS INGESTED INTO THE ENGINE SUBSEQUENTLY CAUSING DAMAGE TO THE CENTRIFUGAL COMPRESSOR, WHICH WAS REPLACED. 3 U E19EU 20040325000452004032500045GL 2004 3 25 CA040108005 120031231G56102056000902 SPRING DIAMONDA20 DA20A1 2990000GL ROTAX 912 ROTAX912 55555EU HOFMANHOV352HOV352F NE CANOPY HOOKS BROKEN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THE LT CANOPY SPRING CLIPS BROKE OFF AT BOTH ENDS OF THE CANOPY SPRING SIMULTANEOUSLY. THE ENERGY RELEASED DURING THE FAILURE WAS SUFFICIENT TO ALLOW ONE OF THE CLIPS TO TRAVEL THE WIDTH OF THE COCKPIT AND STRIKE THE RT SEAT OCCUPANT IN THE REAR OF THE HEAD. THERE HAVE BEEN NUMEROUS FAILURES OF CANOPY SPRINGS NOTED IN THE PAST. IN ALL PREVIOUS CASES ONLY ONE OF THE CLIPS FAILED. IN THE CASE OF A SINGLE-CLIP FAILURE BOTH THE SPRING AND THE BROKEN CLIP HAVE REMAINED ATTACHED TO THE AIRFRAME. THIS IS THE FIRST INSTANCE OF A SIMULTANEOUS FAILURE OF BOTH ENDS. IT IS ALSO THE FIRST INSTANCE IN WHICH AN AIRCRAFT OCCUPANT WAS STRUCK BY A PIECE OF THE FAILED SPRING. 1L71 3O3 INTTA4CH EXPE3I 5 CTP5BO 20040325000472004032500047EA 2004 3 25 CA040109001 120031216G2750601R930507 CONTROL UNIT CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE TE FLAPS FAILED W O OTHER F FLT CONT AFFECTED NRNOT REPORTED 1 CA (CAN) TE FLAPS FAILED ON THREE OCCASIONS. AFTER EXTENSIVE TROUBLESHOOTING THE FLAP ELECTRONIC UNIT WAS AT FAULT AND LT BPSU WAS REPLACED. TEST FLIGHT SUCCESSFUL. 2L72 4F4 FRTA21EA E15NE 20040325000482004032500048EA 2004 3 25 CA040109002 120031214G5270 SENSOR CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE DOOR WARNING SYSOUT OF RIG W K NONE N FALSE WARNING ININSP/MAINT 1 CA (CAN) ON DEC.14 DURING CLIMB 8500 MSL - (PAX DR LATCH CAUTION). A/C LEVELED OFF AT 12000 WITH PRESSURIZATION OK, CAUTION THEN UPGRADED TEICAS CAUTION MSG: PAX DR LATCH: ON DEC.15 WHILE CLIMBING THROUGH 14,000 FT WITH CAB DIFF OF 5.5 PSI. RETURN LEG MESSAGE REAPPEARED. PRESSURE NORMAL. CLIMBED TO 280. PRESS DIFF. WAS 8.0.PRESSURE NORMAL (PASSENGER DOOR) AFTER TROUBLESHOOTING FOUND SENSORS 46, 47 OUT OF RIG. 2L72 4F4 FRTA21EA E15NE 20040325000532004032500053EU 2004 3 25 CA040109005 120031214G243523079005 BRUSHES LUCAS BAG JETSTMJETSTM3212 1500217EU GARRTTTPE331TPE33110UG 01514WP ROTOL R333 R333482F12 GL STARTER GEN FAILED W O OTHER O OTHER TXTAXI/GRND HDL 1 CA 42 1826 (CAN) AFTER PREVIOUS STARTER GEN FAILED. IT WAS REMOVED BECAUSE IT FAILED TO ROTATE ENGINE DURING START. REMOVED BRUSH COVER AND FOUND ONE OF BRUSH LEADS MELTED AND SMALL PIECES OF METAL FALLING OUT OF THE UNIT. TOOK PICTURES, SENT IT TO A THIRD PARTY FOR EVALUATION. DISASSEMBLED THE UNIT AND FOUND NR4 BRAIDED LEAD FROM STATOR TO BRUSH HAD NOT BEEN CONNECTED. SOLE CONTACT WAS WITH BACK OF SCREW ON NR 4 BRUSH ASSEMBLY. IT WAS ABLE TO PASS TESTS BECAUSE OF CONTACT WITH BACK OF BRUSH ASSY. DURING SERVICE, WIRE EVENTUALLY VIBRATED AWAY FROM SCREW OR SIMPLY NOT ENOUGH CURRENT WAS ABLE TO FLOW THROUGH THAT CONNECTION. RESULT WAS A HEAT BUILD UP IN LEADS TO OPPOSITE BRUSH WITH EVENTUAL FAILURE. 2L72 4T4 TRTBA15CAA E4WE 6 CP61GL 20040325000642004032500064NM 2004 3 25 CA040109008 120030909G6120697073001A PITCH CONTROL BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU PROPELLER INOPERATIVE W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING ENGINE GROUND START, THE FLT CREW GOT A POWER PLANT ADVISORY LIGHT ON THE ENGINE DISPLAY UNIT. POWER PLANT ADVISORY DISAPPEARED AFTER RESET PROCEDURE CARRIED OUT IAW TCC REQUEST. THE CENTRAL DIAGNOSTIC SYSTEM (CDS) WAS INTERROGATED AND REVEALED THAT FAULT CODE 224 GBE SWITCH STUCK OFF ON LT SIDE HAD TRIGGERED THE POWERPLANT ADVISORY ONED. PCU PLUGS P20 AND P24 WERE CHECKED IAW FIM WITHOUT REMARKS. PCU WAS REPLACED. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20040325000702004032500070NM 2004 3 25 CA040112002 120030904G2750C1486561 PRESSURE SWITCH BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU TE FLAPS FAULTY W O OTHER F FLT CONT AFFECTED APAPPROACH 1 CA (CAN) ON APPROACH TO BASE, FLAPS 5 WAS SELECTED AND FLAP POWER CAUTION LIGHT CAME ON IMMEDIATELY, QRH WAS CONSULTED AND SYSTEM RESET SUCCESSFULLY ACCORDINGLY. NORMAL LANDING PREFORMED WITH FLAP 15, NEXT CREW BRIEFED AND TCC CONTACTED. INVESTIGATION/ACTION THE CENTRAL DIAGNOSTIC SYSTEM (CDS) WAS INTERROGATED WITHOUT FINDINGS. DUE TO A NUMBER OF PREVIOUS LOG REMARKS REGARDING FLAP POWER, ESPECIALLY LOG REMARK L109 MENTIONING (HYDRAULIC PRESSURE LOSS), IT WAS DECIDED TO REPLACE THE FLAP POWER UNIT (FPU). CONCLUSION, NO SIMILAR PROBLEMS HAVE BEEN EXPERIENCED SINCE THE ABOVE INCIDENT AND IT IS CONCLUDED THAT A FAULTY PRESSURE SWITCH ON THE FPU CAUSED THE INCIDENT. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20040325000952004032500095EU 2004 3 25 CA040113003 120031208G2730F50B273517 CONTROL ROD AMD FALC50FALCON50MYST2730106EU GARRTTTFE731TFE73131C 01518NE ELEVATOR FAILED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING C CHECK INSPECTION, ELEVATOR PUSH/PULL CONTROL ROD WAS FOUND WITH A WEAR MARK OF 1.37 LONG, .34 WIDE AND .0125 DEEP. THE WEAR MARK WAS CAUSED BY INTERFERENCE WITH A GEAR TYPE CLAMP ON AN ECS DUCT UNDER THE AFT CABIN VANITY. THE GEAR/SCREW PORTION OF THE CLAMP WAS POSITIONED AGAINST THE TUBE. LOOSENING THE CLAMP AND ROTATING IT SO SCREW/GEAR PORTION WAS AT 12 O`CLOCK POSITION RECTIFIED THE INTERFERENCE PROBLEM. CONTROL ROD WAS REPLACED WITH NEW UNIT. 2L73 4F4 F A46EU E6WE 20040712001572004071200157GL 2004 7 12 CA040113011 220031201G72106858647 DRIVE ASSY ALLSN CVAC 440 440 2422902WP ALLSN 501D 501D13D 03004GL HAMSTD54H 54H60 NE ALTERNATOR STRIPPED W E ENGINE SHUTDOWN JZYWARNING INDICATION SIGNIFICANT FAILURE REPORTENGINE STOPPAGE CRCRUISE 1 CA 1416 CAG600774 (CAN) AFTER PROPS WENT OUT OF SYNC, ENG DRIVEN COMP LOW OIL LIGHT ILLUMINATED. EDC DISCONNECT WAS SELECTED, FLUCTUATING GB OIL PRESSURE WAS OBSERVED. PRESS FLICKERED FROM 200 PSI TO 120 PSI ABOUT EVERY 5 SECONDS. SHUTDOWN CARRIED OUT, AC RETURNED TO BASE OEI. TEARDOWN, PRELIMINARY REPORT INDICATES STRIPPED SPLINES ON ALTERNATOR DR SHAFT ASSY, ALTERNATOR DR SHAFT NUT FOUND LOOSE, REAR BRG ALTERNATOR DR ASSY FOUND LOOSE DURING DISMANTLING. INCIDENT OCCURED 35.6 HOURS AFTER NOSE CASE WAS REPAIRED FOR EXCESSIVE (.025') RADIAL PLAY OF PROP SHAFT, DURING INVESTIGATION FOR OIL TRANSFER FROM EDC TO REDUCTION GB. EXCESS RADIAL PLAY WAS DISCOVERED WHILE CHANGING PROP SHAFT SEAL FOR OIL LEAKAGE FROM FRONT OF NOSE CASE. 2L72 4R4 T 6A6 E282 6 CP906 20040325001362004032500136EU 2004 3 25 CA040114001 120031208G33003640126 MODULE BOLKMS105 BO105S 5626006EU ALLSN 250C 250C20B 03013GL LIGHT DIMMER CORRODED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) WATER INGRESS AND HUMIDITY FROM AIR VENTS AND DOOR SEAL LEAK. LEADS TO CORROSION AND SUBSEQUENT FAILURE OF THE WARNING LIGHTS, DIMMING MODULE LOCATED BEHIND THE INSTRUMENT PANEL. 1G72 3U3 U H3EU E4CE 20040329000542004032900054NM 2004 3 29 CA040114006 120031111G3297471515 WIRE HARNESS BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU MLG INOPERATIVE W A UNSCHED LANDING N FALSE WARNING CLCLIMB 1 CA (CAN) AFTER T/O CREW WERE UNABLE TO SELECT GEAR UP. WITH GEAR SELECTOR IN UP POSITION THEY HAD NO YELLOW DOOR LIGHTS AND STILL 3 GREENS AND 3 REDS AND LEVER TRANSIT LIGHT. THEY SELECTED LEVER DOWN, BRIEFED CREW AND PAX AND RETURNED TO BASE FOR NORMAL LANDING. INVESTIGATION/ACTION THE UNABILITY TO RETRACT LANDING GEARS WAS CAUSED DUE BREAKAGE OF THE NOSE WHEEL CENTERING PROXIMITY SENSOR WIRES. NOSE WHEEL CENTERING SENSOR REPLACED IAW AMM 32-61-00. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20040329000552004032900055NM 2004 3 29 CA040114007 120031214G3297471515 WIRE HARNESS BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU MLG INOPERATIVE W A UNSCHED LANDING N FALSE WARNING CLCLIMB 1 CA (CAN) AFTER TAKEOFF, CREW WAS UNABLE TO GET LANDING GEAR UP. WHEN MOVING HANDLE NO AMBER LIGHT ONLY GREEN AND RED LIGHTS. RETURNED TO BASE FOR LANDING. THE INABILITY TO RETRACT LANDING GEAR WAS CAUSED DUE BREAKAGE OF THE NOSE WHEEL CENTERING PROXIMITY SENSOR WIRES. NOSE WHEEL CENTERING SENSOR REPLACED IAW AMM 32-61-00. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20040329000562004032900056WP 2004 3 29 CA040114008 120031202G6420D0621 ROTOR HEAD ROBSINR44 R44 7640120WP LYC O540 O540F1B5 41532EA TAIL ROTOR INOPERATIVE W K NONE O OTHER ININSP/MAINT 1 CA (CAN) UPON RECEIPT OF AD2003-24-51 HELICOPTER WAS INSPECTED FOR THE SUSPECT NAS6605-31BOLTS. EVEN THOUGH THE R44 S/N WAS NOT LISTED IN THE AD OR ROBINSON HELICOPTER SERVICE BULLETIN 51 THE T/R HUB NAS6605-31BOLTS WERE FOUND TO HAVE THE VENDOR IDENTIFICATION MARKING 01D0. THE BOLTS WERE REPLACED AND THE A/C RETURNED TO SERVICE. 1G71 3O3 O H11NM E295 20040329000572004032900057NM 2004 3 29 CA040114009 120031214G3297 WIRE BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU PROX SWITCH BROKEN W A UNSCHED LANDING N FALSE WARNING CLCLIMB 1 CA (CAN) GEAR DOORS WOULD NOT CLOSED AFTER GEAR UP SELECTION. RETURNED TO BASE FOR NORMA LANDING. INVESTIGATION/ACTION THE UNABILITY TO RETRACT LANDING GEARS WAS CAUSED DUE BREAKAGE OF THE NOSE WHEEL CENTERING PROXIMITY SENSOR WIRES. NOSE WHEEL CENTERING SENSOR REPLACED IAW AMM 32-61-00. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20040329000582004032900058NM 2004 3 29 CA040114010 120031219G3297464505 WIRE HARNESS BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU RT MLG DOWNLOCK DAMAGED W O OTHER N FALSE WARNING APAPPROACH 1 CA (CAN) WHEN CREW SELECTED GEAR DOWN, NO GREEN LIGHT INDICATION, THEY GOT UNSAFE AND DOOR LIGHT INDICATION ON LT SIDE, GO AROUND, RECYCLING WITH SAME RESULT. ALTERNATE GEAR EXTENSION ACCORDING TO QRH WITH SUCCESSFUL RESULT. LANDING WAS NORMAL. PSEU CHECKED FOR FAULTS. LGD LK1 FAULT FOUND. LT GEAR DOWNLOCK HARNESS REPLACED IAW AMM 32-61-06. OPERATIONAL TEST PERFORMED. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20040329000612004032900061NE 2004 3 29 CA040115004 220031228G8530 CYLINDER HEAD DHAV DHC2 DHC2MK1 2800102EA PWA R985 R985AN14B 52008NE HARTZLHCB3R HCB3R304 GL ENGINE CRACKED W O OTHER B SMOKE/FUMES/ODORS/SPARKS APAPPROACH 1 CA (CAN) HEAD TO BARREL SEPARATION AT THE END OF THE THREADED PORTION OF THE STEEL BARREL. REMOTE AMO HIRED TO REPLACE CYLINDER ASSEMBLY NOTED THAT THE FAILURE WAS A TYPICAL METAL FATIGUE FAILURE. 1H71 3R3 R A806 5E1 5 CP28EA 20040329001012004032900101CE 2004 3 29 CA040115006 120031209G27207173 SOLENOID BEECH 90 C90A 1152911CE PWA PT6 PT6A21 52043EA HARTZLHCB3T HCB3TN3 GL RUDDER BOOST STICKING W O OTHER F FLT CONT AFFECTED APAPPROACH 1 CA (CAN) DURING LOWERING OF THE LANDING GEAR, UNSCHEDULED YAW WAS NOTICED BY THE CREW AND UPON LANDING, THE AIRCRAFT WAS DIFFICULT TO TAXI. THE RUDDER SYSTEM RECEIVES THE INPUT FROM THE RUDDER BOOST SOLENOID. AS THEY ARE LOCATED IN AN UNHEATED AREA OF THE AIRCRAFT, THE MOISTURE IN THE COLD AND HUMID INSTRUMENT AIR SUPPLY TENDS TO FREEZE THE SOLENOID AND STICK. WHEN THE SOLENOID STICKS OPEN, THE MOST COMMON SYMPTOM IS HEAVY RUDDER INPUT, WHILE TAXIING. THUS THE PILOT HAD DIFFICULTY ON THE GROUND. THE SOLENOID WAS REPLACED, GROUND RUN CARRIED OUT AND THE AIRCRAFT WAS RELEASED TO SERVICE. 1L72 3T4 TRT3A20 E4EA 6 CP15EA 20040429000992004042900099GL 2004 4 29 CA040122007 320031118G6114C6760 SPRING PILATSPC12 PC1245 7090551EU PWA PT6 PT6A67B 52043NE HARTZLHCE4A HCE4A3D GL PROP FEATHERING CRACKED W O OTHER O OTHER NRNOT REPORTED 1 CA (CAN) PROPELLER SPRING FAILED INSPECTION. MPI PROCEDURE WAS ACCOMPLISHED AND CRACK INDICATIONS WERE FOUND IN SEVERAL AREAS. PROPELLER WAS REMOVED PRE-MATURELY DUE TO LIGHTNING STRIKE. SPRING WAS NEW FROM MFG AND INSTALLED FOR ONLY 636.4 HRS FROM THE PREVIOUS OVERHAUL. SPRING WAS SENT TO MFG FOR EVALUATION, IT WAS FOUND WITH SEVERAL CRACK INDICATIONS. SPRING REMOVED FROM SERVICE. WARRANTEE SPRING WAS PROVIDED FROM MFG. CRACKS HAVE BEEN FOUND IN OTHER SPRINGS DURING ROUTINE OVERHAUL INSPECTIONS. NO CRACK INDICATION ALLOWED IN THE SPRING. 1L71 3T4 TRTA78EU E26NE 5 CP210NE 20040429001012004042900101EA 2004 4 29 CA040123002 120031220G7110A33721 STRUT CNDAIRCL604 CL604 1900301EA GE CF34 CF343B1 NE CORE COWL UNSECURE W E ENGINE SHUTDOWN E VIBRATION/BUFFET CLCLIMB 1 CA (CAN) SHORTLY AFTER TAKEOFF, THE CREW NOTED THAT LT ENGINE THROTTLE COULD NOT BE RETARDED FROM 92 PERCENT. CREW ELECTED TO SHUT ENGINE DOWN WITH FIRE/PUSH PBA. A/C MADE AN UNEVENTFUL LANDING. SUBSEQUENT INSPECTION REVEALED THAT THE CORE COWL SUPPORT STRUT HAD NOT BEEN PROPERLY SECURED IN CORE COWL WITH SNAP RETAINER AND LOCKPIN AFTER LAST ACCESS. WHEN THE STRUT FELL BACK DOWN ON THE ENGINE, IT FOULED AND APPARENTLY RESTRICTED MOVEMENT OF THE THROTTLE CONTROL BOX LINKAGE TO THE FUEL CONTROL. 2L72 4F4 FRTA21EA E15NE 20040315000192004031500019NE 2004 3 15 CA040123010 220031227G73206047T774P11 FUEL CONTROL CNDAIRCL601 CL6013A 8070802EA GE CF34 CF343A 30015NE LT ENGINE INOPERATIVE W E ENGINE SHUTDOWN EJ VIBRATION/BUFFET WARNING INDICATION DEDESCENT 1 CA (CAN) AT CRUISE ALTITUDE, DURING DESCENT, CREW WERE UNABLE TO RETARD POWER ON THE LT ENGINE THROTTLE. A FEW ATTEMPTS TO REDUCE POWER WERE MADE WITH NO CHANGE. THE CREW MANUALLY SHUTDOWN THE ENGINE AND MADE AN UNEVENTFUL LANDING. SUBSEQUENT TROUBLESHOOTING TRACED THE PROBLEM TO THE FUEL CONTROL UNIT. THE FCU WAS REPLACED AND THE A/C RETURNED TO SERVICE. 2L72 4F4 FRTA21EA E15NE 20040315000362004031500036EA 2004 3 15 CA040127003 120031001G2750C3CF1709 CONTROL ARM DHAV DHC3 DHC3 2800202EA PWA R1340 S3H1G 52016NE HAMSTD23D 23D40 NE LT TE FLAP CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) THIS LT FLAP COANTROL ARM WAS FOUND CRACKED DURING AN INSPECTION. THE CRACK WAS 188 MM/0.7 INCH RUNNING LENGTHWISE FROM THE THREADED END OF THE ROD ENDING AT THE INSPECTION HOLE. THIS PART WAS REPLACED WITH A NEW UNIT. 1H71 3R3 R A815 E142 6 CP719 20040315000372004031500037EA 2004 3 15 CA040127004 220031217G8530LW12966 CYLINDER PIPER PA31 PA31350 7103110SO LYC O540 TIO540J2BD 41532EA HARTZLHCE3Y HCE3YR2A GL RT ENGINE WORN W K NONE O OTHER ININSP/MAINT 1 CA (CAN) RT ENGINE, NR 5 CYLINDER FAILED COMPRESSION TEST. UPON REMOVAL, CYLINDER INTERIOR AND UNDERSIDE OF PISTON HEAD FOUND TO HAVE SOME TYPE OF BROWNISH SURFACE COATING ON THEM. 1L72 3O3 O A20SO E14EA 5 CP33EA 20040315000552004031500055EA 2004 3 15 CA040127012 220031202G8530 EXHAUST VALVE CESSNA172 172L 2072432CE LYC O320 O320E2D 41508EA MCAULY1C160 1C160DTM GL ENGINE FAILED W O OTHER RJ PARTIAL RPM/PWR LOSS WARNING INDICATION CRCRUISE 1 CA L4533127A (CAN) NR 3 CYLINDER EXHAUST VALVE WAS INGESTED BY ENGINE AND EXPELLED OUT THE EXHAUST, CAUSING EXTENSIVE DAMAGE TO ENGINE AND METAL CONTAMINATION. ENGINE REMOVED FOR OVERHAUL. 1H71 3O3 ONT3A12 E274 5 NP910 20040315000562004031500056SO 2004 3 15 CA040127013 220031216G73146533512 PUMP DIAMONDA20 DA20C1 2990001GL CONT O240 IO240B 17063SO SNSNCHW69EK W69EK63 EA FUEL SYSTEM FAILED W A UNSCHED LANDING YKJENGINE STOPPAGE FLUID LOSS WARNING INDICATION CLCLIMB 1 CA (CAN) ENGINE DRIVEN FUEL PUMP P/N 653351-2 FAILED DUE TO THE SEAL BETWEEN THE FUEL PUMP AND THE FUEL PUMP DRIVE. ALLOWING THE FUEL PRESSURE TO DROP AND ENGINE SHUT DOWN FOR LACK OF FUEL. THE FUEL PASSED THROUGH THE FUEL PUMP DRIVE DRAIN & OVER BOARD THE AIRCRAFT. 1L71 3O3 ONTTA4CH E7SO 5 NTA4CH 20040315000572004031500057NE 2004 3 15 CA040127014 220031228G7322 PUMP BELL 205 205A1 1181414SW LYC T53 T5317A 41549NE FUEL CONTROL FAILED W A UNSCHED LANDING J WARNING INDICATION HOHOVERING 1 CA 5ADS1907 (CAN) WHILE HELICOPTER WAS CONDUCTING AERIAL LIFT WORK THE PILOT NOTED THE ENGINE FUEL PUMP LIGHT CAME ON. HE RETURNED TO THE STAGING AREA AND LANDED UNEVENTFULLY. THROUGH TROUBLESHOOTING ON THE GROUND IT WAS DISCOVERED THAT ONE ELEMENT OF A DUAL ELEMENT PUMP FAILED. LIKELY CAUSE IS THE FAILURE OF THE INTERNAL DRIVE SPLINE, A KNOWN PROBLEM WITH -93 FUEL CONTROLS. 1G71 4U4 U H1SW E17EA 20040315000762004031500076WP 2004 3 15 CA040127022 120031223G6520369D25401 HOUSING HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL T/R GEARBOX CRACKED W K NONE O OTHER ININSP/MAINT 1 CA HD1007 (CAN) ALTHOUGH NOT REQUIRED AT THIS TIME, DUE TO THE ABNORMAL WEAR ON THE IP GEAR LARGE BEARING JOURNAL THE HOUSING WAS SENT OUT FOR ALIGNMENT AND NDT INSPECTION. THE RESULTS WERE RECEIVED RECENTLY FROM TRANSPORT APPROVAL FACILITY THAT THE GEARBOX HOUSING WAS FOUND CRACKED IN THE O/P ALIGNMENT BEARING AREA. 1G71 3U3 U H3WE E4CE 20040315000942004031500094NE 2004 3 15 CA040128006 220031228G732285634 PUMP BELL 205 205A1 1181414SW LYC T53 T5317A 41549NE FUEL CONTROL WORN W A UNSCHED LANDING J WARNING INDICATION HOHOVERING 1 CA 5ADS1907 (CAN) FUEL CONTROL P/N 1-170-240-93, S/N 5ADS1907 WAS RECEIVED DUE TO DAMAGED MAIN DRIVE SHAFT SPLINE. DISASSEMBLED AND INSPECTED FCU AND FOUND DAMAGED PUMP ASSEMBLY. RECORD OF INSPECTION IAW SB73-39. FCU S 91 AND 93 HAVE TIP SEAL PUMP, AND THEY CAN BE INSTALLED ON FOLLOWING ENGINE TYPES: T5313B, T5317A, T5317A-1 AND T5317B. INVESTIGATED TWO TIP SEAL PUMP AND MAIN DRIVESHAFT FAILURE ON FCU FITTED WITH TIP SEAL PUMPS. FAILURE OF THESE PARTS LEADS TO LOSS OF FUEL SUPPLY TO FCU, BOTH AUTOMATIC AND EMERGENCY SUPPLY, CAUSING ENGINE FLAMEOUT. IN BOTH CASES THE FCU S INVESTIGATED HAD TSO IN THE MID LIFE RANGE. WAITING FOR FURTHER CLARIFICATION AND GUIDANCE FROM THE MFG. 1G71 4U4 U H1SW E17EA 20040315001072004031500107EU 2004 3 15 CA040129005 120031208G2913704A33690004 PUMP SNIAS 350 AS350BA 8680817EU TMECA ARRIELARRIEL1B 6OO30NE HYD SYSTEM BROKEN W B EMER. DESCENT F FLT CONT AFFECTED CRCRUISE 1 CA (CAN) DURING SLINGING OF SURVEY EQUIPMENT (SO CALLED 'MAG BIRD'). HYDRAULIC FAILURE OCCURRED. PILOT DROPPED OFF SURVEY EQUIPMENT AND MADE UNSCHEDULED LANDING. THE A/C SUSTAINED NO DAMAGE. HYDRAULIC PUMP DRIVEBELT FOUND BROKEN. BELT REPLACED, A/C RETURNED TO SERVICE. 1G71 3U3 UNCH9EU E19EU 20040315001092004031500109CE 2004 3 15 CA040129007 120031210G55201015241099 BRACKET BEECH BEECH 200 B200 1152922CE PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL BALLAST WEIGHT CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) ELEVATOR FORWARD BALLAST WEIGHT STOP BRACKET AND BOLT FOUND BENT APPROXIMATELY 80 DEGREES FROM ITS ORIGINALLY INSTALLED POSITION. DENTS ON WEIGHT FACE INDICATE STOP BOLT AND BRACKET ASSEMBLY WAS SUBJECTED TO SEVERAL SEVERE CONTROL MOVEMENTS OF THE AIRCRAFT ELEVATOR CONTROL SYSTEM. 1L72 4T4 T A24CE E4EA 6 CP15EA 20040315001392004031500139WP 2004 3 15 CA040202002 120031228G3260833703 PROXIMITY SENSOR DOUG DC9 DC983 3022083WP PWA JT8 JT8D219 52053NE NLG FAILED W A UNSCHED LANDING N FALSE WARNING CLCLIMB 1 CA (CAN) AIRCRAFT DEPARTED AND RED NOSE GEAR LIGHT ON WITH GEAR HANDLE UP. AIRCRAFT LANDED BACK. NLG UP LOCK PROXIMITY SENSOR P/N 8-337-03 REPLACED ALSO RELAY R2-262 REPLACED AS PRECAUTIONARY. AIRCRAFT DISPATCHED SERVICEABLE. SAME DEFECT REOCCURS AT DEPARTURE. AIRCRAFT LANDED BACK. NOSEGEAR OLEO FOUND FLAT. OLEO HAS BEEN SERVICED AND SYSTEM CHECKED SERVICEABLE. 2L72 4F4 FRTA6WE E9NE 20040325000602004032500060NM 2004 3 25 CA040204001 120030906G561080260005 WINDSHIELD BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R320 CR3204123F1 GL COCKPIT CRACKED W O OTHER O OTHER CRCRUISE 1 CA (CAN) LT FRONT WINDOW CRACKED AT FL 230 SPEED 240 KTS. (WINDOW HEAT ON) DESCEND TO FL 100, REDUCED SPEED TO 200 KTS, AND DIFF. PRESS TO 3,0 PSI. INVESTIGATION/ACTION, LT FRONT WINDSHIELD, S/N: 419 REPLACED. THE MFG HAS INVESTIGATED, BUT COULD NOT IDENTIFY THE CAUSE OF THE CRACK AS BEING MANUFACTURING OR HANDLING RELATED. 2H72 4T4 TRTA13NM E00062EN6 CP5NE 20040325000612004032500061NM 2004 3 25 CA040204002 120031119G29136617302 PUMP BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU HYD SYSTEM SEIZED W A UNSCHED LANDING O OTHER CRCRUISE 1 CA (CAN) DURING CRUISE A/C LOST HYDRAULIC PUMP NR 1. QRH CONSULTED AND FOLLOWED BY ACTIVATING STBY PUMP. PRESSURE RESTORED TO NR 1 ONE SYSTEM. RETURNED TO BASE AND MADE A UNEVENTFUL LANDING. INVESTIGATION/ACTION, ENGINE DRIVEN PUMP (EDP) FOUND SEIZED AND CONSEQUENTLY REPLACED ACC AMM 29-11-01. HYDRAULIC SYSTEM NR 1 FLUSHED AND BLEED ACC AMM 29-10-00. HYD SYSTEM NR 1, PRESSURE, RETURN AND CASE DRAIN FILTERS REPLACED. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20040325000722004032500072NM 2004 3 25 CA040204003 120031020G561080260006 WINDSHIELD BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU COCKPIT CRACKED W O OTHER O OTHER CRCRUISE 1 CA (CAN) RT WINDSHIELD CRACKED AT FL230. SPEED REDUCED AND DESCEND DOWN TO FL100. QRH PERFORMED. SPEED AT MAX CRUISE AND MAX DIFF PRESSURE AT TIME OF THE CRACKING. RT WINDSHIELD REPLACED IAW AMM 56-10-01-400-801. THE MFG HAS INVESTIGATED THE WINDSHIELD AND FOUND A SCRATCH UNDER THE MOLDED EDGE SEAL AT CRACK INITIATION. THE SCRATCH IS A RESULT OF HANDLING PRIOR TO DELIVERY AND BEFORE INSTALLATION OF THE MOLDED EDGE SEAL AT MANUFACTURE. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20040325000852004032500085NM 2004 3 25 CA040204004 120031121G29109752565 RELIEF VALVE BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU HYD SYSTEM LEAKING W O OTHER KJ FLUID LOSS WARNING INDICATION CRCRUISE 1 CA NA (CAN) PILOT BECAME AWARE OF HYD. QT. 20-30 PERCENT, AND HYD NR 1 ISO VALVE CAUTION LIGHT. PRESSURE WAS AT THIS TIME OK. AFTER 5 MIN. QT. DROPPED TO 0 PERCENT. THIS CAUSED NEW CAUTION LIGHTS, AND QT. IN SYST. NR 1 TO INCREASE TO 50-60 PERCENT. COMPLETED ABNORMAL CHECKLIST FOR FLAPLESS LANDING. SINCE WE HAD QT. 50-60 PERCENT IN NR 1 SYS, AND PRESSURE FLUCTUATING, DECIDED TO TRY FLAPS 5. REACHED 3 DEGREES & STOPPED. NORMAL FLAPLESS LANDING PERFORMED. AFTER SERVICING NR 1 HYD SYSTEM , HYD FLUID WAS FOUND POURING FROM HYD BALANCE RELIEF VALVE DRAIN PORT TUBE. HYD BALANCED RELIEF VALVE REPLACED ACC AMM 29-11-51. LEAK CHECK OF HYD SYSTEM NR 1 PERFORMED WITHOUT ANY REMARKS. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20040503002332004050300233NE 2004 5 3 CA040204006 220030911G7320117024093 FUEL CONTROL BELL 205 205A1 1181414SW LYC T53 T5317A 41549NE ENGINE FAILED W BA EMER. DESCENT UNSCHED LANDING YJ ENGINE STOPPAGE WARNING INDICATION CRCRUISE 1 CA (CAN) ENGINE STOPPED IN-FLIGHT. 1G71 4U4 U H1SW E17EA 20040325000872004032500087NM 2004 3 25 CA040204008 120031112G6120697073001A PITCH CONTROL BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU PROPELLER INOPERATIVE W CD ABORTED TAKEOFF RETURN TO BLOCK E VIBRATION/BUFFET TOTAKEOFF 1 CA (CAN) ENGINE INDICATING POWERPLANT MESSAGE ON ED DURING TAKEOFF ROLL. T/O ABORTED AND RETURNED TO GATE FOR TECHNICAL INVESTIGATION. THE CENTRAL DIAGNOSTIC SYSTEM (CDS) WAS INTERROGATED AND REVEALED THE PRESENCE OF FAULT CODE 224 ON LT ENGINE (THE GBE SWITCH STAYS IN THE CLOSED POSITION). THE PITCH CONTROL UNIT (PCU) WAS THEN REPLACED IAW TASK 61-20-11 AND AN ENGINE TEST RUN PERFORMED, REF. AMM TASK 71-00-00-868-805. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20040325001032004032500103EA 2004 3 25 CA040204013 120030226G33102LA00691307 LIGHT CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE COCKPIT SHORTED W O OTHER B SMOKE/FUMES/ODORS/SPARKS NRNOT REPORTED 1 CA (CAN) CREW REPORTED SMOKE/SPARKS FROM CO-PILOTS FLOOD LIGHTS ON SIDE PANEL BELOW BASE OF WINDSHIELD WITH BURN MARKS ON PLASTIC AREA AT BASE OF W/S AND SIDE WINDOW. REMOVED AND REPLACED F/OS MIDDLE FLOOD LIGHT ASSY IAW AMM 33-11-03 AND OPS CHECKED SERVICEABLE. 2L72 4F4 FRTA21EA EOOO63EN 20040326000022004032600002EA 2004 3 26 CA040208001 120031124G27605120011 CONTROL UNIT CNDAIRCL600 CL6002C10 1390015EA GE CF34 CF348C1 NE SPOILERS DEFECTIVE W A UNSCHED LANDING J WARNING INDICATION CLCLIMB 1 CA (CAN) DURING CLIMB, IB FLT SPOILER CAUTION MESSAGE GOT POSTED AND RT IB FLIGHT SPOILER FULLY DEPLOYED. DECLARED AN EMERGENCY AND LANDED. RT IB MULTI FUNCTION SPOILER PCU WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. NOTE: DFDR ANALYSIS INDICATED THAT THE RT INBOARD MFS DID DEPLOY. THIS DFDR DOWNLOAD WILL BE PROVIDED TO MFG FOR REVIEW. 2L72 4F4 FRTA21EA EOOO63EN 20040507000522004050700052GL 2004 5 7 CA040210007 320030310G6111D3A34C403B BLADE CESSNA185 A185F 2072821CE CONT O520 IO520D 17032SO MCAULYD3A34 D3A34C403 GL PROPELLER SCORED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) AFTER SHUT-DOWN, PILOT NOTICED ONE PROPELLER BLADE ROOT SNAP RING HAD POPPED OUT OF ITS LOCATION DURING PREVIOUS FLIGHT. IN DOING SO, IT DAMAGED THE BLADE ROOT BY SCORING SURFACE. PROPELLER REMOVED AND SENT FOR REPAIR AT PROPELLER SHOP. 1H71 3O3 O 3A24 E5CE 5 CP47GL 20040315000722004031500072WP 2004 3 15 CA040217006 120031106G7810D3181 HEAT SHIELD ROBSINR44 R44 7640120WP LYC O540 O540F1B5 41532EA TAIL PIPE DEPARTED W O OTHER D INFLIGHT SEPARATION CRCRUISE 1 CA (CAN) PART DEPARTED HELICOPTER WHILE IN FLIGHT. DUE TO LOCATION OF DESCRIBED PART, IF (WHEN) PART LEAVES AIRCRAFT IN FLIGHT IT IS QUITE PROBABLE PART WILL COME INTO CONTACT WITH TAIL ROTOR. PART HAS NOT BEEN LOCATED SINCE DEPARTURE. PART HAS NOT BEEN REPLACED DUE TO CONCERNS FOR FLIGHT SAFETY. 1G71 3O3 O H11NM E295 20040315000732004031500073SW 2004 3 15 CA040217007 120031114G3246206050246102 SKID BELL 206 206B 1181511SW ALLSN 250C 250C20 03013GL MLG CORRODED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) SKID TUBE PARTIALLY DISASSEMBLED TO INVESTIGATE ELONGATED HOLE. SIGNIFICANT CORROSION FOUND UNDER 206-050-132-1 DOUBLER. DAMAGE IN NO-REPAIR AREA. SKID TUBE REPLACED. 1G71 3U3 U H2SW E4CE 20040315000822004031500082SW 2004 3 15 CA040217010 120031118G6210206015001107 BLADE BELL 206 206L1 1182107SW ALLSN 250C 250C28B 03013GL MAIN ROTOR SCORED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) MAIN ROTOR BLADE BOLT EXTREMELY DIFFICULT TO REMOVE FROM BOTH BLADES/MAIN ROTOR HUB. BOLTS, BLADE BUSHINGS AND MAIN ROTOR GRIPS ALL HAD HEAVY SCORING. CAUSE UNKNOWN. BOLTS SCRAPPED. BUSHINGS REPLACED IN MAIN ROTOR BLADE AT APPROVED FACILITY, AND MAIN ROTOR GRIPS SCRAPPED DUE TO LOW TIME REMAINING. (HUB REMOVED DUE TO TX , TT STRAPS.) 206-011-132-009 M/R GRIP S/N A1-02662 AND A1-02325206-015-001-107 M/R BLADE S/N A-3341 AND A-3262 206-011-135-5 BLADE BOLT S/N CH1625 AND CH1632. 1G71 3U3 U H2SW E1GL 20040315000832004031500083SW 2004 3 15 CA040217011 120031128G6410222016001131 BLADE BELL 230 230 1182149SW TAIL ROTOR DAMAGED W A UNSCHED LANDING D INFLIGHT SEPARATION CRCRUISE 1 CA (CAN) DURING ROUTINE FLIGHT, A 6.5 INCH PIECE OF DOUBLER BROKE OFF FROM THE BLADE, CAUSING VIBRATIONS. 1G72 3U NCH9SW 20040315001052004031500105WP 2004 3 15 CA040219004 220031231G7200TFE7315BR ENGINE RAYTHNDH125 HAWKER800XP 7150012CE GARRTTTFE731TFE7315BR WP LT & RT MISRIGGED W K NONE W INADEQUATE Q C ININSP/MAINT 1 CA (CAN) FOUND BOTH ENGINES HOOKED UP THE WRONG WAY. INSPECTED AND CORRECTED IAW SB 26-3610. ENGINE, TFE731-5BRS/N P107530 RFE-731-5BR S/N P107531. DUAL-HEAD ENGINE FIRE EXTINGUISHER HOOKED UP IN REVERSE AND COULD RESULT IN A FIRE EXTINGUISHER BOTTLE BEING DISCHARGED INTO THE WRONG ENGINE NACELLE. 2L72 4F4 FRTA3EU E6WE 20040315001552004031500155EU 2004 3 15 CA040223004 120030813G6320350A32392301 DRIVE SHAFT SNIAS 350 AS350B 8680801EU TMECA ARRIELARRIEL1B 6OO30NE OIL PUMP BROKEN W E ENGINE SHUTDOWN J WARNING INDICATION TXTAXI/GRND HDL 1 CA M1968 (CAN) AFTER FIRST START OF THE DAY THE TRANSMISSION OIL PRESSURE LIGHT NEVER WENT OFF. ENGINE WAS SHUT DOWN TO INVESTIGATE THE SOURCE OF THE PROBLEM. IT WAS FOUND THAT THE NEWLY OVERHAUL OIL PUMP WAS NOT DELIVERING ANY PRESSURE. ON REMOVAL OF MAIN TRANSMISSION AND OIL PUMP ASSEMBLY, THE DRIVE PINION SHAFT OF OIL PUMP WAS FOUND BROKEN IN TWO PIECES. NOTE THAT THE AIRCRAFT FLEW THE DAY BEFORE WITH NO PROBLEM AT ALL. CONCLUSION OF THE OVERHAUL FACILITIES STATE THAT THE SHAFT FAILED IN A TORSIONAL MODE OF INSTANTANEOUS OVERLOAD. DAMAGE FOUND ON THE PINION GEAR TEETH INDICATE THAT AN OBJECT PASSSED THROUGH THE MESH OF THE PUMP AND JAMMED OFF THE INTERMESHING OIL PUMP GEAR. 1G71 3U3 U H9EU E19EU 20040315001782004031500178EA 2004 3 15 CA040225006 220030930G732225242192R FLOW DIVIDER BEECH 23 A2324 1151226CE LYC O360 IO360A1A 41514EA MCAULY1B235 1B235BFA GL FUEL SYSTEM FAILED W A UNSCHED LANDING E VIBRATION/BUFFET CRCRUISE 1 CA (CAN) THE AIRCRAFT SAT FOR APPROXIMATELY 7 YEARS. AFTER A POWER LOSS IN FLIGHT, SUBSEQUENT INSPECTION OF THE INJECTOR NOZZLES (TO FIND CONTAMINATION PRESENT) THE FUEL SYSTEM WAS SENT FOR REPAIR. IT WAS GREEN-TAGGED AS REPAIRED. PROBLEM STILL PRESENT, WENT BACK, WAS BENCH-CHECKED AND PASSED. PROBLEM STILL NOT FIXED, SENT BACK, GREEN-TAGGED AGAIN, PROBLEM STILL PRESENT. FINALLY, WE OPENED ONE OF THE UNUSED PORTS AND THE ATTACHED PHOTOS SHOW THE CONTAMINATION THAT WAS FOUND. A NEW (OVERHAULED) FLOW DIVIDER WAS PURCHASED AND INSTALLED. PROBLEM HAS NOT RETURNED. 1L71 3O3 O A1CE 1E10 5 NP12EA 20040315001792004031500179EA 2004 3 15 CA040225007 120030714G5520C3TE37ND HINGE DHAV DHC2 DHC2MK1 2800102EA PWA R985 R985AN14B 52008NE HAMSTD2D 2D30 NE ELEVATOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) LT AND RT ELEVATOR FRONT SPAR P/N C2-TE-37ND UPPER ATTACH HOLES (NR 10) FOR CENTER HINGE POSITION HAS SMALL CRACK(S) AROUND THE UPPER AN3 BOLT HOLE. 1H71 3R3 R A806 5E1 5 CP206 20040503002492004050300249GL 2004 5 3 CA040227004 220031116G72506898663 TURBINE WHEEL BELL 407 407 1182206SW ALLSN 250C 250C47B GL 3RD STG BLADES FAILED W O OTHER T ENGINE CASE PENETRATION CRCRUISE 1 CA (CAN) 3RD TURBINE STAGE WHEEL BLADES SHED IN FLIGHT. PART TIME SINCE NEW : 2852 HOURS. PILOT IDENTIFIED FLIGHT PROBLEM AND LANDED IN AUTOROTATION. 1G71 3U3 UO H2SW E1GL 20040503002502004050300250GL 2004 5 3 CA040227005 220031201G72506898663 TURBINE WHEEL BELL 407 407 1182206SW ALLSN 250C 250C47B GL 3RD STG BLADES FAILED W O OTHER T ENGINE CASE PENETRATION CRCRUISE 1 CA (CAN) M 407 HELICOPTER HAD 3RD STAGE TURBINE WHEEL FAILURE IN FLIGHT. AIRCRAFT CRASHED. TURBINE WHEEL PART TIME 1144 HOURS SINCE NEW. 1G71 3U3 UO H2SW E1GL 20040503002632004050300263NE 2004 5 3 CA040301002 220030817G7230 COMPRESSOR BELL 204 204B 1181404SW LYC T53 T5311B 41549NE ENGINE FAILED W A UNSCHED LANDING XJ ENGINE FLAMEOUT WARNING INDICATION CLCLIMB 1 CA (CAN) THE AIRCRAFT DEPARTED A STAGING AREA, SHORTLY AFTER TAKEOFF, THE AIRCRAFT HAD AN ENGINE FAILURE AND CRASHED IN TALL TREES. THE PILOT WAS THE ONLY OCCUPANT AND WAS KILLED ON IMPACT. THE ENGINE WAS RECEIVED FROM OVERHAUL AND INSTALLED 18 HOURS PRIOR TO THE ACCIDENT. THE NTSB HAS CONFIRMED THAT THE COMPRESSOR ASSEMBLY SUFFERED A SUDDEN AND CATASTROPHIC FAILURE. THEY HAVE NOT YET DETERMINED THE EXACT CAUSE OF THIS FAILURE. 1G71 4U4 U H1SW E1EA 20040507000362004050700036NM 2004 5 7 CA040305003 120031218G3250481505 MANIFOLD BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU NLG STEERING INOPERATIVE W O OTHER O OTHER TXTAXI/GRND HDL 1 CA (CAN) NOSE STEERING CAUTION CAME ON DURING TAXI. VACATED RWY WITH HELP OF BRAKES AND FOOT STEERING. TOWED TO RAMP AND OFF-LOADED PAX THERE. SEVERAL UNSUCCESSFUL RESETS PERFORMED. INVESTIGATION/ACTION, STEERING CONTROL UNIT CHECKED FOR FAULT CODES. FAULT CODES EHVS AND SOVC PRESENT. STEERING MANIFOLD REPLACED IAW AMM 32-51-16. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20040507000392004050700039EA 2004 5 7 CA040306001 120031129G2140601R950681 DUCT CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343B1 NE NR 1 A/C PACK DETACHED W BA EMER. DESCENT UNSCHED LANDING WJ INADEQUATE Q C WARNING INDICATION CLCLIMB 1 CA (CAN) THE A/C WAS DISPATCHED WITH PACK NR 1 INOPERATIVE IAW MEL. AFTER T/O, WHEN TRANSFERRING THE BLEED AIR FROM APU TO THE ENGINES, CABIN ALT CAUTION INDICATION CAME ON ON THE EICAS. THE CREW BEGAN TO FOLLOW QRH PROCEDURE AND, SUDDENLY, CABIN ALT WARNING INDICATION CAME ON ON THE EICAS. THE CREW BEGAN AN EMERGENCY DESCENT AND THEY RETURNED TO THE DEPARTURE AIRPORT. A/C LANDED UNEVENTFULLY. DUCT FROM PRECOOLER TO PRIMARY HEAT EXCHANGER IN PACK NR 2 WAS FOUND MISS ATTACHED AT PRIMARY HEAT EXCHANGER SIDE. DUCT REPOSITIONED. AMM TASK NR 2 AMM NR 21-31-00-710-801 CARRIED OUT. A/C RELEASED INTO SERVICE. 2L72 4F4 FRTA21EA E15NE 20040507000462004050700046EA 2004 5 7 CA040307001 120031217G5610NP1393219 WINDSHIELD CNDAIRCL600 CL6002B19 1900309EA GE CF34 CF343A1 30015NE COCKPIT CRACKED W A UNSCHED LANDING O OTHER CLCLIMB 1 CA (CAN) CAPTAINS WINDSHIELD CRACKED IN FLIGHT. AC DIVERTED TO AND LANDED WITHOUT FURTHER INCIDENT. INSPECTED CAPTAINS WINDSHIELD AND FOUND DAMAGE TO OUTER PLY. AC FERRIED FOR REPAIR. WINDSHIELD REMOVED, REPLACED AND LEAK CHECK PERFORMED. AC RETURNED TO SERVICE. 2L72 4F4 FRTA21EA E15NE 20040405000122004040500012CE 2004 4 5 CA040310006 120030918G712005510171 MOUNT CESSNA172 172M 2072418CE LYC O320 O320E2D 41508EA MCAULY1C160 1C160DTM GL ENGINE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA 1006510065 (CAN) A WELD WAS DISCOVERED CRACKED IN THE LOWER PART OF THE ENGINE SUPPORT. 1H71 3O3 ONT3A12 E274 5 NP910 20040413000092004041300009NE 2004 4 13 CA040315006 220030827G732343012354 GOVERNOR SNIAS 350 AS350D 8680803EU LYC LTS101LTS101600A2 41560NE OVERSPEED FAILED W O OTHER W INADEQUATE Q C CRCRUISE 1 CA (CAN) MAIN ROTOR RPM WAS FOUND TO OSCILLATE DURING CRUISE FLIGHT AND SOMETIMES DROOP DOWN -5 RPM NR. REPLACING FUEL CONTROL UNIT, FUEL PUMP AND GOVERNOR DID NOT HELP THE PROBLEM. REPLACING THE OVERSPEED GOVERNOR ELIMINATED ALL SYMPTOMS. 1G71 3U3 U H9EU E5NE 20040413000102004041300010EU 2004 4 13 CA040315007 120030911G7720406100807 LINK SNIAS 350 AS350D 8680803EU LYC LTS101LTS101600A2 41560NE FLOW FENCE BROKEN W A UNSCHED LANDING M OVER TEMP CRCRUISE 1 CA (CAN) DURING NORMAL CRUISE FLIGHT, THE PILOT NOTICED A SUDDEN SHARP RISE IN T4 (TOT) STILL WITHIN LIMITS. AFTER RETURNING TO BASE, ONE OF THE LINKS CONTROLLING THE FLOW FENCE WAS FOUND TO BE BROKEN. 1G71 3U3 U H9EU E5NE 20040719000722004071900072NE 2004 7 19 CA040316005 220031206G7200 ENGINE CNDAIRCL600 CL600* EA LYC ALF502ALF502L 41580NE FOD W O OTHER E VIBRATION/BUFFET DEDESCENT 1 CA (CAN) CREW REPORTED ENGINE VIBRATION DURING DESCENT. SUBSEQUENT TROUBLESHOOTING ON THE GROUND CONFIRMED THE VIBRATION ON DURING ENGINE DECELERATION. FOD DAMAGE WAS DISCOVERED IN THE ENGINE CORE AND HOT SECTION. THE ENGINE WAS REPAIRED AND THE AIRCRAFT RETURNED TO SERVICE. 2L72 4F4 FRTA21EA E6NE 20040416000362004041600036NM 2004 4 16 CA040323004 120031203G2760 SWITCH BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU PRESSURE CONTROLINOPERATIVE W A UNSCHED LANDING F FLT CONT AFFECTED CLCLIMB 1 CA (CAN) DURING CLIMB, REACHING 185 KTS CREW GOT AN OB SPOILER CAUTION LIGHT AT 4000 FT. REDUCING BELOW 185 CAUTION LIGHT DISAPPEARED, AND CAME BACK AT 185 KTS. CONFIRMED CHECKLIST ITEMS. KEPT SPEED BELOW 200 AND RETURNED BACK TO BASE FOR A NORMAL LANDING. INVESTIGATION/ACTION THE PRESSURE CONTROL SWITCH ON THE OB SPOILER DUMP VALVE WAS REPLACED IAW AMM 27-61-28. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20040416000372004041600037NM 2004 4 16 CA040324006 120031211G526085217051101 GOOSENECK ASSY BOMBDRDHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17EU AIRSTAIR DOOR CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) OPERATORS HAVE REPORTED FINDING FOUR AIRSTAIR DOOR GOOSENECKS CRACKED / BROKEN IN THE FORWARD POSITION. IT WAS ALSO FOUND 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. NOTE, MANUFACTURER OF THE DOOR AND THE GOOSENECK IS MHI. 2H72 4T4 TRTA13NM E00062EN6 CP17BO 20050113000202005011300020CE 2005 1 13 CA040325001 120030920G561010138402515 WINDSHIELD BEECH 200 B200 1152922CE PWA PT6 PT6A42 52043NE COCKPIT FAILED W BA EMER. DESCENT UNSCHED LANDING O OTHER CRCRUISE 1 CA (CAN) INNER PLY ON CAPTAINS WINDSHIELD INSTANTLY SHATTERED AT APPROXIMATELY 28,000 FT, CAUSING THE CREW TO COMMENCE AN EMERGENCY DESCENT AND LANDING. WEATHER WAS FAIR AT THE TIME AND THERE WAS NO WINDSHIELD HEAT ON. 1L72 4T4 T A24CE E4EA 20040709000872004070900087GL 2004 7 9 CA040405003 120031217G2730 CARTRIDGE CIRRUSSR SR20 05628AJGL CONT O360 IO360ES SO ELEVATOR FAILED B O OTHER F FLT CONT AFFECTED APAPPROACH 1 GL15938CD 1338 ON APPROACH, PILOT DISENGAGED AUTOPILOT, FOUND ELEVATOR CONTROL TO BE STUCK IN FIXED POSITION, PITCH TRIM CONTROL WAS STILL AVAILABLE BOTH UP AND DOWN. AFTER SEVERAL ATTEMPTS TO (FREE) CONTROL WITH NO SUCCESS THE PILOT "JERKED" CONTROL BACK. CONTROL BROKE FREE ENOUGH TO PROVIDE "UP" ELEVATOR CONTROL. PILOT LANDED WITHOUT INCIDENT. AC WAS MOVED INTO HEATED HANGAR WHERE INITIAL INSPECTION REVEALED ELEVATOR TO BE VERY DIFFICULT TO MOVE IN EITHER DIRECTION. ELEVATOR WAS ABLE TO BE MOVED TO FULL TRAVELS IN BOTH DIRECTIONS WITH RELATIVE EASE ALTHOUGH PITCH TRIM CARTRIDGE MADE MORE "NOISE" THAN NORMAL. PITCH TRIM CARTRIDGE WAS REMOVED AND REPLACED WITH NEW PART. REMOVED PART WAS INSPECTED WITH NO ANOMALIES NOTED. 1L71 3O3 ONTA00009CHE1CE 20040712002022004071200202GL 2004 7 12 CA040407012 320030326G6114 HUB MCAULY CESSNA150 152 2071835CE LYC O235 O235L2C 41505EA MCAULY1A103 1A103TCM GL PROPELLER CRACKED W K NONE O OTHER ININSP/MAINT 1 CA R777080 (CAN) PROPELLER FOUND CRACKED AT BOLT HOLES WHILE COMPLYING WITH AD 2003-12-05. PROPELLER WAS PREVIOUSLY NOT CRACKED WHILE COMPLYING WITH AD 97-06-16 (PREVIOUS VERSION OF 2003-12-05). TWO RADIAL 1/2 INCH CRACKS AROUND TWO BOLT HOLES WERE LOCATED WITH LPI AND VISIBLE WITH 10X MAGNIFIER. REMOVED PROP FROM SERVICE. SIMILAR PROP PREVIOUSLY REMOVED FROM SERVICE ON ANOTHER COMPANY C-152. 1H71 3O3 ONT3A19 E223 5 NP50GL 20040805000992004080500099WP 2004 8 5 CA040413004 120030813G6210 BLADE HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL MAIN ROTOR DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) PIN FAILURE, SHEARED AT TOP THREAD OF THREADED SHANK FOR ADJUSTER NUT. 1G71 3U3 U H3WE E4CE 20040805001002004080500100EA 2004 8 5 CA040413005 220030906G7250 TURBINE WHEEL BELL 212 212 1181420SW PWA PT6T PT6T3 52045EA NR 2 ENGINE DAMAGED W E ENGINE SHUTDOWN EJ VIBRATION/BUFFET WARNING INDICATION TXTAXI/GRND HDL 1 CA CPPS61014 (CAN) WHEN THROTTLES WERE ROLLED TO IDLE FOR COOL DOWN A LOW GROWL WAS HEARD AT IDLE. ENGINES WERE SPUN UP TO 100 PERCENT AND GROWL WENT AWAY. BOTH ENGINES WERE BROUGHT BACK TO IDLE AND NOISE WAS HEARD AGAIN. ENGINES WERE SPOOLED UP SEPARATELY AND PROBLEM WAS ISOLATED TO NR 2 ENGINE. ENGINEER WAS NOTIFIED. DURING BOROSCOPE INSPECTION OF NR 2 ENGINE IT WAS DISCOVERED THAT PORTIONS OF 7 BLADES WERE MISSING. POWER SECTION REMOVED DUE TO CT WHEEL DISTRESS. 1G71 4U4 U H4SW E22EA 20040806000062004080600006EU 2004 8 6 CA040414005 120030921G2821 FILTER AEROSPATR72 ATR72201 8680943EU PWA PW120 PW124B NE FUEL PUMP CONTAMINATED W E ENGINE SHUTDOWN EM VIBRATION/BUFFET OVER TEMP CLCLIMB 1 CA (CAN) DURING CLIMB, ENGINE ITT ROSE AND ENGINE WAS UNRESPONSIVE TO TLA INPUT. ENGINE WAS SHUT DOWN AND AN UNEVENTFUL SINGLE ENGINE LANDING WAS MADE. POST EVENT EXAMINATION SHOWED THAT METERING VALVE OF THE HMU WAS JAMMED BY A PIECE OF EPOXY MATERIAL. BORE (DOWNSTREAM) SURFACE OF FUEL FILTER SHOWED AN LARGE DEPOSIT OF EPOXY, WHICH APPARENTLY WAS AN EXCESS OVERFLOW OF MATERIAL USED TO SECURE END CAPS TO BARREL OF FILTER. FURTHER INVESTIGATION BY THE SUPPLIER OF THE PUMP ASSEMBLY HAS SHOWN THAT INCIDENT FILTER, WHILE MARKED TO BE VERY SIMILAR TO THAT OF SUPPLIER, WAS NOT, IN FACT, MADE BY SUPPLIER. SUPPLIER HAVE ISSUED INSTRUCTIONS TO FIELD TO INSPECT PW100 FILTERS FOR POSSIBLE PRESENCE OF EPOXY IN BORE OF UNIT.2H72 4T4 TRTA53EU E2ONE 20050223001472005022300147CE 2005 2 23 CA040423002 120030305G5312 BULKHEAD BEECH 200 200BEECH 1152920CE PWA PT6 PT6A41 52043EA HARTZLHCB3T HCB3TN3 GL FUSELAGE CORRODED W K NONE O OTHER ININSP/MAINT 1 CA DURING A SCHEDULED INSPECTION OF THE REAR PRESSURE BULKHEAD A LOCALIZED AREA OF PITTING CORROSION WAS DISCOVERED AROUND THE BULKHEAD FITTING FOR THE RELIEF TUBE CONNECTION. THE AREA WAS CLEANED AND INSPECTED AND AN APPROVED DOUBLER REPAIR CARRIED OUT. THE BULKHEAD FITTING ASSEMBLY WAS REPLACED WITH NEW TO PREVENT THE POSSIBILITY OF ANY FURTHER LEAKAGE. ALL OTHER AIRCRAFT IN THE FLEET WERE INSPECTED WITH NO DEFECTS NOTED. 1L72 4T4 T A24CE E4EA 6 CP15EA 20040805000662004080500066CE 2004 8 5 CA040503004 120030213G324695440263 WHEEL LEAR 35 35LEAR 5170600CE GARRTTTFE731TFE73122B 01518WP MLG CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING ROUTINE TIRE CHANGE, NDT REVEALED SEVERAL CRACKS AROUND THE FLANGE IN THE AREAS WHERE THE BRAKE ASSEMBLY SLIDES INTO THE WHEEL HALF. WHEEL HALF REMOVED FROM SERVICE. 2L72 4F4 F A10CE E6WE 20050224000092005022400009NE 2005 2 24 CA040504007 220030919G8530AE92181 CYLINDER DHAV DHC3 DHC3 2800202EA PWA R1340 R134059 52016NE EXHAUST PORT CRACKED W K NONE O OTHER ININSP/MAINT 1 CA CYLINDER WAS CRACKED FROM SPARK PLUG HOLE TO SPARK PLUG HOLE ON THE EXHAUST SIDE. THE CRACK HAD OPENED UP TO A SIGNIFICANT SIZE HOLE MAKING THE EXHAUST VALVE VISIBLE FROM BETWEEN THE FINS. THE LEAKING EXHAUST GASES HAD BURNED AWAY A PORTION OF THE FINS AROUND THE OPENING. 1H71 3R3 R A815 5E2 20050224000112005022400011CE 2005 2 24 CA040506001 120031121G551107326031 SPAR CESSNA185 A185F 2072821CE CONT O520 IO520D 17032SO MCAULY2A34C D2A34C58 GL HORIZONTAL STAB CRACKED W K NONE O OTHER ININSP/MAINT 1 CA REMOVED HORIZONTAL STABILIZER. REAR SPAR REINFORCEMENT PART NUMBER 0732603-1 CHANGED. AFT ATTACHEMNT POINT REINFORCEMENT BRACKET RT PART NUMBER 0732101-4 REPLACED WITH NEW. ADJACENT RIVETS REPLACED. SERVICE KIT SK185-27 INSTALLED TO FACILITATE SCREW JACK REMOVAL. LT TRIM JACK REMOVED. NEW SCREW PART NUMBER 0712500-11 INSTALLED. TRIM JACK REINSTALLED. RIGGED AND SAFETIED AS PER CESSNA MANUAL. 1H71 3O3 O 3A24 E5CE 5 CP3EA 20050308000262005030800026EU 2005 3 8 CA040528004 120031023G6310330A32600000 FREEWHEEL UNIT SNIAS SA330 SA330J 8680612EU TMECA TURMO4TURMO4C 60008EU M/R GEARBOX FAILED W E ENGINE SHUTDOWN W INADEQUATE Q C TXTAXI/GRND HDL 1 CA ON START UP, ROTORS BEGAN TURNING. A LOUD BANG HEARD. START ABORTED. INSPECTION REVEALED T/R SHAFT SEGMENT TWISTED AT NR 5 SHAFT. FREEWHEEL SLIPPED MOMENTARILY AND RE-ENGAGED. TRANSMISSION SENT TO FRANCE FOR DISASSEMBLY. SPRING IN FREEWHEEL FOUND BROKEN. ENGINE INSPECTED BY MANUFACTURE. ALL SHAFTING REPLACED. GEARBOXES IN T/R SYSTEM INSPECTED, FUSELAGE AND T/BOOM VISUALLY AND NDT INSPECTED, HEAD AND M/R BLADES INSPECTED (VISUALLY & NDT). TRANSMISSION, MOUNTS VISUALLY AND NDT INSPECTED. ALIGNMENT CHECKS OF A/F AND ENGINE MOUNTS CONDUCTED. 2G72 4U4 U H4EU E10EU 20050308000362005030800036SW 2005 3 8 CA040531005 120031203G6230214010404111 SUPPORT BELL 214 214B1 1182105SW LYC T55 T5508D 41555NE SWASHPLATE WORN W K NONE O OTHER ININSP/MAINT 1 CA A1900242 DURING AN INSPECTION CHECK ON THE SWASH PLATE THE FRICTION WAS NOTED AS VERY TIGHT. UPON DISASSEMBLY, IT WAS FOUND THAT ONE OF THE FOUR BEARINGS RIDING ON THE SUPPORT HAD LOST IT'S 'COATING' ENTIRELY. THE RESULTING METAL/METAL CONTACT WORE INTO THE SUPPORT, CAUSING THE FRICTION TO STIFFEN. THE SUPPORT AND ALL FOUR BEARINGS WERE SUBSEQUENTLY SCRAPPED. 2G71 4U4 U H6SW E4NE 20040729000412004072900041NE 2004 7 29 CA040602009 220030530G8530356995 CYLINDER DOUG DC6 DC6B 3021712WP PWA R2800 CB3 52026NE HAMSTD43E 43E60 NE ENGINE CRACKED W EA ENGINE SHUTDOWN UNSCHED LANDING O OTHER DEDESCENT 1 CA P35500 (CAN) DURING DESCENT, NR 2 ENGINE BACKFIRED, THE FLIGHT CREW MOVED THE MIXTURE TO RICH, THE ENGINE STABILIZED FOR 2 MINUTES. THE ENGINE BACKFIRED AGAIN AND THE ENGINE WAS SHUT DOWN AND THE PROPELLER WAS FEATHERED. THE AIRCRAFT LANDED WITHOUT INCIDENT. UPON INVESTIGATION BY MAINTENANCE IT WAS NOTED THAT THE EXHAUST EAR ON CYLINDER NR 18 WAS CRACKED. THE CYLINDER WAS REPLACED, THE ENGINE WAS GROUND RUN AND THE AIRCRAFT WAS RETURNED TO SERVICE. 2L74 4R4 R 6A4 E264 6 CP871 20040729000832004072900083CE 2004 7 29 CA040604005 120030522G5412 BULKHEAD CESSNA414 414 2075908CE CONT O520 TSIO520NB 17040SO HARTZLHCC3Y PHCC3YF2 GL LT NACELLE DAMAGED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) DURING A SCHEDULED ENGINE CHANGE THE LT CANTED BULKHEAD ASSEMBLY ENGINE MOUNT STRUCTURE WAS FOUND TO HAVE BEEN DAMAGED BY EXHAUST GASES. THE INDIVIDUAL PARTS REQUIRING REPLACEMENT ARE AS FOLLOWS. 0851500-47 CAP0851500-39 CHANNEL 0851601-201 WEB FORWARD 0851601-27 WEB AFT. THE IPC DOES NOT GIVE A ASSEMBLY OR PN FOR THE CANTED BULKHEAD ITSELF. 1L72 3O3 ORTA7CE E8CE 5 CP25EA 20040729000102004072900010SO 2004 7 29 CA040622003 220030925G8520 CRANKCASE CESSNA182 182F 2072714CE CONT O470 IO470S 17026SO MCAULY2A34C 2A34C50 GL ENGINE CRACKED W K NONE K FLUID LOSS ININSP/MAINT 1 CA (CAN) CRANKCASE WAS DISCOVERED CRACKED NEAR OIL CAP LOCATION. CRANKCASE REPLACED. 1H71 3O3 ONT3A13 3E1 5 CP3EA 20041018000512004101800051EU 2004 10 18 CA040806008 120030830G6320350A32108203 PLANETARY GEAR AEROSPAS355 AS355F1 8680810EU ALLSN 250C 250C20F 03013GL EPI CYCLIC SPALLED W K NONE O OTHER ININSP/MAINT 1 CA M1538 (CAN) EPI CYCLIC WAS MAKING METAL. SOURCE WAS THE PLANET GEAR INNER RACE WAS SPALLING AND MAKING METAL. 1G72 3U3 U H11EU E4CE 20041013001072004101300107SW 2004 10 13 CA040817001 120031205G28206859177 LINE BELL 206 206L 1181522SW ALLSN 250C 250C20B 03013GL FUEL SYSTEM CRACKED W A UNSCHED LANDING KB FLUID LOSS SMOKE/FUMES/ODORS/SPARKS APAPPROACH 1 CA (CAN) FOUND A CRACK ON FLARE OF FCU SUPPLY LINE FROM FUEL PUMP. REPLACED LINE ON SITE WITH REMOVED SERVICEABLE UNIT FROM ANOTHER AIRCRAFT. LEAK CHECK C/O AND AIRCRAFT RETURNED TO SERVICE. 1G71 3U3 U H2SW E4CE 20041018000312004101800031EU 2004 10 18 CA040827007 120031204G270027529030 MOTOR AMD FALCONFALCON20 2730103EU GE CF700 CF7002D2 30010NE VALVE MALFUNCTIONED W D RETURN TO BLOCK O OTHER TXTAXI/GRND HDL 1 CA 10106 (CAN) THE AIRCRAFT HAD BEEN THROUGH A MAJOR INSPECTION AT CONTRACTOR 4 MONTHS PREVIOUS. THE VALVE HAD BEEN REMOVED FOR ACCESS TO OTHER AREAS. THE PILOT REPORTED CIRCUIT BREAKER POPPED DURING TAXI. PILOT RETURNED TO HANGAR. INVESTIGATION FOUND RODS CONNECTED TO VALVES WERE MISRIGGED, RESULTING IN JAMMING OF RODS, RESULTING IN OVERLOADING OF MOTOR, CAUSING CIRCUIT BREAKER TO POP. VALVE ASSEMBLY REPLACED, RODS RIGGED IAW MM, FUNCTION CHECKED NORMAL. 2L72 4F4 FRTA7EU E7EA 20050303001492005030300149 2005 3 3 CA040902008 420031020G3457CI2480100 ANTENNA BEECH 200 B200 1152922CE PWA PT6 PT6A42 52043NE GPS DATA VIBRATION W O OTHER E VIBRATION/BUFFET NRNOT REPORTED 1 CA A/C ORIGINALLY EQUIPPED WITH ANTENNA MOD CI4510-700 IAW LSTC NR C-LSA02-377/D. ANTENNA LATER RECALLED BY MANUFACTURER. REPLACEMENT ANTENNA MOD CI2480-100. DURING FLT, REPLACEMENT ANTENNA VIBRATED LOUD ENOUGH TO BE HEARD IN COCKPIT. ANTENNA REMOVED. INSTALLED SAME ANTENNA IN SAME LOCATION. ON 2 OTHER BEECH 200'S WITH NO VIBRATION NOTICED. OPERATORS HAVE BEEN KEPT ADVISED OF SITUATION WITH OTHER A/C. SPECS SHEET FOR CI2480-100 ANTENNA STATED 350KTS TAS MAX & A CEILING OF 55,000'. SPECS SHEET FOR CI2480-100 ANTENNA TODAY STATES 210KTS IAS MAX AT 10,000' & CEILING OF 20,000 FT. ANTENNA MANUFACTURER WILL BE CONTACTED FOR CLARIFICATION. 1L72 4T4 T A24CE E4EA 20041110000612004111000061SW 2004 11 10 CA041001001 120030922G29138505141 DRIVE GEAR PARKERHANFIN BELL 206 206B 1181511SW ALLSN 250C 250C20B 03013GL TACH DRIVE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA BD01509 (CAN) DURING A NORMAL O/H OF THE PUMP ASSY MPI INSP OF THE DRIVEN GEAR FOUND A CRACK ON THE TACH DRIVE END OF THE SHAFT. THE CRACK WAS IN THE CORNER OF THE SQUARE DRIVE. PUMP GEARS REPLACED. 1G71 3U3 U H2SW E4CE 20050124000162005012400016SW 2005 1 24 CA041005003 120030409G2197 WIRE BELL 206 206B 1181511SW ALLSN 250C 250C20B 03013GL HEATER WRONG PART W K NONE O OTHER ININSP/MAINT 1 CA 2656 (CAN) CASEY HEATER BLOWER MOTOR CIRCUIT BREAKER TRIPPED TWICE DURING THE FIRST 2 HOURS OF USE AFTER MOTOR OVERHAUL. INSPECTION REVEALED THAT THE CASEY HEATER POWER WIRE BETWEEN THE CB SWITCH AND THE CAPACITOR WAS 16 GAUGE. THE CASEY INSTALLATION INSTRUCTIONS CALL FOR 10 GAUGE WIRE. REPLACED 16 GAUGE WIRE WITH 10 GAUGE WIRE. INSTALLED NEW 35 AMP CIRCUIT BREAKER DUE TO AGE. INSTALLED PANEL AMP METER BETWEEN COB AND BLOWER AND RAN FAN TO VERIFY AMP DRAW. AMP DRAW DETERMINED TO BE 43 AMPS AT START UP AND 23 AMPS CONTINUOUS. SYSTEM OPERATING NORMAL. 1G71 3U3 U H2SW E4CE 20050201000762005020100076NM 2005 2 1 CA041201004 120031129G5330 SKIN BOEING737 737296 1384486NM PWA JT8 JT8D9A 52048NE FUSELAGE CRACKED W K NONE O OTHER ININSP/MAINT 1 CA (CAN) TWO INCH CRACK WAS FOUND ON OUTER FUSELAGE BETWEEN STA 727A, 727B AT STR. 16L. FUSELAGE CRACK REPAIRED IAW SRM 53-30-3 FIG.48 SHEET 34 DETAIL XII. TIMES- 59472:22 CYCLES- 54285. 2L72 4F4 FRTA16WE E2EA 20060705001762006070500176EA 2006 7 5 CA060206011 220030523G8520 PISTON RING PIPER PA23 PA23250 7102308SO LYC O540 IO540C4B5 41532EA HARTZLHCE2Y HCE2YR2 GL NR 6 CYLINDER SEIZED W A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CLCLIMB 1 CA 2193 (CAN) AIRCRAFT WAS AIRBORNE FOR APPROXIMATELY 10 MINUTES WHEN ENGINE OIL TEMPERATURE OBSERVED HIGHER THAN USUAL. ENGINE SEEMED TO RUN ROUGH, AIRCRAFT RETURNED TO AIRPORT AND LANDED WITHOUT INCIDENT. UPON INSPECTION FOUND NR 6 CYLINDER IN AN ALMOST SEIZED CONDITION. RINGS WERE SEIZED TO PISTON. CYLINDER ASSEMBLY REMOVED FROM SERVICE AND NEW ASSEMBLY INSTALLED. GROUND RUNS COMPLETED NO FURTHER FAULTS NOTED. (TC NR 20060206011) 1L72 3O3 O 1A10 1E4 5 CP9EA 20030617002312003061700231EU 2003 6 17 CCHA087050 120030609G6330L633M2010101 MOUNT UROCOPEC135 EC135T1 5620026EU TMECA ARRIUSARRIUS2B1 NE GEARBOX FAILED H CCHAK NONE O OTHER ININSP/MAINT 1 FS01911CK1386 0138 30169 ARIS MOUNT FAILED INSPECTION. REPLACED ARIS MOUNT 1G72 3U3 U H88EU E34NE 20030429000672003042900067 2003 4 29 CDFROTW1 420030425G2562452013002 BATTERY ARTEX 100HM BELL 204 UH1H 1181407SW ELT LEAKING B CF0RO OTHER O OTHER NRNOT REPORTED 1 WP25497DF 64677 11533 AT REMOVAL OF ELT BATTERY AT POSTED REMOVAL DATE IT WAS DISCOVERED THE BATTERY PACK HAD LEAKED AND CORRODED COMPONENTS WITHIN THE CASE. THERE WAS ALSO A CRACK NOTED ON THE BATTERY CASE WHICH APPEARS TO BE CAUSED BY OVER HEAT OR OVER PRESSURE. THE ELT IS CHECKED EVERY 100 HRS AND APPEARED TO BE WORKING CORRECTLY. THE MANUFACTURER WAS NOTIFIED OF THE PROBLEM. NO CAUSE HAS BEEN DETERMINED. 1G71 4U EXPA1G71 20030205000272003020500027CE 2003 2 5 CE03SDRM0001 120030121G25203034242ABS SEAT BACK LEAR 60 60LEAR 5170707CE CABIN BROKEN C K NONE O OTHER ININSP/MAINT 1 CE03 2410 175 AIRCRAFT ARRIVED AT REPAIR STATION WITH DISCREPANCY INDICATING THAT A PASSENGER SEAT BACK WAS BROKEN. PRELIMINARY INSPECTION FOUND SEAT BACK CRACKED ALONG ENTIRE LOWER LENGTH AT THE 8 HOLES USED FOR ATTACHMENT OF UPHOLSTERY. SENT SEAT BACK TO ERDA WHO INDICATED THAT THE HOLES FOR THE UPHOLSTERY ATTACHMENT IS AN UNAUTHORIZED ALTERATION PERFORMED BY WHOEVER COVERED THE SEAT. THE HOLES ARE NOT SUPPOSED TO BE THERE. INSPECTED 3 OTHER LEARJET MODEL 60 SEATS AND FOUND THE SAME HOLES. FINDINGS WERE DISCOVERED AT JETCORP, CRS DELR158D. 2L72 4F RTA10CE 20040301001312004030100131WP 2004 3 1 CHI2741 120030805G6210369D21100516A BLADE HUGHES369 369D 4470706WP MAIN ROTOR CRACKED B CHIRK NONE O OTHER ININSP/MAINT 1 NM09 3340 WHILE PERFORMING OFF AC INSPECTION OF MAIN ROTOR BLADE, UTILIZING EDDY CURRENT, DISCOVERED ONE CRACK EMANATING FROM FIRST LIGHTING HOLE AT APPROX STA 36.5 IN (C) CHANNEL. SECTION BLADE TO VERIFY EDDY CURRENT FINDINGS. CRACK EXTENDS FROM ID OF LIGHTING HOLE UP TO START OF BEND RADIUS. AC PARKED STATIC WITHOUT OR IMPROPER BLADE TIE DOWNS DURING GUSTING WINDS OR AROUND OTHER OPERATING AC. EXCESSIVE TENSION ON BLADE TIE DOWNS. MANUFACTURE DEFECT OR PRACTICES. (K) 1G71 3U H3WE 20030902001202003090200120NE 2003 9 2 CNQ8200360111 220030707G7200PW525A ENGINE CESSNA560 560XL 2076702CE PWA 545 PW545A NE RIGHT BURNED B E ENGINE SHUTDOWN J WARNING INDICATION CLCLIMB 1 SO152HB 5605222 DB0454 RT ENGINE OIL PRESSURE DROPPED ON CLIMBOUT. ALSO HAD A 10 PERCENT POWER LOSS. PILOT SHUT DOWN ENGINE. FOUND ENGINE HAD A FIRE MELTING PARTS OF ENGINE. 2L72 4F4 FRTA22CE E00059EN 20030805000352003080500035CE 2003 8 5 CSE001 220030605G74146224 MAGNETO MOONEYM20 M20K 5870220SW CONT O360 TSIO360MB 17025CE MCAULY2A34C 2A34C* GL ENGINE MISREPAIRED B NUVYK NONE W INADEQUATE Q C ININSP/MAINT 1 EA3590BE 251143 ENGINE WILL NOT RUN ON LEFT MAGNETO. INSPECTION IN THE WORKSHOP REVEALED THAT THE WOODRUFF DRIVE KEY BETWEEN THE DRIVE SHAFT AND DRIVE COUPLING WAS MISSING. 1L71 3O3 O 2A3 E9CE 5 CP3EA 20030124000132003012400013NM 2003 1 24 DHL2003755002 120030123G3260 LIGHT BOEING727 727225 1384077NM A DHLAKO NONE OTHER O OTHER APAPPROACH 1 SO01755DH 21857 1) WHEN LANDING GEAR WAS SELECTED DOWN, LEFT MAIN GREEN LIGHT FAILED TO ILLUMINATE. SECONDARY MAIN GREEN LIGHTS WERE ILLUMINATED. CYCLING LIGHTS DIMMER SWITCH GOT ALL GEAR LIGHTS WORKING. 2) REMOVED AND REPLACED KORRY LIGHT ASSEMBLY IAW B727 M/M 33-10-51 (LT GEAR). SYSTEM OPS CHECKED GOOD ON DUMMY RETRACTION IAW B727 M/M 32-30-00. 2L73 4F A3WE 20030902000492003090200049CE 2003 9 2 DXTA2003MD001 120030620G491066506502 DUCT CESSNA560 560XL 2076702CE APU MISALIGNED B DXTAO OTHER O OTHER NRNOT REPORTED 1 GL07608QS240 5605308 INSTALLATION OF NEW UPGRADED APU STARTER/GENERATOR P/N 9912499-29 IN LIEU P/N 9912499-22, REF: CE-560XL IPC 80-11-00 FIG 01 ITEM NR 1 AND NR 1A. THE NEW STARTER/GENERATOR END BELL IS 1INCH LONGER WHICH CAUSES A MISALIGNMENT IN THE INLET COOLING DUCT, AND HAND WORKING FOR INSTALLATION FOR ALIGNMENT PUTS STRESS ON 4EA. METAL TABS THAT ATTACHS DUCT TO THE INLET PANEL 2L72 4F RTA22CE 20030903001302003090300130WP 2003 9 3 E27R1730A 220030725G720031017262 TORQUE SENSOR CESSNA441 441 2076020CE GARRTTTPE331TPE331* 01514WP ENGINE OUT OF POSITION B EA ENGINE SHUTDOWN UNSCHED LANDING XF ENGINE FLAMEOUT FLT CONT AFFECTED CRCRUISE 1 WP07441SB4700 4410301 P77688 TORQUE SENSOR MATCHED CAM TENSION NUT FOUND TO BE LOOSE CAUSING LOSS OF FUEL PUMP DRIVE AND IN-FLIGHT FLAME OUT. ENGINE TIMES ARE APPROX. 1L72 3T3 TRTA28CE E2WE 20030903000262003090300026EA 2003 9 3 EA01 220030716G74141068255511 MAGNETO MOONEYM20 M20J 5870219SW LYC O360 IO360A1A 41514EA ENGINE FAILED G A UNSCHED LANDING Y ENGINE STOPPAGE CRCRUISE 1 EA011084B 200 243266 ENGINE FAILED IN FLIGHT. AIRCRAFT LANDED IN FIELD WITHOUT INCIDENT. INVESTIGATION REVEALED THAT THE DUAL MAGNETO HAD FAILED FROM BOTH SET OF POINTS NOT OPENING. 200 HRS ON MAGNETO SINCE OVERHAUL. POINTS ADJUSTED BY MECHANIC AT 100 HRS SINCE OVERHAUL WITHOUT REMOVING FROM ENGINE. MAGNETO REMOVED, POINTS SET IAW MM, MAGNETO OPERATION SATISFACTORY ON TEST BENCH AND REINSTALLED ON ENGINE. 1L71 3O3 O 2A3 1E10 20030606000452003060600045GL 2003 6 6 EA332003B0364 320030311G6114FP311A PROPELLER CESSNA206 U206G 2073356CE CONT O520 IO520* 17032SO HARTZLHCJ3Y PHCJ3YF1 GL HUB OVERSERVICED D O OTHER O OTHER NRNOT REPORTED 1 EA33756MS1488 U20604205 564849 FP311A GREASING PROP FOUND GREASE DID NOT COME OUT AFT ZERK FITTING HOLE ON SAME BLADE. AFT/TRAILING EDGE ZERKS WERE REMOVED. RATHER IT CAME OUT ANOTHER AFT GREASE ZERK FITTING HOLE. PROP WAS REMOVED AND SENT TO PROP SHOP WHO UPON DISASSEMBLY FOUND PROP HUB WAS COMPLETELY FILLED WITH GREASE. IT WAS NOTED ON DISASSY THERE IS NO SEAL IN AREA WHERE GREASE GOES. SEAL OCCURES BY A METAL TO METAL CONTACT OF SUFACES. TRACTOR PROP AFT GREASE ZERK. NO MORE THAN 1 OZ (APPROX 6 PUMPS OF A MANUAL GREASE GUN) IS TO BE PUT IN FITTING OR UNTIL IT COMES OUT AFT ZERK HOLE. MFG SAYS PUTTING GREASE IN FWD FITTING ON TRACTOR PROP WILL (REDUCE POSSIBILITY OF GREASE BYPASSING BEARING AREA AND ENTERING HUB CAVITY. 1H71 3O3 O A4CE E5CE 5 CP36EA 20030509001062003050900106CE 2003 5 9 EAE00103 120030417G29102607024324 LINE LEAR 35 35A 5170602CE HYD SYSTEM CRACKED E E18AO OTHER K FLUID LOSS LDLANDING 1 GL23610GA 35A073 LOST HYDRAULIC PRESSURE WHEN LANDING GEAR WAS EXTENDED. NO BRAKES AVAILABLE UPON LANDING. DRAG CHUTE DEPLOYED TO STOP AIRCRAFT. 2L72 4F A10CE 20030509000942003050900094 2003 5 9 EC3R200300001 420030424G2330145111 CONTROLLER GULSTMGV GV 3980116SO ENTERTAIN SYS CORRODED B EC3RO OTHER O OTHER NRNOT REPORTED 1 WP05 515 DURING A ROUTINE SCHEDULED INSPECTION, PASSENGER CABIN ENTERTAINMENT SYSTEM CONTROLLER P/N 1451-1-1 AND 1-1-2 COMPONENTS WERE BEING REPLACED DUE TO CUSTOMER REQUEST, PRIOR TO INSTALLATION A BENCH CHECK WAS PERFORMED ON UNITS AND THE UNITS FAILED TEST. UPON OPENING THE COVER OF THE UNITS FOR INSPECTION, CORROSION WAS NOTED ON THE INSIDE OF THE UNIT DUE TO THE INTERNAL 12 VOLT GELPACK BATTERY LEAKING, CORRODING INTERNAL IC COMPONENTS. UNITS INSTALLED IN THE AIRCRAFT EXHIBITED SIGNS OF CORROSION ALSO. UNITS CAN BE INSTALLED AT VARIOUS LOCATIONS WITHIN THE PASSENGER CABIN AND MAY BE INSTALLED ON VARIOUS OTHER MODEL AIRCRAFT. 2L72 4F RTA12EA 20030509001122003050900112CE 2003 5 9 EC3R200300002 120030425G2520613132421 STUD CESSNA172 172A 2072404CE SEAT CRACKED B EC3RK NONE O OTHER ININSP/MAINT 1 WP05142H 47245 DURING AN UNSCHEDULED INSPECTION IT WAS NOTED THAT THE PASSENGER SEAT ATTACHMENT STUD WAS CRACKED AT THE LOBE. A REPLACEMENT STUD WAS PROCURED AND INSTALLED AND UPON TORQUING THIS STUD TO THE SPECIFIED VALUE IT ALSO CRACKED. A RANDOM INSPECTION OF OTHER G-IV AIRCRAFT AT THIS FACILITY REVEALED CRACKED SEAT STUDS AS WELL. A TOTAL OF TWELVE (12) SEAT STUDS WERE FOUND TO BE CRACKED IN THIS SPECIFIC AIRCRAFT. 1H71 3O 3A12 20031230000872003123000087CE 2003 12 30 ENHA200320002 120031212G54121019100383 BULKHEAD BEECH 200 200BEECH 1152920CE RT NACELLE CRACKED E K NONE O OTHER ININSP/MAINT 1 AL0390PB 12272 BB125 RT NACELLE WAS WEARING AND CRACKING AT CONTACT WITH RT AFT LOWER COWL. REPLACED BULKHEAD. 1L72 4T A24CE 20031230000242003123000024CE 2003 12 30 ENHA20032002A 120031217G54121019100383 BULKHEAD BEECH 200 200BEECH 1152920CE RT NACELLE CRACKED D K NONE O OTHER ININSP/MAINT 1 AL0390PB 12272 BB125 RT NACELLE WAS WEARING AND CRACKING AT CONTACT WITH RT AFT LOWER COWL. REPLACED BULKHEAD 1L72 4T A24CE 20031117000942003111700094GL 2003 11 17 EOO2003F00003 220030913G732323065121 SHAFT HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL GOVERNOR SEIZED B EOORO OTHER J WARNING INDICATION NRNOT REPORTED 1 AL03CGPHC 869 180257D PILOT COMPLAINED OF AN ERRATIC GOV. FOUND THROTTLE SHAFT SEIZED. REPLACED UNIT. 1G71 3U3 U H3WE E4CE 20030115001432003011500143 2003 1 15 ERAA082930 420030102G344240008330208 INDICATOR SKRSKYS61 S61N 8142104NE COCKPIT INTERMITTENT H ERAAO OTHER O OTHER NRNOT REPORTED 1 FS01 1056 RADAR UNIT BLINKS ON & OFF. FOUND RADAR UNIT TO BE INTERMITTANT. RADAR UNIT HAD MAJOR WATER DAMAGE. REPAIRED TRACES, REMOVED CORROSION AND TESTED. 2G72 4U 1H15 20030423000732003042300073NE 2003 4 23 ERAA085141 120030212G62106117020201067 BLADE SKRSKYS61 S61N 8142104NE MAIN ROTOR DAMAGED H ERAAO OTHER O OTHER NRNOT REPORTED 1 FS01 4301 MAIN ROTOR BLADE HAS BLACK BIM. SENT FOR REPAIR. INSPECTED IAW SRM SA 4045-31E CHAPTER / SECTION 65-10-01 REV 5. PERFORMED 2 DAY LEAK CHECK IAW SER 50908; REPLACED BIM TRANSDUCER AND REINSTALLED BIM; RECHARGED SPAR IAW S-61N MM SA4045-80 REV MARCH 1, 1978 AT 4301.3. 2G72 4U 1H15 20030528000332003052800033SW 2003 5 28 ERAA086443 120030425G6510212040600005 HANGER ASSY BELL 412 412 1182202SW T/R DRIVE VIBRATION H ERAAO OTHER O OTHER NRNOT REPORTED 1 FS01169EH12002 33064 HANGER ASSY HAS HIGH FREQUENCY VIBRATION. COUPLING AND BEARING HANGER WERE PAINTED WITH PRIMER. NO DEFECTS NOTED FOR VIBRATION. DISASSEMBLED, STRIPPED PRIMER FROM COUPLINGS, CLEANED & VISUALLY INSPECTED ALL PARTS. HAD COUPLING CAD PLATING TOUCHED UP. REASSEMBLED IAW 412 CR&O INSTALLING NEW SEAL & ALL SERVICEABLE PARTS. PURGED BEARING WITH MOBIL 28 GREASE & REPACKED FLEX COUPLING WITH GREASE DATED 9-20-01. 1G72 4U H4SW 20030701000852003070100085EU 2003 7 1 ERAA087074 120030514G642010531714 HEAD BOLKMS105 BO105S 5626006EU TAIL ROTOR CRACKED H ERAAO OTHER O OTHER NRNOT REPORTED 1 FS01294EH13186 S675 TAILROTOR ASSY HAS CRACKED INNER SLEEVE BUSHING, CONTROL LEVER CLOSE TOLERANCE BOLT WORN. ACTION TAKEN: C/W PRELIMINARY INSPECTION AND FOUND INNER SLEEVE BUSHING CRACKED. DISSASSEMBLED, REMOVED PAINT, PRIMER AND VISUALLY INSPECTED ALL PARTS. INSTALLED NEW RING, NEW BUSHINGS IN BLADE GRIPS AND INNER SLEEVE BUSHINGS. MACHINE AND NDT INNER SLEEVE BUSHINGS. SEE NDT TEST. INSTALLED NEW CLOSE TOLERANCE BOLT AND BUSHING INCONTROL LEVERS, NEW GRIP SEALS, C/W 1200 HR / 2400 HR 6 YR INSPECTION ON TAILROTOR. COMPLIED WITH 300 HR/ 2400 HR BLADE INSPECTION. REASSEMBLED TAILROTOR WITH NEW WASHERS, NUTS. STATIC BALANCED. INSPECTION IAW MM CHAP 33, 34, 101 TABLE 101-10.1 &107 TT 13186.1 TSI -0-. 1G72 3U H3EU 20030701000862003070100086EU 2003 7 1 ERAA087075 120030514G3212D24873102 FLOAT BOLKMS105 BO105S 5626006EU MLG WORN E ERAAO OTHER O OTHER NRNOT REPORTED 1 AL01 6354 RT FLOAT ASSY IS DUE 6 MONTH INSPECTION. FLOAT ASSY HAS WORN FLOAT COVER, LEAKING BAG. 6 MONTH INSPECTION COMPLIED WITH AND REPLACED COVER AND BAG. AD AND SB COMPLIED WITH: ERA AAIP, AIR CRUISER M/M AND SB'S 120-81-3, 120-81-4, 120-82-4, 120-84-1, 802-25-1, 802-25-2. 1G72 3U H3EU 20030701000872003070100087EU 2003 7 1 ERAA087076 120030514G3212D24873101 CHECK VALVE BOLKMS105 BO105S 5626006EU LT FLOAT ASSY INOPERATIVE E ERAAO OTHER O OTHER NRNOT REPORTED 1 AL01294EH11470 S675 LT FLOAT ASSY DUE 6 MONTH INSPECTION, HAS BAD CHECK VALVE. CA: COMPLIED WITH 6 MONTH INSPECTION. COMPLIED WITH AAIP, AIR CRUISER M/M AND 120-81-3, 120-/1-4, 120-82-4. 120-84-1, 802-25-1, 802-25-2. 1G72 3U H3EU 20030701000882003070100088EU 2003 7 1 ERAA087077 120030514G3212D24762102 FLOAT BOLKMS105 BO105S 5626006EU MLG LEAKING E ERAAO OTHER O OTHER NRNOT REPORTED 1 AL01149EH252 S705 FLOAT BAG LEAKS AT SEAMS. PATCHED 4 PIN HOLES AND TESTED. 1G72 3U H3EU 20030701000892003070100089EU 2003 7 1 ERAA087078 120030514G3212D24873102 FLOAT BOLKMS105 BO105S 5626006EU MLG LEAKING E ERAAO OTHER O OTHER NRNOT REPORTED 1 AL01129EH 580 RT FLOAT ASSY DUE 18 MONTH INSPECTION. 18 MONTH INSPECTION COMPLIED WITH AND REPAIRED LEAKS. COMPLIED WITH AAIP, AIR CRUISER M/M SB'S 120-81-3, 120-81-4, 120-82-4, 120-84-1, 802-25-1, 802-25-2. 1G72 3U H3EU 20030701000902003070100090EU 2003 7 1 ERAA087079 120030515G65204619002003 GEARBOX BOLKMS105 BO105S 5626006EU TAIL ROTOR MAKING METAL E ERAAO OTHER O OTHER NRNOT REPORTED 1 AL01130EH11727 558 GEARBOX MAKING METAL. FOUND GEAR SET HAS PITTING ON TEETH, SCRAPPED GEAR SET, FOUND PITTING ON TAPERED ROLLER BEARINGS OUTER RACES. OVERHAULED GEARBOX ASSY IAW REM 304 AND SB BO-105-30-109. COMPLIED WITH SB BO-105-30-109, INSTALLED NEW PINION AND BEVEL GEAR, ALL NEW BEARINGS, SEALS AND PACKINGS. ADJUSTED BACKLASH, DISTANCE AND PATTERNS AS REQUIRED. COMPLIED WITH SB BO-105-30-109, ASB BO-105-30-111. 1G72 3U H3EU 20030701000912003070100091EU 2003 7 1 ERAA087080 120030515G642010531714 ROTOR HEAD BOLKMS105 BO105A EU TAIL ROTOR CRACKED E ERAAO OTHER O OTHER NRNOT REPORTED 1 AL01291EH13361 S842 INNER SLEEVE BUSHING CRACKED. PITCH CHANGE BUSHINGS WORN. DISASSEMBLED FOR INSPECTIONS PERFORMED VISUAL AND NDT INSPECTIONS AS REQUIRED REPAIRED WORN, DAMAGED AND CORRODED PARTS. COMPLIED WITH 1200HR / 6 YEAR INSPECTGION ON HUB. 300 AND 2400 HR BLADE INSPECTONS DONE. REASSEMBLED, TORQUED AND SAFETIED AS REQUIRED. INSTALLED 2 SERVICEABLE BLADES AND STATIC BALANCED. INSPECTED AND REPAIRED IAW BO105-REM301, MM CH 3334,101 AND 107. TT 13361.3 1G72 3U H3EU 20030701000922003070100092EU 2003 7 1 ERAA087081 120030515G3212D24762102 FLOAT BOLKMS105 BO105S 5626006EU MLG FAILED E ERAAO OTHER O OTHER NRNOT REPORTED 1 AL01125EH981 S562 THIS INFO FOR FAA SDR. RT FLOAT BAG HAS A HOLE AROUND TOP OFF VALVE. C/A: REPLACE 2 EA TOP OFF VALVES, REPLACED 1 EA PATCH, C/W 6 AND 18 MONTH INSPECTIONS. 1G72 3U H3EU 20030701000932003070100093SW 2003 7 1 ERAA087082 120030515G6730212076004101 SERVO BELL 412 412 1182202SW PWA PT6T PT6T3 52045EA TAIL ROTOR VIBRATION E ERAAO OTHER O OTHER NRNOT REPORTED 1 AL01418EH8482 33032 TAIL ROTOR SERVO HAS HIGH FREQ BUZZ IN TAIL ROTOR PEDALS WITH HYD SYSTEM TURNED ON. HAS CYLINDER WEAR, INTERNAL LEAKAGE ON PILOT VALVES REPLACED CYLINDER AND PILOT VALVES TESTED IAW CMM. 1G72 4U4 U H4SW E22EA 20030701001402003070100140SW 2003 7 1 ERAA087083 120030515G6410 BLADE BELL 412 412 1182202SW TAIL ROTOR DAMAGED E ERAAO OTHER O OTHER NRNOT REPORTED 1 AL01164EH2484 HB394 33004 TAIL ROTOR ASSY HAS HOLE IN BLADE TIP. TAIL ROTOR BLADE SN A-9675 HAS VOID AT TIP. REMOVED BLADES FROM YOKE ASSY. INSTALLED SERVICEABLE BLADE SN A-10483 AND TOUCHED UP PAINT ON BLADE SN 9724. CHECKED TRUNNION CENTERING AND PURGE LUBED . ASSEMBLED AND BALANCED IAW BHT-412-CR&O CH 64. 1G72 4U H4SW 20030701001412003070100141SW 2003 7 1 ERAA087084 120030515G6410 BLADE BELL 412 412 1182202SW TAIL ROTOR DAMAGED E ERAAO OTHER O OTHER NRNOT REPORTED 1 AL03164EH1553 33004 THIS INFO FOR FAA SDR. HOLE IN BLADE TIP AND FEATHERING BEARINGS LOOSE. PITCH HORN BUSHINGS MISSING. FEATHERING BEARINGS WORN AND BLADE HAD VOID AT TIP. TRUNNION BEARINGS HAD SOME ROUGHNESS. ACTION TAKEN: DISASSEMBLED, CLEANED & VISUALLY INSPECTED PARTS. REASSEMBLED IAW 412-CR&O INSTALLING SERVICEABLE BLADE, NEW TRUNNION ORGS & SEALS, NEW PITCH HORN BUSHINGS, MARVEL BALANCED, TORQUED AND SAFTIES IAW 412-CR&O CH 64. COMPLIED WITH TB 412-95-134. 1G72 4U H4SW 20030701001422003070100142SW 2003 7 1 ERAA087085 120030515G6220 SPINDLE BELL 412 412 1182202SW M/R HEAD DAMAGED E ERAAO OTHER O OTHER NRNOT REPORTED 1 AL03169EH15608 AAD00017M 33064 THIS INFO FOR FAA SDR. M/R HEAD DUE ERA SPINDLE INSPECTION. SINDLE SN A-356 HAD THREAD DAMAGE BEYOND LIMITS IAW 412-CR AND 0 CH. 62 (SCRAPPED) C/A: REMOVED SPINDLES AND VISUALLY INSPECTED ALL PARTS. C/W ERA SPINDLE INSPECTION AND TB 412-03-190. INSPECTED AND REASSEMBLED IAW 412-CR AND O CH 62 AND TB 412-03-190. PURGE LUBED ARM AND CLEVIS ASSEMBLY WITH OBIL 28 GREASE. REASSEMBLED WITH ORIGINAL SERVICEABLE BOLTS. COMPLIED WITH TB 412-03-190 ERA 412 SPINDLE INSPECTION. 1G72 4U H4SW 20030701001432003070100143GL 2003 7 1 ERAA087086 220030516G7321252464430NH FUEL CONTROL BOLKMS105 BO105S 5626006EU ALLSN 250C 250C20 03013GL ENGINE SURGES E ERAAO OTHER O OTHER NRNOT REPORTED 1 AL03292EH13364 562 ENGINE SURGES AT HIGH POWER SETTINGS. REPAIRED AND TESTED IAW MFG OHM FORM 15-602E. 1G72 3U3 U H3EU E4CE 20040205001012004020500101CE 2004 2 5 EWG2003F00001 120031103G2797 WIRE CESSNA525 525 2076601CE WILINTFJ44 FJ44 66000GL SPEED BRAKES CHAFED B EWGRO OTHER O OTHER NRNOT REPORTED 1 SO0592ND 5250186 PILOT REPORTS (SPEED BRAKE) CIRCUIT BREAKER POPS EVERY TIME SPEED BRAKES EXTEND MANUALLY OR IN AUTO MODE PROBLEM WAS ISOLATED TO A CHAFED WIRE BETWEEN PIN 5 AND PIN X AT CONNECTORS JR004 AND PS003. THE WIRE WAS ARCING AGAINST THE RT ENGINE MOTIVE FLOW LINE PN 631600052 LOCATED BEHIND ACCESS PANEL 192CR CAUSING A PIN HOLE AND SUBSEQUENTLY A FUEL LEAK AGGRAVATING THE DANGER. THE WIRE IN QUESTION IS ROUTED IN A BUNDLE AROUND THE FUEL SUPPLY LINE TO THE ENGINE AND THE MOTIVE FLOW LINE. THE WIRE WAS REPAIRED IAW WM AND SECURED AWAY FROM ANY OTHER ADJACENT STRUCTURE OR TUBING. MOTIVE FLOW LINE REPLACED. 1L72 4F4 FRTA1WI E3GL 20030912001182003091200118GL 2003 9 12 FCPR200300011 320030811G6111 SEPARATOR CESSNA180 180A 2072604CE CONT O470 O470* 17026SO MCAULY3A32C D3A32C* GL NR 3 BLADE LEAKING B FCPRO OTHER K FLUID LOSS NRNOT REPORTED 1 NM095004E25 50304 FOUND 1 BALL BEARING MISSING FROM BLADE NR 3, PN A1634-9, SEPARATOR PN B5223. 1H71 3O3 O 5A6 E273 5 CP21EA 20030826001042003082600104 2003 8 26 FCPR20030010 420030506G2210KFC325 AUTOPILOT SYS SOCATATBM TBM700 8682000EU PWA PT6 PT6A6 52043EA COCKPIT MALFUNCTIONED B FCPRO OTHER F FLT CONT AFFECTED CRCRUISE 1 NM09700PX48 249 PILOT REPORTED THAT WHILE FLYING IN IMC CONDITIONS WITH AUTO PILOT ENGAGED IN HEADING MODE, HE COMMANDED A COURSE CHANGE AND THE AUTOPILOT PERFORMED A TURN IN THE OPPOSITE DIRECTION. CONDUCTED AT P-STATIC TEST AND FOUND SEVERAL STATIC WICKS NOT BONDED CORRECTLY, ALSO FOUND THAT WHEN HIGH VOLTAGE APPLIED TO THE PROPELLER THE AUTOPILOT WOULD TURN ITSELF ON AND RANDOMLY GO INTO DIFFERENT MODES. THE AUTOPILOT AND AIRFRAME MANUFACTURES HAVE BEEN CONTACTED. 1L71 3T3 TRTA60EU E4EA 20030313001132003031300113CE 2003 3 13 FJC3869 120030224G281010092007117 ADAPTER BEECH 200 200BEECH 1152920CE FUEL CELLE CORRODED B K NONE O OTHER ININSP/MAINT 1 GL21553R 9400 BB589 WHILE PERFORMING MAINTENANCE TO REPAIR A FUEL LEAK THE TECHNICIAN NOTICED CORROSION ON DEFUEL ADAPTER PLATE IN NACELLE TANK. FURTHER INVESTIGATION FOUND SIGNIFICANT CORROSION ON DEFUEL ADAPTER PLATE ASSY. THIS PLATE ALSO SUPPORTS THE BOTTOM PORTION OF THE NACELLE FUEL PROBE. SECTION 28-40 OF THE KING AIR MM COVERS THE RECURRING 30 MONTH INSPECTION OF THE NACELLE FUEL PROBE FOR CORROSION AND CONTAMINATS. THIS PORTION OF THE PLATE ASSY. IS DIFFICULT TO SEE. MOISTURE IN THE LOW PART OF THE NACELLE TANK CAUSED CORROSION. 1L72 4T A24CE 20030429000462003042900046CE 2003 4 29 FJC4285 120030411G2730AN414 BOLT CESSNA340 340A 2076405CE CONT O520 TSIO520* 17040SO ELE BELLCRANK BENT B CTURK NONE O OTHER ININSP/MAINT 1 GL21234PS3469 340A0368 DURING INSPECTION OF THE ELEVATOR SYSTEM THE TECHNICIAN DISCOVERED THE ELEVATOR BELLCRANK BOLT BENT. WE HAVE FOUND SEVERAL BENT IN OUR FLEET, AND WOULD SUGGEST THAT ALL OPERATORS HAVE THE BOLT AND BEARING INSPECTED AS SOON AS POSSIBLE. 1L72 3O3 O 3A25 E8CE 20030423001732003042300173CE 2003 4 23 FLTICE0303002 120030318G3010CT464 CONTROL PANEL CESSNA210 T210M 2073451CE CONT O520 TSIO520* 17040SO COCKPIT ERRATIC D O OTHER O OTHER CRCRUISE 1 CE0377CF 21062679 CPS-OWNER FOUND THAT THE TKS QUANTITY INDICATOR FLUCTUATES IN FLIGHT FROM 9.8 TO LOWER LEVELS. THIS PROBLEM IS INTERMITTENT. REPLACED QUANTITY INDICATOR. 1H71 3O3 O 3A21 E8CE 20030826001002003082600100WP 2003 8 26 FRISBY03003 120030327G291041022021 HOUSING DOUG DC9 DC982 3022082WP HYD SYSTEM CRACKED B UFHRA UNSCHED LANDING KJ FLUID LOSS WARNING INDICATION CLCLIMB 1 SO05ISMEV 627 49669 AFTER TAKEOFF FLIGHT NR IG81 I-SMEV (MSN 49669) HAD FLIGHT INTERRUPTION, DIVERTED AFTER HYD SYST MALFUNCTION. LANDING GEAR WAS RETRACTED, NLG REMAINED EXTENDED WITH (RED) LIGHT (ON), LT AND RT HYD SYST PRESS WAS (0) PSI, AND (L/R HYD PRESS) ADV ON EOAP. ABNORMAL PROCEDURE WAS CARRIED OUT, SOON AS TRANSFER PUMP WAS SWITCHED (OFF), HYD PRESSURE CAME BACK AND NLG RETRACTED. LT HYD OIL QUANTITY WAS 3 QUARTS,WITH (AMBER) LIGHT (ON). ANALYSIS INDICATED LOSS OF PRESS IN BOTH HYD SYS WAS DUE TO FAILURE OF PTU, P/N 4100310-6, S/N 627, SO PTU WAS REMOVED FOR REPAIR. INSP REVEALED DRAIN PORT HSG., P/N 4102202-1 WAS CRACKED COMPLETELY AROUND CIRCUMFERENCE. PTU WAS SUBJECT OF PREVIOUS SB AND AD AND INCIDENT RPT 016/03.2L72 4F A6WE 20040223000352004022300035 2004 2 23 GARMINGTX327 420031215G34520110049000 TRANSPONDER PIPER PA44 PA44180 7104402SO ATC SYSTEM FALSE INDICATIOND O OTHER HJSELECT. POWER LOSS-50 PC WARNING INDICATION AFFECT SYSTEMS APAPPROACH 1 EA27633TA1174 341 4496052 LANDING GEAR FAILED TO RETRACT CAUSING DC BUS LOW VOLTAGE WARNING LIGHT TO FLASH ON AND OFF THREE TIMES UNTIL GEAR LOCKED UP. UPON SUBSEQUENT A.D.I.Z. REENTRY, TRANSPONDER SET TO 0440 AS PROVIDED BY ATC. TRANSPONDER DISPLAYED 0440 BUT TRANSMITTED 1200. AIRCRAFT PROPERLY ENTERED ADIZ IAW NOTAM PROCEDURES. ATC FILED PILOT DEVIATION REPORT TO FAA FOR FAILURE TO SQUAWK 0440. NOTE: REVERSE CURSOR NOT SEEN BY EITHER PILOT. 1L72 3O A19S0 20030203000932003020300093GL 2003 2 3 HDNA084070 220030131G723023057142 CASE BOLKMS105 BO105CBS 5626008EU ALLSN 250C 250C20B 03013GL COMPRESSOR CRACKED H HDNAK NONE O OTHER ININSP/MAINT 1 FS01915SH S340 CAE830496 ONE 4TH STAGE COMPRESSOR STATOR VANE BROKE OFF SEVERELY DAMAGING THE 4TH & 5TH STAGE COMPRESSOR BLADES WITH SUBSEQUENT COMPRESSOR STALLING AND LOW ENGINE POWER. 1G72 3U3 UNCH3EU E4CE 20030423000752003042300075EU 2003 4 23 HE66085914 120030407G6330L633M2010101 MOUNT UROCOPEC135 EC135T1 5620026EU GEARBOX LEAKING E HEEAO OTHER K FLUID LOSS NRNOT REPORTED 1 FS01135CR763 0164 GEARBOX MOUNT LEAKING, REPLACED. 1G72 3U H88EU 20030423000722003042300072EU 2003 4 23 HE66085916 120030407G6330L633M2010101 MOUNT UROCOPEC135 EC135T1 5620026EU GEARBOX DEFECTIVE E HEEAO OTHER O OTHER NRNOT REPORTED 1 FS01135CR763 0164 GEARBOX MOUNT LEAKING REPLACED 1G72 3U H88EU 20030414000742003041400074 2003 4 14 HE66085919 420030407G221041600297006 MODULE UROCOPEC135 EC135T1 5620026EU TRIM ACTUATOR DEFECTIVE E HEEAO OTHER O OTHER NRNOT REPORTED 1 FS01135CR 0164 AFTER INSTALLING THIS MODULE WE WERE HAVING TRIM ACTUATOR FAILURES AND AUTO PILOT WOULD NOT PASS BIT. REINSTALLED OLD MODULE. 1G72 3U H88EU 20030423000642003042300064EU 2003 4 23 HE66085949 120030411G6330L633M2010105 MOUNT UROCOPEC135 EC135T1 5620026EU GEARBOX FAILED H HEEAO OTHER O OTHER NRNOT REPORTED 1 FS01135CR 0164 AIRCRAFT BECAME ROUGH IN FLIGHT INSPECTED MOUNTS AND NOTICED THEY FAILED 1G72 3U H88EU 20030116000562003011600056 2003 1 16 HEEA083015 420030106G2312N0001552 CONNECTOR BELL 206 206L1 1182107SW VHF ANTENNA DAMAGED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW033905B 45598 BNC CONNECTOR WILL NOT LOCK ALL THE WAY DOWN ON VHF ANTENNA. 1G71 3U H2SW 20030116002152003011600215SW 2003 1 16 HEEA083127 120030108G6420 BEARING BELL 206 206L3 1182108SW DRIVE LINK WORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW033207Q 51540 TAIL ROTOR HEAD DRIVE LINK HAS WORN BEARINGS. REPAIRED. 1G71 3U H2SW 20030117000112003011700011SW 2003 1 17 HEEA083156 120030108G6220 BEARING BELL 206 206B3 1181506SW LINK ASSY WORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW032268V CT3097 3605 MAIN ROTOR HEAD LINK HAS A WORN BEARING. REPAIRED. 1G71 3U H2SW 20030121000512003012100051SW 2003 1 21 HEEA083253 120030108G3212206073926107 RELIEF VALVE BELL 206 206L3 1182108SW EMERGENCY FLOATSLEAKING E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW033207Q 51540 EMERGENCY FLOAT RELIEF VALVE LEAKING. REPAIRED. 1G71 3U H2SW 20030121001032003012100103SW 2003 1 21 HEEA083288 120030109G7720206375007103 INDICATOR BELL 206 206L3 1182108SW TOT INOPERATIVE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW0331077 51520 TOT INDICATOR INOPERATIVE. REPAIRED. 1G71 3U H2SW 20030121001772003012100177GL 2003 1 21 HEEA083327 220030109G732125490925 FUEL CONTROL BELL 206 206L3 1182108SW ALLSN 250C 250C30P 03013GL ENGINE MALFUNCTIONED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW036251X6971 51552 FUEL CONTROL UNIT PRODUCING INTERMITTENT START. UNABLE TO VERIFY DIFFICULTY REPORTED. NO DISCREPANICES NOTED. 1G71 3U3 U H2SW E1GL 20030121002432003012100243SW 2003 1 21 HEEA083362 120030109G79104369 CAP BELL 206 206L3 1182108SW OIL TANK DEFECTIVE E HEEAO OTHER W INADEQUATE Q C NRNOT REPORTED 1 SW0331077 51520 OIL TANK CAP AND ADAPTER DOES NOT FIT PROPERLY. SCRAPPED. 1G71 3U H2SW 20030127002682003012700268SW 2003 1 27 HEEA083743 120030115G7712222375077119 TRANSMITTER BELL 407 407 1182206SW TORQUE INDICATORMALFUNCTIONED E HEEAK NONE O OTHER ININSP/MAINT 1 SW03492PH 53390 DROPS TO ZERO OR PEGS OUT INTERMITTENTLY IN CRUISE FLIGHT. 1G71 3U O H2SW 20030128000322003012800032GL 2003 1 28 HEEA083785 220030115G720023064570 LINER BELL 407 407 1182206SW ALLSN 250C 250C* GL ENGINE DAMAGED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03492PH 53390 ENGINE HOWL AT 63-70 PERCENT N1. REPLACED WITH SERVICEABLE PART. 1G71 3U3 UO H2SW E4CE 20030128000332003012800033SW 2003 1 28 HEEA083786 120030115G779723065805 HARNESS BELL 407 407 1182206SW ENG INDICATING DAMAGED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03492PH 53390 HARNESS HAS HIGH RESISTANCE SHORT PIN C AND D AT TOP. REPLACED WITH SERVICEABLE PART. 1G71 3U O H2SW 20030128000462003012800046GL 2003 1 28 HEEA083799 220030115G732023072725 HYDROMECH UNIT BELL 407 407 1182206SW ALLSN 250C 250C* GL ENGINE DAMAGED E HEEAK NONE O OTHER ININSP/MAINT 1 SW03493PH3907 53393 HMU HAS SPLINE WEAR AND UNABLE TO BLEED. REPLACED WITH SERVICEABLE PART. 1G71 3U3 UO H2SW E4CE 20030128001062003012800106SW 2003 1 28 HEEA083850 120030116G6230 BEARING BELL 407 407 1182206SW ROD ASSY WORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03496PH HBFS17 53398 MAIN ROTOR HAS WORN BEARING ON ROD ASSY. 1G71 3U O H2SW 20030224000512003022400051NE 2003 2 24 HEEA084172 120030212G32437625001101102 MASTER CYLINDER SKRSKYS76 S76A 8143006NE BRAKE SYS LEAKING E HEEAO OTHER K FLUID LOSS NRNOT REPORTED 1 SW034253S 760035 PILOT RT MASTER CYLINDER LEAKS. 1G72 3U H1NE 20030224000632003022400063NE 2003 2 24 HEEA084184 120030212G5246A29261 BRACKET SKRSKYS76 S76A 8143006NE ACCESS DOOR BROKEN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW031546G 760076 RT TRANSMISSION ACCESS DOOR STRUT UPPER ATTACH BRACKET BROKEN. SCRAPPED. 1G72 3U H1NE 20030224000762003022400076NE 2003 2 24 HEEA084197 120030213G771454487129110 INDICATOR SKRSKYS76 S76A 8143006NE ALLSN 250C 250C* GL ENGINE N1 INTERMITTENT E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW034253S 760035 LIGHT INTERMITTENT. REPLACED WITH SERVICEABLE PART. 1G72 3U3 U H1NE E4CE 20030224000782003022400078NE 2003 2 24 HEEA084199 120030213G63207635109011105 BEVEL GEAR SKRSKYS76 S76A 8143006NE M/R GEARBOX CORRODED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW0322342970 A08100268 760096 MAIN ROTOR BEVEL GEAR HAS HEAVY FROSTING AND PITTING - GEAR WAS LOAD TESTED AND ACCEPTED PRIOR BY SIKORSKY PER SO NR DF 624-0001 ON APRIL 18, 2001. TO BE SENT TO VENDOR. 1G72 3U H1NE 20030224001102003022400110SW 2003 2 24 HEEA084225 120030120G2510407070620149 PANEL BELL 407 407 1182206SW SEAT CRACKED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03742PH 53461 SEAT PANEL CRACKED. 1G71 3U O H2SW 20030224001112003022400111SW 2003 2 24 HEEA084226 120030120G5320407070620150 TRIM PANEL BELL 407 407 1182206SW INTERIOR CRACKED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03494PH 53396 INTERIOR TRIM PANEL CRACKED. 1G71 3U O H2SW 20030227001022003022700102SW 2003 2 27 HEEA084406 120030212G2420SM20ACD300A21 CONTACTOR BELL 407 407 1182206SW ELECTRICAL FAILED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03406PH 53198 CAUSING START/AUTO RELIGHT CAUTION LIGHTS TO NOT ILLUMINATE. 1G71 3U O H2SW 20030227001042003022700104SW 2003 2 27 HEEA084408 120030212G2420SM20ACD300A21 CONTACTOR BELL 407 407 1182206SW ELECTRICAL FAILED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03490PH 53378 GENERATOR TAKES SEVERAL SECONDS TO GO OFFLINE WHEN SWITCH IS TURNED OFF. 1G71 3U O H2SW 20030227001152003022700115SW 2003 2 27 HEEA084421 120030212G6510222044003101 HANGER ASSY BELL 222 222U 1182140SW TAIL ROTOR CRACKED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW036992 47521 RUST INSIDE SPLINED ADAPTER; BEARING SEAL DAMAGED; AND HANGER SUPPORT CRACKED ON BOTTOM. REPLACED BEARING 222344606-101 DUE TO SEAL DAMAGED. REPLACED HANGER DUE TO CRACKED. REPAIRED. 1G72 3U H9SW 20030227001162003022700116SW 2003 2 27 HEEA084422 120030212G6510222044003101 HANGER ASSY BELL 222 222U 1182140SW TAIL ROTOR CORRODED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW036992 47521 RUST INSIDE SPLINED ADAPTER; BEARING SEAL DAMAGED; AND HANGER SUPPORT CRACKED ON BOTTOM. REPLACED BEARING DUE TO SEAL DAMAGED. REPLACED HANGER DUE TO CRACKED. REPLACED SHAFT DUE TO CORROSION. REPAIRED. 1G72 3U H9SW 20030227001192003022700119SW 2003 2 27 HEEA084425 120030212G3340930500251 SEARCH LIGHT BELL 230 230 1182149SW EXTERIOR MALFUNCTIONED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03911RC 23037 SEARCH LIGHT DOES NOT RETRACT ALL THE TIME. 1G72 3U NCH9SW 20030304001032003030400103 2003 3 4 HEEA084605 420030214G3442MI585200 INDICATOR BELL 412 412 1182202SW WX RADAR SYS WEAK E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW031202T 33112 WEATHER RADAR PAINTS WEAK RETURNS. FOUND RECEIVER SENSITIVITY WEAK. ADJUSTED TO SPECS. BENCH CHECK GOOD. 1G72 4U H4SW 20030305000402003030500040 2003 3 5 HEEA084622 420030214G344580511400003 CONTROL UNIT BELL 412 412 1182202SW WX RADAR SYS MALFUNCTIONED E O OTHER O OTHER NRNOT REPORTED 1 SW031202T 33112 AIR COLLISION AVOIDANCE SYSTEM SHOWS RS232 NR 2 FAIL - ERROR CODE 13 AT STARTUP. TO BE SENT TO VENDOR FOR REPAIR. 1G72 4U H4SW 20030305000602003030500060 2003 3 5 HEEA084642 420030214G3454066107800 RECEIVER BELL 412 412 1182202SW COCKPIT INOPERATIVE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03107X 33113 VHF NAVIGATION RECEIVER INOPERATIVE. POWER SUPPLY VOLTAGES ARE BAD. REPLACED BURNED RESISTORS R791, R792, R793 AND R794. ALSO REPLACED IC I101, TRANSISTOR Q718, Q719 AND Q103. REPAIRED PROBLEM. BENCH CHECK GOOD. 1G72 4U H4SW 20030305000632003030500063 2003 3 5 HEEA084645 420030214G3454071107600 AMPLIFIER BELL 412 412 1182202SW VOR SYSTEM CORRODED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW032258F 33073 NR 2 KDA CONNECTOR FROZE ON BOX. FOUND UNIT EXCESSIVELY CORRODED. CLEANED CORROSION AND REPLACED 18 HEADER PINS DUE TO CORROSION. BENCH CHECK GOOD. 1G72 4U H4SW 20030305000662003030500066 2003 3 5 HEEA084649 420030212G2312 POTENTIOMETER BOLKMS105 BO105S 5626006EU AUDIO PANEL FAILED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW033071K S859 AUDIO PANEL CONTROL UNIT VOLUME IS SENSITIVE. FOUND FACEPLATE INSERT, VOLUME POTENTIOMETER S101, AND TRANSFER SWITCH S102 BAD. REPLACED. BENCH CHECK GOOD. 1G72 3U H3EU 20030306000012003030600001 2003 3 6 HEEA084713 420030217G3455071121004 CONTROL BOX BELL 412 412 1182202SW COCKPIT DAMAGED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03142PH 33150 ADF CONTROL BOX DAMAGED, CAN'T CHANGE FREQUENCY. FOUND DISPLAY DS302, PHOTOCELL V301, PHOTOCELL LENS BAD AND SWITCH SPOOL NOT PROPERLY ALIGNED WITH SWITCH S304. REPLACED DISPLAY, PHOTOCELL, PHOTOCELL LENS AND ALIGNED SWITCH. REPAIRED. BENCH CHECK GOOD. 1G72 4U H4SW 20030306000172003030600017 2003 3 6 HEEA084730 420030217G2340A3016R MIXER BOX BELL 412 412 1182202SW COCKPIT FAILED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW031202T 33112 ICS MIXER BOX HAS NO SOUND. FOUND ICS AUDIO INTERMITTENTLY CUTTING OUT. CLEANED REAR CONNECTOR AND S1 SWITCHES. RESOLDERED WIRES TO CIRCUIT BOARD AND R72 VOLUME CONTROL. REPAIRED. BENCH CHECK GOOD. 1G72 4U H4SW 20030306000192003030600019 2003 3 6 HEEA084732 420030217G2340 SWITCH BELL 412 412 1182202SW INTERPHONE BOX LOOSE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW032148K 21497 36001 NR 2 COMM SWITCH IS LOOSE. FOUND LIGHT PANEL AND SELECTOR KNOB BAD, SWITCH S1 NOISY AND SWITCH S2 LOOSE. CLEANED SWITCH S1, TIGHTENED SWITCH S2, REPLACED SELECTOR KNOB AND LIGHT PANEL. REPAIRED. BENCH CHECK GOOD. 1G72 4U H4SW 20030306001222003030600122SW 2003 3 6 HEEA084824 120030221G6220412310400103 ROD BEARING BELL 412 412 1182202SW M/R HEAD WORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW0322347 36005 MAIN ROTOR HEAD HAS A WORN ROD BEARING. REPAIRED. 1G72 4U H4SW 20030307001632003030700163 2003 3 7 HEEA084907 420030228G34217660002113103 GYRO SKRSKYS76 S76A 8143006NE VERTICAL DAMAGED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03764P 760276 IMPACT INDICATOR ON VERTICAL GYRO WAS RED, INDICATING EXCESSIVE IMPACT. TO BE SENT TO VENDOR FOR REPAIR. 1G72 3U H1NE 20030311000402003031100040SW 2003 3 11 HEEA085056 120030228G3212206050248113 FLOAT BELL 206 206L3 1182108SW MLG LEAKING E HEEAO OTHER L NO TEST NRNOT REPORTED 1 SW036160Y 51609 DURING PRESSURE TESTING FLOAT BAG LEAKED THROUGH AFT SEAM. 1G71 3U H2SW 20030529000512003052900051NE 2003 5 29 HEEA086506 220030521G73140292858180 VALVE AEROSPAS355 AS355* EU TMECA ARRIELARRIEL1B2 60030NE FUEL PUMP LEAKING E HEEAO OTHER K FLUID LOSS NRNOT REPORTED 1 SW03971AE 3230 22118 FUEL PUMP METERING VALVE IS LEAKING FROM SEAL DRAIN. 1G72 3U3 U H11EU E19EU 20030529000702003052900070NE 2003 5 29 HEEA086512 120030521G2497 WIRE SKRSKYS76 S76A 8143006NE STARTER GEN BROKEN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW031546K 1204 760082 NR 2 GENERTOR WILL NOT COME ON LINE. INSPECTED BY ACCESSORY SHOP AND FOUND STATOR LEAD WIRE TO BRUSH BOX BROKEN OFF. ALSO FOUND BRUSHES CHIPPED. SENT TO NAASCO NORTHEAST FOR WARRANTY REPAIR. 1G72 3U H1NE 20030529000712003052900071NE 2003 5 29 HEEA086513 120030521G2435 ARMATURE SKRSKYS76 S76A 8143006NE STARTER GEN NOISY E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW035435V 808 760158 ARMATURE MAKING NOISE. TESTED OK - NO PROBLEM FOUND. 1G72 3U H1NE 20030529000902003052900090 2003 5 29 HEEA086522 420030521G34217660002113103 GYRO SKRSKYS76 S76A 8143006NE COCKPIT MALFUNCTIONED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03911MJ 760231 GYRO INTERMITTENTLY CAUSES ADI TO ERECT TO 45 DEGREE BANK AND ALSO INTERMITTENTLY CAUSES ADI TO TUMBLE. SENT TO B.F. GOODRICH AEROSPACE FOR WARRANTY REPAIR. 1G72 3U H1NE 20030529000912003052900091 2003 5 29 HEEA086523 420030521G22157690001802106 ACTUATOR SKRSKYS76 S76A 8143006NE AFCS INOPERATIVE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03760PH6850 760078 AFCS ACTUATOR INOPERATIVE. INSPECTED BY ACCESSORY SHOP AND FOUND UNIT NOT RESPONDING TO TEST, NO POWER COMING FROM UNIT. 1G72 3U H1NE 20030529000932003052900093NE 2003 5 29 HEEA086525 220030521G72619560137520 MAGNETIC SEAL AEROSPAS355 AS355* EU TMECA ARRIELARRIEL1D1 NE LEAKING E HEEAO OTHER K FLUID LOSS NRNOT REPORTED 1 SW03974AE 2653 9586 ENGINE MAGNETIC SEAL LEAKING. 1G72 3U3 U H11EU E19EU 20030530000352003053000035 2003 5 30 HEEA086541 420030522G2312071121524 CONTROL UNIT SKRSKYS76 S76A 8143006NE VHF SYSTEM MALFUNCTIONED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03762P 760060 VHF SYSTEM CONTROL UNIT IS UNREADABLE. IN SHOP REPAIR. 1G72 3U H1NE 20030530000362003053000036 2003 5 30 HEEA086542 420030522G3455071121815 CONTROL UNIT SKRSKYS76 S76A 8143006NE ADF SYSTEM MALFUNCTIONED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03762P 760060 ADF CONTROL UNIT IS UNREADABLE. IN SHOP REPAIR. 1G72 3U H1NE 20030609002032003060900203 2003 6 9 HEEA086576 420030522G3442MI585200 TRANSCEIVER SKRSKYS76 S76A 8143006NE WX RADAR SYS FAILED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW034253S 760035 NO DISPLAY MAP AND WEATHER MODE. SHOP REPAIR. 1G72 3U H1NE 20030528000842003052800084SW 2003 5 28 HEEA086598 120030521G6321209040177101 ADAPTER BELL 412 412 1182202SW ROTOR BRAKE CORRODED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW033893P 33012 CORROSION AND WORN. SENT TO H-S TOOL & PARTS FOR INSPECTION AND REPAIR. 1G72 4U H4SW 20030528000852003052800085SW 2003 5 28 HEEA086599 120030521G2844209062003001 SWITCH BELL 412 412 1182202SW FUEL SYSTEM LEAKING E HEEAO OTHER K FLUID LOSS NRNOT REPORTED 1 SW03107X 33113 SWITCH LEAKING - RIVETS ARE LOOSE. SCRAPPED. 1G72 4U H4SW 20030528000872003052800087SW 2003 5 28 HEEA086601 120030521G7921 BEARING BELL 412 412 1182202SW OIL COOLER LOOSE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW036559Z 51003838 36019 BEARING SPINS IN HOUSING; MAKING MUD. REPLACED BEARING 9104-NPP DUE TO WORN; BEARING W202PP DUE TO WORN. REPAIRED. 1G72 4U H4SW 20030528000882003052800088SW 2003 5 28 HEEA086602 120030521G7921209062502101 OIL COOLER BELL 412 412 1182202SW ENGINE OIL VIBRATES E HEEAO OTHER E VIBRATION/BUFFET NRNOT REPORTED 1 SW03142PH 33150 HIGH VIBRATION. REPAIRED. 1G72 4U H4SW 20030528000892003052800089SW 2003 5 28 HEEA086603 120030521G2620 GAUGE BELL 412 412 1182202SW EXTINGUISHER CORRODED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW036559Z 23776B1 36019 CORROSION ON PRESSURE GAUGE. REPLACED PRESSURE GAUGE 2725-709 DUE TO CORROSION. REPAIRED. 1G72 4U H4SW 20030528000912003052800091SW 2003 5 28 HEEA086604 120030521G2437209070264003 AMMETER BELL 412 412 1182202SW COCKPIT STICKS E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW032261D 33076 NR 2 SIDE STICKS WHEN GEN IS BROUGHT ON LINE. 1G72 4U H4SW 20030528001032003052800103SW 2003 5 28 HEEA086612 120030521G7810212061210001 DUCT BELL 412 412 1182202SW EXHAUST STACK CRACKED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW032149S 36002 EXHAUST STACK DUCT HAS LARGE CRACKS. REPLACED. 1G72 4U H4SW 20030529000232003052900023SW 2003 5 29 HEEA086621 120030521G243230126002 BATTERY BELL 412 412 1182202SW MAIN DISCHARGED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW033893P 33012 WENT TO ZERO VOLTS BEFORE START. REPAIRED. 1G72 4U H4SW 20030529000242003052900024SW 2003 5 29 HEEA086622 120030521G2611302319 SMOKE DETECTOR BELL 412 412 1182202SW CABIN WILL NOT TEST E HEEAO OTHER L NO TEST NRNOT REPORTED 1 SW0321498 36003 SMOKE DETECTOR WILL NOT TEST WITH SMOKE. 1G72 4U H4SW 20030529000282003052900028SW 2003 5 29 HEEA086626 120030521G6220 BEARING BELL 412 412 1182202SW M/R HEAD WEAK E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03800Y 9289 A469 33134 MAIN ROTOR HEAD BEARINGS WEAK. REPLACED DAMPER SET 412010145105 ( 2 EA), S/N LK3098 AND LK3109 DUE TO SEPARATING AND DROOP RESTRAINT NAS6607-D21 (4 EA) DUE TO WORN. REPAIRED. 1G72 4U H4SW 20030529000472003052900047SW 2003 5 29 HEEA086638 120030521G6210412015300109 BLADE BELL 412 412 1182202SW MAIN ROTOR DEBONDED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW032234714633 36005 LOWER FRETTING PADS IS UNBONDED, THE TRAILING EDGE POCKET AT THE ROOT HAS WATER TRAPPED INSIDE. SENT TO ROTOR BLADES, INC. FOR INSPECTION AND REPAIR. 1G72 4U H4SW 20030529000502003052900050SW 2003 5 29 HEEA086641 120030521G3212412050013113 FLOAT BELL 412 412 1182202SW MLG LEAKING E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW032149S 36002 EMERGENCY FLOAT LEAKING. 1G72 4U H4SW 20030529000612003052900061 2003 5 29 HEEA086648 420030521G3421504001790116 GYRO BELL 412 412 1182202SW COCKPIT PRECESSES E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW0321498 36003 PRECESS TO RIGHT AFTER ONE HOUR OF FLIGHT. REPAIRED. 1G72 4U H4SW 20030529000622003052900062SW 2003 5 29 HEEA086649 120030521G243551509002R GENERATOR BELL 412 412 1182202SW NR 1 MALFUNCTIONED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW032261D 33076 #1 GENERATOR NEEDS TO BE RESET BEFORE IT WILL GO ON LINE. SENT TO MASCO FOR INSPECTION AND REPAIR. 1G72 4U H4SW 20030529000662003052900066 2003 5 29 HEEA086652 420030521G237080510800001 DATA BOX BELL 412 412 1182202SW SKYWATCH FAILED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW032014K 33020 DATA BOX SKYWATCH FAILED IN FLIGHT. 1G72 4U H4SW 20030529000792003052900079 2003 5 29 HEEA086653 420030521G34168800T ENCODER BELL 412 412 1182202SW ALTIMETER INOPERATIVE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW032261D 33076 MESSAGE OUTSIDE ALTIMETER INOPERATIVE. REPAIRED. 1G72 4U H4SW 20030529000812003052900081SW 2003 5 29 HEEA086655 120030521G3212D24921119 FLOAT BELL 412 412 1182202SW MLG FAILED E HEEAO OTHER L NO TEST NRNOT REPORTED 1 SW032014K 33020 LT AFT FLOAT BAG FAILED 6 MONTH INSPECTION (LEAK). 1G72 4U H4SW 20030529000822003052900082SW 2003 5 29 HEEA086656 120030521G3212D24921119 FLOAT BELL 412 412 1182202SW MLG LEAKING E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW032149S 36002 EMERGENCY FLOAT LEAKING. 1G72 4U H4SW 20030530000032003053000003 2003 5 30 HEEA086665 420030522G3454071107600 INDICATOR KDA697 BELL 412 412 1182202SW NR VOR UNRELIABLE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW032261D 33076 NR 2 VOR NEEDLE UNRELIABLE - ERRATIC WITHIN 9 MILES OF VOR. IN SHOP REPAIR. 1G72 4U H4SW 20030611000912003061100091SW 2003 6 11 HEEA086699 120030522G3213412321104 CROSSTUBE BELL 412 412 1182202SW MLG CORRODED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW033893P602 33012 CROSSTUBE CORRODED BEYOND LIMITS IN ZONE B. TO BE SENT TO VENDOR FOR REPAIR. 1G72 4U H4SW 20030611001092003061100109EU 2003 6 11 HEEA086713 120030521G6420112131521 BEARING BOLKMS105 BO105S 5626006EU TAIL ROTOR WORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03133AE9070 S800 TAIL ROTOR HEAD HAS EXCESSIVE BEARING MOVEMENT. REPAIRED. 1G72 3U H3EU 20030528000032003052800003EU 2003 5 28 HEEA086728 120030522G2435 BRUSHES AEROSPAS355 AS355* EU STARTER GEN WORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03973AE381 9224 3229 WORN BRUSHES. UNIT WILL NOT START. INSPECTED BY ACCESSORY SHOP AND FOUND COMMENTATOR PITTED AND BURNED. IN REPAIR. 1G72 3U H11EU 20030528000542003052800054EU 2003 5 28 HEEA086740 120030522G2841B19030MC02 DISPLAY SNIAS 350 AS350B3 8680954EU COCKPIT FAILED E HEEAO OTHER N FALSE WARNING NRNOT REPORTED 1 SW03973AE 3229 FUEL FLOW RESOLVER INOPERATIVE WITH FAILURE SHOWN ON SHUT DOWN. TO BE SENT TO VENDOR. 1G71 3U H9EU 20030619000922003061900092SW 2003 6 19 HEEA086932 120030603G6420206011728001 TRUNNION BELL 407 407 1182206SW T/R HEAD WORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03498PH 53399 TAIL ROTOR HEAD TRUNNION HAS EXCESSIVE WEAR. 1G71 3U O H2SW 20030701000352003070100035SW 2003 7 1 HEEA086952 120030603G3246206053184121 SKID BELL 407 407 1182206SW MLG CORRODED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03501PH 53401 DISSIMILAR METAL CORROSION AROUND THE FLOAT BAG MOUNT INSERTS. TO BE SENT TO VENDOR. 1G71 3U O H2SW 20030701000532003070100053SW 2003 7 1 HEEA086961 120030603G7810206064203101 DUCT BELL 407 407 1182206SW EXHAUST CRACKED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03742PH 53461 EXHAUST DUCT CRACKED. REPLACED DUCT. 1G71 3U O H2SW 20030701000542003070100054SW 2003 7 1 HEEA086962 120030603G2820206064264101 LINE BELL 407 407 1182206SW FUEL SYSTEM CORRODED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03417PH 53038 DISSIMILAR METAL CORROSION DUE TO STEEL SLEEVE ON ALUMINUM TUBE. 1G71 3U O H2SW 20030701000552003070100055SW 2003 7 1 HEEA086963 120030603G5210206064819031A DOOR BELL 407 407 1182206SW CREW/PAX CRACKED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03492PH 53390 PAX CREW DOOR CRACKED. REPLACED DOOR. 1G71 3U O H2SW 20030701000572003070100057SW 2003 7 1 HEEA086964 120030603G5320206064902036S CHANNEL BELL 407 407 1182206SW FUSELAGE BROKEN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03407PH 53003 CHANNEL BROKEN. REPLACED CHANNEL. 1G71 3U O H2SW 20030701000582003070100058SW 2003 7 1 HEEA086965 120030603G7160206064912103 SEAL BELL 407 407 1182206SW COWLING TORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03417PH 53038 COWLING SEAL TORN. REPLACED SEAL. 1G71 3U O H2SW 20030701000592003070100059SW 2003 7 1 HEEA086966 120030603G2436206075447101 VOLT REGULATOR BELL 407 407 1182206SW GENERATOR INTERMITTENT E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03402PH 53159 GENERATOR FALLS OFF LINE INTERMITTENTLY. TO BE SENT TO VENDOR FOR REPAIR. 1G71 3U O H2SW 20030701000762003070100076SW 2003 7 1 HEEA086967 120030603G2424206075447101 VOLT REGULATOR BELL 407 407 1182206SW GENERATOR INOPERATIVE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03405PH 53207 VOLT REGULATOR TRIPS GEN FIELD CIRCUIT BREAKER. SENT TO MFG FOR CREDIT. 1G71 3U O H2SW 20030701000772003070100077SW 2003 7 1 HEEA086968 120030603G2913206076030117 PUMP BELL 407 407 1182206SW HYD SYSTEM NOISY E HEEAO OTHER E VIBRATION/BUFFET NRNOT REPORTED 1 SW03495PH 53397 HYD SYSTEM PUMP PRODUCING A HIGH PITCH NOISE. SENT TO MFG FOR CREDIT. 1G71 3U O H2SW 20030701000782003070100078SW 2003 7 1 HEEA086969 120030603G6730206076062107 SERVO BELL 407 407 1182206SW CYCLIC WORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03404PH 53188 CYCLIC SERVO HAS A WORN BEARING. TO BE SENT TO MFG FOR CREDIT. 1G71 3U O H2SW 20030701000792003070100079SW 2003 7 1 HEEA086970 120030603G6730206076062107 SERVO BELL 407 407 1182206SW CYCLIC WORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03723PH3741 53283 CYCLIC SERVO HAS A WORN BEARING. SENT TO MFG FOR CREDIT. 1G71 3U O H2SW 20030701000802003070100080SW 2003 7 1 HEEA086971 120030603G6730 BEARING BELL 407 407 1182206SW CYCLIC SERVO WORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03501PH 53401 BEARING THAT RT CYCLIC CONTROL TUBE CONNECTS TO HAS EXCESSIVE RADIAL PLAY. TO BE SENT TO MFG FOR CREDIT. 1G71 3U O H2SW 20030701000812003070100081SW 2003 7 1 HEEA086972 120030603G2810206362002103 CAP BELL 407 407 1182206SW FUEL CELL LEAKING E HEEAO OTHER K FLUID LOSS NRNOT REPORTED 1 SW03720PH 53277 FUEL LEAKING FROM AROUND CAP. TO BE SENT TO MFG FOR CREDIT. 1G71 3U O H2SW 20030701000822003070100082SW 2003 7 1 HEEA086973 120030603G2810206362002103 CAP BELL 407 407 1182206SW FUEL CELL LOOSE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03724PH 53327 PIN AT FUEL CAP KEEPS FALLING OUT. REPLACED. 1G71 3U O H2SW 20030701000832003070100083SW 2003 7 1 HEEA086974 120030603G2931212073905101 GAUGE BELL 407 407 1182206SW HYD PRESSURE LEAKING E HEEAO OTHER K FLUID LOSS NRNOT REPORTED 1 SW03724PH 53327 HYDRAULIC FLUID LEAKING AT GAUGE. REPLACED. 1G71 3U O H2SW 20030701000842003070100084SW 2003 7 1 HEEA086975 120030603G6340 STUD BELL 407 407 1182206SW THERMOSWITCH LOOSE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03724PH 53327 STUD SPINS IN HOUSING. REPLACED. 1G71 3U O H2SW 20030701001092003070100109SW 2003 7 1 HEEA086976 120030603G6340214040806003 PRESSURE SWITCH BELL 407 407 1182206SW TRANSMISSION INTERMITTENT E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03498PH 53399 TRANSMISSION PRESSURE SWITCH INTERMITTENTLY STICKS IN OPEN POSITION WHEN PRESSURE IS REMOVED. REPLACED. 1G71 3U O H2SW 20030701001122003070100112SW 2003 7 1 HEEA086977 120030603G2897222366621103 CONNECTOR BELL 407 407 1182206SW FUEL FILTER CORRODED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03498PH 53399 FUEL FILTER PIN IN CONNECTOR CORRODED OUT. REPLACED. 1G71 3U O H2SW 20030701001132003070100113SW 2003 7 1 HEEA086978 120030603G2810222366649101 VALVE BELL 407 407 1182206SW SUMP INOPERATIVE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03417PH 53038 SUMP VALVE INOPERATIVE. REPLACED. 1G71 3U O H2SW 20030701001142003070100114SW 2003 7 1 HEEA086979 120030603G2844222375077113 TRANSMITTER BELL 407 407 1182206SW OIL PRESSURE INOPERATIVE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03501PH 53401 TRANSMITTER INOPERATIVE, NO PRESSURE INDICATION. SENT TO MFG FOR CREDIT. 1G71 3U O H2SW 20030701001152003070100115SW 2003 7 1 HEEA086980 120030603G7712222375077119 TRANSMITTER BELL 407 407 1182206SW TORQUE OUT OF ADJUST E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03492PH 53390 TORQUE TRANSMITTER OUT OF LIMITS. SENT TO MFG FOR CREDIT. 1G71 3U O H2SW 20030701001162003070100116SW 2003 7 1 HEEA086981 120030603G7712222375077119 TRANSMITTER BELL 407 407 1182206SW TORQUE ERRATIC E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03407PH 53003 TORQUE TRANSMITTER MALFUNCTIONED, PRESSURE FLUCTUATES ERRATICALLY. TO BE SENT TO MFG FOR CREDIT. 1G71 3U O H2SW 20030701001172003070100117SW 2003 7 1 HEEA086982 120030603G6220407010100115 BEARING BELL 407 407 1182206SW M/R HEAD SEPARATED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03494PH3265 53396 BLUE BLADE FEATHERING BEARING SEPARATED. 1G71 3U O H2SW 20030701001182003070100118GL 2003 7 1 HEEA086983 220030603G731323001832 NOZZLE BELL 407 407 1182206SW ALLSN 250C 250C47B GL ENGINE BENT E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03494PH 53396 FUEL NOZZEL BENT. SCRAPPED. 1G71 3U3 UO H2SW E1GL 20030701001192003070100119GL 2003 7 1 HEEA086984 220030603G731323001832 NOZZLE BELL 407 407 1182206SW ALLSN 250C 250C47B GL ENGINE BENT E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03612PH 53199 ENGINE FUEL NOZZEL BENT. SCRAPPED. 1G71 3U3 UO H2SW E1GL 20030701001202003070100120GL 2003 7 1 HEEA086985 220030603G753223005366 BLEED VALVE BELL 407 407 1182206SW ALLSN 250C 250C47B GL ENGINE MALFUNCTIONED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03491PH 53386 BLEED VALVE PRODUCING HIGH MGT AT CRUISE. REPLACED. 1G71 3U3 UO H2SW E1GL 20030701001322003070100132GL 2003 7 1 HEEA086986 220030603G753223005366 BLEED VALVE BELL 407 407 1182206SW ALLSN 250C 250C47B GL ENGINE INOPERATIVE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03 13609 BLEED VALVE PRODUCING LOW POWER. REPLACED. 1G71 3U3 UO H2SW E1GL 20030701001332003070100133GL 2003 7 1 HEEA086987 220030603G753223005366 BLEED VALVE BELL 407 407 1182206SW ALLSN 250C 250C47B GL ENGINE INOPERATIVE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03499PH9188 53400 BLEED VALVE PRODUCING HIGH MGT. REPLACED. 1G71 3U3 UO H2SW E1GL 20030701001342003070100134GL 2003 7 1 HEEA086988 220030603G753223005366 BLEED VALVE BELL 407 407 1182206SW ALLSN 250C 250C20 03013GL ENGINE INOPERATIVE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03467PH 53142 BLEED VALVE PRODUCING HIGH TOT. REPLACED. 1G71 3U3 UO H2SW E4CE 20030701001352003070100135GL 2003 7 1 HEEA086989 220030603G753223005366 BLEED VALVE BELL 407 407 1182206SW ALLSN 250C 250C47B GL ENGINE INOPERATIVE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03496PH 53398 BLEED VALVE PRODUCING HIGH MGT. REPLACED. 1G71 3U3 UO H2SW E1GL 20030701001362003070100136GL 2003 7 1 HEEA086990 220030603G753223005366 BLEED VALVE BELL 407 407 1182206SW ALLSN 250C 250C47B GL ENGINE INOPERATIVE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03407PH 53003 BLEED VALVE PRODUCING HIGH TOT. REPLACED. 1G71 3U3 UO H2SW E1GL 20030701001372003070100137GL 2003 7 1 HEEA086991 220030603G753223005366 BLEED VALVE BELL 407 407 1182206SW ALLSN 250C 250C47B GL ENGINE INOPERATIVE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03612PH5650 53199 BLEED VALVE PRODUCING HIGH TOT. REPLACED. 1G71 3U3 UO H2SW E1GL 20030701001382003070100138GL 2003 7 1 HEEA086992 220030603G753223005366 BLEED VALVE BELL 407 407 1182206SW ALLSN 250C 250C47B GL ENGINE LOOSE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03494PH 53396 BLEED VALVE BODY EXCESSIVELY LOOSE. REPLACED. 1G71 3U3 UO H2SW E1GL 20030701001392003070100139GL 2003 7 1 HEEA086993 220030603G753223005366 BLEED VALVE BELL 407 407 1182206SW ALLSN 250C 250C47B GL ENGINE INOPERATIVE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03723PH4009 53283 BLEED VALVE PRODUCING HIGH TOT. REPLACED. 1G71 3U3 UO H2SW E1GL 20030610001022003061000102GL 2003 6 10 HEEA086996 220030603G7250 STRUCTURE BELL 407 407 1182206SW ALLSN 250C 250C* GL CHECK VALVE NICKED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03499PH 53400 CHECK VALVE SEAT FACE NICKED AND SCORED. REPLACED. 1G71 3U3 UO H2SW E4CE 20030610001072003061000107SW 2003 6 10 HEEA087003 120030604G243231908001 BATTERY BELL 407 407 1182206SW MAIN DISCHARGED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03741PH 53457 MAIN BATTERY DEAD. REPAIRED. 1G71 3U O H2SW 20030610001082003061000108SW 2003 6 10 HEEA087004 120030604G243231908001 BATTERY BELL 407 407 1182206SW MAIN WEAK E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03719PH 53266 MAIN BATTERY WEAK. REPAIRED. 1G71 3U O H2SW 20030610001092003061000109SW 2003 6 10 HEEA087005 120030604G2431 CONNECTOR BELL 407 407 1182206SW BATTERY CRACKED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03467PH 9805883 53142 BATTERY TEMP CONNECTOR CRACKED. REPAIRED. 1G71 3U O H2SW 20030610001102003061000110 2003 6 10 HEEA087006 420030604G34424000038 CONTROL HEAD BELL 407 407 1182206SW WX RADAR SYS ERRATIC E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03496PH 53398 FM CONTROL HEAD VOLUME CONTROL ERRATIC. FOUND VOLUME KNOB LOOSE ON SHAFT AND IS SPINNING DUE TO BEING CRACKED. REPLACED VOLUME KNOB. REPAIRED. BENCH CHECK GOOD. 1G71 3U O H2SW 20030610001112003061000111SW 2003 6 10 HEEA087008 120030604G6230406010401117 SWASHPLATE BELL 407 407 1182206SW MAIN ROTOR LEAKING E HEEAO OTHER K FLUID LOSS NRNOT REPORTED 1 SW03447PH4828 53114 MAIN ROTOR SWASHPLATE GREASE SEAL LEAKING. REPAIRED. 1G71 3U O H2SW 20030610001122003061000112SW 2003 6 10 HEEA087009 120030604G6230406010401117 SWASHPLATE BELL 407 407 1182206SW MAIN ROTOR LEAKING E HEEAO OTHER K FLUID LOSS NRNOT REPORTED 1 SW038595X4288 53267 MAIN ROTOR SWASHPLATE LEAKING GREASE. REPAIRED. 1G71 3U O H2SW 20030610001132003061000113SW 2003 6 10 HEEA087010 120030604G6220406010413119 PITCH LINK BELL 407 407 1182206SW MAIN ROTOR CORRODED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03417PH4419 53038 PITCHLINK HAS CORROSION ON ENDS OF TUBE. DAMAGE NOT VISIBLE UNTIL PAINT WAS REMOVED. 1G71 3U O H2SW 20030610001142003061000114SW 2003 6 10 HEEA087011 120030604G6230406010425107 LEVER BELL 407 407 1182206SW MAIN ROTOR WORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03493PH 53393 MAIN ROTOR LEVER ASSY HAS WORN BUSHINGS. 1G71 3U O H2SW 20030610001152003061000115SW 2003 6 10 HEEA087012 120030604G6230406010425107 LEVER BELL 407 407 1182206SW MAIN ROTOR WORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03447PH964 53114 WORN BUSHINGS. REPLACED 4 EACH BUSHINGS 406310406101 DUE TO WORN. REPAIRED. 1G71 3U O H2SW 20030610001172003061000117SW 2003 6 10 HEEA087014 120030604G6230406010425107 LEVER BELL 407 407 1182206SW MAIN ROTOR WORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03457PH625 53147 WORN BUSHINGS. REPLACED 4 EACH BUSHINGS 406310406-101 DUE TO WORN. REPAIRED. 1G71 3U O H2SW 20030610001192003061000119SW 2003 6 10 HEEA087016 120030604G6230406010426101 PITCH LINK BELL 407 407 1182206SW MAIN ROTOR WORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03493PH 53393 LINK ASSY HAS WORN BUSHINGS. 1G71 3U O H2SW 20030618000182003061800018 2003 6 18 HEEA087120 420030609G2330 SWITCH SKRSKYS76 S76A 8143006NE PA SIREN BROKEN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03911UK 1260 760275 BROKEN ON/OFF SWITCH. FOUND SWITCH S401 AND FUSE F101 BAD. REPLACED. REPAIRED. BENCH CHECK GOOD. 1G72 3U H1NE 20030618000212003061800021 2003 6 18 HEEA087123 420030610G2312064100900 TRANSCEIVER SKRSKYS76 S76A 8143006NE COMMS MALFUNCTIONED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW031546G 760076 SIDETONE GARBLED AND SCRATCHY. SHOP REPAIR. 1G72 3U H1NE 20030618000642003061800064 2003 6 18 HEEA087126 420030610G3451071121627 CONTROLLER SKRSKYS76 S76A 8143006NE DME MALFUNCTIONED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03762P 760060 CONTROLLER CAUSING DME PROBLEM. SHOP REPAIR. 1G72 3U H1NE 20030618000662003061800066 2003 6 18 HEEA087129 420030610G34424000038 CONTROL HEAD SKRSKYS76 S76A 8143006NE WX RADAR SYS STUCK E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03762P 760060 TEST SWITCH STICKS INTERMITTENTLY. SHOP REPAIR. 1G72 3U H1NE 20030618001292003061800129NE 2003 6 18 HEEA087137 120030610G29107665009801105 MODULE SKRSKYS76 S76C 8143008NE HYD SYSTEM CLOGGED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03505PH 760505 RETURN FILTER CLOGGING. TO BE SENT TO VENDOR FOR REPAIR. 1G72 3U NCH1NE 20030618001322003061800132NE 2003 6 18 HEEA087139 120030610G67307826003 SERVO SKRSKYS76 S76C 8143008NE ROTOR LEAKING E HEEAO OTHER K FLUID LOSS NRNOT REPORTED 1 SW03505PH 760505 ROTOR SERVO LEAKING. REPLACED SERVO. 1G72 3U NCH1NE 20030618001672003061800167 2003 6 18 HEEA087145 420030609G2220214074301105 AMPLIFIER BELL 214 214ST 1182106SW SCAS INOPERATIVE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW033897N 28106 DURING INSTALLATION THE SCAS WOULD NOT COME ON LINE WITH THIS AMP. COULD NOT ALIGN SCAS. ADJUSTMENTS COULD NOT BE MADE USING VARIABLE RESISTORS. SENT TO BELL HELICOPTER TEXTRON FOR WARRANTY REPAIR. REFERENCE: DMR 748396. 2G72 4U H10SW 20030618001892003061800189SW 2003 6 18 HEEA087155 120030609G6710 BEARING BELL 206 206L3 1182108SW BELLCRANK ASSY WORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW034835 51131 BELLCRANK ASSY HAS WORN BEARING. REPLACED BEARING MS27647-4 DUE TO WORN. REPAIRED. 1G71 3U H2SW 20030618002142003061800214SW 2003 6 18 HEEA087167 120030609G6320206031590003 BEARING BELL 206 206B3 1181506SW LINK ASSY WORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW0322751 CT2933 3627 WORN CENTER BEARING. REPLACED BEARING 206031590003 DUE TO WORN; BUSHING 206-031-564-003 DUE TO WORN. REPAIRED. 1G71 3U H2SW 20030619000022003061900002SW 2003 6 19 HEEA087173 120030609G6330 BEARING BELL 206 206L3 1182108SW SUPPORT DAMAGED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW038587X 51464 ONE OF THE ELASTOMERIC BEARINGS SEPARATED 360 DEGREES. REPAIRED. 1G71 3U H2SW 20030619000182003061900018SW 2003 6 19 HEEA087181 120030609G7933206075680107 INDICATOR BELL 206 206L3 1182108SW TOT MALFUNCTIONED E HEEAO OTHER N FALSE WARNING NRNOT REPORTED 1 SW0381671 51301 WRONG LIMITS FOR L-3 AIRCRAFT. 1G71 3U H2SW 20030619000322003061900032SW 2003 6 19 HEEA087186 120030609G2844206364601101 TRANSMITTER BELL 206 206L3 1182108SW FUEL PRESSURE FLUCTUATES E HEEAO OTHER N FALSE WARNING NRNOT REPORTED 1 SW036251X 51552 FUEL PRESSURE TRANSMITTER FLUCTUATES. 1G71 3U H2SW 20030619000342003061900034SW 2003 6 19 HEEA087188 120030609G29122111328 FILTER ELEMENT BELL 206 206L3 1182108SW FUEL SYSTEM INOPERATIVE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW0330KH 51527 FILTER ELEMENT INOPERATIVE. REPAIRED. 1G71 3U H2SW 20030619000472003061900047SW 2003 6 19 HEEA087197 120030609G79104369 CAP BELL 206 206L3 1182108SW OIL TANK LEAKING E HEEAO OTHER K FLUID LOSS NRNOT REPORTED 1 SW036748D 51106 OIL TANK CAP LEAKING THROUGH SHAFT. SCRAPPED. 1G71 3U H2SW 20030619000532003061900053SW 2003 6 19 HEEA087202 120030609G7714AG44A202 TACH GENERATOR BELL 206 206L3 1182108SW ENGINE INTERMITTENT E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW036748D 51106 TACH GEN IS INTERMITTENT. REPAIRED. 1G71 3U H2SW 20030619000652003061900065 2003 6 19 HEEA087210 420030609G2350PHI001L0001201 MIXER BOX BELL 206 206L3 1182108SW VHF SYS WEAK E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW0321497 51518 COPILOT VHF SIDE TONE RECEPTION WEAK. REPLACED. 1G71 3U H2SW 20030619000672003061900067SW 2003 6 19 HEEA087212 120030609G6230PHI2062002 DRIVE LINK BELL 206 206L3 1182108SW MAIN ROTOR MAST LOOSE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW0331077 51520 OUTER SPLINE HALF LOOSE ON MAST. REPAIRED. 1G71 3U H2SW 20030619000682003061900068SW 2003 6 19 HEEA087213 120030609G6520PHI2062003 HOUSING BELL 206 206L3 1182108SW SEAL LEAKING E HEEAO OTHER K FLUID LOSS NRNOT REPORTED 1 SW036251X 51552 TAIL ROTOR GEARBOX SEAL LEAKING. REPAIRED. 1G71 3U H2SW 20030619000692003061900069SW 2003 6 19 HEEA087214 120030609G6720PHI206L3957 TUBE BELL 206 206L3 1182108SW PITCH CONTROL CORRODED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW033107N 51512 CORROSION ON CONTROL TUBE. REPAIRED. 1G71 3U H2SW 20030620000172003062000017GL 2003 6 20 HEEA087236 220030610G73143865005 PUMP BELL 206 206B3 1181506SW ALLSN 250C 250C20J 03013GL FUEL SYSTEM MALFUNCTIONED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW032270G 3610 INTERMITTENT HANG STARTS ON FIRST START OF DAY. REPAIRED. 1G71 3U3 U H2SW E4CE 20030701000442003070100044SW 2003 7 1 HEEA087239 120030610G6230 BEARING BELL 412 412 1182202SW DRIVE LINK WORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW032261D A1570 33076 DRIVE LINK HAS A WORN BEARING. SHOP REPAIR. 1G72 4U H4SW 20030701000452003070100045SW 2003 7 1 HEEA087240 120030610G6230412010406109 DRIVE LINK BELL 412 412 1182202SW MAIN ROTOR WORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW032261D 33076 MAIN ROTOR DRIVE LINK HAS A WORN BEARING. SHOP REPAIR. 1G72 4U H4SW 20030701000462003070100046SW 2003 7 1 HEEA087241 120030610G6230412010406115 LINK BELL 412 412 1182202SW MAIN ROTOR WORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW032261D 33076 LINK HAS A WORN BEARING. SHOP REPAIR. 1G72 4U H4SW 20030701000472003070100047SW 2003 7 1 HEEA087242 120030610G6230412010406115 LINK BELL 412 412 1182202SW MAIN ROTOR WORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW032261D 33076 LINK HAS A WORN BEARING. SHOP REPAIR. 1G72 4U H4SW 20030701000482003070100048SW 2003 7 1 HEEA087243 120030610G6230412010406115 LINK BELL 412 412 1182202SW MAIN ROTOR WORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW032261D 33076 LINK HAS A WORN BEARING. SHOP REPAIR. 1G72 4U H4SW 20030701000492003070100049SW 2003 7 1 HEEA087244 120030610G3246412050016101 SHOE BELL 412 412 1182202SW MLG SKID WORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW032149S 36002 MLG SKID TUBE SHOE IS WORN. SHOP REPAIR. 1G72 4U H4SW 20030701000502003070100050GL 2003 7 1 HEEA087245 220030610G741249522 EXCITER BELL 206 206L3 1182108SW ALLSN 250C 250C30 03013GL ENGINE INOPERATIVE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW0341791 51465 EXCITER, INOPERATIVE. TO BE SENT TO VENDOR FOR REPAIR. 1G71 3U3 U H2SW E1GL 20030701000512003070100051 2003 7 1 HEEA087246 420030610G34225050010902 GYRO BELL 206 206L3 1182108SW ALLSN 250C 250C30 03013GL COCKPIT PRECESSES E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03129MR 51129 DIRECTIONAL GYRO PRECESSES. SHOP REPAIR. 1G71 3U3 U H2SW E1GL 20030701000522003070100052NE 2003 7 1 HEEA087247 220030610G75326064T56P04 BLEED VALVE BELL 214 214ST 1182106SW GE CT7TS CT71 30030NE ENGINE INOPERATIVE E HEEAO OTHER J WARNING INDICATION NRNOT REPORTED 1 SW035748M 28102 WITH ENGINE N1 ABOVE 90 PERCENT ANTI ICE LIGHT OFF CYCLED ANTI ICE SWITCH ON FUEL CONTROL. TO BE SENT TO VENDOR FOR REPAIR. 2G72 4U4 U H10SW E8NE 20030701000562003070100056NE 2003 7 1 HEEA087248 220030610G75326064T56P07 BLEED VALVE BELL 214 214ST 1182106SW GE CT7TS CT71 30030NE ENGINE INOPERATIVE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW035748M 28102 ENGINE BLEED VALVE MALFUNCTIONED, TEMPERATURE WOULD NOT RISE DURING ANTI ICE CHECK. TO BE SENT TO VENDOR FOR REPAIR. 2G72 4U4 U H10SW E8NE 20030701000612003070100061SW 2003 7 1 HEEA087249 120030610G2913206076022101 CLAMP CLARK 1000 1000CLARK 2230102SW PUMP DEFORMED E HEEAO OTHER K FLUID LOSS NRNOT REPORTED 1 SW03 10624 HYD PUMP HAS A DEFORMED CLAMP FROM SUPPLY P/N 8505075. TO BE SENT TO VENDOR. 1Q71 3R 2A6 20030701000622003070100062 2003 7 1 HEEA087251 420030610G2350PHI001L0001201 MIXER BOX BELL 206 206L3 1182108SW COMMS SYSTEM FAILED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW0341791 51465 MIXER BOX MALFUNCTIONED, CANNOT HEAR ON COPILOT SIDE. SHOP REPAIR. 1G71 3U H2SW 20030701000632003070100063 2003 7 1 HEEA087252 420030610G2561 LATCH BELL 206 206L3 1182108SW LIFE VEST BROKEN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW036160Y 51609 ONE LATCH ON STRAP IS BROKEN. REPLACED LIFE VEST. 1G71 3U H2SW 20030701000642003070100064 2003 7 1 HEEA087254 420030610G2561PHI10090 LIFE VEST BELL 206 206L3 1182108SW LEAKING E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW036748D 51106 LIFE VEST LEAKING. REPLACED. 1G71 3U H2SW 20030701000652003070100065SW 2003 7 1 HEEA087255 120030610G5302PHI206L13115B FITTING BELL 206 206L3 1182108SW TAILBOOM CRACKED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW036251X 51552 CRACKED UPPER RIGHT TAILBOOM FITTING. SHOP REPAIR. 1G71 3U H2SW 20030701000662003070100066SW 2003 7 1 HEEA087257 120030611G6720204001855001 BEARING BELL 412 412 1182202SW LEVER ASSY WORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW0322347 36005 TEFLON BAD ON BEARING. REPLACED BEARING (2 EA) MS276434 DUE TO WEAR. REPAIRED. 1G72 4U H4SW 20030701000672003070100067SW 2003 7 1 HEEA087258 120030611G6230 SEAL CLARK 1000 1000CLARK 2230102SW SWASHPLATE LEAKING E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03266P 574 REFS298 LEAKING GREASE UNDER BOOT. REPLACED SEAL (2 EA) 206-010-460-001 DUE TO LEAKING AND WEAR. REPAIRED. 1Q71 3R 2A6 20030701000942003070100094SW 2003 7 1 HEEA087259 120030611G6710 BEARING BELL 407 407 1182206SW IDLER ASSY WORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03498PH 53399 TAIL ROTOR IDLER ASSY HAS WORN BEARINGS. REPAIRED. 1G71 3U O H2SW 20030701000952003070100095SW 2003 7 1 HEEA087260 120030611G6510407040303119A BEARING BELL 407 407 1182206SW BLOWER SHAFT ROUGH E HEEAO OTHER K FLUID LOSS NRNOT REPORTED 1 SW03498PH 53399 FWD BEARING ROUGH; EXPELS DARK GREASE. REPAIRED. 1G71 3U O H2SW 20030701000962003070100096 2003 7 1 HEEA087261 420030611G34224020936904 TARSYN BELL 412 412 1182202SW COCKPIT INOPERATIVE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03142PH 33150 WILL NOT ERECT PROPERLY. REPLACED WITH SERVICEABLE PART. 1G72 4U H4SW 20030701000972003070100097SW 2003 7 1 HEEA087262 120030611G28104369 CAP BELL 206 206L3 1182108SW FUEL CELL LEAKING E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03129MR 51129 FUEL CAP LEAKING AROUND STEM. REPLACED WITH SERVICEABLE PART. 1G71 3U H2SW 20030701000982003070100098SW 2003 7 1 HEEA087263 120030611G32121100891S FITTING BELL 407 407 1182206SW MLG FLOAT CORRODED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW038595X 53267 MLG FLOAT FITTING CORRODED EXCESSIVELY, DUE TO IMPROPER PROTECTION DURING THE MANUFACTURING PROCESS. TO BE SENT TO MFG. 1G71 3U O H2SW 20030701000992003070100099SW 2003 7 1 HEEA087264 120030611G5302206032308121S FRAME BELL 407 407 1182206SW TAILBOOM CRACKED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW038595X 53267 TAILBOOM FRAME CRACKED AT UPPER RT MOUNT HOLE. TO BE SENT TO MFG. 1G71 3U O H2SW 20030701001002003070100100SW 2003 7 1 HEEA087265 120030611G3212206050247131 COVER BELL 407 407 1182206SW FLOAT TORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW038595X 53267 LT FWD BAG COVER TORN AND DETERIORATED. TO BE SENT TO MFG. 1G71 3U O H2SW 20030701001012003070100101SW 2003 7 1 HEEA087266 120030611G3212206050247132 COVER BELL 407 407 1182206SW FLOAT TORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW038595X 53267 RT FWD FLOAT BAG COVER TORN AND DETERIORATED. TO BE SENT TO MFG. 1G71 3U O H2SW 20030701001022003070100102SW 2003 7 1 HEEA087267 120030611G3212206050247135 COVER BELL 407 407 1182206SW FLOAT TORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW038595X 53267 LT CENTER FLOAT BAG COVER TORN AND DETERIORATED. TO BE SENT TO BELL HELICOPTER. 1G71 3U O H2SW 20030701001032003070100103SW 2003 7 1 HEEA087268 120030611G3212206050247138 COVER BELL 407 407 1182206SW FLOAT TORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW038595X 53267 RIGHT AFT FLOAT BAG COVER TORN AND DETERIORATED. TO BE SENT TO MFG. 1G71 3U O H2SW 20030701001102003070100110SW 2003 7 1 HEEA087269 120030611G2435206064203101 DUCT BELL 407 407 1182206SW START GEN CRACKED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW038595X 53267 STARTER GENERATOR DUCT CRACKED AT SEVERAL AREAS. TO BE SENT TO MFG. 1G71 3U O H2SW 20030701001212003070100121SW 2003 7 1 HEEA087270 120030611G7160206064909101 BELLMOUTH BELL 407 407 1182206SW FUSELAGE CORRODED E HEEAO OTHER W INADEQUATE Q C NRNOT REPORTED 1 SW038595X 53267 BELLMOUTH ASSY HAS CORROSION DUE TO IMPROPER PROTECTION DURING MANUFACTURER PROCESS. TO BE SENT TO MFG. 1G71 3U O H2SW 20030701001222003070100122SW 2003 7 1 HEEA087271 120030611G7110206064912103 SEAL BELL 407 407 1182206SW COWLING TORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW038595X 53267 COWLING SEAL TORN. TO BE SENT TO MFG. 1G71 3U O H2SW 20030701001232003070100123SW 2003 7 1 HEEA087272 120030611G6310206340300107 DRIVE SHAFT BELL 407 407 1182206SW M/R GEARBOX CORRODED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW038595X 53267 MAIN ROTOR GEARBOX DRIVE SHAFT HAS CORROSION ON EXTERIOR AND INTERIOR OF DRIVESHAFT. TO BE SENT TO BELL HELICOPTER. 1G71 3U O H2SW 20030701001242003070100124SW 2003 7 1 HEEA087273 120030611G6340214040806003 PRESSURE SWITCH BELL 407 407 1182206SW M/R GEARBOX INOPERATIVE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03493PH 53393 PRESSURE SWITCH INOPERATIVE, CAUTION LIGHT WILL NOT COME ON. TO BE SENT TO MFG. 1G71 3U O H2SW 20030701001252003070100125GL 2003 7 1 HEEA087274 220030611G753223005366 BLEED VALVE BELL 407 407 1182206SW ALLSN 250C 250C47B GL ENGINE INOPERATIVE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03723PH 53283 BLEED VALVE PRODUCING HIGH TOT. TO BE SENT TO VENDOR FOR REPAIR. 1G71 3U3 UO H2SW E1GL 20030701001262003070100126SW 2003 7 1 HEEA087275 120030611G793023066697 FILTER BELL 407 407 1182206SW OIL SYSTEM BYPASSING E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03496PH 53398 OIL FILTER INDICATOR POPPED. TO BE SENT TO MFG. 1G71 3U O H2SW 20030701001272003070100127SW 2003 7 1 HEEA087277 120030611G6210406010120101 BOLT BELL 407 407 1182206SW BLADE ERODED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03491PH 53386 BLADE BOLT SURFACE COATING ERODING AT SHANK END. SERIAL NUMBERS REMOVED ARE A-FS5891, A-FS5925 AND A-FS5927. TO BE SENT TO MFG. 1G71 3U O H2SW 20030701001442003070100144SW 2003 7 1 HEEA087278 120030611G6220406010413119 PITCH LINK BELL 407 407 1182206SW MAIN ROTOR CORRODED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW038595X 53267 PITCH LINK HAS CORROSION AT BARREL OF TUBE. SERIAL NUMBERS REMOVED ARE A-6011, A6133, A6137 AND A6138. TO BE SENT TO MFG. 1G71 3U O H2SW 20030701001452003070100145SW 2003 7 1 HEEA087279 120030611G6230406010427109 GIMBAL RING BELL 407 407 1182206SW MAIN ROTOR CORRODED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03491PH3360 53386 GIMBAL RING, CORRODED. TO BE SENT TO MFG. 1G71 3U O H2SW 20030701001462003070100146SW 2003 7 1 HEEA087280 120030611G6230406010428109 BUSHING BELL 407 407 1182206SW MAIN ROTOR GOUGED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW038595X 53267 MASTER SPLINE GOUGED AND OVERSIZED HOLE. TO BE SENT TO MFG. 1G71 3U O H2SW 20030701001472003070100147SW 2003 7 1 HEEA087281 120030611G6230406010428109 BUSHING BELL 407 407 1182206SW MAIN ROTOR WORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03491PH3360 53386 WORN PIVOT BORE. TO BE SENT TO BELL HELICOPTER. 1G71 3U O H2SW 20030701001482003070100148SW 2003 7 1 HEEA087282 120030611G6230406010429101 PIN BELL 407 407 1182206SW MAIN ROTOR WORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03491PH3360 53386 WORN AND PITTED. TO BE SENT TO MFG. 1G71 3U O H2SW 20030701001492003070100149SW 2003 7 1 HEEA087283 120030611G6710406012104103 PLATE BELL 407 407 1182206SW MAIN ROTOR DAMAGED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW038595X 53267 MECHANICAL DAMAGE BEYOND LIMITS. TO BE SENT TO MFG. 1G71 3U O H2SW 20030701001502003070100150SW 2003 7 1 HEEA087284 120030611G6710406012129101 LINK ASSY BELL 407 407 1182206SW MAIN ROTOR LOOSE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW038595X 53267 AXIAL PLAY BEYOND LIMITS. TO BE SENT TO MFG. 1G71 3U O H2SW 20030701001512003070100151SW 2003 7 1 HEEA087285 120030611G6510406040315111 SHAFT BELL 407 407 1182206SW TAIL ROTOR CORRODED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW038595X 53267 TAIL ROTOR DRIVESHAFT CORRODED DUE TO IMPROPER PROTECTION DURING MFG. TO BE SENT TO MFG. 1G71 3U O H2SW 20030701001522003070100152SW 2003 7 1 HEEA087286 120030611G6230406310411101 BOOT BELL 407 407 1182206SW MAIN ROTOR TORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW038595X 53267 MAIN ROTOR BOOT HAS LARGE HOLE/TORN. TO BE SENT TO MFG. 1G71 3U O H2SW 20030701001532003070100153SW 2003 7 1 HEEA087287 120030611G6710 BEARING BELL 407 407 1182206SW IDLER GEAR WORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03417PH 53038 M/R GEARBOX IDLER GEAR HAS A WORN BEARING. TO BE SENT TO MFG. 1G71 3U O H2SW 20030617001642003061700164SW 2003 6 17 HEEA087303 120030611G6300407010206103 BOOT BELL 407 407 1182206SW M/R DRIVE TORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW038595X 53267 MAIN ROTOR DRIVE RUBBER BOOT TORN AROUND CYLINDER. 1G71 3U O H2SW 20030617003352003061700335SW 2003 6 17 HEEA087324 120030611G5302407030801107 SKIN BELL 407 407 1182206SW TAILBOOM ASSY CORRODED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03742PH 53461 CORRODED AROUND LARSEN ANT MOUNT. REPLACED. 1G71 3U O H2SW 20030618000482003061800048SW 2003 6 18 HEEA087336 120030611G6510406040328103 BEARING BELL 407 407 1182206SW T/R DRIVE SHAFT OVERHEATED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03498PH2526 A1939 53399 ROUGH AND GREASE TURNING BLACK. REPLACED ADAPTER 406040328103, S/N A-FS3404 DUE TO CORROSION AND BEARING 407340339101, S/N ZV10920 DUE TO ROUGH ROTATION. REPAIRED. 1G71 3U O H2SW 20030910000032003091000003SW 2003 9 10 HEEA087362 120030611G2520 STRUCTURE BELL 407 407 1182206SW STORAGE BIN CRACKED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03491PH 53386 STORAGE BIN CRACKED. 1G71 3U O H2SW 20030619000282003061900028SW 2003 6 19 HEEA087377 120030611G5210407070620158 PANEL BELL 407 407 1182206SW CREW DOOR CRACKED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW034999 53323 CREW DOOR PANEL CRACKED. 1G71 3U O H2SW 20030619000632003061900063SW 2003 6 19 HEEA087404 120030611G6510407340339101 BEARING BELL 407 407 1182206SW T/R DRIVE OVERHEATED E HEEAO OTHER M OVER TEMP NRNOT REPORTED 1 SW03723PH 53283 TAIL ROTOR DRIVE BEARING PRODUCED HIGH TEMPERATURE. 1G71 3U O H2SW 20030619000732003061900073SW 2003 6 19 HEEA087407 120030611G6510407340339101 BEARING BELL 407 407 1182206SW T/R DRIVE ROUGH E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03407PH 53003 TAIL ROTOR DRIVE BEARING HAS A ROUGH SPOT. 1G71 3U O H2SW 20030701000602003070100060SW 2003 7 1 HEEA087437 120030612G6340407375005101 INDICATOR BELL 407 407 1182206SW TRANS OIL TEMP INOPERATIVE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03406PH 53198 TRANSMISSION OIL TEMP INDICATOR LIGHT DIM. SENT TO MFG FOR CREDIT. 1G71 3U O H2SW 20030701000682003070100068SW 2003 7 1 HEEA087438 120030612G2841407375006101 INDICATOR BELL 407 407 1182206SW FUEL QTY INOPERATIVE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03406PH 53198 FUEL QTY INDICATOR DISPLAY DIM. TO BE SENT TO MFG FOR CREDIT. 1G71 3U O H2SW 20030701000692003070100069SW 2003 7 1 HEEA087439 120030612G2841407375006101 INDICATOR BELL 407 407 1182206SW FUEL QTY INOPERATIVE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03405PH 53207 FUEL QTY INDICATOR GOES BLANK. TO BE SENT TO MFG FOR CREDIT. 1G71 3U O H2SW 20030701000702003070100070SW 2003 7 1 HEEA087440 120030612G2844407075024103 INDICATOR BELL 407 407 1182206SW FUEL PRESS AMP FAILED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03490PH 53378 FUEL PRESS AMP INDICATOR INTERNAL LIGHTS TOO DIM TO SEE INSTRUMENTS. TO BE SENT TO MFG FOR CREDIT. 1G71 3U O H2SW 20030701000712003070100071SW 2003 7 1 HEEA087441 120030612G7714407375012101 WIRE HARNESS BELL 407 407 1182206SW FADEC INOPERATIVE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03496PH 53398 FADEC DEGRADE LIGHT IN FLIGHT. TO BE SENT TO MFG FOR CREDIT. 1G71 3U O H2SW 20030701000722003070100072SW 2003 7 1 HEEA087442 120030612G2840407375016103 SIGNAL COND UNIT BELL 407 407 1182206SW FUEL INDICATION INOPERATIVE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03498PH 53399 FUEL LOW LIGHT REMAINS ON WITH FULL FUEL TANK. SENT TO MFG FOR CREDIT. 1G71 3U O H2SW 20030701000732003070100073SW 2003 7 1 HEEA087443 120030612G3110407375038101 PANEL BELL 407 407 1182206SW COCKPIT BROKEN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03417PH 53038 LIGHTED PANEL IS BROKEN AT AFT END NEXT TO THROTTLE GRIP. TO BE SENT TO MFG FOR CREDIT. 1G71 3U O H2SW 20030701000742003070100074SW 2003 7 1 HEEA087444 120030612G3110407375038101 PANEL BELL 407 407 1182206SW COCKPIT CRACKED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW038595X 53267 PANEL CRACKED ALONG EDGE TWO PLACES. TO BE SENT TO MFG FOR CREDIT. 1G71 3U O H2SW 20030701000752003070100075SW 2003 7 1 HEEA087445 120030612G5210407515108 CYLINDER BELL 407 407 1182206SW PAX DOOR BROKEN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03492PH 53390 LT AFT DOOR GAS CYLINDER SAFETY HOLES FOR END FITTINGS BROKEN OUT. TO BE SENT TO MFG FOR CREDIT. 1G71 3U O H2SW 20030701001042003070100104SW 2003 7 1 HEEA087446 120030612G5210 ROD END BELL 407 407 1182206SW DOOR CYCLINDER WORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03612PH 53199 PAX DOOR GAS CYLINDER ROD ENDS WORN. TO BE SENT TO MFG FOR CREDIT. 1G71 3U O H2SW 20030701001052003070100105SW 2003 7 1 HEEA087447 120030612G5610407541119 WINDOW BELL 407 407 1182206SW COCKPIT CRACKED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03402PH 53159 COCKPIT SLIDER WINDOW CRACKED. TO BE SENT TO MFG FOR CREDIT. 1G71 3U O H2SW 20030701001062003070100106SW 2003 7 1 HEEA087448 120030612G673041000413 SERVO VALVE CLARK 1000 1000CLARK 2230102SW MAIN ROTOR BINDING E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03 STICKING AND BINDING UNDER PRESSURE DURING FINAL TEST OF SERVO. SENT FOR WARRANTY REPAIR. 1Q71 3R 2A6 20030701001072003070100107SW 2003 7 1 HEEA087449 120030612G6520427042440103 ADAPTER BELL 407 407 1182206SW T/R GEARBOX LEAKING E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03495PH A1109 53397 ADAPTER AND WEAR SLEEVE REMOVED DUE TO OIL LEAKING BETWEEN SLEEVE AND ADAPTER. TO BE SENT FOR CREDIT. 1G71 3U O H2SW 20030701001082003070100108 2003 7 1 HEEA087450 420030612G342150400179015 INDICATOR BELL 407 407 1182206SW COCKPIT INOPERATIVE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03467PH 53142 ADI, WILL NOT CAGE WHILE ENERGIZED. REPAIRED. 1G71 3U O H2SW 20030701001112003070100111 2003 7 1 HEEA087451 420030612G34215040017901 INDICATOR BELL 407 407 1182206SW ATTITUDE INACCURATE E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03496PH 53398 ATTITUDE INDICATOR, SHOWS LEFT BANK IN CRUISE FLIGHT. REPAIRED. 1G71 3U O H2SW 20030701001282003070100128 2003 7 1 HEEA087452 420030612G3421 KNOB BELL 407 407 1182206SW ADI SEPARATED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03496PH 2029 53398 ADI INDICATOR CAGING KNOB CAME OFF. REPAIRED. 1G71 3U O H2SW 20030701001292003070100129 2003 7 1 HEEA087453 420030612G3421504001790116 GYRO BELL 407 407 1182206SW COCKPIT MALFUNCTIONED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03406PH 53198 HORIZON GYRO WILL NOT STAY ERECT. REPAIRED. 1G71 3U O H2SW 20030701001302003070100130 2003 7 1 HEEA087454 420030612G34225050010902 GYRO BELL 407 407 1182206SW COCKPIT SPINNING E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03724PH 53327 GYRO MODEL200DCL SPINS CONSTANTLY. SCRAPPED. 1G71 3U O H2SW 20030701001312003070100131GL 2003 7 1 HEEA087455 220030612G742053159 IGNITION LEAD BELL 407 407 1182206SW ALLSN 250C 250C20 03013GL IGNITER INTERMITTENT E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03457PH 53147 INTERMITTENT STARTING PROBLEM. REPLACED IGNITER. 1G71 3U3 UO H2SW E4CE 20030617001242003061700124GL 2003 6 17 HEEA087462 220030612G74216899084 IGNITER BELL 407 407 1182206SW ALLSN 250C 250C47B GL ENGINE MALFUNCTIONED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03491PH 53386 DELAYED LIGHT OFF. REPLACED IGNITER. 1G71 3U3 UO H2SW E1GL 20030617001672003061700167SW 2003 6 17 HEEA087468 120030612G282070079H000Y150 HOSE BELL 407 407 1182206SW FUEL SYSTEM KINKED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03499PH 53400 FUEL HOSE KINKED. REPLACED HOSE. 1G71 3U O H2SW 20030617002492003061700249SW 2003 6 17 HEEA087478 120030612G2497BD131 CONNECTOR BELL 407 407 1182206SW ELECTRICAL CORRODED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03406PH 53198 CONNECTOR CORRODED AND BURNED. SCRAPPED. 1G71 3U O H2SW 20030618000092003061800009SW 2003 6 18 HEEA087487 120030612G6240M8353633003L RELAY BELL 407 407 1182206SW ROTOR HORN STUCK E HEEAO OTHER N FALSE WARNING NRNOT REPORTED 1 SW03404PH 53188 ROTOR HORN RELAY STICKING. 1G71 3U O H2SW 20030618000122003061800012 2003 6 18 HEEA087490 420030612G3457N0010001 CONTROL UNIT BELL 407 407 1182206SW GPS MALFUNCTIONED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03457PH 53147 GPS CONTROL UNIT WOULD NOT ACKNOWLEDGE COMMANDS. SENT TO OUTERLINK FOR INSPECTION AND REPAIR. 1G71 3U O H2SW 20030618001782003061800178 2003 6 18 HEEA087516 420030610G2312064105430 TRANSCEIVER BOLKMS105 BO105S 5626006EU VHF SYS MALFUNCTIONED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW035031U S678 TRANSCEIVER HAS AN INTERMITTENT SQUEAL. SHOP REPAIR. 1G72 3U H3EU 20030618001792003061800179EU 2003 6 18 HEEA087517 120030610G781010562433 DUCT BOLKMS105 BO105S 5626006EU EXHAUST SYS TORN E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW033071K S859 DUCT HALF ASSY ABESTOS TORN. SHOP REPAIR. 1G72 3U H3EU 20030717000292003071700029SW 2003 7 17 HEEA088006 120030622G5610407030118105 CHIN BUBBLE BELL 407 407 1182206SW COCKPIT CRAZED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03491PH 53386 LEFT CHIN BUBBLE CRAZED BEYOND LIMITS. REPLACED WITH SERVICEABLE PART. 1G71 3U O H2SW 20030714001522003071400152EU 2003 7 14 HEEA088089 120030708G6320IFS010015 CLUTCH PLATE AEROSPAS355 AS355* EU TRANSMISSION OVERHEATED E HEEAO OTHER O OTHER NRNOT REPORTED 1 SW03732AE 2873 CLUTCH WON'T HOLD AND OVERHEATED. REPLACED WITH SERVICEABLE PART. 1G72 3U H11EU 20030919000672003091900067WP 2003 9 19 HXS2003F00001 120030603G6210369D21100516A BLADE HUGHES369 369D 4470706WP ALLSN 250C 250C20B 03013GL MAIN ROTOR CRACKED B HXSRO OTHER O OTHER NRNOT REPORTED 1 AL051088N3465 300679D MAIN ROTOR BLADE CRACKED ON TOP ROOT FITTING IN THE AREA OF BOLTS IN A CORDWISE DIRECTION FOLLOWING AD 96-10-09(B). 1G71 3U3 U H3WE E4CE 20030919000682003091900068EU 2003 9 19 HXS2003F00002 120030521G793070BM055010 CHIP DETECTOR SNIAS 350 AS350BA 8680817EU TMECA ARRIELARRIEL1B 6OO30NE ENGINE CONTAMINATED B HXSRO OTHER J WARNING INDICATION NRNOT REPORTED 1 AL056094U3683 2751 4815 PILOT CALLED IN AN AMBER CHIP LIGHT JUST AFTER LIFT OFF AND RETURNED TO BASE. INSPECTED ENGINE CHIP PLUGS AND FOUND A SMALL PIECE OF MATERIAL IDENTIFIED AS A SMALL BLACK PARTICLE OF CARBON WHICH IN THE MAINTENANCE MANUAL PLACES IT AS CATEGORY ONE. CLEANED CHIP PLUG AND PLACED AIRCRAFT BACK INTO SERVICE IAW MM. 1G71 3U3 UNCH9EU E19EU 20030509001212003050900121SW 2003 5 9 I05R086281 120030425G6230350A37112602 BUSHING CLARK 1000 1000CLARK 2230102SW MAIN ROTOR LOOSE B I05RO OTHER O OTHER NRNOT REPORTED 1 WP05 289 BUSHING LOOSE REPLACED LINK AND SPACER. 1Q71 3R 2A6 20030509001222003050900122SW 2003 5 9 I05R086282 120030425G6320704A33640021 SPACER CLARK 1000 1000CLARK 2230102SW SCISSOR LINK STUCK B I05RK NONE O OTHER ININSP/MAINT 1 WP05 289 SPACER STUCK IN LOOSE BUSHING OF SCISSOR LINK. REPLACED SCISSOR LINK AND BUSHING. 1Q71 3R 2A6 20030509001242003050900124EU 2003 5 9 I05R086284 120030425G771478899811 INDICATOR UROCOPEC130 EC130B4 EU TMECA ARRIUSARRIUS2B1 NE ENGINE NG INOPERATIVE B I05RO OTHER O OTHER NRNOT REPORTED 1 WP0526LB 290 3514 FIRST AND SECOND DIGITS ARE INTERMITTENT, ONE N/R BAR INOPERATIVE REPLACED INDICATOR WITH SERVICABLE UNIT. 1G72 3U3 U H9EU E34NE 20030509001252003050900125EU 2003 5 9 I05R086285 120030425G63201184964 OIL COOLER UROCOPEC130 EC130B4 EU TMECA ARRIELARRIEL2B NE GEARBOX LEAKING B I05RO OTHER O OTHER NRNOT REPORTED 1 WP0526LB 683 3514 OIL COOLER HAS FITTING LEAKING, REPLACED COOLER. 1G72 3U3 U H9EU E00054EN 20030509001262003050900126EU 2003 5 9 I05R086286 120030425G21213972A010000 BLOWER UROCOPEC130 EC130B4 EU TMECA ARRIELARRIEL2B NE TAIL BOOM INOPERATIVE B I05RO OTHER O OTHER NRNOT REPORTED 1 WP0529LB 15 3560 SINCE A/C DELIVERY BLOWER HAS NOT BEEN OPERATIONAL. REPLACED BLOWER. 1G72 3U3 U H9EU E00054EN 20030430002312003043000231EU 2003 4 30 I05R086287 120030425G6330L633M2010101 MOUNT UROCOPEC135 EC135P1 8680990EU GEARBOX FAILED H I05RO OTHER O OTHER NRNOT REPORTED 1 FS01551BA 188 MOUNT FAILED REPLACED MOUNT 1G72 3U O H88EU 20030915000272003091500027SO 2003 9 15 IS4R20030806A 120030806G214094E421 PRESSURE SWITCH B4500 PIPER PA31 PA31350 7103110SO HEATER CLOSED B K NONE O OTHER ININSP/MAINT 1 SO09 A97100018 CUSTOMER BOUGHT EXCHANGE HEATER. CORE RETURNED TO US HAD A DISTORTED COMBUSTION TUBE. FOUND COMBUSTION AIR PRESSURE SWITCH IN THE CLOSED POSITION 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 SWITCH DOES NOT GET TESTED IAW AD 96-20-07. THIS FR65D79-3EL HEATER WAS BUILT IN OCTOBER 1997. 1L72 3O A20SO 20030903000692003090300069CE 2003 9 3 IS4R269M 120030717G214051A45 COMBUSTION HEAD BEECH 55 95A55 1152704CE HEATER DEFECTIVE B O OTHER O OTHER NRNOT REPORTED 1 SO09 HEATER CORE RETURNED TO US BY CUSTOMER AFTER PURCHASING AN EXCHANGE/OVERHAUL HEATER. TEAR-DOWN/CLEANING OF CORE REVEALED COMBUSTION HEAD WITH A 3/16 X 1/4 INCH HOLE IN THE WALL OF THE COMBUSTION HEAD. THIS IS THE THIRD HEAD WE HAVE FOUND WITH A HOLE IN IT. A PRESSURE DECAY CHECK OF THE HEATER ASSEMBLY WILL FIND THESE HOLES QUICKLY, IF PERFORMED. RECOMMEND PRESSURE CHECK OF ALL COMBUSTION AIRCRAFT HEATERS FOR CONTINUED SAFE HEATER OPERATION. 1L72 3O 3A16 20030527001192003052700119EA 2003 5 27 ISO11030019 220030520G8530LW12416 EXHAUST VALVE CESSNA172 172K 2072430CE LYC O320 O320E2D 41508EA ENGINE BROKEN C A UNSCHED LANDING RJ PARTIAL RPM/PWR LOSS WARNING INDICATION CRCRUISE 1 SO117355G3449 17259055 L2788227A AIRCRAFT IN CRUISE AT 5000 FT., EXPERIENCED LOSS OF POWER, PILOT LANDED IN WHEAT FIELD, 2 POB, NO INJURIES, MINOR DAMAGE. 1H71 3O3 ONT3A12 E274 20030923000032003092300003GL 2003 9 23 JA00103 120030816G3260864203 PROXIMITY SENSOR BOMBDRBD700 BD7001A10 1390006GL MLG FALSE INDICATIONB O OTHER N FALSE WARNING LDLANDING 1 WP0167RX 840 9067 (BRAKE FAULT) ADVISORY MESSAGE COMES ON AFTER LANDING AND LOSS OF LT INBD AND OUTBD BRAKES. ON LGCEU FOUND LT MAIN GEAR INDICATOR AIR MODE, TARGETS OF BOTH SENSORS FOUND OUT OF PROXIMITY AND LT MAIN GEAR STRUT COMPLETELY DEPLETED, AFTER SERVICING OF STRUT, TARGETS OF PROX. SENSOR COMES TO NORMAL GROUND POSITION. POTENTIAL BRAKE FAILURE OF LT AND RT MLG BRAKES IN CASE OF PRESSURE LOSS ON BOTH MLG STRUTS! 2L72 4F RTT00003NY 20031010000792003101000079CE 2003 10 10 JV2R200300001 120030919G5311265312264004 FRAME RKWELLNA265 NA26565 7630107CE FUSELAGE CRACKED B JV2RK NONE O OTHER ININSP/MAINT 1 CE03801SS9808 9808 46540 CRACK FOUND UPON ROUTINE INSPECTION. CRACK IS APPOXIMATLY FOURTEEN INCHES INTO FRAME. APPOXIMATE LOCATION OF FRAME IS FS 264. 2L72 4J A2WE 20030910000042003091000004EU 2003 9 10 KBMA088820 120030726G6520350A33215300 BEARING AEROSPAS355 AS355* EU TAIL ROTOR WORN B KBMAO OTHER O OTHER NRNOT REPORTED 1 WP19270SH 1864 LAMINATE BEARINGS WORN EXCESSIVELY. REPLACED WITH NEW. 1G72 3U H11EU 20030910000052003091000005EU 2003 9 10 KBMA088821 120030726G6520350A33215300 BEARING AEROSPAS355 AS355* EU TAIL ROTOR WORN B KBMAO OTHER O OTHER NRNOT REPORTED 1 WP19270SH 1864 LAMINATE BEARINGS WORN EXCESSIVELY. REPLACED WITH NEW. 1G72 3U H11EU 20031023000852003102300085SO 2003 10 23 KENT200300001 120030925G5740 MOUNT PIPER PA28 PA28140 7102802SO LYC O320 O320* 41508EA AIL BELLCRANK CRACKED D K NONE O OTHER ININSP/MAINT 1 NM015FN 287625005 LEFT WING AILERON BELLCRANK MOUNT HOUSING IS CRACKED ON FWD HORIZONTAL FLANGE AT MOUNT BOLT LOCATION. TTAF 5665.7 1L71 3O3 O 2A13 E274 20031114000642003111400064CE 2003 11 14 L2498 120031031G571158221661 SPAR CAP CESSNA441 441 2076020CE GARRTTTPE331TPE331* 01514WP ZONE 500 CORRODED B LK0RK NONE O OTHER ININSP/MAINT 1 SO1584LJ 5503 4410084 DURING A ROUTINE INSPECTION SOME PAINT BLISTERING WAS NOTICED ALONG THE LT AFT SPAR UPPER CAP IN THE THE EXPOSED AREA OF THE LT WHEEL WELL. FURTHER INVESTIGATION REVEALED THAT THE SPAR CAP HAD SEVERE EXFOLIATION TYPE CORROSION AND WAS CAUSING THE SPAR CAP TO FLAKE APART. ONCE THE AFT SECTION OF SKIN WAS REMOVED, IT WAS NOTICED THAT THE CORROSION HAD EXTENDED ALL THE WAY THOUGHT THE CAP. INSPECTION OF THE REMAINING SPAR CAPS REVEALED NO CORROSION. 1L72 3T3 TRTA28CE E2WE 20030912000792003091200079SO 2003 9 12 LZ2R996K 220030718G749710357281 WIRE PIPER PA34 PA34200T 7103406SO CONT O360 TSIO360* 17025SO MAGNETO SEPARATED B O OTHER O OTHER NRNOT REPORTED 1 GL272930V 347970384 ENGINE MISSING ON ONE MAGNETO; PULLED MAG AND FOUND WIRE SEPERATED FROM CAPACITOR. 1L72 3O3 O A7SO E9CE 20030902000862003090200086NM 2003 9 2 M7103 120030701G6320A1814 BEARING ROBSINR22 R22BETA 7640110NM ENGINE OUTPUT FAILED G A UNSCHED LANDING F FLT CONT AFFECTED CRCRUISE 1 NM018362L838 42 2642 AIRCRAFT EXPERIENCED CLUTCH LIGHT DURING FLIGHT AND MADE PRECAUTIONARY LANDING IN PARKING LOT. NO DAMAGE TO AIRCRAFT DUE TO LANDING. EXAMINATION OF AIRCRAFT FOUND LOWER DRIVE BELT PULLEY BEARING FAILURE. PART TT 838.6, OVERHAUL LIFE OF PART 2200 HOURS. BEARING ASSEMBLY LAST INSPECTED 42.9 HOURS PRIOR TO FAILURE. ASSEMBLY PART NUMBER: A007-5 1G71 3O H10WE 20031113000412003111300041CE 2003 11 13 MD001 120030918G2750 DRIVE SYSTEM BEECH 90 65A90 1152908CE PWA PT6 PT6* 52043EA TE FLAP DAMAGED B O OTHER D INFLIGHT SEPARATION DEDESCENT 1 SO17290CC LJ132 UPON APPROACH TO SUA A SPLIT FLAP CONDITION WAS REPORTED. THE AIRCRAFT LANDED WITHOUT INCIDENT. SUBSEQUENT INVESTIGATION REVEALED A SEPARATION OF THE SWAGED END FITTING TO THE FLAP ACTUATOR CAUSING A BIND IN THE LEFT FLAP SYSTEM. P/N 12325Y116 FLAP DRIVE CABLE ASSEMBLY WAS REPLACED WITH NEW AND AN OVERHAULED FLAP ACTUATOR P/N 50-521198-3 WAS REPLACED AS A PRECAUTION. 1L72 3T3 T 3A20 E2NE 20041221000752004122100075NE 2004 12 21 MDR03038 120031215G6210151520604000 SPAR SKRSKYS64 S64E 8142604NE M/R BLADE CRACKED B JYDRK NONE O OTHER ININSP/MAINT 1 NM09CGESG10450 64M50895463 64065 THE BLADE WAS INSPECTED DUE TO A BIM INDICATION IN THE FIELD. DURING THE INSPECTION, A LEAK INDICATION WAS NOTED ON THE BOTTOM SIDE OF THE SPAR BETWEEN POCKETS 5 AND 6. AFTER REMOVAL OF POCKETS 5 AND 6, AND FPI INSPECTION REVEALED A CRACK IN THE SPAR RUNNING CHORD WISE, BEGINNING .7500 INCH FROM THE BACK WALL EXTENDING .8750 INCH TOWARD THE LEADING EDGE. PROBABLE CAUSE IS CORROSION PIT ON SPAR .8750 INCH FROM THE BACK WALL. 2G72 4U H4EA 20041221000482004122100048NE 2004 12 21 MDR03039 120031215G5320642066340105 ATTACH ANGLE SKRSKYS64 CH54B 8142610NE PWA JFTD12JFTD12A5A 52047NE FUSELAGE CRACKED B JYDRK NONE O OTHER ININSP/MAINT 1 NM09158AC13527 64081 DURING A SCHEDULED INSPECTION, LT ATTACH ANGLE, PN 6420-66340-105, WAS FOUND CRACKED AT STA 767.8 LBL 5.5, WL 177.1. THE CRACK ORIGINATED AT THE BOTTOM HUCK FASTENER AND TRAVELED DOWN TO THE EDGE OF THE ANGLE. THESE ANGLES ATTACH THE INTERCOSTALS TO THE CANTED WEB AT THE ABOVE-LISTED LOCATIONS. PROBABLE CAUSE IS FATIGUE. RECOMMENDATIONS TO PREVENT RECURRENCE, USE 7078-T6, .063 EXTRUSION, RATHER THAN ORIGINAL MATERIAL 7075-T6, .050 INCH BENT SHEET. 2G72 4U4 U H6EA E15EA 20030606000892003060600089CE 2003 6 6 N154DJ01 120030521G7120643042 BRACKET CESSNA303 T303 2073820CE CONT O520 TSIO520* 17040SO ENGINE MOUNT CRACKED B K NONE O OTHER ININSP/MAINT 1 SW99154DJ209 209 T30300230 246199R THE AIRCRAFT IS ON ROUTINE 100 HR INSPECTION. A CRACK WAS NOTED ON THE LOWER LT ENGINE MOUNT BRACKET. A DIE PENETRANT CHECK REVEALED A TOTAL OF THREE CRACKS. MFG HAS BEEN CONTACTED REGARDING THESES CRACKS, BUT WERE NOT INTERESTED AT ALL. AS THIS PART IS SUCH A LOW TIME ITEM (209HRS) MAYBE A FLEET WIDE CHECK SHOULD BE INITIATED. 1L72 3O3 O A34CE E8CE 20030826001092003082600109CE 2003 8 26 N3571Y 120030610G2710051316714 CONTROL WHEEL CESSNA182 182F 2072714CE COCKPIT STRIPPED G O OTHER F FLT CONT AFFECTED DEDESCENT 1 GL193571Y 18254471 ON ROUTINE SKYDIVING FLIGHT, THE APPROPRIATELY RATED AND QUALIFIED PILOT ENTERED A CROSS CONTROL MANEUVER TO CLOSE CABIN DOOR. UPON RETURNING TO NORMAL FLIGHT THE PIC EXPERIENCED LOSS OF AILERON CONTROL EXHIBITED BY CONTROL WHEEL ROTATING 360 DEGREES WITH NO MOVEMENT OF AILERONS. AFTER LANDING, PILOT INSPECTED THE AIRCRAFT AND FOUND THAT THE 3, AN507-1032R6 SCREWS THAT ATTACH CONTROL WHEEL ASSY (P/N 0513167-14) TO CONTROL COLUMN TUBE HAD BECOME LOOSE AND 2 HAD FALLEN OUT, THIS ALLOWED CONTROL WHEEL TO SPIN ON CONTROL COLUMN TUBE. INSPECTION REVEALED THAT THREADS IN CAST ALUMINUM CONTROL WHEEL WERE WORN AND STRIPPED OUT. 1H71 3O NT3A13 20040218000402004021800040EA 2004 2 18 N4848M 120031008G2432 CHARGER CURTISTRVAIRTRVAIR2000 2621606EA MASTER BATTERY BURNED P F ACTIVATE FIRE EXT. B SMOKE/FUMES/ODORS/SPARKS TXTAXI/GRND HDL 1 SO194848 I PURCHASED A 24 VOLT CHARGER FROM AIRCRAFT SPRUCE ABOUT 6 MONTHS AGO. IT WAS A PRISM BRAND IMPORTED BY CSB BATTERY IN FT. WORTH. IT WAS ADVERTISED NOT TO OVERCHARGE IF LEFT CONNECTED INDEFINITELY. I LEFT IT ON FOR 3 WEEKS WHILE I WAS TRAVELING. I RETURNED TO FIND THE ACID BOILED OUT OF THE BATTERY AND THE BATTERY MELTED. I TRIED TO RESOLVE THE PROBLEM WITH ALL PARTIES. I RETURNED THE CHARGER TO CSB. THEY TOLD ME THEY INSPECTED IT AND THERE WAS NOTHING WRONG AND THE PROBLEM WAS WITH MY BATTERY. 1Q71 3V ATC30 20030313001432003031300143EU 2003 3 13 NASA51181 220030307G7200U125924 NUT GULSTMG1159 G1159 3953505SO RROYCESPEY SPEY5118 54523EU ENGINE MISSING C NASAK NONE CW F.O.D. INADEQUATE Q C ININSP/MAINT 1 SW09848NA607 607 222 8978 IN JUNE 2000 DURING A ROUTINE POSTFLIGHT INSPECTION FOD WAS DISCOVERED ON THE LP COMPRESSOR 5TH STAGE BLADES. DURING A SUBSQUENT TEARDOWN IT WAS DISCOVERED THAT A LP COMPRESSOR OGV BOLT AND NUT AND CAME LOOSE AND CAUSED THE DAMAGE TO THE ENGINE. THE BOLT WAS FOUND LOOSE INSIDE THE LP COMPRSSOR DRUM BUT THE NUT AND WASHER WERE NOT FOUND. AT THE TIME, THE OVERHAUL FACILITY, ROLLS ROYCE CANADA (RRC) AND ROLLS ROYCE UK, THE MANAFACTURER, CONSIDERED IT AN ISOLATED INCIDENT EVEN THOUGH THERE HAD BEEN TWO SERVICE BULLETINS ISSUED FOR THIS ITEM DURING THE YEARS AND THERE WERE SEVERAL OTHER DOCUMENTED OCCURRENCES OF THIS PROBLEM. THE ENGINE HAD 607.8 TSO. IN MARCH 2002, SPEY ENGINE 8815 WHICH WAS INSTALLED ON ANOTHER G2L72 4F4 FRTA12EA E2EU 20040513000212004051300021EU 2004 5 13 NP0001 120030707G2910MY20751634 LINE AMD FALCONFALCON20 2730103EU GARRTTTFE731TFE7312B WP HYD SYSTEM CRACKED C K NONE K FLUID LOSS ININSP/MAINT 1 SW03384K 8679 387 ON POST FLT INSPECTION FOUND HYDRAULIC FLUID UNDER AND AROUND AFT END OF LT HYDRAULIC RESERVOIR. CLEANED AREA AND FOUND SMALL CRACK IN HYD SYSTEM RETURN LINE. REMOVED AND REPLACED LINE. 2L72 4F4 FRTA7EU E6WE 20040512000302004051200030EU 2004 5 12 NP0002 120030909G2910MY20751635 LINE AMD FALCONFALCON20 2730103EU HYD SYSTEM CRACKED C K NONE K FLUID LOSS ININSP/MAINT 1 SW03384K 8752 387 FOUND HYDRAULIC FLUID AROUND AFT END OF LT HYDRAULIC RESERVOIR. CLEANED AREA AND FOUND NOTHING. PRESSURIZED THE NR 1 HYDRAULIC SYST AND FOUND NO LEAK. AFTER SEVERAL FLIGHTS, FOUND SIMILAR HYDR FLUID TRACES AROUND HYD RESERVOIR BUT FOUND NO CRACK. CLEANED AREA AND RAN BOTH ENGINES FOR 30 MINUTES BEFORE LEAK APPEARED. COULD NOT SEE A CRACK VISUALLY. REMOVED AND REPLACED LINE. AFTER REMOVING LINE, IT HAD TO BE BENT BACKWARDS BEFORE CRACK WAS VISIBLE. THE ALUMINUM HYDRAULIC LINES IN THE AFT COMPARTMENT ARE ON THE TOP TEN HIT LIST FOR FAILURES. SUGGEST BEING DILIGENT IN LOOKING FOR LEAKS IN THE AFT COMPARTMENT. 2L72 4F RTA7EU 20031229001902003122900190CE 2003 12 29 OSO0720040003 120031201G561010138402521 WINDSHIELD BEECH 200 200BEECH 1152920CE COCKPIT FRACTURED G A UNSCHED LANDING O OTHER CRCRUISE 1 SO07207CW2387 BB1658 PILOTS FRONT WINDSHIELD SHATTERED AT ALTITUDE. THIS IS THE SECOND PILOTS WINDSHIELD TO BE REPLACED SINCE THE AIRCRAFT WAS MANUFACTURED IN 1999. THE FIRST PILOTS WINDSHIELD WAS REPLACED ON 12/27/2000,AT 1035 CYC,1187 HRS.TTAF(REASON UNKNOWN). THIS OCCURANCE HAPPENED AT TOTAL TIME OF AIR FRAME(TTAF)3574 HRS.AND CYCLES OF 3131. NO REASON GIVEN FOR FRACTURE OF W/S. 1L72 4T A24CE 20030605001602003060500160CE 2003 6 5 PG0306889 120030519G5522 SKIN BEECH 58 58P 1152744CE CONT O550 IO550* SO ELEVATOR CRACKED B HBKRK NONE O OTHER ININSP/MAINT 1 SW11981SS1363 TH1857 TH1857 CRACK FOUND ON TOP SIDE OF LEFT HAND ELEVATOR, JUST FORWARD OF OUTBOARD END OF TRIM TAB. CRACK EXTENDS FORWARD INBOARD FOR APPROXIMATELY THREE INCHES. 1L72 3O3 O A23CE E3SO 20030707001492003070700149EU 2003 7 7 R1561 120030626G2720F10A272129 PUSHROD TUBE AMD FALC10FALCON10 2730101EU ELEVATOR CHAFED B O OTHER O OTHER NRNOT REPORTED 1 CE03982MC8168 114 DURING INSPECTION FOR HYDRAULIC SEEP AT BOTTOM OF RUDDER, FOUND ELEVATOR SERVO PRESSURE LINE CHAFFED THROUGH RUDDER PUSH-PULL TUBE. SUSPECTED LINE WAS TIGHTENED WITH A PRELOAD THAT TWISTED THE LINE TO CHAFE ON THE RUDDER PUSH-PULL TUBE. THE LINE WAS LOOSENED AND REPOSITIONED ITSELF SO AS TO EXTEND AND RETRACT WITH CONTROL MOVEMENT WITHOUT INTERFERENCE WITH THE RUDDER PUSH-PULL TUBE. PUSH-PULL TUBE HAD A HOLE CHAFED THROUGH AND REQUIRED REPLACEMENT. THIS AREA IS ONLY INSPECTED DURING A 3B (3600 HOURS) OR C (6 YEARS) IAW THE MFG MM, CHAPTER 5-10-00. 2L72 4F A33EU 20031113000602003111300060EU 2003 11 13 R1765 120031009G2720F10A272129 PUSHROD TUBE AMD FALC10FALCON10 2730101EU RUDDER CHAFED B K NONE O OTHER ININSP/MAINT 1 CE0310HE 11476 111 INSPECTED RUDDER PUSH-PULL TUBE IAW SDRS AND ALERTS ARTICLE IN AVIATION MAINTENANCE MAGAZINE DATED OCTOBER 2003. FOUND ELEVATOR SERVO PRESSURE LINE CHAFED RUDDER PUSH-PULL TUBE. SUSPECTED LINE WAS TIGHTENED WITH A PRELOAD THAT TWISTED THE LINE TO RUB THE TUBE. THE LINE WAS LOOSENED AND REPOSITIONED ITSELF SO AS TO EXTEND AND RETRACT WITH CONTROL MOVEMENT WITHOUT INTERFERENCE WITH THE RUDDER TUBE. TUBE PART NUMBER F10A272129 HAD TO BE REPLACED. 2L72 4F A33EU 20030513002192003051300219WP 2003 5 13 R5XR2000003 220030422G7230 HOUSING ALIDSGTFE731TFE7313AR WP FAN SUPPORT MISOVERHAULED B K NONE W INADEQUATE Q C ININSP/MAINT 1 SW09 WHILE PERFORMING MODIFICATION TO 70821, THE EDM PROCEDURE BROKE THROUGH THE WALL OF THE HOUSING DUE TO ERROR IN SETUP OF EDM MACHINE. 4 F E6WE 20030513002202003051300220WP 2003 5 13 R5XR2000004 220030422G723030721601 HOUSING ALIDSGTFE731TFE7313AR WP FAN SUPPORT MISOVERHAULED B K NONE W INADEQUATE Q C ININSP/MAINT 1 SW09 P75129 WHILE PERFORMING MODIFICATION TO 70821, THE EDM PROCEDURE BROKE THROUGH THE WALL OF THE HOUSING DUE TO ERROR IN SETUP OF EDM MACHINE. 4 F E6WE 20030513000102003051300010SO 2003 5 13 RE401338 220030509G8520 LIFTER BEECH 35 V35A 1151544CE CONT O550 IO550B SO ENGINE CHIPPED D YYBRK NONE O OTHER ININSP/MAINT 1 GL037653N622 622 D8858 296565R 732 HRS TOTAL TIME, 622 HRS TIME SINCE OVERHAUL DUE TO PROP STRIKE. DURING ANNUAL INSPECTION OF AIRCRAFT, NUMBER 3 CYLINDER WAS REMOVED FOR LOW COMPRESSION 10/80. FOUND METAL, STEEL, ON SKIRT OF CYLINDER. NOTED VISUALLY THAT CAM WAS WORN DOWN IN CONTACT AREA OF LIFTER. REMOVED BOTH NR3 LIFTERS AND FOUND FACE PITTED (EST .030 INCH DEEP .040 DIA) AND EDGE OF FACE HAD SEVERAL PEICES CHIPPED OFF. REPAIR STATION INFORMATION WAS THAT NEW LIFTERS AND CAM WERE INSTALLED AT SUDDEN STOPAGE REPAIR. ENGINE WAS REMOVED FOR OVERHAUL AND SENT TO REPAIR STATION. 1L71 3O3 O 3A15 E3SO 20030205000322003020500032CE 2003 2 5 ROCK012303 120030123G27404014305 SWITCH RKWELLNA265 NA26565 7630107CE ALIDSGTFE731TFE7313AR WP STAB TRIM INOPERATIVE B O OTHER L NO TEST NRNOT REPORTED 1 CE0182CR 5320 46549 PILOT'S TRIM SWITCH BECAME INTERMITTENT AND THEN FAILED TO OPERATE COMPLETELY IN FLIGHT. CO-PILOT AND ALTERNATE TRIM SYSTEMS BOTH REMAINED FUNCTIONAL. TESTED AND REPLACED PILOT'S TRIM SWITCH AT DESTINATION. SYSTEM FUNCTIONED PROPERLY AFTER REPLACMENT OF SWITCH. 2L72 4J4 F A2WE E6WE 20031009001062003100900106WP 2003 10 9 RX8R2003001 120030915G5312369A3018 FIREWALL HUGHES369 369E 4470707WP ALLSN 250C 250C20B 03013GL ENGINE BAY CRACKED B RX8RK NONE O OTHER ININSP/MAINT 1 SO157166M5373 0145E CAE835438 UPON REMOVING THE UPPER ENGINE COMPARTMENT HEAT SHIELD FOR REPLACEMENT, A 4 INCH CRACK WAS DISCOVERED IN THE TOP OF THE ENGINE COMPARTMENT, ALONG THE RIVET LINE, WHERE THE TAIL BOOM STRUCTURE ATTACHES TO THE FIRESHIELD. OUR 2 OTHER M.D. 369E HELICOPTERS WERE INSPECTED AND ALSO HAD SIMILAR CRACKS IN THE SAME AREA. (N5247S, SN 0119E, 6066.0 HRS. 11463 LANDINGS AND N6508U, SN 0084E, 2793.0 HRS. 6816 LANDINGS) THIS AREA IS USUALLY COVERED BY THE HEAT SHIELD BLANKET WHICH IS NOT REMOVED FOR NORMAL INSPECTIONS. RECOMMEND THE MANUFACTURER ISSUE A SB OR AD TO THE INSPECTION CHECKLIST TO INSPECT THIS AREA PERIODICALLY. 1G71 3U3 U H3WE E4CE 20031113000712003111300071EU 2003 11 13 RX8R2003002 120031106G6320704A37630023 THERMOSWITCH UROCOP SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE MAIN GEARBOX INOPERATIVE B RX8RK NONE P NO WARNING INDICATION ININSP/MAINT 1 SO154048L1658 513 3020 9245 WHILE PERFORMING THE 6 YR. 2000 HR. INSPECTION TO TEST THE MAIN GEARBOX OIL TEMPERATURE PROBE, IT WAS DETERMINED THAT THE PROBE WAS INOPERATIVE AND HAD TO BE REPLACED. WE PERFORMED THE SAME TEST ON ANOTHER AS350B2 AIRCRAFT (N4043L, SN 3015) ON OCT. 23, 2003 AND FOUND THE SAME PROBLEM, THE PROBE WAS INOP. 6 YEARS IS A LONG TIME TO WAIT TO PERFORM THE TEST ON THE TEMP PROBE. IT IS IMPOSSIBLE TO SAY HOW LONG THESE PROBES HAVE BEEN INOP. AS EASY AS THE TEST IS, WE WOULD RECOMMEND THAT IT BE PERFORMED EACH 3 YEARS OR 1200 HRS. WHEN THE M.G.B. OIL IS CHANGED. 1G71 3U3 U H9EU E19EU 20030205000332003020500033NE 2003 2 5 S88R554J 220030116G72610292100560 SEAL RING SNIAS 350 AS350B2 8680813EU TMECA ARRIELARRIEL1D1 NE OIL FILTER ASSY DISTORTED B ED ENGINE SHUTDOWN RETURN TO BLOCK O OTHER TXTAXI/GRND HDL 1 SO215202Y 3085 9513 ENGINE OIL PRESSURE LOSS RESULTED FROM DISTORTION OF THE DRAIN VALVE SEALING RING WITHIN THE OIL FILTER ASSEMBLY. INDENTATIONS ON THE SEALING RING CORRESPONDING TO HOLES IN THE FILTER BASE BECAME MISALIGNED DURING FILTER ELEMENT INSPECTION AND FAILED TO PRESENT A FLAT REGISTER TO THE FILTER BASE. THE INDENTATIONS MAY BE ASSOCIATED WITH OVER-TIGHTENING OF THE FILTER BOLT DURING PRIOR MAINTENANCE. THE SEALING RING IS NOT NORMALLY REPLACED DURING OIL FILTER ELEMENT INSPECTION OR REPLACEMENT. 1G71 3U3 U H9EU E19EU 20030313001492003031300149CE 2003 3 13 SDR21903 120030219G793026060152 INDICATOR CESSNA208 208B 2073701CE INSTRUMENT PANELSHORTED E EA ENGINE SHUTDOWN UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 SW1790GL 11493 208B0229 PILOT OBSERVED SMOKE IN AND UPON SCANNING INSTRUMENTS, NOTICED LOWER THAN NORMAL OIL PRESSURE AND HIGHER THAN NORMAL OIL TEMP. ENGINE WAS SHUT DOWN. PILOT ALSO REPORTED FACE OF INSTRUMENT GLOWING AS CABIN FILLED WITH SMOKE. PILOT DONNED O2 MASK AS SMOKE THICKENED. MASTER POWER WAS NEVER SHUTDOWN AND 5 AMP BREAKER NEVER OPENED AUTOMATICALLY NOR WAS IT PULLED. AFTER LANDING AND SECURING THE MASTER SWITCH THE SMOKE CLEARED. ALL DAMAGE APPEARED TO BE CONTAINED INTERNALLY AND SMOKE MOST LIKELY EXITED INSTRUMENT THRU THE VENT FITTING. 1H71 3T A37CE 20031230000222003123000022SO 2003 12 30 SLACK 120031202G3213 STRUT PIPER PA28 PA28140 7102802SO MLG CRACKED D K NONE O OTHER ININSP/MAINT 1 EA25154233690 287325064 DURING 100 HR. INSPECTION IAW SB 1131 THE LT MAIN GEAR UPPER STRUT CYLINDER WAS CRACKED AS DEPICTED IN THE BULLETIN. THE PART WAS DYE CHECKED AT THE PREVIOUS INSPECTION WITH NO CRACK EVIDENT. THE CRACK IS APPROX. 2 IN. LONG STARTING AT THE BOTTOM OF THE OUTBOARD (EAR). 1L71 3O 2A13 20031230000712003123000071CE 2003 12 30 SPT 120031008G2432 CHARGER CESSNA305 305A 2074002CE MASTER BATTERY BURNED P F ACTIVATE FIRE EXT. B SMOKE/FUMES/ODORS/SPARKS TXTAXI/GRND HDL 1 SO194848 N4848M PURCHASED A 24 VOLT CHARGER ABOUT 6 MONTHS AGO. IT WAS A PRISM BRAND IMPORTED BY CSB BATTERY IN FT. WORTH. IT WAS ADVERTISED NOT TO OVERCHARGE IF LEFT CONNECTED INDEFINITELY. I LEFT IT ON FOR 3 WEEKS WHILE I WAS TRAVELING. I RETURNED TO FIND THE ACID BOILED OUT OF THE BATTERY AND THE BATTERY MELTED. TRIED TO RESOLVE THE PROBLEM WITH ALL PARTIES. RETURNED THE CHARGER TO CSB. THEY TOLD ME THEY INSPECTED IT AND THERE WAS NOTHING WRONG AND THE PROBLEM WAS WITH MY BATTERY. 1H71 3O 5A5 20030123000272003012300027NM 2003 1 23 SROM200300018 120030120G71106573773 RIB BOEING737 737205 1384456NM Zone 400 CHAFED A SROMK NONE O OTHER ININSP/MAINT 1 AL03733PA 1310 23466 During C check inspection found # 2 engine OB cowl # 3 rib chaffed 13" from lower edge. Removed damage, fabricated parts and installed fabricated parts per SRM 54-10-2, 51-40-4, 51-10-2 and 51-30-2. Minor repair, 2L72 4F RTA16WE 20030428001092003042800109 2003 4 28 SROM200300022 420030407G34142083081 INDICATOR BOEING737 737205 1384456NM PWA JT8 JT8D17 52049NE AIRSPEED FAILED C SROMA UNSCHED LANDING S AFFECT SYSTEMS CLCLIMB 1 AL03733PA23970647 23466 DURING CLIMB THE NR 2 MACH/AIRSPEED INDICATOR FAILED WITH FLAG PRESENT. RETURNED TO DEPARTURE AIRPORT. DURING APPROACH, JUST PRIOR TO TOUCH DOWN FLAG WENT AWAY AND INDICATOR BEGAN WORKING PROPERLY. REPLACED AIRSPEED/MACH INDICATOR. GROUND FUNCTION CHECKED OK. 2L72 4F4 FRTA16WE E2EA 20030827000552003082700055NM 2003 8 27 SROM200300023 120030623G53106624124 SHEAR TIE BOEING737 737205 1384456NM FUSELAGE CRACKED C SROMK NONE O OTHER ININSP/MAINT 1 AL03736BP329636788 23465 SHEAR TIE AT STATION 616 BETWEEN STINGERS 7 AND 8L HAS .2500 INCH CRACK. REMOVED AND REPLACED SHEAR TIE IAW MFG SRM 51-10-1 AND 51-30-2. 2L72 4F RTA16WE 20030827000562003082700056NM 2003 8 27 SROM200300024 120030624G5320693535214 STRINGER CLIP BOEING737 737205 1384456NM FUSELAGE CRACKED C SROMK NONE O OTHER ININSP/MAINT 1 AL03736BP329636788 23465 DURING D CHECK INSPECTION FOUND STRINGER CLIP AT STA 616, STRINGER 8R WITH 1.5 INCH CRACK. REMOVED AND REPLACED CLIP IAW WITH MFG SRM 51-10-1 AND 51-30-2. 2L72 4F RTA16WE 20030904002042003090400204NM 2003 9 4 SROM200300025 120030625G5320693535214 STRINGER CLIP BOEING737 737205 1384456NM FUSELAGE CRACKED C SROMK NONE O OTHER ININSP/MAINT 1 AL03736BP329636788 23465 DURING D CHECK INSPECTION FOUND STINGER CLIP AT STA 616 AND STRINGER 8L WITH 1 FT CRACK. REMOVED AND REPLACED IAW MFG SRM 51-10-1 AND 51-30-2. 2L72 4F RTA16WE 20030827000572003082700057NM 2003 8 27 SROM200300026 120030625G5320693535214 STRINGER CLIP BOEING737 737205 1384456NM FUSELAGE CRACKED C SROMK NONE O OTHER ININSP/MAINT 1 AL03736BP329636788 23465 DURING D CHECK INSPECTION FOUND STRINGER CLIP AT STA 597 STINGER 8R CRACKED .3 INCH. REMOVED AND REPLACED IAW B737 SRM 51-10-1 AND 51-30-2. 2L72 4F RTA16WE 20030902000732003090200073NM 2003 9 2 SROM200300027 120030626G5320693525214 STRINGER CLIP BOEING737 737205 1384456NM FUSELAGE CRACKED C SROMK NONE O OTHER ININSP/MAINT 1 AL03736BP329636788 23465 DURING D CHECK INSPECTION FOUND STINGER CLIP AT STA 360 5L WITH A .25 INCH CRACK. REPLACED CLIP IAW B737 SRM 51-10-1 AND 53-30-2. 2L72 4F RTA16WE 20030902000742003090200074NM 2003 9 2 SROM200300028 120030629G5313654576820 STRINGER BOEING737 737205 1384456NM FUSELAGE DAMAGED C SROMK NONE O OTHER ININSP/MAINT 1 AL03736BP329636788 23465 DURING D CHECK INSPECTION FOUND SEVERAL ELONGATED HOLES IN STRINGER 23R BETWEEN STA 360 AND 440. REMOVED AND REPLACED STRINGER BETWEEN STA 360 AND 440 IAW SRM 51-30-2, 51-10-2 AND MM 51-21-171. 2L72 4F RTA16WE 20030902000752003090200075NM 2003 9 2 SROM200300029 120030629G5313654576821 STRINGER BOEING737 737205 1384456NM FUSELAGE MISREPAIRED C SROMK NONE W INADEQUATE Q C ININSP/MAINT 1 AL03736BP329636788 23465 DURING D CHECK INSPECTION ELECTED TO REPLACE STRINGER 23R BETWEEN STA 500 AND 540 DUE ELIMINATE A PREVIOUS REPAIR. REMOVED AND REPLACED STRINGER IAW WITH B737 SRM 51-30-2, 51-10-2 AND MM 51-21-171. 2L72 4F RTA16WE 20030902000762003090200076NM 2003 9 2 SROM200300030 120030629G5313654576823 STINGER BOEING737 737205 1384456NM FUSELAGE MISREPAIRED C SROMK NONE W INADEQUATE Q C ININSP/MAINT 1 AL03736BP329636788 23465 DURING D CHECK INSPECTION ELECTED TO REPLACE STINGER 24R FROM STA 500 TO 540 BECAUSE OF A PERVIOUS APPROVED REPAIR. REPLACED STRINGER IAW B737 SRM 51-10-2 AND MM 51-21-171. 2L72 4F RTA16WE 20030904000032003090400003NM 2003 9 4 SROM200300031 120030629G5347654661513 SEAT TRACK BOEING737 737205 1384456NM FUSELAGE GOUGED C SROMK NONE O OTHER ININSP/MAINT 1 AL03736BP329636788 23465 DURING D CHECK INSPECTION FOUND GAUGES IN SEAT TRACK ALONG CENTER AND TOP FLANGES BETWEEN STA 540 AND 727. REMOVED DAMAGED SEAT RACK AND REPLACED IAW SRM 53-10-1, 51-30-2 AND 51-10-2. 2L72 4F RTA16WE 20030902000772003090200077NM 2003 9 2 SROM200300032 120030627G5320694688216 STRINGER CLIP BOEING737 737205 1384456NM FUSELAGE CRACKED C SROMK NONE O OTHER ININSP/MAINT 1 AL03736BP329636788 23465 DURING D CHECK INSPECTION FOUND STRINGER CLIP AT STA 360, STINGER 4 L CRACKED .25 INCH. REPLACED CLIP IAW SRM 51-10-1 AND 51-30-2. 2L72 4F RTA16WE 20030708000112003070800011NM 2003 7 8 SROM200300033 120030629G5512655482U34 SKIN BOEING737 737205 1384456NM HORIZONTAL STAB SCRATCHED C SROMK NONE O OTHER ININSP/MAINT 1 AL03736BP329636788 23465 DURING D CHECK INSPECTION FOUND FOUND SEVERAL SCRATCHES IN LOWER AND UPPER SURFACES OF THE RT IB HORIZONTAL STABLIZER LEADING EDGE. REMOVED AND REPLACED RT IB HORIZONTAL LEADING EDGE IAW SRM 51-30-2. 2L72 4F RTA16WE 20030708000122003070800012NM 2003 7 8 SROM200300034 120030702G5347654681513 SEAT TRACK BOEING737 737205 1384456NM PWA JT8 JT8D17 52049NE FUSELAGE GOUGED I SROMK NONE O OTHER ININSP/MAINT 1 AL03736BP329636788 23465 DURING D CHECK INSPECTION FOUND NUMEROUS GOUGES IN CENTER AND TOP OF SEAT TRACK BETWEEN BS 540 - 727, LBL 24. REMOVED AND REPLACED SEAT TRACK BETWEEN BS 540 TO 727 IAW SRM 51-30-2, 51-10-2 AND MM 51-21-0. 2L72 4F4 FRTA16WE E2EA 20030902001412003090200141NM 2003 9 2 SROM200300036 120030703G5347BAC1505100246 FLOORBEAM BOEING737 737205 1384456NM FUSELAGE CORRODED C SROMK NONE O OTHER ININSP/MAINT 1 AL03736BP329636788 23465 DURING D CHECK INSPECTION FOUND CORROSION ON FLOORBEAM UPPER CAP AT STA 344 FROM LBL 30 TO RBL 30. REMOVED AND REPLACED DAMMAGED CAP IAW SRM 51-30-2, 51-10-6, 51-10-2 AND 53-10-1.CORROSION LEVEL 1 2L72 4F RTA16WE 20030902001422003090200142NM 2003 9 2 SROM200300037 120030706G5320693555214 STRINGER CLIP BOEING737 737205 1384456NM FUSELAGE DAMAGED C SROMK NONE O OTHER ININSP/MAINT 1 AL03736BP329636788 23465 DURING D CHECK INSPECTION FOUND DRILL BIT DAMAGE FROM A PREVIOUS REPAIR TO STRINGER CLIP AT STA 380 AND STRINGER 2 R. REMOVED AND REPLACED STRINGER CLIP IAW SRM 51-30-2 AND 51-10-1. 2L72 4F RTA16WE 20030902001432003090200143NM 2003 9 2 SROM200300038 120030701G53476546815145 SEAT TRACK BOEING737 737205 1384456NM FUSELAGE GOUGED C SROMK NONE O OTHER ININSP/MAINT 1 AL03736BP329636788 23465 DURING D CHECK INSPECTION FOUND BARE METAL AND GOUGES ON SEAT TRACK BETWEEN STAS 727 AND 947, RBL 45.5. REMOVED AND REPLACED SEAT TRACK IAW SRM 51-10-1, 51-30-2, 51-10-2 AND MM 51-21-171. 2L72 4F RTA16WE 20030902001712003090200171NM 2003 9 2 SROM200300039 120030709G53306545774 SKIN BOEING737 737205 1384456NM FUSELAGE GOUGED C SROMK NONE O OTHER ININSP/MAINT 1 AL03736BP329636788 23465 DURING D CHECK INSPECTION FOUND SKIN AT STA 846 BETWEEN STRINGER 24L AND 25L TO HAVE A SMALL DENT AND GOUGE. REMOVED DAMAGED AREA AND REPAIRED IAW B737 SRM 53-30-3, 53-30-2 AND 51-10-2. 2L72 4F RTA16WE 20030903000032003090300003NM 2003 9 3 SROM200300040 120030709G5310BAC15061108 BEAM BOEING737 737205 1384456NM FUSELAGE GOUGED D SROMK NONE O OTHER ININSP/MAINT 1 AL03736BP329636768 23465 DURING D CHECK INSPECTION FOUND LONGITUDINAL BEAM AT STA 707, LBL 24, GOUGED AT FASTNER HOLE INBOARD FLANGE, WL 205. REMOVED DAMAGE, FABRICATED AND INSTALLED REPAIR STRAPS IAW SRM 53-10-1, 53-10-2, EA 53-10-02240 AND AAR EA 05-53-EA239. 2L72 4F RTA16WE 20030903000562003090300056NM 2003 9 3 SROM200300041 120030714G53136573744157 STRINGER BOEING737 737205 1384456NM FUSELAGE GOUGED C SROMK NONE O OTHER ININSP/MAINT 1 AL03736BP329636788 23465 DURING D CHECK INSPECTION FOUND STRINGER 20R AT BS 500 GOUGED BEYOND ALLOWABLE LIMITS. REMOVED DAMAGED AREA OF STINGER, FABRICATED AND INSTALLED REPAIR IAW B737 SRM 53-10-2, 51-10-3, 51-10-2, 51-10-3 AND MM 51-21-171. 2L72 4F RTA16WE 20030903000552003090300055NM 2003 9 3 SROM200300042 120030714G5347654681513 SEAT TRACK BOEING737 737205 1384456NM FUSELAGE GOUGED C SROMK NONE O OTHER ININSP/MAINT 1 AL03736BP329536788 23465 DURING D CHECK INSPECTION FOUND SEAT TRACK AT STA 540 TO 727, RBL 45 GOUGED ALONG CENTER AND TOP FLANGES IN NUMEROUS PLACES. REMOVED AND REPLACED SEAT TRACK IAW B737 SRM 51-30-2, 51-30-5 AND 51-10-2. 2L72 4F RTA16WE 20030912000362003091200036NM 2003 9 12 SROM200300043 120030722G55336552490118 BEAM BOEING737 737205 1384456NM VERTICAL STAB DENTED C SROMK NONE O OTHER ININSP/MAINT 1 AL03736BP329636788 23465 DURING D CHECK INSPECTION FOUND DENT IN RT TRAILING EDGE BEAM OF VERTICAL STABILIZER AT APPROX STA 17.25. REFORMED RT TRAILING EDGE BEAM IAW EA 5530-01100 AND EA 10007. 2L72 4F RTA16WE 20030917000432003091700043NM 2003 9 17 SROM200300045 120030728G533065C3584336 SKIN BOEING737 737205 1384456NM FUSELAGE DENTED C SROMK NONE O OTHER ININSP/MAINT 1 AL03736BP329636788 23465 DURING D CHECK INSPECTION FOUND NUMEROUS DENTS IN FUSELAGE SKIN BETWEEN STR 18R & 20R STA 850 TO 890 THAT WERE OUT OF LIMITS IAW B737 SRM 53-30-1. REMOVED AND REPLACED SKIN PANEL AT STA 727 TO 907 STR 14R TO STR 20R IAW B737 SRM 51-30-2, 51-10-2. 2L72 4F RTA16WE 20030917000442003091700044NM 2003 9 17 SROM200300046 120030726G52306547952162 SKIN BOEING737 737205 1384456NM CARGO DOOR DENTED C SROMK NONE O OTHER ININSP/MAINT 1 AL03736BP 6788 23465 DURING D CHECK INSPECTION CUSTOMER REQUEST TO REMOVED AND REPLACED AFT CARGO DOOR SKIN DUE TO DENTS AND DINGS. REMOVED AND REPLACED IAW B737 SRM 51-30-2, 51-30-5, MM 57-31-0. 2L72 4F RTA16WE 20030912001312003091200131NM 2003 9 12 SROM200300047 120030623G533065C36745116 SKIN BOEING737 737205 1384456NM FUSELAGE DAMAGED C SROMK NONE O OTHER ININSP/MAINT 1 AL03736BP329636788 23465 DURING D CHECK INSPECTION CUSTOMER REQUESTED TO REMOVE AND REPLACE SKIN ASSY P/N 65C36745-116 LOCATED AT BS 908 TO 1016STG 20R TO 25R DUE TO PREVIOUS REPAIRS. REMOVED AND REPLACED IAW B737 SRM 51-30-2 2L72 4F RTA16WE 20030915000112003091500011NM 2003 9 15 SROM200300048 120030728G533065C36745100 SKIN BOEING737 737205 1384456NM FUSELAGE DAMAGED C SROMK NONE O OTHER ININSP/MAINT 1 AL03736BP329636788 23465 DURING D CHECK INSPECTION CUSTOMER REQUEST TO REMOVE AND REPLACE SKIN ASSY P/N 65C36745-100 LOCATED AT BS 727 TO 907 STR 20R TO 25R DUE TO PREVIOUS REPAIRS. REMOVED AND REPLACED SKIN PANEL IAW B737 SRM 51-30-2. 2L72 4F RTA16WE 20030912001332003091200133NM 2003 9 12 SROM200300049 120030724G531065C3584318 SKIN BOEING737 737205 1384456NM FUSELAGE DAMAGED G SROMK NONE O OTHER ININSP/MAINT 1 AL03736BP329636788 23465 DURING D CHECK INSPECTION CUSTOMER REQUEST TO REMOVE AND REPLACE SKIN ASSY P/N 65C35843-18 LOCATED AT BS 360 TO 540 STR 19R TO 26R DUE TO PREVIOUS REPAIRS. REMOVED AND REPLACED SKIN PANEL IAW B737 SRM 51-30-2. 2L72 4F RTA16WE 20030912000342003091200034NM 2003 9 12 SROM200300051 120030728G53306545777 SKIN BOEING737 737205 1384456NM DENTED C SROMK NONE O OTHER ININSP/MAINT 1 AL03736BP 23465 DURING D CHECK, AFTER SKIN REPLACEMENT, FOUND DENT WITH GOUGE ON INNER SKIN AT BS 933.5 BETWEEN STR 22R AND 23R. REPAIRED DENT IAW B737 SRM 53-30-3, 53-30-1, 51-30-2 AND 51-10-2. 2L72 4F RTA16WE 20031113000502003111300050NM 2003 11 13 SROM200300052 120031108G5330 SKIN BOEING737 737205 1384456NM ZONE 100 GOUGED C SROMK NONE O OTHER ININSP/MAINT 1 AL03736BP33329 23465 DURING AN A-3 CHECK FOUND A GOUGE IN BOTTOM OF FUSELAGE SKIN .375 INCH LONG BY .25 INCH. INSPECTED AREA FOR CRACKS USING HFEC. NONE DETECTED. REPAIRED GOUGE AREA WITH FLUSH PATCH PER B737 SRM 53-30-3. 2L72 4F RTA16WE 20031229001982003122900198NM 2003 12 29 SROM200300053 120031118G2121 FAN BOEING737 737205 1384456NM PWA JT8 JT8D17 52049NE COCKPIT FAILED C SROMA UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CRCRUISE 1 AL03733PA 23466 DURING CRUISE FLIGHT AT 330 A BURNING ODOR WAS NOTED IN THE COCKPIT ONLY. ALL SYSTEMS CONTINUED TO FUNCTION NORMAL. PRECAUTIONARY LANDING AT FAI WAS MADE. UPON LANDING MAINTENANCE WAS UNABLE TO FIND THE SOURCE OF THE SMELL AND ALL OPERATIONS NORMAL. IT WAS DECIDED TO FERRY AIRCRAFT TO ANC FOR FURTHER INVESTIGATION. DURING FLIGHT TO ANC ODOR WAS NOTICE MOMENTARILY AND DISSIPATED. NO OTHER PROBLEMS NOTED. ANC MAINTENANCE WAS UNABLE TO CONFIRM SOURCE OF ODOR. PRECAUTIONARY REPLACEMENT OF NORMAL ELECTRICAL EQUIPMENT BLOWER AND ITS CIRCUIT BREAKER WAS ACCOMPLISHED. ON SUBSEQUENT FLIGHT NO PROBLEMS REPORTED. 2L72 4F4 FRTA16WE E2EA 20031230000102003123000010NM 2003 12 30 SROM200300054 120031204G3350582212 POWER SUPPLY BOEING737 737205 1384456NM EMERGENCY LIGHT INOPERATIVE C SROMK NONE L NO TEST ININSP/MAINT 1 AL03733PA 6 23466 DURING PREFLIGHT INSPECTION FORWARD SECTION OF FLOOR TRACK EMERGENCY LIGHTING AND EXIT SIGN AT L1 DOOR INOPERATIVE. CHANGED EMERGENCY BATTERY OVER L1 DOOR. SUSPECT MOISTURE IN THE LIGHT STRIP WAS A CONTRIBUTING, IF NO THE ROOT CAUSE OF THE PROBLEM. 2L72 4F RTA16WE 20030912000202003091200020EA 2003 9 12 SROMDHC200301 120030811G3251711599 LEVER DHAV DHC6 DHC6300 2802606EA NLG STEERING BROKEN C SROMD RETURN TO BLOCK O OTHER TXTAXI/GRND HDL 1 AL03842AR132351502 842 DURING TAXI THE NOSE STEERING TILLER WENT HARD OVER WITH NO EFFECT TO STEERING INPUT. FOUND STEERING LEVER WHICH TRANSFERS HYDRAULIC FORCE FROM STEERING ACTUATOR TO STEERING COLLAR ON STRUT TO BE TOTAL BROKE ON OPPOSITE SIDES OF PIVOT BEARING BORE. ONE SIDE APPEARS TO HAVE FRACTURED PREVIOUS DUE TO SLIGHT FRETTING IN BREAK AREA. 1H72 3T RTA9EA 20031230000112003123000011 2003 12 30 TAM1112200301 420031031G6113U14426000 PLATE PIPER PA18 PA18 7101802SO LYC O320 O320A2B 41508EA MCAULY1A175 1A175* GL SPINNER FAILED D O OTHER O OTHER NRNOT REPORTED 1 AL01 SPINNER BACKPLATE BRACKETS SEEM TO FAIL OFTEN, PICTURE NR 1. THIS PARTICULAR BACKPLATE APPEARS VERY NEW, THE AIRCRAFT HAS FLOWN 35 HOURS SINCE ANNUAL INSPECTION. PICTURE NR 2 SHOWS HOW THE PROPELLER HITS THE BRACKET LEG AND PUSHES THE SPINNER BACKPLATE AFT, SLIGHTLY OUT OF ALIGNMENT. PERHAPS THIS INTERFERENCE IS CAUSING ABNORMAL STRESS ON THE TAB ACUTE ANGLE, THUS CAUSING THEM TO FAIL. A SUGGESTION TO PREVENT INTERFERENCE IS BY SLIGHTLY REWORKING THE BRACKET LEG AS IN PICTURE NR 3. PICTURE NR 4 SHOWS THE PROP MOUNTED FLUSH WITH THE BACKPLATE. 1H71 3O3 O 1A2 E274 5 NP857 20030313001522003031300152EA 2003 3 13 TBM700 220030221G72303041211 BLADE PWC SOCATATBM TBM700 8682000EU PWA PT6 PT6* 52043EA COMPRESSOR FAILED G EBA ENGINE SHUTDOWN EMER. DESCENT UNSCHED LANDING XJ ENGINE FLAMEOUT WARNING INDICATION CRCRUISE 1 GL1912WY 1449 25 112 EXPERIENCED A TOTAL POWER FAILURE WHILE DESCENDING FROM FL250 TO FL240. PILOT MADE A SUCCESSFUL DEAD STICK LANDING. INSPECTION OF THE ENG REVEALED A CATASTROPHIC FAILURE OF A COMPRESSOR TURBINE BLADE WHICH RESULTED IN A COMPLETE ENGINE STOPPAGE AND LOCKING UP THE POWER TURBINE. THIS RESULTS IN A LOSS OF PRESSURIZATION, ELECTRICAL GENERATOR POWER AND INSTRUMENT AIR POWER. LEARNED THAT PWC HAS FOUND MANY CT ASSEMBLIES CRACKED IN THE FIELD ON THE –60 SERIES ENGINES. 1L71 3T3 TRTA60EU E2NE 20031006001232003100600123GL 2003 10 6 TR1031 220030825G723023039797AL COUPLING ALLSN A250C20 ALLSN 250C 250C20 03013GL COMPRESSOR FRETTED B O OTHER O OTHER NRNOT REPORTED 1 SW05XB-DK1063 CAC34134 CAE823092 COMPRESSOR COUPLING ADAPTER (P/N 23039797AL S/N CI17-406) HAS SEVERE FRETTING ON OD OF ADAPTER. SEVERAL OEM ADAPTERS HAVE FAILED AT THIS FRETTING AREA. 3 U E4CE 20030903000412003090300041 2003 9 3 UC2R20030001A 420030715G3431 CLIP PIPER PA28 PA28181 7102807SO NAV COM SYS MISMANUFACTURED B O OTHER LS NO TEST AFFECT SYSTEMS NRNOT REPORTED 1 GL194144K 2843145 NAVIGATION CONTROL OF NAV/COMM TOGGLED FREQUECY UNCOMMANDED, WHICH CAUSED LOSS OF OPERATION OF VOR/LOC DURING FLT. OPERATOR COMPLAINED THAT THIS CONDITION MADE NAV UNRELIABLE FOR USE. TRACED PROBLEM TO KHZ NAV FREQUENCY CONTROL VERY SUSCEPTIBLE TO TRIGGERING FROM NORMAL VIBRATION DUE TO MATERIALS USED IN MANUFACTURE. ASSEMBLY REQUIRES GREATER SECURITY IN ASSEMBLY OF FREQUENCY CONTROL SWITCH AT THE LOCKING SLEEVE AND THE "C" CLIP. MOVEMENT ALLOWED BY IN EFFECTIVE ATTACHMENT BY THE "C" CLIP CAUSES PHOTO CELL TO TRIGGER, TOGGLING THE NAV FREQUENCY. LOCKING SLEEVE NEEDS TIGHTER TOLERANCE WHERE THE "C" CLIP ATTACHES. IMPROVEMENT TO LOCKING SLEEVE MAY REQUIRE USE OF DIFFERENT MATERIAL, METAL IN PLACE OF NYLON. 1L71 3O 2A13 20030916001582003091600158GL 2003 9 16 UIE2003F00000 220030714G7200FJ44 ENGINE CESSNA525 525 2076601CE WILINTFJ44 FJ44 66000GL RIGHT FLAMED OUT B O OTHER O OTHER NRNOT REPORTED 1 SW151000E 5250077 DURING AN APPROACH TO LAND AT 5000 FT AGL, THE THROTTLES WERE RETARDED TO IDLE AND THE NR 2 ENGINE FLAMED OUT. A SINGLE ENGINE LANDING WAS PERFORMED WITHOUT INCIDENT. THE AIRCRAFT HAD RECENTLY BEEN THROUGH AN ENGINE CHANGE AFTER AN OVERHAUL. AFTER THE WORK WAS PERFORMED, IT WAS NOTICED THAT THE RIGHT THROTTLE WAS CREW AND PASSENGERS WERE DISEMBARKED FROM THE AIRCRAFT. THE PILOT AND CO-PILOT CONSULTED WITH GROUND MAINTENANCE. A VISUAL INSPECTION OF THE ENGINE AND ENGINE RUN REVEALED NO DISCREPANCIES. THE AIRCRAFT ENGINE CONTROLS WERE RE-RIGGED AND THE ENGINE WAS TEST RUN ONCE AGAIN TO VERIFY PROPER RIGGING. (SW15200317283) 1L72 4F4 FRTA1WI E3GL 20031010000622003101000062 2003 10 10 VERTEX01 420030919G2561 BATTERY PACK LIFE VEST LIGHT RUPTURED B O OTHER O OTHER NRNOT REPORTED 1 SW09 EMERGENCY WATER ACTIVATED LIGHT FAILURE WITHIN ORIGINAL LIFE VEST. 17 OF 18 VEST INSPECTED SHOWED RUPTURED LIGHT BATTERY PACKS. 20031023000052003102300005CE 2003 10 23 VERTEX2 120030924G2897 WIRE CESSNA500 550 2076604CE FUEL PUMP SPARKS B K NONE B SMOKE/FUMES/ODORS/SPARKS ININSP/MAINT 1 SW13264965957 10AD110 5500607 RIGHT BOOST PUMP WIRING CHAFED ON MOTIVE FLOW FEED LINE IN FUEL BAY. CHAFED WIRE CAUSED ELECTRICAL ARC DAMAGE TO FUEL LINE. THIS APPEARS TO BE AN ORIGINAL BOOST PUMP. PROBLEM WAS NOTED DURING DEFUELING USING THE BOOST PUMP TO REMOVE FUEL FOR MAINTENANCE. THE 15 AMP BOOST PUMP CIRCUIT BREAKER POPPED WHEN THE FUEL REMAINING WAS APX 15 GALS. INSPECTION REVEILED THE ABOVE PROBLEM, BOTH THE BOOST PUMP AND FUEL LINE WERE REPLACED. FIX: THE BOOST PUMP WIRING WAS DOUBLED BACK TO PUMP HOUSING AND SECURED WITH A TIE WRAP/STAND OFF TO INSURE IT COULD NOT COME IN CONTACT WITH THE FUEL LINE IN THE FUTURE. 1L72 4F A22CE 20031023000732003102300073CE 2003 10 23 VERTEX3 120030925G282210712 PUMP CESSNA500 550 2076604CE PWA JT15 JT15D4 52112NE FUEL BOOST SCORED B O OTHER O OTHER NRNOT REPORTED 1 SW0926496 5500607 AFTER FINDING CHAFED FUEL BOOST PUMP WIRING ARCING AGAINST MOTIVE FLOW FUEL SUPPLY LINE ON RT SIDE LT FUEL BOOST PUMP WAS ALSO INSPECTED. WIRING ON LT (NO ARCING AT THIS TIME) HAD RUBBED INTO MOTIVE FLOW FUEL SUPPLY LINE TO A POINT THAT SUPPLY LINE P/N 6526355-37 HAD TO BE REPLACED. ADDITIONALLY ELECTRICAL LINE HAD RUBBED THROUGHT PROTECTIVE COATING ON FLOOR OF FUEL COMPARTMENT NEXT TO BOOST PUMP (P/N 107-12). THIS WAS INSPECTED AND PROTECTIVE COATING REAPPLIED. RECOMEND INSPECT THESE FUEL BAYS. IT MAY BE REQUIRED TO REMOVE MOTIVE FLOW FUEL SUPPLY LINE FOR PROPER INSPECTION. NOTE: RT HAND BOOST PUMP P/N 1C7-12 WAS ORIGNAL AND THE LT HAND PUMP P/N 107-12 WAS A REPLACEMENT PUMP. TIME UNKNOWN AT THIS TIME. 1L72 4F4 F A22CE E1NE 20030903000662003090300066CE 2003 9 3 VG4R595M 120030415G324650300010133 WHEEL BEECH 90 C90A 1152911CE MLG DAMAGED B VG4RO OTHER O OTHER NRNOT REPORTED 1 SO35 423 LJ1659 UPON TAKEOFF, THE LEFT MAIN WHEEL ASSEMBLY DEPARTED THE AIRCRAFT. UPON INSPECTION, FOUND THE AXEL NUT WAS STILL ON, THE BEARINGS WERE DISINTEGRATED AND THE WHEEL WAS DAMAGED. 1L72 3T RT3A20 20040120000222004012000022CE 2004 1 20 WVE2003F0000A 120031123G242130728692 SPLINE ADAPTER LEAR 45 45LEAR 5170805CE GARRTTTFE731TFE731* 01518WP RT ENGINE CRACKED B O OTHER O OTHER NRNOT REPORTED 1 EA09425FX 147 DURING 600 HOUR INSPECTION OF THE ALTERNATOR SPLINE ADAPTOR, DISCOVERED ADAPTER TO BE CRACKED IN TWO LOCATIONS. PROBABLE CAUSE: FATIGUE. 2L72 4F4 FRTT00008WIE6WE 20030314000102003031400010EU 2003 3 14 XG3R084688 120030221G21213972A010000 BLOWER UROCOPEC130 EC130B4 EU TMECA ARRIELARRIEL2B NE TAILBOOM SHORTED H XG3RK NONE O OTHER ININSP/MAINT 1 FS0129LB 15 3560 23004 SINCE DELIVERY OF THE AIRCRAFT THE CONDENSOR BLOWER HAS NOT BEEN OPERATIONAL. REPLACED BLOWER 1G72 3U3 U H9EU E00054EN 20030314000112003031400011EU 2003 3 14 XG3R084689 120030221G771478899811 INDICATOR UROCOPEC130 EC130B4 EU TMECA ARRIELARRIEL2B NE NR & NG SHORTED H XG3RK NONE O OTHER ININSP/MAINT 1 FS0126LB 3514 23017 INSTRUMENT BEGAN TO FAIL INTERMITTENTLY. FINALLY FAILED COMPLETELY. REPLACED INSTRUMENT WITH SERVICEABLE UNIT. 1G72 3U3 U H9EU E00054EN 20030902000472003090200047WP 2003 9 2 XMSR778K 120030620G6210369D21100517 BLADE HUGHES369 369E 4470707WP ALLSN 25OC 250C20R GL MAIN ROTOR CRACKED B K NONE O OTHER ININSP/MAINT 1 SO01525502088 0166E CRACK FROM TRAILING EDGE TO SPAR BOTH BOTTOM AND TOP OF BLADE. CRACK IS APPROX 19 INCHES OUTBOARD OF REAR BLADE PIN HOLE. CRACK 4.6250 INCHES LONG AND T (ED) OF 1.5000 EACH WAY ON THE BOTTOM AND ON TOP SIDE T 2 INCHES TOWARD OUTBOARD AND .5000 INCH TOWARD INBOARD. 1G71 3U3 U H3WE E4CE 20031229002012003122900201 2003 12 29 YHLR200300001 420031126G23006285437001 LEAD BEECH 76 76 1153005CE RADIO ANTENNA UNBONDED B O OTHER O OTHER NRNOT REPORTED 1 SO176626Z ME208 FOUND MOD-17 NOT PERFORMED IAW SB VHF251-SB17. GROUND STRAP FROM ANTENNA CONNECTOR P2 TO GROUND PLANE OF POWER AMPLIFIER ASSEMBLY A3. 2A(2) WAS NOT ACCOMPLISHED. UNIT HAD BEEN MARKED FOR MOD-17, AND WAS TAGGED BY REPAIR STATION, DATED 11/05/2002. MOD-17 COMPLETED IAW SB VHF251-SB17. PROBLEM COULD HAVE BEEN PREVENTED IF SERVICE BULLETIN HAD BEEN PROPERLY COMPLIED WITH. 1L72 3O A29CE 20030423002112003042300211NE 2003 4 23 ZAVR192X 220030225G7250742198 SHAFT PWA JT8 JT8D7B 52053NE LP TURBINE CHAFED B ZAVRO OTHER O OTHER NRNOT REPORTED 1 WP07 648906 TURBINE SHAFT APPROXIMATELY 2 FEET AFT OF THE SPLINED AREA, SHAFT SHOWS EVIDENCE OF TWISTING OR BLENDING THAT REMOVED MATERIAL. 4 F E2EA